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A Cleaner Production and Pollution Prevention in the Chemical Industries

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A Cleaner Production and Pollution Prevention in the Chemical Industries A Cleaner Production and Pollution Prevention In the Chemical Industries Prof. Dr. El-Sayed Khater Cleaner Production and Pollution Abatement Consultant National Research Center Department of Chem. Eng. And Pilot Plant Introduction . The terms Cleaner Production, Pollution Prevention and Responsible Care ® is often used interchangeably. In the case of Cleaner Production and Pollution Prevention, the distinction between the two tends to be geographic -- the term Pollution Prevention tends to be used in North America, while Cleaner Production is used in other parts of the world. The term Responsible Care® is a trade mark within the chemical industry and refers to a specific program -- the term is used universally. Background Information Cleaner Production stands for a proactive and preventive approach to industrial environmental management and aims for process- and/or product-integrated solutions that are both environmentally and economically efficient (‘eco-efficiency’). Pioneers in the field were large process industries in the USA (since the late 1970’s), but it took until the early 1990’s before Cleaner Production was generally recognised as a valuable approach for large and medium sized enterprises in all industry sectors. Cleaner Production/Pollution Prevention • Cleaner Production (CP) and Pollution Prevention (P2) focus on a strategy of continuously reducing pollution and environmental impact through source reduction -- that is eliminating waste within the process rather than at the end-of- pipe. Waste treatment does not fall under the definition of CP or P2 because it does not prevent the creation of waste. Cleaner production (CP) is a general term used to describe a preventative approach to industrial activity .It encompasses: . waste minimisation, . waste avoidance, and . pollution prevention. Scope of Cleaner Production In Production Processes: . conservation of raw materials and energy . elimination of the use of toxic raw materials . reducing the quantity and toxicity of all emissions and wastes before they leave a process In Products : . reducing negative impacts along the life cycle of a product, from raw material extraction to its ultimate disposal In Services : . incorporation of environmental concerns in the design and delivery of services. Techniques of Cleaner Production The waste cost iceberg showing the hidden costs of waste Disposal Costs Raw-material costs Energy costs Management time Lost profit Packaging losses Labour costs Water costs Transport costs Company image Storage Rework Capital depreciation Clean-up costs Responsible Care® Responsible Care® is a program carried out by the chemical industry in approximately 45 countries OR more. Responsible Care® is a voluntary chemical industry action programme to achieve and demonstrate continual improvement with regard to safety, health and the environment.. Responsible Care® The chemical industry is committed to the safe, responsible and sustainable management of chemicals through their entire life cycle, and for their intended end use. Responsible Care is the chemical industry’s world-class performance initiative. Its companies are industry leaders, bound together by a commitment to address challenges and continuously improve the performance of the chemical industry. A History of Excellence For more than 20 years, the Responsible Care program has helped American Chemistry Council (ACC) member companies significantly enhance their performance, discover new business opportunities, and improve employee safety and the health of the communities in which they operate and the environment as a whole, moving us toward a safer, more sustainable future. Types of Chemical Industries Chemical Industries includes the following: • Plastic manufacturing. • Paint Manufacturing. • Organic and In organic Chemicals Manufacturing. • Fertilizers Manufacturing. • Pulp and Paper Industry. Types of Chemical Industries in India • Drugs & Pharmaceuticals • Fine chemicals • Dyes and Dye Intermediate • Basic Inorganic and organic chemicals • Pesticides and Insecticides • Fertilizer The chemical industries featuring highly polluting industries are: •Pesticides/ insecticides • Fertilizers • Dyes • Sodium/ potassium cyanide • Basic Drugs • Acids/ alkalis Types of Chemical Industries in Egypt It consists of 5 industrial divisions: •Diversified Chemicals (Fertilizers, Glass, Industrial gases, ....etc) •Plastics & Rubber. •Detergents. •Paints, Inks & Resins. •Paper & Cardboard. عدد الشركات ااعضاء حتى نهاية 2013 غرف الصناعا الكيماوي مصـــر 2159 911 516 368 285 ور وكرتون منظا بويا كيماويا متنوعه باستيك ومطاط 17 اإستثمارات عام 2013 )مليار جنيه( غرف الصناعا الكيماوي مصـــر 103.2 24.35 19.15 14.17 6.22 منظا ور وكرتون بويا باستيك ومطاط كيماويا متنوع 18 غرف الصناعا الكيماوي مصـــر عدد العمالة فى الصناعات الكيماوية حتى نهاية 2013 121634 83338 63175 43862 26386 منظا ور و كرتون بويا باستيك ومطاط متنوع 19 Emissions = Input - Product gaseous EMISSIONS PRODUCT INPUT solid EMISSIONS fluidic EMISSIONS Presentation Sustainable Chemistry Concept Sustainable (named .green.) chemistry was introduced by EPA in 2002. The idea of Green Chemistry is to develop new products, reaction media, conditions, and/or utility of materials. More specifically, green chemistry is the design of chemical products that reduce or eliminate the use or generation of hazardous substances by offering environmentally friendly alternatives. Sustainable chemistry technologies can be categorized into the following three focus areas, e.g., the use of alternative synthetic pathways, the use of alternative reaction conditions, and the design of safer chemicals that are less toxic than current alternatives or inherently safer with regard to accident potential. Sustainable Chemistry Concept There are equally dozen principles of green chemistry, e.g., 1. prevent waste, by design chemical syntheses to avoid waste to treat or clean up; 2. design safer chemicals and products to be fully effective, with no toxicity; 3. design less hazardous chemical syntheses through use and generate no toxic substances to humans and the environment; 4. use renewable rather than depleting feedstocks. Renewable feedstock is usually made from agricultural products or the wastes whereas depleting feedstock is made from fossil raw materials; 5. use catalysts rather than stoichiometric reagents, which are used in excess and work only once, to minimize waste, 6. avoid chemical derivatives by using blocking or protecting groups or any temporary modifications if possible. Derivatives use additional reagents and generate waste; Sustainable Chemistry Concept 7. maximize atom economy. Design syntheses so that the final product contains the maximum proportion of the starting materials. There should be minimum wasted atoms; 8. use safer solvents and reaction conditions; 9. increase energy efficiency at ambient temperature and pressure whenever possible; 10. design degradable chemicals and products to break down to harmless substances after use to avoid their accumulation in the environment; 11. analyze by real-time monitoring and control during syntheses to minimize or eliminate the formation of byproducts to prevent pollution; 12. minimize the potential for accidents by designing safer chemicals to minimize the potential for chemical accidents, explosions, fires, and releases to the environment. Sustainable Chemistry Concept The green chemistry concept solves the pollution prevention problem at the molecular level by focusing on chemicals whereas clean technologies deals mainly with processes such as separation for recycling, recovery, conservation, and rational use of raw materials, water and energy, optimization of production processes, disposal or recycling of unavoidable waste. In this sense green chemistry is complementary to clean technologies which is based on chemical engineering rather than pure chemistry. Clean Technologies Concept The Commission of the European Communities put the definition of clean technologies as a main objective of proactive strategies: .any technical measures taken at various industries to reduce or even eliminate at source the production of any nuisance, pollution, or waste, and to help save raw materials, natural resources, and energy. Clean Technologies Concept The European Commission defined clean technologies as follows: . Clean technologies are new industrial processes or modifications of existing ones intended to reduce the impact of production activities on the environment, including reducing the use of energy and raw materials.. To support the definition the main attributes of clean technologies were precisely formulated: 1. conservation of raw materials, 2. optimization of production processes, 3. rational use of raw materials, 4. rational use of energy, 5. rational use of water, 6. disposal or recycling of unavoidable waste, 7. accident prevention, 8. risk management to prevent major pollution, and 9. restoring sites after cessation of activities. Pulp and Paper Industry MODERN APPROACH TRADITIONAL APPROACH 100% COMPLEXITY OF SOLUTIONS AVOID CONTRIBUTION MINIMIZE TO PROBLEM REUSE SOLVING AND RECYCLE TREAT DISPOSE LONG TERM COSTS 0% BeginningSituação 1 -– Sem waste Tratamento without any treatment CNTL/SENAI-RS Advanced situation – Emissions and wastewater Situaçãoare treated, 2 - Tratamento solid dewaste Resíduos is disposed e Emissões CNTL/SENAI-RS Situação Cleaner 3 - Tecnologia Production Limpa CNTL/SENAI-RS New El-Amir Sohag, Egypt The Dangerous of Plastic bags .
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