e e e e e e e e e e e e e e e e e e e e

CASE STUDY e e e e e e e e e e e e e e e e e e e e

Background

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 13cacl I lldl1\11 IC\. I IlC' I l l V C \ l I !Urctl I l lC i c ' , l \ l l ~ l I l l \ / 0 1 I L!Clc11 llli ll!! and I CC vcl I Il!! - _ I "

parts to keep the machinery and dies clean. Thus, the drip pan contains

inachining lubricants with a$S,000 Matching Challenge Grant from ConaTAP.

machine lubes, stock lubes, and mineral s. The drip pan waste is then sent te as a hazardous waste. The

remaining lubricant is carried off with the finished parts, which cleaned in a vapor degre Afterwards, the distillati 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 generation. In the Fall of 1990, Bead applied for, and received a Matching

(Continued on Page 6)

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 10-1 92 (THURS. & FRI.) Pollution Prevention I Process Industries Holiday Inn at Newark International Airport, Newark, NJ This workshop will provide techniques to reduce waste generation through improved productlprocess design, production, maintenance and operations. The workshop is sponsored by the EPA and costs from $445-$545 per person. For more information, call Dr. Demetri Petrides at the New

stitute of Technology at 201-596-3614.

MBER 14,1992 (MON.) 33/50 Program Workshop, Framingham, MA Speakers from industry and consulting firms will present

asons for joining the 33/50 program. Afternoon s 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

” The workshop is sponsored by the ental Protection Agency (EPA), Region 1. The cost

is $30, which includes lunch and refreshments. For more call the EPA at 617-565-4993 and ask for Jodi.

BER 14-16,1992 (MON.-WED..) The Environmental Regulation Course Stamford Marriott, Stamford, CT This is a basic survey course intended to explain all major

covered includes the Clean Air Act, the Clean Water Act, RCRA, Superfund (CERCLA), the Toxic Substances Control Act, Right-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

mental regulations and amendments. Legislation

1-800-83 1-8333.

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

grate TQM into environmental programs. formation, 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 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

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) i s 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.

SEPTEMBER 29-OCTOBER 1,1992 (TUES.- THURS.) 1992 International CFC and Halon Alternatives Conference, Washington, 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 cleaning, 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.

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/manufdcturing industries. The event will include a technical panel, case studies, discussion groups, a facility tour, and vendor displays. The conferenc the Connecticut Association of Metal Fi Connecticut Technical Assistance (ConnTAP), Connecticut 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 more information, contact CAMF at 203-527-3036.

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

ConnTAP Quarterly/Summer 1992

U.S. Toxics Release Inventory 8

0

I

1987 1988 1989 1990

Releases Reporting Year

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 I990 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 toxic . Connecticut ranked 34th in the nation, with 21 pounds released. Ammonia topped the list of toxics

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

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, inore accurate measurement of releases, or increased pollution reduction efforts.

chemicals released into the environment nationwide, followed by toluene, methanol, hydrochloric acid, and acetone.

ConnTAP Quarterly/Summerl992 3

the “Pollution Prevention: A Management Perspective For Connecticut Industry, ” Breakfast

ess & Industry Association e Connecticut Hazardous n, Tom Turick of the Con

ment Service, Frank McAbee

A), James DeWitt of the Connecticut Association of Metal Finishers (CAMF), Ron Henson of Pratt & y, Randall Klein of Action Circuits, Inc., and Serle Field of the Connecticut Development Authority.

/Engineers, Tom Turick, Environmental Manager The Connecticut Hazardous Waste evention, are Management Service is the parent r proposals Association (CBIA), opened the organization of ConnTAP. The

Service’s Chairman and Executive Officer, Domenic Forcella, gave an overview of the organization’s responsibilities related to pollution prevention. He provided information on ConnTAP’s waste minimization

of the Connecticut Business & Industry

meeting with a educational presentation on the benefits of pollution prevention. Mr. Turick, who also served as moderator, stressed that the most important people at the conference were the attendees, because their

pollution prevention project. The Executive Director of the

Frank McAbee Jr., Senior Vice Connecticut Association of Metal industries attended a breakfast President of Environmental and Finishers (CAMF), James DeWitt, meeting entitled “Pollution Business Practices at United provided an effective analogy to Prevention: A Management Technologies Corporation, delivered describe the difference between

the keynote presentation, “Pollution pollution prevention and pollution

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.

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. commitment could make or break a services and resources.

, 1992, upper management ves from a wide variety of

nISource Reduction: The control. To reduce automobile Method of Minimizing

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

Waste.” Mr. McAbee then shared how his company incorporates pollution prevention into management decisions.

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 ‘mpleinent 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

enson encouraged

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 pi-evention which will motivate employees to pursue larger projects.

Frank McAbee Jr., Senior Vice President of Environmental and

Business Practices at United echnologies Corporation, gave

the keynote presentation, “Pollution PreventionLSource

Reduction: The Preferred Method of Minimizing Waste.”

I I

Domenic Forcella, Chairman and Executive Officer of

the Connecticut HaLardous Waste Management Service,

gave an overview of the Service’s responsibilities

related to pollution

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 (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 at their to start a of the Connecticut Development Authority (CDA), illustrated the new

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 million dollars available for pollution prevention projects.

Mr. Turick closed the meeting by encouraging attendees to assign an

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.

James DeWitt, Executive Director of the Connecticut

Association of Metal Finishers, answers questions.

I I

ConnTAP Quarterly/Summer 1992

. 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.

The EPA has proposed requiring consumer wa labels on retail products containing or manufactured with chlorofluorocarbons (CFCs) and other stratospheric ozone depleters. To promote recycling, the proposal also calls 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.

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.

0 Promoting cooperation in environmental policy is the mission of the Connecticut Environment Roundtable, Inc. (CER). CER’s directors, drawn from business, government and non-profit sectors, believe cooperation is the key to ensure environmental 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.

m................... ........................................... (Bead Industries Continued from Page 1)

Project Activities and Results Initially the company believed it could significantly reduce the

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 stQck 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. The lubricants were drawn off, and sent through a filter to be cleaned for reuse.

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.

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 approximate cost of the prqject was $10,850. Bead predicts the reduced/eliminated purchases of stock lubricants and mineral spirits, and reduced generation of hazardous waste, will save approximately $ I 1,252 annually. A payback period of less than one year is expected! Furthermore, the colnpany will reduce hazardous aste generation by 1650 gallons annually.

the degreaser by centrifuging the finished r, testing revealed that only a small quantity of

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

tainless 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.

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 ComzTAP) to CnntzTAP, 900 Asylum Avc., Suite 360, Hartford, CT 06105.

6 ConnTAP Quarterly/Summer 1992

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. 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 I988 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

After the audit, a report detailing the ECOs will be prepared. By implementing the recommendations in the report, a company can use energy more efficiently to save money and reduce pollution.

elements for developing and executing a pollution prevention program, measuring pollution reduction, and determining the economic costshenefits 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 service is available to 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 os in-house energy expertise are ineligible.

all-to-medium manufacturing

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

For more information, contact Lawrence Ainbs, EADC Director at 41 3-545-2539.

Has your Connecticut company recently completed a successful pollution prevention project? Would you like an opportunity to show your company’s commitment to pollution prevention? If so, now is your chance. CunnTAP will publish summaries of selected pollution prevention projects in this newsletter. With a circulation of over 1800, CurrrifAP Quarterly is a great way to publicize your project(s). The first step is to tell us about the project: what process was involved, what techniques were used to reduce waste, what types and quantities of’ waste were reduced. Coitnl’AP will select prqjects that best demonstrate source reduction as the primary means of reducing waste. Interested businesses should contact Andrew Vecchio at 203-24 1-0777 for more information.

5 13-569-7562 and orderhocument number EPA/600/R-92/088.

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 examines current trends in pollution prevention. Other chapters focus on trade 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

“SINCE THE INCEPTION OF THE GRANTS PROGRAM IN 1988,

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 availabl

information or to receive an

100,000 HAS BEEN RDED TO FUND PROJECTS.” September 11, 1992. For more

application, contact Andrew Andrew Vecchio Vecchio at 203-241-0777. Technical Specialist

ConnTAP

FIRST CLASS MAIL PRESORTED

US. POSTAGE PAID 900 Asylum Avenue, Suite 36

Hartford, CT 06105-1904 (203) 241-0777