Document mB5vzdapnq5YQaQKN0GZ4DJkd
Pollution and Controls in Industry
K. E. ROBINSON,
Ventilation Engineer, Division of Industrial Health, State Department of Health, Lansing, Michigan
You have heard lectures and discussions that the concentrations of the atmospheric mostly on the general principles and contaminants are toxic rather than a seri
theories involved in the control of air conous nuisance, we have found that most in
taminants. In my discussion, I am going to dustries will consider a practical approach
stress the other side--the practical applica in eliminating the air pollution problem
tion of these principles and theories. A gov arising from their plant. One of the most
ernment agency such as ours is in an ex successful methods we have of working out
tremely favorable position to make this a satisfactory solution is to get both the
typo of presentation because we are direct citizens and the management of the indus
ly involved with the pollution problem from try together. In this manner, management
the time the initial complaint is received realizes the extent of the nuisance, and the
to the time when a study is conducted to people of the community realize the prac
evaluate the collection equipment installed. tical difficulties facing the management in
Whether the contaminant be fly ash, eliminating it.
alpha-napthoquinone, or odors from a near Investigations by the Michigan Depart
by rendering plant or millpond, we are even ment of Health have turned up a wide va
tually called in to investigate. These inves riety of contaminants (Fig. 1), and some
tigations can be initiated by the irate house are very difficult to control. In some in-
wife who is disturbed by sulphide odors, or the plant manager who maintains that dust from a nearby abrasive reclaiming plant is
ATMOSPHERIC CONTAMINANT
Asphalt, mo/ten
NUMBER OF PLANTS INVOLVED*
ruining the bearings in Jnis expensive ma chinery.
Baking omi (point) odors Bromine Buffing dost
Actual legal authority on these problems rests squarely with local governmental
CMdumaxtdo Cataum tydroxide Cement dust
units. In the Michigan Department of Cottondust DDT dust
Health, we can act in an advisory capacity Ffyosh
only. Many of the air pollution cases we are asked to investigate come from local
foundry dust Fluorides Grove!dust
governments who do not have the techni cians and the equipment to work on the cases or because the local officials are re luctant to act, fearing that the company will suspend operation in their town. They
Hydrogen Sulfide Iron dust kon oxide Leod oxide and tomes Mdpondodors MonocNorberuene Nophthotenes Qxxfe of Mtrogen
would rather have the state take the brunt of this burden. In all cases, we make every
Pant mst Phosphate fertilizer dusts Phthatic ontydnde
effort to be of assistance to the local autho rities, to the people of the community, and
ftohng pbnt odors Rendering plant odors Rockwool dust
to the industry involved. The year-to-year increase in the number
Rubber (bumf) odor Rubbish burning SAca dust
of requests received for service on air pol lution problems, from six in 1940 to nearly
Smoke Sotoents Sulphur dtoxide
a hundred in 1949, indicates the prominence of air pollution in our everyday life. Many of the plants at fault are probably not of sufficient size to afford to spend a great
Sutphunc ocxl VNenc (tso) odd Welding tothes Wood dust
Zinc oxide Miscellaneous
deal of money on contaminant control. De
spite the fact that we are not backed by a
Some plants mspons&e for seven! contaminants
specific statute and are rarely able to show
Pig. I.
VOL. 11, No. 1
INDUSTRIAL HYGIENE QUARTERLY
Page 65
stances, a satisfactory method of collection
is still to be found, and we welcome any
suggestions you may have. There is, of
course, no perfect method of collection for
any contaminant.
When faced with the problem of collect
tion, there are four things to be considered:
first, the selection of the method or collector
which is suitable for the job; second, the
initial cost of the equipment and installa
tion--and whether this cost is justifiable
considering the extent of the nuisance;
third, the maintenance on the equipment (a
big item with many collectors), and whether
it is within an acceptable range or requires
frequent expensive replacements and high
maintenance costs; and fourth, whether dis
posal of the collected material is difficult or
costly. The following case histories demon
strate that these considerations are ex
tremely important factors in every air pol
lution problem.
i
^Case No. I
A IR pollution problems involving odors are often extremely difficult to cope with.
One of the biggest problems is the elimina tion of odors. Our sense of smell is often an excellent method of chemical analysis; its delicacy is often greater than any chem ical analysis we can run in the laboratory. There are many materials which we can smell long before the concentrations are high enough to enable us to run a chemical determination. Since odors may be due to these minute concentrations of gases and particulate matter, they are extremely hard and often almost impossible to eliminate from the air. . Inasmuch as rendering operations are practically a necessity in all good-sized communities, this case will serve to sum marize some of the difficulties we have had with them in several of the cities of the state. The complaints concerned obnoxious
stenches which permeated the residential areas near the rendering plant. Upon inves tigation it was observed that the operating techniques in most of the departments were unsatisfactory, and that a good deal of the odor could be eliminated by improved sani tation and work methods. Several recom mendations concerning housekeeping and sanitation procedures were made, including the following:
1. That the sanitation and housekeeping
be well planned to include all operations, and that one or two individuals be delegat ed the responsibility of carrying out the program.
2. That an ample supply of steam and hot water be provided for cleaning and rinsing purposes.
3. That the building receive a thorough initial cleaning, and that certain structural changes be made, such as re-surfacing floors with an impervious material.
4. That a central wash station be pro vided for all containers and a storage space provided for all clean containers.
5. That materials coming into the plant which were not to be used immediately be stored in properly enclosed containers.
6. That a driveway be constructed of im pervious material which could be flushed off.
In addition, local exhaust ventilation for certain operations was recommended.
Shortly after our study of the operations, a group of citizens and the city filed a suit asking that an injunction be issued to re strain the company from polluting the at mosphere with offensive odors. In court, the company stated that in an effort to abate the stenches and smells emanating from the plant, they were acting upon our recom mendations. In addition to our recommen dations, they had installed two modern cookers; a modernized, used cooker; a new septic tank; a condenser water tank; an ad ditional sewer, and an ozone generator. They had enclosed the elevator shaft with steel, entirely segregating it; purchased an additional boiler, and agreed to construct a new driveway. The driveway was to be of concrete or other comparable material, and was to be made non-absorbent. The court found that the nuisance did exist and had existed for a long time, and stated that the plaintiffs were entitled to the relief sought by them. The company was ordered to wholly abate the nuisance within 30 days; with additional time, if necessary, to com plete the installation of the new boiler. The complaints of the residents, the legal action taken and the efforts made by the company to eliminate the odors have helped a great deal to minimize the amount of atmospheric pollution taking place.
Since the completion of the previously mentioned work, there have been no fur ther complaints to the court. It is our opin ion that the ozone generators mask the
Fi*r *
odors for the plant employees but do not affect the odors emanating from the plant. It is obvious that effective sanitation and housekeeping programs have to be main tained if the odors from rendering plants are to be minimized.
Case No. 2 ~\JOW let us consider a plant producing
^ phthalic anhydride. I have selected this plant because it is a good illustration of practically all the four considerations in selecting a collector which I have outlined.
The plant is large and centrally located in a residential district. The neighborhood
is contaminated by a strong pungent odor as well as small quantities of particulate matter. The problem of collecting the an noying stack effluents which are given off by 14 stacks is difficult, and is further ham pered by the pyroligenous acids which are produced and can result in explosions and fires. Correspondence with manufacturers of phthalic anhydride and with industrial hygiene units in this country indicates that the same difficulties of collection exist everywhere.
In an attempt to solve these problems, a committee was formed of members of the
chemical engineering department of a near by university, outside engineering consult ants, representatives of the company, and several of our engineers. The first attempt to control the contaminant was with the use of steam jets in the tall stacks with the thought that the addition of steam might result in satisfactory collection. It was found that the steam did not help and, in fact, increased the nuisance to the neigh borhood. Following this, a standard com mercial wet collector was tried and also found unsatisfactory.
While this was being done, the proper ties of the material were studied and it was found that the contaminant had a tend ency to seed and adhere to the ductwork or any other material it contacted. An experi mental, box-like duct (Fig. 2) was built. The thought was that a large portion of the material going through the tortuous passage would seed sufficiently and adhere
to the baffles, theye amount of objectionabl Although large amouj were collected, the odo: lessened appreciably. P at collection, an attem] dense the vapors on a less steel wall. Howeve the material would no surface, nor was enou to solve the problem.
A good many things box, such as using ori velocity in order to imp a plate. As shown by 1 method removed much as previously brought <
the odor. Following months oi
lectors, a special higl was installed and appe ally well. However, r quired and it was fount ing from the firlt sec had a pH of slightly o of neutralizing this t was prohibitive.
By this time, sufRc carried on in experim lead us to believe that caused by a by-produi
Fig.
Vol. 11, No. 1
INDUSTRIAL HYGIENE QUARTERLY
Page 67
to the baffles, thereby minimizing the amount of objectionable material given off. Although large amounts of the material were collected, the odor did not seem to be lessened appreciably. Following this failure at collection, an attempt was made to con dense the vapors on a water-cooled, stain
less steel wall. However, it was found that the material would not adhere to the wet surface, nor was enough vapor condensed to solve the problem.
A good many things were tried with this box, such as using orifices to increase the velocity in order to impinge the material on a plate. As shown by Figs. 3, 4 and 5, this method removed much of the material but, as previously brought out, did not decrease the odor.
Following months of work on these col lectors, a special high pressure fog unit was installed and appeared to work unusu ally well. However, much water was re quired and it was found that the water com ing from the firlt section of the collector had a pH of slightly over two and the cost of neutralizing this to allow for disposal was prohibitive.
By this time, sufficient work had been carried on in experimental laboratories to lead us to believe that the strong odor was caused by a by-product, alpha-naphthoqui-
none, and that concentrations as low as 1 ppm would be objectionable.
Some time after this fog unit was dis
mantled, the company was approached by
two men who had developed a catalyst for
burning organic matter from stack effluents. They had had very good success with this catalyst in eliminating odors from wire bak ing ovens and, judging from previous in stallations, the system would be reasonably inexpensive to install. Fig. 6 shows the type of system that had been used on the gases from the baking oven. The company de cided to try an experimental unit, and a system which might possibly work was de signed. Experiments in the laboratory with the catalyst showed that a high temperature would be required. Subsequent work with the unit proved that 400C was the mini mum temperature at which the catalyst would operate. Previous trials had proved that the ducts would clog unless arrange ments were made to keep them open, and so a counter-flow system was designed to keep the ducts warm with the thought that the heat from the catalyst would hold the ma terial in the vapor state.
An experimental unit was installed, using a gas flame to increase the air temperature sufficiently for operation of the catalyst. It was found that a good deal of work was
Fig. 6.
Fig. 7.
Page 68
INDUSTRIAL HYGIENE QUARTERLY
March, 1950
necessary to achieve an even temperature lector used when the plant was operated for
and even distribution of air through these the government and also that the power
catalysts. When this was accomplished and house was operated more efficiently and
all of the leaks were finally stopped (this gave off no fly ash.
was very difficult because of the high ex In making our investigation, we found
perimental temperatures), the system oper several reasons for the complaints. One was
ated quite satisfactorily.
that the plant had been built along the
At the present time, work is going for water's edge to take advantage of dock fa
ward on the design of a unit which can be cilities and, unfortunately, the major part
installed to control the contaminant from of the city was on a bluff overlooking the
each of the 14 stacks. Fig. 7 gives an idea plant. Most of the houses of the community
of the size and complexity of the piece of are actually higher than the top of the
apparatus to eliminate odors from this plant stack of the plant. Like many war plants,
in comparison to the very simple catalytic this one was designed for a specific oper
arrangement used in another plant with a ation which utilized the flue gases for a car
different material.
bonization process. The flue gases required
Regarding this air pollution problem, I scrubbing which, while consuming a great
should like to emphasize the desire on the deal of power, was justified by the fact
part of the offending company to find a solu that the gases would be re-used. In peace
tion of the problem which will be economi time operations, the carbonization process
cal and satisfactory to the residents of the could not be used and the company could
community. Practically all reasonable ap not economically justify the use of such a
proaches were tried. One method appeared scrubber. Contrary to the belief of. some
to be satisfactory, but this produced a citizens, the power plant is being operated
water pollution problem almost as great as more efficiently now than ever before. .Fly
the air pollution problem.
ash collectors are in use, but, like all collec
I should also like to bring out here that tors, they are not 100% effective, and some
one of our greatest difficulties results from escaping fly ash settles on the residences
the fact that it is almost ^impossible to use nearby.
a system developed for one operation on At the present time, an addition to the
another operation in a different plant with stack is being planned and will undoubted
out many major and often expensive ly be built when weather permits. It will
changes.
be interesting to see whether the addition
of this extra height will eliminate the com
Case No. 3
plaints, or will simply deposit the fly ash
common atmospheric contaminant is fly on residences a little farther out. It appears
ash. Practically every city and village to us that proper installation of electro
is confronted with this problem. I have se static precipitation might be more justifi
lected one fly ash problem from our files be able than a gamble on high stacks for dilu
cause it brings out a point that may be of tion purposes.
interest.
\
The plant is situated in a community of Case No. 4
9000 people and employs about 120 workers. 'THE collection of air contaminants in the
When the plant was built for war purposes
manufacture of calcium carbide is al
the citizens were elated because it gave a most as important a problem as the manu
big industrial boost to the community. Now facture of carbide itself. In our investiga
there are some citizens who wonder whether tions into the manufacture of carbide by
their elation was not somewhat prematurei one large concern, we found that this was
Throughout the war, the plant worked on a universal problem among the carbide
a round-the-clock basis with no complaints manufacturers. While much work has been
from the people of the community, but after done and many engineering organizations
it was taken over by a private company, the have attempted to solve this problem, we
local city officials began receiving com believe that contaminant control will not be
plaints. The principal complaint was due to satisfactory with present collecting devices
fly ash. The people of the community were unless manufacturing procedures are im
of the opinion that there had been a col proved.
Vol. 11, No. 1
INDUSTRIAL HYGIENE QUARTERLY
Page 69
Calcium carbide is manufactured in the
electric furnace by fusing a mixture of lime and coke. The yield from this reaction varies a great deal depending upon the quality of the coal and lime used. The gases and much of the particulate residue from the reac tion are removed from the electric furnace by exhaust fans. The particulate matter taken off from this reaction can run over 100 tons per day. Now if the efficiency of a collector installed to remove this particu late matter from the air runs as high as 96%--and this figure would be high for any collector--it would leave four tons of this material to be thrown into the open air and over the community. If you disperse this four tons of residue into the atmosphere, you can understand that it would do a fair ly good job in covering the community in 24 hours. This is the actual problem in con-' trolling air pollution created by a carbide plant. While this air pollution is not a health hazard but a nuisance, it reaches extremely annoying proportions. It is par ticularly damaging to the painted surfaces of houses and, in some instances, it ruins the finish on automobiles, furniture, etc. ^
In our work with this particular plant, we collected air samples throughout the plant and in the surrounding neighborhood. The results of the study are shown in Fig. 8. The management, in attempting to alle viate this air pollution, had installed Cott rell precipitators in the stack. The reasons, for selecting electrostatic precipitation as a means of collection were: first, experience has shown that electrostatic precipitation, in most cases, works satisfactorily on par ticulate matter, and, second, the company owned a share of the water rights and pro duced its own power in that community.
On our investigation, we found that there were several limiting factors in attaining complete success in the collection of the ma terial.
We discovered that the dust-laden flue gases were cooled and moistened by a bank of water sprays before entering the precipi tator units. The efficiency of the precipita tor varied considerably, owing to the fluc tuation in temperature and humidity of the flue gases. Another factor controlling the success of these precipitators was the com pany's limited water rights. While what power they produced was cheap, production required the greater portion and the re-
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Fig. 8.
Carbide Chemical Manufacture
mainder was insufficient for constant suc cessful precipitator operation.
We recommended that the company in stall automatic current and voltage controls; that local exhaust ventilation at the fur naces be improved, and that other collectors be installed between each furnace and the precipitator. But every recommendation re quiring an increase in the amount of power used, whether for wet collection or addition al electrical precipitation, brought the re ply that the power consumption could not be increased at the time and that all available power was necessary to produce an amount
of carbide to justify the existence of the jjlant.
In addition to the various aspects of the problem just mentioned, the fact that the company is the largest single plant in the area, employing about 500 people makes its existence necessary if economic stability is to be maintained in the city. While it might be possible for the residents to take legal action against the company, in view of the important place the industry occupies in the community it is doubtful if such action is wise.
The situation I have just outlined is not unusual. Every collector installation has its limiting factors, and you can determine from the account I have given that these can be extremely perplexing.
Page 70
INDUSTRIAL HYGIENE QUARTERLY
March, 1950
Fig. 9.
Case No. 5
pROM inquiries we have received from all over the country, the control of air con
taminants from chemical fertilizer plants is of interest to many engineers and com
munities. For that reason, I have selected
a chemical fertilizer plant in which I be
lieve we have been quite successful. The
usual air contaminant from the phosphate fertilizer plant is due to the dust and vapors
given off during the mixing of sulfuric acid
with calcium phosphate, resulting in exces
sive pollution of the atmosphere with phos
phate, fluoride and sulphate dust and silicic
acid.
-:
The equipment used by the company for
controlling the materials given off during
the mixing consisted of a wooden paddle type blower which sucked the gases and
solid materials from the mixing process up
a tall wooden scrubbing tower. Several hap
hazardly-placed water sprays were used in
an attempt to effect water scrubbing and
collections of the materials given off.
As a result of our investigation, the com
pany, in attempting to determine what
equipment would be suitable for complete
collection of the contaminants, had high-
pressure fog spray equipment installed and
requested that we conduct test runs for de termining its effectiveness. The installation was very effective and the results of our
tests are shown in Figs. 9 and 10. Visual
observance of the stack during operation
of the process with the high-pressure fog
spray collection equipment both on and off indicated satisfactory collection as shown.
After a period of use during which the
fog spray equipment was satisfactory, the
Fig. 10.
company gradually cut down on the water pressure used and finally reached the point where it was considered wise to discontinue the use of a high-pressure pump and install in its place an ordinary pump-capable of delivering pressure up to 120 pounds per square inch. No further complaints about the mixing process have been received. How ever, we recently received complaints con cerning a dusty material which was con taminating the neighborhood, and upon in vestigation we found that a great deal of dust was being liberated by the natural draft ventilators during the mixing of a high nitrate composition fertilizer. It was suggested to the company that bag type collectors be used for collecting this dust. No follow-up investigation has been made, and no additional information is available.
It appeared from our work on this plant that the fog spray method of collection is very well adapted for fertilizer plants of this type, providing, of course, the effluent can be satisfactorily disposed of. Another fertilizer plant which has been constructed since, with fog filters installed, has proved satisfactory.
Case No. 6
'J'he next case is that of a manufacturer of asphaltic base sound-deadening coat
ings. The contaminant involved is once again odors. The plant is located in a city of approximately 2400, and employs about 85 people. Neighborhood residents com plained of the foul-smelling stack effluent given off during the processing of flux oils. The process, known in the trade as "blow ing asphalt," consists of blowing air
VOL. 11, NO. 1
INDUSTRIAL HYGIENE QUARTERLY
Page 71
through molten asphaltic flux oil which is
maintained at a temperature of about
500F.
During the process, certain volatile com
pounds are formed and the lighter por
tions of the flux oil itself may be distilled
off, owing to the elevated temperature.
Requests for information concerning con
trol of the "blowing" process were answered
by two large oil companies who supply the
company in question with their flux oils.
One suggested the use of an electrostatic
precipitator or "routing the vapors through
a furnace where all hydrocarbon particles
are burned, giving off a normal stack gas."
The other suggested condensing the vapors
into a liquid or washing them with water
"by which means the greater part of the
more volatile portions are knocked down in
the form of a liquid." A third inquiry to
the author of an article on petroleum base
protective coatings brought the reply that
he knew of no completely successful method
of controlling the stack effluent but thought
that it could be successfully collected if
passed through "at least two stages of
water spray."
-
The company did not believe that it could
consider the costly electrostatic precipitator
installation and, because of the highly in
flammable nature of the process, ruled out
furnace burning of the stack gases. At our
suggestion it was decided to try a high-
pressure water spray process, and a near
by manufacturer provided the company with
a pilot model so that test runs could be
made. Although it could easily be seen from
the draining water effluent that much oily
type material was being collected, the fog
spray process did not completely eliminate
the foul-smelling white smoky material
which went through the collector and out
of the stacks. Fig. 11 is a data sheet cover
ing our fog spray test findings. Although
additional test runs with a larger capacity
water spray unit might have proved more
effective, no further work has been carried
out.
The problem of collecting the contami
nant remains unsolved, but the company
plans to continue the search for a suitable
collection apparatus and has informed the
city council that it will shut down the blow
ing operations whenever the prevailing
winds result in contamination of the neigh
borhood.
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Case No. 7
WTE WERE requested by a city health de partment to investigate numerous com
plaints concerning hydrogen sulphide odors. Stack samples collected during the mixing of sulphur with hot purified lard oil indi cated high concentrations of hydrogen sul phide.
The gases emanating from the mixing process were passed through beds of lime stone and water in an attempt to collect the hydrogen sulphide. Our study indicated that the collection procedure was ineffective. Knowing of no process which would success fully eliminate the hydrogen sulphide, the company had installed a high-pressure fog spray collection unit so that test runs could be made. The results of our study on this unit are shown in Fig. 12. Ordinary water was used as the spray medium, and the col lection of the hydrogen sulphide was un successful.
In an effort to decrease the amount of hy drogen sulphide given off, the company de creased the reaction temperature and in creased the reaction time. No follow-up study has been conducted since this modi fication of the manufacturing process, but we plan to evaluate the new procedure as soon as possible.
At the time of the test runs using the fog spray collector, it was suggested that an al kali solution in place of plain water also be
Page 72
INDUSTRIAL HYGIENE QUARTERLY
March, 1950
aeuasg
A. Ton spray Installation for eolleetln* nixing tank effluent gases
1. B28 concentration! (Inlet and Outlet)
Staple ge
B*S Concentrations
(nillterme nar cubic fact)
Inlet
Outlet
Collection Ifficl.Aoy if)
l 166 140 24.8 2 *90 415 U.3 3 800 775 3.1
2* Air qoTenent data
tact 4lBeter (inchee) tael area (square feet)
Air velocity (feet Teralmite) Ai r veliaf (euble feet per nlnnte)
Inlet
6 0.199
2865 562
Ontlet
7 0.267
2110 #3
\ tatet Collecting asdlwt water
Fig. 12. Oil and Grease Company
used for testing purposes, but such a run was not made.
Case No. 8 ^OMPLAINTS were received from citizens
living near a chemical company engaged in the manufacture of pharmaceuticals. During part of the processing, atmospheric pollution with bromine took place and caused disturbance throughout the neigh borhood. The complaint was investigated and it was learned that the pollution dis turbance resulted during the warm weather months only.
In order to eliminate the annoyance, the company agreed to compound the
materials involving the use of bromine during the winter months. No further com plaints have been received.
Case No. 9
^OMPLAINTS were received from the people ' residing near a small chemical plant en
gaged in the manufacture of iso-valeric acid. It was learned that the company was considering a new location but its capital was limited. Unable to relocate because of lack of funds, the company was forced to abandon the contract for the manufacture of iso-valeric acid.
Conclusion
VV/E believe these case histories may serve to bring out the importance of
the four considerations previously men tioned; namely, the selection of a suitable method or collector, cost of the equipment and installation, maintenance of the equip ment, and disposal of the collected material. They also show that there is no cut-anddried method of controlling the contam inants involved in the term air pollution. At the present time it is our belief that, in many cases similar to the phthalic plant mentioned, even the plant operators do not know what their problem is. We hear a good deal about smoke and fly ash elimina tion, possibly because we know more about how to eliminate them than most of the other contaminants found. Obviously, the lack of knowledge is the biggest handicap in the control of odors.