Volume 5, Number 3 Summer 1992

Connecticut Technical Assis tance Program

.................... CASE STUDY ....................

Background The company’s high speed swagging process requires constant lubrication to protect the machinery and stock. Lubes with chlorine are used to withstand the high pressure and temperature generated during the process. Lubes are dripped, flowed, or wiped onto the brass and stainless steel stock. Much of the lube is wiped off in the drawing process. A once-through lubricating system is used to ensure the bearings are constantly flushed of contaminants. The lube flows out of the bearings, over the dies, and into a drip pan. A portion of the lube is squeegeed off the dies and funneled into the drip pan. Mineral spirits are brushed onto the machine parts to keep the machinery and dies clean. Thus, the drip pan contahs machine lubes, stock lubes, and mineral spirits. The drip pan waste is then sent off site as a hazardous waste. The remaining lubricant is carried off with the finished parts, which are then cleaned in a vapor degreaser. Afterwards, the distillation of the spent solvent generates still bottoms which are also sent off site as hazardous waste.

With the increasing liability and disposal costs of hazardous waste, Bead needed to find a way to reduce its waste c eeneration. In the Fall of 1990, Bead applied for, and received a Matching Challenge Grant.

(Continued on Page 6)

Bead Industries, Inc. investigated the feasibility of reclaiming and recycling machining lubricants-with a $5,000 Matching Challenge Grant from ConnTAP.

Calendar of Events 2 1990 Toxics Release Inventory Data Completed 3 Pollution Prevention: A Management Perspective 4-5 for Connecticut Industry

News Briefs 6 Free Energy Audits 7 Pollution Prevention Projects Wanted 7 New Publications Available 7 Waste Management Grants Available 8

SEPTEMBER 10-11 1992 (THURS. & FRI.) Pollution Prevention In The Process Industries Holiday Inn at Newark International Airport, Newark, NJ This workshop will provide techniques to reduce waste generation through improved product/process design, production, maintenance and operations. The workshop is sponsored by the EPA and cos& from $445-$545 per person. For more information, call Dr. Demetri Petrides at the New Jersey Institute of Technology at 201-596-3614.

SEPTEMBER 14,1992 (MON.) 33/50 Program Workshop, Framingham, MA Speakers from industry and consulting firms will present their reasons for joining the 33/50 program. Afternoon seminars will include the following training sessions, “Cost Reductions Through Toxics Use Reduction,” “Pollution Prevention in the Fabricated Metals Industry,” “How to do a Waste Audit in Your Facility,” “Metals and Acids Recovery.” The workshop is sponsored by the Environmental Protection Agency (EPA), Region 1. The cost is $30, which indudes lunch and refreshments. For more information, call the EPA at 617-565-4993 and ask for Jodi.

SEPTEMBER 14-16,1992 (M0N.-WED..) The Environmental Regulation Course Stamford Marriott, Stamford, CT This is a basic survey course intended to explain all major environmental regulations and amendmehts. Legislation covered includes the Clean Air Act, the Clean Water Act, RCRA, Superfund (CERCLA), the Toxic Substances Control Act, Rrght-to-Know, and more. Cost is $995 per person and $95 for registration. For more information, contact the sponsor of the course, Executive Enterprises, Inc. at 1-800-83 1-8333.

- SEPTEMBER 22-24,1992 (TUES. - THURS.) National Conference: Minimization and Recycling of Industrial & Hazardous Waste ’92. Arlington, VA. The Hazardous Materials Control Resources Institute (HMCRI) is sponsoring its first annual conference on pollution prevention and reduction. This conference will address the latest techniques in reducing wastes through source reduction, reuse, recycling, and recovery. For more information, call HMCRI at 301 -982-9500.

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SEPTEMBER 29-OCTOBER 1,1992 (TUES.- THURS.) 1992 International C’FC and Hdon Wtelaatives Conterente! Waskingten, DC ’

Sponsored by the Alliance for Responsible CFC Policy, the conference will assist companies in their effort to respond quickly and efficiently to the challenges presented by CFC phaseout. The program includes sessions on electronics cleanipg, metal cleaning, precision cleaning, alternative refrigerants, refrigerant recovery, labeling, business opportunities, and more. Attendees will be able to review the latest equipment, systems, and services of over 100 exhibiting companies. Call 301 -695-3762 for more information.

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OCTOBER 28,1992 (WED.) The 7th Annual Conference on Pollution Prevention in the Metal Finishing and Manufacturing Industries, Ramada Inn, Meriden, CT The conference will highlight new technologies and management strategies to prevent pollution in the metal finishing/manufacturing industries. The event will include a technical panel, case studies, discussion groups, a facility tour, and vendor displays. The conference is sponsored by the Onpecticut Association of Metal Finishers ( Codnecticut Technical Assistance (CofiHTAV,

SEPTEMBER 15-16, 1992 (TUES, & WED.) The Environmental Total Quality Management (TQM) Conference, Sheraton Carlton Hotel, Washington, DC This conference will provide a hands-on forum on how to integrate TQM into environmental programs.

Institute of Water Resources (IWR), Environmental Research Institute (ERI), and the Connecticut Department of Environmental Protection (DEP). The cost is $55, which includes lunch and refreshments. For mote information, contact CAMF at 203-527-3036.

NOVEMBER 12-13,1992 (THURS.-FRI.) Toxics Use and Source Reduction: Compliance and

For more information, call Executive Enterprises, Inc. at 1-800-831-8333.

SEPTEMBER 16,1992 (WED.) Superfund: Solvent Recovery Service (SRS) Today What Tomorrow? Sheraton Hotel, Waterbury, CT With over 1000 potentially responsible parties (PRP) named in the SRS cleanup, many businesses are becoming involved with Superfund for the first time. This dinner meeting will provide information on what can be expected to happen at this site and future waste disposal sites in Connecticut. The

Beyond Washington Marriott Hotel, Washington, DC This course will help attendees meet compliance requirements for planning and updating a source reduction program. It will also demonstrate how to formulate a source reduction plan and how to measure its progress. The cost for the course is $995 plus a $95 registration fee. For more information, call the seminar sponsor, Executive Enterprises, Inc. at 1-800-831-8333. -

event is sponsored by the Connecticut Association of Metal Finishers (CAMF), and costs $30 to attend. For more information, call Karen at CAMF at 203-527-3036.

2 ConnTAP Quarterly/Summer 1992

U S . Toxics Release Inventory 8

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1987

Releases

1988 1989

Rewrtine Year 1990

Releases of industrial toxic chemicals decreased by 11 percent from 1989 to 1990, according to the most recent U S . Environmental Protection Agency (EPA) data. The 1990 Toxics Release Inventory (TRI) indicates that 4.8 billion pounds of toxic chemicals were released by 23,648 facilities nationwide.

Louisiana leads the nation with 209 million pounds of toxjc releases. Connecticut ranked 34th in the nation, with 21 million pounds released. Ammonia topped the list of toxics chemicals released into the environment nationwide, followed by toluene, methanol, hydrochloric acid, and acetone.

TRI reporting is required by the Emergency Planning and Community Right-to-Know Act of 1986 (EPCRA). Releases of approximately 300 toxic chemicals above a prescribed threshold, must be reported by covered industries.

The reduction in 1990 emissions continue a downward trend in toxic releases. Since 1988 there has been a 26 percent reduction in toxic releases and transfers. EPA Administrator William K. Reilly is "encouraged" by the trend. The reduction may be attributed to reduced productivity, more accurate measurement of releases, or increased pollution reduction efforts.

ConnTAP Qlrarterly/Su"erl992 3

Speakers at the “Pollution Prevention: A Management Perspective For Connecticut Industry, ” Breakfast Meeting: (1-r) Domenic Forcella of The Connecticut Hazardous Waste Management Service, Frank McAbee Jr. of United Technologies Corporation, Tom Turick of the Connecticut Business & Industry Association (CBIA), James DeWitt of the Connecticut Association of Metal Finishers (CAMF), Ron Henson of Pratt & Whitney, Randall Klein of Action Circuits, Inc., and Serle Field of the Connecticut Development Authority.

Environmental ManagersEngineers, committed to pollution prevention, are often frustrated when their proposals‘ are rejected by upper management. To help solve this problem, a breakfast meeting was held to emphasize the importance of pollution prevention to vice presidents, presidents, and corporate executive officers.

On May 14, 1992, upper management representatives from a wide variety of industries attended a breakfast meeting entitled “Pollution Prevention: A Management Perspective For Connecticut Industry.”

Sponsored by ConnTAP and United Technologies Corporation, the event was held at the Marriott Hotel in Rocky Hill. Over 40 people from large and small facilities participated in the two hour breakfast meeting.

Tom Turick, Environmental Manager of the Connecticut Business & Industry Association (CBIA), opened the meeting with a educational presentation on the benefits of pollution prevention. Mr. Tyrick, who also served as. moderator, stressed that ihe most important people at the conference were the attendees, because their commitment could make or break a pollution prevention project.

Frank McAbee Jr., Senior Vice President of Environmental and Business Practices at United Technologies Corporation, delivered the keynote presentation, “Pollution PreventiodSource Reduction: The Preferred Method of Minimizing Waste.” Mr. McAbee then shared how his company incorporates pollution prevention into management decisions.

The Connecticut Hazardous Waste Management Service is the parent organization of ConnTAP. The Service’s Chairman and Executive Officer, Domenic Forcella, gave an overview qf theorganization’s , respon$bilit%s relafed to pollution prevention. He provided information on CoqnTAP’s waste minimization services and resources.

The Executive Director of the Connecticut Association of Metal Finishers (CAMF), James DeWitt, provided an effective analogy to describe the difference between pollution prevention and pollution control. To reduce automobile emissions, he explained, a pollution control method such as a catalytic converter could be used. However, pollution prevention methods such as changing an engine design or modifying driving habits are preferred.

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4 ConnTAP Quarterly/Summer 1992

Mr. DeWitt then extolled the benefits of pollution prevention over pollution control. He also identified common barriers industries face when trying to implement pollution prevention.

Key elements of a successful pollution prevention program for a large company were presented by Pratt & Whitney Aircraft’s Vice President of Environment, Health & Safety, Ronald Henson. Mr. Henson spoke on how the management structure and philosophy at Pratt & Whitney supports pollution prevention. Mr. Henson encouraged companies starting a pollution prevention program to begin with small, simple projects or in his words, “the low hanging fruit.” This will help build a positive outlook on pollution prevention which will motivate employees to pursue larger projects.

Frank McAbee Jr., Senior Vice President of Environmental and

Business Practices at United Technologies Corporation, gave

the keynote presentation, “Pollution PreventiodSource

Reduction: The Preferred Method of Minimizing Waste.”

Domenic Forcella, Chairman and Executive Officer of

the Connecticut Hazardous Waste Management Service,

gave an overview of the Service’s responsibilities

related to pollution prevention.

The President of Action Circuits, Inc., Randall Klein, discussed critical success factors for a pollution prevention program at a small company. He presented a video

Environmental Assistance Revolving Loan Fund (EARLF) and other forms of financial assistance available from the CDA. He described the EARLF program, which has a total of ten

(available from ConnTAP) of his company’s “full circle” pollution prevention project. The project was funded, in part, by grants from ConnTAP. Finally, Serle Field, Executive Director of the Connecticut Development Authority (CDA), illustrated the new

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James DeWitt, Executive Director of the Connecticut

Association of Metal Finishers, answers questions.

million dollars available for pollution prevention projects.

Mr. Turick closed the meeting by encouraging attendees to assign an employee at their company to start a pollution prevention program. Evaluations from participants were favorable and many of the executives have since contacted ConnTAP for more information. If there is interest, ConnTAP will sponsor a similar event next year.

ConnTAP Quarterly/Su”er 1992 5

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e The U.S. Environmental Protection Agency (EPA) will not regulate used oil under the Resource Conservation Recovery Act (RCRA). Only if contaminants exceed regulatory levels will used oil be regulated under RCRA. The agency has also said it will not regulate used oil filters as hazardous waste, provided that free flowing oil has been removed from the filter.

e The new reporting form (Form R) for the Toxics Release Inventory (TRI) is available to industry. The new form includes reporting requirements of the Pollution Prevention Act of 1990. Because of delays in finalizing the forms, the U.S. EPA has stated that it will not bring enforcement actions against companies that submit an accurate and complete Form R before September 1, 1992. To receive the new Form R, or for more information, call the EPCRA Hotline at 1-800-535-0202.

e The EPA has proposed requiring consumer warning ,i labels on retail products containing or manufactured with chlorofluorocarbons (CFCs) and other stratospheric ozone depleters. To promote recycling, the proposal also caIls for permanent labels on products containing recoverable ozone depleting chemicals. If adopted, the new requirement will go into effect on May 15, 1993. For a copy of the proposal, contact Barbara Barbieri at 203-241-0777.

e Promoting cooperation in environmental policy is the mission of the Connecticut Environment Roundtable, Inc. (CER). CER's directors, drawn from business, government

tors, believe coop\eration'is the key to- . tal policies 'are developed from the best

ideas of all parties. If you are interested in supporting this approach, call David Rickerby of CER at 203-293-2394.

Project Activities and Results Initially the company believed it could significantly reduce the oil load to the degreaser by centrifuging the finished parts. However, testing revealed that only a small quantity of oil remained on the parts. Therefore, Bead determined that the payback period of 5 years for the centrifuge would not meet the company's guidelines for capital acquisitions.

Early in the project period, the company assessed its costs for purchasing mineral spirits, as well as stock and bearing oils. Bead then purchased cartridge filters, containers, pumps, and other equipment to remove contaminants for the drip pan oils. Further testing and evaluation during the grant project identified necessary procedures to help solve Bead's waste management problem.

The company collected the oil pan wastes in a barrel, and allowed it to settle for approximately 48 hours. The lubricants settled to the bottom, while mineral spirits rose to, the top. Thelubricants were drawn off, and sent through a fiIter to be cleaned for reuse.

Lastly, the mineral spirits are removed from the barrel for reuse. Due to the abrasive nature of stajnless steel, a highly chlorinated stock lubricant is needed to ensure a proper draw and swage operation. Unfortunately, the filtered lubricant contained, insufficient concenti-ations of chlorine to protect the stainless steel stock.

However, since brass is more formable and can tolerate greater variations in lubricant quality, the company found that the recycled lubricant worked well.

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Bead also discovered that the recycled lubricant was ineffective as a bearing oil. The recycled lubricant could not tolerate high pressure and temperature which caused bearing damage and machine down time. v

The company also investigated the possibility of reducing the volume of lubricant applied to the stock and bearings. This reduces the quantity of waste entering the drip pan and the oil remaining on the finished part. This in turn, reduces the volume of oil entering the vapor degreaser, thus decreasing the generation of still bottom wastes.

Payback The addroximate'co

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predicts the reduced/eliminated purchases of stock lubricants and mineral spirits, and reduced generation of hazardous waste, will save approximately $1 1,252 annually. A payback period of less than one year is expected! Furthemore, the company will reduce hazardous waste generation by 1650 gallons annually.

Bead has been a manufacturer of beaded chain and tubular electronic parts for more than 75 years. The company is located in Bridgeport and employs approximately 85.

To receive the report on this project, send a check for $5.00 (made out to ConnTAP) to ConnTAP, 900 Asylum Ave., Suite 360, Hartford, CT 06105.

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Times are tough; companies are looking for new ways to save money. Through a new program, the US Department of Energy (DOE) can help.

The DOE now sponsors free energy efficiency audits. The program is administered by the Energy Analysis & Diagnostic Center (EADC), located at the University of Massachusetts.

An audit team will analyze a facility’s energy costs and identify energy conservation opportunities (ECOs). The focus of the audits will be on process and plant operations.

Afterthe audit, a repoft detailing the ECOs wilI’be prepared. By implementing the recsmmepdations in the report, a company can use energy more efficiently to save money and reduce pollution.

The service is available to small-to-medium manufacturing plants (SIC 20-39) with gross annual sales of $75 million or less, which consume energy at a maximum cost of $1.75 million a year. Facilities with more than 500 employees or in-house energy expertise are ineligible.

For more information, contact Lawrence Ambs, EADC Director at 413-545-2539.

If you are looking for a simple way to reduce waste at no cost, the EPA’s new Facility Pollution Prevention Guide is for you. The guide, the successor to the 1988 Waste ~ -

Minimization Opportunity Assessment Manual, is designed to assist small to medium sized business in developing a pollution prevention program. The guide includes information on the benefits of pollution prevention, key elements for developing and executing a pollution prevention program, measuring pollution reduction, and determining the economic costslbenefits of the program through Total Cost Assessment (TCA). The publication also includes separate pollution prevention checklists for printing, fabricated metal, metal casting, printed circuit board, and coating industries. The free guide is available through the US EPA Environmental Research Information Publications Unit, 26 West Martin Luther King Dr., Cincinnati, OH 45268. Or call 5 13-569-7562 and order document number EPA/600/R-92/08 8.

The very first national summary of pollution prevention efforts has been published! Entitled, Pollution Prevention 1991: Progress on Reducing Industrial Pollutants, the EPA document describes trends in industrial and governmental pollution prevention activities. The first chapter defines pollution prevention and its benefits. Chapter 2 examine? cwent trends in pollution prevention. Other chapters focus on tkade association activities and 63 industrial pollution prevention programs and accomplishments. The publication also includes information on the Pollution Prevention Act of 1990 and state pollution prevention regulations. One chapter contains information on non-industrial sectors, including energy, transportation, agriculture, and municipal projects. To receive the free publication, call the Pollution Prevention Information Clearinghouse at 703-821-4775.

ConnTAP Quarterly/Summer 1992 7

Applications for ConnTAP's Matching Challenge Grants will be available soon! Grants fund projects related to the appropriate management of hazardous waste, wastewater, or air emissions. Eligibility is open to any person or organization.

Frequently, grant projects identify opportunities, evaluate options, or demonstrate a specific technology for a waste managemendminimization problem.

This year, the maximum allocation per grant will be at least $5,000. Recipients are required to match the amount of their grant 100 percent. Matching contributions may include costs of labor, chemical analyses, consultants' fees, rental of pilot equipment, and costs of incidental equipment.

Applications will be available by September 11, 1992. For more information or to receive an application, contact Andrew. Vecchio at 203-241-0777.

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"SINCE THE INCEPTION OF THE GRANTS PROGRAM IN 1988,

AWARDED TO FUND 21- 4 4 ' P RO J ECTS. "

OVER $100,000 HAS BEEN Y

Andrew Vecchio Technical Specialist

ConnTAP \

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900 Asylum Avenue, Suite 360 Hartford, CT 06105-1904

(203) 241-0777

I FIRST CLASS MAIL

PRESORTED U.S. PCBSTAGE PAID

PERMIT NO. 26 MARION, CT 00444

Address Correction Requested