Manufacturing processes, chemical

Hydrogen chloride is produced by the direct reaction of hydrogen and chlorine, by reaction of metal chlorides and acids, and as a by-product from many chemical manufacturing processes such as chlorinated hydrocarbons. 

A completed Form R must be submitted for each toxic chemical manufactured, processed, or otherwise used at each covered facility as prescribed in the reporting rule in 40 CFR Part 372 (published February 16,1988 in the Federal Register). These instructions supplement and elaborate on the requirements In the reporting rule. Together with the reporting rule, they constitute the reporting requirements. All references in these instructions are to sections in the reporting rule unless otherwise indicated. 

Also note that threshold determinations are based upon the actual amounts of a chemical manufactured, processed, or used over the course of the calendar year. The threshold determination may not relate to the amount of a toxic chemical brought on-site during the calendar year. For example, a stockpile of 100,000 pounds of a toxic chemical is present onsite but only 20,000 pounds is applied to a process Therefore, only the 20,000paunds processed is counted toward a threshold determination, not the entire 100,000 pounds of the stockpile... 

Step 1. Identify amounts of the chemical manufactured, processed, or otherwise used. 

Missing or incorrect reporting year. The reporting year is the calendar year during which the reported data were collected it is not the year in which the Form R is sent to EPA. Form Rs are due to EPA on July 1, 1990 for chemicals manufactured, processed or othen/vise used... 

What do we mean when we speak of an inherently safer chemical process Inherent has been defined as existing in something as a permanent and inseparable element, quality, or attribute (American College Dictionary, 1967). A chemical manufacturing process is inherently safer if it reduces or eliminates the hazards associated with materials and operations used in the process, and this reduction or elimination is permanent and inseparable. To appreciate this definition fully, it is essential to understand the precise meaning of the word hazard. A hazard is defined as a physical or chemical characteristic that has the potential for causing harm to people, the environment, or property (adapted from CCPS, 1992). The key to this definition is that the hazard is intrinsic to the material, or to its conditions of storage or use. Some specific examples of hazards include ... 

The importance and sophistication of current chemical manufacturing processes for electronic, photonic, and recording materials and devices are not widely appreciated. A more detailed description serves to highlight their central role in these technologies. 

Whilst total elimination of volatile organic solvents from all chemical manufacturing processes is a worthy goal, the pursuit of this goal must be subject to some caution. Alternative organic solvent-free processes may have poor heat and/or mass transfer and/or viscosity limitations, which could result in excessive energy use or the production of less pure... 

This chapter is an introduction to the nature and methodology of the design process, and its application to the design of chemical manufacturing processes. 

The reaction stage is the heart of a chemical manufacturing process. In the reactor the raw materials are brought together under conditions that promote the production of the desired product invariably, by-products and unwanted compounds (impurities) will also be formed. 

The design work required in the engineering of a chemical manufacturing process can be divided into two broad phases. 

The most comprehensive collection of information on manufacturing processes is probably the Encyclopedia of Chemical Technology edited by Kirk and Othmer (2001) (2003), which covers the whole range of chemical and associated products. Another encyclopedia covering manufacturing processes is that edited by McKetta (2001). Several books have also been published which give brief summaries of the production processes used for the commercial chemicals and chemical products. The most well known of these is probably Shreve s book on the chemical process industries, now updated by Austin and Basta (1998). Comyns (1993) lists named chemical manufacturing processes, with references. 

Clearly, the designer should always select a process that is inherently safe whenever it is practical, and economic, to do so. However, most chemical manufacturing processes are, to a greater or lesser extent, inherently unsafe, and dangerous situations can develop if the process conditions deviate from the design values. 

On January 1, 1977, the chemical industry truly became a regulated industry. The environmental laws up until that time had covered some chemicals, but had been media oriented. That is — they were concerned about certain chemicals that escaped as emissions or pollutants to various media - the air, our water, contaminated our food or entered the workplace. TSCA changed that direction. It was designed to regulate commerce on chemical substances. TSCA potentially applies to all chemicals manufactured, processed, distributed or used in the U.S. except those chemicals already regulated under certain other federal laws. TSCA affects not only the chemical industry itself, but the many other industries whose products are chemical in nature. This includes most all industrial products. 

Current good practice guidelines on how to effectively manage reactive hazards throughout the life cycle16 of a chemical manufacturing process are neither complete nor sufficiently explicit. 

Life cycle" refers to all phases of a chemical manufacturing process-from conceptualization, process research and development (R D), engineering design, construction, commissioning, commercial operation, and major modification to decommissioning. 

Good management practices include not only hazard identification and evaluation early in R D, but also issues such as MOC throughout the life of the chemical manufacturing process. The existing body of... 

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