This document provides benchmarks for resource efficiency in the chemical industry. It defines resource efficiency and material, energy, work and plant efficiency. It gives examples of benchmarks for material, energy and pollution intensity for various chemical subsectors. It also provides benchmarks for chemical consumption and waste production for specific chemical processes like polystyrene and unsaturated polyester production. The document introduces best available techniques reference documents from the European Union that provide information on techniques and performance levels for improving resource efficiency in different chemical industry sectors.
This document provides an overview of good practices for chemicals management at chemical plants. It discusses good practices for core processes like synthesis and formulation, separation processes, equipment cleaning and maintenance, and storage. Specific practices include improving material efficiency, heat recovery, using enclosed cleaning systems, and computerized inventory management. The document also outlines challenges and good practices for infrastructure like boilers, cooling towers, heat exchangers, and pumps. Practices focus on improving energy efficiency, preventing leaks, reusing waste heat and water, and conducting regular maintenance.
This document provides an overview of green chemistry techniques to improve sustainability in chemical processes and products. It begins with examples of green chemistry and green engineering approaches. It then outlines the 12 principles of green chemistry and 12 principles of green engineering which guide the application of these techniques. The principles are organized into three categories: designing systems holistically, eliminating hazards and pollution, and maximizing resource efficiency. The document concludes with an introduction to green chemistry metrics for measuring sustainability and sections on material selection and reaction conditions.
The document discusses identifying and assessing chemicals management hotspots across a company's operations and a product's life cycle. It provides guidance on conducting a pre-assessment audit to collect relevant chemical and process data. It then describes assessing sustainability impacts at the company level by characterizing resource use, productivity, and waste generation. The document outlines mapping a product's full life cycle and indicating important environmental, social, and economic impacts at each stage. Key chemicals management hotspots are then prioritized for further improvement efforts.
This document outlines steps for companies to implement and monitor innovations selected during a previous planning process. It describes defining expected benefits, developing an implementation plan, and creating a monitoring plan to track progress. The implementation plan should identify what will be implemented, responsibilities, timelines, and resources needed. The monitoring plan outlines what will be tracked, who is responsible, frequency of monitoring, and how results will be reported to employees and management. Templates are provided to help structure the implementation and monitoring plans. The overall goal is to support efficient and cost-effective implementation while ensuring objectives are achieved.
E13 1 production planning optimization_final-webDir Jan
The product wheel concept organizes the production of multiple products that share common equipment into a fixed cycle or sequence. This sequence minimizes waste from chemical transitions by grouping products together that require similar changes, allowing easier transitions between products and reducing changeover time and costs. The goal is to maximize higher-volume, lower-cost transitions and minimize lower-volume, higher-cost transitions.
The document provides an introduction to value stream mapping (VSM) for small and medium enterprises in the chemical industry. It explains that VSM is a tool that maps the entire business process to identify sources of waste and their root causes. The goal is to reduce waste, decrease costs and increase productivity. The document outlines the key components of a VSM, including material flow, information flow and timeline. It also explains how a VSM is generated and some best practices. The reader will learn how to use VSM to improve operations in the chemical industry.
1) The document outlines a course on Cleaner Production Techniques, including the course details, outline, and evaluation procedure.
2) It then provides an overview of cleaner production, defining it as a preventative environmental strategy to increase efficiency and reduce risks. It discusses cleaner production principles and how it can identify ways to minimize waste and pollution.
3) The document lists 5 categories of cleaner production options: input material substitution, technology changes, improved operations, product modifications, and reuse/recycling. It provides examples of options within each category.
LCA is a tool to evaluate the environmental impacts of a product throughout its lifecycle, from raw material extraction, manufacturing, transportation, use, and waste management. It involves 5 stages: planning, screening, data collection, evaluation, and improvement assessment. The document then describes each stage of a product's lifecycle in more detail, including raw material extraction, manufacture, transportation, use, and waste management. It also discusses environmental auditing as a systematic review to check if environmental targets are being met and identifies areas for improvement in compliance, performance, and minimizing waste.
This document provides an overview of good practices for chemicals management at chemical plants. It discusses good practices for core processes like synthesis and formulation, separation processes, equipment cleaning and maintenance, and storage. Specific practices include improving material efficiency, heat recovery, using enclosed cleaning systems, and computerized inventory management. The document also outlines challenges and good practices for infrastructure like boilers, cooling towers, heat exchangers, and pumps. Practices focus on improving energy efficiency, preventing leaks, reusing waste heat and water, and conducting regular maintenance.
This document provides an overview of green chemistry techniques to improve sustainability in chemical processes and products. It begins with examples of green chemistry and green engineering approaches. It then outlines the 12 principles of green chemistry and 12 principles of green engineering which guide the application of these techniques. The principles are organized into three categories: designing systems holistically, eliminating hazards and pollution, and maximizing resource efficiency. The document concludes with an introduction to green chemistry metrics for measuring sustainability and sections on material selection and reaction conditions.
The document discusses identifying and assessing chemicals management hotspots across a company's operations and a product's life cycle. It provides guidance on conducting a pre-assessment audit to collect relevant chemical and process data. It then describes assessing sustainability impacts at the company level by characterizing resource use, productivity, and waste generation. The document outlines mapping a product's full life cycle and indicating important environmental, social, and economic impacts at each stage. Key chemicals management hotspots are then prioritized for further improvement efforts.
This document outlines steps for companies to implement and monitor innovations selected during a previous planning process. It describes defining expected benefits, developing an implementation plan, and creating a monitoring plan to track progress. The implementation plan should identify what will be implemented, responsibilities, timelines, and resources needed. The monitoring plan outlines what will be tracked, who is responsible, frequency of monitoring, and how results will be reported to employees and management. Templates are provided to help structure the implementation and monitoring plans. The overall goal is to support efficient and cost-effective implementation while ensuring objectives are achieved.
E13 1 production planning optimization_final-webDir Jan
The product wheel concept organizes the production of multiple products that share common equipment into a fixed cycle or sequence. This sequence minimizes waste from chemical transitions by grouping products together that require similar changes, allowing easier transitions between products and reducing changeover time and costs. The goal is to maximize higher-volume, lower-cost transitions and minimize lower-volume, higher-cost transitions.
The document provides an introduction to value stream mapping (VSM) for small and medium enterprises in the chemical industry. It explains that VSM is a tool that maps the entire business process to identify sources of waste and their root causes. The goal is to reduce waste, decrease costs and increase productivity. The document outlines the key components of a VSM, including material flow, information flow and timeline. It also explains how a VSM is generated and some best practices. The reader will learn how to use VSM to improve operations in the chemical industry.
1) The document outlines a course on Cleaner Production Techniques, including the course details, outline, and evaluation procedure.
2) It then provides an overview of cleaner production, defining it as a preventative environmental strategy to increase efficiency and reduce risks. It discusses cleaner production principles and how it can identify ways to minimize waste and pollution.
3) The document lists 5 categories of cleaner production options: input material substitution, technology changes, improved operations, product modifications, and reuse/recycling. It provides examples of options within each category.
LCA is a tool to evaluate the environmental impacts of a product throughout its lifecycle, from raw material extraction, manufacturing, transportation, use, and waste management. It involves 5 stages: planning, screening, data collection, evaluation, and improvement assessment. The document then describes each stage of a product's lifecycle in more detail, including raw material extraction, manufacture, transportation, use, and waste management. It also discusses environmental auditing as a systematic review to check if environmental targets are being met and identifies areas for improvement in compliance, performance, and minimizing waste.
The document discusses complaint handling and product recalls in pharmaceutical companies. It defines a complaint as an expression of customer dissatisfaction and explains the need for an effective complaint handling system to improve quality, maintain regulatory compliance and build customer relationships. It outlines the objectives, responsibilities and types of complaints, as well as the steps to handle complaints which include receiving, investigating, implementing corrective actions, providing feedback and reporting. The document also defines and discusses the objectives, classification, strategy and procedures for conducting an effective product recall.
Tài liệu GMP được chia sẻ bởi GMPc Việt Nam - Nhà tư vấn Sáng tạo, Chuyên nghiệp, Toàn diện Dự án Nhà máy GMP (EU, PIC/S, WHO, ASEAN), ISO 13485:2012, ISO/IEC 17025:2005, ISO 15189:2012, ISO 15378:2011, ISO 9001:2008
Webinar on Best Environmental Practices (BEP) for Textiles (per- and polyfluo...OECD Environment
On 12 September 2018, Eeva Leinala of the OECD Environment Directorate and Kai Schubert from the Chemours Company presented Best Environmental Practices in the textile industry.
Using Single-use Technology to Overcome the Challenges of ADC ProcessingMerck Life Sciences
Participate in the interactive webinar: http://bit.ly/SU-ADCWebinar
Challenges of ADC manufacturing can be tackled by adopting single-use technology. Solutions will be presented about how to overcome concerns and implement a processing platform, supported through a strong vendor-manufacturer relationship.
Explore our webinar library: www.merckmillipore.com/webinars
The document discusses cleaner production as a strategy for sustainable industrial development. It defines cleaner production as the continuous application of preventive environmental strategies to processes, products, and services to increase efficiency and reduce risks to humans and the environment. The document outlines the principles of cleaner production, including precaution, prevention, and integration. It also describes the methodology, which involves 6 phases: commitment, analysis, opportunity generation, solution selection, implementation, and maintenance. Examples of cleaner production strategies and applications in industry are provided.
Current Goods Manufacturing Practice & Industrial ManagementLukman N Kerur
This document provides an overview of CGMP (Current Good Manufacturing Practice) and industrial management. It discusses key aspects of CGMP such as plant layout, services, equipment, production organization, materials management, handling and transportation, inventory management, production planning and control, sales forecasting, budgeting, quality management, and industrial relationships. The objectives of CGMP are to ensure product quality and consistency in manufacturing. Key elements outlined include facilities and equipment requirements, quality control of materials, production systems, and regulatory compliance.
Webinar on greener water and oil repellents in the textile industry: Occupati...OECD Environment
On 30 October 2018, Eeva Leinala of the OECD Environment Directorate; Ruth Garcia, Gemma Janer and Marc Torrentellé from LEITAT Technological Center; and Julio Fierro of the Centro Tecnológico de Investigación Multisectorial (CETIM) presented the MIDWOR-LIFE project that aims to mitigate the environmental, health and safety impacts of current Durable Water and Oil Repellents and available alternatives by looking at their environmental impact and technical performance.
The document discusses key aspects of equipment and raw materials in pharmaceutical quality assurance. It covers topics like equipment selection criteria, purchase specifications, maintenance, calibration, and documentation. For raw materials, it discusses purchase, receiving, sampling, testing, storage and maintenance procedures. Selection of reliable vendors, approved specifications, and ensuring quality of materials is important. Proper identification, storage conditions, and FIFO principle must be followed for raw materials.
Cleaner production is an approach that focuses on preventing pollution at the source by reducing raw material, water and energy usage, minimizing waste generation, and increasing production efficiency. [1] Traditional "end-of-pipe" corrective controls are costly and do not address the root causes of pollution, whereas cleaner production considers the entire lifecycle and prioritizes pollution prevention over treatment. [2] Implementing cleaner production techniques such as process modifications, good housekeeping practices, material substitutions and equipment upgrades can boost profits through increased productivity while decreasing environmental impacts. [3]
The document discusses pilot plant scale-up techniques. A pilot plant allows examination of a product and process on an intermediate scale before committing to full-scale production. It is important for identifying critical process parameters, producing samples for evaluation, and providing data to determine feasibility of full-scale production. The document outlines general considerations for pilot plant setup and operation including personnel requirements, equipment needs, production rates, process evaluation, and GMP compliance.
Introduction to Platform Technology for Bio pharmaceutical IndustrySenthil Kumar
This document provides an introduction to platform technology in the biopharmaceutical industry. It discusses how platform technology involves engineering antibodies and biologics using standardized processes to enhance drug effectiveness. Platform processes are most established for manufacturing monoclonal antibodies. The use of platform technologies emerged in the 1990s and focuses on leveraging prior knowledge from molecule to molecule to improve efficiency, quality and reduce risks. Platform technologies allow for more rapid and cost-effective product development and commercialization. They provide benefits like reduced development costs and times, consistency in quality and performance, and improved asset utilization.
This document discusses MnTAP's efforts to help Minnesota businesses reduce solvent usage for degreasing operations while maintaining effectiveness. MnTAP evaluated products at 23 facilities to identify alternatives that reduce VOC emissions and human health risks. Some successful substitutions included replacing lacquer thinner containing HAPs with acetone at one company, and replacing three solvents with a single water-based cleaner at another company. These changes helped businesses reduce pollution while lowering costs. The document provides additional examples of facilities that achieved VOC and waste reductions through alternative brake cleaners and degreasing products recommended by MnTAP.
The document outlines FDA procedures and responsibilities for product recalls. It discusses how recalls are initiated and classified into three classes based on health hazard. FDA monitors recall effectiveness and will terminate a recall when corrective actions are complete. Recalling firms are responsible for determining the scope and depth of recalls, communicating with FDA and customers, and issuing any necessary press releases. The document provides an overview of drug recalls that occurred in 2013.
Webinar on Best Environmental Practices for Class B Firefighting Foams - Tom ...OECD Environment
On 29 January 2019, Eeva Leinala of the OECD Environment Directorate and Thomas Cortina from the Fire Fighting Foam Coalition and Mitch Hubert from Perimeter Solutions have addressed Best Environmental Practices for Class B Firefighting Foams in the context of management of per- and polyfluoroalkyl Substances (PFASs).
The development of new chemistry-based products for life science markets requires the expertise of talented researchers. However, these same researchers are typically not prepared to solve the many other critical problems necessary for successful commercialization. Without the requisite expertise in scale up and commercialization, many early-stage companies find that competitors beat them to the market or resources run out before success can be achieved.
This document discusses cleaner technology and waste reduction strategies. It defines cleaner technology as the continuous application of preventative strategies to increase efficiency and reduce risks. It discusses various cleaner technology practices like good housekeeping, input substitution, and technology changes. The benefits of cleaner technology include improving the environment, increasing economic benefits and productivity, and gaining competitive advantage. Barriers include a lack of information and competing priorities, while drivers include improvements in productivity and environmental reports.
This document outlines the process and considerations for pilot plant scale-up of pharmaceutical manufacturing. It defines a pilot plant as transforming a lab-scale formula into a viable product through developing a reliable manufacturing procedure. The objectives of a pilot plant are to produce stable dosage forms, review equipment, establish production guidelines and controls, evaluate and validate processes and equipment, and determine a master manufacturing formula. Key steps involve reviewing the formula, approving raw materials, selecting appropriate sized equipment, determining production rates, developing standard operating procedures, and conducting stability testing. Personnel with both scientific and engineering knowledge are needed, and facilities must allow for physical testing, equipment, raw materials storage, and record keeping. Adherence to good manufacturing practices is also important for a
This document provides guidance on generating innovative options to improve chemicals management. It outlines collecting additional necessary information, developing a chemicals management innovation diagram to define challenges and opportunities, searching for potential solutions by analyzing causes and trends, considering different dimensions of innovation, and capturing options in a summary table. The final step is to build an innovation network to help develop and implement options by filling knowledge gaps.
This document provides an introduction to classifying chemicals according to their hazards. It discusses the Globally Harmonized System of Classification and Labelling of Chemicals (GHS), which provides a common approach to classifying chemicals and communicating hazard information. The GHS system classifies chemicals according to their physical, health, and environmental hazards. It then provides standardized pictograms, signal words, and hazard statements to communicate these hazards on labels and Safety Data Sheets. The goal of the GHS is to harmonize chemical classification and hazard communication globally in order to better protect human health and the environment.
B12 2 assess customer unmet needs_final-pdfDir Jan
The document discusses identifying customer unmet needs to drive innovation. It describes characterizing customer segments and jobs, assessing desired and undesired outcomes, and using this information to complete a value proposition canvas to identify unmet needs. The unmet needs are customer jobs, pains, and gains that are not fully addressed by current product offerings. Identified unmet needs will be combined with chemicals management hotspots to generate innovative solutions.
E11 1 intro to operational-excellence_final-webDir Jan
Operational excellence tools can help chemical companies continuously improve performance. The document discusses SMED, mistake proofing, statistical process control, and design of experiments. SMED aims to reduce waste and changeover times. Mistake proofing prevents errors from causing defects. Statistical process control monitors processes to ensure quality. Design of experiments identifies key process parameters and opportunities to optimize processes using minimal experiments. These approaches support waste reduction and maximizing resource efficiency in chemical production.
The document discusses complaint handling and product recalls in pharmaceutical companies. It defines a complaint as an expression of customer dissatisfaction and explains the need for an effective complaint handling system to improve quality, maintain regulatory compliance and build customer relationships. It outlines the objectives, responsibilities and types of complaints, as well as the steps to handle complaints which include receiving, investigating, implementing corrective actions, providing feedback and reporting. The document also defines and discusses the objectives, classification, strategy and procedures for conducting an effective product recall.
Tài liệu GMP được chia sẻ bởi GMPc Việt Nam - Nhà tư vấn Sáng tạo, Chuyên nghiệp, Toàn diện Dự án Nhà máy GMP (EU, PIC/S, WHO, ASEAN), ISO 13485:2012, ISO/IEC 17025:2005, ISO 15189:2012, ISO 15378:2011, ISO 9001:2008
Webinar on Best Environmental Practices (BEP) for Textiles (per- and polyfluo...OECD Environment
On 12 September 2018, Eeva Leinala of the OECD Environment Directorate and Kai Schubert from the Chemours Company presented Best Environmental Practices in the textile industry.
Using Single-use Technology to Overcome the Challenges of ADC ProcessingMerck Life Sciences
Participate in the interactive webinar: http://bit.ly/SU-ADCWebinar
Challenges of ADC manufacturing can be tackled by adopting single-use technology. Solutions will be presented about how to overcome concerns and implement a processing platform, supported through a strong vendor-manufacturer relationship.
Explore our webinar library: www.merckmillipore.com/webinars
The document discusses cleaner production as a strategy for sustainable industrial development. It defines cleaner production as the continuous application of preventive environmental strategies to processes, products, and services to increase efficiency and reduce risks to humans and the environment. The document outlines the principles of cleaner production, including precaution, prevention, and integration. It also describes the methodology, which involves 6 phases: commitment, analysis, opportunity generation, solution selection, implementation, and maintenance. Examples of cleaner production strategies and applications in industry are provided.
Current Goods Manufacturing Practice & Industrial ManagementLukman N Kerur
This document provides an overview of CGMP (Current Good Manufacturing Practice) and industrial management. It discusses key aspects of CGMP such as plant layout, services, equipment, production organization, materials management, handling and transportation, inventory management, production planning and control, sales forecasting, budgeting, quality management, and industrial relationships. The objectives of CGMP are to ensure product quality and consistency in manufacturing. Key elements outlined include facilities and equipment requirements, quality control of materials, production systems, and regulatory compliance.
Webinar on greener water and oil repellents in the textile industry: Occupati...OECD Environment
On 30 October 2018, Eeva Leinala of the OECD Environment Directorate; Ruth Garcia, Gemma Janer and Marc Torrentellé from LEITAT Technological Center; and Julio Fierro of the Centro Tecnológico de Investigación Multisectorial (CETIM) presented the MIDWOR-LIFE project that aims to mitigate the environmental, health and safety impacts of current Durable Water and Oil Repellents and available alternatives by looking at their environmental impact and technical performance.
The document discusses key aspects of equipment and raw materials in pharmaceutical quality assurance. It covers topics like equipment selection criteria, purchase specifications, maintenance, calibration, and documentation. For raw materials, it discusses purchase, receiving, sampling, testing, storage and maintenance procedures. Selection of reliable vendors, approved specifications, and ensuring quality of materials is important. Proper identification, storage conditions, and FIFO principle must be followed for raw materials.
Cleaner production is an approach that focuses on preventing pollution at the source by reducing raw material, water and energy usage, minimizing waste generation, and increasing production efficiency. [1] Traditional "end-of-pipe" corrective controls are costly and do not address the root causes of pollution, whereas cleaner production considers the entire lifecycle and prioritizes pollution prevention over treatment. [2] Implementing cleaner production techniques such as process modifications, good housekeeping practices, material substitutions and equipment upgrades can boost profits through increased productivity while decreasing environmental impacts. [3]
The document discusses pilot plant scale-up techniques. A pilot plant allows examination of a product and process on an intermediate scale before committing to full-scale production. It is important for identifying critical process parameters, producing samples for evaluation, and providing data to determine feasibility of full-scale production. The document outlines general considerations for pilot plant setup and operation including personnel requirements, equipment needs, production rates, process evaluation, and GMP compliance.
Introduction to Platform Technology for Bio pharmaceutical IndustrySenthil Kumar
This document provides an introduction to platform technology in the biopharmaceutical industry. It discusses how platform technology involves engineering antibodies and biologics using standardized processes to enhance drug effectiveness. Platform processes are most established for manufacturing monoclonal antibodies. The use of platform technologies emerged in the 1990s and focuses on leveraging prior knowledge from molecule to molecule to improve efficiency, quality and reduce risks. Platform technologies allow for more rapid and cost-effective product development and commercialization. They provide benefits like reduced development costs and times, consistency in quality and performance, and improved asset utilization.
This document discusses MnTAP's efforts to help Minnesota businesses reduce solvent usage for degreasing operations while maintaining effectiveness. MnTAP evaluated products at 23 facilities to identify alternatives that reduce VOC emissions and human health risks. Some successful substitutions included replacing lacquer thinner containing HAPs with acetone at one company, and replacing three solvents with a single water-based cleaner at another company. These changes helped businesses reduce pollution while lowering costs. The document provides additional examples of facilities that achieved VOC and waste reductions through alternative brake cleaners and degreasing products recommended by MnTAP.
The document outlines FDA procedures and responsibilities for product recalls. It discusses how recalls are initiated and classified into three classes based on health hazard. FDA monitors recall effectiveness and will terminate a recall when corrective actions are complete. Recalling firms are responsible for determining the scope and depth of recalls, communicating with FDA and customers, and issuing any necessary press releases. The document provides an overview of drug recalls that occurred in 2013.
Webinar on Best Environmental Practices for Class B Firefighting Foams - Tom ...OECD Environment
On 29 January 2019, Eeva Leinala of the OECD Environment Directorate and Thomas Cortina from the Fire Fighting Foam Coalition and Mitch Hubert from Perimeter Solutions have addressed Best Environmental Practices for Class B Firefighting Foams in the context of management of per- and polyfluoroalkyl Substances (PFASs).
The development of new chemistry-based products for life science markets requires the expertise of talented researchers. However, these same researchers are typically not prepared to solve the many other critical problems necessary for successful commercialization. Without the requisite expertise in scale up and commercialization, many early-stage companies find that competitors beat them to the market or resources run out before success can be achieved.
This document discusses cleaner technology and waste reduction strategies. It defines cleaner technology as the continuous application of preventative strategies to increase efficiency and reduce risks. It discusses various cleaner technology practices like good housekeeping, input substitution, and technology changes. The benefits of cleaner technology include improving the environment, increasing economic benefits and productivity, and gaining competitive advantage. Barriers include a lack of information and competing priorities, while drivers include improvements in productivity and environmental reports.
This document outlines the process and considerations for pilot plant scale-up of pharmaceutical manufacturing. It defines a pilot plant as transforming a lab-scale formula into a viable product through developing a reliable manufacturing procedure. The objectives of a pilot plant are to produce stable dosage forms, review equipment, establish production guidelines and controls, evaluate and validate processes and equipment, and determine a master manufacturing formula. Key steps involve reviewing the formula, approving raw materials, selecting appropriate sized equipment, determining production rates, developing standard operating procedures, and conducting stability testing. Personnel with both scientific and engineering knowledge are needed, and facilities must allow for physical testing, equipment, raw materials storage, and record keeping. Adherence to good manufacturing practices is also important for a
This document provides guidance on generating innovative options to improve chemicals management. It outlines collecting additional necessary information, developing a chemicals management innovation diagram to define challenges and opportunities, searching for potential solutions by analyzing causes and trends, considering different dimensions of innovation, and capturing options in a summary table. The final step is to build an innovation network to help develop and implement options by filling knowledge gaps.
This document provides an introduction to classifying chemicals according to their hazards. It discusses the Globally Harmonized System of Classification and Labelling of Chemicals (GHS), which provides a common approach to classifying chemicals and communicating hazard information. The GHS system classifies chemicals according to their physical, health, and environmental hazards. It then provides standardized pictograms, signal words, and hazard statements to communicate these hazards on labels and Safety Data Sheets. The goal of the GHS is to harmonize chemical classification and hazard communication globally in order to better protect human health and the environment.
B12 2 assess customer unmet needs_final-pdfDir Jan
The document discusses identifying customer unmet needs to drive innovation. It describes characterizing customer segments and jobs, assessing desired and undesired outcomes, and using this information to complete a value proposition canvas to identify unmet needs. The unmet needs are customer jobs, pains, and gains that are not fully addressed by current product offerings. Identified unmet needs will be combined with chemicals management hotspots to generate innovative solutions.
E11 1 intro to operational-excellence_final-webDir Jan
Operational excellence tools can help chemical companies continuously improve performance. The document discusses SMED, mistake proofing, statistical process control, and design of experiments. SMED aims to reduce waste and changeover times. Mistake proofing prevents errors from causing defects. Statistical process control monitors processes to ensure quality. Design of experiments identifies key process parameters and opportunities to optimize processes using minimal experiments. These approaches support waste reduction and maximizing resource efficiency in chemical production.
This document provides information on skin protection methods for chemical handling personnel. It discusses how harmful substances can damage the skin through chemical or physical reactions. The presentation then outlines various measures to protect skin, including substitution of dangerous chemicals, technical controls like ventilation, organizational controls like training and rules, and behavioral controls like wearing protective equipment and cleaning skin. It emphasizes performing a risk assessment and consulting safety data sheets to determine the proper protective measures for specific chemicals.
This document discusses container cleaning techniques to minimize risks from explosive atmospheres. It notes that residues and vapors in empty containers can create explosive mixtures when combined with air if ignited. It recommends cleaning containers through repeated rinsing or steam cleaning for at least 10 minutes to remove residues. It also suggests reducing air volume in containers by filling them with water or inert gas before working on them to prevent explosions. Proper cleaning and disposal of containers is important to prevent environmental contamination and health risks from inhalation of vapors.
C12 1 moving towards safer chemicals_final-webDir Jan
This document provides guidance on assessing and substituting chemicals with safer alternatives. It outlines a 5-step process for moving towards safer chemicals: 1) define the problem and prioritize chemicals, 2) search for alternatives, 3) assess and compare alternatives, 4) test alternatives at a pilot scale, and 5) implement and improve the alternative. It also introduces several tools for comparing chemical hazards, such as the GHS Column Model, which allows comparing the hazards of chemicals based on their GHS classifications and process conditions. The document emphasizes that the goal of substitution is to reduce risks to human health and the environment by transitioning to less hazardous chemical substances and processes.
C22 2 voc substitution techniques _final-webDir Jan
This document provides an overview of cleaning techniques and solvent substitution methods in the chemical industry, with a focus on reducing VOC emissions. It introduces water-based cleaning systems, carbon dioxide cleaning, plasma technology, UV cleaning, laser cleaning, and thermal paint stripping as alternatives to VOC solvents. These new techniques can help reduce solvent consumption, emissions, and improve environmental and health impacts compared to traditional solvent-based cleaning.
This document provides an introduction to universal safety rules for workers handling chemicals. It outlines key safety rules regarding hazard identification, preventing slips and falls, not rushing, using personal protective equipment, ergonomic workstations, skin protection, electricity safety, keeping escape routes clear, emergency response, and asking questions. Specific safety rules for chemical use cover obtaining information on chemicals and their hazards, proper storage quantities and containers, ventilation during decanting, waste handling, and solvent safety. The goal is to introduce basic safety practices to ensure personnel safety.
Emergency escape routes must be planned, indicated, and properly maintained in chemical facilities to ensure safety. A designated person should periodically check escape routes and their safety features. Escape routes must be obstacle-free, clearly marked paths that lead to open spaces. Their design must be approved by authorities and accommodate the building layout and number of occupants. Workers should be trained on escape routes and informed of any modifications.
This document discusses solvents used widely in industry and their hazards. It explains that solvents can harm human health and the environment if not properly handled or substituted. The document outlines prevention measures including substitution, technical measures like ventilation, and organizational measures to reduce exposure to solvents. It provides examples of ventilation systems and storage practices that can help minimize risks from solvents.
This document provides recommendations for establishing safe internal pedestrian routes in industrial facilities. It discusses minimizing risks from falls, trips, slips, and collisions by ensuring walkways are level and clear of obstacles. Proper lighting, railings on stairways and high-risk areas, and clearly marked hazards are emphasized. The document also stresses the importance of training workers and appointing those responsible for route maintenance and emergency response.
This document provides an overview of pigging systems, which are used to recover product remaining in pipes after processing by pushing it along with a "pig". It describes the components and functioning of single and dual pig systems, including the steps of product pumping, propellant pumping to push the pig, rinsing the pig, and returning it to the starting position. Potential constraints like pipe and valve specifications and pig material resistance are reviewed. Case studies demonstrate how pigging systems provided infrastructure and operational cost savings for chemical and polymer plants over conventional pipeline systems.
D14 1 personal protective equipment_final-webDir Jan
The document provides an overview of personal protective equipment (PPE). It discusses the different types of PPE including head, eye, hearing, hand, foot, respiratory, and body protection. It provides examples of equipment for each type and guidance on selecting the appropriate PPE for different hazards. The document also discusses an example of PPE requirements for spray varnishing and painting.
D18 1 safety in gas tank handling_final-webDir Jan
Gas tanks must be properly handled to avoid damage. This presentation outlines safety precautions for handling gases, including proper storage, transport, ventilation, and maintenance. Technical measures include using appropriate materials for pipes and fittings, installing shut-off valves, and grounding equipment. Organizational measures involve training workers, classifying hazard zones, and ensuring emergency equipment and escape routes.
The document outlines the process for selecting innovative options generated in an earlier phase. It involves screening options to determine suitability for further analysis, analyzing economic, environmental and social impacts of suitable options, prioritizing options according to benefits, and scheduling high priority options for implementation. Key steps include using matrices to rate and rank options, considering factors like costs, savings, feasibility and priority to select the options with the highest potential for the company to implement.
This document provides an overview of green chemistry techniques to improve sustainability in chemical processes and products. It begins with examples of green chemistry and green engineering approaches. It then outlines the 12 principles of green chemistry and 12 principles of green engineering which guide the application of these techniques. The principles are organized into three categories: designing systems holistically, eliminating hazards and pollution, and maximizing resource efficiency. The document concludes with an introduction to green chemistry metrics for measuring sustainability and sections on material selection and reaction conditions.
This document outlines the initial steps for conducting an Innovation Assessment and Management Cycle (IAMC) project with a company. It involves selecting a suitable company, understanding its value chain and experience with sustainability and innovation. The consultant forms an innovation team with the company and sets project ambitions. The goal is to lay the foundation for identifying opportunities to improve the company's management of chemicals and increase business performance through innovation.
The document discusses reviewing implementation results and setting up a continuous improvement program. It recommends that companies (1) compare achieved results to targets, learn lessons, and identify new opportunities for improvement; (2) establish key performance indicators to measure progress towards goals; and (3) develop an ongoing program including redefining goals and identifying activities to continuously improve chemical management and innovation capabilities. The continuous improvement program will help companies sustain long-term success.
Some physical measures that can be taken to limit the propagation of a fire include:
- Using fire-resistant construction materials for walls, ceilings, pillars/beams
- Establishing safety distances between buildings based on their construction type and materials
- Treating exterior walls to make them fire-resistant, for example by applying fire-resistant coatings
- Limiting and treating openings in walls, such as installing fire-resistant doors and windows or not aligning openings
- Segregating hazardous materials storage areas and compartments with fire-resistant walls
- Establishing fire compartments within buildings
Dyes and Pigments Manufacturing Industrial Waste Water Treatment MethodologyIRJET Journal
This document discusses treatment methods for wastewater from dyes and pigments manufacturing industries. It analyzes the characteristics of the wastewater, which contains high levels of ammonia, chemical oxygen demand (COD), and total dissolved solids. It evaluates different coagulation and flocculation treatments using various coagulants like ferrous sulfate, ferric chloride, and polyaluminum chloride. The best treatment found was a combination of ferric chloride and polyaluminum chloride coagulants with sodium hydroxide as a flocculant, which achieved the highest removal rates of COD, ammonia, and total dissolved solids.
The petrochemical industry in the Netherlands consumes a large amount of energy, accounting for over 20% of the country's total energy consumption. Incorporating the industry's energy use into national energy statistics poses challenges due to the complex nature of petrochemical processes that transform oil and gas into both energy products and chemical products. Close communication with industry is needed to properly classify products and collect accurate data. Recommendations include improving communication within companies and between statistical agencies and industry, developing rules to classify products, and adapting international reporting guidelines to better account for energy transformations in the chemical industry.
Optimising Sludge Handling & Digester Operationmatthewsmyth
The document discusses opportunities for optimizing sludge handling and digester operation at wastewater treatment plants to reduce energy usage and costs. It notes that the water industry uses a significant amount of energy and that reductions are needed to meet climate change targets. Specific examples are given where optimizing hydraulic retention time in sludge storage tanks, adjusting aeration levels, reducing polymer usage, and improving thickener operation could yield substantial cost savings through reduced energy and chemical usage. The document emphasizes that large plants have the most potential for savings, and realizing those savings requires understanding basic design principles and operator training.
TREATMENT OF DISTILLERY EFFLUENT BY USING ADVANCED OXIDATION PROCESSIRJET Journal
This document summarizes a study on treating distillery effluent using an advanced oxidation process called electro-Fenton process. It discusses the characteristics of raw distillery effluent and its negative environmental impacts. The electro-Fenton process uses Fenton's reagent of hydrogen peroxide and ferrous ions along with electrodes to effectively treat distillery effluent. Response surface methodology was applied to optimize the process parameters - Fenton dosage, reaction time, and applied current. The results showed that a Fenton dosage of 0.01 mol/L, reaction time of 30 minutes, and current of 2A achieved over 90% removal efficiency of COD from distillery effluent.
This document discusses AGC's efforts to reduce its environmental impact and produce more sustainable products. It provides data on AGC's CO2 emissions and goals for reduction. It also outlines AGC's research focused on energy efficiency, renewable energy, and reducing hazardous materials. AGC aims to decrease raw material and energy usage in production, lower emissions, boost recycling, and develop glass products that provide energy savings to customers.
This document provides an overview of surface cleaning techniques and their role in reducing solvent emissions. It introduces improved cleaning technologies that can abate solvent use, such as enclosed cleaning machines and solvent recovery systems. Enclosed cleaning systems can reduce direct solvent emissions by over 90% compared to open systems, and solvent consumption by 60-80%. The latest generation of closed loop systems with vacuum technology achieve very low VOC emissions of under 0.1 kg/h. Adopting best practices like solvent recycling and recovery through distillation can recover up to 99.9% of solvents.
This document provides an overview of key concepts for preparing a greenhouse gas inventory for the waste sector according to the IPCC 1996 Guidelines and Good Practice Guidance 2000. It discusses major methane and nitrous oxide emission sources from waste including solid waste disposal sites, wastewater treatment, and waste incineration. The document also outlines the steps for inventory preparation using the IPCC methodology including identifying key source categories, selecting calculation methods, estimating uncertainties, and reporting emissions.
Ricoh aims to reduce its environmental impact through technical innovation and encouraging employee participation in environmental activities. It has set goals to reduce environmental impact by 25% by 2013, 30% by 2030, and 87.5% by 2050 from a 2010 baseline. Ricoh is developing a circular economy approach through remanufacturing used products and parts to extend their lifecycles and reduce waste. This includes remanufacturing copiers, printers, toner cartridges, and other components, saving costs compared to new production and lowering environmental impact. Ricoh's long term strategy is transitioning to resource conservation and keeping environmental impact within Earth's limits.
The document discusses various oxygen measurement applications across different industries including storage and environment, upstream and processing, recovery and waste, downstream and purification. It provides examples of successful oxygen measurement applications in pharmaceutical API manufacturing, blanketing in mixing stirrers, centrifuge inertization, general manufacturing tank storage, and chemical manufacturing such as oxidation in extruders and waste-gas reclaiming.
This document provides an outline and overview of a presentation on controlling emissions of volatile organic compounds (VOCs) through biofiltration. It discusses VOCs emissions in Canada, traditional removal technologies and their limitations, and how biofiltration works as a green alternative. It then presents a case study of a commercial-scale biofiltration system used by a printed circuit board industry in Toronto to remove VOCs such as glycol and acetates from its air streams, achieving over 90% removal efficiency. The system used two biofilter units with different media that maintained effective operation even in winter.
This document summarizes the characteristics and polluting effects of textile organic dyes, and procedures for separating and eliminating them from industrial effluents. It discusses that textile dyeing is a major source of organic water pollution worldwide. Textile dyes are recalcitrant and can remain in the environment for long periods. The document outlines the classification and characteristics of natural and synthetic textile dyes. It also describes common textile processing steps that generate large volumes of contaminated wastewater containing dyes, chemicals, and other pollutants. Current treatment methods aim to remove over 70% of contaminants like COD, BOD, dyes before wastewater discharge to meet environmental standards.
The document summarizes a presentation about sustainability in the textile industry. It discusses current challenges around managing environmental, health and safety issues. It introduces the bluesign standard, which takes a holistic approach to sustainability by focusing on optimizing input streams and processes throughout the textile production chain. The standard aims to increase transparency, reduce resource usage, and move the industry towards best available technologies.
This document outlines a thesis project studying effluent treatment plant (ETP) processes for tanneries in Hazaribagh, Bangladesh. The objectives are to study wastewater quality, installation and operating costs of different ETPs, and develop a theoretical cost-effective ETP model. The methodology includes laboratory experiments to test wastewater parameters and an industrial data analysis of ETP costs. Preliminary results found that biological treatment processes had higher installation costs but lower operating costs than chemical treatment. The thesis will conclude by recommending an optimized ETP design for tanneries based on the analysis.
The document summarizes the European Commission's Eco-Design regulation for electricity transformers. It established efficiency tiers in 2015 and 2021 to reduce transformer losses and greenhouse gas emissions. By optimizing transformer designs, the regulation is expected to save 16.2 TWh of energy per year by 2025, reducing CO2 emissions by 3.7 million tons. The regulation standardized transformer types and significantly reduced the allowed losses for new transformers to meet the tiers. This led manufacturers to offer fewer, more efficient transformer models.
Ricoh: Manufacturing in the Circular Economy - Base Cities Birmingham - April...Andy Whyle
Presentation made at Base Cities Birimingham (April 2013) showing Ricoh's approach to Zero Waste, Remanufacturing and how these aspects engage with the circular economy.
The presentation shows how Ricoh has implemented reverse logistics to retain control of it's assets (products), and then remanufactured the assets to reduce environmental impact and increase resource conservation. This falls in line with Ricoh's Comet Circle life cycle philosophy and Zero Waste to Landfill standard.
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The document discusses life cycle assessment (LCA) of palm biodiesel production in Brazil. It presents the LCA methodology and inventory for palm biodiesel, including energy inputs and outputs for agricultural, extraction and processing stages. Cogeneration using biomass residues significantly improves energy efficiency and sustainability indicators. Compared to fossil diesel, palm biodiesel production with cogeneration reduces impacts across multiple categories like land use, ozone depletion and non-renewable energy consumption. LCA is an important tool for sustainability certification but has limitations that can be addressed through standardization and considering uncertainties.
1) Newreka Green Synth Technologies developed a green chemistry solution for manufacturing an anti-retroviral drug that reduced the E-factor and improved yield.
2) Their solution reduced the E-factor from 32 to 6 and improved the theoretical yield from 25% to 86% across six stages of production.
3) Their approach included recycling aqueous and solvent streams, replacing hazardous solvents, and eliminating the use of solvents in some steps.
This document reviews biomass gasification technologies for producing hydrogen-rich syngas to be used in ammonia production as an alternative to natural gas. It summarizes the conventional natural gas-based process and outlines a potential process using biomass gasification. Several gasification technologies are assessed based on syngas composition, efficiency, operating conditions, scale, and experience with biomass. The goal is to evaluate biomass gasification for ammonia production through life cycle assessment and techno-economic analysis to identify environmental and economic impacts compared to conventional production.
This document provides an introduction to green chemistry, including its goals and principles. Green chemistry aims to reduce pollution by designing chemical products and processes that minimize hazardous substances. Its goals are to make chemistry safer and more efficient while producing less waste. The 12 principles of green chemistry were introduced by Paul Anastas and John Warner, including preventing waste, safer solvents and reagents, energy efficiency, and atom economy. Atom economy measures how many atoms from the reactants end up in the final product versus byproducts and waste, with 90% or higher considered good. Examples show how new synthetic methods can improve atom economy from 47% to 100%.
This document provides an overview of three tools - asking "why" five times, fishbone diagrams, and nine windows - that can be used to analyze the causes of problems and generate innovative solutions during chemical management assessment and option generation phases. The tools are intended to be used in brainstorming workshops to identify root causes of hotspots and develop options by considering different factors, perspectives, and time dimensions involved in the system. Templates and instructions are provided for each tool.
The document introduces Clean-in-Place (CIP) technology, which allows for cleaning of processing equipment internally without disassembly using automated cleaning cycles. It discusses the benefits of CIP systems including improved cleaning results, safety, and resource savings. The document also provides an overview of CIP system design considerations and optimization strategies.
Cleaning operations are performed by all manufacturers and industrial users of chemicals. They are typically not value-adding and can be a significant source of waste, costs, and pollution if not conducted properly. This document provides an overview of cleaning purposes, techniques, and the differences between clean-in-place (CIP) and clean-out-of-place (COP) methods. CIP involves circulating cleaning solutions through tanks and pipelines while parts are in place, while COP requires disassembling equipment and placing parts in cleaning tanks. The document aims to improve understanding of cleaning to enhance operational productivity and efficiency.
C13 1 secondary raw materials (polymers)_final-webDir Jan
This document discusses recycling plastics and polymers. It begins by outlining the global production and environmental impacts of plastics. Different waste management options are described, with recycling presented as preferable to disposal. Two main types of recycling are discussed: mechanical recycling and chemical recycling. Examples are provided of companies recycling internally, using secondary raw materials, and reclaiming waste. Overall recycling is positioned as beneficial for substituting raw materials, improving efficiency and reducing pollution.
The document discusses explosion hazards and preventing the formation of potentially explosive atmospheres. It explains that an explosion occurs when a combustible substance is dispersed in air and an ignition source is present, forming a potentially explosive atmosphere. To prevent explosions, measures aim to avoid creating explosive atmospheres or igniting them. This involves substituting dangerous substances, limiting concentrations, inerting containers, using closed systems, ventilation, proper storage and labeling, and protecting equipment from thermal impacts.
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The document discusses fire protection measures for welding and cutting operations. It identifies the main hazards of these operations as flames, sparks, and droplets which can ignite fires. It recommends obtaining permits, preparing work areas, removing combustible materials, installing fire protections, wearing protective equipment, and monitoring work areas after operations to prevent fires and explosions from welding and cutting activities.
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This document discusses rules for the storage of hazardous materials. It begins by outlining potential dangers of improper storage, such as fires, explosions, and toxic vapors. It then describes a storage concept that matches storage conditions and measures to substance hazards. This involves identifying substances, quantities, hazards and storage locations on a map. It also discusses general storage rules like using original containers, clear identification, excluding incompatibilities, and containing leakages. Specific rules are then outlined for different storage categories including gases, flammable liquids, and corrosive/toxic substances.
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This document discusses recommendations for safe internal transport and storage of chemicals. It notes that incorrect transport and storage often leads to accidents and spills. The document recommends that containers be properly sealed and adapted for transport. It also recommends that vehicles used to transport flammable liquids be explosion-proof. Traffic routes and temporary storage areas should be classified as explosion risk zones unless measures are taken. The document also stresses the importance of having an emergency plan in place that includes worker training, guidelines for scenarios, and means to respond to incidents.
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Gender and Mental Health - Counselling and Family Therapy Applications and In...PsychoTech Services
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This document provides an overview of wound healing, its functions, stages, mechanisms, factors affecting it, and complications.
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The recent surge in pro-Palestine student activism has prompted significant responses from universities, ranging from negotiations and divestment commitments to increased transparency about investments in companies supporting the war on Gaza. This activism has led to the cessation of student encampments but also highlighted the substantial sacrifices made by students, including academic disruptions and personal risks. The primary drivers of these protests are poor university administration, lack of transparency, and inadequate communication between officials and students. This study examines the profound emotional, psychological, and professional impacts on students engaged in pro-Palestine protests, focusing on Generation Z's (Gen-Z) activism dynamics. This paper explores the significant sacrifices made by these students and even the professors supporting the pro-Palestine movement, with a focus on recent global movements. Through an in-depth analysis of printed and electronic media, the study examines the impacts of these sacrifices on the academic and personal lives of those involved. The paper highlights examples from various universities, demonstrating student activism's long-term and short-term effects, including disciplinary actions, social backlash, and career implications. The researchers also explore the broader implications of student sacrifices. The findings reveal that these sacrifices are driven by a profound commitment to justice and human rights, and are influenced by the increasing availability of information, peer interactions, and personal convictions. The study also discusses the broader implications of this activism, comparing it to historical precedents and assessing its potential to influence policy and public opinion. The emotional and psychological toll on student activists is significant, but their sense of purpose and community support mitigates some of these challenges. However, the researchers call for acknowledging the broader Impact of these sacrifices on the future global movement of FreePalestine.
1. TRP 1
Resource Efficiency Benchmarks
in the Chemical Industry
IAMC Toolkit
Innovative Approaches for the Sound Management of
Chemicals and Chemical Waste
2. Introduction
Raw materials and waste are often the highest costs of
production in the chemical industry. Improving material
efficiency and reducing waste can significantly improve
economic performance at a company and improve its
environmental performance.
This presentation provides:
Formulas for calculating material, energy work and plant
efficiency;
Example resource and pollution intensity benchmarks for
selected chemical subsectors;
Example benchmarks for chemical consumption and waste
for the production of specific chemicals (e.g. polystyrene).
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 2
3. Contents
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1. Introduction to Resource Efficiency in the Chemical
Sector
2. Example Benchmarks
Chemical sector overview
Specific chemical processes
3. Introduction to EC BREF Documents
5. Definition of Resource Efficiency
Resource efficiency
Material efficiency (e.g. kg/kg): higher potential in core
techniques
Energy efficiency (e.g. kg/kWh): higher potential in peripheral
techniques
Work efficiency (e.g. kg/personnel hour)
Plant efficiency (e.g. kg/plant hour)
The amount of resources used is the basis of resource
efficiency.
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 5
Resource efficiency* = Productivity
Product output
Resource input
=
*at full load
6. Resource Efficiency Potential of the Chemical
Industry
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Significant amounts of feedstock and
residual waste result in:
Low productivity
High costs
Disposal/environmental issues
Influence of state and society
[Stoichiom. yield
approx. 90%]
100 kg
Approx.
40 kg
Approx.
60 kg
Process
Products
Waste
Raw
materials
Personnel
Energy
Investment/capital
(amortization)
Example: The stoichiometric efficiency for this process is 90%.
However, the material efficiency is only 40%.
Source: based on Steinbach
7. 7
Resource Efficiency Potential of the Chemical
Industry
Common characteristics and challenges in the chemical
industry:
High amount of input resources and high related costs
High amount of by-products and waste
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
Source: based on CEFIC, 2009
8. Example: Wasted Potential in the Pigment
and Dyestuff Industry
The potential for reducing resource consumption and costs in the
chemical industry is high.
Example: Wasted potential in the pigment and dyestuff
industry:
1 ton of product…
Requires 700 kg of solvent
Produces 100 kg of organic residual waste to be
incinerated
Generates 72,500 kg of process wastewater
Potential to improve material efficiency, reduce the amount
of waste, improve profitability and sustainability performance
8UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
9. Example Benchmarks
Chemical sector overview
Specific chemical processes
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 9
10. Resource Efficiency Potential at a Chemical
Plant
The entire chemical plant production system should be considered to
identify areas with resource efficiency potential.
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Source: ISSPPRO
11. Example Benchmarks for Chemical Synthesis
High amounts of waste in the chemical industry even
when applying best practice
Example: stoichiometric and material efficiency in selected
German chemical subsectors (synthesis):
11
Selected subsectors Stoichiometric
conversion (%)
Material efficiency (%)
Pharmaceuticals 86 20
Pigments and dyestuffs 88 26
Plant protection 89 36
Other specialty chemicals 90 62
Commodity chemicals 90 76
Average 88 38
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
Source: based on Steinbach
12. Material Efficiency in the Chemical Sector
Average solvent and water consumption and halogen
input as waste
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Selected subsectors Solvent
consumption
[kg/t of product]
Water
consumption
[kg/t of product]
Halogen
[Input, kg/t of
product; per cent
input as waste]
Pharmaceuticals 3,200 5,400 363 kg; 78%
Pigments and
dyestuffs
700 71,200 368 kg; 88%
Agrochemicals 250 6,400 364 kg; 74%
Specialty chemicals 100 1,500 59 kg; 75%
Basic chemicals 0 1,900 --
Material efficiency can still be improved.
Source: based on Steinbach
13. Example: Effluent Load Typical of LVOC*
Processes
* LVOC = Large volume organic chemicals
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 13
Emission prior to biological treatment
Wastewater volume COD AOX
Product m3 / t Kg / t g / t mg / t
<0.1 0.1-1 1-10 >10 <0.1 0.1-1 1-10 >10 <0.1 0.1-1 1-10 10-100 >100 <0.3 <1 1-10 >10
L. Olefins
C1=;C2=;C3= X X
1.3-Butadiene X X
Acetylene X X
2. BTX
Benzene /Toluene X X
Ethylbenzene/Cumene X X X
Styrene X X
3. EDC/VC,
organochlorides
EDC X X X X X
EDC X X X X
Methyl chloride X X X X X
Epichlorohydrin X X X X
Source: based on EC LVOC D1, 2014
14. Waste in the Chemical Sector
Average amount of residual waste incinerated
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 14
Selected
subsectors
Inorganic material
[kg/t of product]
Organic material
[kg/t of product]
Water
[kg/t of product]
Pharmaceuticals 150 3,600 1,400
Pigments and
dyestuffs
1 100 5
Plant protection 90 330 620
Specialty chemicals 1 40 5
Commodity
chemicals
5 20 130
Source: based on Steinbach
15. Waste in the Chemical Sector
Average amount of process wastewater treated in
wastewater treatment plants
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 15
Selected
subsectors
Inorganic material
[kg/t of product]
Organic material
[kg/t of product]
Water
[kg/t of product]
Pharmaceuticals 590 320 5,000
Pigments and
dyestuffs
3,600 480 72,500
Plant protection 630 160 8,200
Specialty chemicals 120 40 1,400
Commodity
chemicals
1 20 1,900
Source: based on Steinbach
16. Energy Efficiency in the Chemical Sector
Example: consumption of electricity in process and peripheral
technologies in Germany
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 16
Process-specific
reduction potential
Periphery-specific
reduction potential
Remaining consumption
Energy efficiency potential exists mainly in peripheral technologies.
Source: based on Fleiter et al 2013
17. Energy Efficiency in the Chemical Sector
Energy efficiency potential in peripheral technologies
(analysis from selected German companies)
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 17
Area
Average
(%)
Range
(%)
Compressed air (n*=4) 22.5 5-50
Motors (n*=2) 19 2-50
Pumps (n*=3) 30 5-50
Heat and cooling
utilities, heat
integration (n*=3) 17.5 5-30
*n= number of companies analyzed
The potential for improvement is still high.
Source: based on BiPRO et al.
18. Example Benchmarks
Chemical sector overview
Specific chemical processes
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 18
19. BAT Specific to Polystyrene (PS) Production
(GPPS Method)
Chemicals consumption and waste produced in PS production
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Source: based on EC 2007, page 263
Notes:
1) The emission values in
the water are measured
after treatment.
Wastewater can either be
treated at an in-plant
facility or at a centralized
location.
2) Cooling water, purge
water not included
3) Hazardous waste (for
treatment or incineration)
in kilograms per ton of
product (kg/t)
4) Inert waste (for landfilling)
in kilograms per ton of
product (kg/t)
GPPS Unit per ton of product BAT AEL
Air emissions
Dust g 20
VOC, total g 85
Water emissions
COD g 30
Suspended solid g 10
Hydrocarbons total g 1.5
Wastewater t 0.8
Cooling tower purge water t 0.5
Waste
Hazardous kg 0.5
Non-hazardous kg 2
Consumption
Total energy GJ 1.08
Styrene t 0.985
Mineral oil t 0.02
Cooling water (closed
circuit)
t 50
Process water t 0.596
Nitrogen t 0.022
Diluent t 0.001
Additives t 0.005
20. Unsaturated Polyester Production
Energy and water consumption and emissions
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 20
UP Unit BAT AEL range
Consumption
Energy GJ/t 2 3.5
Water m3/t 1 5
Emissions to air
VOC to air g/t 40 100
CO to air 50
CO2 to air kg/t 50 150
NOX to air g/t 60 150
SO2 to air g/t ~0 100
Particles to air g/t 5 30
Waste
Hazardous waste for
external treatment
kg/t 7
Source: based on EC 2007, page 269
21. Styrene from Ethylbenzene (EB)
Dehydrogenation
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 21
VOC emissions from fugitive emissions:
Composition: CO, CO2, NMVOCs, methane, EB, styrene, aromatics
Monitoring: kg per ton of EB or kg per year, using the method described in the
CWW BREF
Amount: 3–16 g per ton of styrene monomer
Source: based on EC LVOC 2014, page 502
VOC emissions from shared end-of-pipe abatement:
Composition: VOCs, CH4, SO2, NOX, COX, dust, NMVOCs
Monitoring: normally after abatement device, spot samples
VOC emissions in grammes per ton of styrene monomer (SM)
SO2 1.4–3
NOX 130–160
CO 4–7
PM 5–9
NMVOC 2–3
22. Styrene from Ethylbenzene Dehydrogenation
Emissions to water: ethylbenzene, styrene, benzene
Monitoring: TSS, pH, COD
Effluent concentration after pretreatment prior to wastewater
treatment plant
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Source: based on EC LVOC 2014, page 504
Analytical method MN 31147 (mg/l)
Ethylbenzene 0.75 0.1
Styrene 1.25 0.0
Benzene 0.1 0.0
TSS 5 100
pH n/a 7.6
23. Styrene from Ethylbenzene Dehydrogenation
Energy consumption:
Raw material consumption:
The main raw materials used are ethylbenzene and the catalyst.
EB consumption: 1,040-1,166 kg per ton of styrene monomer
Water consumption:
Most of the water is used as boiler feed water to generate the
steam needed in the reaction, up to 4 m3 per ton of styrene
monomer (Cefic).
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Source: based on EC LVOC 2014, page 505
Values of energy-related utilities in kWh per ton of EB
Electricity 70-170
Steam 1,350-2,300
Total 1,500-2,350
Energy recovery 0-800
24. Styrene from Ethylbenzene Dehydrogenation
Co-products and by-products:
Waste generation:
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Source: based on EC LVOC, 2014, page 505
Principal co-products and by-products in kg per ton of SM
Hydrogen up to 50
Benzene up to 20
Toluene 16-94
Waste streams in kg per ton of SM
Spent catalyst waste up to 0.4
Coke from the reaction --
Tar up to 22 (9-71)
Gums, oligomers of polystyrene up to 5
Spent solvents (1.5-6)
25. Introduction to EC BREF
Documents
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated 25
26. BREFs and Where to Find Them
What are BREFs?
Best Available Techniques (BAT) reference documents
BREFs
Increase process efficiency, rate of yield, etc.
Reduce environmental pollution, chemical input, etc.
Where to find them?
http://eippcb.jrc.ec.europa.eu/reference/
26UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
27. Content of BREFs
Each document provides information on a specific
industrial/agricultural sector in the EU including
Techniques and processes used in the sector
Current emission and consumption levels
Techniques to consider in the determination of the best available
techniques (BAT) and emerging techniques
A list of references (background material) is quoted in the
reference document.
Links to websites containing relevant legislation/standards
Additional technical information
27UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
28. Overview of Available BREFs
28
Title, acronym, year Key chemicals addressed
Production of Chlor-alkali, CAK, 2014 Chlorine, brine
Production of Cement, Lime and Magnesium
Oxide, CLM, 2013
Cement, lime, magnesium
Common Waste Water and Waste Gas Treatment,
CWW, 2003 (Final draft 2014)
Wastewater and waste gas
Emissions from Storage, EFS, 2006 Liquids, liquefied gases and solids
Industrial Cooling Systems, ICS, 2001
Large Volume Inorganic Chemicals – Ammonia,
Acids and Fertilisers, LVIC-AAF, 2007
Ammonia, nitric acid, sulphuric acid, NPK (nitrogen,
phosphorus, potassium) fertilizers, etc.
Large Volume Inorganic Chemicals – Solids and
Others Industry, LVIC-S, 2007
Aluminium fluoride, calcium carbide, carbon
dilsulphide, etc.
Large Volume Organic Chemical Industry, LVOC,
2003 (Draft 1, 2014)
Lower olefins, benzene, toluene, acrylonitrile, etc.
Manufacture of Organic Fine Chemicals, OFC,
2006
Dyes and pigments, organic explosives,
pheromones
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
29. Overview of Available BREFs
29
Title, acronym, year Key chemicals addressed
Production of Polymers, POL, 2007 Synthetic fibres and rubbers, etc.
Production of Pulp, Paper and Board, PP, 2001 Sulphate, sulphite
Refining of Mineral Oil and Gas, REF, 2015 Lower olefins
Production of Specialty Inorganic Chemicals, SIC,
2007
Silicones, specialty inorganic pigments, cyanides,
etc.
Surface Treatment of Metals and Plastics, STM,
2006
Surface Treatment Using Organic Solvents, STS,
2007
Metal coils, waterproofing, adhesive application,
etc.
Tanning of Hides and Skins, TAN, 2013
Textiles Industry, TXT, 2003 Fibre preparation, dyeing, etc.
Wood-based Panels Production, WBP, 2014 (only
Final Draft available)
Waste Incineration, WI, 2006 Incineration, pyrolysis, gasification
Waste Treatment, WT, 2006 Hazardous and non-hazardous
UNIDO│IAMC Toolkit│Images may not be copied, transmitted or manipulated
30. Key Messages
Raw materials and waste are often the highest costs of
production in the chemical industry.
Improving material efficiency and reducing waste can
significantly improve economic performance at a company
and improve its environmental performance.
Resource and pollution intensity indicators can be
developed to drive continuous improvement and reduce
costs at companies
Industry and sector-specific indicators can be used as a
benchmark
Using the EC BREFS can
Increase process efficiency, rate of yield, etc.
Reduce environmental pollution, chemical input, etc.
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32. Sources
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34. Disclaimer
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