BREF for the Production of Polymers.pdf
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Pobierz
EUROPEAN COMMISSION
DIRECTORATE-GENERAL JRC
JOINT RESEARCH CENTRE
Institute for Prospective Technological Studies
Integrated Pollution Prevention and Control
Reference Document on
Best Available Techniques in the Production of
Polymers
Dated October 2006
Edificio EXPO, c/ Inca Garcilaso s/n, E-41092 Sevilla - Spain
Telephone: direct line (+34-95) 4488-284, switchboard 4488-318. Fax: 4488-426.
Internet:
ht
tp://eippcb.jrc.es
;
Email:
J
RC-IPTS-EIPPCB@cec.eu.int
This document is one of a series of foreseen documents as below (at the time of writing, not all
documents have been finalised):
Reference Document on Best Available Techniques . . .
Code
Large Combustion Plants
LCP
Mineral Oil and Gas Refineries
REF
Production of Iron and Steel
I&S
Ferrous Metals Processing Industry
FMP
Non Ferrous Metals Industries
NFM
Smitheries and Foundries Industry
SF
Surface Treatment of Metals and Plastics
STM
Cement and Lime Manufacturing Industries
CL
Glass Manufacturing Industry
GLS
Ceramic Manufacturing Industry
CER
Large Volume Organic Chemical Industry
LVOC
Manufacture of Organic Fine Chemicals
OFC
Production of Polymers
POL
Chlor – Alkali Manufacturing Industry
CAK
Large Volume Inorganic Chemicals - Ammonia, Acids and Fertilisers Industries
LVIC-AAF
Large Volume Inorganic Chemicals - Solid and Others industry
LVIC-S
Production of Speciality Inorganic Chemicals
SIC
Common Waste Water and Waste Gas Treatment/Management Systems in the Chemical Sector
CWW
Waste Treatments Industries
WT
Waste Incineration
WI
Management of Tailings and Waste-Rock in Mining Activities
MTWR
Pulp and Paper Industry
PP
Textiles Industry
TXT
Tanning of Hides and Skins
TAN
Slaughterhouses and Animals By-products Industries
SA
Food, Drink and Milk Industries
FDM
Intensive Rearing of Poultry and Pigs
ILF
Surface Treatment Using Organic Solvents
STS
Industrial Cooling Systems
CV
Emissions from Storage
ESB
Reference Document . . .
General Principles of Monitoring
MON
Economics and Cross-Media Effects
ECM
Energy Efficiency Techniques
ENE
Executive Summary
EXECUTIVE SUMMARY
1)
Introduction
The BAT (Best Available Techniques) Reference Document (BREF) entitled “Best Available
Techniques for the Production of Polymers” (POL) reflects an information exchange carried out
under Article 16(2) of Council Directive 96/61/EC (IPPC Directive). This executive summary
describes the main findings, a summary of the principal BAT conclusions and the associated
emission and consumption levels. It should be read in conjunction with the preface, which
explains this document’s objectives; how it is intended to be used and legal terms. It can be read
and understood as a standalone document but, as a summary, it does not present all the
complexities of this full document. It is therefore not intended as a substitute for this full
document as a tool in BAT decision making.
2)
Scope of this document
This document focuses on the main products of the European polymer industry both in
production figures and in environmental impact, mainly produced in dedicated installations for
the production of one specific polymer. The list of products covered is not conclusive but
includes polyolefins, polystyrene, polyvinyl chloride, unsaturated polyesters, emulsion
polymerised styrene butadiene rubbers, solution polymerised rubbers containing butadiene,
polyamides, polyethylene terephthalate fibres and viscose fibres.
For polymer production installations, no specific threshold was established in drawing a
borderline between IPPC installations and non IPPC installations as this is not foreseen in the
IPPC Directive.
3)
The sector and environmental issues
Polymer companies produce a variety of basic products, which range from commodities to high
added-value materials and are produced in both batch and continuous processes covering
installations with a capacity of some 10000 tonnes per year up to some 300000 tonnes per year.
The basic polymers are sold to processing companies, serving an immense range of end-user
markets.
The chemistry of polymer production consists of three basic reaction types, polymerisation,
polycondensation and polyaddition, thus the number of operations/processes used remains
reasonably small. These include preparation, the reaction itself and the separation of products.
In many cases cooling, heating, or the application of vacuum or pressure is necessary. The
unavoidable waste streams are treated in recovery and/or abatement systems or disposed of as
waste.
The key environmental issues of the polymer sector are emissions of volatile organic
compounds, in some cases waste waters with the potential for high loads of organic compounds,
relatively large quantities of spent solvents and non-recyclable waste as well as the energy
demand. Given the diversity of the sector and the wide range of polymers produced, this
document does not provide a complete overview of the releases from the polymer sector.
However, emission and consumption data are presented from a broad range of currently
operational plants in the sector.
4)
Techniques to consider in the determination of BAT
The techniques to consider in the determination of BAT are grouped in a generic section and
product specific sections for certain polymers. The former includes environmental management
tools, equipment design and maintenance, monitoring and some generic techniques related to
energy and end-of-pipe measures.
MP/EIPPCB/POL_BREF_FINAL
October 2006
i
Executive Summary
5)
Best available techniques
The summary presented below does not include background statements and cross referencing
which is found in the full text. Additionally, the full text contains BAT on environmental
management which is not mentioned in this executive summary.
The interface with the BREF on CWW
The BREF on “Common waste gas and waste water treatment/management systems in the
chemical sector” describes techniques which are commonly applicable to the whole spectrum of
the chemical industry. Detailed descriptions of recovery or abatement techniques can be found
in the BREF on CWW.
The BAT associated emission levels of the end-of-pipe techniques described in the CWW
BREF are BAT wherever these techniques are applied in the polymer sector.
Mass flow and concentration levels
This document mostly refers to production related BAT associated emission and consumption
levels, and also refers to end-of-pipe techniques whose concentration related performance can
be found in the CWW BREF. All BAT associated emission levels relate to total emissions
including both point sources and fugitive emissions.
Understanding the application of the BAT
The BAT that are listed include generic BAT and specific BAT for the different polymers
covered in this document. The generic BAT are those that are considered to be generally
applicable to all types of polymer installations. The polymer specific BAT are those that are
considered to be specifically BAT for installations dealing mainly or wholly with certain types
of polymers.
Generic BAT is
• to reduce fugitive emissions by advanced equipment design including:
o
use of valves with bellow or double packing seals or equally efficient equipment.
Bellow valves are especially recommended for highly toxic services
o
magnetically driven or canned pumps, or pumps with double seals and a liquid barrier
o
magnetically driven or canned compressors, or compressors using double seals and a
liquid barrier
o
magnetically driven or canned agitators, or agitators with double seals and a liquid
barrier
o
minimisation of the number of flanges (connectors)
o
effective gaskets
o
closed sampling systems
o
drainage of contaminated effluents in closed systems
o
collection of vents.
• to carry out a fugitive loss assessment and measurement to classify components in terms of
type, service and process conditions to identify those elements with the highest potential
for fugitive loss
• to establish and maintain an equipment monitoring and maintenance (M&M) and/or leak
detection and repair (LDAR) programme based on a component and service database in
combination with the fugitive loss assessment and measurement
ii
October 2006
MP/EIPPCB/POL_BREF_FINAL
Executive Summary
• to reduce dust emissions with a combination of the following techniques:
o
dense phase conveying is more efficient to prevent dust emissions than dilute phase
conveying
o
reduction of velocities in dilute phase conveying systems to values as low as possible
o
reduction of dust generation in conveying lines through surface treatment and proper
alignment of pipes
o
use of cyclones and/or filters in the air exhausts of dedusting units. The use of fabric
filter systems is more effective, especially for fine dust
o
use of wet scrubbers.
• to minimise plant start-ups and stops to avoid peak emissions and reduce overall
consumption (e.g. energy, monomers per tonne of product)
• to secure the reactor contents in case of emergency stops (e.g. by using containment
systems)
• to recycle the contained material or to use it as fuel
• to prevent water pollution by appropriate piping design and materials. To facilitate
inspection and repair, effluent water collection systems at new plants and retrofitted
systems are, e.g.:
o
pipes and pumps placed above ground
o
pipes placed in ducts accessible for inspection and repair.
• to use separate effluent collection systems for:
o
contaminated process effluent water
o
potentially contaminated water from leaks and other sources, including cooling water
and surface run-off from process plant areas, etc.
o
uncontaminated water.
• to treat the air purge flows coming from degassing silos and reactor vents with one or more
of the following techniques:
o
recycling
o
thermal oxidation
o
catalytic oxidation
o
adsorption
o
flaring (only discontinuous flows).
• to use flaring systems to treat discontinuous emissions from the reactor system. Flaring of
discontinuous emissions from reactors is only BAT if these emissions cannot be recycled
back into the process or used as fuel
• to use, where possible, power and steam from cogeneration plants. Cogeneration is
normally installed when the plant uses the steam produced, or where an outlet for the steam
produced is available. The electricity produced can either be used by the plant or exported
• to recover the reaction heat through the generation of low pressure steam in processes or
plants where internal or external consumers of the low pressure steam are available
• to re-use the potential waste from a polymer plant
• to use pigging systems in multiproduct plants with liquid raw materials and products
• to use a buffer for waste water upstream of the waste water treatment plant to achieve a
constant quality of the waste water. This applies to all processes producing waste water,
such as PVC and ESBR
• to treat waste water efficiently. Waste water treatment can be carried out in a central plant
or in a plant dedicated to a special activity. Depending on the waste water quality,
additional dedicated pretreatment is required.
MP/EIPPCB/POL_BREF_FINAL
October 2006
iii
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