PROJECT DESCRIPTION
BACKGROUND
The production of PMMA sheets takes place in batches. Between each batch, the piping, mixing vessel and de-aerating vessel are rinsed in order to be sure that there is no colour contamination for the next batch. Before this LIFE project, Atoglas Leeuwarden used a chlorinated solvent, DCM (Dichloromethane), for the rinsing/cleaning process. DCM is a reputed air and water pollutant and is toxic for the working environment. If the annual DCM emission exceeds 1 000 kg/year a company is obliged to report on its DCM emission in the European Pollutant Emission Register (EPER), which is a key element of the 1996 Integrated Pollution Prevention and Control Directive (IPPC). Atoglas Leeuwarden had an emission 10 times higher than the aforementioned threshold value. For these reasons Atoglas made plans to replace DCM by a less toxic compound. The relevance of this project for EU policy is twofold: on the one hand the elimination of the use of DCM and consequently of its air pollution by an innovative technique, on the other hand the development and demonstration of a new technology that might be considered as a BAT in this industry and in similar sectors.
OBJECTIVES
The objective of this project was to demonstrate an innovative and environmentally friendly technique for the production of PMMA sheets: an integrated cleaning-in-process system without the use of the chlorinated solvent, DCM.
RESULTS
The beneficiary successfully demonstrated the substitution of the rinsing agent DCM by MMA, which is the monomer and basic raw material in the production of the PMMA sheets. The beneficiary also demonstrated that it was possible to filtrate and re-use the spent rinsing MMA twice, leading to important cost reductions. The beneficiary upgraded the cleaning process to a cleaning-in-process (CIP) system with MMA as the cleansing agent. The use of DCM was completely abolished. MMA is used to rinse pipelines and vessels in the closed system. After a rinsing cycle, the cleansing fluid is filtrated in a cricket filter where the colour agents are absorbed on activated carbon, and then re-used. The whole system is entirely integrated in the production process. The main project tasks were: project preparation and engineering, civil construction and installation, mechanical and electrical installation, start-up, test and monitoring, and dissemination. The project generated considerable environmental results. By eliminating the chlorinated solvent DCM, its emission of 10 000 kg/a was thus also completely eliminated. By installing the closed loop rinsing system, the MMA emission to air was reduced by 97%. Workers conditions improved in a significant way. The installation of the filtration unit made it possible to re-use the spent rinsing MMA twice before sending it to distillation. This resulted in a 50% reduction of the waste stream. Furthermore, positive economic results were achieved. The product quality has improved by eliminating the chlorinated cleansing agent DCM and the production yield has increased. The reported total benefit is 1%. The direct costs of the cleansing process decreased by 60% because the rinsing agent monomer MMA is re-used twice after filtration. The possibilities for transferability and reproduction are anticipated to be high, in particular for manufacturers with batch processes that switch to other product types often so that frequent cleaning between batches is required. This applies for instance to manufacturers of coatings, adhesives, resins and polymer specialities. The project results could indeed be used within the preparation of BAT reference documents in several types of industries. In order to disseminate the knowledge acquired, Atoglas published several articles on the project and sent the project results to 73 organisations across Europe, including national chemical sector organisations, Atoglas sister companies, companies in the polymer, adhesives and paint industry. The IPPC bureau in Sevilla was also informed. The demonstration value of the project is high: it is the first application within Atoglas and probably within this sector. The beneficiary is a market leader in PMMA production and part of a reputed chemical company (TotalFinaElf-Atofina). By means of this project, the beneficiary has found a solution in order to be able to stay at its current location near to the city centre of Leeuwarden. The project has had good results, it has shown that the substitution of the cleansing agent DCM by a process-own substance in a closed loop CIP-system, as well as the re-use of this cleansing agent, are both examples of environmental and economic win-wins, which means that the sustainability of the concept is high. The press has acknowledged the high demonstration value: the reputed Dutch ‘Chemisch magazine’ contacted the beneficiary for an interview and article one week after the mailing of the project results. . According to latest information, from the LIFE external monitoring team in 2005, following project termination, the beneficiary has sent its results to over 70 organisations across Europe, including national chemical sector organisations, the Atoglas sister companies, and companies in the polymer, adhesives and paint sectors. The IPPC bureau in Sevilla, Spain was also informed of the project’s results. See, the company website at: www.atoglas.com/
