Industrial Environmental Management

TAPAS K. DAS, PhD, P.E., BCEE, is a fellow member of the American Institute of Engineers; past chair of the AIChE's Environmental Division; and former chair of the Air Pollution Control Committee of the American Academy of Environmental Engineers. Dr. Das also served as an adjunct faculty member at several colleges and universities in Washington, and taught both undergraduate and graduate courses in environmental, civil, chemical, and mechanical engineering programs, and was a former assistant professor in the College of Natural Resources at the University of Wisconsin, Stevens Point.

• About the Author xxiPreface xxiiiAcknowledgements xxvAbout the Companion Website xxvii1 Why Industrial Environmental Management? 11.1 Introduction 11.2 Environmental Management in Industries 31.3 Waste as Pollution 41.4 Defining Pollution Prevention 41.5 The ZDZE Paradigm 51.6 Zero Discharge Industries 51.7 Sustainability, Industrial Ecology, and Zero Discharge (Emissions) 61.8 Why Zero Discharge is Critical to Sustainability 81.9 The New Role of Process Engineers and Engineering Firms 91.10 Zero Discharge (Emissions) Methodology 101.11 Making the Transition 121.12 Constraints and Challenges 171.13 The Structure of the Book 18Problems 21References 222 Genesis of Environmental Problem Worldwide: International Environmental Regulations 232.1 Introduction 232.2 Genesis of the Environmental Problem 252.3 Causes of Pollution and Environmental Degradation 262.4 Industrialization and Urbanization in the United States 272.5 Important Technological Developments 332.6 Industrial Disasters 342.7 Environmental Law 392.8 Pollution Control Laws 392.9 Resource Sustainability 412.10 Polluter Pays Principle 422.11 Theory/Environmental Law Debate 422.12 International Law 432.13 The Legal and Regulatory Framework for Environmental Protection in India 472.14 United States Environmental Law 552.15 ISO 9000 and 14000 572.16 Current Environmental Regulatory Development in the United States: From End-of-Pipe Laws and Regulations to Pollution Prevention 602.17 Greenhouse Gases 60Examples (Multiple Choice) 64Problems 65References 653 Industrial Pollution Sources, Its Characterization, Estimation, and Treatment 713.1 Introduction 713.2 Wastewater Sources 713.3 Wastewater Characteristics 713.4 Chemical Characteristics 733.5 Industrial Wastewater Variation 753.6 Industrial Wastestream Variables 773.7 Concentration vs. Mass of the Pollution 783.8 Industrial Wastewater Treatment 823.9 Air Quality 833.10 The Ideal Gas Law and Concentration Measurements in Gases 943.11 Other Applications of the Ideal Gas Law 963.12 Gas Flow Measurement 973.13 Flow at Standard Temperature and Pressure 983.14 Gas Flowrate Conversion from SCFM to ACFM 983.15 Corrections for Percent O2 983.16 Boiler Flue Gas Concentrations Are Usually Corrected to 3% Oxygen 983.17 Air‐to‐Fuel Ratio and Stoichiometric Ratio 983.18 Material Balances and Energy Balances 993.19 Wastes in the United States 1023.20 Hazardous Waste 1043.21 Incineration, Destruction, and WtE 1053.22 Hazardous Waste Landfill (Sequestering, Isolation, etc.) 1063.22.1 Pyrolysis 1063.23 Radioactive Waste 1063.24 Coal 1073.25 Low‐ Level Waste 1083.26 Nuclear Waste Management 109Problems 110References 1114 Industrial Wastewater, Air Pollution, and Solid and Hazardous Wastes: Monitoring, Permitting, Sample Collections and Analyses, QA/QC, Compliance with State Regulations and Federal Standards 1154.1 Introduction 1154.2 Industrial Process Water 1154.3 Common Elements, Radicals, and Chemicals in Water Analysis 1154.4 Purposes and Objectives for Inspecting and Sampling 1164.5 Sampling and QA/QC Plan 1204.6 Whole Effluent Toxicity Testing 1304.7 Flow Measurements 1334.8 The Point of Compliance with the Water Quality Standards 1394.9 Water Quality Modeling 1424.10 Example NPDES Permits (for Refinery and Aluminum Smelter are shown in Section D.1) 1454.11 Air Pollution Perspective 1464.12 Prevention of Significant Deterioration (PSD) Permitting Process 1494.13 An Overall Permitting Process 1504.14 Best Available Control Technology 1524.15 Atmospheric Dispersion Modeling 1574.16 Dispersion Models: Indoor Concentrations 1594.17 State Implementation Plan 1624.18 Compliance 1644.19 CAA Enforcement Provisions 1684.20 Industrial Solid Wastes and Its Management 1734.21 Hazardous Waste Landfill (Sequestering, Isolation, etc.) 1804.22 Industrial Waste Generation Rates 1814.23 Comprehensive Environmental Response, Compensation, and Liability Act and Superfund 1824.24 Industrial Waste Management in India: Shifting Gears 185Problems 187References 1895 Assessment and Management of Health and Environmental Risks: Industrial and Manufacturing Process Safety 1935.1 Health Risk Assessment 1935.2 Assessing the Risks of Some Common Pollutants 2015.3 Ecological Risk Assessment 2075.4 Risk Management 2175.5 Communicating Information on Environmental and Health Risks 2275.6 Environmental Information Access on the Internet 2315.7 Health and Occupational Safety 2345.8 Industrial Process Safety System Guidelines 2355.9 Industrial Hygiene 2365.10 Atmospheric Hazards 2375.11 Safety Equipment 2415.12 Communication Devices 2435.13 Noise 2465.14 Radiation 2495.15 Effects of Global Warming: Climate Change – The World’s Health 2535.16 Key Vulnerabilities 2575.17 Energy Sector 258Problems 259References 2606 Industrial Process Pollution Prevention: Life-Cycle Assesvsment to Best Available Control Technology 2656.1 Industrial Waste 2656.2 What is Life Cycle Assessment? 2676.3 LCA and LCI Software Tools 2806.4 Evaluating the Life Cycle Environmental Performance of Chemical-, Mechanical-, and Bio-Pulping Processes 2826.5 Evaluating the Life Cycle Environmental Performance of Two Disinfection Technologies 2916.6 Case Study: LCA Comparisons of Electricity from Biorenewables and Fossil Fuels 2996.7 Best Available Control Technology (for Environmental Remediation) 3036.8 BACT: Applications to Gas Turbine Power Plants 304Problems 312References 3127 Economics of Manufacturing Pollution Prevention: Toward an Environmentally Sustainable Industrial Economy 3177.1 Introduction 3177.2 Economic Evaluation of Pollution Prevention 3177.3 Cost Estimates 3187.4 Economic Criteria for Technology Comparisons 3217.5 Calculating CF 3217.6 From Pollution Control to Profitable Pollution Prevention 3237.7 Resource Recovery and Reuse 3257.8 Profitable Pollution Prevention in the Metal-Finishing Industry 3267.9 Use of Treated Municipal Wastewater as Power Plant Cooling System Makeup Water: Tertiary Treatment vs. Expanded Chemical Regimen for Recirculating Water Quality Management 3357.10 Consequences of Dirty Air: Costs–Benefits 3407.11 Some On-Going Pollution Prevention Technologies 3417.12 Cost Indices and Estimating Cost of Equipment 3487.13 Waste-to-Energy 3507.14 Sustainable Economy and the Earth 354Problems 357References 3598 Lean Manufacturing: Zero Defect and Zero Effect: Environmentally Conscious Manufacturing 3638.1 Introduction 3638.2 Engineering Data Summary and Presentation 3648.3 Time Series: Process over Time 3698.4 Process Capability 3718.5 Lean Manufacturing 3748.6 Types of Waste 3808.7 Six Sigma in Industry 3818.8 Lean Implementation Develops from TPS 3818.9 Manufacturing System Characteristics: Process Planning Basics 3858.10 Design for Life Cycle 3868.11 Sustainable Design and Environmentally Conscious Design and Manufacturing 3878.12 Lean Six Sigma 3908.13 Six Sigma and Lean Manufacturing 3928.14 Cost vs. Quality Analysis 3938.15 Assessing and Reducing Risk in Design: Cost to Manufacturer 3958.16 The Heart and Soul of the Toyota Way: Lean Processes 3968.17 Essential Roles of Industrial Environmental Managers 4008.18 Goals of IEMs 4018.19 Environmental Compliance and Compliance Assurances 4018.20 Waste Reduction 401Problems 403References 4059 Industrial Waste Minimization Methodology: Industrial Ecology, Eco-Industrial Park and Manufacturing Process Intensification and Integration 4099.1 Introduction 4099.2 Industrial Ecology 4099.3 Water–Energy Nexus 4179.4 CE Indicators in Relation to Eco-Innovation 4269.5 Process Intensification and Integration Potential in Manufacturing 4279.6 Manufacturing Process Integration 4329.7 New Sustainable Chemicals and Energy from Black Liquor Gasification Using Process Integration and Intensification 4339.8 Chemical Recovery and Power/Steam Cogeneration at Pulp and Paper Mills 4369.9 Conclusions 445Problems 447References 44810 Quality Industrial Environmental Management: Sustainable Engineering in Manufacturing 45310.1 Introduction: Industry and the Global Environmental Issues 45310.2 Integrating LCA in Sustainable Product Design and Development 46310.3 Green Chemistry: The Twelve Principles of Green Chemistry 46410.4 The Hannover Principles 46710.5 Sustainable Industries and Business 46810.6 Six Essential Characteristics 47010.7 Social Services 47110.8 Environmental Regulatory Law: Command and Control Market Based, and Reflexive 47110.9 Business Ethics 47210.10 International Issues 47310.11 Ethical Sustainability 47310.12 Social Sustainability 47410.13 Conclusions 47510.14 Strategy for Corporate Sustainability 476Problems 477References 477Appendix A Conversion Factors 481Appendix B International Environmental Law 483Appendix C Air Pollutant Emission Factors: Stationary Point and Area Sources 487Appendix D Frequently Asked Questions and Answers: Water Quality Model, Dispersion Model and Permits 493Appendix E Industrial Hygiene Outlines 511Appendix F Environmental Cost-Benefit 513Appendix G Resource Recovery: Waste-To-Energy Facility, City of Spokane, Washington, USA 515Appendix H The Hannover Principles 519Appendix I Environmental Goals and Business Goals Are Not Two Distinct Goal Sets 521Appendix J Sample Codes of Ethics and Guidelines 523Index 527