March 3, 2008

AUSTIN, TX – Bolstered by new technology and advancements in green manufacturing, the Texas chemical industry has demonstrated emissions reductions of nearly 10 percent in a two-year period, according to data released recently by the U.S. Environmental Protection Agency (EPA).

Statistics from the EPA's annual inventory of public and private chemical facilities showed that total industry emissions in Texas declined from 144.6 million pounds in 2004 to 130.8 million pounds in 2006, the latest year reported in the study. Overall emissions also fell 4 percent from 2005 to 2006, according to EPA findings.

Even better results were reported for the Houston area, home of about 80 percent of the state's chemical producers. The chemical industry in Harris County slashed its emissions by 20 percent from 2004 to 2006, and by 7 percent in 2005-06. Emissions of benzene also fell in Harris County by 12 percent in the two-year period and 7 percent in 2005-06.

Year-by-Year Chemical Emissions Reductions in Texas (millions of pounds)

   2004 2005 2006 % Reduction 2004-06 % Reduction 2005-06
 Texas Chemical Industry 144.6 136.7 130.8 9.54 4.31
 Harris County Chemical Industry 32.4 28.0 25.9 20.1 7.5
 Harris County Benzene Emissions 0.94 0.89 0.83 11.7 6.7
 Source: EPA TRI study, 2006

"The Texas chemical industry has been very focused on using the best available technology and state-of-the-art processes to protect the environment, and these statistics quantify the effect of our efforts," said Hector Rivero, President of the Texas Chemical Council (TCC).

"Like any human activity, chemical manufacturing leaves an environmental footprint - but we are continuously working to make our imprint smaller and smaller," Rivero added. "The chemical industry continues to seek out and develop processes and technology than can improve efficiency and reduce emissions, while preserving workplace safety."

An example of developing technology is the industry's voluntary use of infrared (IR) imaging to detect leaks that otherwise can be found only by visual and manual inspections requiring thousands of person-hours. An IR camera costing about $100,000 can be used to quickly scan large production areas and miles of pipeline to deliver thermal images of gas leaks in real time.

"The greatest benefit is that it allows us to pinpoint fugitive emissions much sooner than we would by using other technologies," said Dave Seitz, a plant manager for LyondellBasell's Channelview, TX complex. "We are using IR cameras in our olefins and refining facilities across the United States."

Russ Roberts, spokesperson for ExxonMobil Chemical Company in Baytown, TX, added: "With this camera, you can scan 3500 pieces of equipment in an hour, versus 500 a day with older, conventional methods. We're using this technology in our facilities all over the world."

Currently, IR technology cannot detect all chemical compounds or quantify the volume of emissions. However, the chemical industry continues to research IR and other technologies, and is collaborating with EPA to improve leak-detection capabilities.

Other companies cite these examples of how the industry has lowered emissions:

  • An emphasis on lowering fugitive sources and achieving more efficient and reliable operations has enabled Shell's complex in Deer Park, TX to cut its benzene air emissions by 23 percent since 2005.
  • Petrochemical companies in East Texas have used advanced process controls, flare gas recovery systems, process gas compressor upgrades and other upgrades to slash unplanned emissions by 90 percent over the seven-year period ending in 2005, according to a recent survey by business group Industry of the Golden Triangle. The study reported that 30 surveyed plants operating in Jefferson, Hardin and Orange counties "have spent over $700 million since 1998 on 239 air emissions reductions projects."
  • In Baytown, Texas, improvements in process reliability enabled the three ExxonMobil petrochemical facilities to reduce benzene emissions to the air by 41% from 2004 to 2006. 
Texas chemical companies also have made good progress in reducing greenhouse gas emissions, which are not reflected in the EPA report. For example, DuPont's Sabine River Works in Orange, TX partnered with the U.S. Department of Energy to identify 55 improvement projects that reduced energy consumption by 20 percent, which in turn eliminated 1.5 million metric tons of greenhouse gas emissions per year. Also, DuPont's Corpus Christi facility received an American Chemistry Council award for reducing its energy consumption 8 percent and so eliminating 8,000 metric tons of carbon dioxide emissions annually.