Implementing
Pollution Prevention
“P2 Dee-fusion”
Clearwater, FL
June 7, 2000
Cam Metcalf
Executive Director
jcmetc01@gwise.louisville.edu
502-852-0965
1
Driving Forces on Legislation
 Property Owners: NIMBY, “Universal Backyard”
 Taxpayers: Pressured by rising disposal fees
 Environmentalists: Concerns of ecological effects
 Industries: Fear punitive regulations & legislation
2
Driving Forces on Legislation
 Property Owners: NIMBY, “Universal Backyard”
 Taxpayers/Agency: Pressured by rising treatment fees
 Environmentalists: Concerns of ecological effects
 Industries: Fear punitive regulations & legislation
3
Our “Universal Backyard”
 NIMBY
 NOTE
 BANANA
 CAVE
 NOPE
4
‘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.
5
Hierarchy for Pollution
Prevention (P2)
 Source Reduction
 Reuse/Recycling
 Energy Recovery
 Treatment
 Disposal
6
P2 Programs are Selling
Multi-Media Approaches
W ater
A ir
S olids
T ime
E nergy
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Cross-Media Transfer
Waste
Gaseous/
Particles
Waste
Processing
Waste
Processing
Waste
Processing
Solid
Residuals
Wastewater
Gaseous/
Particles
Land
Watercourse
or
Impoundment
or
Deep Well
Air
8
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
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Process Flow
Flow Diagram
Diagram
Process
10
P2 Means
 Process modifications;
 Feedstock substitutions;
 Product reformulation;
 Management practices or housekeeping
alterations;
 Recycling within industrial processes; or
 Equipment replacement or
modifications.
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Good Housekeeping
 Leads to Pride &
Commitment
 Keep It Clean In
the First Place
 Waste, Leaks &
Spills Easier to
Spot
 Dry Cleanup
12
Inventory Management
 Procurement Control
 Material Types &
Quantities
 Container Sizes &
Packaging
Requirements
 Raw Material Quality
 MSDS’s
 Material Control
 Unloading & Storage
 Handling & Use
13
Source Reduction Options
for Packaging
Light weighting
Selecting another material
Bulk packaging
Switching from single-use to
reusable containers
14
Preferred Packaging
Guidelines
 NO Packaging
 Minimal Packaging
 Consumable
 Returnable/Reusable
 Recyclable
Packaging, Recycled
Material
15
Returnable for Reuse
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Packaging Designed for
Ease of Breakdown & Reuse
L’Oreal USA
Florence, KY
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Plastic Container, Strap &
Sheet Recycling
L’Oreal USA
Florence, KY
18
Redesign Packaging for Reuse
to Avoid Recycling
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Parallel
Paradigms
TQM
P2
Customer Satisfaction
Stakeholder Satisfaction
Continuous Improvement
Continuous Reduction
Mgmt. By Measurement
Monitor Waste
Maximize Productivity
Minimize Waste
Zero Defects
Zero Emissions
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The Future of Pollution
Prevention (P2)...
Environmental Management
Systems
(EMSs)
“Environmental
Management
System
”
21
P2 &EMSs
“Systems Approach”
Prevent Waste:
Involvement or
Commitment
Add Value:
 Fullfillment
 Expectations
 Exceed Expectations
“Owner”
Employees
Supplier
Process
Customer “Delight”
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P2 Sustainable Phases
Payoff
Big ROI
Today
What
When
Now
OPERATIONS
Smaller
ROI Today EQUIPMENT/
(Future??) SYSTEMS
Near-term
Smallest
Long-term
ROI Today PRODUCTION
(Future??) PROCESS
23
Waste Reduction
Operation Phase
Start
Recognized Need
Assessment & Trng.
Good Housekeeping
Waste Separation
0-6 months, Big Return on
Investment
Simple Recycling
24
Agency & Industry
Management Strategies
Objectives
To meet regulatory requirements
To be cost-effective
To improve environmental quality
To produce a quality product
25
Implementing Pollution
Prevention (P2)
In General
 Corporate
Commitment
 Team
selection
In an IPP
 Municipality Agrees
to & SUPPORTS P2
Activities of its Staff.
 IPP Staff, Industry &
Business Personnel
26
Implementing P2
In General
In an IPP
 Background
 Headworks Analysis
Information
 Flow Diagram
& Plant Survey
 Materials
Balance
 Sewer Line Blueprints
 SIU Process Flow
Diagrams
 Permit Applications
 Indirect Discharge
Monitoring Reports
 Self-monitoring Reports
27
Implementing P2
Alternatives Analysis
In The Past
Present & Future
 Best Available
 Source Reduction
Control
Technology
(BACT
Treatment)
Opportunities
 Reuse Potential
 Recycle Potential
 Energy Recovery
 Treatment (BACT)
 Disposal
28
Evaluate Why P2 is Important
to Communities
 Water is a limited resource
 Statewide Water Quality - Once
quantity is restricted, the quality must
be monitored
 TMDL’s - Limits to what a watershed
can receive
 P2 may be the first step to encourage
nonpretreatment cities to reduce
pollutant contributions
29
Incorporate P2
Language
Restate the City’s environmental
policy statements in City
Ordinances, wastewater permits
& permit applications
Require P2 plans & best
management practices (EMS) as
part of all department’s goals
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Source Reduction Training
 Manager Training
 Employee Training
 Process / Job / Shift
 EMS/Systems Approach
 Internal Assessment
 Show Corporate & Agency
Commitment
31
42 Cubic Yard Compactor Boxes
15 - 22 Loads per Day
32
Closer View of Compactor
Loads
33
ID Solid Waste Materials
Cardboard
Wood
Plastics
Polystyrene
Office Paper
34
Compactor Box Load
Total = 10,560 lbs.
35
Cardboard Separation
Total = 2,940 lbs. (27.8%)
 Conveyor of
Mixed Solid
Wastes
 Cardboard
Sorting by Hand
 Uncontaminated
Cardboard is
Baled
36
Solid Waste w/ Cardboard
Removed = 7,620 lbs. (71.2%)
37
Wood Separation
38
Wood = 2,400 lbs. (22.7%)
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Trash = 5,220 lbs. (49.4%)
40
Plastic in the Solid Waste
Stream
What types?
$0.03/lb. Or
$60/Ton
41
Reclaim,Recover & Reuse
On-site
Off-site
Materials Exchange
42
Challenges to Recycling
 Cheaper to use virgin
materials
 Recycled materials
often fail to meet
Buyer Specs
 Consumer mistrust of
recycled materials
 Inadequate supply of
Post-consumer
materials
43
Kentucky Industrial
Materials Exchange
What is KIME?
A database
A matching service
A way to reduce landfill volume
A way for organizations to reduce
waste disposal costs & raw
material costs
44
Kentucky Industrial
Materials Exchange
9%
Miscellaneous
48%
Hazardous
•Acid
•Solvent
•Etc.
Hazardous
Non-Hazardous
Miscellaneous
43%
Non-Hazardous
•Glass
•Wood
•Paper
•Etc.
45
Types of Companies
Using KIME
Laboratory
Electrical/
Computer
6%
Plastic
7%
Government
Organizations
6%
Wood/Furniture
30%
Pigments/
Coating
10%
Automotive
Parts
5% Metal/Mineral
11%
Environmental/
Recycling
Rubber/Tire 16%
Chemical
4%
4%
46
Waste Reduction
Equipment Phase
Process Controls
Equipment Modifications
Source Treatment
6 months - 2 years
Some Return on Investment
47
General P2
Considerations
 Management
 Process & equipment selection
 Vehicle Maintenance
 Sludge management
 Construction methods & materials
 Laboratories
 Operational Control & Maintenance
48
Equipment Maintenance &
Preventive Maintenance
 Routine Inspections
 Proper setup & adjustment
 Repairing Leaks
Immediately
 Replace Parts Before
Expected Failure
 Reduce Unexpected
Downtime
 Tracking Maintenance
 Operator training
49
P2 Process & Equipment
Selection Considerations
Solid Waste (Reduce/Reuse/Recycle)
Energy demand (efficiency)
Chemical use (disinfect, odors, aids)
Air emissions (VOCs, aerosols)
Water use & conservation
Sludge generated (heavy metals,
etc.)
50
Waste Reduction
Process Phase
Complex Recycling, Refining, Reuse
Process Changes
Raw Material and Catalyst Changes
Product Reformulations
2 years - 5 years
Little Return on Investment
51
Material Substitution
Less-toxic, lower-emitting substitutes
May effect process elsewhere
May require equipment
modifications
52
P2 Perspective:
Minimization
 Reduce Materials Usage & Losses
 Reduce Toxics Use with Alternative
Materials
 Reduce Water Usage
 Reduce Energy Usage
53
Business Perspective:
Optimization
 Increase Market Share
 Improve Cash Flow
 Reduce Cycle Time
 Reduce Set-up Time
 Reduce Work In-Progress
 Reduce Defect & Reject rate
 Improve Flexibility of Manufacturing
 Reduce Production Bottlenecks
54
Integrating P2 into
Existing Programs
 Productivity Enhancement
 Quality Management Systems
 Preventive Maintenance
 Operation Automation
 Inventory Control (JIT)
 Product Development
 Computer Integrated Mfg.
 Employee Health & Safety
 Environmental Management
55
P2 Program Paradigm Shift
Old Paradigm: “Doers”
Investigation & Implementation
 Creates pollution prevention






programs
Creates new channels of
communication
Implements existing
opportunities
Focuses on information transfer
Modifies existing activities
Seeks to create awareness
Builds upon trust
New Paradigm: “Finishers”
Long-term Organizational Change
 Integrates P2 w/ existing
programs
 Co-opts existing channels of
communication
 Prepares for new opportunities
 Focuses on information analysis
 Modifies existing contexts
 Seeks to move to action
 Builds on credibility
56
Integrated P2 Assessment
EMS Audit
 An expanded assessment…EMS Gap Audit
 Examining:
 Business Systems
 Business Practices
 Overall Manufacturing Context
 So that:
 P2 strategies are tailored to the organization’s
objectives & targets
 P2 is implemented with EMPs
57
Senior Management Track
 Investigate:
 Business goals & policies
 Management perspectives on current operations
 Decision-making methods
 Amounts & types of planning
 Organizational structure
 To Determine:
 Expressions & amount of management commitment
 Management triggers & priorities
 Sacred Cows--What P2 must be respectful of!
 Who holds key power & influences positions
58
Production/Activities
Management Track
 Investigate:
 Purchasing & procurement methods
 Production scheduling methods
 Inventory control systems
 Relationships with suppliers/quality assurance
 To Determine:
 Opportunities for P2 through production control
improvements
 Opportunities to link P2 to existing production
management changes
 Possible coordination with buyers/suppliers
59
Support Functions/Services
Track
 Investigate:
 Cost accounting/overhead allocation systems
 Capital budgeting process
 Training Programs
 Compensation & incentive programs
 Environmental data gathering & management
 Quality improvement programs, methods & tools
 To Determine:
 Total environmental management costs
 Amount & quality of resources available for P2 planning
 Ways to integrate P2 into quality improvement efforts
60
Impediments to Success
 Emphasis on Process
 Inadequate Training
 Lack of Planning
 Poor Communications
 Lack of Patience
 Assign to Person, Not a Team
 Treating as a Special Program
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Institutional Barriers
 Supply Practices
 Materials Usage Patterns
 Materials Management Practices
 Waste Disposal Practices
 Resource Consumption Patterns
 Preferential Use of Equipment or
Techniques
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www.kppc.org
The Next Steps: P2 & EMSs
Clearwater, FL
June 7, 2000
Cam Metcalf
Executive Director
jcmetc01@gwise.louisville.edu
502-852-0965
63