An integrated approach to process waste minimization research

Abstract Waste minimization for industrial processes is evolving, with at least three generations of activity apparent. Initially, waste minimization programs focussed on good housekeeping practices, inventory control and minor changes in operating practices. This generation of waste minimization resulted in impressive reductions of waste, but the methods are rapidly reaching their limits. A second generation of waste minimization is underway. In this second generation, current technologies are being used to modify processes, reducing effluents. These retrofit operations employing current technologies will also reach their limits, however, and a third generation of waste minimization activity is inevitable. In this third generation, highly selective separation and reaction technologies, specifically designed for waste minimization applications, will be employed. Further, new methods for process synthesis will be developed which minimize effluents (maximizing mass efficiency), evolving in the same way as energy efficient process design methods. This paper will describe an integrated research effort aimed at addressing these third generation technological needs. The research results are demonstrated through case studies focussing on particular waste streams. The streams selected for research emphasis were chosen by examining and prioritizing the nationwide mass flow of pollutants. This quantitative, nationwide flow mapping of waste streams will also be presented, along with the prioritization scheme used to select targets for waste minimization research.