Embed Size (px)
Citation preview
Reducing hazardous waste in thechemical and pharmaceuticalindustries
GG
681
This Good Practice Guide was produced by
Envirowise
Prepared with assistance from:
ARL Consulting Ltd
Reducing hazardous waste in thechemical and pharmaceuticalindustries
Summary
The chemical and pharmaceutical industries are significant producers of hazardouswaste. The introduction of new hazardous waste legislation in 2005 has requiredcompanies to consider carefully the management and disposal of their site waste -especially since certain categories of waste are newly defined as hazardous.
Many factors, including the Pollution Prevention and Control (PPC) regulations, are encouragingthe chemical and pharmaceutical industries to be more resource efficient and thus reduce theproduction of hazardous waste.
This Good Practice Guide focuses on ways to prevent and reduce hazardous waste, rather thanits disposal. It brings together information on current industry practice plus suggestions forfurther improvements. The Guide contains:
n general guidance that provides managers with strategic, policy and procedural informationto help prevent and reduce hazardous waste at their sites;
n technical guidance relevant to the chemical and pharmaceutical industries based on adviceprovided in other Envirowise publications;
n sources of further information and advice including Envirowise, Environment Agencyguidance and trade associations.
Free advice on all aspects of hazardous waste can be obtained from the Environment and EnergyHelpline on 0800 585794. Envirowise publications can be ordered through the Helpline ordownloaded from the Envirowise website (www.envirowise.gov.uk).
Contents
Section Page
1 Introduction 11.1 Waste hierarchy 11.2 Drivers to reduce hazardous waste 21.3 Aim and structure of this Guide 4
2 General guidance 52.1 Management systems and controls 52.2 Training 62.3 Integrated Product Policy 72.4 Material management 72.5 Material storage 82.6 On-site waste management and disposal 82.7 Waste segregation 92.8 Filter cake management 92.9 ‘Green chemistry’ manufacturing 10
3 Technical guidance 113.1 Vessel design 113.2 Optimising production processes (batch and continuous chemistry) 123.3 Effective solvent management 133.4 Vacuum systems 153.5 Water management 15
4 Sources of further information 164.1 Envirowise 164.2 Environment Agency 164.3 Useful websites 19
11
sect
ion
1
Introduction
The UK chemical and pharmaceutical industries have a diverse range of manufacturingoperations and products. Products range from finished goods through to the basicorganic and inorganic chemicals used as raw materials in almost all manufacturingindustries and in agriculture. They include fertilisers, pesticides, plastics, adhesives, paints,soaps, detergents, cosmetics and pharmaceutical intermediates, and finished products.
The manufacturing sites in these industries are characterised by the production of chemicals andpharmaceuticals in small, medium and large volumes using multi-functional plant. Theyfrequently involve batch manufacturing and fermentation processes, as well as dedicatedcontinuous production plant.
The chemical and pharmaceutical industries have historically produced a number of wastematerials. Reflecting the complexity of their manufacturing processes, they have always operatedwith what is considered a high waste to product ratio compared with other sectors.
In recent years, the industries have reduced the environmental impact of their productionactivities, particularly through reduced discharges to air and water. This improvement is partly inresponse to legislation and partly the result of the industries’ own initiatives. For example, thereduction of hazardous waste in the chemical industry is being promoted as part of the ChemicalIndustries Association (CIA) Sustainable Development target to reduce the quantity of hazardouswaste by 25% per tonne of product by 2010.
This Good Practice Guide is intended to help the chemical and pharmaceutical industries reducethe quantities of hazardous waste requiring management and disposal.
1.1 Waste hierarchy
The waste hierarchy (see Fig 1) emphasises elimination and reduction as being the most cost-effective and best environmental options. The Guide therefore focuses on prevention,elimination and reduction of hazardous waste, following the waste hierarchy in order to securecost savings and environmental benefits within the pharmaceutical and chemical industries.Disposal should always be the last option and is outside the scope of this Guide.
Wider environmental impacts associated with the full life-cycle of chemicals also requireconsideration. Integrated Product Policy (IPP) (see section 2.3) asks more fundamental questionsabout such issues as:
n product use and disposal;
n raw material selection;
n whether a particular chemical should be produced in the first place.
11se
ctio
n
2
1.2 Drivers to reduce hazardous waste
Preventing and reducing hazardous waste will help UK chemical and pharmaceutical companies to:
n save money by reducing waste management and disposal costs, which continue to increaseas a result of stricter controls on hazardous waste;
n improve their environmental performance;
n meet the challenges posed by the environmental legislation governing hazardous waste.
1.2.1 Hazardous waste legislation
The introduction in July 2005 of the Hazardous Waste Regulations (HWR) and similar legislationin Scotland and Northern Ireland required industry to examine carefully the management anddisposal of its site waste - especially as certain categories of waste are newly defined ashazardous. The HWR apply to a large section of the chemical and pharmaceutical industries inthe UK.
Through the List of Wastes Regulations 2005, the HWR also implement the European WasteCatalogue (EWC). This classifies hazardous waste according to strictly defined criteria (see section1.2.2).
As a result of the new legislation and additional changes to the EU Hazardous Waste List in 2002,approximately 180 additional waste materials are now classified as hazardous.
In addition, any landfilled waste is also required to meet certain Waste Acceptance Criteria (WAC).
Implementation of the Landfill Directive means that there are now only a limited number ofhazardous waste landfill sites available in the UK. Both landfill and alternative treatment technologiesfor hazardous waste (e.g. incineration) are relatively high in terms of disposal costs.
UK industry is thus having to commit a large amount of time (and associated cost) to ensureappropriate management and disposal in complying with the HWR.
In addition to these cost and disposal issues, other legislation is already being applied to ensurethat production processes are optimised to reduce waste at source (see section 1.2.3).
5
Material
Dispose
4Recycle
3Re-use
2Reduce
1Eliminate
Product
Avoid producingwaste in the
first place Minimisethe amount
of waste youdo produce
Use items asmany times as
possible Recycle whatyou can only
after youhave re-used it
Dispose ofwhat’s left in a responsible way
Start here
WASTEONLY
Fig 1 Waste hierarchy
11
sect
ion
3
1.2.2 European Waste Catalogue
The EWC includes both hazardous and non-hazardous waste.
Hazardous waste is identified with an * (asterisk) after the six-figure code. The code is shown in:
n red when the waste is hazardous, irrespective of any threshold concentration;
n blue when the waste is hazardous only if dangerous substances are present above thresholdconcentrations.
The most relevant chapter headings in the EWC for the chemical and pharmaceutical industries are:
n 06 Wastes from inorganic chemical processes;
n 07 Wastes from organic chemical processes;
n 08 Wastes from the manufacture, formulation, supply and use of coatings, adhesives,sealants, and printing inks.
However, the diverse nature of the UK chemical and pharmaceutical industries meanshazardous waste may fall within a number of subsections of the other EWC chapter headings.Examples include:
n 16 08 Spent catalysts;
n 15 01 10* Packaging containing residues of or contaminated by dangerous substances.
1.2.3 Pollution Prevention and Control regime
Most of the sites covered by this Guide will already be regulated under the Pollution Preventionand Control (PPC) regime, which implements the requirements of the Integrated PollutionPrevention and Control (IPPC) Directive in the UK.
Fundamental to IPPC is the requirement that each site must operate according to predefined BestAvailable Techniques (BAT), the details of which are given in a BAT Reference (BREF) documentfor its industry or sector published by the European IPPC Bureau.1
The use of BAT helps to define what is considered as operational best practice across theindustries. It also introduces the concept of ‘benchmarking’. The BREF provides guidance, forexample, on specific waste production (ie kg of waste produced per kg of production) for aparticular manufacturing process.
If a site is considered to be operating inefficiently (according to the industry standard‘benchmark’) then it may be required, as part of an Environment Agency controlled ImprovementPlan, to implement specific process improvements to rectify the situation. This also covers theproduction and reduction of hazardous waste, if appropriate.
1.2.4 REACH
The new EU Chemicals Strategy - Registration, Evaluation, Authorisation and Restriction ofChemicals (REACH)2 - will affect hazardous chemicals used and ultimately may affect thedischarge of hazardous waste.
1 See http://eippcb.jrc.es/2 See http://ec.europa.eu/enterprise/reach/index_en.htm
11se
ctio
n
4
Contact the Environment and Energy Helpline on 0800 585794 for initial advice on REACH andwhere to obtain further information.
1.3 Aim and structure of this Guide
This Guide aims to:
n highlight opportunities for further and/or enhanced savings for sites already working to BATand accepted industry standard ‘benchmarks’;
n introduce other sites to the concept of hazardous waste minimisation and the idea of thewaste hierarchy.
The Guide has three main parts:
n Section 2 suggests ways in which the Board and general managers can improve the overalloperation of the supply chain and manufacturing processes so as to prevent and reducehazardous waste.
n Section 3 contains a series of checklists3 offering practical advice to technical managers andoperators on practical measures to prevent and reduce hazardous waste arisings fromchemical and pharmaceutical manufacturing processes. The suggestions in these checklistsare drawn from Envirowise publications containing detailed advice on issues such as vesselwashing, optimising production processes, solvent management, vacuum systems and watermanagement.
n Section 4 contains details of the further information and advice available from Envirowise, theEnvironment Agency and other sources.
All the Envirowise publications mentioned in this guide can be either downloaded from thewebsite (www.envirowise.gov.uk) or ordered free of charge through the Environment and EnergyHelpline on 0800 585794.
Please note that the legislation mentioned in this publication was checked foraccuracy in June 2007 before going to press. However, legislation is constantlychanging and being updated. For information on current environmental legislation,please contact the Environment and Energy Helpline free on 0800 585794.
The information is largely based on the regimes applying to England and Wales.
Guidance on all regulatory regimes across the UK is published by the regulatingagencies on their respective websites:
n Environment Agency (England and Wales): www.environment-agency.gov.uk
n Northern Ireland Environment and Heritage Service: www.ehsni.gov.uk
n Scottish Environment Protection Agency (SEPA): www.sepa.org.uk
The NetRegs website (www.netregs.gov.uk) also provides UK businesses withconsiderable information and advice on environmental legislation.
3 Can be printed out or photocopied as required.
22
sect
ion
5
General guidance
This section describes a number of general management and high-level operationalmeasures that will contribute to minimising hazardous waste in the chemical andpharmaceutical industries.
2.1 Management systems and controls
2.1.1 Environmental management systems
Site operations should be undertaken according to specific management and environmentalmanagement systems. An environmental management system (EMS) provides a framework formanaging environmental responsibilities so they become more efficient and more integrated intooverall business operations.
An EMS is based on standards which specify a process of achieving continuously improvedenvironmental performance and compliance with legislation. A suitably accredited EMS offersregistration to the internationally recognised environmental standard ISO 14001. Registration can:
n remove uncertainty and inconsistency by managing disruption and waste;
n give competitive advantage to avoid international trade barriers;
n help companies stay compliant with regulatory requirements;
n improve overall performance.
For free advice and information from Envirowise on setting up an EMS, visit the website(www.envirowise.gov.uk) or call the Environment and Energy Helpline on 0800 585794.
2.1.2 Operator and Pollution Risk Appraisal
To limit the impact of pollution, including the production of hazardous waste, the chemical andpharmaceutical industries in England and Wales are monitored by the Environment Agencythrough a methodology known as Environmental Protection Operator and Pollution RiskAppraisal (EP OPRA)4. This looks at two aspects of the pollution hazard.
The first is the environmental risk of the specific processes. This includes the following:
n What hazardous substances are stored?
n What hazardous substances could be emitted?
n How frequent is the process and how complicated is it?
n How is the hazard controlled at source?
n How are environmental emissions reduced?
n How sensitive is the local environment to pollution?
n Are emissions likely to cause annoyance, such as a smell?
4 A different approach is taken by Regulators in Scotland and Northern Ireland.
22se
ctio
n
6
Each of these attributes is scored from 1 (low hazard) to 5 (high hazard). These are then addedtogether to give a total Pollution Hazard Appraisal (PHA) score. The resultant map shows thesescores for each process divided into bands, from Band A for lowest pollution hazards to Band Efor highest pollution hazards.
The second aspect looks at the operator and their ability to manage the environmental risks ofthe processes they are engaged in. This involves an evaluation of the following attributes:
n recording and use of information;
n knowledge and implementation of authorisation requirement;
n plant maintenance;
n management and training;
n process operation;
n incidents, complaints and non-compliance events;
n recognised environmental management systems.
All of these attributes are scored from 1 (low performance) to 5 (high performance). They arethen added together to give the Operator Performance Appraisal (OPA). The datasets show BandA for the best operator down to Band E for the worst operator.
Hazard scores (PHA) in the chemical and pharmaceutical industries are higher compared withother industrial sectors, though this is a reflection of the nature and scale of chemical inventoriesprevalent within the chemical and pharmaceutical industries.
On the other hand, the chemical and pharmaceutical industries are well managed (OPA) and thisis reflected in generally low OPRA scores.
2.2 Training
Site management and operational staff should be made aware of the implications of dealingwith hazardous waste and associated legislation. This should include:
n all necessary health and safety training;
n the importance of legislation compliance;
n the potential implications of any breach of the regulations.
Training and awareness-raising should be extended to cover a number of operational aspectsincluding:
n accurate mixing of reactant batches;
n process control optimisation;
n solvent use and conservation;
n raw material use and stock control;
n correct waste disposal procedures;
n environmental awareness.
22
sect
ion
7
2.3 Integrated Product Policy
Chemical and pharmaceutical raw materials and products need to be managed along the supplychain. This should include all relevant processes including:
n manufacture;
n packaging;
n distribution;
n handling;
n use;
n ultimate disposal.
There should, therefore, be a constant dialogue between manufacturers, distributors, haulagecompanies and others involved in the marketing of chemical and pharmaceutical products. Thiswill promote effective communication and improved environmental performance up and downthe supply chain.
For example, companies are encouraged to:
n request that suppliers take back and re-use packaging (especially drums and intermediatebulk containers (IBCs));
n consider bulk chemical supply for certain high-volume raw materials;
n consider re-use of raw material drums for finished product despatch.
The effective management of chemicals throughout industry will be further monitored andcontrolled through the implementation of REACH, which is likely to result in significant medium-to long-term changes in the way that chemicals are managed.
2.4 Material management
A number of useful techniques are available to reduce hazardous waste by optimising rawmaterial management.
n Purchasing and supply chain raw material control mechanisms (see section 2.3) thatrationalise the number of raw material suppliers and the raw materials themselves to reducethe number of different raw materials kept in stock. This, in turn, reduces the number ofincompatible wastes and simplifies both storage and collection arrangements for hazardouswastes.
Rationalising the raw material inventory:
- reduces the cost of raw material purchasing;
- reduces the risk of raw materials becoming out-of-specification or out-of-date;
- simplifies raw material control;
- reduces the amount of packaging classed as hazardous waste.
n Centralised raw material and waste control areas ensure that accountability for stockand waste management rests with a small number of individuals. This typically results in lesswaste and more effective raw material and waste management. Wastes can be sorted andseparated in a defined area to await collection by a specialist contractor.
22se
ctio
n
8
2.5 Material storage
Larger bulk purchasing and storage arrangements reduce storage space requirements and bringdown the unit cost of raw materials. This is especially relevant for larger volume containers for rawmaterials, acids, solvents, etc (eg IBCs as opposed to 25-litre tins/drums). Typical benefits include:
n less residual waste because fewer containers are used and less material is left behind whenemptying due to use of self-draining containers with fewer ‘blind spots’;
n more effective storage with increased environmental protection (easier to bund);
n fewer spillages;
n less need for frequent movements of raw materials;
n easier material accountancy (fewer containers to track);
n easier for the supplier to recover containers.
Significant saving opportunities can be identified by monitoring the volumes of raw materialsused. This should include specific consumption of feedstock chemicals and solvents (eg kg ofsolvent/unit of production).
Empty chemical drums should ideally be returned to the supplier or, if this is not practical orpossible, sent to a specialist drum recycling contractor.
Chemicals should be stored off-ground on suitably bunded decking or, where this is notpracticable, on pallets that are contained within suitably bunded structures.
Different types of chemicals (eg acids and alkalis) should be segregated to prevent any potentialfor mixing in case of spills.
2.6 On-site waste management and disposal
Fundamental to the principles of the waste hierarchy and as emphasised in IPPC Sector GuidanceNotes (see section 4.2), sites should be operated so as to reduce waste volumes.
Where waste is produced, the IPPC Directive requires that it is recovered unless ‘technically andeconomically impossible’. If waste is to be disposed of either by the operator or via a wastemanagement company, the operator must ensure that the chosen disposal option avoids orreduces any impact on the environment.
Further details can be found in the Environment Agency publications (see section 4.2):
n Sector Guidance Note IPPC S5.06. Guidance for the recovery and disposal of hazardous andnon hazardous waste. Integrated Pollution Prevention and Control (IPPC).5
n Best practice guidance. Guidance for the recovery and disposal of hazardous and nonhazardous waste (other than by incineration and landfill). Waste management licensedfacilities.6
5 www.environment-agency.gov.uk/commondata/acrobat/sgn_issue_4_968872.pdf6 www.environment-agency.gov.uk/commondata/acrobat/chemicalbestpract_652800.pdf
22
sect
ion
9
2.7 Waste segregation
Clear procedures and mechanisms for waste segregation are essential. One example is colour-coded bins for different types of non-mixable wastes, eg:
n red for general hazardous;
n black for oily rags and spill absorbents;
n brown for contaminated packaging;
n green for non-hazardous wastes (or as appropriate for different re-usable/recyclable materials).
Centralisation of waste collection facilities means that all waste must come to the same point forrecovery/disposal. This reduces the chance of employees consigning waste to the incorrect bin.
Segregation is also an important element in the management of hazardous waste as thepresence of just a small amount of hazardous waste in a general waste container could result inthe whole container being classified as hazardous waste - thus increasing its disposal costdramatically.
2.7.1 Dealing with contaminated packaging and PPE
If raw material packaging is contaminated with low levels of hazardous raw material, then thatpackaging material must also be considered as hazardous waste and disposed of accordingly.This can result in the disposal of large amounts of packaging as hazardous waste.
Sites should therefore consider, for example, removing the material (eg using vacuum systems)from the packaging for subsequent disposal as hazardous waste. It may then be possible to rinsethe packaging material with water (or other suitable solvents) and so concentrate the remainingwaste in an aqueous stream that can be managed/treated/disposed of through the normal tradeeffluent route. The now non-contaminated waste packaging can be disposed of as non-hazardous waste or, ideally, recycled through normal packaging recycling routes.
The same principle applies to, for example, contaminated personal protective equipment (PPE)(eg gloves and overalls), which may be washed and recycled rather than disposed of. However,it is again important to consider the downstream treatment of the resulting aqueous waste.
Although such cleaning and recycling techniques have associated costs, these can often be morethan offset against the increasing cost of hazardous waste disposal.
2.8 Filter cake management
A large number of the batch and continuous production techniques used in the chemical andpharmaceutical industries produce waste solid materials in the form of filter cakes. Themanagement of these process by-products is important especially in terms of:
n increasing the dry solids content through dewatering and chemical conditioningtechniques;
n ensuring the segregation of filter cakes according to their chemical content to facilitateregeneration/recycling of components;
n recycling recovered solids;
n re-using filtrate liquors.
22se
ctio
n
10
Spent reactant solutions and process liquors/washings should be segregated according totype to:
n avoid the mixing of incompatible waste streams;
n make it easier to regenerate/recycle components.
2.9 ‘Green chemistry’ manufacturing
One aspect of green chemistry involves identifying and substituting hazardous rawmaterials with less hazardous alternatives, eg water-based solvents or bio-cleaners.
In addition, there is a substantial move, particularly in the pharmaceutical industry, toredesign certain manufacturing and fermentation processes to ‘design out’ thoseprocesses that result in significant quantities of hazardous waste. This may involve:
n completely altering the manufacturing process;
n considering alternative raw materials which do not give rise to hazardous residues andwaste.
For more information see Resource efficiency through green chemistry (GG679).
33
sect
ion
11
Technical guidance
This section highlights specific areas within the chemical and pharmaceutical industrieswhere there are significant opportunities for preventing and reducing hazardous waste.
Further information is given in Practical ways to manage and minimise hazardous waste(GG490). GG490 also signposts detailed guidance on the area of interest.
3.1 Vessel design
A large number of reactions in both the chemical and pharmaceutical industries take place indedicated reaction vessels, which subsequently require washing. This process can generatesignificant quantities of hazardous waste.
The pharmaceutical and speciality chemicals industries overwhelmingly use stirred tank reactors(STRs) in batch mode, offering wide flexibility in the reactions that can be carried out. However,this flexibility is often at the expense of reaction specificity and efficiency, and optimal rawmaterials usage. Use of batch mode also tends to necessitate substantial subsequent separationand purification stages, which generate both wastewater and waste organic liquids or solids.
Larger volume chemical manufacturing processes frequently use vessels for mixing, reaction andproduct separation. These vessels may have blind spots or non-optimum mixing blade anddrainage design.
When replacing a vessel, the new design should be optimised to:
n avoid wastage of chemicals when emptying;
n reduce cleaning requirements.
Vessel design should facilitate cleaning-in-place (CIP) and automated charging/emptying.
Low inventory ‘fast’ reactors have the potential to improve all these aspects. They consist ofrelatively small-scale vessels able to react a large number of small-scale reactions relativelyquickly. The small reactor therefore means:
n less cleaning required;
n less product waste at the end of a campaign;
n less void space/dead legs where product can ‘hide’;
n it is usually designed specifically for one particular process.
They can be particularly helpful on ‘multi-product toll-conversion plants’ where it isunlikely that the use of just a few STRs can meet BAT for the whole range of preparationsmade.
Table 1 lists specific vessel operational and management suggestions. Detailedinformation can be found in Cost-effective vessel washing (GG120).
33se
ctio
n
12
3.2 Optimising production processes (batchand continuous chemistry)
For both batch and continuous manufacturing processes, it is important to optimise theefficiency of the process (eg in terms of yield). This reduces hazardous waste volumes andalso improves the profitability of the business.
Table 2 lists example techniques for process optimisation. Detailed information can befound in Increasing product output in batch chemical manufacture (GG216).
Suggestion Objective
Establish appropriate Avoid over-washing.washing procedures. Reduce the amount of wash liquor used and effluent
generated.
Improve staff awareness. Improve staff awareness of the environmental andfinancial implications of activities.Generate practical ideas for improvement.
Optimise production Minimise the need for vessel washing betweenscheduling. product batches and thus reduce wash frequency.
Enhance inspection and Identify efficient vessel washing practices.monitoring. Changes need to be based on accurate data
provided by systematic inspection and monitoring (ie learning by logging).
Redesign process/product. Change the production process to reduce oreliminate the need for vessel washing.
Consider technical Increase washing efficiency.improvement options.
Recover and re-use wash Reduce effluent volumes and discharge costs.liquors. Reduce product loss.
Switch to alternative wash Reduce the costs of washing and effluent liquors.liquors. Reduce environment impact.
Improve health and safety.
Ensure complete vessel Avoid need for re-wash.drain-down.
Install high-pressure wash Improve efficiency of cleaning.systems. Help to reduce the volume of wash liquor required.
Automate vessel washing Achieve exact washing performance.control systems.
Install closed-loop wash Minimise the release of gaseous emissions.systems. Allow recirculation of solvent to maximise its use.
Table 1 Vessel operation and management
33
sect
ion
13
3.3 Effective solvent management
Organic solvents are used extensively throughout the chemical and pharmaceutical industries, asreaction solvents and cleaning agents. Many solvents will evaporate readily at room temperatureand are known as volatile organic compounds (VOCs).
The high cost of many solvents makes recovery and re-use critical to the economics of theproduction process. In addition, solvent disposal requires careful monitoring in order to complywith legislative requirements.
Solvents differ from other hazardous wastes in that they have a relatively high calorific valueand can, therefore, be used as a fuel supplement in various combustion processes (egcement kilns) as a disposal route. However, it is more cost-effective to reduce solvent useat source.
The drafting and implementation of a written solvent management plan reflects bestpractice and is in keeping with the requirements of the Solvent Emissions Directive. Thisshould be coupled with ‘Measuring to Manage’ - a systematic method of analysing andcontrolling solvent consumption. Excessive solvent use should be eliminated through goodmaintenance practice, good housekeeping measures, adequate operating procedures andimproved production planning.
Table 3 provides general solvent management advice. Further details are given in:
n section 11 of Practical ways to manage and minimise hazardous waste (GG490);
n Better solvent management in speciality chemicals manufacture (GG395).
There is also a general move away from organic solvents to water-based solvents. Thisessentially involves a switch to products and processes in which a large proportion of theorganic solvent used is replaced by water, but key properties are retained. A good exampleof this manufacturing trend can be seen in the paint industry.
Suggestion Objective
Prepare a mass balance. Identify where the greatest losses are occurringand thus the potential for improvement.
Set targets and benchmark. Ensure adequate standards.
Review the number, quality and Achieve significant cost savings and othersource of raw materials used. benefits.
Reduce spillages by using Reduce wastage from spillages.automated filling methods and Avoid surplus material.whole containers.
Optimise production of small Reduce mass, yield loss and stockpiling.batches.
Train staff in new procedures. Ensure optimum conditions are maintained.
Monitor and control the yield. Maintain improvement.
Table 2 Production process optimisation
33se
ctio
n
14
Suggestion Objective
Eliminate/reduce solvent use as Reduce solvent waste requiring disposal.part of a solvent management Reduce VOC emissions requiring abatement.plan. Reduce risk of pollution.
Measure solvent use and set Save money by producing more product for targets (ie Measuring to Manage). the same amount of solvent.
Investigate causes of excessive Reduce solvent consumption.solvent use and waste. Reduce solvent purchase costs.
Reduce pollution abatement costs.
Train staff to operate and Improve solvent management performance.maintain equipment correctly. Reduce costs.
Segregate hazardous waste. Avoid contamination and thus minimisevolume for disposal as hazardous waste.
Install solvent recovery systems. Use of appropriate recovery techniques tominimise waste.
Re-use recovered solvent in the Reduce solvent purchase and disposal costs.process itself or for other duties.
Minimise spills during solvent Avoid spillage due to poor connections, etc.delivery by paying attention to procedures and design of tankers/storage tanks.
Buy in bulk. Reduce costs and wastage in terms ofpackaging (possibly contaminated) andmaterial residues.
Avoid over-ordering. Prevent stock going out-of-date or becomingobsolete.Avoid tying up money in stock that is notrequired.
Preserve shelf-life of products by Minimise deterioration and wastage.avoiding temperature extremes and exposure to light.
Avoid over-estimating when Use measure of known size to prevent waste.decanting.
Undertake planned preventative Prevent vapour release, leaking and spillage.maintenance.
Use drip trays. Recover spilled solvents for re-use.
Use alternative cleaning products Reduce the quantity of solvent used.and systems.
Consider purchasing an enclosed/ Reduce VOC emissions.closed loop wash machine. Recover a large proportion of ‘waste’ solvents.
Reduce waste storage and disposal problems.
Table 3 General solvent management
33
sect
ion
15
3.4 Vacuum systems
Vacuum systems are widely used throughout the chemical and pharmaceutical industries(e.g. in distillation columns and reaction vessels) to improve reaction efficiency at lowertemperatures. This also helps to reduce product degradation at high temperature. Inaddition, the application of vacuum to operations often brings material handling benefits.
A consequence of the complex chemical reactions taking place in vacuum systems is thatthe waste products are frequently classified as hazardous waste. Optimising the efficiencyof vacuum systems is therefore critical.
Reducing vacuum costs (GG101) provides a comprehensive guide to optimising theoperation of vacuum systems, including reduced water consumption and effluentproduction. Table 4 summarises some of its themes and suggestions.
3.5 Water management
Water is used in a number of processes throughout the chemical and pharmaceuticalindustries - as a solvent, reagent, diluent or washing medium to name but a few.
A large proportion of the hazardous waste leaving a manufacturing site may therefore bein solution as a consequence of one or more of these processes. Correct and efficientwater management is therefore vital to:
n minimise the release of aqueous hazardous waste;
n optimise upstream minimisation and recovery.
For further information see Managing water use in speciality chemicals’ manufacture: asignposting guide (GG363).
Suggestion Objective
Improve filtration rates. Improve the properties of the filter cakeand reduce the material lost in it.
Make effective use of vacuum system. Reduce running costs.
Use a dead-end filling technique. Reduce problem of excessive dischargesof pollutants.
Undertake planned/preventative Identify and repair faults before they maintenance. become more serious.
Table 4 Vacuum systems
44se
ctio
n
16
Sources of further information
4.1 Envirowise
The Environment and Energy Helpline on 0800 585794 can:
n put you in touch with a technical expert - free of charge;
n provide free, up-to-date advice on environmental issues;
n tell you about relevant environmental and other legislation that could affect your business,eg the latest hazardous waste legislation;
n send you copies of free, relevant Envirowise publications;
n suggest other sources of information;
n arrange for a free, confidential on-site waste review (known as a FastTrack visit) by anEnvirowise advisor;
n arrange for a counselling visit from an Envirowise advisor to discuss a specific environmentalissue at your site.
All Envirowise’s free information and advice can also be accessed via its website(www.envirowise.gov.uk).
Particular publications of interest include:
n Resource efficiency through green chemistry (GG679);
n Practical ways to manage and minimise hazardous waste (GG490);
n Better solvent management in speciality chemicals manufacture (GG395);
n Managing water use in speciality chemicals’ manufacture: a signposting guide (GG363);
n Increasing product output in batch chemical manufacture (GG216);
n Cost-effective vessel washing (GG120);
n Reducing vacuum costs (GG101).
4.2 Environment Agency
The Environment Agency website (www.environment-agency.gov.uk) offers considerable adviceand information about different aspects of hazardous waste, including:
n Waste - including dealing with hazardous wastewww.environment-agency.gov.uk/subjects/waste/
n Information for business sectors including the chemical industrywww.environment-agency.gov.uk/business/
n Delivering for the environment - a 21st century approach to regulationwww.environment-agency.gov.uk/business/444217/444661/571853/
n Pollution Inventorywww.environment-agency.gov.uk/pi
44
sect
ion
17
n Environmental Protection Operator and Pollution Risk Appraisal (EP OPRA)www.environment-agency.gov.uk/epopra/ and search for “EP OPRA”
A number of useful publications (see Table 5) are also available from the Environment Agency’swebsite (www.environment-agency.gov.uk).
44se
ctio
n
18
Titl
ePu
blic
atio
nd
ate
Pro
du
ctco
de
Co
nte
nt
Haz
ard
ou
sw
aste
.In
terp
reta
tio
no
fth
ed
efin
itio
nO
ct20
06G
EHO
0705
BJG
X-E
-EPr
ovi
des
gu
idan
ceo
nth
eas
sess
men
tan
dcl
assi
fica
tio
no
fan
dcl
assi
fica
tio
no
fh
azar
do
us
was
te.
Tech
nic
al2n
ded
itio
n,
haz
ard
ou
sw
aste
sto
all
invo
lved
inth
ep
rod
uct
ion
,G
uid
ance
WM
2V
ersi
on
2.1
man
agem
ent
and
con
tro
lo
fh
azar
do
us
was
te.
Wh
atis
haz
ard
ou
sw
aste
?A
gu
ide
toth
eH
azar
do
us
May
2006
GEH
O05
06B
KTR
-E-E
Pres
ents
ad
esk-
bas
edap
pro
ach
tofi
nd
ou
tif
was
teis
Was
teR
egu
lati
on
san
dth
eLi
sto
fW
aste
Reg
ula
tio
ns
haz
ard
ou
s.U
ses
afl
ow
char
tto
hel
pp
eop
lew
ork
ou
tth
ein
Eng
lan
dan
dW
ales
(HW
R01
)ri
gh
tcl
assi
fica
tio
nto
use
.
Imp
rovi
ng
envi
ron
men
tal
per
form
ance
.Se
cto
rp
lan
No
v20
05G
EHO
1105
BJV
M-E
-EPr
od
uce
djo
intl
yb
yth
eEn
viro
nm
ent
Ag
ency
and
the
for
the
chem
ical
ind
ust
ryV
ersi
on
1ch
emic
alin
du
stry
.O
utl
ines
the
sect
or’
sen
viro
nm
enta
lp
erfo
rman
cean
did
enti
fies
the
mai
nar
eas
for
imp
rove
men
t.Pr
op
ose
sen
viro
nm
enta
lp
rio
riti
es,
ob
ject
ives
and
ind
icat
ors
for
per
form
ance
cove
rin
gth
en
ext
5-
15ye
ars.
Sect
or
Gu
idan
ceN
ote
IPPC
S4.0
1.G
uid
ance
for
the
Ap
r20
03G
EHO
1205
BJZ
D-E
-EU
Kg
uid
ance
bas
edo
nth
eB
AT
Ref
eren
ce(B
REF
)d
ocu
men
tla
rge
volu
me
org
anic
sse
cto
rfo
rth
ese
cto
rp
rod
uce
db
yth
eEu
rop
ean
Co
mm
issi
on
.
Sect
or
Gu
idan
ceN
ote
IPPC
S4.0
2.G
uid
ance
for
the
Ap
r20
03G
EHO
1205
BJZ
B-E
-EU
Kg
uid
ance
bas
edo
nth
eB
AT
Ref
eren
ce(B
REF
)d
ocu
men
tsp
ecia
lity
org
anic
chem
ical
sse
cto
rfo
rth
ese
cto
rp
rod
uce
db
yth
eEu
rop
ean
Co
mm
issi
on
.
Sect
or
Gu
idan
ceN
ote
IPPC
S4.0
3.G
uid
ance
for
the
May
2004
GEH
O12
05B
JZC
-E-E
UK
gu
idan
ceb
ased
on
the
BA
TR
efer
ence
(BR
EF)
do
cum
ent
ino
rgan
icch
emic
als
sect
or
for
the
sect
or
pro
du
ced
by
the
Euro
pea
nC
om
mis
sio
n.
Sect
or
Gu
idan
ceN
ote
IPPC
S5.0
6.G
uid
ance
for
the
Dec
2004
§G
uid
ance
for
Eng
lan
d,
Wal
esan
dN
ort
her
nIr
elan
db
ased
reco
very
and
dis
po
sal
of
haz
ard
ou
san
do
nB
AT
Ref
eren
ce(B
REF
)d
ocu
men
tfo
rth
ese
cto
rp
rod
uce
dn
on
haz
ard
ou
sw
aste
.In
teg
rate
dPo
lluti
on
by
the
Euro
pea
nC
om
mis
sio
n.
Prev
enti
on
and
Co
ntr
ol
(IPP
C)
Bes
tp
ract
ice
gu
idan
ce.
Gu
idan
cefo
rth
ere
cove
ryM
ay20
02,
#Se
tso
ut
stan
dar
ds
toen
sure
faci
litie
sac
hie
veth
eo
bje
ctiv
esan
dd
isp
osa
lo
fh
azar
do
us
and
no
nh
azar
do
us
was
teV
ersi
on
1.1
of
the
Was
teM
anag
emen
tLi
cen
sin
gre
gim
ew
hile
bei
ng
(oth
erth
anb
yin
cin
erat
ion
and
lan
dfi
ll).
Was
teco
nsi
sten
tw
ith
the
likel
yre
qu
irem
ents
of
the
IPPC
reg
ime.
man
agem
ent
licen
sed
faci
litie
sPr
od
uce
din
tan
dem
wit
hth
eth
enve
rsio
no
fSe
cto
rG
uid
ance
No
teIP
PCS5
.06.
Tab
le5
Use
ful
pu
blic
atio
ns*
*To
loca
tean
ddo
wnl
oad
aPD
Fof
apa
rtic
ular
docu
men
t,en
ter
the
prod
uct
code
inth
eap
prop
riate
box
ofth
eA
dvan
ced
Sear
chfa
cilit
yof
the
Envi
ronm
ent
Age
ncy’
son
line
Publ
icat
ions
Cat
alog
ue(w
ww
.env
ironm
ent-
agen
cy.g
ov.u
k;A
bout
Us
>Pu
blic
atio
ns>
Publ
icat
ions
Cat
alog
ue).
§w
ww
.env
ironm
ent-
agen
cy.g
ov.u
k/co
mm
onda
ta/a
crob
at/s
gn_i
ssue
_4_9
6887
2.pd
f
#w
ww
.env
ironm
ent-
agen
cy.g
ov.u
k/co
mm
onda
ta/a
crob
at/c
hem
ical
best
prac
t_65
2800
44
sect
ion
19
4.3 Useful websites
4.3.1 Trade associations
* This list is not intended to be exhaustive and Envirowise takes no responsibility for the contents of thesewebsites or the services/information offered by these organisations. If you do not have access to the internet,contact the Environment and Energy Helpline (0800 585794) for more contact details.
4.3.2 Other
NetRegsThis website offers simple but comprehensive advice to help businesses understand what theyneed to do to comply with environmental legislation. www.netregs.gov.uk
European Waste Catalogue (EWC) The EWC classifies waste materials according to what they are and how they were produced. www.environment-agency.gov.uk [Enter ‘European Waste Catalogue’ in the Search box.]
Organisation Website*
Agricultural Industries Confederation (AIC) www.agindustries.org.uk
Association of the British Pharmaceutical Industry www.abpi.org.uk(ABPI)
British Adhesives and Sealants Association (BASA) www.basa.uk.com
British Association for Chemical Specialities (BACS) www.bacsnet.org
British Coatings Federation (BCF) www.coatings.org.uk
British Colour Makers Association (BCMA) www.bcma.org.uk
Photo Imaging Council www.pic.uk.net
British Pest Control Association (BPCA) www.bpca.org.uk
British Pyrotechnists Association (BPA) www.bpa-fmg.org.uk
British Rubber Manufacturers’ Association www.brma.co.uk
Chemical Business Association (CBA) www.chemical.org.uk
Chemical Industries Association (CIA) www.cia.org.uk
Chemistry Leadership Council (CLC) www.chemistry.org.uk
Cosmetic Toiletry & Perfumery Association (CTPA) www.ctpa.org.uk
Crop Protection Association (CPA) www.cropprotection.org.uk
European Chemical Industry Council (CEFIC) www.cefic.org
International Council of Chemical Associations (ICCA) www.icca-chem.org
Society of Chemical Industry (SCI) www.soci.org
Society of Dyers and Colourists (SDC) www.sdc.org.uk
Specialised Organic Chemicals Sector Association www.socsa.org.uk(SOCSA)
UK Cleaning Products Industry Association (UKCPI) www.ukcpi.org
Table 6 Trade associations
44se
ctio
n
20
HAZRED ProjectHAZRED is a three-year European project co-funded by the EU Life Environment programme thataims to help small and medium-sized enterprises (SMEs) to save money by preventing andreducing their production of hazardous waste. The manufacture of speciality organic chemicalsis one of its six priority sectors.www.hazred.org.uk
Envirowise - Practical Environmental Advice for Business - is a Government programmethat offers free, independent and practical advice to UK businesses to reduce waste atsource and increase profits. It is managed by Momenta, an operating division of AEATechnology plc, and Serco TTI. Envirowise is funded across the UK by the DTI and Defraand the Business Resource Efficiency and Waste (BREW) Programme in England, theScottish Executive in Scotland and the Materials Action Programme (MAP) in Wales.
Envirowise offers a range of free services including:
Free advice from Envirowise experts through the Environment and EnergyHelpline.
A variety of publications that provide up-to-date information on wasteminimisation issues, methods and successes.
Free, on-site waste reviews from Envirowise advisors, called FastTrack visits, thathelp businesses identify and realise savings.
Guidance on resource efficiency clubs across the UK that provide a chance forlocal companies to meet regularly and share best practices in waste minimisation.
Best practice seminars and practical workshops that offer an ideal way toexamine waste minimisation issues and discuss opportunities and methodologies.
For further informationplease contact the
Environmentand EnergyHelpline0800 585794© Crown copyright. First printed June 2007. Printed on paper containing 80% recycled post-consumer fibre.
This material may be freely reproduced in its original form except for sale or advertising purposes.
Harwell Science and Innovation Campus | Didcot | Oxfordshire | OX11 0QJE-mail: [email protected] Internet: www.envirowise.gov.uk
Practical Environmental Advice for Business
