Waste

Waste Reduction
Reduction and
and Pollution
Pollution
Prevention
PreventionAssessment
Assessment

Georgia Institute of Technology

Systems Realization Laboratory
 Module
ModuleObjective
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.

Georgia Institute of Technology

Systems Realization Laboratory
 History
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.

Georgia Institute of Technology

Systems Realization Laboratory
 Hazardous
HazardousWastes
Wastes and
and Toxic
ToxicChemicals
Chemicals
The following laws exemplify legislation about hazardous and/or toxic chemicals:

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.

Georgia Institute of Technology

Systems Realization Laboratory
 Regulatory
Regulatorycompliance
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)
Georgia Institute of Technology
Systems Realization Laboratory
 Regulatory
RegulatoryCompliance
ComplianceCertification
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.
Georgia Institute of Technology
Systems Realization Laboratory
 Who
Whoare
areSmall
Small Quantity
QuantityGenerators?
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.
Georgia Institute of Technology
Systems Realization Laboratory
 SQG
SQG Industries
Industriesand
andwastes
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 Vehicle maintenance

Photography Printing
Ceramics Dry cleaning
Construction Equipment repair
Textile manufacturing Chemical manufacturing
Paper industry Wood preserving
Motor freight terminals General manufacturing
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
Georgia Institute of Technology
Systems Realization Laboratory
 Waste
WasteReduction
Reduction
Definition
Definitionand
andGood
GoodPractices
Practices

Georgia Institute of Technology

Systems Realization Laboratory
 What
What is
isWaste
Waste Reduction?
Reduction?

Any activity that REDUCES or ELIMINATES the

generation of waste AT THE SOURCE
Changes in:
Operating Practive
Technologies
Inputs
Products
Recycling
In process
In-Line
Closed-Loop

Georgia Institute of Technology

Systems Realization Laboratory
 Good
Good Operating
OperatingPractices
Practices

Waste Minimization Programs

Management and Personnel Practices
Material Handling / Inventory Practice
Loss Prevention
Waste Segregation
Cost Accounting Practices
Production Scheduling

Georgia Institute of Technology

Systems Realization Laboratory
 Technology
TechnologyChanges
Changes

Production process
Equipment, layout or piping
Automation
Operating conditions
Flow rates
Temperatures
Pressures
Residence times

Georgia Institute of Technology

Systems Realization Laboratory
 Basic
BasicMaterial
Material&&Product
ProductChanges
Changes

Input Material Changes

Material purification
Material substitution

Product Changes
Product substitution
Product conservation
Product composition

Georgia Institute of Technology

Systems Realization Laboratory
 Use
Useand
andReuse
Reuse

Return the material:

To the originating process as a substitute
To another process as an input

Georgia Institute of Technology

Systems Realization Laboratory
 What
What is
isNOT
NOT Waste
WasteReduction?
Reduction?

Dewatering
Dilution
Evaporation
Waste burning in industrial furnaces, boilers, cement
kilns
Waste shifting
Off-site recycling
Any other end-of-pipe management

Georgia Institute of Technology

Systems Realization Laboratory
Procedure
Procedure &&Tools
Tools

Georgia Institute of Technology

Systems Realization Laboratory
 Basic
BasicAssessment
AssessmentFlow
FlowDiagram
Diagram

Airemissions

Productand
Raw solid/
Process
materials hazardous
waste

Wastewaterdischarges
Georgia Institute of Technology
Systems Realization Laboratory
 Materials
MaterialsBalance
Balance

List the raw materials

How much is:
Used
In the product
Lost as air emissions
Lost in wastewater
Found in waste

Used = amount in product + air emissions +

wastewater + waste

Georgia Institute of Technology

Systems Realization Laboratory
 Materials
MaterialsBalance
BalanceExample
Example

Airemissions
Mineral
spirits Spentsolvent
Process
Parts
Cleanedparts
dragout
Rawmaterials=mineralspirits

25gal/monthused=0(product)+15 Airemissions
gal/monthspentsolvent+airemissions

Airemission=10gal/month
Georgia Institute of Technology
Systems Realization Laboratory
 Describe
Describethe
theWaste
Waste

Is it:
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?

Georgia Institute of Technology

Systems Realization Laboratory
 Describe
Describethe
theWaste
WasteExample
Example

Airemissions
Mineral
spirits Spentsolvent
Process
Parts Cleanedparts
dragout

Airemissions=10gal/monthx8lbs/
galx12month/year=960lbs/year Airemissions

Hazardouswaste=15gal/monthx8lbs/
galx12month/year=1,440lbs/year
Georgia Institute of Technology
Systems Realization Laboratory
 Electroplating
ElectroplatingIn-Class
In-ClassExample
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

Georgia Institute of Technology

Systems Realization Laboratory
Industrial
IndustrialExamples
Examples

Georgia Institute of Technology

Systems Realization Laboratory
 Waste
WasteReduction
Reduction by
by Dow
Dow Chemical
Chemical
Several chemical process industries have compiled an outstanding record in minimizing
waste generated at their facilities.

Dow Chemical is one example.

Dow takes a balanced approach to reducing environmental impact of operations with a

focused effort on source reduction and recycling.

The environmental policy places a priority on waste and emission reduction, and
environmental guidelin support the hierarchy of waste management, that is,
1) source reduction,
2) recycling,
3) treatment,
4) and land disposal as the last option

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.

Georgia Institute of Technology

Systems Realization Laboratory
 Waste
WasteReduction
ReductionAlways
AlwaysPays
Pays(WRAP)
(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.
Georgia Institute of Technology
Systems Realization Laboratory
 WRAP
WRAPImplementation
Implementation

The following iterative process is used to implement the

WRAP program:

1) Inventory of all process loss to air, water, and land.

2) Identify the sources of those losses.
3) Prioritize reduction efforts.
4) Allocate resources and implementation projects.
5) Document and report progress.
6) Communicate progress internally and externally.
7) Plan for future reductions.
Georgia Institute of Technology
Systems Realization Laboratory
Polution
PolutionPrevention
PreventionAssessment
Assessment (PPA)
(PPA) procedure
procedure(1)
(1)
EPA Waste Minimization Opportunity
Assessment Manual (EPA/625/7-88/003)
Planning
Planningand
andorganization
organization
Get
Get managementcommitment
management commitment
Set
Set overall assessmentprogram
overall assessment programgoals
goals
Organize
Organize assessment program taskforce
assessment program task force
Assessment organization and commitment to proceed.

Assessment
AssessmentPhase:
Phase:
Collect
Collectprocess
processand
andfacility
facilitydata.
data. Select new assessment
Prioritize
Prioritize and select assessmenttables.
and select assessment tables. targets and reevaluate
Select people for assessment teams.
Select people for assessment teams. previous options.
Review
Reviewdata
dataand
andinspect
inspectsites.
sites.
Generate
Generateoptions.
options.
Screen
Screen andselect
and selectoptions
optionsfor
forfurther
furtherstudy.
study.
Assessment report of selected options.

Georgia Institute of Technology

Systems Realization Laboratory
Polution
PolutionPrevention
PreventionAssessment
Assessment (PPA)
(PPA) procedure
procedure(2)
(2)

Feasibility
FeasibilityAnalysis
AnalysisPhase:
Phase:
Technical evaluation.
Technical evaluation.
Economic
Economicevaluation.
evaluation.
Select
Select optionsfor
options forimplementation.
implementation.
Final report, including
recommended options.

Implementation:
Implementation:
Justify
JustifyProjects
Projectsand
andobtain
obtainfunding.
funding.
Installation (equipment). Repeat the process
Installation (equipment).
Implementation
Implementation(procedure).
(procedure).
Evaluate
Evaluateperformance.
performance.

Georgia Institute of Technology

Systems Realization Laboratory
Focusing
FocusingYour
Your Efforts
Efforts

Georgia Institute of Technology

Systems Realization Laboratory
 Criteria
Criteriafor
forselecting
selecting principal
principal waste
wastestreams
streams

The
Thefollowing
followingcriteria
criteriacan
canbebeused
usedtotoidentify
identifyprincipal
principalwaste
wastestreams:
streams:
Composition
Composition
Quantity
Quantity
Toxicity
Toxicityofofwastes
wastes
Method
Methodandandcost
costofofdisposal
disposal
Compliance
Compliancestatus
status
Potential
Potentialfor
forminimization
minimization
Priorization
Priorizationofofwaste
wastestreams
streamstotobe
betackled
tackledshould
shouldalso
alsoinclude
include
consideration of available budget for the
consideration of available budget for the PPA PPA

The
Thebest
bestmeans
meansfor
foridentifying
identifyinginformation
informationon
onall
allwaste
wastestreams
streamsisisthe
theuse
useofof
flow
flowdiagrams
diagramsand,
and,then,
then,material
materialbalances.
balances.

Georgia Institute of Technology

Systems Realization Laboratory
 Technical
Technical Evaluation
Evaluationof
ofOptions
Options

When
Whenevaluating
evaluatingthetheoptions
optionsfor
forminimizing
minimizingwaste
wastestreams,
streams,the
thefollowing
following
technical criteria should be considered:
technical criteria should be considered:
Technical
Technicalreliability
reliability
System
Systemsafety
safety
Product
Productquality
qualitymaintenance
maintenance
Space
Spacerequirements
requirements
Compatibility
Compatibilityofofproposed
proposedsystem
systemwith
withexisting
existingsystems
systems
Downtime
Downtimenecessary
necessaryfor
forinstallation
installation
Special
Specialexpertise
expertiserequirements
requirements
Labor
Laborand
andutility
utilityrequirements
requirements

For
Foreconomic
economicevaluation,
evaluation,make
makeaabreak-down
break-downinin
capital
capitalcost
cost
operating
operatingcost
cost
Georgia Institute of Technology
Systems Realization Laboratory
 Economic
EconomicEvaluation
Evaluation

For
Foreconomic
economicevaluation,
evaluation,make
makeaabreak-down
break-downinincapital
capitalcost
costand
and
operating cost/savings.
operating cost/savings.

Capital
Capitalcosts
costsinclude:
include:
fixed
fixedcapital
capitalcost
costfor
fordesigning,
designing,purchasing,
purchasing,andandinstallation
installationequipment
equipment
cost
costfor
forworking
workingcapital,
capital,permitting,
permitting,training,
training,start-up,
start-up,and
andfinancing
financing
charges.
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.
Georgia Institute of Technology
Systems Realization Laboratory
 Profitability
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:
Rule:
Options
Optionsrequiring
requiringno
nocapital
capitalinvestment
investmentshould
shouldbe
be
implemented
implementedasassoon
soonas
aspossible.
possible.

Georgia Institute of Technology

Systems Realization Laboratory
 The
TheProblem
Problemwith
withPollution
PollutionPrevention
Prevention
and
andEnd-of-Pipe
End-of-PipeApproaches
Approaches

Society
1:EnvironmentalEngineering
2:PollutionPrevention
ScopeofEnvironmentalConcerns

XManufacturers 8 3:Envir.ConsciousD&M
4:DesignfortheEnvironment
5:LifeCycleDesign
OneManufacturer 6:GreenEngineering
7 7:IndustrialEcology
8:SustainableDevelopment
XProducts
OneProductLifeCycle

Disposal
3,4,5,6
Use

Manufacturing 2 1

Manufacturing Use Disposal Human Civilization

Lifetime Span
ProductLifeCycle
ScopeofTemporalConcern
Georgia Institute of Technology
Systems Realization Laboratory