United States
Environmental Protection
Agency
National Risk Management
Research Laboratory
Cincinnati OH 45268
Research and Development
EPA/600/SR-96/110 September 1996
4>EPA Project Summary
Pollution Prevention Assessment
U.S. Postal Inspection Service
National Forensic Laboratory
Carole O. Bell, Mary Hoel, John Nuckels, and John Conrick
As part of its Waste Reduction Evalu-
ation at Federal Sites Program, the U.S.
Environmental Protection Agency (EPA)
National Risk Management Research
Laboratory worked cooperatively with
the U.S. Postal Service (USPS) to inte-
grate waste prevention and recycling
activities into the waste management
programs at various postal facilities
through the conduct of pollution pre-
vention opportunity assessments
(PPOA).
This PPOA documented and quanti-
fied waste generation at the National
Forensic Laboratory, a Postal Inspec-
tion Service crime laboratory that ex-
amines physical evidence and performs
chemical analyses relevant to crimes
involving USPS operations.
The report makes recommendations
concerning procurement of office sup-
plies, maintenance supplies and haz-
ardous materials; management of
hazardous materials and wastes; pur-
chase of chemicals on EPA's 33/50 list;
improvement of source separation and
recycling of paper and paper products,
metals, and plastics; management of
unwanted equipment; and other options
for reducing or eliminating pollution.
This Project Summary was developed
by EPA's National Risk Management
Research Laboratory, Cincinnati, OH,
to announce key findings of the research
project that is fully documented in a
separate report of the same title (see
Project Report ordering information at
back).
Introduction
Since 1988, EPA's National Risk Man-
agement Research Laboratory (NRMRL)
has managed a technical support effort
known as the Waste Reduction Evalua-
tions at Federal Sites (WREAFS) Program.
WREAFS was established to provide pol-
lution prevention solutions to environmen-
tal issues through research, development
and demonstration of pollution prevention
techniques and technologies, and trans-
ferring lessons learned within the federal
community and related private sector in-
dustries.
The U.S. Postal Service (USPS), in co-
operation with NRMRL's WREAFS pro-
gram, is engaged in an effort to integrate
pollution prevention and recycling activi-
ties into the waste management programs
at postal facilities. The purpose of this
project was to perform pollution preven-
tion opportunity assessments (PPOAs) at
Postal Service facilities, recommend imple-
mentation strategies, and develop facility
guidance that could be incorporated into a
revision of the USPS Waste Reduction
Guide. The project was funded by the
U.S. Postal Service through an interagency
agreement with EPA NRMRL.
This report describes the findings of the
PPOA conducted for the U.S. Postal In-
spection Service, Forensic and Technical
Services Division's National Forensic Labo-
ratory in Dulles, VA. The PPOA was con-
ducted during the week of November 14,
1994.
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Facility Description
The National Forensic Laboratory is situ-
ated in a rural industrial park several miles
from Dulles International Airport. Three
other Postal Service facilities are located
at this site: a Stamp Distribution Network,
a Vehicle Maintenance Facility, and a mail
Processing and Distribution Center. The
Forensic Laboratory is a two-story build-
ing of approximately 44,000 square feet,
divided into six functional areas or sec-
tions. The Chemistry Section examines
controlled substances submitted by postal
inspectors; Forensic Photography provides
photographic support to all the sections;
Technical Services supports a national
communications network; the Physical Evi-
dence Section examines explosive de-
vices, firearms, and toolmarks; the Latent
Fingerprint Section processes evidence to
develop latent fingerprints; and the Ques-
tioned Document Section identifies hand-
writing and establishes document
authenticity.
Waste Description
The nature and volume of the workload
at the Forensic Laboratory depends on
Postal Inspection Service criminal cases.
Quantities of waste disposed or released
to air and water may vary considerably
from month to month and year to year;
however, on the average, the Forensics
Laboratory generates approximately 31
tons of solid waste per year. Annual cost
of solid waste management is approxi-
mately $6,000. Exhibit 1 presents the pri-
mary components of the Forensic
Laboratory's solid waste stream. In addi-
tion to solid waste, the Forensic Labora-
tory generates small quantities of hazard-
ous wastes. Most hazardous materials are
utilized in very small quantities. The Fo-
rensic Laboratory has had occasion to
dispose of hazardous waste only once in
the past three years.
Pollution Prevention
Opportunities
The PPOA identified several pollution
prevention opportunities at the site. Some
of these opportunities simply reduce the
quantity or toxicity of the waste stream,
while others offer the USPS economic as
well as environmental benefits. Exhibit 2
presents the pollution prevention opportu-
nities that offer the USPS significant cost
reductions in addition to reducing pollu-
tion. The annual savings for the combined
facilities could be as high as $25,000. In
addition, by marketing dependable quanti-
ties of quality materials, the postal facili-
ties increase the possibility of receiving
revenues from the sale of their recyclables.
All of the pollution prevention opportuni-
ties identified by the PPOA team are ad-
dressed below.
General Recommendations
Reduce the amount of packaging,
including corrugated containers,
shrink/stretch wrap, and strapping,
entering the facility. Reuse incom-
ing containers and utilize reusable
packaging whenever possible.
Introduce and promote a variety of
techniques to reduce the quantity
of paper generated for disposal.
Repair unwanted equipment and/or
donate to schools and other facili-
ties for reuse.
Exhibit 1. Forensic Laboratory Solid Waste Stream
Waste Waste components
Paper Mixed office paper, computer printout, corrugated cardboard, paperboard packaging,
paper towels
Food Food scraps, food-contaminated paper products
Metal Food and beverage containers, aerosol cans, paint cans, electronic equipment, wire
Glass Containers from laboratory and photoprocessing chemicals, food and beverage con-
tainers, broken laboratory glass
Plastic Containers from photoprocessing chemicals, food and beverage containers, gloves,
shrink/stretch wrap, bubble wrap, packaging peanuts
Wood Pallets, cable spools
Other Toner cartridges, circuit boards, communication equipment, computer equipment,
carbon filters
Batteries Various sizes and types
Provide training for professional and
custodial staffs on source separa-
tion.
Establish a multi-facility recycling
program for the four Postal Service
operations located in Dulles, VA.
Affirmative Procurement
Establish preference programs and
adopt EPA guideline recommenda-
tions for the purchase of products
made with recovered materials.
Substitute products that do not con-
tain ozone depleting chemicals; ex-
haust the current stock and then
modify procurement specifications
to prohibit purchase of products
containing 33/50 chemicals.
Procurement of Chemicals and
Laboratory Supplies
Centralize ordering and stock/inven-
tory control, including budgeting for
supplies, at the laboratory director
level. Utilize the existing on-line in-
ventory program to track current
and future chemical inventory and
optimize ordering and stock rota-
tion to avoid the need to dispose of
expired chemicals.
Establish a single point of respon-
sibility for receipt and labeling of
chemicals.
Carbon Filters
The Forensic Laboratory uses 22
Flanders Model T-2V-N63-F16, GG-16, V-
Bed Carbon Adsorber Cells, located within
seven ventilation systems, the largest of
which includes nine cells. The filters con-
tain nuclear grade carbon and have an
estimated life expectancy of three years,
according to the manufacturer. Actual use
of the filter systems is very light so the
replacement of the filters on a three-year
schedule may not be warranted. The
changeout of all of the filters will generate
2,200 pounds of spent nuclear grade car-
bon and will cost more than $30,000. As
shown in Exhibit 3, during the first
changeout of the filters, the cost per filter
will be slightly lower due to the purchase
of spare filters. During subsequent
changeouts, however, the per filter cost
should be significantly lower than the pur-
chase of new filters and will prevent the
disposal of spent carbon. In addition, as
shown in Exhibit 4, the per pound re-
placement cost of nuclear grade carbon is
substantially higher than commercial grade
carbon. If the Forensic Laboratory con-
verts from nuclear grade to commercial
grade carbon, cost savings of $5,455 can
be realized when the carbon in replaced.
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Exhibit2. Cost-Saving Pollution Prevention Opportunities
Item(s) of Concern
Current Practice
Pollution Prevention
Opportunity
Estimated Potential Savings
Carbon filters
Carbon filters
Carbon filters
Recyclables
Procurement of
chemicals and
laboratory supplies
Replace all carbon filters
after 3 years
Replace all carbon filters
after 3 years
Filters contain nuclear
grade carbon
Collect aluminum,
plastic and glass mixed
food and beverage
containers, and paper
products
Decentralized process
Measure filter
breakthrough
Rejuvenate filters on
rotating schedule
Convert from nuclear
grade to commercial
grade carbon filters
Establish one multi-facility recycling
program for 4 local
Postal Service
operations
Centralize ordering
and inventory control
Eliminate costs associated with
unnecessary filter replacement*
$600-$ 1055 in filter
replacement and disposal fees**
$1,000 certification fee for
disposal of nuclear grade
carbon
$4,455 replacing 22 nuclear
grade carbon filters with
commercial grade carbon
filters
$4,440 in fees for container
rental and collection of
recyclables
$544 for smaller container and
less frequent pick up charges
Eliminate expenses associated
with overstocking and disposal
of expired chemicals*
* Dollar figure associated with potential savings is unknown.
** The per filter cost to replace and dispose of the carbon filters is estimated to be approximately $1600. The estimated per filter cost to regenerate the carbon
filters is between $545 and $1005; however, for the first changeout, the per filter cost is estimated to be approximately $1600 due to the extra expense
of purchasing spare filters.
Conclusions and
Recommendations
The USPS has encouraged reduction
and recycling activities in its facilities. Emis-
sions to air and water from the Forensics
Laboratory are minimal. The Laboratory
faces a significant expenditure in replac-
ing the carbon filters and should seek a
regeneration option. The full report pro-
vides detailed analyses regarding the cost
of various filter options.
Additionally, annual solid waste expen-
ditures could be reduced 83%, from $6,000
to $1,016, by coordination of reduction
and recycling activities with the other
USPS facilities. The laboratory could also
establish a centralized system for chemi-
cal receipt and labelling to reduce waste
and minimize disposal of expired or un-
needed chemicals.
The full report was submitted in partial
fulfillment of Contract No. 68-C2-0148,
Work Assignment No. 3-10 by Science
Applications International Corporation un-
der the sponsorship of the U.S. Environ-
mental Protection Agency.
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Exhibit 3. Options for Filter Management
Option 1:
Dispose of 22 spent filters
and replace
Option 1
Costs
Option 2:
Regenerate carbon
in the filters
Option 2
Costs
Testing costs:
Prior to disposal, the Forensics Laboratory must
test the carbon to determine whether it is
a hazardous waste.
Disposal costs including collection and
transport:
22 spent Flanders Filters at an estimated
weight of 2,200 Ibs. as nonhazardous
waste at $80 per filter (the steel may
have recycling value)
22 spent Flanders Filters at an estimated
weight of 2,200 Ibs. as hazardous waste
at $130 per filter.
Purchase costs:
22 Flanders Filters Model T-2V-
C63-F16, GG-16, V-Bed
Carbon Adsorber Cells complete
with an initial charge of
commercial grade carbon.
Total
First Changeout Cost Per Filter
Second Changeout Cost Per Filter
$230
$1,760
or
$2,860
$32,150
$34,140-$35,240
$1,552 - $1,602
$1,552 - $1,602
Testing costs:
Prior to regeneration
or disposal, the nuclear
grade carbon must be tested
for contaminants.
Regeneration costs:
Regeneration of
Flanders Filters V-bed
Carbon adsorber cells
Purchase costs:
One time purchase of
nine spare Flanders Filters
Model T-2V-C63-F16, GG-16,
V-Bed Carbon Adsorber
Cells. Each adsorber
complete with an initial
charge of commercial grade
carbon.
$450-600 *
$525-978 each
$11,595-14,400
Second Changeout does not
require purchase of new
filters
$23,537-$36,516
$1,070-$1,660
$545-$1,005
* Price range reflects bids from different vendors.
Exhibit 4. Replacement Cost of Carbon
Material Quantity
Cost/lb
Total
Nuclear grade carbon
Activated carbon
90 Ibs./filter; 22 filters
90 Ibs./filter; 22 filters
$3.75
$1.50
$7,425
$2,970
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Carole O. Bell, Mary Hoe/, John Nuckels, and John Conrick are with Science
Applications International Corporation, Newport, Rl 02840.
James S. Bridges and N. Theresa Hoagland are the EPA Project Officers (see
below).
The complete report, entitled "Pollution Prevention Assessment, U. S. Postal In-
spection Service National Forensic Laboratory," (Order No. PB97-100010; Cost:
$21.50, subject to change) will be available only from
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officers can be contacted at
National Risk Management Research Laboratory
U.S. Environmental Protection Agency
Cincinnati OH 45268
United States
Environmental Protection Agency
Center for Environmental
Research Information (G-72)
Cincinnati, OH 45268
BULK RATE
POSTAGE & FEES PAID
EPA
PERMIT No. G-35
Official Business
Penalty for Private Use
$300
EPA/600/SR-96/110
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