process characterization for tur · gg-04 thermal oxidizer gg-01 gg-04 . gg-04 blending /...
TRANSCRIPT
Process Characterization for TUR
Rich Bizzozero – OTA
Objectives
Understand why it’s important to be thoughtful in the
selection of a production unit and unit
of product
Understand why a whole-facility production unit, or
a poorly selected one, may mask progress in
tracking toxics use reduction
Understand what processing steps need to be included in the
description of a production unit
Differentiate between chemical use, product,
byproduct and emission
After this module, you will…
Key Definitions
Production unit
Chemical use
Byproduct
Emission
Unit of Product
Production Ratio
Production Unit
A process, line, method, activity, or technique, or a combination or series thereof, used to produce a product.
The production unit is where chemical tracking is performed, TUR planning performed and TUR progress is documented and reported on Form-S.
Chemical Use
• Manufacture – Create a reportable chemical • Process – Incorporated into product • Otherwise use – manufacturing aid, not part
of the product
• A + B = C • (C = Manufactured product) Manufacture
• A + B = A + B • (Mixture) Process
Byproduct
All non-product outputs of toxic or hazardous substances generated by a production unit, before handling, transfer, treatment or release. Otherwise used substances shall be counted as byproduct when they leave a production unit.
Emission
A release of a toxic or hazardous substance to the environment (on or off site) or a transfer of a toxic or hazardous substance in waste to an off-site location.
Unit of Product
• A measure that reflects the level of production or activity associated with the use of the toxic or the generation of the toxic as byproduct.
• Examples: – 1000’s square yards of coated fabric – Amp hours, pounds of product manufactured – Gallons of adhesive manufactured – Pounds of metal product clean, square feet of product
cleaned
Production Ratio / Activity Index
• Most cases - must be based on some variable other than the reportable chemical usage – Why?
• Ratios based on reportable chemical use may reflect the effects of source reduction (TUR)
• Examples: pounds of ethylene glycol used to manufacture water-based paint vs gallons of water based paint manufactured containing ethylene glycol
• Reportable chemical usage is not an appropriate activity index for “otherwise used” category of use
Facility-Wide Materials Accounting
Manufactured ____________ Processed ____________ Otherwise Used _______ Generated as Byproduct ______ _ Shipped in Product __________ Section 2: Optional Chemical was recycled on-site_________ Chemical was consumed ______ _ Chemical was held in inventory________ Chemical was a compound_________ Other (explain)__________________________________
Mass Balance
Does
Manufactured + Processed + Otherwise Used
= Byproduct + Shipped in Product ?
If not, has the optional section been filled in to explain why?
Chemical Recycled On-Site Chemical is a Compound
Chemical Held in Inventory Chemical Consumed or Transformed
Byproducts & Emissions
Byproducts should = Emissions unless you have:
• destructive treatment
• on-site recycling
• waste staying on site
BYPRODUCT
EMISSION
Byproducts & Emissions
Byproducts = Amount of the reportable chemical that leaves the production unit that is NOT consumed, chemically transformed or shipped in product
Byproducts = “Waste” BEFORE treatment
Emissions = Releases to environment (on or off site) or transfers off-site
BYPRODUCT
EMISSION
Let’s Get Started - Process Characterization Requirements - 1
Must Include For EACH Production Unit: – Production Unit Number – Unit of Product – Process Flow Diagram with:
• Each step including treatment and recycling • Movement of each reportable chemical through
process including all points of entry and exit as product, byproduct or emission
Process Characterization Requirements - 2
For EACH reportable chemical used by Production Unit: – Purpose – Total amounts & amounts per unit of product – Byproduct fate: amounts released on-site, treated on-site and off-
site, recycled on-site and off-site, and disposed of on-site and off-site
– Emissions to each media: amounts released on-site, disposed on-site, transferred off-site, and treated, recycled and disposed of off-site to air, surface water, ground water, and land
– Cost of toxics (qualitative or quantitative) • Quantitative if technically feasible options identified • Qualitative if no technically feasible options identified
Product Sodium Hydroxide Wastewater
Sodium Hydroxide
Pulper
Clean Pulp
Holding
Machine Chest
Paper
Dryer
Wastewater Treatment
Steam
Fresh Water
Cotton
Paper (product) (residual NaOH)
50,000 lbs.
Condensate
1,000 lbs
river
Off-spec paper
Paper-making Production
Unit
Fabric Coating with Solvent Adhesive Process
AA-03 BB-09
Adhesive Roll Coating
Cotton fabric
Finished Goods Storage
GG-04
Thermal Oxidizer
GG-01
GG-04
GG-04
Blending / Compounding
Adhesive storage
Drying
Toluene + MEK + Antimony Compound
Receipt & Storage Product flow
Toluene liquid phase
MEK liquid phase
Antimony
Production Operation
Fabric Coating with Solvent Adhesive – Byproducts
AA-03 BB-09
Adhesive Roll Coating
Cotton Fabric
Finished Goods Storage
GG-04
Thermal Oxidizer
GG-01
GG-04
GG-04
Blending / Compounding
Adhesive storage
Drying
Toluene + MEK + Antimony Compound
Receipt & Storage Product flow
Toluene liquid phase
MEK liquid phase
Antimony
Production Operation
Byproduct
Toluene Byproduct
MEK Byproduct
Byproduct
Byproduct
Byproduct Byproduct
Coating Byproduct (Antimony, Toluene,
MEK)
Fabric Coating Equipment Cleanup
FF-01 FF-01
Cleaning Operation
Adhesive Roll Coating
Finished Goods Storage
GG-04
Thermal Oxidizer
Blending / Compounding
Adhesive storage
Drying
MEK
Byproduct
Byproduct Byproduct Byproduct
Byproduct
MEK Byproduct
Coating Byproduct (Antimony, Toluene, MEK)
MEK
Fabric Coating with Solvent Adhesive – Process and Clean-up PFD
FF-01 FF-01
MEK
Cleaning Operation
Toluene Byproduct
MEK Byproduct
AA-03 BB-09
Adhesive Roll Coating
Cotton Fabric
Finished Goods Storage
GG-04
Thermal Oxidizer
GG-01
GG-04
GG-04
Blending / Compounding
Adhesive storage
Drying
Toluene + MEK + Antimony Compound
Receipt & Storage Product flow
Toluene liquid phase
MEK liquid phase
Antimony
Production Operation
Byproduct
Byproduct Byproduct
Coating Byproduct (Antimony, Toluene, MEK)
Byproduct
Byproduct
Byproduct
