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Separation Technologies for the Industries of the Future Panel on Separation Technology for Industrial Reuse and Recycling Committee on Industrial Technology Assessments National Materials Advisory Board Commission on Engineering and Technical Systems National Research Council Publication NMAB-487-3 NATIONAL ACADEMY PRESS Washington, D.C.1998
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NOTICE: The project that is the subject of this report was approved by the Governing Board of the National Research Council, whose members are drawn from the councils of the National Academy of Sciences, the National Academy of Engineering, and the Institute of Medicine. The members of the committee responsible for the report were chosen for their special competencies and with regard for appropriate balance. The National Academy of Sciences is a private, nonprofit, self-perpetuating society of distinguished scholars engaged in scientific and engineering research, dedicated to the furtherance of science and technology and to their use for the general welfare. Upon the authority of the charter granted to it by the Congress in 1863, the Academy has a mandate that requires it to advise the federal government on scientific and technical matters. Dr. Bruce Alberts is president of the National Academy of Sciences. The National Academy of Engineering was established in 1964, under the charter of the National Academy of Sciences, as a parallel organization of outstanding engineers. It is autonomous in its administration and in the selection of its members, sharing with the National Academy of Sciences the responsibility for advising the federal government. The National Academy of Engineering also sponsors engineering programs aimed at meeting national needs, encourages education and research, and recognizes the superior achievements of engineers. Dr. William Wulf is president of the National Academy of Engineering. The Institute of Medicine was established in 1970 by the National Academy of Sciences to secure the services of eminent members of appropriate professions in the examination of policy matters pertaining to the health of the public. The Institute acts under the responsibility given to the National Academy of Sciences by its congressional charter to be an advisor to the federal government and, upon its own initiative, to identify issues of medical care, research, and education. Dr. Kenneth I. Shine is president of the Institute of Medicine. The National Research Council was organized by the National Academy of Sciences in 1916 to associate the broad community of science and technology with the Academy’s purposes of furthering knowledge and advising the federal government. Functioning in accordance with general policies determined by the Academy, the Council has become the principal operating agency of both the National Academy of Sciences and the National Academy of Engineering in providing services to the government, the public, and the scientific and engineering communities. The Council is administered jointly by both Academies and the Institute of Medicine. Dr. Bruce Alberts and Dr. William Wulf are chair and vice chair, respectively, of the National Research Council. This study by the National Materials Advisory Board was conducted under a contract with the Department of Energy. Any opinions, findings, conclusions, or recommendations expressed in this publication are those of the author(s) and do not necessarily reflect the view of the organizations or agencies that provided support for the project. Library of Congress Catalog Card Number 98-83160 International Standard Book Number: 0-309-06377-9 Available in limited supply from: National Materials Advisory Board 2101 Constitution Avenue, NW Washington, D.C. 20418 202-334-3505 nmab@nas.edu Additional copies are available for sale from: National Academy Press Box 285 2101 Constitution Ave., N.W. Washington, DC 20055 800-624-6242 202-334-3313 (in the Washington, D.C. metropolitan area) http://www.nap.edu Copyright 1998 by the National Academy of Sciences. All rights reserved. Cover: Background photograph: Hydrogen plant at refinery. Courtesy of Air Products and Chemicals, Inc. Top inset photograph: Glass containers and cullet for recycling. Courtesy of the Glass Packaging Institute. Middle inset photograph: Paper drying on a laboratory scale. Courtesy of the Institute of Paper Science and Technology. Bottom inset photograph: Refined alumina. Courtesy of Alcan Aluminum Ltd. Printed in the United States of America.
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PANEL ON SEPARATION TECHNOLOGY FOR INDUSTRIAL RECYCLING AND REUSE GEORGE E. KELLER II (chair), consultant, South Charleston, West Virginia R. RAY BEEBE, consultant, Tucson, Arizona RICHARD J. FRUEHAN, Carnegie-Mellon University, Pittsburgh, Pennsylvania NORMAN N. LI, NL Chemical Technology, Inc., Arlington Heights, Illinois EVE L. MENGER, Corning, Inc. (retired), Corning, New York GUIDO P. PEZ, Air Products and Chemicals, Inc., Allentown, Pennsylvania PETER H. PFROMM, Institute of Paper Science and Technology, Atlanta, Georgia RONALD W. ROUSSEAU, Georgia Institute of Technology, Atlanta MICHAEL P. THOMAS, Alcan Aluminum Corporation, Shelbyville, Tennessee National Materials Advisory Board Staff THOMAS E. MUNNS, Associate Director BONNIE A. SCARBOROUGH, Program Officer AIDA C. NEEL, Senior Project Assistant LOIS LOBO, Research Associate Government Liaison CHARLES RUSSOMANNO, U.S. Department of Energy, Washington, D.C.
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COMMITTEE ON INDUSTRIAL TECHNOLOGY ASSESSMENTS R. RAY BEEBE (chair), consultant, Tucson, Arizona GARY A. BAUM, Institute of Paper Science and Technology, Atlanta, Georgia PHILIP H. BRODSKY, Monsanto Company, St. Louis, Missouri JOHN V. BUSCH, IBIS Associates, Wellesley, Massachusetts NORMAN A. GJOSTEIN, consultant, Dearborn, Michigan FRANCIS C. MCMICHAEL, Carnegie-Mellon University, Pittsburgh, Pennsylvania MAXINE L. SAVITZ, AlliedSignal Aerospace Corporation, Torrance, California Government Liaisons DENISE SWINK, U.S. Department of Energy, Washington, D.C. JAMES E. QUINN, U.S. Department of Energy, Washington, D.C.
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NATIONAL MATERIALS ADVISORY BOARD ROBERT A. LAUDISE (chair), Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey G.J. ABBASCHIAN, University of Florida, Gainesville MICHAEL I. BASKES, Sandia National Laboratories, Livermore, California JESSE L. BEAUCHAMP, California Institute of Technology, Pasadena FRANCIS DISALVO, Cornell University, Ithaca, New York EARL DOWELL, Duke University, Durham, North Carolina EDWARD C. DOWLING, Cyprus AMAX Minerals Company, Englewood, Colorado THOMAS EAGAR, Massachusetts Institute of Technology, Cambridge ANTHONY G. EVANS, Harvard University, Cambridge, Massachusetts JOHN A.S. GREEN, The Aluminum Association, Washington, D.C. SIEGFRIED S. HECKER, Los Alamos National Laboratory, Los Alamos, New Mexico JOHN H. HOPPS, JR., Morehouse College, Atlanta, Georgia MICHAEL JAFFE, consultant, Maplewood, New Jersey LISA KLEIN, Rutgers, The State University of New Jersey, Piscataway, New Jersey SYLVIA M. JOHNSON, SRI International, Menlo Park, California HARRY A. LIPSITT, Wright State University, Dayton, Ohio ALAN G. MILLER, Boeing Commercial Airplane Group, Seattle, Washington RICHARD S. MULLER, University of California, Berkeley ROBERT C. PFAHL JR., Motorola, Schaumburg, Illinois ELSA REICHMANIS, Bell Laboratories, Lucent Technologies, Murray Hill, New Jersey KENNETH L. REIFSNIDER, Virginia Polytechnic Institute and State University, Blacksburg JAMES WAGNER, Johns Hopkins University, Baltimore, Maryland BILL G.W. YEE, Pratt and Whitney, West Palm Beach, Florida RICHARD CHAIT, Director
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ACKNOWLEDGMENTS
The Panel on Separation Technology for Industrial Recycling and Reuse would like to thank the presenters and participants in the two workshops that served as the principal data-gathering sessions for this study. Presenters at the October 1997 workshop on industrial separation technology were: Earl Beaver, Monsanto; David Carter, Allied Metals Corp.; Robert P. Foley, Illinois Institute of Technology; Donald R. Hubbard, Champion International; H.S. Muralidhara, Cargill, Inc.; Ray D. Peterson, Reynolds Metal Co.; Charles G. Scouten, Amoco; and Malcolm B. Wood, consultant. Presenters at the December 1997 workshop on separation technology research were: Thomas J. Bruno, National Institute of Standards and Technology; Edward C. Dowling, Cyprus Amax Minerals Company; Richard R. Klimpel, RK Associates; Garry R. Kenny, Magnetic Separation Systems, Inc.; Frank S. Knoll, Carpco, Inc.; H.S. Muralidhara, Cargill, Inc.; Elwin L. Rooy, Elwin Rooy and Associates; Anna Lee Y. Tonkovich, Pacific Northwest Laboratory; and Norman L. Weinberg, Electrosynthesis.
This report has been reviewed by individuals chosen for their diverse perspectives and technical expertise, in accordance with procedures approved by the NRC' s Report Review Committee. The purpose of this independent review is to provide candid and critical comments that will assist the authors and the NRC in making the published report as sound as possible and to ensure that the report meets institutional standards for objectivity, evidence, and responsiveness to the study charge. The content of the review comments and draft manuscript remain confidential to protect the integrity of the deliberative process. We wish to thank the following individuals for their participation in the review of this report: Mari Chesser, Weyerhauser; Edward Dowling, Cleveland Cliffs, Inc.; Merton Flemings, Massachusetts Institute of Technology; C. Judson King, University of California;
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William Koros, University of Texas at Austin; Alexander MacLachlan, E.I. du Pont de Nemours (retired); Philip Ross, consultant; Richard Stein, University of Massachusetts at Amherst; and Raymond Zolandz, The DuPont Experimental Station. While the individuals listed above have provided many constructive comments and suggestions, responsibility for the content of this report rests solely with the authors. Finally, the panel gratefully acknowledges the support of the staff of the National Materials Advisory Board, including Thomas E. Munns, Bonnie A. Scarborough, Aida C. Neel, and Lois Lobo.
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PREFACE The seven industries discussed in this report have widely divergent interests, concerns, and priorities. During the course of this project, the panel discovered how broadly and narrowly "separation" can be defined and had to grapple with the task of focusing the definition in a way that would be useful to our sponsors. In the process, we all learned a great deal about the various industries and changed our definitions of separation technology. I wish to thank the members of the panel for their hard work and enthusiasm in searching out potential cross-cutting areas of research in separation technology. I hope that readers will find this report to be enlightening and worthwhile. Comments and suggestions can be sent via electronic mail to nmab@nas.edu or via facsimile to the National Materials Advisory Board at (202) 334–3718. GEORGE E. KELLER II, CHAIR PANEL ON SEPARATIONS TECHNOLOGY FOR INDUSTRIAL RECYCLING AND REUSE
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CONTENTS
Executive Summary
1
1
Introduction
6
Industrial Separation Processes,
6
Office of Industrial Technology Research Program,
7
National Research Council Industrial Technology Assessments,
9
Panel on Separation Technology for Industrial Recycling and Reuse,
9
Organization of the Report,
10
Part I:
Separation in the Chemical and Petroleum Refining Industries
2
Chemical Industry
13
Traditional Chemical Engineering Separation Processes,
13
Separation Needs,
16
Summary,
27
3
Petroleum Refining Industry
28
Separation Needs,
28
Summary,
34
4
Cross-Cutting Issues for the Chemical and Petroleum Refining Industries
36
Introduction,
36
Common Needs,
36
Separation Technologies,
37
Enabling Technologies,
43
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Part II: Separation in the Materials Processing Industries 5 Aluminum Industry 51 Separation Needs, 51 Separation Technologies, 56 Summary, 58 6 Steel Industry 59 Separation Needs, 59 Separation Technologies, 65 Summary, 67 7 Metal Casting Industry 68 Separation Needs, 68 Separation Technologies, 72 Summary, 72 8 Glass Industry 74 Separation Needs, 74 Separation Technologies, 77 Summary, 78 9 Forest Products Industry 79 Separation Needs, 79 Separation Technologies, 84 Summary, 85 10 Cross-Cutting Issues for the Materials Processing Industries 87 Introduction, 87 Common Needs, 87 Separation Technologies, 89 Enabling Technologies, 93 Part III: Cross-Cutting Separation Issues 95 11 Conclusions and Recommendations 97 Key Separation Process Needs, 97 Research Opportunities, 98 Research Opportunities in Enabling Technologies, 100 Recommended Criteria, 102 References 105 Appendix A: Biographies of Panel Members 111
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TABLES AND FIGURES
Tables
1-1
Status of Vision Documents and Road Maps for the Industries of the Future,
8
2-1
Projected Sizes of Semiconductor Devices and Gas Purity Requirements for Contaminant-Free Manufacturing,
19
2-2
Candidates for Energy Savings of 33 Percent through Hybrid Technologies Involving Membranes and Distillation,
22
Figures
1-1
Separation in manufacturing processes,
7
4-1
Membrane reactor configuration used in dehydrogenation technology,
40
4-2
Schematic illustration of affinity chromatography,
41
4-3
Schematic illustration of the relationship between energy costs, product purity, and process variability,
45
5-1
Separation issues for the aluminum industry,
52
9-1
Schematic illustration of bleached pulp production emphasizing chlorine, a nonprocess element (NPE),
82
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