Industrial Environmental Management

TAPAS K. DAS, PhD, P.E., BCEE, is a fellow member of the American Institute of Engineers; past chair of the AIChE's Environmental Division; and former chair of the Air Pollution Control Committee of the American Academy of Environmental Engineers. Dr. Das also served as an adjunct faculty member at several colleges and universities in Washington, and taught both undergraduate and graduate courses in environmental, civil, chemical, and mechanical engineering programs, and was a former assistant professor in the College of Natural Resources at the University of Wisconsin, Stevens Point.

About the Author xxi

Preface xxiii

Acknowledgements xxv

About the Companion Website xxvii

1 Why Industrial Environmental Management? 1

1.1 Introduction 1

1.2 Environmental Management in Industries 3

1.3 Waste as Pollution 4

1.4 Defining Pollution Prevention 4

1.5 The ZDZE Paradigm 5

1.6 Zero Discharge Industries 5

1.7 Sustainability, Industrial Ecology, and Zero Discharge (Emissions) 6

1.8 Why Zero Discharge is Critical to Sustainability 8

1.9 The New Role of Process Engineers and Engineering Firms 9

1.10 Zero Discharge (Emissions) Methodology 10

1.11 Making the Transition 12

1.12 Constraints and Challenges 17

1.13 The Structure of the Book 18

Problems 21

References 22

2 Genesis of Environmental Problem Worldwide: International Environmental Regulations 23

2.1 Introduction 23

2.2 Genesis of the Environmental Problem 25

2.3 Causes of Pollution and Environmental Degradation 26

2.4 Industrialization and Urbanization in the United States 27

2.5 Important Technological Developments 33

2.6 Industrial Disasters 34

2.7 Environmental Law 39

2.8 Pollution Control Laws 39

2.9 Resource Sustainability 41

2.10 Polluter Pays Principle 42

2.11 Theory/Environmental Law Debate 42

2.12 International Law 43

2.13 The Legal and Regulatory Framework for Environmental Protection in India 47

2.14 United States Environmental Law 55

2.15 ISO 9000 and 14000 57

2.16 Current Environmental Regulatory Development in the United States: From End-of-Pipe Laws and Regulations to Pollution Prevention 60

2.17 Greenhouse Gases 60

Examples (Multiple Choice) 64

Problems 65

References 65

3 Industrial Pollution Sources, Its Characterization, Estimation, and Treatment 71

3.1 Introduction 71

3.2 Wastewater Sources 71

3.3 Wastewater Characteristics 71

3.4 Chemical Characteristics 73

3.5 Industrial Wastewater Variation 75

3.6 Industrial Wastestream Variables 77

3.7 Concentration vs. Mass of the Pollution 78

3.8 Industrial Wastewater Treatment 82

3.9 Air Quality 83

3.10 The Ideal Gas Law and Concentration Measurements in Gases 94

3.11 Other Applications of the Ideal Gas Law 96

3.12 Gas Flow Measurement 97

3.13 Flow at Standard Temperature and Pressure 98

3.14 Gas Flowrate Conversion from SCFM to ACFM 98

3.15 Corrections for Percent O2 98

3.16 Boiler Flue Gas Concentrations Are Usually Corrected to 3% Oxygen 98

3.17 Air‐to‐Fuel Ratio and Stoichiometric Ratio 98

3.18 Material Balances and Energy Balances 99

3.19 Wastes in the United States 102

3.20 Hazardous Waste 104

3.21 Incineration, Destruction, and WtE 105

3.22 Hazardous Waste Landfill (Sequestering, Isolation, etc.) 106

3.22.1 Pyrolysis 106

3.23 Radioactive Waste 106

3.24 Coal 107

3.25 Low‐ Level Waste 108

3.26 Nuclear Waste Management 109

Problems 110

References 111

4 Industrial Wastewater, Air Pollution, and Solid and Hazardous Wastes: Monitoring, Permitting, Sample Collections and Analyses, QA/QC, Compliance with State Regulations and Federal Standards 115

4.1 Introduction 115

4.2 Industrial Process Water 115

4.3 Common Elements, Radicals, and Chemicals in Water Analysis 115

4.4 Purposes and Objectives for Inspecting and Sampling 116

4.5 Sampling and QA/QC Plan 120

4.6 Whole Effluent Toxicity Testing 130

4.7 Flow Measurements 133

4.8 The Point of Compliance with the Water Quality Standards 139

4.9 Water Quality Modeling 142

4.10 Example NPDES Permits (for Refinery and Aluminum Smelter are shown in Section D.1) 145

4.11 Air Pollution Perspective 146

4.12 Prevention of Significant Deterioration (PSD) Permitting Process 149

4.13 An Overall Permitting Process 150

4.14 Best Available Control Technology 152

4.15 Atmospheric Dispersion Modeling 157

4.16 Dispersion Models: Indoor Concentrations 159

4.17 State Implementation Plan 162

4.18 Compliance 164

4.19 CAA Enforcement Provisions 168

4.20 Industrial Solid Wastes and Its Management 173

4.21 Hazardous Waste Landfill (Sequestering, Isolation, etc.) 180

4.22 Industrial Waste Generation Rates 181

4.23 Comprehensive Environmental Response, Compensation, and Liability Act and Superfund 182

4.24 Industrial Waste Management in India: Shifting Gears 185

Problems 187

References 189

5 Assessment and Management of Health and Environmental Risks: Industrial and Manufacturing Process Safety 193

5.1 Health Risk Assessment 193

5.2 Assessing the Risks of Some Common Pollutants 201

5.3 Ecological Risk Assessment 207

5.4 Risk Management 217

5.5 Communicating Information on Environmental and Health Risks 227

5.6 Environmental Information Access on the Internet 231

5.7 Health and Occupational Safety 234

5.8 Industrial Process Safety System Guidelines 235

5.9 Industrial Hygiene 236

5.10 Atmospheric Hazards 237

5.11 Safety Equipment 241

5.12 Communication Devices 243

5.13 Noise 246

5.14 Radiation 249

5.15 Effects of Global Warming: Climate Change – The World’s Health 253

5.16 Key Vulnerabilities 257

5.17 Energy Sector 258

Problems 259

References 260

6 Industrial Process Pollution Prevention: Life-Cycle Assesvsment to Best Available Control Technology 265

6.1 Industrial Waste 265

6.2 What is Life Cycle Assessment? 267

6.3 LCA and LCI Software Tools 280

6.4 Evaluating the Life Cycle Environmental Performance of Chemical-, Mechanical-, and Bio-Pulping Processes 282

6.5 Evaluating the Life Cycle Environmental Performance of Two Disinfection Technologies 291

6.6 Case Study: LCA Comparisons of Electricity from Biorenewables and Fossil Fuels 299

6.7 Best Available Control Technology (for Environmental Remediation) 303

6.8 BACT: Applications to Gas Turbine Power Plants 304Problems 312

References 312

7 Economics of Manufacturing Pollution Prevention: Toward an Environmentally Sustainable Industrial Economy 317

7.1 Introduction 317

7.2 Economic Evaluation of Pollution Prevention 317

7.3 Cost Estimates 318

7.4 Economic Criteria for Technology Comparisons 321

7.5 Calculating CF 321

7.6 From Pollution Control to Profitable Pollution Prevention 323

7.7 Resource Recovery and Reuse 325

7.8 Profitable Pollution Prevention in the Metal-Finishing Industry 326

7.9 Use of Treated Municipal Wastewater as Power Plant Cooling System Makeup Water: Tertiary Treatment vs. Expanded Chemical Regimen for Recirculating Water Quality Management 335

7.10 Consequences of Dirty Air: Costs–Benefits 340

7.11 Some On-Going Pollution Prevention Technologies 341

7.12 Cost Indices and Estimating Cost of Equipment 348

7.13 Waste-to-Energy 350

7.14 Sustainable Economy and the Earth 354

Problems 357

References 359

8 Lean Manufacturing: Zero Defect and Zero Effect: Environmentally Conscious Manufacturing 363

8.1 Introduction 363

8.2 Engineering Data Summary and Presentation 364

8.3 Time Series: Process over Time 369

8.4 Process Capability 371

8.5 Lean Manufacturing 374

8.6 Types of Waste 380

8.7 Six Sigma in Industry 381

8.8 Lean Implementation Develops from TPS 381

8.9 Manufacturing System Characteristics: Process Planning Basics 385

8.10 Design for Life Cycle 386

8.11 Sustainable Design and Environmentally Conscious Design and Manufacturing 387

8.12 Lean Six Sigma 390

8.13 Six Sigma and Lean Manufacturing 392

8.14 Cost vs. Quality Analysis 393

8.15 Assessing and Reducing Risk in Design: Cost to Manufacturer 395

8.16 The Heart and Soul of the Toyota Way: Lean Processes 396

8.17 Essential Roles of Industrial Environmental Managers 400

8.18 Goals of IEMs 401

8.19 Environmental Compliance and Compliance Assurances 401

8.20 Waste Reduction 401

Problems 403

References 405

9 Industrial Waste Minimization Methodology: Industrial Ecology, Eco-Industrial Park and Manufacturing Process Intensification and Integration 409

9.1 Introduction 409

9.2 Industrial Ecology 409

9.3 Water–Energy Nexus 417

9.4 CE Indicators in Relation to Eco-Innovation 426

9.5 Process Intensification and Integration Potential in Manufacturing 427

9.6 Manufacturing Process Integration 432

9.7 New Sustainable Chemicals and Energy from Black Liquor Gasification Using Process Integration and Intensification 433

9.8 Chemical Recovery and Power/Steam Cogeneration at Pulp and Paper Mills 436

9.9 Conclusions 445

Problems 447

References 448

10 Quality Industrial Environmental Management: Sustainable Engineering in Manufacturing 453

10.1 Introduction: Industry and the Global Environmental Issues 453

10.2 Integrating LCA in Sustainable Product Design and Development 463

10.3 Green Chemistry: The Twelve Principles of Green Chemistry 464

10.4 The Hannover Principles 467

10.5 Sustainable Industries and Business 468

10.6 Six Essential Characteristics 470

10.7 Social Services 471

10.8 Environmental Regulatory Law: Command and Control Market Based, and Reflexive 471

10.9 Business Ethics 472

10.10 International Issues 473

10.11 Ethical Sustainability 473

10.12 Social Sustainability 474

10.13 Conclusions 475

10.14 Strategy for Corporate Sustainability 476

Problems 477

References 477

Appendix A Conversion Factors 481

Appendix B International Environmental Law 483

Appendix C Air Pollutant Emission Factors: Stationary Point and Area Sources 487

Appendix D Frequently Asked Questions and Answers: Water Quality Model, Dispersion Model and Permits 493

Appendix E Industrial Hygiene Outlines 511

Appendix F Environmental Cost-Benefit 513

Appendix G Resource Recovery: Waste-To-Energy Facility, City of Spokane, Washington, USA 515

Appendix H The Hannover Principles 519

Appendix I Environmental Goals and Business Goals Are Not Two Distinct Goal Sets 521

Appendix J Sample Codes of Ethics and Guidelines 523

Index 527