Air Quality 101 Workshop: The Role of Pollution Prevention (P2) January 2006 Sherry Davis, CHMM

Air Quality 101 Workshop: The Role of Pollution Prevention (P2)

January 2006Sherry Davis, CHMM

SBEAP: 800-578-8898 Jan. 2006 Air Quality 101 Workshop

Role of P2

P2 opportunities can: Reduce regulatory responsibilities Reduce operating costs Reduce long-term environmental liabilities

Pollution prevention assessments can help identify supplemental environmental project (SEP) options

Compliance and pollution prevention are integral parts of EPA’s voluntary programs

Compliance and P2 are integral parts of any EMS Compliance and P2 can help companies save

money and jobs!


SBEAP and P2The SBEAP can provide specialized P2

project assistance to your business to find ways to reduce air emissions from your processes by:

Changing the Material Changing the Process Changing the TechnologyMACTs mandate technologies to achieve

required emissions reductions, however, there are many opportunities to further reduce emissions through P2!


P2: Change the MaterialMany emissions can be greatly reduced by

changing to another raw material that emits less or no HAP or other regulated substances.

Ingredients in product production materials: Reformulate products from powder to pellet. Use less toxic biocides instead of chlorine. Use a non- or low-HAP/VOC releasing agent Use in-process recovery processes where

possible


P2 Change the MaterialIngredients in cleaning solutions: most utilized

P2 substitution option; usually easier and cheaper, many “drop-in” replacements available that work with existing equipment Switch to a non-HAP cleaner, such as mineral

spirits Toluene and xylene

Switch to a solvent/water cleaner Fountain solution in printing in industry Use water and solvent in sink-on-a-drum systems

Switch to an aqueous cleaner Switch to a mechanical cleaning process

CO2 blasting, baking soda and water


P2 Change the Material Ingredients in coating or finishing

materials Switch to lower VOC coatings Switch to low- or no-HAP adhesives and

coatings Switch to water-based coatings Ask for coatings with no regulated metals Finish the surface with powder coatings


P2: Change the MaterialCase studiesSolvents: reduce air emissions

Trailer manufacturer uses toluene in paint-gun cleaning; material change to mineral spirits results in:

No HAP emissions from cleaning process Eliminated need for air operating permit

Automotive shop in Johnson County uses a high-vapor pressure solvent parts washer to clean parts; material change to a compliant, low-vapor pressure solvent results in:

RACT rule avoidance and less recordkeeping


P2: Change the MaterialCase studies Hamilton Beach/Proctor-Silex,

eliminated vapor degreaser cleaning process with aqueous batch cleaning processes, eliminated 90,000 lbs. HAP, 80,000 lbs. VOC, and 2,200 gallons of F001 HazWaste.


P2: Change the Process

Changing the WAY you use materials can drastically impact your emissions: Review operating and maintenance practices Review management practices Initiate inventory control / material tracking

program Explore production scheduling


P2: Change the ProcessOperating and maintenance practices often

provide many P2 opportunities: Cover solvent tanks and cleaners when not in use. Recover seal flushes and recycle to process. Turn

off flush when not in use. Use seal-less pumps. Don’t change-out cleaners until needed. Repair leaks ASAP and establish leak detection

systems. Use staged-heating to recoup heat and reduce

energy needs. Shift from batch operations to continuous, if

possible.


P2: Change the ProcessHow you manage materials in your processes

can reduce emissions from your operations: Use a “staging” approach to reduce solvent use-

Use air pressure to clean as much product from process lines to reduce contamination of cleaner.

Use a dirty solvent for first-pass cleaning. Use a cleaner solvent for final- or intermediate- cleaning

Recycle solvent to reclaim virgin solvent Can reduce solvent purchase costs by 90% Can reduce hazardous waste disposal significantly

Examine layout of facility; does material flow minimize worker labor and time, energy use, and reduce reworks?


P2: Change the ProcessInitiate inventory control/material tracking

program to ID specific work practices or process associated with excessive material use. Limit regulated solvent’s use by employee and

purpose. An “open” stock room, invites overuse and misuse!

Review materials use at each stage of production. Ask employees’ help in reduction strategies and

offer incentives for raw materials use reductions—they do the job, and know where wastes can be cut.


P2: Change the Process

Production scheduling often results in excessive material use and waste generation. Schedule coating from light to dark to reduce

line cleaning. Review scheduling and production flows to

make sure your paint line doesn’t change colors excessively or prematurely

Establish separate color lines to reduce color change out and line flushing


P2 Change the Process Case StudiesChanging material flow, process layout, and

work practices Custom wood finishing changes to a mix-at-gun

coating delivery system; eliminated >50% of solvent used to wash 25’delivery lines; reduced haz waste by 43% with a 38% production increase.

Printer used excessive amounts of press cleaning solvents; company implements a solvent “check-out” inventory control and changed to “dauber” dispenser cans; estimated 50% reduction in solvent use.

Wood product manufacturer: identified $900,000 savings potential on rejects, wood waste and labor reductions based on process layout changes.


P2: Change the TechnologyTechnology changes can include the

following: New equipment that is more efficient, uses less

energy, has leak detection systems. New equipment that changes the way your

product is produced: Automated processes that uses less materials Switch to alternative materials such as powder coating

or UV cured coatings Recycling systems that allow waste materials to be

reused such as powder coating recycling systems that yield almost 99% transfer efficiency

New process equipment or designs to improve material utilization and energy conservation


P2 Change the Technology New equipment can drastically reduce

emissions and/or materials use Closed-loop vapor degreasers can reduce

solvent emissions by 98%. Closed-loop aqueous cleaners can eliminate

solvent emissions by 100%. Closed-molding process for parts production

can reduce solvent use 95%


P2 Change the Technology Automated processes can reduce material

use and more consistent process, while reducing workers to hazardous exposures.

Alternative coating technologies can eliminate emissions: UV and powder coatings can achieve 90-98%

transfer efficiency with no solvent use High-volume, low-pressure spray guns can

reduce overspray by 20-40%, resulting in less materials use, less emissions.


P2 Change the Technology Case StudiesAlternative equipment and materials

Fleet management operations P2 assessment identified $4000 savings for energy recovery from used oil with oil space heaters

Boat manufacturing operation changed to solvent recycle system saved $72,000 in solvent purchases and reduced 137,000 tons of hazardous waste at a cost savings of $41,000


P2 Change the Technology Case Studies

Lockheed Martin changed from vapor-degreasing parts to a closed-loop cleaning system;

initial investment costs: $88,000 eliminated solvent use for parts cleaning

process, reduce Decrease water use and sewer discharge by

2 million gallons Wash and rinse water life is ~ 18 months Waste reduced to 165 gallons/year.


P2 in the Emissions Reduction For more information about P2 opportunities

for your business, please visit the Pollution Prevention Resource Exchange network and topic hubs Web site:http://www.p2rx.org/home.cfm

Or call the Kansas SBEAP 800-578-8898 for detailed assistance with air permit questions and emissions reduction strategies.


SBEAP Services SBEAP services are available throughout

the state with staff in Olathe, Salina, Wichita, and Manhattan. All personnel can be contacted at 800-578-8898.

Any questions?

Documents

Air Quality 101 Workshop: The Role of Pollution Prevention (P2) January 2006 Sherry Davis, CHMM