Implementing Pollution Prevention P2 Dee-fusionClearwater, FLJune 7, 2000Cam MetcalfExecutive Directorjcmetc01@gwise.louisville.edu502-852-0965

Driving Forces on LegislationProperty Owners: NIMBY, Universal BackyardTaxpayers: Pressured by rising disposal feesEnvironmentalists: Concerns of ecological effectsIndustries: Fear punitive regulations & legislation

Driving Forces on LegislationProperty Owners: NIMBY, Universal BackyardTaxpayers/Agency: Pressured by rising treatment feesEnvironmentalists: Concerns of ecological effectsIndustries: Fear punitive regulations & legislation

Our Universal Backyard NIMBY NOTE BANANA CAVE NOPE

90 Pollution Prevention Act Defines Source Reduction as:Any practice which reduces the amount of any hazardous substance, pollutant, or contaminant entering any waste stream or otherwise released into the environment (including fugitive emissions) prior to recycling, treatment, or disposal;and reduces the hazards to public health and the environment associated with the release of such substances, pollutants, or contaminants.

Hierarchy for Pollution Prevention (P2)Source ReductionReuse/RecyclingEnergy RecoveryTreatmentDisposal

P2 Programs are Selling Multi-Media ApproachesW aterA irS olidsT imeE nergy

Cross-Media TransferWasteGaseous/ParticlesWasteProcessingWasteProcessingWasteProcessingSolidResidualsWastewaterGaseous/ParticlesLandWatercourse orImpoundment or Deep WellAir

Cross-Media Transfer (cont.)An example of cross-media transfer:Facility installs a wet scrubber: VOCs transferred from air to water, which is discharged into a nearby stream.Discharge to stream requires water permit modification: air stripper is installed to meet permit requirements--VOCs transferred back to the air.New air stripper requires another air permit.After 3 permits, 3 years, & $3,000,000 the same amount of contaminants are reaching the air!Pollution Prevention Review, Steven Anderson & Jeanne Herb

Process Flow DiagramProcess Flow Diagram

P2 MeansProcess modifications;Feedstock substitutions;Product reformulation;Management practices or housekeeping alterations;Recycling within industrial processes; orEquipment replacement or modifications.

Good HousekeepingLeads to Pride & CommitmentKeep It Clean In the First PlaceWaste, Leaks & Spills Easier to SpotDry Cleanup

Inventory ManagementProcurement ControlMaterial Types & QuantitiesContainer Sizes & Packaging RequirementsRaw Material QualityMSDSs Material ControlUnloading & StorageHandling & Use

Source Reduction Optionsfor PackagingLight weightingSelecting another materialBulk packagingSwitching from single-use to reusable containers

Preferred Packaging GuidelinesNO PackagingMinimal PackagingConsumableReturnable/ReusableRecyclable Packaging, Recycled Material

Returnable for Reuse

Packaging Designed forEase of Breakdown & ReuseLOreal USA Florence, KY

Plastic Container, Strap & Sheet RecyclingLOreal USA Florence, KY

Redesign Packaging for Reuse to Avoid Recycling

ParallelParadigms

TQM

P2

Customer Satisfaction

Stakeholder Satisfaction

Continuous Improvement

Continuous Reduction

Mgmt. By Measurement

Monitor Waste

Maximize Productivity

Minimize Waste

Zero Defects

Zero Emissions

The Future of Pollution Prevention (P2)...Environmental Management Systems(EMSs)EnvironmentalManagementSystem

Prevent Waste:Involvement orCommitmentAdd Value: Fullfillment Expectations Exceed ExpectationsSupplierProcessCustomer DelightOwnerEmployeesCan / should P2 become a strategic thrust for the Company?P2 &EMSsSystems Approach

P2 Sustainable PhasesOPERATIONSPRODUCTION PROCESSEQUIPMENT/ SYSTEMS

Payoff

What

When

Big ROI Today

Now

Smaller ROI Today (Future??)

Near-term

Smallest ROI Today (Future??)

Long-term

Waste Reduction Operation Phase0-6 months, Big Return on InvestmentPHASE ONEStartSimple RecyclingWaste SeparationGood HousekeepingAssessment & Trng.Recognized Need

Agency & Industry Management StrategiesObjectivesTo meet regulatory requirementsTo be cost-effectiveTo improve environmental qualityTo produce a quality product

Implementing Pollution Prevention (P2)Corporate CommitmentTeam selectionMunicipality Agrees to & SUPPORTS P2 Activities of its Staff.IPP Staff, Industry & Business PersonnelIn GeneralIn an IPP

Implementing P2Background InformationFlow Diagram & Plant SurveyMaterials BalanceHeadworks AnalysisSewer Line BlueprintsSIU Process Flow DiagramsPermit ApplicationsIndirect Discharge Monitoring ReportsSelf-monitoring ReportsIn GeneralIn an IPP

Implementing P2Alternatives AnalysisBest Available Control Technology (BACT Treatment)Source Reduction OpportunitiesReuse PotentialRecycle PotentialEnergy RecoveryTreatment (BACT)DisposalIn The PastPresent & Future

Evaluate Why P2 is Important to CommunitiesWater is a limited resourceStatewide Water Quality - Once quantity is restricted, the quality must be monitoredTMDLs - Limits to what a watershed can receiveP2 may be the first step to encourage nonpretreatment cities to reduce pollutant contributions

Incorporate P2 LanguageRestate the Citys environmental policy statements in City Ordinances, wastewater permits & permit applicationsRequire P2 plans & best management practices (EMS) as part of all departments goals

Source Reduction TrainingManager TrainingEmployee TrainingProcess / Job / ShiftEMS/Systems ApproachInternal AssessmentShow Corporate & Agency Commitment

42 Cubic Yard Compactor Boxes15 - 22 Loads per Day

Closer View of Compactor Loads

ID Solid Waste MaterialsCardboardWoodPlasticsPolystyreneOffice Paper

Compactor Box LoadTotal = 10,560 lbs.

Cardboard SeparationTotal = 2,940 lbs. (27.8%)Conveyor of Mixed Solid WastesCardboard Sorting by HandUncontaminated Cardboard is Baled

Solid Waste w/ Cardboard Removed = 7,620 lbs. (71.2%)

Wood Separation

Wood = 2,400 lbs. (22.7%)

Trash = 5,220 lbs. (49.4%)

Plastic in the Solid Waste StreamWhat types?$0.03/lb. Or $60/Ton

Reclaim,Recover & ReuseOn-site

Off-siteMaterials Exchange

Challenges to RecyclingCheaper to use virgin materialsRecycled materials often fail to meet Buyer SpecsConsumer mistrust of recycled materialsInadequate supply of Post-consumer materials

Kentucky Industrial Materials ExchangeWhat is KIME?A databaseA matching serviceA way to reduce landfill volumeA way for organizations to reduce waste disposal costs & raw material costs

Kentucky Industrial Materials Exchange48%HazardousAcidSolventEtc.43%Non-HazardousGlassWoodPaperEtc.9%Miscellaneous

Types of CompaniesUsing KIME

Waste ReductionEquipment Phase6 months - 2 yearsSome Return on InvestmentPHASE TWOSource TreatmentEquipment ModificationsProcess Controls

General P2 ConsiderationsManagementProcess & equipment selectionVehicle MaintenanceSludge managementConstruction methods & materialsLaboratoriesOperational Control & Maintenance

Equipment Maintenance &Preventive MaintenanceRoutine InspectionsProper setup & adjustmentRepairing Leaks ImmediatelyReplace Parts Before Expected FailureReduce Unexpected DowntimeTracking MaintenanceOperator training

P2 Process & Equipment Selection ConsiderationsSolid Waste (Reduce/Reuse/Recycle)Energy demand (efficiency)Chemical use (disinfect, odors, aids)Air emissions (VOCs, aerosols)Water use & conservationSludge generated (heavy metals, etc.)

Waste Reduction Process Phase2 years - 5 years Little Return on InvestmentPHASE THREE Process Changes Complex Recycling, Refining, ReuseRaw Material and Catalyst ChangesProduct Reformulations

Material SubstitutionLess-toxic, lower-emitting substitutesMay effect process elsewhereMay require equipment modifications

Reduce Materials Usage & LossesReduce Toxics Use with Alternative MaterialsReduce Water UsageReduce Energy UsageP2 Perspective: Minimization

Increase Market ShareImprove Cash FlowReduce Cycle TimeReduce Set-up TimeReduce Work In-ProgressReduce Defect & Reject rateImprove Flexibility of ManufacturingReduce Production BottlenecksBusiness Perspective: Optimization

Productivity EnhancementQuality Management SystemsPreventive MaintenanceOperation AutomationInventory Control (JIT)Product DevelopmentComputer Integrated Mfg.Employee Health & SafetyEnvironmental ManagementIntegrating P2 into Existing Programs

Old Paradigm: DoersInvestigation & ImplementationCreates pollution prevention programsCreates new channels of communication Implements existing opportunitiesFocuses on information transferModifies existing activitiesSeeks to create awarenessBuilds upon trustNew Paradigm: FinishersLong-term Organizational ChangeIntegrates P2 w/ existing programsCo-opts existing channels of communicationPrepares for new opportunities

Focuses on information analysisModifies existing contextsSeeks to move to actionBuilds on credibility P2 Program Paradigm Shift

An expanded assessmentEMS Gap AuditExamining:Business SystemsBusiness PracticesOverall Manufacturing ContextSo that:P2 strategies are tailored to the organizations objectives & targetsP2 is implemented with EMPsIntegrated P2 AssessmentEMS Audit

Investigate:Business goals & policiesManagement perspectives on current operationsDecision-making methodsAmounts & types of planningOrganizational structureTo Determine:Expressions & amount of management commitmentManagement triggers & prioritiesSacred Cows--What P2 must be respectful of!Who holds key power & influences positionsSenior Management Track

Investigate:Purchasing & procurement methodsProduction scheduling methodsInventory control systemsRelationships with suppliers/quality assuranceTo Determine:Opportunities for P2 through production control improvementsOpportunities to link P2 to existing production management changesPossible coordination with buyers/suppliersProduction/Activities Management Track

Investigate:Cost accounting/overhead allocation systemsCapital budgeting processTraining ProgramsCompensation & incentive programsEnvironmental data gathering & managementQuality improvement programs, methods & toolsTo Determine:Total environmental management costsAmount & quality of resources available for P2 planningWays to integrate P2 into quality improvement efforts

Support Functions/Services Track

Emphasis on ProcessInadequate TrainingLack of PlanningPoor CommunicationsLack of PatienceAssign to Person, Not a TeamTreating as a Special Program

Impediments to Success

Supply PracticesMaterials Usage PatternsMaterials Management PracticesWaste Disposal PracticesResource Consumption PatternsPreferential Use of Equipment or Techniques

Institutional Barriers

www.kppc.org

The Next Steps: P2 & EMSs

Clearwater, FLJune 7, 2000Cam MetcalfExecutive Directorjcmetc01@gwise.louisville.edu502-852-0965