Hoechst Celanese Chemical Group, Inc.
A Waste and Release Reduction (WARR) project was initiated company wide in 1992 when upper management decided the company should make a concerted effort to reduce releases. The Pampa Plant, the first to implement a WARR project, installed three new processes to meet a minimum goal for reducing Superfund Amendment Reauthorization Act (SARA) releases by at least 75%.
The WARR project applied catalytic oxidation technology to a high-pressure air oxidation reaction process. Traditional incineration would not work well in this application because of the low VOC concentration and high concentration of unburnable nitrogen in the gas stream. A closed-dome rail car loading system was implemented. This special rail car captures and treats the VOC vapors displaced while loading other rail cars with liquid chemical products. Process vents and tank controls were installed at the various point source locations. The individual vents and controls were tied into larger vent collection systems and air pollution control devices.
Overall SARA releases have been reduced 85%, 10% more than required. The projects significantly reduce point source air emissions and generate an additional 3 Mega Watts of electricity.
Details of Reductions
Additional Information :
The initial capital costs were $6.5 million with annual savings of $400,000. The savings are due to reductions in costs due to compliances with hazardous waste regulations, hazardous waste disposal, and air emissions. The payback period is 16 years.