de - Beste verfügbare Techniken (BVT) - Umweltbundesamt

Best Available Techniques Reference Document for
the Manufacture of Organic Fine Chemicals
ZUSAMMENFASSUNG .......................................................... I
VORWORT ............................................................................ XI
1 GENERAL INFORMATION....................................1
1.1 The sector ..............................................................1
1.2 Environmental issues ............................................4
1.3 Some products.......................................................5
1.3.1 Organic dyes and pigments...................................5
1.3.1.1 Overview ...............................................................5
1.3.1.2 Pigments................................................................6
1.3.1.3 Economics .............................................................7
1.3.2 Active pharmaceutical ingredients (APIs)............8
1.3.2.1 Overview ...............................................................8
1.3.2.2 Legal requirements and process modifications.......
...............................................................................8
1.3.2.3 Economics .............................................................9
1.3.3 Vitamins ................................................................9
1.3.4 Biocides and plant health products .....................10
1.3.4.1 Overview .............................................................10
1.3.4.2 Process modifications in manufacturing crop
protection agents .................................................11
1.3.4.3 Economics of crop protection .............................12
1.3.5 Fragrances and flavours ......................................13
1.3.6 Optical brighteners..............................................14
1.3.7 Flame-retardants..................................................15
1.3.8 Plasticisers...........................................................16
1.3.9 Explosives ...........................................................17
2 APPLIED PROCESSES AND TECHNIQUES.........
.....................................................................................19
2.1 Conception: unit processes and operations.........19
2.1.1 Intermediates .......................................................20
2.1.2 Isomers and by-products .....................................21
2.2 Multipurpose plants.............................................22
2.3 Equipment and unit operations ...........................24
2.3.1 Reactors...............................................................24
2.3.1.1 Liquid addition to reactors ..................................25
2.3.2 Equipment and operations for product work-up.....
.............................................................................25
2.3.2.1 Drying..................................................................25
2.3.2.2 Liquid-solid separation .......................................26
2.3.2.3 Distillation...........................................................26
2.3.2.4 Liquid-liquid extraction ......................................26
2.3.3 Cooling................................................................27
2.3.4 Cleaning ..............................................................27
2.3.5 Energy supply......................................................28
2.3.6 Vacuum systems..................................................29
2.3.7 Recovery/abatement of exhaust gases ................30
2.3.8 Recovery/abatement applied to waste water
streams.................................................................31
2.3.9 Groundwater protection and fire fighting water .32
2.3.10 Solvent recovery..................................................33
2.4 Site management and monitoring .......................34
2.4.1 Emission inventories and monitoring .................34
2.4.2 Overview to sources and parameters/pollutants .....
.............................................................................35
2.4.2.1 Waste gas emissions............................................35
2.4.2.2 Solvents and volatile organic compounds ..............
.............................................................................36
2.4.2.3 Waste water emissions........................................37
2.4.2.4 Biodegradability and elimination of organic
compounds ..........................................................38
2.5 Unit processes and connected operations ...........40
2.5.1 N-acylation..........................................................40
2.5.2 Alkylation with alkyl halides ..............................41
2.5.3 Condensation.......................................................42
2.5.4 Diazotisation and azo coupling...........................43
2.5.5 Esterification .......................................................45
ZUSAMMENFASSUNG .......................................................... I
VORWORT ............................................................................ XI
1 ALLGEMEINE INFORMATIONEN ......................1
1.1 Der Sektor .............................................................1
1.2 Umweltaspekte......................................................4
1.3 Einige Produkte.....................................................5
1.3.1 Organische Farbstoffe und Pigmente....................5
1.3.1.1 Überblick...............................................................5
1.3.1.2 Pigmente................................................................6
1.3.1.3 Wirtschatliche Aspekte .........................................7
1.3.2 Pharmazeutische Wirkstoffe .................................8
1.3.2.1 Überblick...............................................................8
1.3.2.2 Gesetliche Anforderungen und
Verfahrensumstellungen .......................................8
1.3.2.3 Wirtschatliche Aspekte .........................................9
1.3.3 Vitamine................................................................9
1.3.4 Biozide und Pflanzenschutzmittel ......................10
1.3.4.1 Überblick.............................................................10
1.3.4.2 Verfahrensumstellung bei der Herstellung von......
Pflanzenschutzmitteln .........................................11
1.3.4.3 Wirtschatliche Aspekte .......................................12
1.3.5 Duft- und Geschmackstoffe ................................13
1.3.6 Optische Aufheller ..............................................14
1.3.7 Flammschutzmittel..............................................15
1.3.8 Weichmacher.......................................................16
1.3.9 Explosivstoffe .....................................................17
2 ANGEWANDTE PROZESSE UND TECHNIKEN .
.....................................................................................19
2.1 Konzeption: "unit processes" und "operations"..19
2.1.1 Zwischenprodukte...............................................20
2.1.2 Isomere und Nebenprodukte...............................21
2.2 Vielzweckanlagen ...............................................22
2.3 Anlagen und "unit operations"............................24
2.3.1 Reaktoren ............................................................24
2.3.1.1 Befüllen von Reaktoren mit Flüssigkeiten .........25
2.3.2 Anlagen und Arbeitsschritte zur
Produktaufarbeitung............................................25
2.3.2.1 Trocknung ...........................................................25
2.3.2.2 Fest/flüssig-Trennung .........................................26
2.3.2.3 Destillation ..........................................................26
2.3.2.4 Flüssig/flüssig-Extraktion...................................26
2.3.3 Kühlung...............................................................27
2.3.4 Reinigung ............................................................27
2.3.5 Energieversorgung ..............................................28
2.3.6 Vakuumanlagen ..................................................29
2.3.7 Rückgewinnung/Minderung von Abgasen .........30
2.3.8 Rückgewinnung/Minderung von
Abwasserteilströmen...........................................31
2.3.9 Grundwasserschutz und Löschwasser ................32
2.3.10 Rückgewinnung von Lösemitteln .......................33
2.4 Standort-Management und Überwachung ..........34
2.4.1 Emissionskataster und Überwachung.................34
2.4.2 Überblick zu Quellen und Parametern/
Schadstoffen........................................................35
2.4.2.1 Abgasemissionen ................................................35
2.4.2.2 Lösemittel und flüchtige organische Verbindungen
.............................................................................36
2.4.2.3 Emissionen in das Abwasser...............................37
2.4.2.4 Biologische Abbaubarkeit und Elimination von
organischen Verbindungen .................................38
2.5 "Unit processes" und zugehörige "operations"...40
2.5.1 N-Acylierung.......................................................40
2.5.2 Alkylierung mit Alkylhalogeniden .....................41
2.5.3 Kondensation ......................................................42
2.5.4 Diazotierung und Azokupplung..........................43
2.5.5 Veresterung .........................................................45
OFC_BREF Dezember 2005 xv