| Waste Minimization at a Pesticide Manufacturing Plant | Poland | 1992 | Full scale |
MANUFACTURE OF CHEMICALS AND CHEMICAL PRODUCTS # 43
Background
"Organika Azot" is a leading manufacturer of pesticides in Poland as well as other crop protection products and sanitary agents for agriculture. The company was founded in 1917 and initially produced fertilizers. Today, the plant employs 800 people and produces a wide variety of chemicals including insecticides, herbicides, and funcigides. Products are formulated and packaged at the plant. There is a synthesis plant for organochlorophosphates and a reaction facility for copper oxychloride manufacture. Other manufacturing lines produce aerosol containers and polyethylene packaging. Products are primarily marketed in Poland, but some are exported to the Netherlands.
The cleaner production measures were initiated under the Industrial Waste Minimization Program in Poland carried out by WEC with the financial support of the United States Agency for International Development. The objectives of the program include, demonstrate and support economic and environmentally motivated low-cost waste minimization and cleaner production measures.
Cleaner Production Principle
Process modification; Recovery, Reuse and Recycle
Cleaner Production Application
A.
During the manufacture of the insecticide "Birlane" one of the process steps is the distillation of raw dichloroacetophenone (DCAP). During the distillation step, heavy organic wastes containing about 50 percent (by weight) of DCAP are generated. In the past, all organic wastes were combusted in an on-site incinerator.
During the waste minimization project, a comprehensive evaluation of the DCAP production process was performed. The results indicated that economic and environmental benefits could be realized by redistillation of a part of the organic waste generated during the first distillation of raw DCAP.
B.
During normal operations, "Organika-Azot" needed to purchase about 50,000 m3/year of water to satisfy the requirements of all production plants. Process wastewater generated at the facility underwent primary and biological treatment in the existing wastewater treatment plant before discharge into a nearby river.
During the waste minimization project, the feasibility of recycling and reusing a part of the treated wastewater in selected processes was investigated. The results of the investigation indicated that about 150,000 m3/year of treated wastewater could be reused in specific operations.
C.
Dichloroacetophenone (DCAP) is an intermediate material in the production process of the insecticide "Brilane" during the production process, DCAP is first hydrolyzed and then extracted with benzene. Subsequently, the benzene organic phase containing the DCAP is subjected to a three-step washing operation. During the washing operation, wastewater containing aluminum salts is generated. In the past, some of the wastewater was sold as a 25 percent solution of aluminum chloride, but the majority (second and third step washings) was discharged into the wastewater treatment plant.
During the waste minimization project, experiments confirmed that the wastewater from the second and third washings of the organic phase of DCAP could be reused in the hydrolysis process and replace fresh water.
D.
Due to a lack of appropriate monitoring equipment, "Organika-Azot" has been experiencing excessive consumption of hot water in their central heating system and fresh and industrial water throughout the plant.
During the waste minimization project, a thorough analysis of hot and fresh water distribution and usage was conducted. The results of the analysis showed that the appropriate water monitoring equipment would significantly decrease the hot and industrial water consumption at the plant. Hot water is distributed through pipe branches to many buildings and spaced which need heat. Many of these branches were overheated which resulted in excessive hot water consumption and heat losses. By monitoring the hot water flow through each branch, orifices could be installed to minimize water consumption. Monitoring capabilities would also be helpful in locating leaks through out the factory's water network by checking and comparing the water flows at both ends of the pipelines.
To implement this project, a portable liquid flow meter, with adapters for various pipe sizes, was purchased and installed. This monitoring equipment is being used by plant personnel to continuously improve management of their hot and Process water.
Environmental and Economic Benefits
A.
As a result of the project, the facility is recovering 7.5 kg DCAP/ton of product and has reduced the amount of organic waste incinerated. The facility's raw material requirements have also been decreased by 4500 kg/year.
| Investment | 800 US$ |
| Savings | 11,900 US/year |
| Payback period | <1 month |
B.
Implementation of the project resulted in a decrease in the purchase requirements for fresh water of 150,000 m3/year. The facility also reduced wastewater discharges by 150,000 m3/year and paid less environmental fees.
| Investment | 1050 $US |
| Savings | 1,600 US/year |
| Payback period | <3 weeks |
C.
Implementation of this project resulted in raw material savings and in decreased wastewater discharges and environmental fees.
| Investment | 1100 US$ |
| Savings | 13,000 US/year |
| Payback period | 1 month |
D.
The project resulted in saving of hot water in the central heating system and fresh and industrial water throughout the plant.
| Investment | 5965 US$ |
| Savings | 11,900 US/year |
| Payback period | < 4 month |
Constraints
None reported.
Contacts
Review Status
This case study was taken from the document "Economic and Environmental Benefits of Industrial Waste Minimization in Poland", the World Environment Center, 419 Park Avenue South, Suite 1800, New York, NY 10016 United States, Tel: +1 212 683 4700, Fax : +1 212 683 5053. It was reviewed and edited by UNEP IE in December, 1995.
Subsequently the case study has undergone a technical review by Dr Prasad Modak at Environmental Management Centre, Mumbai, India, in September 1998.