Reference Document on Best Available Techniques in the

2,21
MB Production of Speciality Inorganic Chemicals

348
stron

6069
ID JRC-IPTS Instituto de Prospectiva Tecnológica (IPTS)

2007
rok

EXECUTIVE SUMMARYI

PREFACEXI

SCOPE XXV

1 GENERAL INFORMATION. 1

1.1 The chemical industry in Europe . 1

1.2 The SIC sector in Europe . 1

1.2.1 Production and market features 2

1.2.2 Companies’ profiles . 2

1.2.3 Sector’s outlook . 3

1.2.4 Competition. 3

1.3 Key environmental issues in the SIC sector . 4

2 COMMON APPLIED PROCESSES AND TECHNIQUES 5

2.1 General features of a SIC production process 5

2.2 Common process steps. 6

2.2.1 Dissolution of raw materials 7

2.2.2 Mixing. 8

2.2.3 Synthesis/reaction 9

2.2.4 Calcination . 9

2.2.5 Washing . 10

2.2.6 Drying 10

2.2.7 Size reduction and separation operations . 11

2.2.7.1 Dry milling/grinding 11

2.2.7.2 Wet milling 12

2.2.7.3 Sieving . 12

2.2.8 Condensation 13

2.2.9 Distillation. 13

2.2.10 Evaporation 15

2.2.11 Solid-liquid and solid-gas separations 16

2.2.12 Hydrolysis 17

2.2.13 Extraction 17

2.3 Raw and auxiliary materials and finished products storage and handling 18

2.4 Process-integrated measures for emissions prevention and reduction 18

2.5 Emissions abatement systems 19

2.5.1 General overview. 19

2.5.2 Waste gas treatment techniques . 20

2.5.3 Waste water treatment techniques 22

2.6 Process equipment and infrastructure. 23

2.6.1 Reactors . 23

2.6.2 Pumps, compressors and fans 25

2.6.3 Pipes 25

2.6.4 Valves 26

2.6.5 Utility fluids . 26

2.6.6 Cooling and refrigeration systems . 27

2.6.7 Cleaning systems . 28

2.6.8 Vacuum systems 29

2.6.9 Storage systems 29

2.6.10 Transfer and handling systems. 30

2.6.11 Monitoring practices 30

2.7 Energy supply 31

2.8 Management systems . 31

3 COMMON CONSUMPTION AND EMISSION LEVELS . 33

3.1 Air emissions. 33

3.1.1 Diffuse emissions to air 36

3.1.2 Point source emissions to air 36

3.2 Water emissions . 36

3.3 Wastes . 38

3.4 Odour and noise emissions .41

3.5 Energy consumption .41

3.6 Water consumption.41

3.7 Factors influencing consumption and emission levels41

3.7.1 Installation boundary definition and degree of integration.41

3.7.2 Determination of consumption and emission levels .42

3.7.3 Definition of waste .42

4 COMMON TECHNIQUES TO CONSIDER IN THE DETERMINATION OF BAT43

4.1 Structure of this chapter44

4.2 Raw and auxiliary materials and finished products supply, storage, handling and preparation44

4.2.1 Recycling or re-use of used containers/drums 44

4.2.2 Recycling of used ‘soft’ packaging materials.45

4.2.3 Storage of liquid and liquefied gas .46

4.2.4 Transfer and handling of liquid and liquefied gas 46

4.2.5 Storage of solids .46

4.2.6 Handling of solids.46

4.3 Synthesis/reaction/calcination 47

4.3.1 Substitution of raw materials 47

4.3.2 Improving reactor efficiencies48

4.3.3 Improving catalyst systems 49

4.3.4 Optimising processes50

4.4 Emissions abatement 51

4.4.1 Waste water treatment techniques 51

4.4.1.1 Separation or clarification techniques.53

4.4.1.1.1 Sedimentation (including coagulation/flocculation) of solids.53

4.4.1.1.2 Air flotation 55

4.4.1.1.3 Filtration .56

4.4.1.1.4 Membrane filtration (microfiltration or ultrafiltration).57

4.4.1.2 Physical and/or chemical techniques 58

4.4.1.2.1 Precipitation58

4.4.1.2.2 Crystallisation .60

4.4.1.2.3 Chemical oxidation .61

4.4.1.2.4 Chemical reduction .62

4.4.1.2.5 Nanofiltration (NF)/Reverse Osmosis (RO) .63

4.4.1.2.6 Adsorption 64

4.4.1.2.7 Ion exchange.66

4.4.1.2.8 Evaporation.67

4.4.1.2.9 Stripping .68

4.4.1.2.10 Incineration .69

4.4.2 Waste gas treatment techniques70

4.4.2.1 Waste gas treatment techniques to abate particulate matter70

4.4.2.1.1 Separators .70

4.4.2.1.2 Cyclones .72

4.4.2.1.3 Wet dust scrubber .73

4.4.2.1.4 Electrostatic precipitator (ESP).75

4.4.2.1.5 Fabric and ceramic filters76

4.4.2.1.6 Two-stage dust filter .78

4.4.2.1.7 Absolute High Efficiency Particule Arrestation (HEPA) filter.79

4.4.2.1.8 High Efficiency Air Filter (HEAF).81

4.4.2.1.9 Mist filter 82

4.4.2.2 Waste gas treatment techniques to abate VOCs and inorganic compounds84

4.4.2.2.1 Membrane separation84

4.4.2.2.2 Condensation and cryogenic condensation .86

4.4.2.2.3 Adsorption 87

4.4.2.2.4 Wet gas scrubber.89

4.4.2.2.5 Removal of HCN and NH3 from waste gases .91

4.4.2.2.6 Twin-bed oxidiser systems .93

4.4.2.2.7 Incineration of exhaust gases containing Volatile Organic Compounds (VOCs)94

4.4.2.2.8 Catalytic oxidation96

4.4.2.3 Waste gas treatment techniques to abate gaseous pollutants in combustion exhaust gases

.97

Speciality Inorganic Chemicals xvii

4.4.2.3.1 Sorbent injection for abating acid gases and fluorides . 97

4.4.2.3.2 Selective reduction of NOX (SNCR and SCR) . 99

4.4.2.3.3 Wet SO2 abatement techniques 100

4.4.3 Combined waste water and waste gas treatment techniques 101

4.4.3.1 Scrubbing and recycling of cyanides from waste gases and waste waters using hydrogen

peroxide (H2O2) as the oxidising agent 101

4.4.4 Treatment techniques of liquid (non-aqueous) and solid residues . 103

4.4.4.1 Thickening and dewatering 103

4.4.4.2 Stabilisation and conditioning 105

4.4.4.3 Thermal sludge reduction. 106

4.5 Infrastructure. 106

4.5.1 Cleaning-In-Place (CIP) systems of equipment contaminated with solid hazardous compounds

. 106

4.5.2 Use of a computerised control system to operate the plant 108

4.6 Energy . 109

4.6.1 Pinch methodology 109

4.7 Cross-boundary techniques 110

4.7.1 Ground protection 110

4.7.2 High level of education and continuous training of personnel. 112

4.7.3 Application of an Industry Code (IC) 113

4.7.4 Rainwater collection and treatment 114

4.7.5 Safety assessment. 115

4.7.5.1 Physico-chemical safety assessment of chemical reactions . 115

4.7.5.2 Prevention of runaway reactions 119

4.7.6 Environmental management tools 120

5 GENERIC BEST AVAILABLE TECHNIQUES . 129

6 ILLUSTRATIVE FAMILIES OF SPECIALITY INORGANIC CHEMICALS. 137

6.1 Speciality inorganic pigments 137