Pollution problems

The refining industry generally seeks either to eliminate asphaltenes or to convert them to lighter materials because the presence of heteroelements cause pollution problems, e.g., sulfur and nitrogen, catalyst poisoning, and corrosion (formation of metal vanadates during combustion). 

Even ia 1960 a catalytic route was considered the answer to the pollution problem and the by-product sulfate, but nearly ten years elapsed before a process was developed that could be used commercially. Some of the eadier attempts iacluded hydrolysis of acrylonitrile on a sulfonic acid ion-exchange resia (69). Manganese dioxide showed some catalytic activity (70), and copper ions present ia two different valence states were described as catalyticaHy active (71), but copper metal by itself was not active. A variety of catalysts, such as Umshibara or I Jllmann copper and nickel, were used for the hydrolysis of aromatic nitriles, but aUphatic nitriles did not react usiag these catalysts (72). Beginning ia 1971 a series of patents were issued to The Dow Chemical Company (73) describiag the use of copper metal catalysis. Full-scale production was achieved the same year. A solution of acrylonitrile ia water was passed over a fixed bed of copper catalyst at 85°C, which produced a solution of acrylamide ia water with very high conversions and selectivities to acrylamide. 

Selection of pollution control methods is generally based on the need to control ambient air quaUty in order to achieve compliance with standards for critetia pollutants, or, in the case of nonregulated contaminants, to protect human health and vegetation. There are three elements to a pollution problem a source, a receptor affected by the pollutants, and the transport of pollutants from source to receptor. Modification or elimination of any one of these elements can change the nature of a pollution problem. For instance, tall stacks which disperse effluent modify the transport of pollutants and can thus reduce nearby SO2 deposition from sulfur-containing fossil fuel combustion. Although better dispersion aloft can solve a local problem, if done from numerous sources it can unfortunately cause a regional one, such as the acid rain now evident in the northeastern United States and Canada (see Atmospheric models). References 3—15 discuss atmospheric dilution as a control measure. The better approach, however, is to control emissions at the source. 

Vapors emitted from the materials of closed storage and exhibit cases have been a frequent source of pollution problems. Oak wood, which in the past was often used for the constmction of such cases, emits a significant amount of organic acid vapors, including formic and acetic acids, which have caused corrosion of metal objects, as well as shell and mineral specimens in natural history collections. Plywood and particle board, especially those with a urea—formaldehyde adhesive, similarly often emit appreciable amounts of corrosive vapors. Sealing of these materials has proven to be not sufficiently rehable to prevent the problem, and generally thek use for these purposes is not considered acceptable practice. 

The most common method of converting iron ore to metallic iron utilizes a blast furnace wherein the material is melted to form hot metal (pig iron). Approximately 96% of the world s iron is produced this way (see Iron). However, in the blast furnace process energy costs are relatively high, pollution problems of associated equipment are quite severe, and capital investment requirements are often prohibitively expensive. In comparison to the blast furnace method, direct reduction permits a wider choice of fuels, is environmentally clean, and requires a much lower capital investment. 

Granulation processes offer a number of important advantages. The most significant are decreased pollution problems and the abiUty to produce granules of almost any reasonable size allowing close size matching with granular ammonium phosphates and potassium chloride in the preparation of NPK fertilizers (26). 

Use of mercuric catalysts has created a serious pollution problem thereby limiting the manufacture of such acids. Other catalysts such as palladium or mthenium have been proposed (17). Nitration of anthraquinone has been studied intensively in an effort to obtain 1-nitroanthraquinone [82-34-8] suitable for the manufacture of 1-aminoanthraquinone [82-45-1]. However, the nitration proceeds so rapidly that a mixture of mono- and dinitroanthraquinone is produced. It has not been possible, economically, to separate from this mixture 1-nitroanthraquinone in a yield and purity suitable for the manufacture of 1-aminoanthraquinone. Chlorination of anthraquinone cannot be used to manufacture 1-chloroanthraquinone [82-44-0] since polychlorinated products are formed readily. Consequentiy, 1-chloroanthraquinone is manufactured by reaction of anthraquinone-l-sulfonic acid [82-49-5] with sodium chlorate and hydrochloric acid (18). 

The bottoms from the stripper (40—60 wt % acid) are sent to an acid reconcentration unit for upgrading to the proper acid strength and recycling to the reactor. Because of the associated high energy requirements, reconcentration of the diluted sulfuric acid is a cosdy operation. However, a propylene gas stripping process, which utilizes only a small amount of added water for hydrolysis, has been described (63). In this modification, the equiUbrium quantity of isopropyl alcohol is stripped so that acid is recycled without reconcentration. Kquilibrium is attained rapidly at 50°C and isopropyl alcohol is removed from the hydrolysis mixture. Similarly, the weak sulfuric acid process minimizes the reconcentration of the acid and its associated corrosion and pollution problems. 

EPA has also developed pretreatment standards for industrial faciHties that discharge directiy to pubHcly owned treatment works (POTWs). The three types of pollutants of principal concern are pollutants that interfere with the operation of the POTW, pollutants that contaminate the sludges produced in the POTW, and pollutants that pass through the POTW or that are otherwise incompatible. One particular concern is volatile contaminants that can be stripped into the air during conventional wastewater treatment and become air pollution problems. These pretreatment standards are included in the effluent guidelines for the different industries. 

Solvent Extraction. Solvent extraction has widespread appHcation for uranium recovery from ores. In contrast to ion exchange, which is a batch process, solvent extraction can be operated in a continuous countercurrent-fiow manner. However, solvent extraction has a large disadvantage, owing to incomplete phase separation because of solubihty and the formation of emulsions. These effects, as well as solvent losses, result in financial losses and a potential pollution problem inherent in the disposal of spent leach solutions. For leach solutions with a concentration greater than 1 g U/L, solvent extraction is preferred. For low grade solutions with <1 g U/L and carbonate leach solutions, ion exchange is preferred (23). Solvent extraction has not proven economically useful for carbonate solutions. 

Solving water pollution problems today involves a multidisciplinary approach in which the required water quaUty is related to agricultural, municipal, recreational, and industrial requirements. In many cases, a cost—benefit ratio must be estabUshed between the benefit derived from a specified water quaUty and the cost of achieving that quaUty. 

To alleviate the air pollution problem associated with charcoal kilns and furnaces, the gases from the kiln and furnaces are burned (see Airpollution CONTROLMETHODS). They can be burned with additional fossil fuel to recover heat and steam (110,111), or in afterburners to nearly eliminate visible air pollution and odors (112). 

Hori ntalEetort. In 1800, the first commercial zinc process made use of the horizontal retort. In 1980, only three such plants remain because they are not competitive in terms of labor and fuel costs. Furthermore, the dust produced presents a serious pollution problem. Nevertheless, in 1956, the tonnage of zinc produced from horizontal retorts was above that of any previous year. The only remaining operation is in Russia with a capacity of 10,000 annual MT. 

Air pollution problems and labor costs have led to the closing of older pyrometaHurgical plants, and to increased electrolytic production. On a worldwide basis, 77% of total 2inc production in 1985 was by the electrolytic process (4). In electrolytic 2inc plants, the calcined material is dissolved in aqueous sulfuric acid, usually spent electrolyte from the electrolytic cells. Residual soHds are generally separated from the leach solution by decantation and the clarified solution is then treated with 2inc dust to remove cadmium and other impurities. 

In-plant controls are perhaps the best approach to eliminate waste generation and pollution problems, and many times good payback exists on recovery of products lost because of poor process controls. If the production department is responsible for the generation and in-plant control of wastes, this will help ensure that initial standards for water use and process loss are reasonable and that they are maintained (33). 

In 1976, over 3,000,000 tons of soda ash were produced in the United States using the Solvay process. This process has been discontinued in the United States because of pollution problems and high processing costs. It is stUl an important process in other countries. 

Coatings Industries. Surface coating processes (qv) produce similar air pollution problems in a number of different industries (see also... 

Such sources constitute background pollution and that portion of the pollution problem over which control activities can have little, if any, effect. 

Incomplete combustion, possibly creating potentially worse pollution problems... 

The predominant air pollution problem of the nineteenth century was smoke and ash from fhe burning of coal or oil in the boiler furnaces of stationary power plants, locomotives, and marine vessels, and in home heating fireplaces and furnaces. Great Britain took the lead in addressing this problem, and, in the words of Sir Hugh Beaver (3) ... 

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