Successes emerge in search for cleaner processes

Faced with mounting public and regulatory pressures, many chemical producers have long adopted pollution reduction efforts. But increasingly, firms are eyeing fundamental process changes to achieve cleaner technologies. In addition to environmental benefits, the promised economic payoffs are clear: higher yields and an escape from soaring waste treatment and disposal costs. Having such technologies, says Paolo Galli, Montecatini's (Milan) director/corporate research, is a tremendous tool. It's becoming an increasingly important competitive element. Indeed, suggests David Hyde, ICI's (London) manager/environmental technology, everyone is looking to use cleaner technologies for a competitive advantage. A number of leading technology groups, including UOP (Des Plaines, IL), are working on replacing hydrofluoric acid (HF) with solid catalysts in alkylation processes. Although it is technologically tough to replace HF or alternative sulfuric acid technology, the rewards could be huge in producing high-octane fuel additives. Catalytica (Mountain View, CA), for one, is building a pilot plant with partners Neste (Helsinki) and Du Pont's Conoco. The company has developed a process to manufacture high-purity DMC by direct synthesis from carbom monoxide, methanol, and oxygen. The medium-pressure process uses a copper salts catalyst system; EniChem says the only significant by-product is carbon dioxide, and there are no chlorinated impurities