Transcript Waste Reduction and Pollution Prevention Assessment

Waste Reduction and Pollution
Prevention Assessment
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Module Objective
Having read this, you should know the following:
1. Basic motivation and history of waste reduction and
pollution prevention in manufacturing
2. What a generator and SQG are
3. The definition and good practices of waste reduction
4. How to perform a pollution prevention assessment
and improvement using mass (& energy) balances.
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History
• Practiced in industry, pollution prevention usually focuses
on elimination of pollutants from existing products and
process technologies
• Pollution prevention and waste reduction procedures are
predecessors to DFE and ECDM and are well established
and well known in the US.
• Initial impetus came from the 1960s when the US pollution
became to high to bear in some locations and the US
Environmental Protection Agency was formed.
• Pollution prevention efforts are often mandated by
legislation.
– For example, US regulations require pollution prevention programs for
companies emitting hazardous substances.
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Hazardous Wastes and Toxic Chemicals
The following laws exemplify legislation about hazardous and/or toxic chemicals:
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National Emission Standards for Hazardous Air Pollutants (NESHAP); Hazardous Air
Emissions. Asbestos, beryllium, mercury, vinly chloride, benzene, arsenic, and
radionuclides in general.
Clean Water Act; Priority Pollitants. 126 individual chemicals, including volatile
organic substances, acid compounds, pesticides, heavy metals, etc.
Resource Conservation and Recovery Act (RCRA); Hazardous Wastes. More than 400
discarded commercial chemical products and specific chemical constituents of
industrial waste streams destined for treatment or disposal on land.
Superfund Amendments and Reauthorization Act (SARA) Title II, Section 313; Toxic
subtances. More than 320 chemicals and chemical categories released into air, water
and land. Under specified conditions, facilities must report releases of these chemicals
to EPA's annual Toxics Release Inventory.
Superfund Amendments and Reauthorization Act (SARA) Section 302; Extremely
Hazardous Substances. More than 360 chemicals for which facilities are required to
prepare emergency action plans if these chemicals are present at the facility above
certain treshold quantities. Releases trigger required reporting by the facility to the
State Emergency Response Committee (SERC) and the Local Emergency Planning
Committee (LEPC) under SARA Section 304.
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Regulatory compliance
• Federal and state laws require all firms classified as hazardous waste generators or
small quantity generators (SQGs) to implement a pollution prevention program to
reduce the quantity of waste to the extent that it is economically feasible.
• Small quantity generators are facilities that generate more than 100 kg/month but
less than 1000 kg/month of hazardous waste.
• A facility generating more than a 1000 kg/month is classified as a generator.
• Firms permitted as hazardous waste generators are generally required under the
Resource Conservation and Recovery Act (RCRA) to report sampling data on a
regular basis. When hazardous wastes are minimized, the frequency of sampling
and data reporting is also minimized.
• If a disposal facility releases contaminants, then the original generators of the
waste are also reponsible/liable for these releases under the Comprehensive
Environmental Response, Compensation, and Liability Act (CERCLA)
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Regulatory Compliance Certification
• Generators are required to sign the following statement:
Unless I am a small quantity generator who has been
exempted by statute or regulation from the duty to make
waste minimization certification under Section 3002(b) of
RCRA, I also certify that I have a program in place to
reduce the volume and toxicity of waste generated to the
degree I have determined to be economically practicable,
and I have selected the method of treatment, storage, or
disposal currently available to me which minimizes the
present and future threat to human health and the
environment.
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Who are Small Quantity Generators?
• It is estimated that there are 600 to 700 thousand SQGs in
the nation.
• These businesses may generate as much as 940,000 metric
tons of hazardous wastes annually.
• These generators generally have fewer than 5 to 10
employees and are managed by persons with limited
training in identification and management of hazardous
wastes.
• Technical Assistance Programs and some EPA grant
programs are focused on SQGs.
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SQG Industries and wastes
Major Waste Types
Spent solvents
Strong acids and alkalis
Photographic wastes
Dry cleaning filtration residues
Pesticide solutions
Waste formaldehyde
Empty pesticide containers
Ignitable wastes
Major Industry Groups – Small Quantity Generators
Metal manufacturing
Photography
Ceramics
Construction
Textile manufacturing
Paper industry
Motor freight terminals
Wholesale and retail establishments
Analytical and chemical laboratories
Furniture/wood manufacturing and refinishng
Pesticide formulators, applicators and end-users
Cleaning agents and cosmetic manufacturing
Educational and vocational establishments
Vehicle maintenance
Printing
Dry cleaning
Equipment repair
Chemical manufacturing
Wood preserving
General manufacturing
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Waste Reduction –
Definition and Good Practices
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What is Waste Reduction?
• Any activity that REDUCES or ELIMINATES the
generation of waste AT THE SOURCE
• Changes in:
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Operating Practive
Technologies
Inputs
Products
• Recycling
– In process
– In-Line
– Closed-Loop
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Good Operating Practices
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Waste Minimization Programs
Management and Personnel Practices
Material Handling / Inventory Practice
Loss Prevention
Waste Segregation
Cost Accounting Practices
Production Scheduling
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Technology Changes
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Production process
Equipment, layout or piping
Automation
Operating conditions
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Flow rates
Temperatures
Pressures
Residence times
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Basic Material & Product Changes
• Input Material Changes
– Material purification
– Material substitution
• Product Changes
– Product substitution
– Product conservation
– Product composition
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Use and Reuse
• Return the material:
– To the originating process as a substitute
– To another process as an input
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What is NOT Waste Reduction?
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Dewatering
Dilution
Evaporation
Waste burning in industrial furnaces, boilers, cement
kilns
• Waste shifting
• Off-site recycling
• Any other end-of-pipe management
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Procedure & Tools
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Basic Assessment Flow Diagram
Air emissions
Raw
materials
Product and
solid/
hazardous
waste
Process
Waste water discharges
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Materials Balance
• List the raw materials
• How much is:
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Used
In the product
Lost as air emissions
Lost in wastewater
Found in waste
Used = amount in product + air emissions +
wastewater + waste
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Materials Balance Example
Air emissions
Mineral
spirits
Spent solvent
Process
Parts
Cleaned parts
dragout
Raw materials = mineral spirits
25 gal/month used = 0 (product) + 15
gal/month spent solvent + air emissions
Air emissions
Air emission = 10 gal/month
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Describe the Waste
• Is it:
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An air emission?
A waste water discharge?
A sludge?
A liquid?
Mixed with other wastes?
A hazardous waste
• How much:
– Is generated in a year?
– If in batches, how often and how much?
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Describe the Waste Example
Air emissions
Mineral
spirits
Spent solvent
Process
Parts
Cleaned parts
dragout
Air emissions = 10 gal/month x 8 lbs/
gal x 12 month/year = 960 lbs/year
Air emissions
Hazardous waste = 15 gal/month x 8 lbs/
gal x 12 month/year =1,440 lbs/year
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Electroplating In-Class Example
• Draw a process flow chart for electroplating
operation
• Set up a basic material balance
• Describe the wastes
• Identify opportunities for waste reduction and
pollution prvention
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Industrial Examples
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Waste Reduction by Dow Chemical
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Several chemical process industries have compiled an outstanding record in minimizing
waste generated at their facilities.
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Dow Chemical is one example.
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Dow takes a balanced approach to reducing environmental impact of operations with a
focused effort on source reduction and recycling.
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The environmental policy places a priority on waste and emission reduction, and
environmental guidelin support the hierarchy of waste management, that is,
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source reduction,
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recycling,
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treatment,
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and land disposal as the last option
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When efforts to reduce a waste stream either at the source or by recycing have not been
successful, Dow (like many others) still has the responsibility to manage and treat the waste
stream. Dow uses state-of-the art incineration and biological treatment facilities.
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Waste Reduction Always Pays (WRAP)
• Dow has implemented a WRAP program and an
individual contact in each of its division.
• The WRAP contacts design their activities around the
following broad goals:
1) Reduce waste to the environment.
2) Give recognition for excellence.
3) Develop a pollution prevention mentality.
4) Provide support for pollution prevention projects.
5) Measure and track progress.
6) Strive for continuous improvement.
7) Reduce long term costs.
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WRAP Implementation
The following iterative process is used to implement the
WRAP program:
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Inventory of all process loss to air, water, and land.
Identify the sources of those losses.
Prioritize reduction efforts.
Allocate resources and implementation projects.
Document and report progress.
Communicate progress internally and externally.
Plan for future reductions.
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Polution Prevention Assessment (PPA) procedure (1)
EPA Waste Minimization Opportunity
Assessment Manual (EPA/625/7-88/003)
Planning and organization
• Get management commitment
• Set overall assessment program goals
• Organize assessment program task force
Assessment organization and commitment to proceed.
Assessment Phase:
• Collect process and facility data.
• Prioritize and select assessment tables.
• Select people for assessment teams.
• Review data and inspect sites.
• Generate options.
• Screen and select options for further study.
Select new assessment
targets and reevaluate
previous options.
Assessment report of selected options.
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Polution Prevention Assessment (PPA) procedure (2)
Feasibility Analysis Phase:
• Technical evaluation.
• Economic evaluation.
• Select options for implementation.
Final report, including
recommended options.
Implementation:
• Justify Projects and obtain funding.
• Installation (equipment).
• Implementation (procedure).
• Evaluate performance.
Repeat the process
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Focusing Your Efforts
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Criteria for selecting principal waste streams
The following criteria can be used to identify principal waste streams:
– Composition
– Quantity
– Toxicity of wastes
– Method and cost of disposal
– Compliance status
– Potential for minimization
• Priorization of waste streams to be tackled should also include
consideration of available budget for the PPA
The best means for identifying information on all waste streams is the use of
flow diagrams and, then, material balances.
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Technical Evaluation of Options
When evaluating the options for minimizing waste streams, the following
technical criteria should be considered:
– Technical reliability
– System safety
– Product quality maintenance
– Space requirements
– Compatibility of proposed system with existing systems
– Downtime necessary for installation
– Special expertise requirements
– Labor and utility requirements
For economic evaluation, make a break-down in
• capital cost
• operating cost
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Economic Evaluation
For economic evaluation, make a break-down in capital cost and
operating cost/savings.
Capital costs include:
• fixed capital cost for designing, purchasing, and installation equipment
• cost for working capital, permitting, training, start-up, and financing
charges.
Operating costs and savings:
– reduction in waste treatment, storage and disposal
– raw material cost savings
– insurance and liability savings
– increased cost or savings associated with product quality
– decreased or increased use of utilities
– decreased or increased revenues from changes in production of
marketable by-products.
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Profitability
• If capital cost and operational costs/savings are known,
then profitability can be calculated.
• Also consider that violation of environmental regulations
may result in shut-down and criminal penalties.
Rule:
Options requiring no capital investment should be
implemented as soon as possible.
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The Problem with Pollution Prevention
and End-of-Pipe Approaches
8
X Ma nufac turers
One Manufa cture r
7
X Products
One Produc t L ife Cycl e
Scop e of En viron men tal Con cerns
Socie ty
1:
2:
3:
4:
5:
6:
7:
8:
Envi ronme nta l E ngine eri ng
Pollution Prevention
Envi r. Consci ous D&M
De sign for the E nvi ronme nt
Li fe Cycle De sign
Gree n E ngine eri ng
Industria l E cology
Susta ina ble Deve lopment
Disposa l
3 ,4, 5,6
Use
Manufa cturing
2
1
Manufa cturing
Use
Disposa l
Human
L ifet ime
Civil iza tion
Span
Product Li fe Cyc le
Scop e of Temp oral Co ncern
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