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This document has not been fully peer reviewed and ong>theong> ong>informationong> within is not validated nor endorsed by ong>theong> TWG on LVIC-S or by ong>theong> European Commission, it is meant for ong>informationong>, only The basic chemical equation governing this process is: 28 2Na – COOH + H2SO4 2HCOOH + Na2SO4 A flow scheme of ong>theong> production of sodium sulphate in ong>theong> formic acid process is given in Figure 1.15. Cooling water Steam Air Cooling water Sodium formate Reactor Centrifuge Drier Cooler Sieve Na 2 SO 4 Sulphuric acid Combustion gases Condensate Evaporator Combustion gases Cooling water Figure 1.15: Flow scheme of sodium sulphate production in ong>theong> formic acid process [64, CEFIC-SSPA, 2004] 1.6.3 Current emission and energy consumption levels Formic acid The current levels of emissions to air and water, as well as of emissions of solid residues and energy consumption levels are briefly summarised in ong>theong> following Tables. Aspects of key environmental issues are also addressed. Emissions to air are given in Table 1.10. Process Volume exhaust gas Cl2 HCl SOx NOx NH3 CO2 Dust m 3 /t Na2SO4 All SSPA except kg/t kg/t kg/t kg/t kg/t kg/t kg/t natural 131 – 5000 0 – 0.0007 0 – 0.063 0 – 1.1 0 – 0.46 0 0 – 24 * 0.0003 – 0.66 *No data available for some processes Table 1.10: Sodium sulphate production – emissions to air (aggregated data: min – max) [64, CEFIC-SSPA, 2004]

This document has not been fully peer reviewed and ong>theong> ong>informationong> within is not validated nor endorsed by ong>theong> TWG on LVIC-S or by ong>theong> European Commission, it is meant for ong>informationong>, only Emissions to water are given in Table 1.11. Process Volume of waste water Cl- SO4 2- NO3 - NH4 + F - COD Suspended matter m 3 /t Na2SO4 kg/t kg/t kg/t kg/t kg/t ppm mg/l All SSPA except natural 0 – 5 0 – 1.1 0.00006 – 20.0 0 0 0 0 – 60 * 0 – 5 * *No data available for some processes Table 1.11: Sodium sulphate production – emissions to water (aggregated data: min – max) [64, CEFIC-SSPA, 2004] Emissions of solid residues are given in Table 1.12. Process All SSPA except natural Solid waste tonne/tonne Na2SO4 0 – 0.002 in total Nature of residue Contaminated salts Various solid waste Metals Destination/ Re-use Landfill Landfill/Incineration Recycling Table 1.12: Sodium sulphate production – solid residues (aggregated data: min –max) [64, CEFIC-SSPA, 2004] Energy consumption in ong>theong> production of sodium sulphate is given in Table 1.13. Process Electricity kWh/t Na2SO4 Oong>theong>rs (coal, fuel, gas, hydrogen, etc.) kWh/t Na2SO4 Total energy consumption kWh/t Na2SO4 All SSPA except natural 0.17 – 237 0 – 1540 120 – 1660 Table 1.13: Sodium sulphate production - energy consumption (aggregated data: min - max) [64, CEFIC-SSPA, 2004] Production of sodium sulphate as a by-product has a positive impact on ong>theong> environment. All ong>theong> processes described in this section are treating a stream from its primary process and turning it into a useful product (or by-product). It is a classic example of sustainable development where a potential waste from one industry has useful applications in oong>theong>r fields. 1.6.4 Techniques to consider in ong>theong> determination of BAT Apart from being produced from naturally occurring sources (mining), sodium sulphate is produced as a by-product from different chemical processes such as rayon production, chromium chemicals, hydrochloric acid, methionine, and formic acid. As ong>theong> sodium sulphate derived from ong>theong>se chemical processes could be considered as a by-product, ong>theong> six main processes described in Section 1.6.2 have been taken into account when analysing techniques to consider in ong>theong> determination of BAT for ong>theong> production of sodium sulphate. This is because all of ong>theong>m – except ong>theong> Mannheim furnace process, dedicated for ong>theong> co-production of HCl as a main product and sodium sulphate as a co-product – are, in principle, recovery processes and ong>theong>ir application in ong>theong> industrial practice reduces ong>theong> impact of several oong>theong>r industries on ong>theong> environment [64, CEFIC-SSPA, 2004], [EIPPCB, 2004-2005 #85]. 29

This document has not been fully peer reviewed and <str<strong>on</strong>g>the</str<strong>on</strong>g> <str<strong>on</strong>g>informati<strong>on</strong></str<strong>on</strong>g> within is not validated nor endorsed by <str<strong>on</strong>g>the</str<strong>on</strong>g> TWG<br />

<strong>on</strong> LVIC-S or by <str<strong>on</strong>g>the</str<strong>on</strong>g> European Commissi<strong>on</strong>, it is meant for <str<strong>on</strong>g>informati<strong>on</strong></str<strong>on</strong>g>, <strong>on</strong>ly<br />

The basic chemical equati<strong>on</strong> governing this process is:<br />

28<br />

2Na – COOH + H2SO4<br />

2HCOOH + Na2SO4<br />

A flow scheme of <str<strong>on</strong>g>the</str<strong>on</strong>g> producti<strong>on</strong> of sodium sulphate in <str<strong>on</strong>g>the</str<strong>on</strong>g> formic acid process is given in<br />

Figure 1.15.<br />

Cooling water<br />

Steam<br />

Air<br />

Cooling water<br />

Sodium formate<br />

Reactor<br />

Centrifuge<br />

Drier<br />

Cooler<br />

Sieve<br />

Na 2 SO 4<br />

Sulphuric acid<br />

Combusti<strong>on</strong> gases<br />

C<strong>on</strong>densate<br />

Evaporator<br />

Combusti<strong>on</strong> gases<br />

Cooling water<br />

Figure 1.15: Flow scheme of sodium sulphate producti<strong>on</strong> in <str<strong>on</strong>g>the</str<strong>on</strong>g> formic acid process<br />

[64, CEFIC-SSPA, 2004]<br />

1.6.3 Current emissi<strong>on</strong> and energy c<strong>on</strong>sumpti<strong>on</strong> levels<br />

Formic acid<br />

The current levels of emissi<strong>on</strong>s to air and water, as well as of emissi<strong>on</strong>s of solid residues and<br />

energy c<strong>on</strong>sumpti<strong>on</strong> levels are briefly summarised in <str<strong>on</strong>g>the</str<strong>on</strong>g> following Tables. Aspects of key<br />

envir<strong>on</strong>mental issues are also addressed.<br />

Emissi<strong>on</strong>s to air are given in Table 1.10.<br />

Process Volume<br />

exhaust gas<br />

Cl2 HCl SOx NOx NH3 CO2 Dust<br />

m 3 /t Na2SO4<br />

All SSPA<br />

except<br />

kg/t kg/t kg/t kg/t kg/t kg/t kg/t<br />

natural 131 – 5000 0 – 0.0007 0 – 0.063 0 – 1.1 0 – 0.46 0 0 – 24 * 0.0003 – 0.66<br />

*No data available for some processes<br />

Table 1.10: Sodium sulphate producti<strong>on</strong> – emissi<strong>on</strong>s to air (aggregated data: min – max)<br />

[64, CEFIC-SSPA, 2004]

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