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

Air Quality 101 WorkshopSBEAP: Jan Role of P2 P2 opportunities can: Reduce regulatory responsibilities Reduce operating costs Reduce long-term environmental liabilities Pollution prevention assessments can help identify supplemental environmental project (SEP) options Compliance and pollution prevention are integral parts of EPA’s voluntary programs Compliance and P2 are integral parts of any EMS Compliance and P2 can help companies save money and jobs!

Air Quality 101 WorkshopSBEAP: Jan SBEAP and P2 The SBEAP can provide specialized P2 project assistance to your business to find ways to reduce air emissions from your processes by: Changing the Material Changing the Process Changing the Technology MACTs mandate technologies to achieve required emissions reductions, however, there are many opportunities to further reduce emissions through P2!

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Material Many emissions can be greatly reduced by changing to another raw material that emits less or no HAP or other regulated substances. Ingredients in product production materials: Reformulate products from powder to pellet. Use less toxic biocides instead of chlorine. Use a non- or low-HAP/VOC releasing agent Use in-process recovery processes where possible

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Material Ingredients in cleaning solutions: most utilized P2 substitution option; usually easier and cheaper, many “drop-in” replacements available that work with existing equipment Switch to a non-HAP cleaner, such as mineral spirits Toluene and xylene Switch to a solvent/water cleaner Fountain solution in printing in industry Use water and solvent in sink-on-a-drum systems Switch to an aqueous cleaner Switch to a mechanical cleaning process CO2 blasting, baking soda and water

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Material Ingredients in coating or finishing materials Switch to lower VOC coatings Switch to low- or no-HAP adhesives and coatings Switch to water-based coatings Ask for coatings with no regulated metals Finish the surface with powder coatings

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Material Case studies Solvents: reduce air emissions Trailer manufacturer uses toluene in paint-gun cleaning; material change to mineral spirits results in: No HAP emissions from cleaning process Eliminated need for air operating permit Automotive shop in Johnson County uses a high- vapor pressure solvent parts washer to clean parts; material change to a compliant, low-vapor pressure solvent results in: RACT rule avoidance and less recordkeeping

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Material Case studies Hamilton Beach/Proctor-Silex, eliminated vapor degreaser cleaning process with aqueous batch cleaning processes, eliminated 90,000 lbs. HAP, 80,000 lbs. VOC, and 2,200 gallons of F001 HazWaste.

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Process Changing the WAY you use materials can drastically impact your emissions: Review operating and maintenance practices Review management practices Initiate inventory control / material tracking program Explore production scheduling

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Process Operating and maintenance practices often provide many P2 opportunities: Cover solvent tanks and cleaners when not in use. Recover seal flushes and recycle to process. Turn off flush when not in use. Use seal-less pumps. Don’t change-out cleaners until needed. Repair leaks ASAP and establish leak detection systems. Use staged-heating to recoup heat and reduce energy needs. Shift from batch operations to continuous, if possible.

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Process How you manage materials in your processes can reduce emissions from your operations: Use a “staging” approach to reduce solvent use- Use air pressure to clean as much product from process lines to reduce contamination of cleaner. Use a dirty solvent for first-pass cleaning. Use a cleaner solvent for final- or intermediate- cleaning Recycle solvent to reclaim virgin solvent Can reduce solvent purchase costs by 90% Can reduce hazardous waste disposal significantly Examine layout of facility; does material flow minimize worker labor and time, energy use, and reduce reworks?

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Process Initiate inventory control/material tracking program to ID specific work practices or process associated with excessive material use. Limit regulated solvent’s use by employee and purpose. An “open” stock room, invites overuse and misuse! Review materials use at each stage of production. Ask employees’ help in reduction strategies and offer incentives for raw materials use reductions—they do the job, and know where wastes can be cut.

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Process Production scheduling often results in excessive material use and waste generation. Schedule coating from light to dark to reduce line cleaning. Review scheduling and production flows to make sure your paint line doesn’t change colors excessively or prematurely Establish separate color lines to reduce color change out and line flushing

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Process Case Studies Changing material flow, process layout, and work practices Custom wood finishing changes to a mix-at-gun coating delivery system; eliminated >50% of solvent used to wash 25’delivery lines; reduced haz waste by 43% with a 38% production increase. Printer used excessive amounts of press cleaning solvents; company implements a solvent “check-out” inventory control and changed to “dauber” dispenser cans; estimated 50% reduction in solvent use. Wood product manufacturer: identified $900,000 savings potential on rejects, wood waste and labor reductions based on process layout changes.

Air Quality 101 WorkshopSBEAP: Jan P2: Change the Technology Technology changes can include the following: New equipment that is more efficient, uses less energy, has leak detection systems. New equipment that changes the way your product is produced: Automated processes that uses less materials Switch to alternative materials such as powder coating or UV cured coatings Recycling systems that allow waste materials to be reused such as powder coating recycling systems that yield almost 99% transfer efficiency New process equipment or designs to improve material utilization and energy conservation

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Technology New equipment can drastically reduce emissions and/or materials use Closed-loop vapor degreasers can reduce solvent emissions by 98%. Closed-loop aqueous cleaners can eliminate solvent emissions by 100%. Closed-molding process for parts production can reduce solvent use 95%

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Technology Automated processes can reduce material use and more consistent process, while reducing workers to hazardous exposures. Alternative coating technologies can eliminate emissions: UV and powder coatings can achieve 90-98% transfer efficiency with no solvent use High-volume, low-pressure spray guns can reduce overspray by 20-40%, resulting in less materials use, less emissions.

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Technology Case Studies Alternative equipment and materials Fleet management operations P2 assessment identified $4000 savings for energy recovery from used oil with oil space heaters Boat manufacturing operation changed to solvent recycle system saved $72,000 in solvent purchases and reduced 137,000 tons of hazardous waste at a cost savings of $41,000

Air Quality 101 WorkshopSBEAP: Jan P2 Change the Technology Case Studies Lockheed Martin changed from vapor- degreasing parts to a closed-loop cleaning system; initial investment costs: $88,000 eliminated solvent use for parts cleaning process, reduce Decrease water use and sewer discharge by 2 million gallons Wash and rinse water life is ~ 18 months Waste reduced to 165 gallons/year.

Air Quality 101 WorkshopSBEAP: Jan P2 in the Emissions Reduction For more information about P2 opportunities for your business, please visit the Pollution Prevention Resource Exchange network and topic hubs Web site: Or call the Kansas SBEAP for detailed assistance with air permit questions and emissions reduction strategies.

Air Quality 101 WorkshopSBEAP: Jan SBEAP Services SBEAP services are available throughout the state with staff in Olathe, Salina, Wichita, and Manhattan. All personnel can be contacted at Any questions?