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B. A BRIEF TEXT DESCRIPTION OF INDIVIDUAL CASES
1. Supplemental Environmental Projects
a. Casted Metal Products Manufacturer (CMPM)
CMPM produces casted ferrous metal products using a variety of operations, including: wax
pattern and sand/plaster mold production; mold dewaxing with heat; acid and caustic cleaning,
degreasing, bluing, phosphate coating, and tumbling of metal parts. CMPM has approximately
1,200 employees and 3 buildings at the subject facility. The company owns two other plants; one
plant makes similar products, another produces only aluminum products.
The company was cited with two violations under the Clean Water Act: failure to file a Baseline
Monitoring Report (Section 403.12) and exceeding the chromium discharge limits and effluent
pH. The company was originally fined $95,000. In consideration of their willingness to include
a SEP in their settlement, EPA reduced the fine to $30,000.
The SEP has two parts. The first part consists of process and facility modifications to be made
by the company to reduce water and chemical use, and wastewater and hazardous waste. The
second part consists of a Water Use and Wastewater Reduction Program designed to identify
further measures to reduce water use and wastewater generation.
Part I requires the company to:
A. Reduce flow in its dewax cooling plates to reduce non-contact cooling water to the
maximum extent safely possible.
B. Implement the following measures in the acid cleaning process:
1. Install a countercurrent rinse tank following the Hydrochloric Acid baths;
and
2. Route caustic rinse water as a reactive rinse to the countercurrent rinse
tank.
C. Implement the following measures in the acid cleaning area:
1. Eliminate the use of Nitric Acid;
2. Install countercurrent rinse tanks following the Sodium Hydroxide bath and
the caustic neutralizer baths;
3. Route water from the countercurrent rinse tank following the caustic
neutralizer bath to the cold water rinse following the Hydrochloric Acid
bath; and
4. Route the water from the cold water rinse following the Hydrochloric Acid
bath to the countercurrent rinse following the Sodium Hydroxide bath.
D. Implement the following measures in the bluing area:
1. Install a two-stage bluing bath on the electric bluing line;
2. Install flow control devices;
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3. Investigate during summer shutdown, and if doing so will not negatively
impact product quality or manufacturing efficiency, route rinse water from
the cold water rinses following the bluing tanks in both lines .to the,cold
water rinses following the caustic cteane* baths; and.
4. Investigate during summer shutdown, and to the extent doing stj.will not
negatively impact product quality or manufacturing efficiency, reduce flow
in all process lines.
E. Implement the following measures in the phosphate coating area:
1. Replace caustic water rinse with a dead rinse and a countercurrent rinse;
2. Use rinse water from the dead rinse as make-up water for caustic cleaner;
3.% Use a single cold water rinse following the phosphoric acid solution;, 7
4. Use a cold water rinse following the phosphoric acid solution bath as a
reactive rinse for the countercurrent rinse; and .
5. Install a timer or conductivity flow controls to limit flow to after usage
, necessary for product quality or manufacturing efficiency.,
F. Install flow control devices as appropriate in the tumbling area of Building C to
reduce water use to the maximum extent possible without negatively impacting
product quality or manufacturing efficiency.
G. Eliminate the use of perchloroethylene, Freon, and nitric acid in those processes
discharging wastewater. ; , :,'
H. Reduce the use of 1-1-1 trichloroethane and isopropyl alcohol to the extent
possible.
Part II includes implementation of a Water Use/Wastewater Reduction Program designed to
reduce the Facility's water consumption and wastewater generation to the maximum extent
practicable without negatively impacting product quality or manufacturing efficiency as follows:
A. The company shall complete and provide to EPA a Water Balance Survey of the
Facility and a report describing all sources and amounts of intake water, all points
of wastewater discharge, including evaporation, and a description of the Facility's
processes and activities that generate wastewater, including contact and non-
contact cooling water. The report shall include a water balance schematic diagram
illustrating the above information, including daily volumes of water used and
wastewater generated.
B. The company shall complete and provide to EPA a Water Use/Wastewater
Reduction Study for the Facility. The Study shall include plans and a schedule
for, facility and process modifications that the company will implement to
minimize the Facility's water use and wastewater generation.
C. The company shall implement those plant and process modifications identified in
the Water Use/Wastewater Reduction Study to minimize the Facility's water
consumption and wastewater generation.
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Through process modifications, the company has reduced wastewater discharges by approximately
100,000 gallons per day (approximately 75% reduction) and energy consumption by close-looping
water cooling processes. The SEP will leverage additional wastewater and energy reductions
since the company's ultimate goal is to close-loop the entire plant. The following table illustrates
chemical use reductions made by the company from the period of 1989 to May of 1991.
Chemical Use Reduction
(Pounds Purchased, 1989 to 1991)
Freon
Perchloroethylene
1,1,1 -Trichloroethane
Nitric Acid
Isopropyl Alcohol
1989
55,280
35,700
30,000
2,275
32,485
Pounds
1990
51,060
14,000
27,000
3,500
24,525
1991*
0
0
9,000
0
4,683
*Quantity of chemical purchased from January 1, 1991 through May 31, 1991. Source:
CMPM's Environmental Program Summary, June 1991.
While the changes made by the company are significant, they have not fundamentally changed
their core manufacturing processes, e.g., metal casting, acid and caustic cleaning, bluing, and
phosphate coating.
The average payback period of all SEP projects implemented is 5 to 8 years. While the
company's investment threshold is one year, they believe that the projects ware in their best
interest—economically and environmentally. They have realized water savings of about 100,000
gallons per day and energy savings from close-looping water cooling processes.
The company was dissatisfied with their technical consultants~a geotechnical/environmental
engineering consulting firm. In the course of the negotiations, the consultants recommended a
large and expensive treatment plant that the company ultimately realized was not needed. The
consultant contributed to some degree with process change ideas—by reviewing and modifying
recommendations from the EPA case officer-but largely recommended traditional technical
problem-solving approaches. The EPA attorneys, however, trusted the consultants and therefore,
the consultants helped to win agency approval for the technical changes that the company sought
to implement. The consultants were "educated" in the course of this process and they now use
the company as a reference for their pollution prevention work. The company would not use
them again.
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EPA compelled the company to implement water-use reduction measures far in advance and in
excess of what they would have done without the enforcement action. In addition, the company
has implemented some waste and water reduction measures in another plant.
Many of the technical ideas for the SEP came from the EPA case officer, who obtained insight
and project ideas from the shop floor, particularly from the line supervisors. Often, when the case
officer had a question about a process, he was invited to talk to the supervisors for explanations
and suggestions.
The company now sees the connections between all of their emissions/waste compliance
obligations and source reduction activities; they have "tied it all together." They will not allow
any new chemicals into the plant without prior approval from the environmental engineer and
compliance officer.
Because the company did not initially have the capacity (i.e., mode of inquiry and knowledge of
basic techniques), it was necessary for the EPA case officer to take a very technically involved
role in the process. Today, the company does not need an external actor to play this role, they
now have the in-house capacity to pursue further pollution prevention. Prior to the complaint,
the company had one person in charge of environmental compliance, and compliance was only
one of his many responsibilities. Today, there are four people with environmental compliance
responsibilities-one full-time and three part-time.
b. Industrial Coater (1C)
Industrial Coater manufactures coated plastic film. In 1989,1C had projected sales of $20 million
and employed 150-170 people. The company is a wholly-owned subsidiary of a foreign
corporation. This parent corporation operates a coating research and development facility at the
same site. The research facility provides R&D support to Industrial Coater.
In August 1989, EPA issued a complaint against the company stating that they had failed to file
Form Rs for toluene and methyl ethyl ketone under EPCRA 313.
During the settlement process, the company proposed, and ultimately agreed to, implement a SEP
consisting of the reformulation of a toluene-based coating to a low or non-organic solvent-based
coating and alteration of the production process used to apply this coating to plastic film. The
settlement requires the company to reduce by 90% the concentration of toluene (as compared to
dry chemical) in the coating and reduce by at least 50% the ratio of methyl ethyl ketone used in
cleaning to production volume.
The current process of applying a coating to film involved the liquefaction, floating or dissolving
of a dry chemical in a solution with the solvent toluene. The new process will use a heat source
to melt the dry chemical mix to a point where its liquefaction will be sufficient for it to coat the
film without the use of toluene. The project will include the installation of two banks of high
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intensity infrared heat lamps to flow the coating prior to curing, and to stabilize and dry the
coating on the plastic web. While solventless coating technology is not new in other industrial
applications, to the company's knowledge, this was the first attempt at solventless coating in this
niche of the coatings industry.
The company expects the new infrared heat lamps to dry the product more quickly thereby
allowing them to increase the speed of the coating machine. With increased speed, the company
can produce the same quantity of product during fewer production runs; fewer runs means fewer
clean-ups; 1C estimates that this changes will enable them to reduce its use of methyl ethyl ketone
in cleaning by an estimated 50% of current levels, from 4,600 to 2,300 pounds of MEK per
million feet of product.
The current solution of dry chemical and toluene applied as a coating consists of approximately
70% toluene and 30% dry chemical. Approximate levels of use in 1991 were 24,000 pounds of
dry chemical and 56,000 pounds of toluene. The proposed change to the process would,
assuming a constant level of production, reduce the level of toluene used by 90%, to 5,600
pounds annually. The amount of dry chemical used would remain the same.
The coating process currently uses an estimated total of 3.7 million Btus per hour, of which
approximately 525,000 Btus come from burning solvent and the balance (3.2 million Btus) from
natural gas. Approximately 3,500 cubic feet per hour of natural gas are currently used in the
process. The process also uses approximately 9.7 kw per hour of electricity. The project is
expected to eliminate the use of natural gas and the burning of solvent in the coating process.
It will, however, require an increase of approximately 190 kw per hour of electricity to operate
the infrared heaters. Because the project is expected to reduce gas and solvent energy use by the
equivalent of 1,080 kw per hour, the project is projected to reduce net energy use by 890 kw per
hour.
The total cost of the project was projected at $54,000, including $5,000 for development of the
new coating formulation done under contract by a consultant (Phase I), $25,200 for installation
and testing of new infrared lamps (Phase II), $19,000 for installation and testing of new coating
heating unit (Phase III). The CA/FO stipulated that the company shall expend not less than
$25,000 on the project. In consideration of the SEP, the penalty was reduced from $50,000 to
$30,000.
The company estimated the payback for this project to be 6 months to 2 years, including
approximately $800 saved per day in energy conservation alone.
In developing their SEP proposal, the company had assumed that they could use their existing
coating equipment to apply the new formulation. During pilot testing, they experienced problems
with this equipment and sought alternatives; as a result they were not able to switch to the new
formulation in time to meet the SEP implementation deadline. The company asked for an
extension and EPA granted one. However, the company found it necessary to pay the penalty
and table the project because of seasonal, high production demands, and the time and
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administrative pressures created by the SEP process. They are planning to re-initiate the project
in the near future since they consider it to be a "bonefide win-win situation" for the environment
and [their] enterprise.
The environmental benefits from this project derive from reductions in toluene and MEK use.
Based on the CA/FO Scope of Work, the quantity of MEK used would be reduced by 50%, or
2,300 pounds of MEK per million feet of product. Since the CAFO did not contain an annual
production figure, we are unable to estimate MEK reductions in pounds per year. Assuming a
constant level of production, toluene use would drop from 56,000 to 5,600 pounds annually—a
90% reduction. The amount of dry chemical used would remain the same.
Fugitive toluene and MEK air emissions are released into the plant and to the outdoor
environment in virgin and waste material handling and storage. Fugitive toluene emissions (i.e.,
emissions not captured by the thermal oxidizer) are also released from the coating process.
Toluene emissions from the coating operation may not be completely combusted in the thermal
oxidizer or may react under high temperature with other volatile materials in the coating to form
toxic substances. These emissions are released into the environment. Waste MEK solvent from
cleaning activities and waste coating containing toluene is sent to a hazardous waste incinerator.
By reducing the use of toluene and MEK, both fugitive and point source emissions from the
thermal oxidizer will be reduced. A reduction in fugitive emissions inside the plant will reduce
exposure of workers to these solvents. The reduction of MEK and toluene waste will result in
reduced hazards associated with transport of waste as well as reductions in emissions from
hazardous waste incineration.
Recently, the company has used the services of the state technical assistance office and was very
pleased with their service and the fact that they are separate from the regulatory process. They
now use the state office for technical advice and a private consultant for compliance audits.
c. Lid Manufacturer (LM)
The subject plant is one of several owned by a large manufacturing company. The plant
employees approximately 200 people in the production of metal lids with gaskets on four
production lines.
The company applied coatings containing VOCs in excess of limitations set forth in the federal
revisions to the State Implementation Plan under the Clean Air Act, Section 133d, and failed to
certify to EPA that its coating lines would either be exempt or in compliance with SIP emissions
limitations. The subject plant is located in a non-attainment area for VOCs. The complaint was
issued in July 1992.
Prior to the implementation of the SEP, the company produced a gasket material by blending
rubber, heptane and other substances (the mixture is referred to as "compo"). Compo was coated
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onto a metal lid and sent through curing ovens to drive off the heptane and form the gasket. The
heptane vapors were pulled into a recovery system. Since this system operated at approximately
76% efficiency, almost a quarter of the heptane emissions (VOCs) were released to the
environment.
The SEP consisted of the conversion of one of four production lines (constituting 1/3 of total lid
production) from the rubber and heptane-based gasket formulation to a new material containing:
PVC, BaSO4, dioctyl phthalate (DOP), soybean oil, CO2, and carbon black (the mixture is called
Plastisol). DOP--20% of the new formulation—is an organic plasticizer and is not listed as a
toxic substance under the Clean Air Act Amendments of 1990. The formulation does not contain
VOCs other than soybean oil which has a negligible vapor pressure.
The conversion requires the modification of the gasket coating applicator and purchase of a new
curing'Oven. The company elected to equip the new process with a thermal oxidizer (afterburner)
to control air opacity if the Plastisol smokes in the drying oven. It was not necessary to modify
its coating formulation process or change its operation of the gasket coating process. The cost
of the SEP, according to the company's October 1992 estimate was $298,000, and includes the
purchase price of the curing oven, thermal oxidzer (18% of the total cost), and lid curing trays;
in addition to oven installation, lid curing tray R&D, modifications to and relocation of the dryer
front.
The company estimated that heptane usage would decrease by 203 tons per year, resulting in a
reduction in VOC emissions of 50 tons per year. They projected a potential emissions rate of
particulates from manufacturing, natural gas usage and oven emissions of 3.65 tons per year, and
less than 1 ton per year of each NOx, CO, HC and SO2 from the new process.
The original penalty of $123,947 was reduced to $76,000 for good faith and to $38,000 for the
SEP.
The company utilized a technical consultant who is a former employee of the state environmental
agency. Her knowledge of environmental regulations and the materials and techniques that satisfy
regulatory requirements was extremely beneficial to the company. Her main focus was technical
assistance for compliance, but she assisted in the design of the new system as well.
The company is working to ensure that all of their plants are in compliance with environmental
regulations. It held a compliance workshop for representatives of each plant to stress the
importance of environmental compliance. LM has a corporate environmental manager and each
plant has an on-site person who is responsible for plant environmental compliance.
The environmental benefit of the project is the elimination of 203 tons per year of heptane usage,
resulting in a reduction in VOC emissions of 50 tons per year. The subject plant is located in
a non-attainment area for VOCs.
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The conversion may increase the plant's particulate emissions by 3.65 tons per year from
manufacturing, natural gas usage and oven emissions, and less than 1 ton per year of each NOx,
GO, HC.and SO2.
Plastisol contains PVC. Thermal decomposition products of PVC have been shown to cause
"asthma"-like symptoms in workers who were heat sealing PVC films, although proper ventilation
and worker protection have tended to minimize toxic effects.1 This may be a concern in the
subject facility since the Plastisol gaskets are dried with heat.
Dioctyl phthalate (DOP) is one of a number of commonly used organic plasticizers which has
shown a low order of acute toxicity in laboratory animal trials2. In studies of teratogenic effects,
DOP and other esters of Phthalic Acid showed deleterious effects on the developing embryo
and/or fetus although DOP was considered one of two of the least toxic esters of the eight
phthalate esters evaluated in this study.3 Barium sulfate, an insoluble form of barium metal has
been found to be non-toxic owing to its inability to absorbed by the body.4
d. Medical Device Manufacturer (MDM)
MDM is a medical device manufacturer that is highly regulated by the FDA. In 1991, MDM
generated more than $50,000,000 in annual sales from several manufacturing facilities. Today,
through acquisition of several small companies, sales are considerably greater. At the time of
violation, the subject plant employed approximately 100 people.
MDM failed to file Form Rs for xylene, trichloroethane and trifluoroethane. They agreed to
include a SEP in their settlement with the agency and, as a result, the agency lowered their
penalty from $31,350 to .$24,000.
The medical device manufactured in the subject plant is degreased and sterilized using freon. At
the time of the agreement, the company used approximately 16,000 pounds of freon per year.
For their SEP, the company agreed to engineer and test deionized water degreasing machinery
to determine if deionized water can be used in place of freon. If the testing demonstrated that
the new machinery is effective, the company will purchase, install and calibrate the machinery.
If the new machinery is not effective, the company will either stop manufacturing products that
require the use of freon, or pay an additional penalty.
1 Casarett arid Poult's Toxicology: The Basic Science of Poisons. Doull, J., Klaassen, C.D., and
Amdur, M.O. (ed.) New York, New York: Macmillan Publishing Co., Inc., 1980, page 551.
2 ibid, page 547 • . • •
3 Ibid, page 549.
"' Ibid, page 438.
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The deionized water system uses a two-step cleaning process. First the product is washed with
deionized water and detergent; second, it is rinsed with deionized water in an ultrasonic bath.
The vendor has sold this system, with and without ultrasonic cleaners, for degreasing computer
chips in clean room environments.
The cost of the project is approximately $80,000, including second-stage testing, design
engineering and equipment purchase. The project is not considered to be economically beneficial
to the company; it is favorably regarded by the Division Head for its environmental rather than
economic benefits.
The SEP stipulates that the company will incur no less than $10,000 for engineering and testing
of deionized water process machinery and not less than $65,000 to purchase, install and calibrate
machinery (unless they choose to discontinue production of products that use freon).
The company required FDA approval prior to changing their manufacturing process. This
requirement complicated the negotiation process—the company was able to test the new process
but had to submit the test data to the FDA prior to implementation and wait for FDA approval.
This additional step made it difficult for the company and EPA to structure the agreement, and
particularly to develop the implementation schedule. The CA/FO had to be designed to give the
company an alternative to implementing the deionized water process in the event that: (a) the
tests were unsuccessful, (b) their process change proposal was rejected by FDA, or (c) FDA
approval was not received prior to the SEP deadline. In addition, the time line had to be
sufficiently long (16 months), and structured in several steps, to allow for the FDA approval
process.
The company undertook the second stage evaluation, as outlined in the SEP, and considered the
new system to be a technical success. However, for two reasons they have chosen not to
purchase the equipment and to pay the stipulated penalty. First, the subject facility is scheduled
to close in February of 1994. The company is moving its operations to another plant. Second,
the company is in a long and complex FDA product approval process and the submission of a
request to modify their process at this time could jeopardize the entire approval.
MDM's engineering group has advanced the deionized project to a point where they have shown
that it can work well on their products. The engineer that had worked on this project in the
subject plant will be transferred to the new site and will work to secure FDA approval for the
deionized system on that production line. This line will use a freon-based degreasing system until
FDA makes a decision.
If the company had implemented the deionized water system in the subject plant, the SEP would
have accelerated the elimination of Freon in this facility. The company, however, is planning
to pursue FDA approval for the deionized system in their new facility, based in part on the
research and development conducted under the SEP. The SEP, therefore, may have had the
effect of accelerating Freon reduction in the new facility. Additionally, the deionized water
equipment vendor may be able to use the results of its evaluations on the company's product in
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other applications and for other Companies. To this extent, there may be future technology
transfer benefits associated with this project. ,
e. Metal Filing Manufacturer (MFFM)
MFFM employs 65 factory workers in the manufacture of steel filing equipment and steel
shelving, using a thermal setting paint resin on an automatic electrostatic paint line. Paint
overspray is captured by filters and cardboard on the floor of the spray booths. This waste and
straight paint waste are considered hazardous wastes. When these wastes are dried in a curing
oven they are no longer considered hazardous waste; just as the products painted and dried are
not considered hazardous waste. Therefore, this company and many others like it sought to
reduce their hazardous waste disposal costs by drying their paint wastes. Under RCRA, this
activity is considered waste treatment and in October 1991, the company was cited for conducting
this activity without a waste treatment permit.
The company agreed to a SEP which required them to investigate, and insofar as practicable
implement several identified process changes in an amount not less than $218,000. The company
committed to, and ultimately implemented, the following: installation of an on-site solvent
recycling system, installation of a baffle collection system for paint overspray in their electrostatic
sprayer, installation of improved paint collection systems in paint bays and electrostatic sprayer
to prevent overspray from collecting on floor, installation of paint drum agitators and pumps for
nonstandard color paint transfer, improvement of spray efficiency of the electrostatic sprayer and
hand held spray guns, and continuous training of painters and operators in efficient painting
techniques.
As agreed to in the SEP, the company instituted several administrative measures, including:
development of a pollution prevention policy, promotion of plant engineer to vice president for
manufacturing and environmental quality to carry out the pollution prevention policy and
Program, training of all plant employees on pollution prevention strategies and opportunities for
waste reduction, attendance by management personnel at pollution prevention seminars for the
industry, development of an inventory control system, improve the spray efficiency of the
electrostatic sprayer and hand held spray gun, and continuous training of painters and operators
in efficient painting techniques.
The original penalty was reduced from $360,000 to $330,000 as a result of a downward
recalculation of the willfulness/negligence component of the penalty, and to $93,130 for the SEP.
All capital projects implemented under the SEP were completed in beginning of June 1993. It
is too early to tell whether the projects are economically successful. The President has not seen
any payoffs so far from these changes although he thinks they may payoff in the future. He
thinks that they are reducing pollution to a small extent.
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f. Metal Finishing Company (MFC)
MFC manufactures solid cast brass nuts and bolts and chrome plated tubular plumbing supplies.
In 1991, they employed approximately 80 people and sales were in the range of $18 million. The
company operates one nickel and chrome plating line. They discharge directly, after treatment,
to a canal with low water flow.
Prior to the SEP, the company generated a variety of hazardous wastes: metal hydroxide sludge
(F006) and spent alkaline solution (which were manifested as characteristically hazardous for
chromium and lead), and lead contaminated polishing waste and spent chromic acid. The facility
is a treatment, storage and disposal facility (TSDF).
The company was found to be out of compliance with several requirements under RCRA,
including: failure to properly close hazardous waste storage containers of oil and alkaline
solutions from machine shop and chromic acid from plating area; failure to label hazardous waste
containers of lead contaminated polishing dust, mixed oil and alkaline solutions, and chromic
acid.
After the EPA inspection, the V.P. of Operations learned of EPA's SEP policy in a class that he
attended on environmental compliance and pollution prevention. This class is sponsored in part
by the state's technical assistance program. He decided to propose a SEP to EPA that would
eliminate the activities that contributed to the company's violations. The SEP proposed by the
company consists of significant modifications to the company's automatic plating line to reduce
the generation of lead contaminated polishing dust waste and to convert from hexavalent to
trivalent chromium plating solution. At the request of the EPA negotiators, the company agreed
to implement a second SEP which was a measure designed to collect lead containing polishing
dust waste more effectively.
In order to reduce the generation of lead contaminated polishing dust waste, the company
replaced the existing nickel tank with a longer tank. The longer tank, plus an increase in the part
cycle time, is designed to improve the surface finish of the part so that a larger percentage of
parts do not need polishing to achieve satisfactory chrome plating. Prior to the SEP, the
company generated 77 pubic yards of polishing dust waste annually. The reduction in polishing
was designed to reduce generation of polishing dust by 65 to 85%, and to decrease the lead
content in the dust. The change was projected to increase the company's use of nickel by 130%,
from 5,500 to 12,650 pounds per year.
To reduce the generation of metal hydroxide sludge, the company proposed to convert the chrome
bath from hexavalent chromium to trivalent chromium. The company generated 16,700 gallons
of F006 metal hydroxide sludge from its nickel and chromium plating operation prior to the SEP.
They projected this change to reduce the proportion of solids in the waste stream (metal
hydroxide sludge) by 33% and reduce metal hydroxide sludge generation by 5,500 gallons per
year.
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Prior to the SEP, the company generated approximately 330 gallons of chromic acid per year
during their annual clean up and disposal of the chrome plating tank--a source of one violation
alleged in the complaint. The switch to trivalent chromium eliminates this activity and the
resultant wastestream. In addition, the elimination of hexavalent chromium decreases their use
of sulfur dioxide which is used to reduce hexavalent chromium in the waste water treatment
process.
The company estimated that the lengthening of the nickel tank and conversion to trichrome (i.e.,
the first SEP) would cost $167,149, take two to four weeks to implement, and would require the
company to invest $70,000 in inventory to supply their customers while the conversion is under
way. The company was required to spend not less than $165,000 (including capital, design and
engineering labor costs, and construction labor) on these two components of the SEP, according
to the CA/FO. The actual cost, determined after implementation, was $244,110. The estimated
cost for the second SEP (i.e., the dust collection system) was $5,400; the actual cost was $5,173.
The original penalty was set at $325,000, was revised to $150,900 as a result of documentation
and affidavits provided by the company. The final penalty was set at $23,300 in consideration
of the two SEPs.
The company projected a net yearly positive operating cash flow of $4,000 in the first year of
full operation.5 This includes a reduction in hazardous waste disposal costs of approximately
$29,000 per year and a reduction in chromic acid costs of $1,000 per year. Increased nickel and
utility costs (100% increase due to increased cycle time and size of nickel bath) were projected
at $38,000 and $2,000 per year, respectively. By planning to reconfigure product holding racks,
the company did not project a slow down in output or increased labor costs.
Finally, at the request EPA, the company agreed to modify their polishing dust collection system
by the constructing a fixed sheet metal waste collection unit that, when closed, provides
secondary containment around fifty-five gallon storage drums. This system is intended to provide
additional protection to the environment which is beyond the requirements of existing law and
regulations. The company was required to spend not less than $5,000 on these modifications.
The SEP promised a 65 to 85% reduction in the generation of polishing dust waste. The
company has cut its waste by 83 - 85%. By reducing the generation of lead contaminated
polishing dust and the lead content in the dust, the SEP reduces worker lead exposure and
disposal of lead and nickel waste generation. However, the company accomplished this by
increasing its use of nickel and electricity and consequently their associated environmental and
resource utilization impacts.
The switch from hexavalent chromium to trivalent chromium, results in several environmental
and worker health and safety benefits. First, less chromium is used in trivalent chrome systems
5 This calculation included depreciation. However, the agreement subsequently reached prohibited the
company from depreciating its capital costs for the SEP. When recalculated omitting depreciation, the net yearly
operating cash flow is reduced to -$10,000.
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than in hexavalent systems (their trivalent chromium bath is 1/30 as strong as their former
hexavalent bath and is considered about 1/10 as toxic). In addition, the trichrome process has
decreased their F006 metal hydroxide sludge generation by about 2/3. This has the benefit of
reducing environmental, public and worker health and safety impacts all along the lifecycle of
the product: chromium extraction, processing, transportation, use in plating, and ultimate product
disposal.
Hexavalent chrome has been shown to cause adverse health effects in workers. While hexavalent
is considered more harmful, health effects from trichrome have not been well researched or
documented. Trivalent baths have a higher pH than hexavalent and thus pose less of an acute
hazard to workers when bath materials are handled. In addition, trivalent chromium systems
produce less hazardous chromium hydroxide sludge waste, eliminate the need for annual cleanup
and disposal of chromic acid bath, and elimination of use of sulfur dioxide in wastewater
treatment.
The company thinks that the change to trivalent chromium is in their long term interest. They
believe that regulations are getting tighter and that all companies will eventually be required to
eliminate hexavalent chromium from their process. They feel that they have an advantage over
companies who have not yet made this change—trivalent technology may get more expensive and
they will have the experience of operating the system. The company instituted three major
changes in its operating procedures as a result of the enforcement action and SEP. First, they
set up a chemical laboratory to monitor and maintain proper plating bath chemistry. Second,
the Vice President takes an "environmental compliance" tour of the facility every six weeks; the
President participates in every second tour. Third, the company will not bring new chemicals
into the plant without: a thorough review of the Material Safety Data Sheet (MSDS) for each,
consideration of the type of waste that will be created by the use of the material, and
consideration of how the waste will have to be handled if the material is used. If the material
will pose problems in waste management and/or disposal, the company will not purchase the
material.
While the company did not use the state technical assistance program prior to or during the SEP
process, they are working with them now and are satisfied with their assistance.
g. Metal Machining Company (MMC)
MMC is a plant owned by a multinational corporation; the plant employs 1,000 people and
generates sales of about $200 million per year. The company produces engineered pump
components from metal and ceramic materials using machining and lapping6 equipment.
A process designed to accurately refine the surface of parts using abrasive, rotating plates.
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In April of 1990, a EPA issued a complaint stating that MMC failed to file Form R's in 1988
for phosphoric acid; 1,1,1 trichloroethane; xylene; methyl ethyl ketone under EPCRA 313. In
October 1991 the company signed a CA/FO agreeing to implement a SEP. In consideration of
the SEP and good faith efforts, the original assessed penalty was reduced from $76,000 to
$11,400. ,
Prior to the SEP, the company utilized 1,1,1 trichloroethane (abbreviated 1,1,1) solvent immersion
cleaning units for the majority of both in-process and final cleaning operations. Cleaning is done
for both functional and aesthetic reasons. The SEP consists of several changes to a subset of
the company's parts cleaning systems designed to reduce the amount of 1,1,1 used by 130,000
pounds per year^ MMC agreed to spend no less than $201,000, by September 30, 1991, to
retrofit a 1,1,1 degreaser used on non-metal lapped parts to reduce organic solvent use and
emissions (estimated reduction in use of 1,1,1 of 3,000 gallons per year); and purchase, install
and test equipment to switch from organic solvent to semi-aqueous-based cleaning of ferrous and
non-ferrous metal parts.
The primary environmental benefit of this project is the reduction in the use, emission and
disposal of 1,1,1 trichloroethane~an ozone depleting substance. 1,1,1 is also a central nervous
system depressant7 and is therefore hazardous to workers. Since emissions within the plant will
be reduced, the project will have a positive effect on worker health. Since 1,1,1 is slated for
phase-out under the Montreal Protocol, this and many other companies have been working toward
the elimination of this ubiquitous and effective cleaning solvent. The SEP has accelerated the
company's reduction and ultimate elimination of this substance.
In addition, the company conducted extensive evaluations of aqueous and semi-aqueous cleaning
systems at a time when there was relatively little field experience with this technology. This
project has paid-off in several ways: in-plant 1,1,1 reductions; transfer of knowledge and
experience to other parts of the plant, other plants, and repair shops owned by the company;
transfer of knowledge and experience to other companies invited to examine the equipment and
talk to plant technical staff; and education of the manufacturers and vendors of cleaning systems
that plant personnel dealt with during the course of their cleaning system evaluations.,
Tbid.
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The company considers the return on investment (ROI) for the project to be good, particularly
given the rising cost of 1,1,18. 1,1,1 use in the plant has been reduced from 30,000 to 17,000
gallons per year.9
There are about 43 other MMC plants and maintenance shops. All of these plants are moving
to eliminate the use of 1,1,1, in part because of the work done at the subject plant. Other plants
have contacted the subject plant's plant engineer for information on alternatives. Some plants
have already eliminated 1,1,1.
The company has recently engaged the services of a consulting branch of a organic solvent
manufacturer to help them convert their remaining 1,1,1-based cleaning systems over to non-
organic solvent systems. They chose this company because they are a manufacturer of 1,1,1 and
other organic solvents used for cleaning and they specialize in cleaning operations. The
manufacturing engineer is not satisfied with the consultants because they proposed a very
expensive new cleaning system and the engineer does not trust that they are providing complete
information. Therefore, the company is conducting their own investigation of the systems that
the consultants have suggested as well as other alternatives.
//. Powder Metallurgy Manufacturing Company (PMMC)
PMMC uses brass, steel, stainless steel, and metal alloy powders to produce machine screw nuts,
steel structural and special parts, and steel fasteners. Powder metallurgy technology produces
precision parts that require little or no secondary machining. The company has 50 employees.
and sales of between $5-6 million per year. The company is a member of the Metal Powder
Industrial Federation—a federation of four trade associations. There are about 140 similar
companies in this country.
In 1989, the company was cited with failure to file Form R's under EPCRA 313 for the reporting
year 1987, for copper, chromium, trichloroethylene, and ammonia.
Prior to the SEP, production of a finished part typically included the following steps: (1)
compaction of metal powder in a mold to create "green" parts, (2) sintering of "green" parts in
electric ovens in either a disassociated ammonia (hydrogen-nitrogen) or methanol/nitrogen
atmosphere to prevent oxidation and corrosion, (3) burnishing of sintered parts to remove excess
metal and provide a smooth finish, (4) brightening of brass parts with chromic acid, (5) drying,
(6) resin impregnation for corrosion prevention, (7) tapping (thread cutting) of brass parts using
1 1,1,1 trichloroethane is an ozone-depleter and is being phased-out under the Montreal Protocol. Phase-out
is scheduled to begin in 1994 and prices for this widely-used solvent have been escalating.
9 This converts to approximately 300,000 and 170,000 Ibs per year (based on a specific gravity of 1,1,1 of
1.3390), for a reduction of 130,000 Ibs per year of 1,1,1 trichloroethane.
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a water soluble cutting fluid or a heavy black sulfur oil cut with kerosene, (8) water washing to
remove the tapping fluid, (9) vapor degreasing with trichloroethylene in a vapor degreaser.
In their settlement with the agency, the company agreed to implement a SEP costing $78,300.
The SEP consisted of five components: an environmental audit ($4,350), the implementation
of a blended hydrogen/nitrogen sintering atmosphere system to eliminate the use and storage of
anhydrous ammonia ($50,598), decontamination and replacement of an existing 10,000 gallon
anhydrous ammonia storage tank, with a 1,000 gallon tank ($2,400), elimination of a
trichlorethylene vapor degreaser by switching from an oil-based tapping fluid to a water-based
alternative ($500), and the implementation of a closed loop cooling system for non-contact
furnace water which will reduce the discharge of non-contact cooling water to the POTW and
conserve water ($20,451). , ,.-.-
By switching from ammonia to blended hydrogen/nitrogen gases, the company eliminated the use
of 1.5 million pounds per year of ammonia and the threat of a catastrophic release of ammonia
gas. By eliminating the trichloroethylene vapor degreaser, the plant cut approximately 26,860
pounds per year of fugitive trichloroethylene air emissions. Trichloroethylene is an ozone
depleting substance, targeted for phase-out under the Montreal Protocol. In addition, the company
significantly reduced its generation of waste oil by switching to a water-based coolant. The
company generated 1,600 gal per year of waste oil prior to this change. ,
According to the company, the projects implemented under the SEP are expected to payback in
the "long run"~5 to 7 years.
While not included as part of the CA/FO, the company also eliminated their chromic acid-based
brightening process. This action eliminated the chromic acid treatment sludge generated in this
process. In addition, through a series of energy conservation projects, the company has cut its
energy costs by $4,000 per month.
In consideration of the SEP, the agency reduced the company's fine from $76,000 to $30,550.
The company was required to implement all components of the SEP within a 360 day time line.
The projects implemented under the SEP policy had been considered by various members of the
company prior to the issuance of the complaint. The SEP process was the impetus for their
implementation.
Through the process of implementing "environmental investments" under the SEP, the company
President has "changed his thinking" about "environmental investments." He realized that
environmental standards are going to get tighter and decided that instead of trying- to keep up
with them, it is better to lead them. He decided to eliminate trichloroethylene, chromic acid and
ammonia. While it has not been easy, the company has been able to move away from certain
hazardous operations and these changes have been economically and environmentally sensible for
the company.
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The President believes that a vision of cultural change must come from the top. He is trying to
apply TIM principles to productivity, quality, environment and worker health and safety.
L Pump Service and Sales Company (PSSC)
The subject facility is one of several owned by a large, diversified holding company. The plant
markets, sells and services pumps manufactured by a sister plant. Pumps received for repair by
the plant must be decontaminated and degreased for service and testing. As a result of PSSC's
failure to file a Form R for Freon (under EPCRA 313), the company entered into a Consent
Agreement and Order with EPA on October 1991.
Prior to the Consent Agreement, the company was using freon for decontamination and
degreasing. The company had begun efforts to reduce Freon use in late 1988 with the purchase
of a soap and water-based spray washer for some decontamination of its pumps. In the their
settlement, the company agreed to reduce, by not less than 66%, its December 1990 Freon use
rate in connection with its pump repair processes both at the subject facility and at a second
facility owned by the company.
The SEP consisted of two phases: the first phase consisted of the installation at the subject
facility of two semi-aqueous cleaning units, each of which includes an in-line paniculate filtration
system, and the conversion of the facility's existing ultrasonic finishing system from a freon-
based system to an agitation/filtration system utilizing a biodegradable cleaning agent. The
second phase consisted of the installation at a second facility, in a different state and EPA region,
two semi-aqueous cleaning units of the same type as described above.
The company estimated the cost for the two plants to be $69,475, including $56,475 for
equipment and $13,000 for installation. The Original penalty was reduced from $17,000 to
$8,500.
The environmental benefits associated with the project is the elimination of the use of Freon 113,
an ozone depleting chemical, at two plants—the subject facility and another facility in another
state and EPA region.. While the company agreed to a 66% reduction in Freon, the project
resulted in the complete elimination.
According to the Material Safety Data Sheets (MSDS), the cleaning agent contains: 1-T-Butoxy-
2-Propanol, Dipropylene Glycol 1 Monoethyl Ether, and Monocyclic Terpene Hydrocarbons.
While animal studies conducted by NIOSH has found that certain glycol ethers10 are fetotoxicants,
such evidence has not been found for Dipropylene Glycol Monoethyl Ether. Monocyclic terpene
10 Ethylene glycol monomethyl ether (EGME), ethylene glycol monoethyl ether (EGEE) and their acetates.
Based on evidence of fetotoxicity in animals, for these glycol ethers, OSHA has proposed a downward revision in
the TLV for certain glycol ethers from 100 to 0.1 ppm.
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hydrocarbons are a class of plant-based materials which many companies are turning to as an
alternative to chlorinated organic solvents. Recent discoveries, however, have linked water
effluent containing terpenes with ecotoxicty.
Through the SEP, the company has completely eliminated their freon use. The project had an
8 month payback period and the company estimates that it has saved them between $300-
$400,000 over the past four years.
2. Iniunctive Relief
a. Bleached Kraft Pulp Mill (BKPM)
BKPM is a manufacturer of bleached kraft pulp from woodchips.
In July 1991, the Company entered into a Consent Decree with EPA and a citizen's group to
come into compliance with chronic toxicity limits under the Clean Water Act and to minimize
potential impacts of effluent on recreational users. The CA/FO required the Mill to study a range
of potential remedial measures (including fluent treatment systems and in-plant process changes)
and propose to EPA a measure(s) to bring the Mill into compliance with chronic toxicity limits
under the Clean Water Act. In addition, the mill was required to construct an outfall extension
pipe capable of ensuring that the surf zone will be essentially free of mill effluent.
The mill conducted a variety of effluent treatabiliry studies, trials involving different levels of
chlorine dioxide substitution and use of hydrogen peroxide, and five full-scale trials of totally
chlorine-free (TCP) bleaching. The mill assessed the environmental benefits (e.g., chronic
toxicity, dioxin levels and AOX11; and effluent color), pulp quality, and production cost
differentials during each trial. Based on information generated during treatability studies and
bleaching trials, chose to propose the TCP pollution prevention project highlighted here. This
remedial measure, as well as the construction of an extended outfall pipe and a system for steam
stripping of condensate from digesters and black liquor recovery system12 was agreed upon, in
a second Consent Order (signed by company in September 1992), as the means by which the Mill
would come into compliance with the chronic toxicity limit established in the Clean Water Act
and improve surf zone water quality for recreational use.
The pollution prevention project consists of the total elimination of chlorine in pulp bleaching.
The Mill will eliminate their use of both elemental chlorine and chlorine dioxide and substitute
other process steps. In the new process, the pulp will be bleached with hydrogen peroxide and
oxygen, rather than chlorine and chlorine dioxide. Anthraquinone will be added to the digester
A measure of chlorinated organic compounds.
Condensates contain toxic materials that, in part, end up in discharged effluents. Steam stripping removes
most of these materials for wastewater streams.
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to increase lignin removal. The Mill's conversion to chlorine-free bleaching will also include
the re-routing of bleach plant wastewater from the sewer to the oxygen delignification system and
ultimately to the black liquor recovery cycle and incineration in the recovery boiler. As a result,
the organic materials (BOD) in the bleach plant effluent will be removed from the wastewater
stream and burned for energy in the recovery boiler.
The conversion requires the construction of new chemical storage tanks and replacement of
certain equipment such as pumps, chemical mixers, piping and possibly corrosion-resistant linings
in retention towers (to handle different bleaching chemicals). The project must be completed in
September 1995. The cost of the project is not available.
From the Mill's standpoint, the advantages of eliminating chlorine were improvements in
environmental quality, occupational health and safety, public health and "psychological comfort".
This strategy results in maximum reductions in chlorinated organic compounds, color, odor, foam,
and contact irritation for a wide array of Mill constituencies: beach walkers, surfers, kayakers,
and anglers. During the first trial they realized that the Mill was a more hospitable place without
the use of chlorine and chlorine dioxide. This translates into worker health and safety
improvements (e.g., eliminating the occasional acute hazard of inhalation of high concentrations
of chlorine and chlorinated byproducts) and reduced public health hazards associated with the
elimination of chlorine transport and storage.
The Mill will benefit economically from TCP pulping through savings in such things as: worker
safety training and safety equipment purchases (e.g., self-contained breathing apparatus),
expensive metals needed to provide resistance to the corrosive properties of chlorine), expensive
corrosion-resistant plastic, and paint films (chlorine is inhospitable to paint). During a recent
two-week run, the Mill saw improvements in operating costs, but it is still more expensive to
product TCP pulp than the normal chlorine bleached product.
A key factor in considering chlorine elimination was market demand for TCP pulp. The mill is
not able to achieve maximum pulp brightness, as seems to be required by a large share of the
bleached kraft pulp market. In some U.S. markets, in Germany, and in other parts of the world,
TCP pulps are in demand because of the environmental concerns associated with chlorine
bleaching. The Mill has not fully developed a marketing strategy. They have located end-users
for whom chlorine use or chlorine content in the final product is a concern. They are promoting
the use of TCP pulp to governmental and institutional purchasing agents.
As a result of this experience, the company has changed the way it approaches regulatory matters.
Although they have traditionally involved technical personnel early in the process, they will seek
to involve these personnel in initial discussions with Regulatory Agencies and bring attorneys in
later on in the process. In this way, the company believes that they can have more productive
discussions about the technical aspects of the project and then negotiate a final agreement.
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C. CASE COMMENTARY AND ANALYSIS
1. SEPs versus Iniunctive Relief
Of our ten case studies of pollution prevention in enforcement, only one case involves pollution
prevention as a means to come into compliance (i.e., injunctive relief). The other nine cases
involve SEPs. The case study selection criteria were not inherently biased toward SEPs; rather
we sought innovative, somewhat unique pollution prevention projects from among our sample
population of both SEPs and injunctive relief cases. One case that we selected, Bleached Kraft
Pulp Manufacturer (BKPM), was the only injunctive relief case reported that contained a
pollution prevention compliance strategy. We selected it because the pollution prevention project-
-elimination of chlorine in kraft pulp bleaching—was innovative and had great technology transfer
potential.
2. Companies
Since our selection of case studies was made largely on the basis of the nature of the
technological change, the distribution of company type and size are an artifact and not criteria
of, our selection strategy. Our sample is dominated by metal products manufacturers (six out of
ten companies). Considering that many processes used by these manufacturers are
environmentally problematic (e.g., metal plating, painting, and degreasing), and that historically,
a great deal of attention has been focused on pollution prevention in these industries, the
dominance of these firms in our sample is not surprising. The other four case study firms
represent a rather broad array of industries: plastics coating, medical device manufacturing, pump
service and sales, and bleached kraft pulp production.
With regard to size, three case study firms-MFFM, MFC, and PMMC~are single plant
companies ranging from 50 to 80 employees. Two case studies~IC and PSSC-involve small,
autonomous divisions of larger holding companies. Four case studies-CMPM, LM, MDM, and
MMC~involve small/medium-sized plants (100 to 1,200 workers) that are owned-by medium-
sized, multiplant companies. The injunctive relief case--BKPM~is a large manufacturing plant
owned by a large corporation.
3. Nature of the Violation CRegulatory Program')
Of our ten case studies, five arose out of violations of Form R reporting requirements under
EPCRA, Section 313; two stem from CWA violations; one from a CAA violation; and one from
RCRA. The predominance of EPCRA cases in our study sample reflects the relatively large
number of pollution prevention SEPs in the larger sample population that were negotiated in
EPCRA 313 settlements. There are several reasons why the majority of SEPs have arisen in
EPCRA cases. EPCRA violations occur in companies that are using or producing toxic chemicals
(so called 313 chemicals). In recent years, pollution prevention efforts, within and outside the
agency have focused heavily on the elimination, reduction or recycling of toxic substances (e.g.,
EPA'c 33/50 Program). Thus, EPCRA cases tend to be natural candidates for pollution
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prevention SEPs. This is particularly true for companies using chlorinated organic solvents that
are slated to be phased-out under the Montreal Protocol and amended U.S. Clean Air Act.
Spurred by the London Amendments (1990) to the Montreal Protocol, the amended U.S. Clean
Air Act established a phase-out of CFC-113 (also called Freon) and 1,1,1-trichloroethane (also
called TCA or 1,1,1) in the years 2000 and 2002, respectively. HCFCs will be banned between
2020 and 2040 or earlier as spelled-out in the London Amendments. As these dates approach,
the costs of these materials are increasing and, as a result, the alternatives are becoming more
economically favorable. Numerous, relatively low-cost aqueous or semi-aqueous systems are now
widely available. A switch to these alternatives typically poses relatively low or no technological
risk to the firm13 and may save the firm considerable amounts of money.14 These features are
motivations for both the firm and the agency to negotiate SEPs into these cases.15
Finally, according to one regional attorney, since the penalty assessed for 313 violations constitute
"gravity" only, and not "economic benefit" (because there is no economic benefit to be gained
by not filing a Form R), a large percentage of the penalty can be used to leverage a SEP.16
4. Original and Final Penalties, Project Cost and Payback
Table A-2 summarizes the penalty information and pollution prevention project costs for the nine
SEP case studies. Penalty reductions granted for SEPs range from $7,350 to $237,000. In seven
of nine cases, the penalty reduction leveraged a significantly greater pollution prevention
expenditure by the firm. One notable case is LM which expended $298,000 to reformulate their
lid gasket material for a penalty reduction of $38,000. In one case, MFC, the cost of the
pollution prevention project was 25% higher than the penalty reduction.
11 FDA-regulated firms, such as pharmaceutical and medical device manufacturers, are a notable exception.
In these cases, manufacturers must obtain FDA approval to switch from solvent to aqueous-based cleaners (FDA
regulates product and process). The approval process can take several years and can be very costly. Therefore, these
firms tend to choose solvent recycling strategies rather than chemical substitution since recycling does not generally
require FDA approval.
M The SEP policy contains a limitation on projects that represent a "sound business practice", i.e., capital or
management improvements where the firm, rather than the public, is likely to receive the substantial share of the
benefits. However, this limitation can be waived only for pollution prevention projects having significant
environmental benefit (SEP policy, page 9).
15 • Region V Attorneys and Case Officers offered several other reasons for the preponderance of 313 SEPs.
The EPCRA 313 reporting requirement is relatively new (since 1988); it virtually "grew up" with the Agency's
initiative to include SEPs and pollution prevention in enforcement agreements. According to a Case Officer in the
Region's Pesticides and Toxic Substances Branch (housing the TSCA and EPCRA programs), company attorneys
and private law firms are as unfamiliar with 313 as they are with SEPs, and it is easier to couple SEPs with 313
settlements than with settlements arising out of other regulatory programs.
" According to the SEP Policy, only the gravity portion of the penalty can be mitigated by the SEP.
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Table A-2. SEP Case Study Original and Final Penalties, and Project Costs
Company
CMPM
1C
LM
MDM
MFFM
MFC
MMC
PMMC
PSSC
Original Penalty
$ 95,000
$ 50,000
$123,947/$76,000*
$31,350
$360,000/$330,000*
$150,900
$ 76,000
$ 76,000
$ 17,000
Final Penalty
$30,000
$30,000
$38,000
$24,000
$93,130
$23,300
$11,400
$30,550
$ 8,500
Penalty
Reduced for
SEP
$ 65,000
$ 20,000
$ 38,000
$ 7,350
$218,000
$127,600
$ 64,600
$ 45,450
$ 8,500
Project Cost
not avail.
$ 54,000
$298,000
$ 80,000
$218,000
$249,000
$201,000
$ 78,300
$ 69,475
*First number is original penalty. Second number reflects a reduction for good faith.
We obtained payback information from case study firms during our interviews. In one case,
MFC, we acquired a copy of the company's profitability analysis which they had submitted to
EPA during their SEP negotiations. Our data are a mixture of numerical payback estimates and
qualitative impressions of project profitability. In some cases we were unable to gain this
information, either because it was too soon for the company to know (MFFM) or because they
considered this information to be somewhat sensitive (LM).
Project payback ranges from a very profitable 8 months ($300-400,000 saved over a four year
period) to a less profitable 5-8 years. Projects that involve the reduction or elimination of ozone-
depleting chemicals seem to be more profitable than others because the cost of these organic
solvents is steadily increasing as the final phase-ou;t date^ approaches.
It is important to note that profitability analysis of pollution prevention investments is highly
subjective. In particular, companies tend to omit certain financial benefits of pollution prevention
projects, such as avoided liability and regulatory costs, because these costs are difficult to
estimate and are speculative. Therefore, caution should be exercised in drawing conclusions from
reported payback data.
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5. Environmental and Human Health Benefits
There are two categories of environmental benefits that arise from pollution prevention SEPs and
injunctive relief projects. The first category constitutes environmental benefits directly
attributable to the SEP or injunctive relief project; these benefits are the subject of this section.
The secondary category consists of the indirect benefits from pollution prevention implemented
"beyond" the enforcement settlement which were leveraged by the SEP/injunctive relief either
through technology transfer within/outside of the firm, or through organizational change within
the firm. While the former is easier to measure and evaluate, the latter may be significant and
should not be overlooked. We address indirect benefits in the section on technology transfer
below.
To evaluate environmental benefits of pollution prevention, used as a means to compliance, i.e.,
injunctive relief, we can analyse the absolute benefits of the project and the benefits relative to
the technology that the company might have implemented had they not chosen a preventative
strategy. In the case of BKPM, the absolute benefits of eliminating chlorine are quite significant,
they include: the elimination of chlorinated organic compounds from wastewater; reductions in
wastewater color, odor, and foam; elimination of worker hazards associated with chlorine and
chlorine dioxide; and public health hazards associated with the elimination of chlorine transport
and storage. In addition, by eliminating chlorine, the mill can cycle bleach plant effluent into
their black liquor recovery system to recover energy and pulping chemicals from bleach plant
effluent and reduce BOD in discharged effluent.
When considering how to meet the wastewater toxicity limits in their Consent Decree, BKPM
initially considered increasing chlorine dioxide and hydrogen peroxide substitution of elemental
chlorine—process changes that constitute preventative strategies for reducing chlorinated organic
compounds. In addition, they considered conventional secondary wastewater treatment and non-
traditional treatment technologies (e.g.coagulation/precipitation, ultrafiltration, and catalyzed
ultraviolet light treatment). The mill's,chosen strategy appears far superior on environmental,
occupational/public health grounds to bom the alternative prevention strategies and the treatment
alternatives. The TCP option will eliminate rather than simply reduce chlorinated organics in
effluent, will eliminate chlorine hazards to workers and the public rather than reducing them
under the other prevention options ~ or having no effect under the treatment strategies.
*
To evaluate the environmental benefits of pollution prevention SEPs, we can also consider the
absolute benefits of the project and the benefits relative to a hypothetical scenario of the
settlement without a SEP. The environmental benefits of SEPs—summarized in Table A-l and
in more detail in the full case studies—are presented again in summary form in Table A-3 for ease
of reference.
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The following is an characterization of the types of environmental benefits achieved,
The implementation of five of the nine SEPs have/will result in significant
reductions in use and emissions of ozone-depleting chlorinated organic solvents-Freon
and 1,1,1 trichloroethane. While the use of these solvents will be phased-out under the
Montreal Protocol, and amended U.S. Clean Air Act, these SEPs achieve an accelerated
reduction of long-lived ozone-depleting substances.
The use and emissions of seven of the list of 17 target chemicals of EPA's
Industrial Toxics Project were/will be reduced in the nine SEPs studied: chromium -and
compounds, lead & compounds, methyl ethyl ketone, nickel and compounds, toluene,
1,1,1-trichloroethane, trichloroethylene.
Two SEPs--IC and MFFM-will/have achieved reductions in non-chlorinated
solvent use (including methyl ethyl ketone and toluene) that will, among other benefits,
improve the quality of the work environment.
MFC switched from hexavalent to trivalent chromium, resulting in an improvement
in conditions for workers as well as reduced chromium emissions to the environment. By
reducing the generation of polishing dust containing lead and nickel, MFC's SEP reduces
worker lead exposure and environmental loading of lead and nickel.
• Through the reformulation of jar lid gaskets, LM has significantly reduced its VOC
emissions in a non-attainment area for VOCs.
While the pollution prevention projects implemented under the nine SEPs studied result in
significant environmental and human health benefits, it is important to point but that in some
cases new sources of exposure or pollution are created by the new technology. For example,
aqueous and semi-aqueous cleaning agents, used in several SEPs to replace organic solvents,
become a new wastestream either released in wastewater to wastewater treatment plants or
drummed and disposed of as hazardous waste. Aqueous cleaners are not typically hazardous but
may become contaminated with hazardous substances during cleaning.17 If this is the case, spent
cleaner must either be treated to remove contaminants before discharge to the sewer or, like the
organic solvents they replaced, must be disposed of as hazardous waste. In these cases, it is the
contaminant (i.e., the material "cleaned-off the product) that is the culprit, not the aqueous
cleaner itself.
U.S. Environmental Protection Agency. "Guide to Clean Technology: Alternatives to Chlorinated Solvents
for Cleaning and Degreasing." July, 1992.
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Table A-3. Summary of Environmental and Health Benefits of Pollution Prevention in
Enforcement Case Studies
Company
SEPs;
Casted Metal Products
Manufacturer (CMPM)
Industrial Coater (1C)
Lid Manufacturer (LM)
Medical Device
Manufacturer (MDM)
Metal Filing Furniture
Manufacturer (MFFM)
Metal Finishing
Company (MFC)
Metal Machining
Company (MMC)
Powder Metallurgy
Manufacturing
Company (PMMC)
Pump Service and Sales
Co. (PSSC)
Injunctive Relief:
Bleached Kraft Pulp
Manufacturer (BKPM)
Environmental and Health Benefits
Reduced wastewater discharges by approx. 100,000 gpd (75%
reduction), reduced energy consumption and use of Freon,
perchloroethylene, 1,1,1-trichloroethane,
nitric acid, and isopropyl alcohol
Reduction in toluene use (56,000 to 5,600 Ibs) and MEK use (50%
reduction) and toluene and MEK emissions, waste and worker
exposure. Net energy savings of 890 kw per hour.
The Company estimated that heptane usage would decrease by 203
tons per year, resulting in a reduction in VOC emissions of 50 tons per
year. Particulates from manufacturing, natural gas usage and oven
emissions may increase by 3.65 tons per year, and NOx, CO, HC and
SO2 may increase by less than 1 ton per year each.
Elimination of the use of 16,000 Ib/yr of Freon
Project designed to reduce paint and solvent use, waste and emissions.
(Small success to date.)
Reduction in lead contaminated dust generation (83-85%), elimination
of health hazard assoc. with hexavalent chromium, reduce chromium
use (bath strength decreased by 1/30) and sludge generation (67%).
Nickel use will increase from 5,500 to 12,650 Ib/yr.
.Reduction in the use (30 to 17,000 gal/yr), emission (130,000 Ib/yr)
and disposal of 1,1,1 trichloroethane-an ozone depleting substance and
a health hazard to workers.
Elimination of ammonia release threat, elimination of
trichloroethylene use and approx. 26,860 Ib/yr of fugitive emissions
and reduction of 1,600 gal/yr of waste oil.
Elimination of the use of Freon 113, an ozone depleting chemical, at
the subject facility and another facility in another state.
Elimination of threat of chlorine gas release (a public and workplace
hazard), reductions in the creation of chlorinated organic compounds;
wastewater color, odor, and foam.
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While semi-aqueous cleaners are biodegradable, non-ozone depleting and often recyclable, they
may contain slightly hazardous constituents. For example, the cleaner adopted by PSSC contains
terpene, a plant-based hydrocarbon material which pose the risk of flashing at room temperature.
While EPA has not fully studied terpenes, limited testing of a terpene called d-limonene by the
National Toxicology Program in 1990 has shown positive carcinogenicity in male rats. The
strong odor of terpenes may be offensive to workers, requiring adequate ventilation.18 Like their
aqueous counterparts, semi-aqueous cleaners may be contaminated by hazardous materials during
cleaning. For example, spent semi-aqueous cleaner used to de-contaminated pumps at Pump
Service and Sales Company (PSSC) is disposed of as a hazardous waste.
In the case of LM, reductions of VOC emissions came at the price of small increases in NOx,
CO, HC and SO2 emissions and MFC reduced the generation of lead contaminated nickel dust by
increasing its overall use of nickel by 130%.
What would have happened if SEPs were not included in these nine settlements? Certainly, the
nine companies would have paid higher penalties to the U.S. Treasury. Beyond this, in some
cases it is possible and in some cases it is virtually guaranteed (e.g., Freon users), that the
pollution prevention projects implemented as SEPs would have been implemented by the firms
some time in the future. Several firms stated that they would have eventually implemented the
projects. This issue will be examined in a subsequent section. It is relevant to consider the
environmental benefits of accelerated implementation where projects would most likely have been
implemented eventually. The environmental benefit of accelerated elimination of long-lived
ozone-depleting substances-the outcome of five SEPs studied here~is probably most profound.
All but one case study consisted either entirely or partially of .multi-media pollution prevention
projects, i.e., they reduced or eliminated two or more of the following: emissions to air,
emissions to water, generation of waste, and exposure of workers to hazardous substances. The
exception is the gasket reformulation project implemented as a SEP by LM which was designed
as a VOC reduction measure and had no positive impacts on other media. None of these SEPs
with multi-media impacts, however, were explicitly negotiated via a multi-media enforcement
initiative.
6. Source of the Technical Idea
Case study companies sought and obtained technical ideas from: their own staff, environmental
consultants, technical consultants, trade journals, vendors, and their EPA case officer. Several
companies used more than one source.
Companies switching from organic solvent to aqueous degreasing relied heavily on the expertise
of equipment/chemical vendors. MFC learned of trivalent chromium technology from the
chemical supplier. One company, MDM, saw an advertisement for deionized water cleaning
Ibid.
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equipment in a trade journal. One company, LM, used a technical rather than environmental
consultant, to help with equipment design.
In only one case, CMPM, did the case officer play a significant role in providing technical
expertise and specific suggestions. In the case of MFFM, all technical ideas contained in the SEP
came from an environmental consultant hired by the firm. The company did not feel that they
had the necessary expertise to develop pollution prevention ideas.
Most case study firms stated that they would prefer not to involve the agency in the process of
developing technical proposals for a SEP, particularly if it would require repeated agency site-
visits. Many of these firms typically had, or quickly developed, project ideas that were
on/consistent with their long-term critical technology path. One firm stated that they would not
reject a good idea provided by the agency, but they were certainly not looking to the agency for
ideas.
In one exceptional case, MMC, company representatives indicated that they sought technical
assistance from the regional case officer but the case officer was unwilling to provide help.
MMC's manufacturing engineer was seeking (and was strongly encouraged by the agency to seek)
alternatives to 1,1,1-trichloroethane-based cleaning systems for technically demanding
applications, at a time when aqueous and semi-aqueous technology was fairly immature.
Several case officers reported that they were reluctant to provide technical advice for two
principal reasons. First, they are concerned that if the company follows their advice and the
project fails, the case will be jeopardized and the case officer will be reprimanded. Second, :
because companies understand their processes better, they are in a better position than case
officers to develop appropriate and creative technical ideas. A suggestion from a case officer
may also short-circuit the company's own creative technical process and lead to a less innovative
and/or less effective project. Generally, case officers prefer to have the violator propose a SEP,
and then once proposed, the case officer can perform their role as evaluator of the project's
environmental merit and technical feasibility.
The role of the environmental consultant19 in the CMPM and MFFM cases was particularly
important and worth noting. At the outset of the enforcement process, neither company was
familiar with pollution prevention concepts or techniques, nor did they have the technical
capability to develop or implement prevention projects. Therefore, these companies entrusted
their hired consultants with the development of project proposals and implementation during the
settlement process. In addition, the regional negotiators, knowing that the companies lacked
necessary capabilities, openly relied on the expertise of the consultants (and in some ways used
the consultants as neutral arbiters) and thereby invested these consultants with significant power
in the settlement process. These factors elevated the role of the consultants in this process and,
19
By environmental consultant, we mean consultants engaged primarily in studies, engineering design, and
implementation projects for environmental compliance, remediation and pollution prevention.
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to a large degree, the outcome was determined by the consultant's knowledge, expertise,
experience with specific technologies (e.g., baffle collection system for paint overspray), and
technical orientation (e.g., waste minimization vs. product reformulation), rather than the
knowledge, etc. of the companies.
In the case of 1C, the environmental consultant designed the SEP and assumed a primary role hi
monitoring and reporting project progress during the implementation phase. It may be that the
focus in this case-waste minimization as opposed to more "up-stream" process changes-is a
result of the technical orientation of the consultant rather than a factor of what made most sense
from a technical/environmental and economical standpoint. If this is so, both the lack of
technical expertise within the company and the orientation of the consultant may help to explain
why the projects implemented are not performing well environmentally or economically.
At first, CMPM's environmental consultant-a geotechnical/environmental engineering firm-took
a major role in making technical recommendations for bringing the company into and beyond
compliance. The consultants recommended a $250,000 combined-flow treatment plant that the
company realized they did not need.20 This realization came about as a result of a process
investigation that the company performed at the request of the regional case officer. At this
point, the company lessened the role of the hired consultant and, to a significant degree, the
regional case officer assumed the consultant's role in developing pollution prevention options.
The outcome of the case—a SEP consisting mainly of the redesign of several rinsing and coating
lines in the metal finishing area-is largely a function of the case officer's expertise. The case
officer had just finished a year-long rotation with the state's pollution prevention technical
assistance program which has participated in numerous metal finishing, plating/rinsing redesign
projects. According to CMPM, the regional attorneys trusted the consultants and therefore, they
assisted the company throughout much of the negotiation process by helping to win EPA approval
for the technical changes that the company sought to implement.
In contrast to 1C and CMPM is the case of PMMC. PMMC hired an environmental consultant
to perform an audit (one part of the SEP), but all of the pollution prevention ideas included in
the audit came from within the plant. The consultant served primarily-to endorse the ideas. It
is interesting to note that in this case, the company became extremely motivated by the success
of the pollution prevention projects implemented in the SEP.
7. Type of Pollution Prevention Implemented in the Case Study Firms
The case studies contain a wide array of pollution prevention techniques, including: chemical
substitution, product reformulation/redesign, process modifications to conserve water/energy, and
waste reduction measures.
If CMPM built this plant, they would have had significantly less incentive to implement pollution prevention
in the context of the SEP and into the future.
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Six SEPs dealt with chemical substitution in cleaning processes. Four consisted of substitution
of chlorinated organic solvent-based cleaning/degreasing systems with aqueous/semi-aqueous
degreasing or deionized water-based processes. In one case, PMMC, the company switched its
tapping fluid to an aqueous formulation which enabled them to shut-down their 1,1,1
trichloroethane degreasing unit—formerly needed to remove an oil-based tapping fluid.
Three cases involved chemical substitution in non-cleaning processes. MFC substituted trivalent
chromium for hexavalent chromium in its chrome plating line. PMMC replaced its ammonia
sintering atmosphere with a safer blend of nitrogen and hydrogen gases. BKPM eliminated
chlorine use in bleaching by making significant changes to the chemistry of its pulping and
bleaching processes.
Three cases involved product reformulation/redesign (usually necessitating process changes as
well). LM reformulated their gasket coating material to eliminate VOC-producing heptane from
the recipe. This change required modifications to drying equipment. 1C agreed to reformulate
their coating in order to eliminate the toluene coating vehicle. This change required significant
equipment redesign. MFC reduced lead contaminated dust generation by redesigning their
product. They increased the thickness of the nickel plate on the product to improve surface finish
so that a larger percentage of parts do not need polishing—the dust-generating process. This
change also required significant process modifications.
Two cases involved process modifications to conserve water and energy, and to reduce
wastewater. CMPM redesigned rinsing systems on several process lines to conserve water and
reduce wastewater discharge. PMMC implemented a closed-loop cooling system.
One case, MFFM, implemented a SEP consisting of several waste reduction measures designed
to reduce organic solvent and paint waste generation; these included a solvent recycling system
and a paint overspray recycling system (baffled collection system).
8. Innovation vs. Diffusion and the Locus of Technological Change
The technological changes undertaken by case study firms can be categorized by a framework
that classifies pollution prevention projects according to the locus and innovativeness of
technological change. By locus we mean whether the change was made to a primary, secondary
or ancillary production process. A primary process is one which yields the key functional
property or properties of the product (i.e., defines the product). Using the example of a steel
bolt, the primary production process is the casting of the part. An example of a secondary
process is the metal plating of the part. Plating may provide a functional (e.g., non-corrosive)
or aesthetically-pleasing finish, but it is not primary to the function of the product. An ancillary
process is, for example, cleaning of the bolt prior to plating. Ancillary does not mean
unimportant. As any metal plater will tell you, dirty parts do not plate properly.
Innovation is the first commercial application of a new technical idea. To categorize the
innovativeness of the technological change, we use three general headings: major innovation,
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incremental innovation and diffusion. Major innovation involves a significant shift in technology
incremental innovation involves smaller changes or the adaptation of existing technology, and
diffusion is the widespread adoption of existing technology (i.e., involving little or no
innovation).
When the "locus" and "innovativeness" characterizations of technological change are combined
we produce the three-by-three matrix pictured in Table A-4. Projects that are located in the upper
left-hand corner of the matrix, i.e., major innovation in primary production processes, represent
. dramatic changes m the core technology of the firm. Generally, these projects tend to require
relatively high capital investment and pose greater risk to the firm, particularly when changes in
product characteristics may disrupt established markets or when new technical expertise is needed
and old expertise becomes obsolete.21
When we locate the technological changes made by case study firms within this matrix (Table
A-4), we can see that the majority of changes are diffusion driven, while a smaller number can
be considered incremental innovations and only one-BKPM--can be considered a major'
innovation. There is a fairly even distribution of technological changes across the spectrum of
primary, secondary and ancillary processes.
When this distribution is considered in the context of the selection criteria used to choose case
studies, we note that although we selected me most innovative projects for study, our sample was
largely made up of diffusion-driven technological changes. In addition, by seeking case studies
involving process redesign and product reformulation, our sample contains a significant number
of changes to primary or secondary production processes. If we had used a random case study
selection process, our sample would have been much more heavily weighted toward the lower
right-hand corner of the matrix, i.e., diffusion-driven changes to ancillary production processes
since a large number of SEPs consisted of the replacement of organic solvent-based cleaning
systems with aqueous/semi-aqueous-based systems.
In Section 14 below, we discuss the length of the project implementation period as a factor in
the inclusion of innovative projects in enforcement settlements.
Abernathy, W.J., Clark, K.B., "Innovation: Mapping the Winds of Creative Destruction" in Tushman M W
& Moore, W.L. Readings in the Management of Innovation. 2nd edition. Cambridge: Ballinger, 1988.
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Table A-4. Characterization of Pollution Prevention Technological Changes Made by Case
Study Firms According to Locus and Degree of Change
Locus of Change
Primary Production
Process
Major
Innovation
EKPM-TCF
bleaching
Degree of Change
Incremental Innovation
IC-organic solvent-free
coating
LM-reformulate gasket
Diffusion
PMMC-ammonia to
nitrogen/hydrogen atm.
Secondary
Production Process
CMPM-redesign of
rinse systems
MFC-nickel tank
extension
MFFM-paint and
organic solvent
recycling/waste
reduction
MFC-conversion to
trivalent chromium
Ancillary Process
MDM-substitution of
deionized water
decreasing system
CMPM-substitution of
aqueous cleaners
MMC-substitution of
semi-aqueous cleaners
PMMC-substitution of
aqueous tapping fluid
and closed loop cooling
PSSC-substitution of
semi-aqueous cleaners
9. Technology Transfer Benefits
In two cases, CMPM and MMC, the companies have transferred the ideas for solvent use
reduction and water use reduction, respectively, to other plants. The SEP implemented in the
PSSC settlement included the substitution of aqueous cleaning systems in both the subject plant
and another plant in another state and EPA region (even though no violation had been cited in
the second region).
1C and LM will evaluate the success of the SEP projects to decide whether to implement the
technology on other product lines within the subject facilities. In two cases, MFC and PMMC,
there is particularly significant potential for technology transfer to other firms since MFC
participates in a state-sponsored pollution prevention group of industries and uses the state
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pollution prevention technical assistance office; the President of PMMC is active in his trade
association. . , ,
In the case of MDM, the company will not implement the deionized water degreasing system in
the subject facility, since this facility will soon close. However, the company will seek FDA
approval to install the system in a new facility that will replace the production capacity of the
subject plant.
Finally, the technology transfer benefits arising from the implementation of TGF pulping in1
BKPM are quite significant. When the project is completed, BKPM will be the first mill in the
U.S. to produce bleached kraft pulp without the use of chlorine. Since the company has disclosed
information regarding process changes that they are implementing, the project will certainly push
an important technological/environmental frontier in pulp and paper industry.
10. Organizational Change ; ,/
In our interviews with case study firms, we attempted to identify whether and how the company
has made organizational changes as a result of implementing pollution prevention SEPs or
injunctive relief projects. It is difficult, in some cases, to determine whether changes made were
a result of implementing pollution prevention or a result of the enforcement action in general.
With this caveat in mind, this section contains an overview of the organizational changes made
by case study firms as communicated to us by the companies.
In the case of PMMC, the President's perception of environmental investments has
changed. He now believes that ii is economically sensible to stay one step ahead of
environmental regulations by eliminating hazardous operations.
• CMPM increased their environmental staff by adding one full time engineer and
three part-time technicians. .. . ,, ',,: ., . , ,.„.„.,'
Through the SEP process, technical staff at CMPM and MMC developed,
knowledge and skills to enable them to pursue pollution prevention beyond the SEP, and
they are applying their abilities to management goals of total elimination of organic
solvents and zero-discharge, respectively.
MFFM's SEP contained specific organizational change initiatives, proposed by the
firm's environmental consultants, including pollution prevention training and the
promotion of plant engineer to vice president for manufacturing and environmental quality
to carry out a pollution prevention policy and program.
It was not apparent that the SEP process catalyzed organizational change in MDM.
Prior to the enforcement action, a new state hazardous waste reduction law motivated the
company to reevaluate their approach to environmental compliance and the true cost of
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the materials they use. They had already made significant strides toward reduction of
Freon use and pollution prevention in general.
• BKPM had also implemented many process changes, prior to their consent order,
to improve the efficiency and reduce the waste generated by its processes. Their
experience in seeking EPA approval for the TCP project has changed their views on the
best way to approach regulatory matters in the future. They will seek to involve technical
people only in initial discussions with EPA and bring attorneys in later on in the process.
• Two companies have instituted new policies that prohibit new chemicals from the
plant without approval of environmental personnel.
Two companies started working with state pollution prevention technical assistance
offices.
• No organizational change was apparent in either LM or PSSC.
It is also important to consider whether in-house counsel or retained private bar were supportive
or skeptical of SEPs and whether their views changed. With respect to in-house counsel, we have
only one case upon which to draw insight. In the case of MDM, we interviewed the company's
in-house corporate environmental attorney who played a significant role in negotiating the SEP.
The attorney was, and continues to be, supportive of the SEP policy as a way to recognize the
efforts of a violator (via penalty mitigation) to make environmental improvements through a
project that is beneficial to the company as well.
The majority of case study firms relied primarily on outside counsel during the negotiation
process. The next section considers the role of outside counsel in the settlement process.
11. The Role of Outside Counsel (Retained Private Bar)
Six out of the ten case study firms stated that their outside counsel was instrumental in
negotiating SEPs and, in particular, helping to establish implementation schedules, milestones,
and stipulated penalties. The following summarize relevant portions of our interviews.
• MFC stated that they had a good outside attorney—with experience in
environmental litigation—who was instrumental in crafting the company's SEP proposal.
• MDM's in-house environmental counsel gives substantial credit for the successful
inclusion of the SEP to their outside counsel. The idea of a SEP came out of an initial
meeting between EPA negotiators and the outside attorney who conveyed to the company
that the agency was very interested in including a pollution prevention SEP in the
settlement and asked the company if they had an appropriate project. The attorney was
both assertive and creative in his dealings with the company and EPA and he managed
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to work out an agreement between the two parties despite the difficulties that arose over
the implementation schedule.
According to EPA negotiators, MFFC's outside counsel was formerly with the
U.S. Attorney General's Office and had worked on EPA settlements in that capacity. She
was very familiar with the settlement process and this made the negotiations much
smoother. The region considered her involvment to be a contribution to the success of
the SEP negotiation.
The regional negotiators stated that LM used an outside attorney who understood
the SEP policy well and was very proactive.
• PMMC stated that their outside counsel was very helpful in negotiating the SEP,
particularly in establishing the implementation schedule.
In one case, CMPM, the firm stated that their outside attorney hampered the process because he
was unfamiliar with environmental regulations and agencies.
Although we did not have the opportunity to directly interview the outside counsels spoken of
by the case study firms and described above, our general impression is that these counsels were
supportive of SEPs. Since the firms view SEPs positively, the outside counsels role is viewed
as a beneficial contribution since they helped the firm to negotiate a SEP. For their part, the
counsels can point to their role in reducing the penalty--a tangible "value added" service.
We were not able to determine whether the views of outside counselors changed in the course
of the settlement process.
12. Change in Vendor/Consultant Relations
Two case provide contrasting experiences in changed relations with consultant/vendor. CMPM
was dissatisfied with their technical consultants~a geotechnical/environmental engineering
consulting firm that contributed to some degree with process change ideas~by reviewing and
modifying recommendations from the EPA case officer-but largely recommended traditional
technical problem-solving approaches. The company would be hesitant to use them again. LM
was very pleased with their technical consultants who were knowledgeable about both
manufacturing technology and environmental regulations.
Two companies now have begun to use state pollution prevention technical assistance programs.
MMC hired a consulting branch of a chemical manufacturing company. MMC's manufacturing
engineer has found that his knowledge of pollution prevention technology has enabled him to be
a better evaluator of technical options for his company than these potentially biased consultants.
In four cases, no change in vendor/consultant relations was apparent.
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13. Projects Not Completed Under the SEP
In two cases, 1C and MDM, the companies did not fully implement the SEP projects within the
established timeline and, as a result, paid stipulated penalties to the agency. During project
implementation, 1C experienced unanticipated technical problems in using their existing coating
equipment to apply the new coating formulation. Therefore, they were not able to meet the SEP
implementation deadline. Despite the regions' willingness to grant an extension, the company
paid the penalty to eliminate the SEP deadline pressures. They are planning to re-initiate the
project in the near future since they consider it to be a "bonafide win-win situation for the
environment and [their] enterprise."
MDM has chosen not to purchase the deionized water cleaning system for the subject plant
because they will be closing the subject facility in February of 1994 and will be moving its
operations to another plant. However, given the success of the technical evaluation conducted
under the SEP, the company will seek FDA approval for the deionized system at the new site and
implement it if approval is granted.22
14. Time to Implement the Pollution Prevention Project
For each case study, Table A-5 below presents information on the timeline established in the
consent agreement and final order (CA/FO) for SEP/injunctive relief project implementation.
Specifically, the table contains: the date of the agency's complaint23, the date of the CA/FO (i.e.,
the date it received final signature(s)), and the implementation deadline contained within the
CA/FO.
By reading the notes that accompany the entries, one can see that these dates do not always
present a clear picture of the actual time taken to implement the projects. In three cases—CMPM,
MMC, and PSSC~the companies began implementation of the projects prior to the finalization
of the CA/FOs. In two cases~IC and MDM~the projects were not completed as SEPs (see
Section 13 above). Looking only at those SEPs where project implementation began at or near
the CA/FO date, and was completed under the agreement (i.e., LM, MFFM, MFC, and PMMC),
implementation periods ranged from 3 to 17 months. The shortest period,, 3 months for the MFC
case, is a result of the fact that the company needed to compress the implementation process into
its one-week scheduled shut-down period, which fell within 3 months of CA/FO finalization.
22
Given the uncertainty of FDA approval and the need for R&D, agency and company negotiators put
significant effort into developing the stipulated penalty schedule. Stipulated penalties did not appear to be a major
concern, or to require much negotiation effort, in other cases.
21
The agency files a complaint, after an inspection, if violations were found during the inspection. The
complaint typically contains the findings of the violation, notice of the proposed assessment of a civil penalty against
the respondent, and notice of respondent's opportunity to request a hearing on the proposed penalty assessment.
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Table A-5. Time to Implement Pollution Prevention Projects
Company
SEPs:
Casted Metal Products
Manufacturer (CMPM)
Industrial Coater (1C)
Lid Manufacturer (LM)
Medical Device Manufacturer
(MDM)
Metal Filing Furniture
Manufacturer (MFFM)
Metal Finishing Company
(MFC)
Metal Machining Company
(MMC)
Powder Metallurgy
Manufacturing Company
(PMMC)
Pump Service and Sales Co.
(PSSC)
Iniunctive Relief:
Bleached Kraft Pulp
Manufacturer (BKPM)
Date of
Complaint
September
1989
August 1989
July 1992
April 1991
October 1991
February 1992
March 1989
September
1989
March 1990
September
1989
Date of CA/FO
(signature date)
August 1992
(company began studying
and implementing pollution
prevention process changes
in August 1990)
March 1992
December 1992
April 19,92 ..•
May 1992 /
July 1992
October 1991
(project initiated in April
1990)
January 1992
October 1991
(company initially
proposed, and began to
implement, SEP in
September 1990)
September 1992
Project Implementation Deadline
(per CA/FO)
September 1993
(per CA/FO, extended to
September 1994)
December 1992
(project not completed, see
Section 13 above)
May 1993
(plus 4 month grace period)
September 1993
(project not completed, see
Section 13 above)
November 1992 - project
implementation,
May 1993 - documentation of
P.P. program implementation
September 1992
September 1991
(protracted negotiation period
led to project implementation
prior to official signing of
CA/FO)
January 1993
December 1991
September 1995
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The unique circumstances of each case, and the limited size of our sample, make it difficult to
draw generalizations on the length of time needed to implement projects. However, it is worth
noting one point that relates the type of technological changes made (as discussed in Section 8
above) to implementation periods. The changes characterized as incremental innovations in Table
A-4 are: CMPM (redesign of rinse systems), 1C, LM, MDM and MFC (nickel tank extension
project), and with the exception of MFC, each of these required more than one year for
implementation. The single case of major innovation~BKPM~is on a 3-year implementation
timeline. With the exception of 1C, agency negotiators were willing to accommodate longer
timelines in these cases. The approximately 10 month timeline established in the 1C case was
a factor in the company's inability to complete the project as a SEP. These observations provide
a preliminary indication that innovative projects may often require more than the "maximum 1-
year implementation timeline rule-of-thumb that is often applied by agency negotiators.
15. An Examination of Whether Pollution Prevention Projects Have Been Implemented Without
the SEP
Most of the projects implemented as SEPs had been considered by the case study firms before
they were cited for violations by the agency. It is difficult to know whether, and when, these
projects might have been undertaken if the regions had not granted penalty reductions in
exchange for the firm's commitment to implement the projects. By examining the information
that the companies provided during our interviews, we can gain insight into this question.
• 1C considered reformulating their coating prior to the SEP, but the concept and
implementation had been accelerated through the SEP process in two principal ways: the
project was initiated sooner and it maintained high priority status despite difficulties in
development and pilot testing.
• LM had considered the gasket formulation project prior to the enforcement action
and may have otherwise implemented it. The SEP provided an impetus to undertake the
project and was, from the company's perspective, an alternative to litigation over the
penalty amount and to spending additional money on attorneys' fees.
The projects implemented by PMMC under the SEP policy, had been proposed by
various members of the company (in manufacturing) prior to the issuance of the
complaint The SEP process was the necessary impetus for implementation.
• In the months prior to the complaint, MDM explored the possibility of eliminating
freon use in degreasing through the substitution of a deionized water degreasing system.
They began conducting first-stage evaluations of the performance of the equipment on the
company's products.
• MMC's plant engineer stated that the plant would have eventually moved to
eliminate their use of 1,1,1-trichloroethane, particularly given the increasing cost of the
material. The SEP process was considered a stimulus.
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The facilities manager at PSSC stated that the SEP did not accelerate the aqueous
degreasing system; the company would have implemented the project on roughly the same
schedule without the SEP.
Prior to EPA's complaint, CMPM realized their water usage costs were high and
that they should reduce water consumption but had made no efforts to do so. The
company stated that EPA compelled them to implement water-use reduction measures far
in advance and in excess of what they would have done without the enforcement action.
• MFC had reviewed vendor information on trivalent chromium plating prior to the
complaint but there were no plans to convert over at that time since the trivalent system
produced an unacceptable surface finish. They felt able to propose the trichrome system
as a SEP because by that time, the process had been sufficiently improved.
It is unlikely that MFFM would have implemented the pollution prevention
measures without the SEP.
The EPA case officer believes that BKPM chose to implement the TCP project to
meet the toxicity limits in the consent order in anticipation of state promulgation of new,
stringent effluent limitations for dioxin.
It is difficult to evaluate the validity of these statements particularly because discretionary projects
(e.g., many pollution prevention projects) are often carried along from year-to-year and only
implemented when and if the will and resources exist to do them. In many cases it appears that
the SEPs serve as a catalyst to pollution prevention implementation by overcoming financial and
institutional barriers within firms.
D. IMPACT ON THE FIRM
There are many impacts on the firm stemming from the inclusion of pollution prevention in
enforcement. In this section we present our observations and analysis, organized into two parts:
impact during the enforcement process and impact beyond enforcement. We note the same
limitation of our study here as is given in Section D above, namely that the majority of our
observations came about in the context of studying SEPs; however, we believe that most of the
conclusions reached in this section apply both to SEPs and injunctive relief.
1. The Enforcement Process
All nine SEP case study firm representatives interviewed stated that they support the SEP policy.
Whether or not their projects were successfully implemented as spelled out in the CA/FO, and
whether or not they expended far more or slightly more resources on the project than they
received in penalty relief, they were gratified to have had the option to implement a pollution
prevention project in exchange for some penalty reduction. Before discussing the reasons why
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these companies support this policy, it is important to note that while in the final analysis, the
SEPs took some of the sting out of the enforcement process for our case study companies, it did
not eliminate the very significant economic and psychological impacts associated with being
caught out of compliance by EPA.
With or without a SEP, attorney's fees and staff resources needed to negotiate the settlement take
a direct economic toll on the firm. Some firms, particularly those still in the implementation
stages of their projects, were initially reluctant to talk to us. This indicated to us that these firms
were concerned about continued agency oversight. This factor may be more pronounced in our
SEP case study firms because they tended to be either small or medium-sized companies for
which the impact of an enforcement case was particularly significant.
In most of our cases, the companies were pleased to have negotiated a pollution prevention SEP
because they could achieve a reduction in the fine for implementing a project that was beneficial
to them either because the project cut their costs, eliminated a source of current24 or future
regulation, or gave them a competitive edge (e.g., switching from hexavalent to trivalent
chromium). In some cases, pollution prevention projects secured a combination of these benefits.
In many cases the projects had been considered prior to the enforcement action. The reasons why
these firms did not implement the projects prior to the enforcement action vary from the lack of
top management interest/approval, to a profitability estimate that did not meet company
performance criteria, to the absence or shortage of the necessary in-house technical staff or time
burdens on existing staff.
All companies see SEPs as an opportunity to turn a negative situation into a more positive one..
Some companies stated that SEPs help to recognize their efforts to make improvements. They
rekindle staff morale because they send out a message that while the company broke the law,
EPA reduced the fine because the company elected to implement an environmentally beneficial
project,
2. Beyond Enforcement
While the pollution prevention projects themselves create environmental benefits, greater benefits
may be realized if pollution prevention implemented in an enforcement context is a catalyst for
additional prevention beyond the enforcement process. The discussions on technology transfer
and organizational change in Section C demonstrate that many of the firms studied have taken
or are working toward, further pollution prevention steps and that these steps seem to be linked
to their experience with SEPs.
It is difficult to tell, at this stage, which firms will implement the most pollution prevention
beyond their SEP/injunctive relief project. It appears that within the most active firms-CMPM,
24 This does not mean being required by the Agency to implement the project under current regulations.
Rather, this refers to, for example, eliminating a wastewater pollutant for which the company has a permitted
discharge limit. The SEP policy explicitly excludes projects that are required by regulation.
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MFC, MMC-there is great potential for fur-tiiec pollution prevention. At this early stage, we
cannot conclude that the type of project impkmented~classified by the framework presented in
Table A-4--is a strong determinant of the company's pollution prevention activities beyond the
enforcement settlement.
3- The Impact of Pollution Prevention SEPs on the Deterrence Effect of the Agency';
Enforcement Programs
Based on our interviews, we learned that none of the case study firms knew of the SEP policy
prior to EPA's inspection.25 This is not surprising since the policy is relatively new and many
of the inspections were conducted between 1988-91, We can be reasonably sure, that within our
sample, knowledge of the SEP policy did not act to compromise the deterrence effect of the
agency's enforcement programs. This profile is changing. According to one EPCRA case
officer, several attorneys representing EPCRA 313 violators have asked him at the outset of the
negotiation process whether a SEP can be included in the settlement As more arid more
companies and corporate attorneys learn of the SEP policy this may become the norm.
It is difficult to predict whether and to what degree, the SEP policy will compromise the
deterrence impact of the agency's enforcement programs. Some critics believe that firms will
make a calculated decision to save money by not investing in pollution control or prevention
because the financial risk of enforcement coupled with the "relief offered through SEPs is less
than the savings associated with non-compliance. "
Under this scenario, our research tells us that these incentives for non-compliance should be
weighed against incentives for compliance, such as:
a company's desire to avoid bad publicity and the associated negative outcomes
from their geographical community, community of manufacturers, and current/potential
customers
a company's desire to avoid future regulatory scrutiny and the financial risk that
such scrutiny poses
a company's desire to avoid the expenditure on attorney's fees and staff resources
in negotiating an enforcement settlement
a company's desire to avoid closure costs for improper waste treatment operations
the agency's right to refuse to negotiate a SEP based upon a company's prior non-
compliance history or "bad faith" negotiating posture.
One firm, MFC, learned about SEPs after the EPA inspection and before the first settlement conference.
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The collective experience of our case study firms illustrates a different scenario since these firms
believed, through their ignorance or misunderstanding of the regulations, that they were in
compliance. Thus, for them there is no balance sought between incentives for compliance and
incentives for non-compliance; SEP policy would not be expected to encourage non-compliance.
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*U.S. GOVERNMENT PRINTING OFFICE: 1995- 621 - 752 / 82109
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