Integrated Evaporation and Treatment System for Incineration Waste Gases

Objective: The objective of this study is to analyze and evaluate the technical, environmental, and operational efficiency of an integrated treatment system for agrochemical industrial waste, consisting of physicochemical treatment stages, multiple-effect vacuum evaporation, fixed-bed incineration, and wet gas treatment, with emphasis on volume reduction, thermal destruction of hazardous compounds, and reuse of the treated condensate within the process itself. Specifically, it seeks to verify the system’s performance in the concentration and removal of contaminants originating from waste generated in the manufacture of the herbicide Tebuthiuron, as well as to evaluate the effectiveness of the condensate polishing stages in reducing micropollutants, ensuring environmental compliance, operational safety, and sustainability of the hazardous waste management process. Theoretical Framework: The management of hazardous industrial waste requires technologies capable of reducing volume, toxicity, and environmental impacts. In the agrochemical sector, these wastes present high complexity, requiring integrated treatment systems. Physicochemical treatment, through coagulation, flocculation, and sedimentation, is used to separate solids and reduce the initial pollutant load. Evaporation concentrates effluents by removing the solvent, being more efficient when operated under vacuum and in multiple effects. Incineration promotes the thermal destruction of hazardous compounds at high temperatures, with reduction of mass and volume. The generated gases must be treated by cooling, washing, and particle removal systems to ensure environmental compliance. The reuse of internal streams, such as treated condensate, follows principles of cleaner production and circular economy, being enabled by polishing with membranes and activated carbon. The integration of these processes constitutes an efficient and sustainable solution for the treatment of hazardous waste. Method: The research is characterized as an applied case study, with qualitative and quantitative approaches, developed in an industrial agrochemical waste treatment facility. The study has a descriptive and analytical character, aiming to evaluate the performance of an integrated hazardous waste treatment system. Initially, a technical-operational survey of the process units was carried out, covering the stages of physicochemical treatment, multiple-effect vacuum evaporation, fixed-bed incineration, and wet gas treatment. This stage included document analysis, direct field observation, and data collection from automation systems. Representative samples were collected from the main process streams: raw waste, clarified effluent, concentrate, condensate, and treated effluents. Liquid samples were subjected to physicochemical analyses to determine pH, solids, and target compound concentration, allowing evaluation of the efficiency of each stage. The data were analyzed by comparing inlet and outlet streams of each unit, enabling the calculation of removal rates, concentration factors, and volumetric reduction. In parallel, operational parameters such as temperature, pressure, flow rate, and energy consumption were evaluated, seeking to correlate technical performance and operational efficiency. The results were interpreted in light of the theoretical framework and current environmental legislation, allowing assessment of the technical, environmental, and operational feasibility of the integrated hazardous waste treatment system. Results and Discussion: The results demonstrated high efficiency of the integrated system in volume reduction and removal of contaminants from agrochemical waste. In the physicochemical treatment stage, coagulation and flocculation enabled efficient phase separation, generating a clarified effluent with low solids content and a concentrated sludge directed to incineration. In the multiple-effect vacuum evaporation system, an average reduction of approximately 80% of the initial volume was observed, concentrating hazardous organic compounds and significantly reducing the volume to be thermally treated. This stage proved to be essential for the economic and operational optimization of the process. Condensate polishing showed high efficiency in removing the target contaminant, with successive reductions after reverse osmosis and ultrafiltration, reaching concentrations compatible with internal reuse in the gas scrubbing system. This result highlights the system’s potential to promote water savings and alignment with cleaner production principles. Incineration of the sludge and concentrate ensured the thermal destruction of hazardous compounds, with stable operation in the primary and secondary chambers. The gas treatment system, composed of cooling, washing, and particle separation stages, proved to be efficient in controlling atmospheric pollutants, ensuring environmental compliance. In an integrated manner, the results confirm the technical, environmental, and operational feasibility of the proposed system for the treatment of hazardous industrial waste. Research Implications: The research demonstrates that the integration of physicochemical treatment, evaporation, incineration, and gas treatment is technically feasible and effective for hazardous industrial waste. From an environmental perspective, the system ensures high contaminant removal and control of atmospheric emissions, reducing pollution risks and meeting legal requirements. The reuse of treated condensate contributes to water savings and cleaner production practices. From an economic standpoint, the prior concentration of waste reduces the volume sent for thermal destruction, lowering operational costs. In terms of management, the results support strategic decisions focused on sustainability and socio-environmental responsibility. Originality/Value: The study presents originality by integrating, within a single operational system, stages of physicochemical treatment, multiple-effect vacuum evaporation, fixed-bed incineration, and wet gas treatment, applied specifically to highly complex agrochemical wastes. Unlike isolated approaches, the work evaluates in a systemic manner the interaction among the stages and their effects on operational efficiency, volumetric reduction, and environmental control. The scientific value of the study lies in the generation of empirical data on the real performance of an integrated system, contributing to a body of literature that still lacks applied studies at industrial scale involving persistent agrochemical wastes. The results provide technical support for replicating the model in other industrial units. In the field of social and environmental management, the study adds value by demonstrating the feasibility of technological solutions aligned with sustainability, circular economy, and legal compliance, supporting managers and policymakers in decision-making regarding investments in clean and safe technologies.