United States Environmental Protection Agency Office of Pollution EPA 745-K-94-007 Prevention and Toxics May 1994 7408 &EPA EPA's 33/50 Program Company Profile Carpenter Technology Corporation Printed on Recycled Paper ------- THE 33/50 PROGRAM This Company Profile is part of a series of reports being developed by EPA to highlight the accomplish- ments of companies participating in the 33/50 Program. The 33/50 Program is an EPA voluntary pollution reduction initiative that promotes reductions in direct environmental releases and offslte transfers of 17 high- priority toxic chemicals. The program derives its name from its overall goals -- an interim goal of a 33% reduction by 1992 and an ultimate goal of a 50% reduction by 1995. The program uses 1988 Toxics Release Inventory (TRI) reporting as a baseline. In February, 1991, EPA began contacting the parent companies of TRJ facilities that reported using 33/50 Program chemicals since 1988 to request their participation in the 33/50 Program. As of April, 1994, a total of 1,216 companies had elected to participate in the Program, pledging to reduce emissions of the 17 target chemicals by more than 355 million pounds by 1995. Companies are encouraged to set their own reduction targets, which may vary from the Program's national 33% and 50% reduction goals. Company commitments and reduction pledges continue to be received by EPA on a daily basis. 17 PRIORITY CHEMICALS TARGETED BY THE 33/50 PROGRAM BENZENE CADMIUM & COMPOUNDS CARBON TETRACHLORIDE CHLOROFORM CHROMIUM & COMPOUNDS CYANIDES DICHLOROMETHANE* LEAD & COMPOUNDS MERCURY & COMPOUNDS METHYL ETHYL KETONE METHYL ISOBUTYL KETONE NICKEL & COMPOUNDS TETRACHLOROETHYLENE TOLUENE 1,1,1-TRICHLOROETHANE TRICHLOROETHYLENE XYLENES Also ref&rred to as methylene chloride The 1992 TRI data revealed that releases and transfers of 33/50 Program chemicals de- clined by 40% between 1988 and 1992, surpass- ing the Program's 1992 interim reduction goal by more than 100 million pounds. This accom- plishment, together with evidence from analysis of facilities' projected releases and transfers of the 17 priority chemicals, reported to TRJ under the Pollution Prevention Act, offers strong en- couragement that the 33/50 Program's ultimate goal of a 50% reduction by 1995 will be achieved. EPA is committed to recognizing compa- nies for their participation in the 33/50 Program and for the emissions reductions they achieve. The Program issues periodic Progress Reports, in which participating companies are listed and highlighted. In addition, Company Profiles, such as this one, are being prepared to provide more detailed information about companies that have written to EPA describing significant emissions reduction initiatives. Information presented in these profiles is drawn primarily from the company's written 33/50 Program communications and the annual TRI reports submitted by their facilities (including Pollution Prevention Act data reported to TRI in Section 8 of Form R). All company communications to EPA regarding the 33/50 Program are available to the public upon request. EPA does not endorse the performance, worker safety, or environmental acceptability of any of the technical options discussed in this Profile. Mention of any product or procedure in this document is for informational purposes only, and does not constitute a recommendation of any such product or procedure, either express or implied, by EPA. For information on the 33/50 Program, contact the TSCA Hotline at (202) 554-1404 or contact 33/50 Program staff directly by phone at (202) 260-6907 or by mail at Mail Code 7408, Offke of Pollution Prevention and Toxics, U.S. EPA, 401 M Street, SW, Washington, D.C 20460. 33/50 Program Company Profile: Carpenter Technology Corporation ------- Carpenter Technology Corporation Carpenter Technology Corporation reduced total releases and transfers of 33/50 Program chemicals by 96% (2,710,230 pounds) from 1988 to 1992, surpassing its goal of an 86% reduction. In 1993, the company received an award from the Governor of Pennsylvania recognizing its achieve- ments in reducing emissions of toxic substances. I. CORPORATE BACKGROUND Carpenter Technology Corporation manufac- tures stainless steel and other specialty metals for a variety of industries including aerospace, nuclear, and electronics. The company is headquartered in Reading, Pennsylvania and has four facilities that report emissions of 33/50 Program chemicals. Its two largest facilities are in Reading, Penn- sylvania and Orangeburg, South Carolina. The former produces a variety of bar wire and strip metal products while the latter produces fine wire. In addition, a small plant in Fryeburg, Maine and a plant in El Cajon, California also make metal products. (A fifth facility in Bridgeport, Con- necticut reported significant releases of several 33/50 Program chemicals in 1988 but ceased all manufacturing operations shortly thereafter and no longer reports to TRI.) Carpenter's facilities use six 33/50 Program chemicals: chromium (and compounds), cyanides, nickel (and compounds), tetrachloroethylene, 1,1,1- .trichloroethane, and trichloroethylene. Chromium rand nickel are used as raw materials in the produc- tion of metals while the chlorinated solvents are vtused primarily for cleaning finished metal products. Carpenter Technology reduced releases and transfers of 33150 Program chemi- cals by 96% from 1988 to 1992. Carpenter reported a total of 2,808,918 pounds of releases and transfers of 33/50 Program chemi- cals in 1988 (see Table I at the end of this profile). Of this amount, chromium, primarily in sludge and dissolved in waste acids, accounted for two-thirds of the total. In addition, the company reported 3,486,414 pounds of releases and transfers of other TRI chemicals in the same base year. The vast Releases and Transfers of TRI Chemicals Reported by Carpenter Technology Corporation (1000 Ibs.) 1988 1992 33/50 Chemicals Chromium & compounds 1,855 38 Cyanide <1 <1 Nickel & compounds 469 16 Tetrachloroethylene 40 8 1,1,1-Trichloroethane 182 18 Trichloroethylene 263 18 33/50 Subtotal 2,809 98 Other TRI Chemicals 3^486 104 Total* 6,295 202 * Columns do not sum to total due to rounding. majority of these other TRI chemicals were hydro- chloric and nitric acids used to remove metal oxide scale from hot metal pieces after they leave the furnace. II. CORPORATE ENVIRONMENTAL STRATEGY Carpenter asserts that it will conduct all opera- tions with concern for employees, the public, and the environment. Carpenter aims to maintain or exceed compliance with all applicable environ- mental regulations. The company also strives to minimize discharges in order to eliminate or reduce the hazards of all by-products and waste materials. The company's environmental strategy identi- fies a series of methods by which the company can make continuous improvements to meet its envi- ronmental objectives. These methods are: • identify and control environmental hazards stemming from operations; • conduct pollution control and monitoring programs to protect employees, the public, the environment, the corporation's assets, and the continuity of operations; 33/50 Program Company Profile: Carpenter Technology Corporation ------- • scrutinize products purchased, processes, and waste management methods for waste minimization opportunities (including the recycling of wastes which must be generated and avoid the landfilling of wastes); • communicate applicable information on regu- lations, procedures, and compliance status to all employees; and • work constructively with trade associations, government agencies and others to develop equitable and realistic laws, regulations, and standards to protect the environment. Closely related to Carpenter's environmental strategy is another set of principles that emphasizes on health and safety issues. In its statement on health and safety, the company encourages all workers to devote the necessary time and resources to perform their tasks safely. in. 33/50 PROGRAM GOALS AND POLLUTION REDUCTION ACTIVITIES In May 1991, Carpenter committed to reduce its total releases and transfers of 33/50 Program chemicals by 86% (2,415,670 pounds) from 1988 to 1995. Its commitment was based on a review of its 1989 data on releases and transfers and a projec- tion for its 1991 data to be reported later that year. The company noted that most of these reductions would be accomplished at its three largest facilities - Reading, Bridgeport, and Orangeburg - through source reduction (e.g., consolidation of production facilities and changes in operating practices) and recycling. In 1988, as a first step in identifying source reduction opportunities, Carpenter set up a team dedicated to continuous environmental improve- ments. This team consisted of key staff from engineering, production, and research and develop- ment. The team identified several types of projects including solvent substitution, reduction in solvent emissions through process modifications, increased recycling of metal-bearing waste streams, and changes in operator procedures to reduce the amount of acid used for metal descaling. Specific changes implemented by Carpenter to reduce solvent emissions include: Substituting mineral spirits (petroleum-based solvents) for trichloroethane for cleaning certain types of metal parts. Eliminating non-cleaning uses of 1,1,1-trichlo- roethane (e.g., as a lubricant). Improving vapor degreaser process control to minimize the amount of solvent needed to clean metal components, and reducing by 50% the number of vapor degreasers used. Improving process control to minimize the amount of waste acid generated and eliminate the need for sending acid bath wastes off-site for treatment. As a first step in identifying source reduction opportunities, Carpenter set up a team dedicated to continuous improvements Two additional changes resulted in the elimi- nation of all releases of metals (1,608,250 pounds of chromium and nickel) to land and a significant reduction in the amount of metals transferred off- site for treatment: • Improving sludge drying operations and recy- cling rolling mill sludges, resulting in a 400% increase in the amount of metal oxides that can be recycled. These wastes were previously transferred off-site for treatment. • Adding chemical inhibitors to acid bath solu- tions to reduce the amount of dissolved metals being transferred to the acid waste streams. In addition, for economic reasons, the compa- ny consolidated its operations in 1989 by closing the Bridgeport plant while maintaining similar company-wide production levels through operation of four other plants. Through this action, Carpen- ter was able to achieve a 35% reduction in releases and transfers of 33/50 Program chemicals. Carpenter has also achieved a 97% reduction in non-33/50 chemicals, primarily acids. The company used to replace acid baths on a routine, time-based schedule. Acids are now tested and stabilized, a process that extends the life of the 33/50 Program Company Profile: Carpenter Technology Corporation ------- baths. Acids are now treated on-site only when rendered unusable. IV. PROGRESS TOWARDS 33/50 REDUCTION GOALS As a result of these initiatives, Carpenter has already far exceeded its 33/50 Program goals. Corporate-wide releases and transfers of 33/50 Program chemicals have been reduced by 96% from 1988 levels. In addition, as part of Carpenter's overall environmental goals, the company has reduced its releases and transfers of non-33/50 TRI chemicals by 97%. In total, Car- penter has eliminated over 6 million pounds of total releases and transfers of all TRI chemicals since 1988 while maintaining the same overall level of production. Carpenter projects additional reductions in overall releases and transfers of 33/50 Program chemicals in 1994 (see Table II), primarily through elimination of its use of 1,1,1-trichloroethane. V. SUMMARY OF CARPENTER'S EXPERIENCE By seeking continuous improvements, Carpen- ter has achieved significant reductions in releases and transfers of 33/50 Program chemicals. The company's 96% reduction to date has far surpassed its ambitious goal of an 86% reduction in 33/50 Program chemicals by 1995. In addition, it has Carpenter Technology's Progress Towards Meeting 33/50 Goals 7000 6000 o 5000 o o JJ4000 « n •o c a (A « 3000 2000 £ 1000 a Non-33/50 Chemicals • 33/50 Chemicals! 33/50 Goal 1988 1989 1990 1991 1992 33/50 Goal: 86% reduction in releases and transfers of 33/50 chemicals by 1995 managed to reduce releases and transfers of TRI chemicals by 97% from 1988. The company other expects to achieve additional reductions through further adoption of source reduction and recycling initiatives. 33/50 Program Company Profile: Carpenter Technology Corporation ------- Table I Carpenter Technology Corporation Releases and Transfers of TRI Chemicals, 1988-1992 (all data from TRI unless otherwise noted) Chemical Chromium Cyanide compounds Nickel Tetrachloroethylene 1,1,1 -Trichloroethane Trichloroethylene 33/50 Program Chemicals Year 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 Surface Total Air Water Emissions Discharges (pounds) (pounds) 12,290 7,872 8,416 9,592 7,429 100 58 58 58 58 6,510 3,671 3,661 3,817 3,128 36,700 56,606 23,408 2,648 7,826 169,113 163,032 99,364 5,752 18,275 263,046 299,544 22,907 13,100 17,800 487,759 530,783 157,814 34,96.7 54,516 220 207 141 189 277 100 83 41 70 46 770 938 1,017 111 235 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,090 1,228 1,199 1,036 558 Transfers Percent Off-site Change Releases Transfers for Treatment/ Total Releases 1988-1992 to Land to POTW Disposal/Other and Transfers (1) Total Releases (pounds) (pounds) (pounds) (pounds) and Transfers 1,384,700 270,105 103,029 0 0 0 0 0 0 0 223,550 73,842 28,166 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1,608,250 343,947 131,195 0 0 214 9 301 263 430 0 0 0 0 0 702 377 267 280 360 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 916 386 568 543 790 457,430 223,907 40,289 25,099 30,167 100 33 3 85 285 237,253 150,283 36,193 13,474 12,372 3,400 19,319 6,552 0 0 12,654 49,089 15,456 0 0 66 75 2,303 0 0 710,903 442,706 100,796 38,658 42,824 1,854,854 502,100 152,176 35,143 38,303 300 174 102 213 389 468,785 229,111 69,304 18,348 16,095 40,100 75,925 29,960 2,648 7,826 181,767 212,121 114,820 5,752 18,275 263,112 299,619 25,210 13,100 17,800 2,808,918 1,319,050 391,572 75,204 98,688 -98% 30% -97%' -80% -90% -93% -96%, ------- Table I Carpenter Technology Corporation Releases and Transfers of TRI Chemicals, 1988-1992 (all data from TRI unless otherwise noted) Chemical Non 33/50 Program Chemicals All TRI Chemicals Percent Change, 1988-1992 33/50 Program Chemicals Non 33/50 Program chemicals 11 TRI Chemicals Year 1988 1989 1990 1991 1992 1988 1989 1990 1991 1992 Total Air Emissions (pounds) 92,658 76,025 101,834 1 1 1 ,402 95,787 580,417 606,808 259,648 146,369 150,303 -89% 3% -74% Surface Water Discharges (pounds) 977 876 945 945 896 2,067 2,104 2,144 1,981 1,454 •49% -8% -30% Releases to Land (pounds) 841,100 145,400 56,355 2,123 1,594 2,449,350 489,347 187,550 2,123 1,594 -100% -100% -100% Transfers Off-site Transfers for Treatment/ Total Releases to POTW Disposal/Other and Transfers (1) (pounds) 201 59 59 250 250 1,117 445 627 793 1,040 -14% 24% -7% (pounds) 2,551,478 1,702,296 481,000 4,379 5,044 3,262,381 2,145,002 581,796 43,037 47,868 -94% -100% -99% (pounds) 3,486,414 1,924,656 640,193 119,099 103,571 6,295,332 3,243,706 1,031,765 194,303 202,259 -96% -97% -97% Percent Change 1988-1992 Total Releases and Transfers -97% -97% Notes: (1) Total Releases and Transfers for 1991 and 1992 do not include on- or off-site recycling or energy recovery. ------- Table II Carpenter Technology Corporation Pollution Prevention Act Reporting (1) Chemical Chromium Cyanide compounds Nickel Tetrachloroethylene 1,1,1 -Trichloroethane Trichloroethylene Year 1991 1992 1994 1991 1992 1994 1991 1992 1994 1991 1992 1994 1991 1992 1994 1991 1992 1994 Recycled On-Site (pounds) 1,588,233 1,513,012 1,500,000 0 0 0 1,113,573 966,433 1,000,000 0 0 0 0 0 0 27,000 26,700 25,200 Recycled Off-Site (pounds) 1,767,732 1,954,812 2,000,000 0 0 0 1,156,418 1,546,292 1,500,000 24,993 14,122 10,000 21,668 10,226 1,000 4,900 1,350 700 Energy Recovery Off-Site (pounds) 0 0 0 0 0 0 0 0 0 7,669 1,021 500 14,116 1,069 0 0 0 0 Treated On-Site (pounds) 0 0 0 12,614 13,614 14,295 0 0 0 0 7 0 0 42 0 0 0 0 Treated Off-Site (pounds) 18 15 10 85 285 200 150 92 85 0 0 0 0 0 0 0 0 0 Percent Change Quantity 1991-1994 Released Quantity (pounds) Released 34,589 37,646 9,525 -72% 128 104 109 -15% 17,845 15,510 3,721 -79% 2,648 10,611 4,000 51% 12,452 18,630 500 -96% 12,800 15,400 13,600 6% Total Production Related Wastes (pounds) 3,390,572 3,505,485 3,509,535 12,827 14,003 14,604 2,287,986 2,528,327 2,503,806 35,310 25,761 14,500 48,236 29,967 1,500 44,700 43,450 39,500 Percent Change 1991-1994 Production Related Wastes' 4% 14% 9% -59% -97% -12% ------- Table II Carpenter Technology Corporation Pollution Prevention Act Reporting (1) . Chemical 33/50 Program Chemicals Non 33/50 Program Chemicals All TRI Chemicals Percent Changes. 1991-1994 33/50 Program chemicals Non 33/50 Program chemicals All TRI Chemicals Year 1991 1992 1994 1991 1992 1994 1991 1992 1994 Recycled On-Site (pounds) 2,728,806 2,506,145 2,525,200 1,279,493 1,974,705 2,037,175 4,008,299 4,480,850 4,562,375 -7% 59% 14% Recycled Off-Site (pounds) 2,975,711 3,526,802 3,511,700 521,801 1,269,888 1,289,000 3,497,512 4,796,690 4,800,700 18% 147% 37% Energy Recovery Off-Site (pounds) 21,785 2,090 500 0 0 0 21,785 2,090 500 -98% - -98% Treated On-Site (pounds) 12,614 13,663 14,295 3,818,629 4,816,093 4,515,000 3,831,243 4,829,756 4,529,295 13% 18% 18% Treated Off-Site (pounds) 253 392 295 3 7 5 256 399 300 17% 67% 17% Percent Change Quantity 1991-1994 Released Quantity (pounds) Released 80,462 97,901 31,455 -61% 117,393 103,614 94,188 -20% 197,855 201,515 125,643 -36% -61% -20% -36% Total Production Related Wastes (pounds) 5,819,631 6,146,993 6,083,445 5,737,319 8,164,307 7,935,368 11,556,950 14,311,300 14,018,813 5% 38% 21% Percent Change 1991-1994 Production Related Wastes 5% 38% 21% Notes: (1) Actual data for 1991 and 1992, projections for 1994. ------- |