Recycle to the Original Manufacturing Process

When this is done, the calcium hydroxide is included in the melting furnace slag, and the unspent calcium carbide is either used or oxidized in the melting furnace. Little testing has been done to determine the actual fate of the sulfur. Most of it may be included in the slag, but it may also be emitted to the air as sulfur dioxide, or, for foundries with wet emission control systems, it may be dissolved in the water. 

We have seen that the state-of-the-art methods for spraying or immersing the desulfurization slag in water have the potential to cause difficult air emissions and industrial hygiene problems. Several foundry companies and research groups have evaluated three different basic types of reactors for treatment of calcium carbide desulfurization slag. 

The first, a reactor system involving immersion of the slag in water, is really a more controlled version of the methods commonly used by foundries at this time. The British Cast Iron Research Association has done work on these types of reactors over the past 10 years, and has developed prototypes for systems to introduce the slag into the water. 

A second major type of reactor involves thermal destruction of the calcium carbide. At about 1,S00°F, both calcium carbide and acetylene are thermally oxidized. Therefore, a system such as a rotary kiln could be used for thermal destruction of the reactivity characteristics. The additional benefit of thermal destruction is that it will also effectively deal with potential sulfide reactivity problems. Large chunks of metals often included in the desulfurization slag will tend to be a problem for many types of thermal units. Concern over air emissions and cost are other hurdles to the use of thermal systems for calcium carbide desulfurization slag. 

there is serious question as to whether such a system would be capable of obtaining a RCRA Part B Permit to operate without formal air emission control systems. These open tank systems are designed to be crude but effective. When one begins to collect flammable and toxic gases over such open tanks and to allow access of fork lift trucks to deliver and retrieve hoppers of slag, the logic of the system falls apart very quickly and one returns to the reactor concept or other options. 

---

Closed-Mill Concept. The closed-mill concept, or water circuit closure, has been studied by the pulp and paper industry for many years. In some parts of the paper manufacturing process, up to 98% of the water is recycled within the process, eg, the wet end of the paper machine. However, in the pulp mill, especiaUy kraft mills, effluents are produced owing to the need to purge from the system various metals that come in with the wood, as weU as organic by-products from the pulping process, additives, and especially chloride ions that originate in the bleach plant. 

For the organic contaminants, the required bromine product quality wilt also be site specific. If the catalytic oxidation unit is dedicated to a single bromination process, phase separation and drying may be the only purification required. Contaminants in the recovered bromine which are either the starting materials or products of the original bromination reaction should not present a problem if present in bromine recycled to the bromination reactor. In this case, the catalytic reactor would be operated to minimize the formation of undesirable brominated byproducts. For example, if phenol is present in the waste HBr from a tribromo-phenol manufacturing process, minor tribromophenol contamination of the bromine recycled to the reactor should not be a problem. Similarly, fluorobenzene in bromine recycled to a fluorobenzene bromination process should not present a problem. 

Mitsubishi Kasei introduced a process to manufacture isononyl alcohol, an important PVC (polyvinyl chloride) plasticizer, via the hydroformylation of octenes (a mixture of isomers produced by dimerization of the C4 cut of naphtha cracker or FCC processes).95 First a nonmodified rhodium complex exhibiting high activity and selectivity in the formation of the branched aldehyde is used. After the oxo reaction, before separation of the catalyst, triphenylphosphine is added to the reaction mixture and the recovered rhodium-triphenylphosphine is oxidized under controlled conditions. The resulting rhodium-triphenylphosphine oxide with an activity and selectivity similar to those of the original complex, is recycled and used again to produce isononanal. 

Hachette UK s policy is to use papers that are natural, renewable and recyclable products and made from wood grown in sustainable forests. The logging and manufacturing processes are expected to conform to the environmental regulations of the country of origin. 

Froth flotation is used to raise the low mineral concentrations in ores to concentrations that can be more economically processed. A concentration of 25-30% is suitable for economical smelting of copper. The froth flotation technique was originally developed in about 1910 to raise the copper concentrations of the strip-mined ores of Bingham Canyon, near Salt Lake City [9], and was further perfected for the differential separation of lead, zinc, and iron sulfides at Trail, B.C., at about the same time [10]. Flotation technologies are now widely used for separations such as the beneficiation of low grade Florida phosphate ores from 30-40% to 60-70% concentrations of calcium phosphate (BPL), and the separation of about 98% potassium chloride from sylvinite, a natural mixture of potassium and sodium chlorides. It is also used for bitumen separation from tar sand, removal of slate from coal, and removal of ink from repulped paper stock preparatory to the manufacture of recycled paper stock. More details of these separations are discussed in the relevant chapters. 

---