Reference Document on Best Available Techniques in the Large

3,76

MB

Volume Organic Chemical Industry (adopted February 2003)

478

stron

1106

ID

JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2003

rok

EXECUTIVE SUMMARY I

PREFACE. XXIII

SCOPE AND DOCUMENT ORGANISATION.XLI

1 BACKGROUND INFORMATION 1

2 GENERIC LVOC PRODUCTION PROCESS7

2.1 Unit processes8

2.1.1 Oxidation 9

2.1.2 Halogenation10

2.1.3 Hydrogenation 10

2.1.4 Esterification11

2.1.5 Alkylation .11

2.1.6 Sulphonation .12

2.1.7 Dehydrogenation12

2.1.8 Hydrolysis13

2.1.9 Reforming13

2.1.10 Carbonylation .14

2.1.11 Oxyacetylation.14

2.1.12 Nitration.14

2.1.13 Dehydration 14

2.1.14 Ammonolysis.14

2.1.15 Condensation 15

2.1.16 Dealkylation.15

2.1.17 Ammoxidation 15

2.2 Unit operations.16

2.2.1 Absorption 17

2.2.2 Distillation 17

2.2.3 Extraction.18

2.2.4 Solids separation.19

2.2.5 Adsorption 19

2.2.6 Condensation 19

2.3 Process equipment and infrastructure .20

2.3.1 Reactors 20

2.3.2 Emission abatement 21

2.3.3 Energy supply .22

2.3.4 Cooling .22

2.3.5 Refrigeration .23

2.3.6 Storage and handling 23

2.3.7 Pressure relief .24

2.3.8 Vacuum24

2.3.9 Pumps, compressors and fans .24

2.3.10 Pipes 25

2.3.11 Valves 25

2.3.12 Utility fluids26

2.4 Management systems26

3 GENERIC APPLIED PROCESSES AND TECHNIQUES27

3.1 Chemical products with a process description28

3.2 Lower olefins.29

3.3 Aromatics.31

3.4 Oxygenated compounds34

3.4.1 Alcohols.35

3.4.2 Aldehydes .41

3.4.3 Ketones .41

3.4.4 Carboxylic acids .42

3.4.5 Esters. 46

3.4.6 Acetates 46

3.4.7 Ethers. 47

3.4.8 Epoxides 47

3.4.9 Anhydrides . 48

3.5 Nitrogenated compounds 51

3.5.1 Amines . 51

3.5.1.1 Aliphatic amines. 51

3.5.1.2 Aromatic amines 52

3.5.2 Amides . 53

3.5.3 Nitrous / nitro / nitrate compounds. 54

3.5.4 Nitriles. 55

3.5.5 Cyanates / isocyanates 55

3.5.6 Other 56

3.6 Halogenated compounds 59

3.7 Sulphur compounds 62

3.7.1 Generic issues in the production of sulphur compounds 64

3.8 Phosphorus compounds 66

3.9 Organo-metal compounds 66

4 GENERIC EMISSIONS 69

4.1 Air pollutants. 69

4.1.1 Emission sources 70

4.1.2 Pollutant types 71

4.1.2.1 Volatile Organic Compounds (VOCs) . 71

4.1.2.2 Particulate matter 72

4.1.2.3 Combustion gases. 72

4.1.2.4 Acid gases 73

4.1.2.5 Dioxins . 73

4.2 Water pollutants . 73

4.2.1 Emission sources 73

4.2.2 Pollutant types 74

4.3 Wastes . 75

4.3.1 Emission sources 75

4.3.2 Pollutant types 76

4.4 Factors influencing consumption and emissions 76

4.4.1 Plant boundary definition and the degree of integration 76

4.4.2 Definition of emission basis . 76

4.4.3 Measurement technique 76

4.4.4 Definition of waste . 77

4.4.5 Plant location 77

5 GENERIC TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT. 79

5.1 Management systems . 79

5.1.1 Management commitment 80

5.1.2 Organisation and responsibility 80

5.1.3 Training. 81

5.1.4 Process design and development 81

5.1.5 Industrial planning and logistics. 83

5.1.6 Process control . 83

5.1.7 Maintenance . 84

5.1.8 Monitoring. 84

5.1.9 Auditing. 85

5.1.10 Cost awareness & financing . 85

5.2 Pollution prevention . 86

5.2.1 Source reduction. 87

5.2.1.1 Product changes 89

5.2.1.2 Input material changes 89

5.2.1.3 Technology changes . 89

5.2.1.4 Good operating practices 90

5.2.2 Recycling. 91

5.2.3 Waste minimisation initiatives . 92

5.2.4 Examples of process-integrated measures 93

5.3 Air pollutant control .99

5.3.1 Volatile Organic Compounds (VOCs)100

5.3.1.1 Process vents.100

5.3.1.2 Storage, handling and transfer 104

5.3.1.3 Fugitives .106

5.3.1.4 Intermittent Vents .113

5.3.2 Combustion gases .113

5.3.3 Particulate matter 114

5.3.4 Performance of air pollutant control techniques .115

5.3.5 Monitoring of air emissions115

5.4 Water pollutant control .116

5.4.1 General prevention techniques116

5.4.2 Abatement techniques.118

5.4.3 Monitoring of water emissions .121

5.5 Wastes122

5.5.1 Waste prevention 122

5.5.2 Waste control122

5.6 Heat123

5.7 Vibration124

5.8 Noise124

5.9 Tools for the evaluation of techniques125

5.10 Application of techniques to existing installations .127

6 GENERIC BAT (BEST AVAILABLE TECHNIQUES) 131

6.1 Introduction 131

6.2 Management systems132

6.3 Pollution prevention and minimisation.133

6.4 Air pollutant control .136

6.5 Water pollutant control .140

6.6 Wastes and residues control141

7 ILLUSTRATIVE PROCESS: LOWER OLEFINS.143

7.1 General information143

7.1.1 Production capacity.144