DPA/7'42/R-93/QO'4
              REVISED EXECUTIVE SUMMARY

.  •       .       ''";'"   'JUNE  1993     ,.     .        /     ,  .-
                       - "           '      s        ,      j  •


                TOTAL COST ASSESSMENT:

 ACCELERATING INDUSTRIAL POLLUTION PREVENTION

 THROUGH INNOVATIVE PROJECT  FINANCIAL ANALYSIS

            With Applications to the Pulp and Paper Industry


                           Prepared for:

                     U.S. Environmental Agency     /            .
                Office of Policy Planning and Evaluation
                    Office of Pollution Prevention
                        Allen L. White, Ph.D.
                        Deborah Savage, Ph.D
                          Monica Becker
                        Risk Analysis Group
                          Tellus Institute
                         11 Arlington Street
                       Boston, MA 02116-3411
                          Tel: 617-266-5400
                          Fax:617-266-8303

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PREFACE

       This Executive Summary supercedes aversion originally published in a December 1991
report to EPA entitled:  Total Cost Assessment:  Accelerating Pollution Prevention Through
Innovative Project Financial Analysis, With Applications to the Pulp and Paper Industry.
This revised version includes changes to the text for purposes of clarification and completeness,
as well as new results of the financial analysis of two pollution prevention projects  in the pulp
and paper industry.  The latter changes reflect both  refinements to the analytical tool used in
the original profitability  analysis and the  availability of new data on the  costs and savings of
the projects themselves.                                     ,                            ,

       In the case of Project 1, a white water and  fiber  reuse project in a coated/fine  paper
mill the revised analysis substantially strengthens the Total Cost Assessment in relation  to the
Company  analysis  using three indicators of profitability. . The  revised analysis shows  an
increase'in Net Present Value (NPV, 15  years) from approximately  $360,300 to $2,851,930;
Internal Rate of Return (IRR, 15 years)  increases  from 21% to 48%;  and Simple  Payback
decreases from 4.2 years to 1.6 years.  In contrast, the revised analysis for Project No.  2, shows
a  TCA analysis less  profitable than the  Company analysis,  largely  owing to  substantial
increases  in utility costs  for operating an aqueous-based coating process.  NPV decreases from
approximately -$203,600 to -$395,600; IRR decreases from  11% to 6%;  and Simple Payback
increases  from 7.6 to  11.7 years.

       Taken together, the two revised analyses  reinforce the central finding of the original
study - that improved managerial accounting systems, including  accurate measurement  and
allocation of both physical and cost aspects of waste generation, are essential for achieving, a
cFear, unbiased perspective  on the profitability of industrial pollution prevention investments.
 BACKGROUND

        In its February 1991 National Pollution Prevention Strategy, EPA set in motion a series
 of initiatives  aimed at deepening and widening bom government and private sector activities
' hi pollution  prevention.   Recognizing  the inherent  limitations  of  traditional "end-of-pipe"
 approaches, the Strategy called  for joint agency-industry action to redirect resources toward
 elimination of pollutants  instead  of continued reliance on  downstream,  control-oriented
 approaches that, while effective in solving one pollution problem, often create others. Without
 a transition from control to prevention strategies, cross-media shifting of pollution among land,
 water and air will continue, and reduction of pollution from dispersed, non-point sources will
 remain extremely  difficult to achieve.

        For many firms, EPA's call for accelerated prevention served  as a reaffirmation of what
 they already knew and, to varying degrees, practiced-that in  the medium and long-term,
 pollution  prevention  generally  is' more sensible than  pollution control.   Early initiatives,


                           •    • '             1          '                       .

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beginning'  in the 1970's. were motivated-by a simple  bottom-line consideration:  .continued
•expenditures on. pollution control  investments  to .handle  steadily increasing waste  volumes
presented.' firms with the  specter  of.an' endless capital drain that would divert resources from
more lucrative opportunities in R&D, product development, manufacturing and marketing.

    '  /' By  the mid 1980s' other forces were  encouraging the  shift to prevention-oriented
strategies,   including  liability under  the • federal  Superfund  Act,  public concerns  with
environmental degradation, increasingly  stringent pollution disclosure requirements, and widely
publicized'industrial accidents in both the U.S. and abroad.  As a result, firms have faced a
'rising'tide1 of public demands for shifts to  clean technologies and environmentally  friendly
products.

       Notwithstanding pressures from various quartets, and the noteworthy progress of a few,
typically large firms, manufacturers have been slow to move away from traditional end-of-pipe.
strategies  toward more prevention-oriented practices.  If, as many argue, pollution prevention  .
nays what accounts for  this  slow pace of change?  If prevention investments  are, in fact, in
the s'elf-interest of the  firm, what accounts for the continuing reluctance to move aggressively
toward a more preventative pollution management mode? And why, in light of the publicized
benefits of pollution  prevention,  do firms, even  large  sophisticated  ones  continue to be
 surprised  when prevention-oriented  projects produce advantages to the firm far beyond those
 expected of many conventional  "must-do,"  compliance-driven  capital investments?

        The explanation  for this  apparent  contradiction seems to be  two-fold:    (1)  the
 organizational  structure and behavior  of firms inhibits pollution prevention  projects from
 entering their decision-making process from the outset, thereby precluding  these-alternatives
 from consideration by  the  firm  altogether; and  (2)  economic/financial  barriers  linked to
 methods of capital allocation and budgeting after  a pollution  prevention- project successfully
 enters  the capital  budgeting process and  competes with other projects  for  limited  capital
 resources.  A priori,  it appears that both these factors, acting  in concert,  -contribute to the
 sluggish paceof investment hi  industrial pollution prevention.

         Economic/financial barriers,  the second of the explanations we propose, is the focus of
 this study    Within a  capital  budgeting  framework,  we examine  if, and to what  extent,
 conventional  methods of investment analysis act  to impede pollution prevention projects in
 favor of  end-of-pipe alternatives. -Two projects actively under consideration  by firms in the
 pulp and paper  sector  serve  to demonstrate how different  definition, measurement  and
  allocation of project costs/savings,  longer time horizons, and  the use of multiple profitability
  indices may remove the biases inherent in conventional  financial methods.

                                ••-''.'                     r
  THE  PULP AND PAPER SECTOR

         As amajor source of industrial pollution,  the pulp and paper sector provides a useful
  context, for examining these alternative methods.  Historically, environmental regulation of the

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industn. has focused on reduction of BOD and TSS in water effluent, and particulates. sulfur
dioxide and  organic  sulfur compounds in air. ,' Reductions of these pollutants have been
achieved principally throueh end-of-pipe controls.  Nonetheless, pollution prevention is by no
means a new  concept  to^pulp and  paper firms.   In-plant recovery  and reuse of  pulping
chemicals,  for example, is an integral part of the kraft pulping process.  Other preventive
measures  include:  .in-plant fiber and water recovery and reuse in  the paper  mill, counter-
current washing in the  pulp mill,  and  dry  wood  debarking in  the woodroom.   These
technologies  have been widely implemented to reduce pollution generation and to reduce raw
material and  energy costs.  Current environmental regulation of toxic air and water pollutants,
toxic constituents in mill sludge,' and pulp mill  effluent standards for foam, odor, and color are
posing new challenges to pulp and paper firms.  Meeting  many of these regulations will require
materials and process changes rather than traditional end-of-pipe controls.  Dioxin  reduction,
for example,  requires process changes targeted  at reducing dioxin formation, such as decreased
use of chlorine in bleaching or oxygen delignification.
       In a compliance context, a mill's choice  between an end-of-pipe or a prevention strategy
will depend  heavily on the comparative  economics of these  options.  This  is so  even in
instances  where profitability  is  negative,  that is, when  the firm expects a net loss on  its
investment. Unlike most end-of-pipe technologies, pollution prevention projects tend to reduce
operating  costs by reducing  waste  generation, regulatory, activities, and pollution  related
liabilities.  In addition, investments in pollution prevention may increase revenue by  improving
product or corporate image.  Including' these indirect or less tangible savings in the financial
analysis of projects may enhance the estimated  profitability of the prevention strategy, and may
be decisive  in selecting  a pollution prevention versus an end-of-pipe option.  It is at this
decision point that the  concepts and  methods  of Total  Cost Assessment  (TCA) ~ the
comprehensive, long-term financial analysis of pollution prevention projects - can play a role
in improving  the  financial picture  of a pollution  prevention  investment, and enhance  its
competitiveness vis a vis pollution control projects.  TCA techniques can also improve the
projected  financial  performance  of  discretionary pollution  prevention projects,  thereby
increasing their ability to compete for limited capital resources.


 CASE STUDIES

        To assess how TCA works in practice, we worked in close collaboration with the staff
 of two mills to analyze the economics of two  pollution  prevention projects. The first (Project
 1) is a white water and fiber  reuse project at a coated fine paper mill.  This investment would
 permit fiber, filler, and water reuse on two paper machines at all tunes, thereby conserving raw
 materials  and reducing water use, wastewater generation, and energy use for fresh and waste
 water  pumping and freshwater, heating.  The  second (Project  2) is  a conversion  from
 solvent/heavy metal paper coating to aqueous/heavy metal-free  coating at a paper coating mill.
 This investment would substantially reduce solvent and heavy-metal usage, VOC emissions,
 and hazardous waste  generation, while  increasing water, steam, and electricity  usage and
 increasing wastewater generation.  For  both projects,  we developed  a  "company analysis"
 comprising  costs  typically used by the firms:  We compared these  to "TCA analyses" of the
                                             3

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 same project, in which a full accounting of less tangible,  longer term, and indirect costs and  •
 savings was made.'  To do this,: we'developed a spreadsheet system  called P2/FINANCE, to  -
 collect  and organize capital  and operating  cost  data, to  calculate cash flows and financial
 indices,'and to perform sensitivity analyses  of the case studies.
 COST INVENTORY

        While, cost categories considered in a financial analysis will tend to differ according to
 the nature of the project, we can infer from the Company, Analyses the types of costs that these
"firms  typically  consider in project analysis..  Table ES-1 presents an overview of the costs
 .estimated in the Company Analyses and the TCA.  The TCA column represents a-complete set
 of known internal costs and revenues  affected by the project.  By  comparing  the Company
 Analysis column against  the TCA column, a picture emerges  of the firm's project  costing
 approach.                 -.                                       .

        Direct and Indirect Costs. Had a full financial analysis of the white water/fiber reuse
 project (Project'!) been done  by the mill prior  to this study, energy savings associated with.
 reduced fresh and waste water pumping and treatment and freshwater heating would have been
 omitted.  These energy savings, which  are included hxthe TCA,. represent a substantial benefit
 of the project.   Their  omission  in a traditional financial analysis would have  drastically
 underestimated the profitability of the investment.        ,

        In the  case  of  Project 2, the Paper Coating firm omitted  all non-disposal waste
 management costs, utilities (energy, water and sewerage),'solvent recovery,  and regulatory
 compliance  costs from its analysis of  the aqueous conversion project.  The firm also  omitted
 several costs associated with  the storage needs and  shorter shelf  life  of aqueous coatings,
 namely a steam heating system for the coating  storage shed,  lost raw material  value,  and the
 cost to dispose of spoiled coating.
 t                          __       .                    -             •           '     •
        Future Liability Costs. In this study  we have focused on two general forms of future
 liability  costs:   liability from personal injury or property  damage (e.g., Superfund  liability
 stemming from a  leaking landfill), and  penalties and fines for violation of  environmental
 .regulations.  In the case  of Project 2, the Paper Coating firm did not include  an estimate of
 avoided future liability costs owing to  reduced hazardous waste  disposal in their own financial
. analysis.  They did, however,  allude to this benefit in a qualitative way in their Appropriations
 Request:  "...major  reductions  in levels of fugitive emissions,, and amounts of solid hazardous
 waste going to landfill, is very positive  from a regulatory  and community standpoint".  The
 TCA developed for this project includes  an estimate of avoided future liability. Since Project
  1 does not  involve hazardous  materials or waste,  neither the Company Analysis nor the TCA
 contains a future liability estimate,

         Less Tangible Benefits.  Less tangible benefits from pollution prevention investments,
  such as increased  revenue from  enhanced .product quality, company or product  image,  and

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reduced worker  health maintenance  costs or productivity are certainly the  most difficult to
predict and quantify.  Neither Company Analyses nor TCAs contain estimates of less tangible
benefits  In the  case of Project 2, the coated paper product is sold domestically, on the basis
of  cost  visual  appearance,  and performance  durability,  to  book  publishers  and  other
intermediate   product  manufacturers.     Although  the  company  expects  some  quality
improvements using  aqueous coating,  it does  not  anticipate  an increase  m market value.
Therefore,  it  expects  no increase  in  domestic sales  as a result of  the conversion to  the
aqueous/heavy metal-free coating. The company hopes to improve its competitive advantage
in the European market if the European Economic Community implements lead-free packaging
standards (which would apply to  books) as expected.  However, it would ndt .speculate on the
potential revenue effects associated with increased European market share.

       The Coated/Fine  Paper Mill  does not expect an increase in market share or product
value  from  its white water/fiber  reuse  project.  Both  the  mills  are   manufacturers  of
intermediate, rather than consumer products, and cannot directly market their products on the
basis of environmental performance in the way that a consumer products company like Procter
and Gamble  can and does.

       A reduction  in solvent use at the Paper  Coating firm  will certainly reduce worker
exposure to fugitive solvent emissions, and the elimination  of nitrocellulose from the coating
mix "ore will reduce flammability and explosivity hazards.   While reduced solvent  exposure
may  result in a lower incidence  of worker  illness over the. long-term, and the elimination of
nitrocellulose may result in fewer worker injuries, we did not  have adequate information to
estimate the potential impact of these benefits on either the company's health care costs or
long-term  worker productivity.  This issue was  dealt with qualitatively in a section of an
Appropriations  Request,  developed  by  the  company,  called  "Safety/Health  Impact  of
Converting from Solvent to Aqueous Coating", which listed specific project benefits  that will
improve safety  and industrial hygiene.

        Many company representatives noted that project benefits are more  persuasive if they
 are monetized and included in the project financial analysis. However, when costs are difficult
 or impossible to monetize, a qualitative approach may be more credible with management.

        Omitted non-environmental costs.  In developing the TCAs for the two projects, we
 attempted to add to the Company Analyses any capital or operating costs or savings that could
 be attributed to the project and reasonably  estimated.  While our focus was on environmental
 costs typically omitted from project analyses, the process of developing a more comprehensive
 list of costs (or "casting the cost net wider") unearthed other, "non-environmental"  costs that
 were not considered by the company.   In the case of Project 2, all previous company analyses
 of the aqueous/heavy-metal free  conversion had omitted the costs of heating system installation,
 the energy needed 'to prevent the aqueous  coating from freezing, and the additional  energy
 needed to dry aqueous versus solvent-based coating.  While the latter cost  was acknowledged
 by several production  engineers and managers  in meetings with Tellus,  it had never been
 estimated nor included  in previous analyses.

                                     '   '    '5                          .  '   .

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       The effect of such costs on a project's,financial performance depends upon whether the
 item represents a cost or a savings  for the project.  In the case of Projects 1 and  2, these
 non-environmental costs tended to increase the total cost of,the project by adding to capital and
 operating costs.   While this finding  is probably not a surprise to those who prepare project
 analyses  it is important to point out  that the TCA process may reveal additional costs as well
 a* savings for the project.  If the financial impact fromlhe addition of regulatory compliance
 or waste management activities is marginal, they.may.be negated by the addition of one or two
 previously  omitted  non-environmental costs.                               ;     ,.


 FINANCIAL INDICATORS       ,

        Financial indicators are a critical, though not exclusive, ingredient in justifying pollution
 prevention projects.  Firms typically use such  indicators  as guideposts rather than decisive
 elements in judging the-merits of a  proposed project.  Their application tends to be flexible,
 that is, subject to substantial management discretion as proposals move through the formal or
.informal budgeting process and compete  against one another for scarce capital.

        For the relatively large companies included in this study, payback (or the slightly more
 sophisticated ROI) is typically'used, as a first screen.  If a project passes  a prescribed hurdle
 rate a more in-depth analysis that computes NPV and/or IRR is common. The Paper Coating
 Company uses ROI to screen proposed projects before subjecting them to  more in-depth NPV
 and IRR analyses.   The  Fine/Coated Mill uses payback in a similar fashion.  This practice
 provides the project  proponent with an  informal estimate of expected performance prior to
 investment of staff resources - (and  personal capital) in advocating  a proposal.  Once  this
 milestone  is passed,  the proposal typically moves into a divisional or sectoral review where
 more complex calculations are  developed to capture the longer-term costs/savings.

        In  none  of these cases is  the   hurdle rate inflexibly  applied.   Instead,   there are
 perceptions associated with each project  that are defined by the project's place in the strategic
 thinking  of top management  and  the degree  to which  outside pressures  from customers,
 regulators, or the  community are applied.  In the case of the Coated Fine Paper  Mill, the
 professed  hurdle rate for projects is a 2  year payback. However, certain  production-oriented
  projects have been implemented without meeting this rate, primarily because there was a
  general  perception among decision-makers that these projects were  needed  to  maintain
  productivity    On the  other  hand, discretionary  environmental projects are more rigidly
  measured against the company's hurdle  rate.  This seems to be a result of an impression that
  environmental projects by nature are virtually always unprofitable.

         To examine the effect of the choice of financial indicators and time horizon, we created
  two functional  categories of indices: discounted cash flow methods that  consider a stream of
  future cash flows  for the investment (e.g. NPV and IRR), and one which does not (e.g. simple
  payback period).
                                              6

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TIME HORIZON

       Time horizon, of course, is closely tied to financial indicators. Simple payback and ROI
calculations  are  not capable "of capturing long-term  costs/savings,  a particularly  severe
shortcoming in the case of liability estimation where benefits may materialize 10 years or more
into a project's lifecycle.  NPV and IRR, on the other hand, can account for costs and savings
as they occur in future years.  Their use is typically  associated with large  firms  and large
investments whose market  and budgeting horizons are expansive, and who  are able to wait
many years for a stream of benefits to materialize.

       In preparing the TCA for  the Paper Coating  Mill, managers indicated that  a time
horizon of 10 years is typical for major investments. The need for extending  this figure to 15
years to capture the liability avoidance benefits became evident in •preparing the TCA analysis;
if the time  horizon  was  less than  13 years,  the liability estimate would  not  have been
incorporated into  the financial indicators.   In the case of the Fine/Coated Paper Mill,  once a
discretionary project such as the white  water/fiber  reuse system passes an informal payback
screening  it is subjected to a 10 year discounted  cashflow analysis.  Since the  TCA for  this
project did not involve any costs (e.g. future liability costs) that would be incurred in the out-
years  the time horizon is less critical to capturing  the full financial impact of the project. In
any case  the linkage between financial indicator, time horizon, and cost inclusion is a powerful
rationale  for promoting and practicing TCA in pollution prevention project analysis.


PROFITABILITY ANALYSIS

       The comparative  analyses  for each project yield substantially different results.  For
Project 1  the white water and fiber reuse investment, the net present value (over 15 years) for
this $1.5 million capital expenditure shifts from' $0.36 million in the Company Analysis  to
 $2.85 million using a TCA approach; the internal  rate of return (IRR) increased from  21% to
 48%- and the simple payback, of 4.2 years decreased to 1.6 years, well within the mill's 2-year
 payback  rule  of thumb.   By excluding  the  savings associated with  freshwater  pumping,
 treatment,  and heating, and waste water, pumping, the Company  Analysis makes the project
 appear substantially  less profitable than it actually is.

        Contrasting results  are produced for Project 2, the aqueous conversion investment. NPV
 for this  $0.9  million  capital expenditure  shifts from -$0.2  million to -$0.4 million in the
 company versus TCA analyses,  respectively; IRR shifts from  11% to 6%; and simple payback
 rises from 76  to  11.7  years.   The inclusion  of  previously  omitted  savings  for waste
 management,  regulatory compliance,  and future liability in the TCA are outweighed by the
 previously omitted utility costs.  As a result,  the  TCA analysis  illustrates that the proposed
 project is actually less profitable than originally thought.  Nonetheless,  the exercise achieves
 its ultimate goal - providing a clear, comprehensive picture of the investment option.

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 IMPLICATIONS
        Analysis of this limited sample of two projects does not suggest that, a priori,  more .
 comprehensive treatment of project costs and savings necessarily yields higher performance for
 prevention  investments.   Much  depends  on the .original capital  cost of, the project  the
 completeness of the company  analysis,  and the  magnitude and  timing of indirect. and less
- tangible benefits.  And, surprisingly, TCA is equally likely to turn up additional costs as well
 as additional savings, potentially diminishing the appeal of prevention investments.  Moreover,
 the effort expended in preparing the TCA analysis, though partially attributable to startup costs
 of any new practice, is substantial. enough to make even large firms wary of adopting such an
 approach for all projects competing for capital, resources. „

        The limited  number of cases  examined here precludes generalizations about overall
 corporate receptivity to TCA approaches and the  degree/to which pollution prevention will be
 accelerated by its adoption.  Within the limitations of our study, however/it is clear that TCA
 can serve as valuable tool for translating discretionary judgements into  concrete dollar values
 during the  capital budgeting process.   Insofar as pollution prevention  projects produce  less
 tangible and indirect costs and benefits, TCA equips managers to develop  a more precise .
 estimation  of the real financial returns  to such  projects.  Though  TCA does not insure an
 attractive.profitability level for prevention projects, the cost  characteristics  of such projects
 suggests that their financial performance in general will  be enhanced by TCA.  This is likely
 to be particularly true for industrial prevention projects that are materials and process-focused,
 that is  well upstream in the production process.  Over the longer  term, TCA can serve  as a
 substantial force in recasting  the  "must-do" and  "inherent loser" image of environmental
 projects into a more positive, profit-adding'and market-expanding image.,

        Several approaches for promoting  TCA in the context of E?A's pollution prevention
 strategy emerge  from this study.  In general, it is clear that moving  firms to modify their
 analytical  procedures requires a  belief that  TCA  will produce  a  clearer  picture of the
 profitability of prevention projects and thereby managerial decision-making. Thus, the primary
 goal of a promotion program should be to convince  firms that TCA  is not  simply another
 regulatory mandate, but a vehicle for rationalizing their internal  capital budgeting process.'  .

         More concretely, EPA has already worked to promote TCA by developing the Pollution
•  Prevention Benefits  Manual,  the Waste Minimization  Opportunity Assessment Manual, and
  sponsoring the initial work on PRECOSIS, all of which contain discussions  of TCA concepts
  and provide analytical tools.  Further efforts to disseminate more widely these and other tools
  such as P2/FINANCE,  a tool developed for this study, will accelerate the advancement of the
  TCA concept. Published  case studies which use a TCA approach to project financial analysi?
  could be a valuable  supplement to past initiatives.                                   :

         At the state level,  TCA may be built into pollution prevention policies and programs
  in several ways. State technical assistance programs may offer TCA guidance and training as
  a complement to their technical services, by providing TCA training seminars, with specialized

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modules aimed at large versus small firms, or for firms in certain lines of business.  A number
of states have instituted  requirements  for industry to develop pollution  prevention plans that
must contain technical and economic  feasibility assessments of specific prevention projects.
The New Jersey Pollution Prevention  Act, for example, explicitly requires that plans, include
a comprehensive analysis of the costs associated with the use, generation, release or discharge
of hazardous  substances  for  current production  processes  and  the  savings realized by
investments  in pollution prevention.  Planning for Success Through Waste  Reduction,  the
planning guidance document created by the Washington State Department of Ecology under,
the State's Hazardous Waste Reduction  Act, instructs  companies  to evaluate the costs  and
benefits of selected waste reduction options  over a  five year period. It  also requires firms to
describe the accounting systems used to track hazardous  substance and waste management costs
which  must include  "liability, compliance, and oversight costs".

       Requiring  a, TCA approach  in  pollution prevention  planning  may direct  firms to
incorporate   unconventional  cost  items and/or   longer  time  horizons  to  enhance  the
competitiveness of prevention  investments.   The long-term effectiveness of this approach,
however, is unproven and should be approached cautiously and with a strong emphasis on the
company self-interest alluded to earlier.   While rigid, prescriptive approaches are undesirable,
some  type  of standard  could  facilitate  the implementation of emerging federal and  state
regulations  requiring TCA in pollution prevention planning.

        The limited sample size of firms  in this study allows for only indicative findings that
must be corroborated by the analysis of additional  cases.  Existing TCA methods have been
available for several  years, yet no systematic assessment of user experience among the several
hundred purchasers  of various systems is available. This presents, a potentially rich data base
for further  assessing the organizational and economic issues  in  TCA  adoption which we
uncovered in this study.

        Quantifying  the  benefits of green technologies,  green products and green corporate
image remains a  major challenge.  It is precisely these benefits that are heard by corporate
managers as reasons for approving otherwise marginal projects.  Developing methodologies to
quantify these benefits  and incorporate them into  project financial analysis  is an unfinished
task.

        Finally, what is  financially optimal  for the  firm, of course, is not necessarily optimal
 from  a social cost  standpoint.  In this sense, TCA is  no substitute  for  lifecycle assessment
 (LCA), in which the choice of a material input or the manufacture of a product is assessed for
 its full societal costs regardless of whether they fall within or outside the purview of the firm.
                                             9

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 Tattle ES- 1  Qvervieu; of Cost  Inclusion by 'Comparn  and TCA for  Projects .'I  and 2

•'.\-=Costfsl  Included-   ,                  ';'        Project I1 .                  ;   V  Project 2;
 P =  Cost(s)  Partially Included .       .     .Company-   •   -TCA.            Company
 Capita] Costs                          ,,;-.'

 Purchased Equipment       ,     ,          x               X               X
 Materials (e.g.  Piping, Elec.)     ,    .      X             >  X,
 Utility Systems       •       .    .          X        • . ,     X    •             ;        '       X
 Site Preparation                  -         x        ._      X         •;•.-.
 Installation           •                     X   '            X                 ,
 Engineefing.'Contractor                     X               X               X               X
 Start-up/Training        ,...-',     .         -..'.     •     ^                 x     .  •        x.     •
 Contingency                          •  .  X              '-X                          .
 Permitting                                      '           ,      .  •
 Initial  Chemicals           •           ""              -
 Working Capital  '      '   '    .
 Salvage Value "               \            .        . '•  ,  ' ;    '   .                                      ,    >

 Operating  Costs
 Direct Costs:?  /                                       .,                                     Y
 Raw Materials/Supplies                     ,p               x                P .
 Waste Disposal                             '              v        /        I                v
 Labor         ,.                           X       .        *        ;   '     X                X
 Revenues - General                   ,          ,                                         '
 Revenues - By-products                                              •       ..               -          - -  •
 Other:
          Transportation

1 Indirect  Costs:4         ,                                                    .  •    , :
 Waste Management                                                  -     '•                 ,
          Hauling                    '..''•••.       .                                 Y  "'  '- >  '
          Storage                  •         |'                                                  X     '
          Handling                                                                            X
          Waste-end Fees/Taxes       ,          -              ,                                 x        ,  >
          Hauling  Insurance                                      '      .
  Utilities    '                                         .                         '.-••'      v
          Energy                            P                x                           :    X   '    '
          Water                                  '    .       X     .          •    '    "•    '    C    '
          Sewerage (POTW)                'X               X •                              X
 •Pollution Control/Solvent Recovery                                                           x
  Regulatory Compliance
  Insurance                                                                                    „." •  '      ,
  Future Liability                                                                  .   "

  Notes:     _                                    .  .'..'     '           •  '  • .                      •   •
  1.       White water/fiber reuse project
  2       Solvent/heavy-metal  to aqueous/heavy metal-free coating  conversion
  3.       We use the term "direct costs" here to mean costs that are  typically allocated to a product or process line (i.e.
           not charged to an overhead account) and are typically included in project financial analysis.
  4.       We use the term "indirect costs" here to mean cost that  are typically charged to  an overhead account and
        •   typically not included in project financial analysis.
                                                         10

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Table ES-2  Summary of Financial Data for Project 1 - White Water and Fiber Reuse
Project

                                             Company Analysis     .      TCA

      Total Capital Costs   '   '                 $1,469,404          '    $1,469,404

      Annual Savings (BIT)*                 '   $350,670              $.911,240

      Financial Indicators
      Net Present Value - Years 1-10             $  47,696              $2,073,607
      Net Present Value - Years 1-15             $ 360,301              $2,851,834
      Internal'Rate of Return-Years 1-10           17%                    46%
      Internal  Rate of Return-Years 1-15           21%  .                  48%
      Simple Payback (years)                       .4.2  .                .1-6

      * Annual operating cash flow before interest and taxes
Table ES-3 Summary of Financial Data for Project 2 - Aqueous/Heavy Metal Conversion
Project

                                              Company Analysis            TCA

       Total Capital Costs                         $893,449               $923,449

       Annual Savings (BIT)*          '           $1 18,1 12               $79,127'

       Financial Indicator
       Net Present Value .- Years 1-10            ($314,719)
       Net Present Value - Years 1-15            ($203,643)              ($395,625)
       Internal Rate of Return - Years 1-10           6%                   .  0%
       Internal Rate of Return -Years 1-15           11%                     6/°
       Simple Payback (years)                     -7.6                    11.7

       *  Annual operating cash flow before  interest and taxes
                                           11

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