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Case Study Database

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E. I. du Pont de Nemours & Co., Inc.

Year Submitted: 2003

Process: Catalyst Recovery

Industry: Chemical Manufacturing

Wastes Reduced: Catalyst

Location: Orange, Orange County TX

No. of employees: 2000

Contact: Steve M. McIntosh

Phone: (409) 883-8411



Description:

Increase Fresh Catalyst Recovery with the installation of a larger and improved design catalyst decanter. The increased fresh catalyst recovery allowed an increase of catalyst feed to the manufacturing process and consequent reduction of the amount of the "once through" catalyst promoter fed.

P2 Application:

Process basic data showed that less catalyst promoter had to be fed, for an equivalent reaction rate and conversion, if catalyst concentration was increased by increased catalyst feed. This is highly desirable as the catalyst promoter cannot be recovered due to its sensitivity to temperature in the process and leaves the process as solid waste. The plant was limited on catalyst recovery however until a $2.5MM project for a catalyst decanter was installed. The decanter met design goals for fresh catalyst recovery and allowed the plant to increase the catalyst fed and lower the promoter feed. The lower promoter feed reduced the solid waste generated by the process.

Environmental Benefits:

Reduced waste solids generation by 1MM lbs per year or approximately 10%. The solids are normally fed to an incinerator and the ash landfilled.

Details of Reductions

Additional Information :

It is estimated that savings of $1.5MM/yr in reduced promoter consumption and $0.5MM/yr in reduced waste disposal costs will result. Pay back period approximately 1.5 yrs.

Source: TCEQ



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