The Tennessee Pollution Prevention Roundtable - …infohouse.p2ric.org/ref/26/25690.pdf · tn- Pollution Prevention % %W,& ,e ... American Lung Association DuPont Company - New Johnsonville

The Tennessee

Pollution Prevention Roundtable

A

1998 Report

Pollution Prevention Success Stories

1998 Report: Pollution Prevention Success Stories is a publication of the Tennessee Pollution Prevention Roundtable,

a consortium of public and private agencies, organizations and industries. Copyright 1998. All rights reserved.

For reprints or permissions, contact the Tennessee Department of Environment and Conservation, Division of Community Assistance, 8th Floor, L&C Annex, 401 Church Street, Nashville, TN 37243-1551.

Tel: (615) 532-0760. Fax: (615) 532-8007.

June 1998 Kingsport, Tennessee

E z a o eo o~ P R E V + ~ O ~ Members of the Tennessee

;+&\: tn- Pollution Prevention % %W,& ,e ?+ + * Roundtable

*a@ N tl3 bo8

American Lung Association DuPont Company - New Johnsonville and Memphis Environmental Action Fund Fisk University Inland Paperboard & Packaging Lenzing Fibers Corporation Dr. Ruth H. Neff Nissan Motor Manufacturing Corporation PCS Nitrogen Fertilizer, L.P. Quebecor Printing - Memphis Saturn Corporation Sierra Club Tennessee Association of Business Tennessee Conservation League Tennessee Department of Environment and Conservation Tennessee Eastman Division, Eastman Chemical Company Tennessee Environmental Council Tennessee Environmental Education Association Tennessee Technological University Tennessee Valley Authority The University of Tennessee Center for Industrial Services The University of Tennessee Energy, Environment and Resources Center Vanderbilt University Viskase Corporation Zeneca Specialties, Inc.

Special thanks to the following for making this publication possible: Tennessee Department of Environment and Conservation, Division of Community Assistance - coordination and administration -

The University of Tennessee Center for Industrial Services - design and editing -

Tennessee Eastman Division, Eastman Chemical Company - paper and printing - and the thirty-one industries and agencies who shared their success stories with us.

Contents

The Tennessee Pollution Prevention Roundtable

Why A Roundtable? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

A Message From the Commissioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

A Brief History of the Roundtable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

The TRI: Minus 50 Counting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

For More Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Send Us Your Story . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

The Success Stories

Arnold Engineering Development Center . . . . . . . . . . . . . . . . 8.9

Aluminum Company of America .................... 10- 1 1

BridgestoneBirestone, Incorporated ..................... 12

Chemetals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1 3

Delta Faucet Company of Tennessee .................... 13

DuPont Company . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Excel of Tennessee. L.L.P .............................. 15

General Electric Company ............................ 15

General Shale Products Corporation ..................... 16

Heckethorn Manufacturing Company. Inc . . . . . . . . . . . . . . . . . 17

International Comfort Products ......................... 17

Jones-Blair Company. Southeast Region . . . . . . . . . . . . . . . . . 18

M&M Mars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

McKee Foods Corporation ............................ 19

Murray. Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Nashville Electric Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Philips Consumer Electronics Company . . . . . . . . . . . . . . . . . . 20

Quebecor Printing. L.P. ............................... 21

Saturn Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Teksid Aluminum Foundry. Inc ......................... 23

Tenneco Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Tennessee Army National Guard ....................... 25

Tennessee Department of Transportation . . . . . . . . . . . . . . . . . 26

Tennessee Eastman Division.

Eastman Chemical Company ....................... 27

Tennessee Valley Authority ............................ 28

Viskase Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Westvaco Consumer Packaging Division . . . . . . . . . . . . . . . . . 29

Whirlpool Corporation ............................... 30

Willamette Industries .............................. 3 1-32

Y-12 Plant, Lockheed Martin Energy Systems . . . . . . . . . . . . . 33

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Yale Security Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Why A Roundtable?

Vision The Tennessee Pollution Prevention Roundtable will be a national model program for improving the environment and quality of life through cooperation and communication among educational institutions, environmental advocates, government and industry. Knowledge, understanding and trust will foster a spirit of cooperation leading to shared goals and objectives that enhance environmental stewardship in Tennessee.

The Tennessee Pollution Prevention Roundtable will be viewed as a credible, respected source of factual information on environmental issues. All Tennesseans will benefit from the committee’s education outreach, through a better understanding of the issues, their risks, the priorities and the solutions.

The spirit of cooperation exhibited by the Roundtable will motivate Tennesseans to work together to achieve meaningful and measurable environmental improvements.

Mission Statement The Tennessee Pollution Prevention Roundtable will facilitate and implement activities designed to achieve significant and meaningful improvements in the quality of the environment of Tennessee and the quality of life for Tennesseans now and for future generations.

Customers

0 Business/industry 0 Media 0 Medical community 0 Educators/students 0 Public citizens

0 Governor of Tennessee 0 Legislative branch of government 0 Government agencies with

environmental responsibilities e Environmental advocacy groups

A Message From the Commissioner

June 1998

Welcome to the 1998 edition of Pollution Prevention Success Stories.

This is the third edition of Success Stories to be produced in Tennessee. Like earlier publications, this year’s report is a catalog of accomplishments, a guide to innovation and foresight in environmental management and industrial waste reduction.

The fifty-two success stories compiled here represent a total of thirty-one companies and agencies, more than the two previous reports combined. Two-thirds of these are first-time contributors. They range from well-known corporations to public and government groups. Examples of the corporations are ALCOA, BridgestoneFirestone and Saturn Corporation. Some of the public/government groups are Nashville Electric Service, TVA, the Tennessee Army National Guard, the Tennessee Department of Transportation and the Oak Ridge Y-12 Plant. The projects included activities from recycled concrete to constructed wetlands.

This edition of Success Stories is not only the largest to date; it is also the first to appear since the Tennessee 2000 Initiative was renamed the Tennessee Pollution Prevention Roundtable. This change was made necessary by a most welcome event. I am pleased to report that the members of the 2000 Initiative have achieved their original goal, to cut by half the state’s EPA-reportable toxic releases by the year 2000. In fact, if you look at the chart on page 7, you’ll see that they did so a full three years ahead of schedule.

After this victory, the members of the Initiative could have dissolved and considered their mission complete. However, in a state that is growing, in an economy that is booming and among industries that are thriving, pollution prevention remains a priority. The 50-percent reduction, while important, is simply a benchmark, a way to measure progress and inspire further efforts.

That’s why the members of the Tennessee 2000 Initiative renamed their group the Tennessee Pollu- tion Prevention Roundtable (TP2R). TP2R’s new slogan, Pollution Prevention: Tennessee ’s Gift for the Future, is a phrase that sums up the philosophy of the thirty-one Tennessee industries and agencies whose stories appear in this booklet. On behalf of the citizens of the state of Tennessee, we thank you, and keep up the good work.

Milton Hamilton, Jr. Commissioner Tennessee Department of Environment and Conservation

A Brief History of the Roundtable

1986

1989

1990-1 993

1993

1993

1994

1994

1994

1995

1996

1 996

1997

1938

Congress passes the Superfund Amendments and Reauthorization Act (SARA), including the landmark Section 313-the Emergency Planning and Community Right-to-Know Act. Section 313 requires the U.S Environmental Protection Agency to publish an annual Toxics Release Inventory (TRI), listing regulated chemical releases for every state and major industry in the country.

The first TRI is published, containing national emissions data for 1987. Tennessee ranks second in the country (after Texas) in pounds of TRI chemicals released.

Tennessee continues to rank among the top three states in volume of TRI emissions.

The Tennessee Department of Environment and Conservation (TDEC) announces the formation of a Division of Pollution Prevention and Environmental Awareness. TDEC also announces the “Toxics 2000 Initiative” (soon renamed the Tennessee 2000 Initiative), a collaborative effort to reduce Tennessee’s toxic releases “significantly” by the year 2000.

The top thirteen industrial dischargers in the state (based on 1991 TRI data) form a coalition to address Tennessee’s toxic emissions. In December, they begin meeting with TDEC as an industrial subcommittee of the Tennessee 2000 Initiative.

The Industry Subcommittee of the Tennessee 2000 Initiative announces the Tennessee Corporate Challenge, a goal to reduce voluntarily the state’s aggregate TRI emissions by 50 percent (from 1989 levels) by the year 2000.

A coalition of environmental organizations, universities and public interest groups begins meeting as a separate subcommittee of the Tennessee 2000 Initiative. In December, the industrial and conservation subcommittees begin meeting jointly.

The Tennessee 2000 Initiative begins hosting a series of regional Pollution Prevention Conferences across the state.

The Tennessee 2000 Initiative is a finalist for the Council of State Governments’ 1995 award for innovative programs. The Initiative sponsors a booth at Nashville’s Riverside Park to mark the twenty-fifth anniversary of Earth Day.

The Comparative Risk Subcommittee of the Tennessee 2000 Initiative releases a study of air pollutants in Tennessee, based on 1993 TRI emissions and EPA’s 1993 emissions database. Rather than focusing strictly on gross volume of releases, the study calculates a “Relative Potential Toxicity” index, reflecting both volume and potential hazard of each TRI chemical released in the state.

’

The Tennessee 2000 Initiative sponsors the 1996 Pollution Prevention Week in Tennessee. The event features in-service training in selected schools in northeast Tennessee.

The 1997 TRI (containing data for 1995) shows that Tennessee has exceeded its goal of 50-percent reductions in total TRI emissions.

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The Tennessee 2000 Initiative changes its name to the Tennessee Pollution Prevention Roundtable. The members revise their original mission and vision statements to reflect this new name and new direction. The Roundtable continues to be administered by the Department of Environment and Conservation, under its new Division of Community Assistance.

The TRI: Minus 50 and Counting

250

200 UJ ‘0

150 -I- O

0 2 100 .- - - .- E

50

0 -

Last year marked a landmark moment for the Volunteer State.

With the cooperation of many industries across the state, Tennessee achieved its goal of 50-percent reductions in toxic chemical releases. These are the hazardous emissions monitored by the U.S. Environmental Protection Agency under EPCRA-the 1986 Emergency Planning and Community Right-to-Know Act. Tennessee accomplished this milestone a full three years ahead of schedule, despite the fact that EPA had added 286 new chemicals to its Toxics Release Inventory (TRI) list in 1994.

Tennessee’s air, lands and waters are cleaner today than they have been for many years, at least with regard to the 647 chemicals on the TRI list. Reported emissions have dropped a net 58 percent, from 245 million pounds in 1987 (when TRI reporting went into effect) to 103 million pounds in 1996 (the most recent filing year). The 1996 numbers would look even better, had the EPA not revised its “total release” definition to include, for the first time ever, wastes transferred off site for disposal. If we don’t count those wastes (which totaled 9 million pounds in 1996), Tennessee’s TRI would have dropped below 100 million pounds for the first time in its history.

Keep in mind that these reductions have been entirely voluntary. Dozens of Tennessee companies are working hard to reduce or eliminate their emissions, not out of fear of any penalties, but out of concern for their environment, their communities and their desire to maintain a quality of life in this state that is unsurpassed anywhere in the world.

Toxics Release Inventoq (TMI emissions in Tennessee. 1987 to 1996, with 2000 goal

245 nnn

227 21 6 21 5 194 188

156

102 103*

1987 1988 1989 1990 1991 1992 1993 1994 1995 1996 (2000 goal)

* Due to a change in EPA’s “total release” definition, includes 9 million pounds of wastes transferred off site for disposal

Reducing Emissions

Pollution Prevention

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T H R 0 U G H ___ ~~

I Pollution Prevention: Tennessee’s Gift for the Future I

ARNOLD ENGINEERING DEVELOPMENT CENTER Tullahoma, Tennessee

(931) 454-7743

AEDC’s Engine Test Facility develops a method to reuse TCE in its flight simulation system.

The Challenge To simulate flight over varying flight speeds and atmospheric conditions, AEDC’s Engine Test Facility (ETF) must use precisely condi- tioned air. The system provides 2,760 tons of continuous mechanical refrigeration, much of which uses trichloroethylene (WE) as a refrigerant medium. To maintain or service the system, technicians routinely drained the TCE into small containers, which were then disposed of as hazardous waste. In 1996, AEDC reported 3,223 pounds of this waste.

The Solution Working with plant operators, pipefitters and environmental staff, AEDC engineers modilied the piping to allow the drained TCE to be reintroduced back into the cooling system.

The Benefits The new system eliminates 50 percent of TCE from the Engine Test Facility’s hazardous waste stream. For a capital investment of $1,500, it also saves $7,500 annually in disposal and refrigerant replacement costs, as well as the associated labor costs of handling, safety training, labeling and reporting. Meanwhile, AEDC is considering adding fine filters to the system, both to minimize the possibility of sediment col- lecting in the reintroduction chamber, and to extend the service life of the equipment.

By changing to water-based paints, AEDC cuts one of its largest waste streams by twodhirds.

The Challenge The AEDC paint shop refinishes structural steel, ductwork and equipment for such customers as the Engine Test Facility, Propulsion Wind Tunnel, Rocket Test Facility and Gas Dynamics Facility. In the past, solvent-based paints were used exclusively, and painting operations generated one of the largest hazardous waste streams at the center.

The Solution Paint shop personnel researched latex paint substitutes that worked at least as well as solvent-based products. The shop now uses water-based paints in roughly 70 percent of all applications basewide.

The Benefits The switch to latex paints has cut one of AEDC’s largest waste streams by more than two-thirds-from 7,170 pounds in 1995 to 1,912 pounds in 1996-without affecting system performance. It also saves $3,000 a year in disposal costs, with no capital investment to date. However, because the paints must have temperatures above 50 degrees to dry properly, AEDC is planning to build a heated facility so latex paints can be applied year round.

For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760 I

T H R 0 U G H

Pollution Prevention Pollution Prevention: Tennessee’s Gift for the Future I

ARNOLD ENGINEERING DEVELOPMENT CENTER Tullahoma, Tennessee

(931) 454-7743

AEDC cuts its use of Freon in rocket testing by 98 percent.

The Challenge As part of its testing process for propellant-fueled rocket engines, AEDC compares the performance of the engine with the quality of the fuel being used. As soon as the engine shuts down, technicians draw a sample of the fuel, pumping it through a pipe into a collection bottle. It is imperative that this collection device, called a sample panel, be kept scrupulously clean. Otherwise, it would contaminate the fuel and invali- date the test. In the past, AEDC used Freon 113, an ozone-depleting chemical, to flush the system. As many as twenty-eight gallons of Freon might be used to conduct a single test.

The Solution A contract engineer developed an alternative process that cuts Freon use by 98 percent. Technicians begin by disassembling the panels and precleaning them with aqueous cleaners, acid, and deionized water rinses. The panels then go into an ultrasonic bath with more aqueous cleaners, followed by another deionized water rinse and high-purity drying. The only time Freon is used is in the final verification process, when a gallon of the chemical is run through the system and analyzed for contaminants. The excess, usually about a half-gallon, is then processed in a solvent distillation still and reused.

The Benefits The new process not only eliminates 55 1 pounds of Freon emissions annually; it saves $13,920 in the cost of new Freon. Since the capital cost was only $25,000 to begin with, AEDC’s recycling project should pay for itself within two years.

AEDCC model shop streamlines its production processes to reduce hazardous wastes.

The Challenge Because they are used for wind tunnel research, the scale-model aircraft and other components fabricated by AEDC’s model shop must be machined to precision tolerances and finished free of surface defects. These processes generated 43,000 pounds of hazardous wastes annually, including acetone and 1 , 1 , 1 trichloroethane (used to clean liquid oxy- gen). An Air Force Environmental Compliance and Management Audit inspired a number of improvements.

The Solution H By removing oils and bacteria, a new “coolant wizard” now extends

coolant life by 40 percent and reduces nonhazardous wastewater by a like amount.

H To extend the life of two acid baths, the acid is now reused until it is too spent or duty to be effective. The shop installed filters to remove solids and precleaning oils. It is also considering an in- process heater to evaporate the water and reconcentrate the acid.

H The shop substituted Freon for 1,1,1 trichloroethane, then bought a Freon reclamation unit that extends Freon life sixfold.

H A fluid eliminator now collects and processes nonhazardous wastewaters.

The shop also changed the way it uses Dykem, a dyeing chemical requiring removal with acetone. By replacing the spray method of application with a dauber applicator, the shop reduced the amount of Dykem it uses and so reduces the amount of acetone needed to remove it.

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The Benefits These changes have meant a 70-percent reduction in hazardous wastes at the model shop, from a high of 43,000 pounds annually, to 11,693 pounds today. They also offset the $30,000 capital costs, yielding savings of 81 percent: $14,550 a year instead of $77,267.

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For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760

IPI

Reducing Emissions T H R 0 U G H

Pol I u t ion Prevent ion I Pollution Prevention: Tennessee's Gift for the Future I

ALUMINUM COMPANY OF AMERICA Alcoa, Tennessee (423) 977-3358

ALCOA reduces its hydrogen fluoride emissions by 90 percent.

The Challenge In 1989, ALCOA's releases of hydrogen fluoride (m topped 856,000 pounds. The company wanted to reduce the amount of HF releases to the environment.

The Solution Over the next several years, ALCOA instituted a series of changes to reduce HF releases, including:

W one-on-one employee meetings to explain the problem. W low-cost process improvements. W more control over process variability. W new emissions controls. W greater reliability in existing emissions controls.

The Benefits By fine-tuning controls and operating conditions, and adding new emissions controls, ALCOA has reduced its hydrogen fluoride releases by roughly 90 percent since 1989.

Hvdrogen .tlouride released [in thousands ofpounds1

1000 I

ALCOA reduces landfilled pallets by 66 percent.

The Challenge In 1996, ALCOA's Can Reclamation Facility generated 1,400 tons of waste wood pallets, disposing of them in the community landfill. The company averaged more than 120 pallets per month.

The Solution ALCOA's waste minimization coordinator teamed with the pallet supplier and others to find a permanent solution. Using the pallet supplier's access to various markets, ALCOA began exchanging pallets with com- petitors, repairing damaged pallets, and returning reusable pallets to the supplier whenever it took delivery on new ones. The company also installed a shredder to convert broken pallets into fuel for the local community college.

The Benefits Besides providing fuel, ALCOA's partnership with its pallet supplier has boosted industry recycling efforts. Since January 1997, ALCOA has reduced by two-thirds the number of waste pallets it sends to the landfill, and recycled 2,718 tons of wood as valued products. Moreover, the program generates enough revenue to cover both the costs and capital- ization of equipment.

Waste pullet reduction in 1997 (in tons) ~ 200 194

- 800

600

400 ,

200 50

150

100 -

I

0 0 1989 1990 1991 1992 1993 1994 1995 1996 1997 Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec



Pol I ut ion Prevent ion I Pollution Prevention: Tennessee’s Gift for the Future I

ALUMINUM COMPANY OF AMERICA Alcoa, Tennessee (423) 977-3358

ALCOA’s Tennessee plant reduces chlorine emissions by neatly 91 percent.

1 ALCOA’s Tennessee operation eliminates use of I ,I ,I 4richloroethane.

The Challenge In 1992, annual chlorine emissions from ALCOA’s smelting process totaled 65,000 pounds. The company wished to reduce this to a much lower annual value.

The Solution ALCOA embarked on a series of low-cost process improvements, con- trolling operating conditions and substituting raw materials at the source wherever possible.

The Benefits ALCOAs campaign to reduce chlorine generation has resulted in approximately 90-percent emissions reductions since 1992.

Chlorine released (in thousands ofvounds)

The Challenge In 1992, ALCOA’s l,l,l-trichloroethane (TCE) emissions reached 60,000 pounds. TCE is identified on the EPA 33/50 list as a toxic sub- stance and has been identified as a contributor to stratospheric ozone depletion. ALCOA wished to reduce or eliminate the use of TCE at its Tennessee site.

The Solution ALCOA embarked on a process change involving the substitution of a less hazardous chemical for TCE.

The Benefits By 1994, material substitutions had resulted in the total elimination of

1 TCE releases from the site.

1.l.l-Trichloroethane released {in thousands ofpoundsl

60

40 40

20 I 20

0 1992 1993 1994 1995 1996

0 1992 1993 1994 1995 1996 1997


Reducin issions T H R 0 U G H

Pollution vention I Pollution Prevention: Tennessee’s Gift for the Future I

BRIDGESTONE/FIRESTONE, INCORPORATED Morrison, Tennessee

(931) 668-5500

CHEMETALS New Johnsonville, Tennessee

(931) 535-2151

Bridgestone/Firestone’s Warren plant aims to eliminate landfilled wastes.

Plastic covers and careful accounting lower reported and actual manganese emissions.

The Challenge As a tire manufacturer, it is not sqrising that BndgestoneFirestone’s Warren plant produces large volumes of solid waste and waste lubricant, more than 11 million pounds a year. However, the plant felt that too much of this waste was being landfilled. One of the goals of the plant’s C95 Pollution Preventioflaste Reduction Costdown Project was to eliminate, eventually and entirely, its landfill dumping of waste.

The Solution By aggressively seeking recycled uses and markets for its wastes, the plant managed to divert more than four million pounds of waste material from the landfill in 1996. The company also began addressing two of its most problematic waste products, plastic wrap and uncured scrap tires.

The Benefits By the end of 1996, the pollution prevention project had moved more than a third of the way toward its goal of zero discharge to landfills. The weight of landfilled waste had dropped by 3 1.28 percent, the volume by 36.98 percent, and the actual costs of disposal by 33.64 percent. Com- bined with revenues from recycling, the project represented an annual costs savings of $288,326, a 55-percent reduction from pre-project levels. The project was so successful, in fact, that it won the 1997 Industrial Pollution Prevention Award from the Tennessee Department of Environ- ment and Conservation.

The Challenge Because Chemetals processes 30,000 tons of manganese ore each year, it operates several high-efficiency collectors to minimize particulate air emissions. Nevertheless, the plant had been reporting relatively high estimates for these emissions in its annual TRI (Toxics Release Inven- tory) report. When it came time to apply for a Title V permit under the Clean Air Act, the company decided to look more closely at its operations. The review led to two interesting discoveries.

On one hand, Chemetals found that it had been greatly overestimating its manganese emissions on the TRI report. On the other hand, it dis- covered a second source of emissions that it had not even considered: the uncovered storage pads where raw ore is held before processing.

The Solution Chemetals used the new emissions calculations to determine its actual TRI emissions for 1996. The result of these revisions was a 45-percent reduction in reported manganese emissions for the year. As for the fugi- tive emissions from the ore storage pads, that was solved easily enough. Beginning in 1997, Chemetals simply began covering the pads with plastic.

The Benefits The plastic covers are expected to reduce Chemetals’ manganese emissions by as much 50 or even 60 percent. And though the firm still errs on the conservative side when filling out its TRI reports, at least now its reported emissions are more in line with its actual ones.

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Reducing T H R 0 G H

Polluti vention I Pollution Prevention: Tennessee’s Gift for the Future I

CHEMETALS New Johnsonville, Tennessee

(931) 535-2151

New manganese purification system reduces losses, recovers trace metals and eliminates odors.

The Challenge At Chemetals’ plant in New Johnsonville, the manganese ore head feed used in the electroplating process contains traces of cobalt and other heavy metals. In order to meet tight customer specifications, these impurities must be removed prior to processing. The purification operation used reagents that precipitated the trace metals as a sulfide. There were several problems with the sulsding operation. I First, along with the metallic impurities, it removed considerable mounts of raw manganese. Second, the sullide residue became part of the plant’s solid waste stream, reportable under EPA or TRI guidelines. And third, the process created an odor that sometimes extended beyond Plant Property.

The Solution Chemetals invested in several new technologies to improve the efficiency of the sulfiding operation. The system creates a concentrate of trace metals marketable in the heavy-metals refining industry. It also reduces the odors associated with the purification process.

The Benefits Besides rescuing a great deal of manganese that would otherwise have been lost, these refinements have removed cobalt from Chemetals’ annual TRI reporting, improved its public image and saved money. Sales of the trace metal concentrate now earn the plant revenues of $500,000 a year, while odors associated with the purification process are no longer detectable.

DELTA FAUCET COMPANY OF TENNESSEE Jackson, Tennessee

(901) 427-8228

Metal recovery and water treatment systems reduce environmental impacts of electroplating.

The Challenge When Delta Faucet Company of Tennessee (DFCT) began building a new manufacturing facility in Jackson, it wished to design a more efficient waste management system. In particular, it wanted to reduce the toxic sludge from its electroplating operations, projected to be 210,000 pounds annually for a plant of that size. At the same time, the firm hoped to capitalize on the value of the chromium, copper, nickel and other heavy metals recovered from the electroplating process.

The Solution DFCT designed a series of metal recovery units, individual systems that isolate, treat and remove copper, chromium and nickel from the plating and process rinsewaters. When enough metal has collected on a filter, the “filter cake” is removed and recycled as raw material.

The Benefits The new filter system removes as much as 95 percent of the metals from the process waters. It also reduces by at least 30 percent the volume of sludge that is disposed of off site as hazardous waste. Moreover, because the remaining sludge is only one-fifth as toxic as it would have been otherwise, it requires fewer regulatory controls and less restrictive handling and disposal. Finally, the system represents a significant cost savings, not only in waste-treatment chemicals and disposal costs, but in a cleaner wastewater effluent.

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For more information, contact t h e lenticg ~ I


Pollution Prevention I Pollution Prevention: Tennessee’s Gift for the Future I

DUPONT COMPANY Nashville, Tennessee

(61 5) 256-1 400

A cyanide recovery system cuts hazardous air pollutants at DuPont’s Memphis plant.

The Challenge The hazardous wastewater from Dupont’s solid cyanides processing in Memphis had to be thermally decomposed and chemically treated before it could be discharged. As a result, the plant was emitting more than 150,000 pounds of ammonia annually, generating 35 million pounds of waste, and spending more than half a million dollars on treatment and handling.

The Solution Using new equipment designed on site, the plant now recycles the cyanide washwater and uses the recovered cyanide to make product in the adjacent hydrogen cyanide facility.

The Benefits The cyanide recovery system eliminates the need for waste treatment, streamlines labor, recovers a useful raw material and reduces the costs (mainly new raw materials and steam) associated with the treatment process. In fact, the new system saved money from the start. Capital costs of the new system were less than those of the original chemical treatment facilities.

DuPont’s Old Hickory site eliminates its use of chlorine gas.

The Challenge The DuPont Old Hickory site operates its own potable drinking water plant on Old Hickory Lake. Historically, the lake water was disin- fected with chlorine gas, a SARA 313 chemical. Because the gas tank was locatedjust 500 yards from a residential Neighborhood, use of this gas posed an array of safety, health and environmental hazards. Moreover, the 1990 Clean Air Act requires sites using chlorine gas to develop a risk management plan by 1999.

The Solution After some study, DuPont concluded that the best plan was to eliminate chlorine gas as a disinfectant and use sodium hypochlorite (bleach) instead. AU chlorine gas and associated equipment have now been removed from the site.

The Benefits Replacing chlorine gas with a liquid bleach has eliminated the potential for a catastrophic accidental release. It also eliminates the need for a comprehensive risk management plan. Finally, since the site no longer requires emergency response plans or other special handling, the switch saves DuPont approximately $50,000 a year in operating costs.

DuPont Old Hickory reduces pollution at the source.

The Challenge At DuPont Old Hickory, process wastewaters are treated at an on-site wastewater treatment facility. In 1995, a new discharge permit called for large reductions in biochemical oxy- gen demand. DuPont soon identified two major sources of BOD: ethylene glycol, a SARA 313 chemical generated as an impurity of the methanol recovery process; and acetic acid, a volatile organic compound resulting from processing inefficiencies. Though the plant recycled some of this acid, its existing recovery system was not very efficient.

The Solution A new, more efficient separation column now recovers an additional 2 million pounds a year of acetic acid. DuPont also lowered its ethylene glycol discharges simply by urging its customers to refine or monitor their methanol recovery processes. Today, many impurities are being recovered along with the methanol, and reused as raw material.

The Benefits By keeping 5 million pounds of chemicals out of the environment, the two programs have enabled DuPont to meet its new wastewater discharge limits. They also saved the plant $900,000 a year in raw materials and treatment costs; and avoided an estimated $2 million to upgrade the wastewater plant.

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Reducing Emissions

Pollution Prevention T H R 0 U G H


EXCEL OF TENNESSEE, L.L.P. Lawrenceburg, Tennessee

(931) 762-2090

Excel replaces methyl ethyl ketone with a nonhazardous chemical.

The Challenge At Excel of Tennessee, one of the steps in making automobile window assemblies is molding the urethane gaskets that seal the window glass. As the two-part urethane paint is hand-sprayed onto molds, the paint lines and nozzles tend to clog. In the past, the paint lines were purged hourly with the solvent methyl ethyl ketone (MEK). Not only is MEK hazardous and highly flammable (its flash point is 24 degrees Fahren- heit). During storage it becomes gelatinous, resulting in higher disposal costs.

The Solution To reduce the dangers and costs of using MEK without sacrificing the performance of a solvent, Excel converted to Tarksol HTF-85B to flush the paint lines. Tarksol is considered nonhazardous and non-reportable under federal rules, and, with a flash point of 200 degrees Fahrenheit, is significantly less flammable than its predecessor.

The Benefits Excel employees are no longer exposed to the hazardous fumes and fire danger of MEK, Excel’s hazardous-waste reporting burden has been lightened; and disposal and other costs have dropped from $85,000 annually to less than $10,000.

GENERAL ELECTRIC COMPANY Morristown, Tennessee

(423) 581 -0307

GE lowers VOC and HAP emissions by making changes to its paint formula.

The Challenge In the past, the cathodic acrylic electrodeposition paint line at GE gave off high amounts of both VOCs (volatile organic compounds) and HAPS (hazardous air pollutants). The principal culprits were glycol ethers, but these were an integral component of the paint. GE briefly considered switching to powder paints, but that was not an option. It would mean scrapping the existing system, and that equipment was still in good condition.

The Solution Working with a paint vendor, GE developed a low-VOC, low-HAP paint; installed an anolyte recirculating system; and installed appropriate piping to close the loop. In addition, the thermostat on the paint chiller system was raised ten degrees, increasing electrical efficiency and allowing the post-rinse pumps to operate only during operation, rather than 24 hours a day.

The Benefits Besides reducing VOCs and HAPS, the conversion also:

W improved paint quality, from color to gloss to hardness. W removed all combustible materials from the painting process. W eliminated butyl cellosolve, 2-ethyl hexanol and Surfynol as chemi-

allowed GE Morristown to avoid Title V permitting and its associ-

W eliminated permeate, keeping 450,000 gallons of wastewater out of

cal additives.

ated costs.

the wastewater treatment facility each year.

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saved significantly on power, disposal and assorted other costs, for an annual overall savings of $1 19,000.

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I For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760

Reducing Emissions

Pollution Prevention T H R 0 U G H ~ ~


GENERAL SHALE PRODUCTS CORPORATION Kingsport, Tennessee

(423) 282-4661

General Shale reprocesses boiler waste to make I 8 million concrete blocks every year.

The Challenge Every year, General Shale Products Corporation manufactures 18 million lightweight, eight-inch concrete blocks at its four facilities in Eliza- bethton, Kingsport, Bristol and McMinnville. The process consumes 275,000 cubic yards of aggregate annually. General Shale wanted to economize on its use of raw materials and promote recycling generally.

The Solution Since cinders are commonly used in building blocks, General Shale contracts with several nearby industries for the removal of cinders and bottom ash from their coal-fired boilers. General Shale processes the materials for use in the production of concrete block. Today, more than half the aggregate consumed annually-about 140,000 cubic yards- comes from these waste products.

The Benefits Factoring in the costs of transportation, handling and reprocessing, the cinder recycling program results in an economic benefit and reduces possible disposal of 140,000 cubic yards of these waste streams in local landfills. It also conserves the limestone deposits and other natural resources that would otherwise be tapped.

At General Shale, 36,000 tons of substandard brick find new life on baseball fields and garden paths.

The Challenge When you produce 850 million high-quality bricks every year, you are bound to have a few that don’t pass inspection. At General Shale F’rod- ucts Corporation, the company must deal with 36,000 tons of substandard brick every year. Though this is but a fraction of the original 1.78 million tons of raw materials used, it still presents a sizable (and poten- tially expensive) disposal problem.

The Solution The solution was to crush the bricks to varying degrees of fineness, and market it appropriately. Larger chips make an elegant cover for walk- ways, garden areas and in landscape design; smaller chips form an ideal surface for field tracks. And because they are attractive, quick-draining, and relatively maintenance-free, the fines are popular on baseball and softball diamond infields.

The Benefits Instead of spending money for possible disposal at a cost estimated to be in excess of $450,000, General Shale through reprocessing the waste stream generates an income of approximately $500,000 and keeps a bulky waste out of the landfill.

For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760 1



HECKETHORN MANUFACTURING COMPANY, INC.

Dyersburg, Tennessee (901) 285-3310

By using watebbased degreasers, Heckethorn cuts its hazardous wastes by I00 percent.

The Challenge Heckethorn Manufacturing Company makes automobile exhaust parts-nearly a quarter of a million pieces every day. To remove the greasy residue from completed parts, Heckethorn had been using trichloroethylene (TCE), a hazardous solvent. In 1996, the company shipped 61,958 pounds of the compound to a disposal facility in Mem- phis.

The Solution In 1996, Heckethom stopped using TCE and started using waterbome solvents instead. Then, to reduce the volume of oily wastewater generated by the new cleaning system, the company installed an evaporator.

The Benefits Within months of the switch to water-based cleaners, Heckethorn had gone from being classified as a large-quantity generator of hazardous wastes, to being ranked conditionally exempt. By switching to aqueous degreasers, Heckethom had cut its hazardous wastes to zero. It also saved the firm thousands of dollars in waste disposal fees, as well as the associated costs of special handling and worker training. Today, Heck- ethorn disposes of just 50 drums of used oil per month.

INTERNATIONAL COMFORT PRODUCTS Lewisburg, Tennessee

(931) 270-3348

ICP launches acrossmthe-board waste reduction programs at its Lewisburg plant.

The Challenge When International Comfort Products (ICP) decided to focus on production improvements, it meant improving many of the plant’s systems and processes, especially those that contributed to hazardous waste streams in excess of a quarter-million pounds annually over the past decade.

The Solution ICP took a number of aggressive steps to make the new cost- and waste-reduction process a reality. For instance, it:

W temporarily substituted Freon for trichloroethylene as a degreaser for air-conditioner coils-then replaced both systems with evapora- tive die lubricants in the coil fin presses, thereby eliminating the need for degreasers altogether.

W temporarily replaced 80 percent of its solvent-based paints with water-based paints, then was able to eliminate both systems by using prepainted steel and galvanized metal for all manufactured product parts. This change completely removed the use of paint from the production process.

W reformulated certain products to emit fewer volatile organic compounds.

W switched from a solvent-based to a water-based glue.

The Benefits

than 1,000 kilograms of hazardous waste per month. This year, the company plans to achieve conditionally-exempt SQG status by generating still smaller amounts of hazardous waste: less than 100 kilograms monthly. ICP has reduced its waste stream from some 254,000 pounds annually in years past, to as little as four drums a year today. Most of this waste is generated from painting the facility itself.

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ICP became a small-quantity generator (SQG) in 1997, generating less ~~

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Reducing Emissions

Pollution Prevention

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T H R 0 U G H


JONESBLAIR COMPANY, SOUTHEAST REGION Chattanooga, Tennessee

(423) 752-3000

Creative recycling efforts result in significant cost savings.

The Challenge From discarded containers to landfilled waste, Jones-Blair was spending tens of thousands of dollars a year on waste disposal. The paint and wallcovering manufacturer wanted to reduce both the costs and impacts of its various waste streams.

The Solution In a plant-wide sweep, Jones-Blair H installed a solvent recovery system. H installed conservation vents on all its bulk solvent tanks. H reformulated certain products to reduce the level of VOCs (volatile

H installed a trash compactor to reduce the volume of waste going to

1 facilitated employees’ efforts to collect aluminum cans, cardboard

H began cleaning and reusing a portion of its 1-, 5- and 55-gallon con-

organic compounds).

the landfill.

and computer paper.

tainers as raw material.

The Benefits Jones-Blair’s waste management program has improved morale, environmental performance and the bottom line. Specifically, it has saved an estimated 75 percent ($30,249) in disposal costs for solvent waste; saved $4,200 a year in landfill costs; and downgraded its rating with the state Air Pollution Control Board to that of a “synthetic minor” generator.

M&M MARS Cleveland, Tennessee

(423) 479-861 1

Constructed wetlands serve as a natural water treatment system.

The Challenge In the past, M&M Mars discharged large amounts of wastewater to the municipal treatment plant in Cleveland. The system was costly, not only in terms of disposal fees and water bills. It also put considerable stress on the environment: M&M Mars discharged 9 million gallons of wastewater every year, and hauled off 300 truckloads of sludge.

The Solution The company decided to invest in its own, all-natural waste treatment system: five acres of constructed wetlands on nearby Mouse Creek. Instead of discharging to the Cleveland POW, effluent from the plant’s aerobic pretreatment system would now flow among native cattails, bul- rushes, lilies and reeds. The plants’ natural microorganisms would act on the wastes to break down organic materials and filter out pollutants. Once purified, the water could then be reused in a range of applications. At the same time, M&M Mars was taking steps to reduce pollutants at the source, including installing a syrup recovery system and a new ozone treatment system for the water in its cooling towers.

The Benefits The constructed-wetlands project has reduced sludge disposal from 300 truck loads annually to 25; eliminated all discharges to the public sewage system; and cut water purchases in half. The wetlands also provide habitat for an array of native plants and wildlife. M&M Mars made a sizable capital investment ($2.64 million) in this and the two related projects, but so far, it seems to be worth it. Savings from all three projects average $1,730,000 a year.

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The innovative project was one of two top winners in the 1996 Indus- trial Pollution Prevention Award competition sponsored by the Ten- nessee Department of Environment and Conservation.

r For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760


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MCKEE FOODS CORPORATION Collegedale, Tennessee

(423) 238-71 11

MURRAY, INC. Lawrenceburg, Tennessee

(931) 762-0100

By sorting and selling recyclable materials, McKee Foods cuts its landfilled wastes by half.

The Challenge As the maker of Little Debbie Snacks and other packaged eatables, McKee Foods generates a lot of solid waste-up to 1,800 tons a year of paper, plastic, stretch wraps and so on. The company wanted to minimize its disposal costs as well as its impact on the environment.

The Solution In 1997, McKee invested $85,000 in a s m d (36’ by 36’) Materials Recovery Facility (MRF). Paper is sorted into three types-corrugated, office and kraft bags-while plastic is sorted into PET (polyethylene terephthalate, which includes the stretch wraps) and LDPE (low-density polyethylene). All of these items are sold to recycling firms.

The Benefits In the first year of operation, McKee saved $15,673 in trash compactor pulls, avoided $13,587 in landfdl tipping fees, and achieved a 4Gper- cent reduction in materials being landfilled. The trash compactor that was once pulled six times a week now goes to the landfill only half as often. Today, the only materials being landfilled are wrapper film, wastes from the employee break room, plastics heavily contaminated with food inpdients, and fiber drums heavily soiled with peanut butter.

Because the mini-MRF can be operated by two employees with mini- mal training, it required no additional staff. Best of all, instead of paying disposal fees, McKee is actually making money from its trash. Last year, sales of recyclables exceeded $1 10,000.

Replacing liquid paints with powder coatings lowers Murray’s VOC emissions by 93 percent and saves more than $1 million in paint sludge disposal.

The Challenge For years, liquid coatings produced the hard, shiny finish on Murray bicycles and lawn mowers. However, the paint process also produced significant amounts of volatile organic compounds (VOCs) and waste paint sludge.

The Solution In 1988, Murray was among the first in the industry to start using nonhazardous powdered coatings, beginning with its line of riding mowers. Though the switch was expensive in terms of research, development and capital investment (Murray had to buy the equipment that applies the powder as well as the ovens that fuse it into a solid coating), it immediately reduced VOC emissions. The following year, Murray added push mowers to its list of powder-coated products, followed by bicycles in the 1990s. Today, more than 80 percent of Murray bikes are powder-coated, and the percentage continues to rise.

The Benefits Before 1988, Murray’s VOC emissions averaged 1,080 tons a year. That figure has dropped by 93 percent from 1986-1987 levels, to less than 47 tons today. Altogether, 1,412,800 pounds of emissions have been eliminated from the coating of bicycles, and 748,000 pounds from the coating of lawn mowers. Moreover, because the company now sprays, on average, only 22,800 gallons of paint a year, it has reduced its paint sludge generation by 3,000 barrels, saving more than $1 million annually in disposal costs.

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Pollution Prevention I Pollution Prevention: Tennessee’s Gift for the Future

NASHVILLE ELECTRIC SERVICE Nashville, Tennessee

(61 5) 747-3781

NES finds a beneficial reuse for its wood utility poles and reduces landfill volume by 70 percent. ~

The Challenge Every year, Nashville Electric Service must replace about 2 percent of its 185,000 wood utility poles. Although the public typically purchased a fifth of the old, creosote-treated poles, the remaining 80 percent were disposed of in a landfill. To the NES environmental team, the challenge was to reduce the volume going to the landfill while also finding a feasi- ble, beneficial reuse.

The Solution The problem inspired multiple solutions, including: H longer service life. The NES team found that poles receiving an

additional in-service treatment with an antifungal agent lasted up to eight years longer than poles that did not receive the secondary treatment.

H an anti-buildup sawmill. An NES contractor developed a propri- etary, environmentally safe method for sawing the poles into usable lumber without the usual sticky buildup of creosote on the saw blades.

H reuse as an outdoor building material. After they have been squared off in the mill, the poles can be used for decking and other outdoor projects, while the sliced-off sides are marketed as weather-resistant siding for bams and sheds.

The Benefits Thanks to this project, NES has reduced both its storage and disposal costs as well as its risk of personal injury liability. The volume of poles being landfilled has shrunk by 70 percent a year, with a targeted 90-percent reduction likely by 2000.

PHILIPS CONSUMER ELECTRONICS COMPANY

Greeneville, Tennessee (423) 636-51 00

Philips shows its commitment to environmental management by gaining IS0 14001 certification.

The Challenge IS0 14001 is the world’s first (and only) uniform standard for environmental management systems (EMS). Though 3,000 companies world- wide have been certified, very few of these firms are in the United States, and barely a half-dozen are in Tennessee. However, since Philips Consumer Electronics does much of its business overseas, the company felt it was important to gain international certification.

The Solution With support from its parent company in New York, Philips embarked on the lengthy road to certification. The process involved not only extensive training and documentation. It also meant adjusting certain processes to meet IS0 14001’s strict standards for accountability, uni- formity and compatibility.

The Benefits Last year, the Tennessee Department of Environment and Conservation recognized Philips’ efforts by naming the company a joint winner of its 1996 Industrial Pollution Prevention Award. Besides giving Philips a rare distinction, IS0 14001 certification has assured the company equal footing in an increasingly global marketplace. For customers, regulatory agencies and fellow businesses, certification should inspire a fair measure of confidence in Philips’ products, policies and procedures.



Pollution Prevent ion I Pollution Prevention: Tennessee’s Gift for the Future .I

QUEBECOR PRINTING, L.P. Memphis, Tennessee

(901) 348-651 0

Quebecor reduces toxic air emissions.

The Challenge When you are dealing with 30-year-old gravure presses, it isn’t easy to recover used solvent. Yet Quebecor’s Memphis plant wanted to reduce its toxic air emissions, especially toluene and xylene from the printing process, while remaining profitable.

The Solution Quebecor took a number of actions, including: H tightening administrative control monitoring and operational proce-

H installing ducting to exhaust vapors from the proof press. H plumbing its ink tanks, solvent storage tanks and truck loading

H installing additional exhausts from the gravure presses. H installing variable-speed motors in the adsorption system and

dures.

facility back to the carbon adsorption system.

adding and balancing the carbon.

The Benefits The changes helped Quebecor comply with the 1999 MACT standard, increased production, and lowered toluene and xylene emissions by 40 percent.

Toluene and xylene released (in thousands ofuounds)

1,887 z , w

1,500

1 , m

500

n

Quebecer designs press blade scavengers to reduce waste print solvent.

The Challenge All gravure presses have a laminar air flow along the paper web surface area. This boundary layer of air contains high levels of printing solvent. Quebecor was losing solvent at the doctor blade print nip area because these presses at the Memphis plant were designed 40 years ago, when there was no need to capture used solvent.

The Solution Using exhaust measurements and calculations, a committee of Que- becor employees designed a “scavenger bar” to recover used solvent. Mounted near the doctor blade, the bar covers the full width of the web and exhausts to the solvent recovery system. Yet the press operator can work around it safely.

The Benefits Quebecor estimates that it captures nine pounds of solvent per press, per scavenger, per day. With six scavengers on each of five presses, this works out to 270 pounds of recaptured solvent daily, for an annual savings of $17,600. Since the scavengers cost $140 each, ($4,200 total), Quebecor’s return on investment exceeds 400 percent. Even better, the scavengers improve printability and reduce employees’ potential exposure to the solvent.

” 1989 1990 1991 1992 1993 1994 1995 1996




SATURN CORPORATION Spring Hill, Tennessee

(931) 486-5000

Quality controls allow Saturn to reduce its use of paintdeaning solvents.

The Challenge Painting vehicle components is a three-step process that begins with a primer coat, followed by a water-based (color) base coat, followed by a two-part clear (top) coat. Various solvent mixtures are used to clean the paint delivery system and purge the spray application equipment. The spent solvents, including chemicals such as ketones and alcohols, are collected in a 7,500-gallon storage tank and eventually transported off site. At the off-site facility, usable solvents are reclaimed via distillation, remanufactured, and returned to Saturn. As efficient as the system is, Saturn wanted to reduce further its use of solvents as well as their waste stream.

The Solution While the fundamental painting process remained the same, Saturn made a number of improvements. It improved first-time paint quality, upgraded production output, and implemented a system for tracking and measuring use.

The Benefits W The changes have reduced waste solvent production from 4.1

W Safety and environmental risks have been lowered, both on-site and

! Saturn has saved $78,000 in raw material costs. W The system has improved both productivity and operational effi-

Because waste solvents still represent more than 75 percent of Saturn’s total annual hazardous waste generation, the company is looking into various other improvements, such as material substitutions, that will further minimize health and environmental risks.

pounds per car to 2.4 pounds.

Off.

ciency.

Color injection molding eliminates some painting.

The Challenge In the past, Saturn produced colored interior car parts by injection- molding them in black plastic substrate, then painting them. To prepare them for painting, the parts were sent through an alkaline wash, followed by a water rinse and a deionized water rinse. The cleaned parts were then dried in an oven, cooled to ambient temperature, and sprayed with a water-based paint. Only after the painted parts were flash-cured and oven-dried a second time were they finally ready to be installed.

The Solution A new process, implemented in July 1996, eliminated the need for painting injection-molded interior parts. Interior parts are now molded in natural, clear plastic, with color concentrates and ultraviolet stabiliz- ers added during the molding process to achieve the desired colors. Parts produced in this manner are ready for immediate assembly.

The Benefits Besides speeding up the production process, tightening inventory controls and increasing throughput, the change:

W eliminated 17 tons a year of air emissions, 290 tons of hazardous chemicals and 260 tons of paint waste. eliminated workers’ exposure to hazardous chemicals.

W saved more than $148,400 in reduced raw material and waste man-

i reduced operational and per-pat costs. W improved the consistency and quality of the product.

agement expenses.

1 For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760


Pollution Prevention I Pollution Prevention: Tennessee's Gift for the Future I

Teksid reuses foundry sand in aluminum cylinder head production and on Tennessee highways.

TEKSID ALUMINUM FOUNDRY, INC. Dickson, Tennessee

(615) 446-8110

New water scrubber does away with hazardous scrubber solution waste.

The Challenge In an average year, Teksid Aluminum Foundry produces nearly two million automotive cylinder heads. The process generates almost 85 million pounds of solid waste in the form of resin-coated foundry sand. Though not hazardous, the sand presented a major disposal question.

The Solution TAF developed, built and installed a closed-loop sand reclamation system that heats the sand to 500 degrees Centigrade in a fluidized bed. Once the resin has been thermally removed, the sand is cooled, screened and transported to storage silos for later reuse.

The Benefits The new system has enabled Teksid to reuse 95 percent of its sand on site. But even the remaining 5 percent is not wasted. Contractors for the Tennessee Department of Transportation buy the sand for use in road- building projects.

The Challenge The major hazardous waste generated at Teksid Aluminum Foundry, Inc., is a triethylamine and sulfuric acid scrubber solution, a corrosive

operation of air emission control equipment for Teksid's sand core production process. The scrubber solution was hazardous for corrosivity and was shipped off site for hazardous waste treatment and disposal.

~ chemical compound. This scrubber solution is generated during the

The Solution In 1995-1996, Teksid installed a new primary scrubber for the sand core process, leaving the old scrubber as a 100-percent backup. State-of-the- art process controls on both scrubbers allow Teksid to control air emissions more precisely as well as prevent the scrubber solution from becoming hazardous. The nonhazardous solution can then be shipped back to the triethylamine manufacturer to be reprocessed for reuse.

The Benefits In 1995, Teksid produced 915,724 pounds of hazardous scrubber solution waste. By 1996, that figure had dropped to 32,400 pounds, and last year, it disappeared entirely. Moreover, since the scrubber solution is no longer hazardous, it is returned to the manufacturer, who reprocesses it and sells it back to Teksid and other foundries.


Reducing Emissions T H R 0 u G H


TENNECO PACKAGING Counce, Tennessee

(901) 689-1356

Tenneco recycles old cowugated containers, then uses the teject material as boiler fuel.

The Challenge Virgin lumber provides only a part of the raw material for Tenneco’s pulp and paper production. The rest comes from old corrugated containers (OCC) purchased from recycling centers. Though the mill consumes 500 tons of recycled boxes daily, there is always a big pile of reject material-plastic, Styrofoam, tape and damaged paper fiber-that cannot be used in paper production. This reject material, comprising as much as 10 percent of total OCC volume, was traditionally sent to the landfill. Tenneco’s Millwide Recycling Team convened a special task team to find a more suitable end for the OCC rejects.

The Solution On the team’s recommendation, Tenneco decided to use the material as an altemative fuel in the mill‘s power boiler. The task team developed a procedure to separate the material and convey it to the boiler. However, the mill also had to have permission to burn the product from the state Division of Air Pollution Control. It requested, and received, a variance to allow a trial burn. The trial was successful, and the mill got its permit.

The Benefits During 1996,63 percent of the OCC rejects were burned as an alternative fuel. (The unused portion contains wire used to bale the OCC, so is not suitable as a fuel source.) The project kept 27,300 cubic yards out of the landfill, avoided $273,000 in disposal costs, and contributed an estimated $80,625 in fuel value.

A millwide recycling team agrees to buy a distillation unit to reuse solvent.

The Challenge At Tenneco’s pulp and linerboard mill, solvents used for cleanup in the paint shop were sealed in drums, then disposed of as hazardous waste.

The Solution Tenneco put the disposal question to a task team of painters and environmental managers. On their recommendation, Tenneco installed a distillation unit that cleans and recovers dirty solvent. The process leaves only a small amount of solids to be disposed of.

The Benefits In 1996, Tenneco recycled 632 gallons of used solvent; of these, 486 gallons were suitable for reuse. By recycling solvent instead of buying new, Tenneco saved $1,890. It also avoided $3,756 in disposal costs, reduced the amount of hazardous waste reported to regulatory agencies, and set a good example for staff and the larger community.

For more information, contact the Tenne __I__ I



TENNESSEE ARMY NATIONAL GUARD Nashville, Tennessee

(61 5) 31 3-0606

Mobile fuel-filtering systems save thowands of gallons of contaminated fuel.

The Challenge At the Tennessee Army National Guard (TNARNG)., it is not uncommon for tanks, bulldozers, helicopters and even Howitzers to sit idle for months. During this downtime, a fungus may grow in the fuel system, clogging the lines and contaminating several hundred gallons of diesel or other fuel. Running the engines without first purging the system can do still more damage.

The Solution In 1996, the TNARNG acquired the first of three mobile fuel-filtering systems (FFS). Using household paper towels (Bounty@!) as a filter, the system traps the fungus, along with water and any other contaminants. The used filter does not require special handling or disposal.

The Benefits By salvaging large quantities of fuel, the FFS eases the demand on a limited natural resource. It keeps thousands of gallons of petroleum products out of the environment. And, though the systems cost taxpayers about $20,000 each, they are worth many times their purchase price in fuel dollars saved and dis-

TNARNG replaces hazardous solvents with aqueous washers.

The Challenge The Tennessee Army National Guard main- tains thousands of vehicles, aircraft and arma- ments at its twenty maintenance shops throughout the state. To clean gears and other metal parts, workers would dip the part (often with their bare hands!) into a sort of open sink filled with mineral spirits, a hazardous solvent. So high was the volume of use that the National Guard was classed as a large-quantity generator, responsible for 80,000 pounds of hazardous waste a year.

The Solution Starting in 1996, TNARNG maintenance shops stopped using hazardous solvents and switched to water-based cleaners instead. It also began phasing out the manual, sink-type parts washers in favor of automatic jet-spray units that operate more like a dishwasher.

The Benefits Having eliminated a major portion of its hazardous waste stream, the TNARNG is no longer classified as a large-quantity generator. The switch has already saved $30,000 a year in operating and disposal costs. As for the automated washers, they are saving not only the workman’s time; they may be saving his

posal costs avoided. ~ skin. I

Recycling antifreeze protects the environment and saves money.

The Challenge The Tennessee Army National Guard operates an estimated five thousand to six thousand ground vehicles. To keep this fleet running properly, the antifreeze in each vehicle must be changed every other year. Assuming an average of two gallons of antifreeze per vehicle, the maintenance program was having a significant, if not strictly hazardous, impact on the environment.

The Solution In late 1995, the TNARNG bought six antifreeze recyclers. Though they cost a total of $30,000, the units neutralize the pH of the antifreeze, remove any iron and particulate matter, and otherwise bring the product back up to useable standard. They also work fast- one unit can process 50 gallons an how-and are portable enough to be hauled to any of the guard‘s facilities statewide.

The Benefits Besides the obvious benefit of keeping

ment, the system also saves money. Even at the bargain rate of a dollar per gallon for new antifreeze, the recyclers will have paid for themselves in five or six years.

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ethylene glycol antifreeze out of the environ- ~

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I For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760 I



TENNESSEE DEPARTMENT OF TRANSPORTATION Nashville, Tennessee

(61 5) 741 -2331

Concrete from an old tunnel is being used to build its replacement.

The Challenge When the Tennessee Department of Transportation decided to replace the old Winchester Tunnel that runs beneath the Memphis airport, it meant finding a resting place for 28,000 cubic yards of busted-up concrete and several tons of bent and twisted rebar. In the past, the contractor would probably have hauled the debris to a landfill or interred it on site. This time, the builders wanted to make more thoughtful use of the construction debris.

The Solution At the suggestion of a third party, TDOT and the project contractor agreed to break up the old concrete, remove the steel rebar, and use the crushed rock as bacHll to stabilize the new tunnel. To ensure that the recycled concrete is stable and durable enough to be used in a vital public transportation structure, TDCYT engineers wrote a customized specifi- cation for it. As for the salvaged rebar, it will likely be sold to a metals recycler.

The Benefits In sandy west Tennessee, rock is a scarce commodity. By reusing the old concrete, the Winchester Tunnel project conserves a none-too-plen- tiful resource. Likewise, for every ton of rebar it recycles, the tunnel project saves the equivalent in raw materials, to say nothing of the production emissions represented by so much steel. The project also saves money: the estimated benefit to the American taxpayer already stands at $200,000. And finally, it saves space. Instead of languishing in a landfill for the next few eons, the concrete that once supported the old tunnel will serve the same function in its new life.

TDOT's creative dewatering system protects a river and its endangered mussels.

The Challenge TD(YT contractors encountered a problem while building the State Route 52 bridge over a steep, narrow gorge of the Clear Fork River, on the Cumberland Plateau. When they dug the hole for one of the subfoot- ings, they noticed that the water refilling the pit was cloudy, almost milky-white. Apparently they had penetrated a layer of shale that produced this turbid runoff. Though the footing hole was 33 feet deep and 60 feet from the river's edge, TDOT's environmental staff were con- cerned that the sedimentation would pollute Clear Fork, known habitat for a federally endangered mussel called the Cumberland elktoe. There was also a risk to water quality in the surrounding Big South Fork National River and Recreation Area.

The Solution Borrowing from a system already in use at one of its interstate rest areas, TDOT's engineers decided to pump the water out of the hole and spray it upland. The system consisted of two pumps (one at the bottom of the hole and one at the top); 350 feet of quick-disconnect water hose; and several 600-foot branch lines, each fitted with a fire nozzle. The nozzles were placed in the forks of trees, aiming their spray uphill. When the ground grew saturated from one branch line (usually after 24 hours of constant watering), a valve in the main line would redirect the flow to a different line.

The Benefits The system worked so well that neither the Cumberland elktoe nor the Clear Fork itself appear to have suffered from the runoff. Both the National Park Service and the state water pollution control division have commended TDOT's inventiveness, and the egency is now looking at using the system in other applications.

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1 For more information, contact the Tennessee Department of Environment and Conservation at (61 5) 532-0760



TENNESSEE EASTMAN DIVISION, EASTMAN CHEMICAL COMPANY Kingsport, Tennessee

(423) 229-2000

Tennessee Eastman reduces solid waste by 744,000 pounds per year.

The Challenge Tennessee Eastman’s Acetate Tow Division uses a filtration process in its manufacturing operations. In the past, the filtration process used both disposable and reusable filter media, and generated an average 92,000 pounds of nonhazardous waste per month. This waste was incinerated on site.

The Solution A fileation optimization team recommended changes that included the use of reusable filters exclusively, as well as certain process motlilications.

The Benefits The two strategies have reduced solid waste by 744,000 pounds a year.

Eastman reduces its acid waste stream by 730,000 pounds.

The Challenge In the acid concentration department at Ten- nessee Eastman, a single rotary vacuum blower serves all the distillation columns in one building. Because the blower was on the bottom floor of a multistory complex, acid vapors from the columns condensed in the water stream that seals the blower. This water eventually discharged to Eastman’s wastewater treatment plant.

The Solution By relocating the vacuum blower to the sev- enth floor, Eastman initially hoped to decrease the amount of acid discharged to the wastewater treatment plant. In fact, the move eliminated the waste altogether. Eastman’s team renovated the blower in such a way that the

Eastman uses SPC to improve pep formance and reduce waste.

The Challenge A process review in Tennessee Eastman’s Polymers Division identified a significant waste minimization opportunity.

The Solution In an effort to reduce the amount of total organic carbon being discharged to the wastewater treatment plant from its manufacturing operations, the Polymers Division developed an interceptor sewer statistical process control (SPC) strategy. The strategy relies on improvements in monitoring, training and discharge controls.

acid can now be recovered and the water recycled.

The Benefits Between the new equipment and the modified processes, Tennessee Eastman’s Cellulose Esters Division keeps 730,000 pounds of organic carbon out of its wastewater treatment plant.

The Benefits The SPC strategy has reduced by 365,000 pounds a year the total organic carbon sent to the wastewater treatment plant. As a bonus, the project also provides easy access to process discharge data, allowing operators to respond more quickly to operational control problems.




TENNESSEE VALLEY AUTHORITY Chattanooga, Tennessee

(61 5) 751 -3522

TVA% Shawnee power plant cuts its use of oil absorbents by 25 percent.

The Challenge At TVA, absorbent pads are used underneath heavy equipment and machinery to collect fluid leaks and small spills and to keep used oil from entering floor drains and ultimately into the environment. They also prevent a safety hazard due to slippery floors. TVA's Shawnee fossil plant typically spent about $75,000 annually to properly dispose of these spent absorbents.

The Solution TVA's multistep response included

explaining ways to avoid them. H training employees to recognize the impacts of oil absorbents and

H developing a procedure to report and repair leaks. H buying more durable pads. H buying colored pads as opposed to white ones, because employees

tended to discard white ones long before they were used up.

The Benefits TVA's efforts resulted in: H a 25-percent reduction in the use and disposal of oily absorbents. H an annual cost savings of approximately $20,000. H an expedited procedure to identify and repair oil leaks.

TVA's Cumberland plant recycles gypsum into wallboard.

The Challenge Several years ago, TVA added flue-gas scrubbing equipment to its Cumberland fossil plant, the largest coal-fired steam electric plant the agency operates. The new scrubbers cut air emissions, but they also created more than a million tons of synthetic gypsum as a byproduct. TVA began at once to seek a market for this valuable material, but in the meantime, it continued to pump the gypsum into holding ponds.

The Solution TVA negotiated a three-party arrangement whereby the synthetic gypsum will be used to make a premium wallboard product. Under this partnership, TVA will supply the synthetic gypsum to a dewatering facility currently being built by one of the partners. Once dried, the gypsum will then be transported to a new, state-of-the-art wallboard plant, one of the largest in North America, that is now under construction by the third partner. Both the dewatering facility and the wallboard plant are being built solely with private funding.

The Benefits TVA as well as the local community will realize several significant benefits from this arrangement, including: H decreased landfill requirements and disposal costs.

H improved safety conditions thanks to fewer slip hazards. H for employees, a heightened awareness of pollution prevention and

a steady revenue source for the Cumberland steam plant. a useful source of raw material for the wallboard industry.

~ conservation of the natural resources that would have been depleted

~ H as many as 146 new industrial jobs in the region, as well as numer- '

-

its benefits. by mining natural gypsum.

ous jobs in service-related industries and trucking. -

~

~


Ea

Reducing Emissions

80

60

40

20

0

T H R 0 U G H

19 11

0


VISKASE CORPORATION Loudon, Tennessee

(423) 458-2071

Viskase’s Loudon plant recycles cellulosic casings.

The Challenge Viskase’s Loudon plant is the world‘s largest producer of small cellulose casings for the meat industry. With production in excess of 11 million pounds of semi-finished casing annually, the disposal of as little as 1 percent of this waste could take up valuable landfill space. Unfortu- nately, the dry waste film cannot be recycled into more casing due to the nature of the viscose process.

Semi:finished casing recvcled (in thousands ofuounds)

1995 1996 1997 thruY98

The Solution Viskase fbund another company that could take any and all of its clear, dry waste, then grind it down for use as a feed stock in the production of sodium carboxyl methyl cellulose (CMC). For the cost of transportation, this other company now has a reliable source of cellulose which it can reprocess to make CMC.

The Benefits The local community benefits by conserving landfill space, and Viskase benefits by avoiding the cost of tipping fees at the landfill. Finally, by recycling this waste instead of using wood pulp as a cellulose source in CMC, the project also saves a few trees.

WESTVACO CONSUMER PACKAGING DIVISION

Cleveland, Tennessee (423) 479-9783

By using less hazardous solvents, Westvaco drops its toluene emissions below reportable levels.

The Challenge The Westvaco Consumer Packaging Division facility in Cleveland had to use toluene in its printing operations. The chemical was used prima- rily in a single, high-volume coating and was required to keep certain particulates in suspension during the printing process. The toluene was also necessary to promote efficient operations in the solvent recovery process which removes solvents from the exhaust air stream.

The Solution Working in conjunction with the coating supplier, Westvaco personnel engineered ways to substitute less harmful solvents for toluene with no effects on the printing process or impacts to product quality.

The Benefits The facility has reduced TRI-reportable emissions by more than 98 percent since 1988. Releases of toluene specifically, which is a TRI- reportable chemical, have dropped from more than 52,000 pounds in 1992, to below reportable levels in 1997. In short, the company greatly exceeded EPA’s challenge to reduce toluene by 50 percent.




WHIRLPOOL CORPORATION LaVergne, Tennessee

(61 5) 641 -751 1

Improvements to Whirlpool Corporation’s metal finishing operations reduce water and chemical usage and waste disposal.

The Challenge Since the 1992 creation of its Environmental Partnership award, Whirlpool Corporation’s LaVergne Division has successfully developed and implemented numerous environmentally-friendly process improvements by working together with its suppliers. One of the most recent efforts focused on process improvements relating to the metal finishing operations. A team of operators, suppliers and engineers worked together to identify opportunities to create a healthier work environment, decrease water and chemical usage, reduce waste generation and improve process efficiency.

The Solution The Whirlpool LaVergne Division significantly reduced water usage by redesigning portions of its metal finishing system to include additional recovery and reuse opportunities. Bath life was extended by installing two oil coalescing units on the cleaner baths and bag filters on the E-coat rinse tanks. The division also replaced existing deionized water units with a reverse osmosis system, virtually eliminating the use of hydrochloric acid and sodium hydroxide. When combined, these improvements resulted in a significant decrease in wastewater pretreatment operation and sludge generation. Additional process improvements include: I conversion to more environmentally-friendly chemicals. I replacement of the phosphate system’s traditional steel piping with chemical-resistant CPVC piping with clip-on nozzles. I a more effective way of acquiring metal pretreatment chemicals: purchasing them in 300-gallon (bulk) packaging instead of drums. I improved definition of process map and procedures. This minimizes bath variation and improves consistency of bath conditions within specified

These modifications support the division’s process improvement objective by minimizing chemical usage and handling, as well as reducing extensive monitoring and maintenance requirements.

control parameters.

The Benefits By decreasing its use of water and chemicals, Whirlpool Corporation has been able to reap considerable benefits, including: I a 44-percent reduction in water usage since 1994, with the expectation of an additional reduction in 1998. I decreased handhg of hazardous chemicals resulting from an estimated 19-percent reduction in metal-finishing chemical usage. I an average decline of 50 percent in hazardous waste generation for the past three years. I a savings of approximately $388,000 a year in labor, materials, utilities and waste disposal.




WILLAMETTE INDUSTRIES Kingsport, Tennessee

(423) 247-71 11

Willamette reduces particulate emissions and odor with refurbishments and replacements.

The Challenge The chemical recovery furnace system at Willamette Industries’ Kingsport mill was operating inefficiently. This resulted in higher emissions levels as well as increased odors, which in turn drew complaints from the community.

The Solution As soon as it acquired the mill in 1995, Willamette teamed with Ten- nessee regulatory officials to resolve the situation. Engineering staff began making plans to install a new precipitator and refurbish the existing control system, while management agreed to meet stricter limits for opacity and particulates.

The Benefits The project offered a number of benefits, including:

W particulate reductions of 38 tons annually. W reduced odor emissions. W reduction of opacity limits from 50 to 35 percent. W enhanced working relationships with state regulators. W enhanced community image and relationships. W reduction in community complaints and concems.

Beneficial reuse of waste bark and wood residue reduces landfill use by 80 percent.

The Challenge When Willamette’s Kingsport mill discontinued whole-tree chipping in 1992, the modernization resulted in a new waste stream of removed bark. Though the bark could have been burned to produce energy, Willamette did not yet have a biomass boiler. Therefore, the mill had to rely on shrinking landfill space for disposal.

The Solution Willamette assembled a team to assess this challenge and work with state regulators. Together they determined that the waste bark could be ground into commercial mulch suitable for nursery and landscaping use.

The Benefits By recycling a bulky though nonhazardous material, the mill eliminated disposal costs, reduced the burden on the local landfill by 9,600 cubic yards, and earned the community’s respect.


Reducing Emissions

H expanded, relocated and modernized mill processes to further con-

H strengthened ties and teamwork with local regulatory officials. replaced an abandoned brownlield site with a view considerably more attractive to passing motorists and the community at large.

trol environmental emissions and concems.

1

T H R 0 U G H

Pollution Prevention I Pollution Prevention: Tennessee’s Gift for the Future

WILLAMETTE INDUSTRIES Kingsport, Tennessee

(423) 247-71 11

Boiler replacement improves energy efficiency and reduces waste emissions by 75 percent.

Willamette’s brownfield site reclaims and eliminates i high pH runoff.

The Challenge The Kingsport mill operated four vintage coal-fired power boilers. These boilers were expensive to operate, emitted excessive amounts of waste, and produced an ash that was high in volume and carbon con- tent. Because of the high carbon, the ash could not be reused benefi- cially, so it had to be discarded in an industrial landfill. Moreover, such old boilers were not equipped to burn bark or sludge, waste products that might otherwise offer a cheap alternative source of energy.

The Solution Willamette decided to replace the coal-fired boilers with a biomass fuel boiler. Thanks to early and open communication between mill personnel and state regulatory officials, the mill was issued a pre-construction permit within 90 days.

The Benefits H The new boiler reduces annual nitric oxide emissions by 452 tons,

lowers sulphur dioxide emissions by 1,478 tons, and reduces particulate emissions by 91 tons, for combined reductions in excess of 75 percent annually.

H Landfill requirements have dropped by 32,970 cubic yards a year. H The new boiler turns waste bark and sludge into energy and pro-

duces power and steam with greater efficiency.

The Challenge Until 1978, a cement kiln was in operation on property acquired in 1995 by Wdamette’s Kingsport mill. Kiln dust from the operation was landfilled on site, in waste piles up to 60 feet deep. Rainwater percolating through the kiln dust created a high-pH leachate which was polluting the South Fork of the Holston River. State regulatory officials had had no luck getting the former owners to correct the problem.

The Solution In cooperation with state regulatory officials, Willamette eventually reclaimed this brownlield site. They capped the area with a liner and topped it with clay, sludge and bark. They hauled off asbestos and old fuel tanks and demolished a number of old buildings. As for the leachate, that was collected and treated in the mill’s wastewater system.

I For more information. contact the Tennessee DeDartment of Environment and Conservation at (61 5 ) 532-0760

Reducing Emissions

The Challenge For 40 years at least, Yale Security had used trichloroethylene (TCE) in

T H R 0 U G H

After looking closely at various altematives (including the possibility of retrofitting existing equipment), Yale installed two new aqueous degreasers in 1996. The capital cost was about $SOO,OOO. However, fac-

Pollution Prevent ion I Pollution Prevention: Tennessee’s Gift for the Future i

Y-I2 PLANT, LOCKHEED MARTIN ENERGY SYSTEMS, INC.

Oak Ridge, Tennessee (423) 241-2581

YALE SECURITY INC. Lenoir City, Tennessee

(423) 988-0400

With the help of disabled adults, Y-I 2 recycles old books, old tools and old protective gear.

’ Switching to aqueous degreasers allows Yale to elimi. nate trichloroethylene.

The Challenge When the biology library at they-12 Plant cleaned out its shelves recently, it found itself with 25,000 outdated journals and obsolete sci- ence books. However, the plant’s recyclables vendor would accept the books only if their covers were first removed. The plant also wanted to get rid of several tons of obsolete carbon-paper forms, surplus sizes of protective clothing and an assortment of old gauges and hand tools.

The Solution Y-12 contacted Dunn Diversified Industries, a private, nonprofit corporation that provides employment opportunities for adults with disabili- ties. At a very small cost to the plant, DDI workers:

W removed the books from the shelves, and the pages from the books. W unpacked boxes of protective clothing, removed any identifying

labels, and repacked the items for shipping. (The clothing was donated to another country for its environmental cleanup program.)

W removed identifying marks from $9 million worth of tools and gauges so they could be donated or sold to schools.

W separated the carbon from five skids of old carbon-paper forms, allowing the white paper to be recycled.

The Benefits Between them, the four projects kept 60,000 pounds of paper out of the landfill, along with 40,000 pounds of clothing and 2G,000 pounds of tools. They saved $907,000 in handling and disposal costs and earned $2,000 in sales of white paper. In doing so, they provided meaningful jobs to adults with special needs and earned the good will of the Oak Ridge community.

The Oak Ridge Y-12 Plant is managed by Lockheed Martin Energy Systems, Inc., and the U.S. Department of Energy under Contract No. DE-AC05-840R21400.

The Benefits The most obvious benefit of the switch is that Yale can now meet new federal standards for hazardous air pollutants. (None of its old degreas- ing machines did so.) The new system also reduces Yale’s regulatory burden, both for Title V air emissions and sanitary sewer discharges. And finally, there is the added benefit of improved morale.


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Documents

The Tennessee Pollution Prevention Roundtable - …infohouse.p2ric.org/ref/26/25690.pdf · tn- Pollution Prevention % %W,& ,e ... American Lung Association DuPont Company - New Johnsonville