Analysis of mass flow and proposal of key technologies for establishment of zero-emission processes

通过分析各工序的质量流和能量流，建立数据库，开发减排所需的关键技术，对具有代表性的高排放行业的零排放流程的建立进行研究。以食品工业为例，对酱油生产工艺进行了研究。对各工序线的质量流进行了全面分析，绘制了总固液、总TOC、总N、总P、总Cl的质量平衡图。对饼粕进行干馏、加压热水处理和酶解脱盐，以达到有效的农业回用效果。以化工为例，研究了氯乙烯单体（VCM）的生产工艺。基于流程分析，首次提出了日本氯气的总质量资产负债表。提出了一种减少氯乙烷等副产物的途径，通过生物转化法实现这些副产物的零排放。道路工程产生了大量的副产品，如沥青、混凝土、刮砂土等，同时也利用了大量的天然原始资源。在建立先进的副产品回收系统时，重要的是要明确当地每项道路工程的原材料和副产品的质量流。研究了金属工业中铁、铜、锌生产工艺的零排放。向铜市场供应铜约240万吨，使用废铜约90万吨。作为回收技术的一个课题，研究了空气吹炼法去除铜液中的铁。在2000秒内，铁含量从1%左右下降到100ppm以下。研究了半导体工业的物料流动，分析了未回收材料的排放。还研究了这种排放与其他制造过程的过程间网络。对减少废物需要解决的问题进行了评估，并提出了一些减少废物的方案。这些结果在本调查中得到了建议，并作为研究论文发表在各种期刊上。少

The establishment of zero-emission processes in representative industries which discharge a lot of emissions was studied by analyzing the mass and energy flows in each process to make the data-base and by developing the key technologies necessary to reduce the emission. A soy-sauce production process was investigated as an typical example of food industry. The mass flow in the process was completely analyzed for all operating lines and the mass balance charts of total solid and liquid, TOC, N, P and Cl were drawn. The dry distillation, pressurized hot water treatment, and enzymatic hydrolysis of cake were investigated for effective re-use in agriculture by removing salt. Vinyl chloride monomer (VCM) production process was investigated as an example of chemical industry. The total mass balance sheet of chlorine in Japan was first presented based on the flow analysis. A satisfactory way to reduce the byproducts such as chloroethane was proposed to realize the zero-emission of those bypro … More ducts by biological conversion method. The road works generated a large quantities of byproducts such as asphalt, concrete and gravelly soil scraped, while they utilized a lots of natural virgin resources. In establishing an advanced recycle system of byproducts, it was important to clarify the mass flow of raw materials and byproducts for each road work in a local area. The zero-emission in metal industries was studied for iron, copper and zinc production processes. About two million and four thousand tons of copper was supplied to the copper market and nine hundred thousand tons of copper scrap was used in total. As a topic of recycling technology, the removal of iron in molten copper was studied by air blowing process. Iron content decreased from about 1% to less than 100ppm within 2000 sec. Material flow in semiconductor industry was investigated to analyze the emission of unrecycled materials. Inter-process networking of such emissions with the other manufacturing processes was also investigated. The problems to be solved for waste minimization were assessed and some waste minimization options were proposed.Those results obtained in the present investigation were proposed to industries and also published as research papers in various journals. Less