Production Related Waste Management for Selected Chemical
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Waste Management Comparison - 2013
Pollution Prevention Activities for Selected Chemical
| Reporting Year | Section 8.10: Newly Implemented Source Reduction Activity | Section 8.10: Methods to Identify Activity | Section 8.11: Optional Pollution Prevention Information* |
|---|---|---|---|
| 2019 |
Source Reduction:: W19: Other changes in operating practices[-25-49%]
Source Reduction:: W33: Installed overflow alarms or automatic shutoff valves[-0-4%] |
Methods to Identify SR Opportunities: T06: Employee recommendation (under a formal company program)
Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program) |
W19: Changed procedure for reusing clean up solvent to reduce the amount of hazardous waste generated. W33: Installed overfill prevention system on the shear mixer. Shear mixer can only fill for a set period of time before a manual reset button has to be pressed if the operator wants the mixer to keep filling. Source Reduction - Engineering came up with better ways to prevent potential spill due to operator errors. |
| 2018 |
Source Reduction:: W52: Modified equipment, layout, or piping[-0-4%]
|
Methods to Identify SR Opportunities: T03: Materials balance audits
Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program) |
W52: Modified applicator roller to apply more precise resin to the fabric. Source Reduction - Calculate percentage of waste and waste was reduced as a result. Source Reduction - Engineering came up with a better ways Source Reduction - group effort to reduce the waste by more precisely controlling the metering of the material. Other Environmental Practices: Recycling - Better control of materials and using materials that have been stored overnight rather than sending to waste. Better use of solvents to clean the machine and reduce the amount of accumulated waste. |
| 2017 |
Source Reduction:: W14: Changed production schedule to minimize equipment and feedstock changeovers
Source Reduction:: W82: Modified design or composition of product[-0-4%] Source Reduction:: W56: Reduced or eliminated use of an organic solvent |
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T10: Vendor assistance Methods to Identify SR Opportunities: T03: Materials balance audits |
W14: Worked longer shifts to minimize startup and shutdown waste and inefficiencies W56: Offset styrene consumption by using a less volatile reactive diluent, vinyl toluene W82: Optimized fabric widths to accommodate new military panels. Reduced length to reduce trim scrap. Source Reduction - Determined that emission factor would reduce with less volatile compound and began emission calculations with the addition of the lower styrene resin. Source Reduction - Narrowing the fabric width from 48 to 43" for some of the military panels and reducing the width from 49 to 48" would be more than a 2% reduction in trim scrap and estimated reduction in resin consumption (and therefore Styrene emissions) of 100 lbs per week, or 5,200 lbs per year. Source Reduction - Qualified a lower styrene version of an existing resin and implemented. Source Reduction - Record keeping shows reduced resin waste numbers Source Reduction - Calculations show that resin consumption as a percentage of total product produced has reduced. Source Reduction - Team identified efficiencies of narrowing width to reduce trim scrap as well as reducing length on certain panels by modifying the equipment to accommodate more length variations. |
| 2016 |
Source Reduction:: W14: Changed production schedule to minimize equipment and feedstock changeovers[-5-14%]
Source Reduction:: W82: Modified design or composition of product[-0-4%] |
Methods to Identify SR Opportunities: T04: Participative team management
Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T03: Materials balance audits |
W14: Worked longer shift to avoid additional waste and potential emissions W82: Optimized fabric width to reduce inherent process scrap, thus reducing the amount of resin consumed and scrapped. Source Reduction - Producing more with less resin per panel produced because of reduction activity and because of increased efficiency in the process. Source Reduction - Calculations show that reduced fabric width can reduce material consumption by more than 1%. Source Reduction - Production manager with production workers agreement for shorter work week. Source Reduction - collaborative effort to optimize width. Other Environmental Practices: Recycling - Continue to reduce catalyst ratio to extend life of resin for recycling in the process purposes. |
| 2015 |
Source Reduction:: W49: Other raw material modifications[-0-4%]
Source Reduction:: W52: Modified equipment, layout, or piping Source Reduction:: W58: Other process modifications |
Methods to Identify SR Opportunities: T03: Materials balance audits
Methods to Identify SR Opportunities: T10: Vendor assistance Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T06: Employee recommendation (under a formal company program) Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T10: Vendor assistance |
W49: Continued reduction in glass width and better monitoring of vendors to ensure that they minimize width to our standards and meet our product/process requirements. Source Reduction - Measured resin applicator gap (blade) and reduced to a controlled thickness. Source Reduction - Production manager instructed to focus on resin usage and recycling in the process-better capture of resin to help reduction of resin that is not used in the product. |
| 2014 |
Source Reduction:: W49: Other raw material modifications[-0-4%]
Source Reduction:: W52: Modified equipment, layout, or piping Source Reduction:: W58: Other process modifications |
Methods to Identify SR Opportunities: T03: Materials balance audits
Methods to Identify SR Opportunities: T10: Vendor assistance Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T06: Employee recommendation (under a formal company program) Methods to Identify SR Opportunities: T04: Participative team management |
W49: Further reduced fabric widths and increased filler content to help reduce the amount of resin. Producing more product and using less resin, therefore less emissions Source Reduction - Better management of reused solvent. Rather than changing it every week even though it was not fully loaded, decided to go to every other week and try to get CESQG status for HW stream. Source Reduction - Betterways program instituted a screen over resin capture that allowed for more resin recirculated since it was not contaminated with resin chips that prevented the resin from flowing to the recirculation buckets. |
| 2013 |
Source Reduction:: W82: Modified design or composition of product
Source Reduction:: W15: Introduced an in-line product quality monitoring or other process analysis system Source Reduction:: W56: Reduced or eliminated use of an organic solvent |
Methods to Identify SR Opportunities: T03: Materials balance audits
Methods to Identify SR Opportunities: T10: Vendor assistance Methods to Identify SR Opportunities: T01: Internal pollution prevention opportunity audit(s) Methods to Identify SR Opportunities: T03: Materials balance audits Methods to Identify SR Opportunities: T04: Participative team management Methods to Identify SR Opportunities: T10: Vendor assistance |
W15: Started analyzing production spreadsheet for waste analysis. Realized large usage of resin compared to required usage and identified multiple areas for potential reduction. W56: Increased use of non-hazardous water based solvent W82: Increased inorganic filler content in the resin to help reduce resin usage. Source Reduction - With vendor's assistance, we estimated maximum filler loading and ran the scenario by the vendor. Source Reduction - Analysis of the spreadsheet Source Reduction - Better Ways program identifies areas for potential safer products and processes, Safer work practices and areas for improvement in waste reduction. Source Reduction - Calculated resin requirements and realized we were using much more resin than what ends up in the product. Source Reduction - Increased inorganic filler content to extend resin by reducing resin usage.Production decrease over previous years also accounted for some reduction in emissions.Created spreadsheet to monitor resin waste and this identified areas for conservation. Resulted in better management of resin mixing based on controlling resin mix size to amount of resin required. Also, resulted in tightening of resin metering equipment on roller to reduce amount of resin applied. |
| 2012 |
Source Reduction:: W82: Modified design or composition of product
Source Reduction:: W56: Reduced or eliminated use of an organic solvent |
Methods to Identify SR Opportunities: T10: Vendor assistance
Methods to Identify SR Opportunities: T10: Vendor assistance |
W56: went to release paper on all products, reducing liquid release agent. W82: increased catalyst content to increase cure completion rate of thermoset resin. |
| 2011 |
Source Reduction:: W53: Use of a differant process catalyst
Source Reduction:: W82: Modified design or composition of product |
Methods to Identify SR Opportunities: T10: Vendor assistance
Methods to Identify SR Opportunities: T10: Vendor assistance |
W53: Used a catalyst with better dispersant properties and increased the amount used in order to fully polymerize all available styrene monomer W82: Ran with a lower styrene version of the resin in order to reduce styrene emissions. Source Reduction - Increased production due to the fulfillment of a large military contract. The contract ended in March of 2012, so future year quantities are expected to be much lower. This was not due to a process change, but due to a decrease in orders back to their normal level of 2009. Due to election year politics and the current state of the country''s finances, we are not expecting an increase in orders that will match what we produced in 2010 and 2011. But we cannot forsee the military needs in the future and what potential conflicts the US might encounter. |
| 2010 |
Source Reduction:: W32: Improved procedures for loading, unloading, and transfer operations
Source Reduction:: W53: Use of a differant process catalyst |
Methods to Identify SR Opportunities: T06: Employee recommendation (under a formal company program)
Methods to Identify SR Opportunities: T10: Vendor assistance |
|
| 2009 |
Source Reduction:: W13: Improved maintenance scheduling, recordkeeping, or procedures
Source Reduction:: W39: Other spill or leak prevention |
Methods to Identify SR Opportunities: T06: Employee recommendation (under a formal company program)
Methods to Identify SR Opportunities: T06: Employee recommendation (under a formal company program) |
Source Reduction - Made process improvements to reduce the amount of resin directed toward disposal and increased the amount of resin recycled within the process. |
| 2008 |
Source Reduction:: W51: Instituted recirculation within a process
|
Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program)
|
Other Environmental Practices - Raised stack for more dispersion. Have looked at alternative (non-HAP) resin substitutes and additives to the resin to reduce emissions. Sealed building and created airflow to prevent fugitive emissions. Investigated air treatment options. |
| 2007 |
Source Reduction:: W51: Instituted recirculation within a process
|
Methods to Identify SR Opportunities: T05: Employee recommendation (independent of a formal company program)
|
Source Reduction - Our facility has sealed off the production area so that all emissions are now through the stack of our facility. In 2007 the height of the stack was also increased to a final dimension of 56 feet from ground level. We also are participating in the Texas P2 plan for future reductions in pollution. Finally we are undergoing research into non-voc alternative processes. |
TRI Pollution Prevention Glossary
The Waste Management Hierarchy |
The waste management hierarchy established by the Pollution Prevention Act (PPA) guides waste generators toward the best options for managing wastes.
The preferred option is to prevent pollution at its source, but for waste that is generated, the preferred management methods are recycling, followed
by burning for energy recovery, treatment and, as a last resort, disposing of the waste.
|
- A breakdown of production-related waste managed. This includes all amounts of the chemical released directly to the environment or otherwise managed as waste, other than waste generated by one-time events not associated with normal production processes (e.g., fires or remedial actions).
- A production ratio or activity index to provide context for reported toxic chemical quantities. For example, if a chemical is used in the manufacture of refrigerators, the production index would track the number of refrigerators produced and could be used to help gauge how much of the chemical is being released per unit of production.
- Any newly implemented source reduction activities, reported using "W-codes" (e.g., "W41: Increased purity of raw materials")