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. ------- 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. ------- 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. ------- 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 ------- 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 ------- |