INTERNATIONAL CLEANER PRODUCTION INFORMATION CLEARINGHOUSE

CASE STUDY # 157

1.   Headline:  On-site recycle and reuse of alcohol wash
     solution

2.   Background:  See below.

3.   Cleaner Production Principle:  internal recycling

4.   Description of Cleaner Production Application:  This plant
     generated 6,000 gal/yr of reactor wash solution containing
     approximately 50% alcohol, phenol formaldehyde resin, and
     water.  Economic considerations prompted the plant to
     recycle on site by distilling and reusing the alcohol.
     The distillation kettle was already available on site.
     Steam was available at negligible costs.  The resin
     removed from the reactor can also be reused.  Laboratory
     analysis of synthetic resins also generates waste which is
     disposed off-site.  Segregation of these wastes was
     attempted, but it was impractical due to the small
     quantities generated, i.e. 2-3 drums/month.  Proper
     disposal is the only option available for managing these
     wastes.

     Case Study Summary

     Original Manufacturing Process and Previous Waste/Emission
     Management Methods:  Phenol formaldehyde is manufactured
     in batch reactors.  The reactors are cleaned with alcohol
     every time a change is made in product specifications.

     Scale of Operation: This facility has 50 employees, and
     annual revenues of 5-10 million dollars.

      Stage of Development:  Fully implemented

     Level of Commercialization:  Alcohol recovery systems are
     readily available

     Results of Application:  Better than 67% reduction of
     waste generated and disposed off-site.

     Wastes generated - 6,000 gal/yr (before), less than 2,000
     gal/yr (after)

     Waste and/or Emission Description

                         Physical state:    Slurry

                         Composition:      Alcohol, resin,
                         water

                         Description:      Reactor wash
                         solution


5.   Economics

                         Other costs:      $140/drum of waste
                         to treat off site.   Alcohol costs
                         $1.60/gal.

                         Economic Benefits: $15,000 annual
                         savings in material and treatment
                         costs

6.   Advantages:

     Liability:  Liabilities by reducing the quantity of
     hazardous waste generated

     Regulatory compliance:  Regulatory compliance is easier
     with reduced volumes of F003 wastes disposed off-site.
7.   Constraints:  No information provided.

8.   Contacts and Citation

     Industry/Program Contact and Address:  Richard J. Gimello,
     Susan B. Boyle,  New Jersey Hazardous Waste Facilities
     Siting Commission,  28 West State Street, Trenton, N.J.
     08608, United States

     Citation:  Environmental Resources Management, Inc.  A
     Study of Hazardous Waste Reduction and Recycling in Four
     Industrial Groups in New Jersey.  April 1987

9.   Keywords:  United States, USA, chemical, recycling, SIC
     2821, reactor, alcohol, distillation, resin.

10.  Reviewer's Comments:  This case study was originally
     abstracted for the US EPA's Pollution Prevention
     Information Clearinghouse from a document compiled by the
     USA New Jersey Hazardous Waste Facilities Siting
     Commission.  It underwent a UNEP IE funded technical
     review in 1994 for quality and completeness.  It was
     edited for the ICPIC diskette in July 1995.

( Docno UNEP07: 031-001-A-435 )