Pollution control in the petrochemicals industry

191 Pages·1987·3.287 MB·English

by  Middlebrooks, E. Joe, Borup, M. Brett

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www.crcpress.com
POLLUTION CONTROL IN THE
PETROCHEMICALS INDUSTRY
M. Brett Borup
E. Joe Middlebrooks
Tennessee Technological University
Cookeville, Tennessee
LEWIS PUBLISHERS. INC.
Boca Raton London New York
CRC Press is an imprint of the
Taylor & Francis Group, an informa business
First published 1987 by CRC Press
Taylor & Francis Group
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Boca Raton, FL 33487-2742
Reissued 2018 by CRC Press
© 1987 by LEWIS PUBLISHERS, INC.
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
This book contains information obtained from authentic and highly regarded sources. Reasonable efforts have been
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Trademark Notice: Product or corporate names may be trademarks or registered trademarks, and are used only for
identification and explanation without intent to infringe.
Library of Congress Cataloging-in-Publication Data
Borup, M. Brett.
Pollution control in the petrochemicals industry.
Bibliography: p.
Includes index.
1. Petroleum chemicals industry–Waste disposal–
Environmental aspects. 2. Pollution–Environmental
aspects. I. Middlebrooks, E. Joe. II. Title.
TD899.P4B67 1987 661’ .804 87-3724
ISBN 0-87371-039-8
A Library of Congress record exists under LC control number: 87003724
Publisher’s Note
The publisher has gone to great lengths to ensure the quality of this reprint but points out that some imperfections in
the original copies may be apparent.
Disclaimer
The publisher has made every effort to trace copyright holders and welcomes correspondence from those they have
been unable to contact.
ISBN 13: 978-1-315-89676-2 (hbk)
ISBN 13: 978-1-351-07586-2 (ebk)
Visit the Taylor & Francis Web site at http://www.taylorandfrancis.com and the
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PREFACE
The petrochemicals industry is very complex and requires considerable
knowledge of the individual processes to develop effective pollution control plans
and processes. Information in this small book is intended to provide a base from
which one can build. It is not exhaustive in describing the segments of the industry
or pollution control techniques; however, it does provide a basic knowledge that
should lead to intelligent, environmentally sound solutions to pollution prevention,
control, and treatment.
The characteristics of various waste streams are summarized. A synopsis of
treatment techniques and performance of these procedures is presented. All aspects
of pollution control (air, water, solid wastes, hazardous wastes, and power
consumption) are discussed.
Processes used to treat petrochemical manufacturing plants' wastes are as varied
as the processes used in the manufacturing plants themselves. Pollution control
costs vary significantly, and the basic approach to pollution control will signif-
icantly affect costs. Great care must be exercised when selecting pollution control
equipment. Guidelines for the proper selection of pollution control equipment are
presented throughout this book.
This book should meet the needs of many people: the engineer or scientist assigned
the task of solving pollution problems; the consulting engineer seeking a solution for
a client; the municipal engineer working with waste processing systems treating
combined municipal and petrochemical wastes; the professor teaching an
industrial waste processing course; and the state and federal regulatory agencies'
personnel involved in the control of industrial pollution, the enforcement of
standards, and the management of industries planning or operating waste
processing facilities.
Many users of this book may find more detail than they require for a particular
task, and others seeking more detail than is available may consult the reports and
papers cited. Regardless of the needs of individuals, however, the book contains
specifics or references that should make the task of pollution control easier.
We have made extensive use of many people's work and wish to thank these
authors. Credit is given at the point in the text where the borrowed material
appears.
We are especially grateful to Ms. Arlene Grover for her preparation of the
original manuscript and the many hours of proofreading. Without her untiring
efforts, the quality of the book would have suffered greatly. We wish to thank
Messrs. Bob Hagemann and Ed Vail for the preparation ofthe final manuscript and
Ms. Joann Carver for her typesetting efforts.
When people's contributions to such an extensive task as preparing a book are
acknowledged, worthy candidates are unfailingly omitted. We apologize for any
omissions and hope to do better next time.

CONTENTS
Preface iii
Chapter 1. Introduction to the Petrochemical Industry 1
The Industry
Processes and Waste Streams
Management Philosophy
Summary
References
Chapter 2. Air Pollution 19
References
Chapter 3. Water Pollution 35
Wastewater Streams
Wastewater Characteristics
Treatment Methods
Process Modification, Conservation
and Treatment
Case Histories
Economics
References
Chapter 4. Solid Wastes Management 71
Introduction
Types of Solid Wastes
Disposal Techniques
References
Chapter 5. Disposal of Hazardous Wastes 81
References
Chapter 6. Petrochemicals Industry in Developing Countries 89
References
Chapter 7. Energy Consideration in Pollution Control 95
References
Chapter 8. Summary and Conclusions 103
Air Pollution Control
Wastewater Treatment and Disposal
Solid Waste Management
Hazardous Wastes Control
Energy Use
Industry Growth
Management Philosophy
References
Appendix A. Glossary 113
Appendix B. Air Emissions from Various Petrochemical Processing Plants 121
Appendix C. Alternative Hazardous Waste Treatment Processes 155
Appendix D. Conversion Factors 169
TABLES
Number
1-1. Petrochemical processes as waste sources 2
1-2. Organic chemical effluents with concentrations greater 8
than 0.5 ppm of priority pollutants
1-3. Air pollutants emitted from petrochemical processing plants 16
2-1. Petrochemical processes surveyed 20
2-2. Estimated air emissions from United States petrochemical plants 21
2-3. Hydrocarbon emission rates for fugitive sources by process, gjhour 23
2-4. Operating conditions and costs of incinerator systems used 24
for hydrocarbon emission reduction
2-5. Operating conditions and costs of condensation systems used 25
for hydrocarbon emission reduction
2-6. Operating conditions and costs of absorption systems used 26
for hydrocarbon emission reduction
2-7. Cost effectiveness of alternative emission control devices 28
in polyvinyl chloride manufacture
2-8. Cost effectiveness of alternative emission control devices 29
in vinyl chloride monomer manufacture by the balanced process
3-1. Total plant effluent analyses: typical petrochemical plants 36
3-2. Critical precursor/generic process combinations that 40
generate priority pollutants
3-3. Petrochemical processes 42
3-4. Components of a wastewater survey and treatability study program 46
3-5. Petrochemical wastewater treatment systems 47
3-6. Removal of specific organics in anaerobic lagoons 49
3-7. Pollutants and control options in nitric acid production process 53
3-8. Pollutants and control options in TNT production process 54
3-9. Pollutants and control options in nitrocellulose production 55
3-10. Conserving and reusing water 56
Water conservation and reuse technologies
that are seeing wide application
3-11. Wastewater treatment plant data sheet 59
4-1. Petrochemical solid waste survey 72
4-2. Forms of polymer wastes 73
4-3. Pyrolysis process economic estimates 78
5-1. Hazardous wastestreams identified in some petrochemical 84
manufacturing processes
5-2. Plastics/synthetic fibers effluents with concentrations 86
greater than 0.5 ppm of priority pollutants
6-1. Increase in demand and estimated new investment for 90
major petrochemicals in developing countries by 1990
6-2. Water standards for various uses in Taiwan, China 91
7-1. Cost effectiveness of alternative emission control devices used 96
in the manufacture of phthalic anhydride from ortho-xylene
7-2. Energy requirement of a 2.8 x 104 m3/d (7.5 mgd), 99
advanced wastewater treatment system
FIGURES
Number
2-1. Simplified flow scheme for ethylene plant showing recycle of 30
off-specification products to reduce air emissions
and produce economic savings
3-1. Waste treatment flow diagram 60
3-2. El Tablazo Treatment Complex 61
3-3. Flow diagram of wastewater treatment facility at Ponce, Puerto Rico 63
3-4. Simplified flow sheet, wastewater treatment, Guayama 64
Petrochemical Complex
4-1. Pyrolysis process 77
6-1. Schematic flow diagram of Linyuan Industrial Wastewater 93
Treatment Plant
POLLUTION CONTROL IN THE
PETROCHEMICALS INDUSTRY