&EPA
United States
Environmental Protection
Agency
Office of Pollution
Prevention and Toxics
Washington, DC 20460
EPA745-K-94-017
October 1994
33/50 Program
Company Profiles:
Reduction Highlights
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33/50 PROGRAM COMPANY PROFILES:
REDUCTION HIGHLIGHTS
This document summarizes information presented in 33/50 Program Company Profiles, which are a series
of brief reports describing the pollution prevention and reduction activities undertaken by companies
participating in EPA's 33/50 Program. The 33/50 Program is an EPA voluntary pollution reduction initiative
that promotes reductions in direct environmental releases and offsite 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 TRI facilities that
reported using 33/50 Program chemicals since 1988 to request their participation in the 33/50 Program. As
of October, 1994, a total of approximately 1,250 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. All company communications to EPA regarding the 33/50 Program are available to the public upon
request
The 1992 TRI data revealed that releases and
transfers of 33/50 Program chemicals declined by
40% between 1988 and 1992, surpassing the
Program's 1992 interim reduction goals by more
than 100 million pounds. This accomplishment,
together with evidence from analysis of facilities'
projected releases and transfers of the 17 priority
chemicals, reported to TRI under the Pollution
Prevention Act, offers strong encouragement that the
33/50 Program's ultimate goal of a 50% reduction
by 1995 will be achieved.
EPA is committed to recognizing companies 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 are being prepared to
provide more detailed information about companies
that have written to EPA describing significant
emissions reduction initiatives. Fourteen Company
Profiles have been prepared to date. 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 Form R).
highlighted in this document can be obtained by contacting
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
TRICHLOROETHANE
TRICHLOROETHYLENE
XYLENES
* Also referred to as methylene chloride
Copies of the complete profiles of each company
EPA's TSCA Hotline (see box below).
EPA does not endorse the performance, worker safety, or environmental acceptability of any of the
technical options discussed in these Profiles. Mention of any product or procedure in this document and the
complete Profiles is for informational purposes only, and does not constitute a recommendation of any such
product or procedure, either expressly or implied, by EPA.
For information on the 33/50 Program, contact the TSCA Hotline at (202) 554-1404 or contact the 33/50
Program staff directly by phone at (202) 260-6907 or by mail at Mail Code 7408, Office of Pollution
Prevention and Toxics, U.S. EPA, 401 M Street, SW, Washington, D.C. 20460.
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33/50 PROGRAM
ACME METALS INCORPORATED
Acme Metals Incorporated manufactures steel
strapping tools, is an integrated producer of steel
products,, and operates coke and steelmaking
processes at its 15 facilities located across the United
States. Two of these facilities are responsible for
nearly all the reported releases and transfers of 33/50
Program chemicals. The reduction efforts which
have taken place at its facilities have resulted in a
decrease in releases and transfers of 33/50 Program
chemicals (benzene, chromium compounds, cyanide
compounds, lead compounds, nickel compounds,
toluene, and xylene) by 89% from 1988 to 1992.
Additionally, Acme reduced releases and transfers of
non-33/50 TRI chemicals by nearly 2,600,000 pounds
(75%) between 1988 and 1992. Major reduction
activities include:
*• Replacement of its contact gas cooling system
with a non-contact, wet surface air cooler in the
coke byproducts recovery process. The
replacement of the cooling system resulted in
reductions of releases of approximately 143,000
pounds of benzene, 276,000 pounds of cyanide,
28,000 pounds of toluene, and 6,000 pounds of
xylene, as well as 1,450,000 pounds of ammonia,
and 10,000 pounds of naphthalene.
* Installation of emission collector headers to
remove volatile chemicals, such as benzene,
toluene, and xylene, from the headspaces of
process units and storage tanks. This process
uses steam moving under negative pressure to
sweep the volatile chemicals into the byproduct
recovery'system. Emission collector headers
were installed at the light oil storage tank, the
wash oil decanter, and the wash oil circulation
tank and resulted in a 14,000 pound reduction in
releases of benzene, as well as smaller reductions
of toluene and xylene.
> At the company's Riverdale, IL facility, spent
lead dross from the steel strapping production
process is now sent to an off-site recycler.
Previously, the lead was landfilled. The in-
creased recycling of lead resulted in a reduction
of approximately 333,000 pounds of releases and
transfers of lead.
/llsddin
Aladdin Industries Incorporated is a manufacturer
of metal and plastic hardware for consumer and
industrial use. Headquartered in Nashville,
Tennessee, the company operates eleven facilities in
Delaware, Tennessee, and Puerto Rico, one of which
reports 33/50 Program chemical releases and
transfers. A wide variety of products such as lunch
kits, thermos bottles, hospital trays, coffee cups,
lamps, and coolers are produced at its facilities. As
a result of the reduction activities, Aladdin has
reduced its total releases and transfers of 33/50
Program chemicals (chromium, dichloromethane,
methyl isobutyl ketone, toluene, 1,1,1-trichloroethane,
and,trichloroethylene) by 38% from 1988 to 1992.
In,addition, Aladdin achieved a 99.8% reduction in
releases and transfers of non-33/50 TRI chemicals
from 1988 to 1992. Major reduction activities
include:
*• Elimination of all trichloroethylene.
Trichloroethylene was required to remove
petroleum oils from metal parts during metal
forming processes. Synthetic lubricants are now
used in place of petroleum oils and are removed
from parts with an aqueous alkaline cleaner. The
water from the alkaline cleaning process is
treated on-site.
*• Elimination of the dichloromethane use from the
facility by replacing the polystyrene used in trays
i -^.withi polypropylene. Previously, the polystyrene
*,, trays were cut from a sheet and blemishes around
f the edges were removed using dichloromethane.
Since the polypropylene trays are now injection
molded, there are no blemishes to remove.
*• Elimination of the use of toluene and methyl
isobutyl ketone by replacing a thinner containing
toluene and methyl isobutyl ketone with a
thinner containing 25% toluene and 75% 1,1,1-
trichloroethane. This thinner was later replaced
with a thinner containing acetone in place of the
toluene. The company is currently investigating
options to eliminate the 1,1,1-trichloroethane
from this formulation.
REDUCTION HIGHLIGHTS
Page.2;^1"
.u^T -t/.-w •
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33/50 PROGRAM
+ Elimination of all releases and transfers of chro-
mium, along with two non-33/50 TRI chemicals
— phosphoric acid and sulfuric acid. Using a
newly installed on-site waste treatment facility,
toxic materials are removed from a water mixture
containing chromium, phosphoric acid, and
sulfuric acid. Fifty percent of the water is
recycled, while the remainder is of sufficient
quality to discharge to the sanitary sewer. The
sludge is of sufficient quality to be considered
nonhazardous and is disposed of in a landfill.
Prior to the installation of the on-site treatment
facility, all of these wastes were transferred off-
site for treatment or disposal.
*• Elimination of the lacquer painting process by
switching to a dry powder coating, thereby elimi-
nating the use of lead, xylenes, and ketones.
Small quantities (not reportable to TRI) of lead,
xylenes, and ketones were previously used in the
painting process for thermos bottles.
L D A N
RUBBER CO.
COATED FABRICS
Aldan Rubber Company is a manufacturer of
rubber-coated fabrics that are used in a wide 'variety
of applications, including protective clothing for fire
fighting, flexible duct connectors, convertible tops,
and baby products. Aldan is headquartered and
located in Philadelphia, Pennsylvania. The total
releases and transfers of 33/50 Program chemicals
(methyl ethyl ketone and toluene) has been reduced
by 85% from the company's 1988 releases and
transfer levels. Major reduction activities include:
> Expansion of solvent emissions hood. An earlier
project undertaken by the company involved the
installation -of a hood to capture solvent
emissions over part of its spreader. The captured
solvent was then routed to a recovery unit.
• Recently, the entire spreader was enclosed so
that all solvent emissions are captured and
recycled, rather than just those under the partial
hood.
»• Renovation of the solvent recovery system. As
part of the renovation, the recovery unit received
a complete overhaul, including replacement of
the carbon recovery media, cooling coils, and old
seals and valves. The company reported the
solvent recovery unit's efficiency at 98% - 99%
after the renovation, an increase of approximately
20% from the previous efficiency level.
Use of an alternative cleaner for machinery
clean-up. Traditionally, toluene was used in a
hand-wipe application to clean its equipment on
a periodic basis. This cleaning removes excess
rubber, dirt, and other contaminants from
production machinery. To eliminate this use of
toluene, a d-limonene cleaner is now used in a
similar hand-wipe application, with reduced but
satisfactory performance, and somewhat higher
but still acceptable cost.
Institution of an employee awareness program.
Recognizing that a significant quantity of solvent
emissions could be eliminated simply by im-
proving the handling of process materials, an
employee awareness program, mandatory for all
employees who. handle solvents, was
implemented. During the program, environmen-
tal problems associated with the solvent emis-
sions were explained and suggestions made for
reducing emissions.
Development of a proprietary process by which
it is able to reduce solvent emissions from rubber
scrap. This process is one in which the scrap is
processed to remove excess solvent prior to scrap
disposal. The company has found that, not only
does the process reduce emissions of solvent to
the air, but it also renders the rubber scrap
nonhazardous. The scrap can then be disposed
of in a municipal landfill.
Anchor Fence, Inc. is a manufacturer of high quality
chain link fencing systems, gates, and specialty
fencing products. The company has three facilities
located in Maryland, New York, and Pennsylvania,
one of which reports 33/50 Program chemical
releases and transfers. The reduction activities
implemented by Anchor Fence have resulted in a
REDUCTION HIGHLIGHTS
Page3
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33/50 PROGRAM
reduction of total releases and transfers of 33/50
Program chemicals (dichloromethane, lead and
compounds, methyl ethyl ketone, methyl isobutyl
ketone, nickel and compounds, toluene; and xylene)
of 98% from 1988 to 1993. Major reduction
activities include:
> Reduction of the releases of methyl ethyl ketone
by 93% (113,000 pounds) through substitution of
" water-based formulations of primers for pipes
1. and fittings. This action accounts for all of the
n. ,*h • m A.M. ..IN,,. ... *"•' .. , . ..... . - ^-fldiw.wiB* - *"-. ™ .,-,..„. . -,.
observed decrease in releases of this chemical.
In addition, all solvent-based paint applications
are being strictly monitored to determine which
can be converted to water based products in the
future.
*• Improvements in the operation of the company's
wastewater treatment system have resulted in a
50% reduction in releases of lead, nickel, and
zinc compounds between 1988 and 1992. These
' improvements consist primarily of adjusting the
«# pH of the system to increase efficiency of metals
""'removal. *
»• Elimination of the use of dichloromethane at the
plant by shifting the PVC stripping process for
off-quality products to an off-site cleaning com-
pany that uses a hot salt bath PVC removal pro-
cess. This change resulted in cost savings for
the company.
•• Examination of solvent-based cleaning processes
using toluene and methyl ethyl ketone to
determine where solvent evaporation can be
reduced. The company intends to install a water-
cooled component cleaning tank to further reduce
releases of the solvents. •
Carpenter Technology Corporation manufactures
stainless steel and other specialty metals for a variety
of industries including aerospace, nuclear, and elec-
tronics. The company is headquartered in Reading,
Pennsylvania and has twenty-eight'facilities located
"throughout the United States, four of which report
33/50 Program chemical releases and transfers.
Carpenter Technology has reduced its total releases
, • •
and transfers of 33/50 Program chemicals (chromium
and compounds, cyanide, nickel and 'compounds,
tetrachloroethylene, 1,1,1-trichloroethane, and
trichloroethylene) by 86% from 1988 to 1992. Major
reduction activities include:
» Substitution of mineral spirits (petroleum-based
solvents) for trichloroethane for cleaning certain
types of metal parts.
> Elimination of non-cleaning uses of 1,1,1 -trichlo-
roethane •(eTg.j as a lubricant).
*• Improvement of 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.
+ Improvement of process control to minimize the
amount of waste acid generated and eliminate the
need for sending acid bath wastes off-site for
treatment. - - -
\t~ ; - r- V1"
*• Improvement of sludge drying operations'and
recycling rolling mill sludges, resulting in a
400% increase in the amount of metal oxides
that can be recycled that were previously trans-
ferred off-site for treatment.
* Addition of chemical inhibitors to acid bath solu-
tions to reduce the amount of dissolved metals
being transferred to the acid waste streams.
Dexter Shoe Company is a manufacturer of shoes
for men, women, and children. The company is
headquartered in Dexter, Maine and has fourty-seven
facilities in the eastern United States, four of which
report 33/50 Program chemical releases and transfers.
As a result of the reduction activities undertaken by
the company, total releases and transfers of 33/50
Program chemicals (dichloromethane, methyl ethyl
ketone, toluene, and 1,1,1-trichloroethane) were
reduced by 47%,from 1988 to 1992. Major reduction
activities include: . "*"~?'"
REDUCTION HIGHLIGHTS
Page 4
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33/50 PROGRAM
> At the Skowhegan, ME facility, two solvent-
based waterproofing agents have been replaced
with aqueous-based products. These new prod-
ucts are more expensive than their solvent prede-
cessors, but provide better coverage using less
product
+ Replacement of methyl ethyl ketone as a
cleaning solvent with heptane. Because heptane
still poses some risk, however, the company is
continuing to investigate other alternatives.
+ Employment of a solvent recovery for cleaning
solvents, such as methyl ethyl ketone and
heptane. At the Skowhegan, ME facility, solvent
recovery, both for reuse of individual solvents
and for generalized recovery of mixed cleaning
solvents have been used at the company. Some
of the solvent recovery is done within the
process for which the chemicals are used and,
thus, can be considered source reduction.
*• At the headquarters facility in Dexter, ME,
substitution of solvents and cleaners containing
methyl ethyl ketone, methylene chloride, and
toluene with water-based products has created
reduction of releases and transfers.
* Replacement of a filler product containing 40%
acetone with a cut insert material bonded to the
upper part of the shoe with a hot melt adhesive
has been implemented.
>• The headquarters facility has installed a solvent
recovery system for reuse of cleaning solvents.
Douglas & Lomason Company is a manufacturer of
automobile and truck components, primarily seat and
trim parts. The company is headquartered in
Farmington Hills, Michigan and operates twenty-one
manufacturing facilities nationwide, of which seven
reported releases and transfers of 33/50 Program
chemicals. Douglas & Lomason has reduced its total
releases and transfers of 33/50 Program chemicals
(methyl ethyl ketone, toluene, 1,1,1-trichloroethane,
xylene, and chromium/nickel) by 88% from 1988 to
1992 as a result of its reduction activities. Major
reduction activities include:
*• Implementation of a new mold-release agent for-
mulation at the Havre-de-Grace, MD, facility.
The manufacture of foam seat pads involves
applying a wax mold-release agent to a mold to
facilitate the removal of the finished molded
product. The company's traditional mold-release
agent, that contained 1,1,1-trichloroethane as a
solvent, was replaced with a water-based
formulation. This substitution completely
eliminated the use of 1,1,1-trichloroethane, a
reduction of 350,000 pounds.
*• Use of "high-solids" paint formulations. At the
Phenix City, AL facility, manufactured metal
trim parts are painted. The amount of solvent,
such as toluene, xylene, and methyl ethyl ketone,
used in these paints was reduced through the use
of reformulated "high-solids" paint. "High-
solids" paint uses a reduced percentage of
solvent in formulating the paint, thereby
increasing the percentage of solids.
*• Use of water-based paint. At several facilities,
metal seat frames are manufactured which are
painted for rust protection. At the Columbus,
NE facility the use of solvents in the paint has
been eliminated by using water-reducible paints,
in which the solvents (in this case toluene and
xylene) are replaced with ethylene glycol. This
approach, contributed to reductions of 86,454
pounds of toluene and xylene releases between
1988 and 1992 at the facility.
*• Elimination of the use of paints. Solvent use has
been reduced or eliminated through the imple-
mentation of two new processes that eliminate
the need to paint certain parts. First, the spray-
application of rust inhibitors has eliminated the
need for painting, thereby reducing and in some
cases eliminating the use of solvents. A second
process involves the chemical application of a
coating to metal parts using a process that
requires no solvents. The Red Oak, IA facility
used this process to eliminate releases and
transfers of 61,000 pounds of toluene and xylene.
REDUCTION HIGHLIGHTS
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33/50 PROGRAM
HADCO Corporation manufactures custom printed
circuit boards and backplanes for use in electronic
components. HADCO's reduction efforts allowed the
company to reduce releases and transfers of 33/50
Program chemicals (dichloromethane, lead, methyl
ethyl ketone, and 1,1,1 -trichloroethane) by 95%
between 1988 and 1992, reflecting a reduction of
almost 2.2 million pounds. HADCO is headquartered
in Salem, New Hampshire, and operates ten facilities
throughout the United States, of which two report
releases and transfers of 33/50 Program chemicals.
Major, reduction activities include: ;— *
'' " '<• ..... * . . •>(':•*
*• Implementation of new aqueous-based chemicals
in the cleaning and dry film processes at its
Deny, NH facility. The dry film process was
modified to include carbonate-based developers
instead of 1,1,1 -trichloroethane, and hydroxide
solutions instead of dichloromethane.
*• At its Owego, NY facility, a screen cleaning use
of dichloromethane was replaced with an
aqueous cleaning solution.
Johnson & Johnson is the world's largest health '
care company, with 185 manufacturing locations at.,
home and abroad. The company manufactures
toiletries and baby care products, medical supplies,
and pharmaceutical products. As a result of the
reduction activities undertaken at the six facilities
which report releases and transfers of 33/50 Program
chemicals, Johnson & Johnson has reduced its total
releases and transfers of 33/50 Program chemicals
(chloroform, dichloromethane, methyl ethyl ketone,
methyl isobutyl ketone, toluene, 1,1,1 -trichloroethane,
and xylene) by 77% from 1988 to 1992. Major
reduction activities include:
•• Elimination of the use of methyl ethyl ketone,
methyl isobutyl ketone, and xylene at the Con-*
* surner* Products plant in' North Brunswick^ : NJ. **
' Vinyl -extrusion and the use of a water-based
emulsion have been substituted in the Band-
Aid™ Brand adhesive bandages manufacturing
process where these chemicals are used, resulting
in a decrease of over 380,000 pounds in releases
and transfers of these three 33/50 Program
solvents between 1988 and 1992.
*• Equipment and procedure changes in several
processes at the Noramco facility in Wilmington,
DE, resulting in a combined reduction in releases
and transfers of dichloromethane and toluene of
over 131,000 pounds between 1988 and 1992.
These changes by Noramco include: using
dichloromethane and toluene as the seal fluid in
liquid ring vacuum pumps, instead of water,
thereby reducing wastewater transfers; imple-
*- menting a leak detection and repair program to
reduce fugitive emissions; and eliminating one
product recovery step, further^*- reducing
dichloromethane transfers in wastewater.
> Material substitution at Ethicon plants in
Somerville, NJ and San Angelo, TX, as well as
the Advanced Materials facility in Gainesville,
GA and the Vistakon plant in Jacksonville, FL,
resulting in a decrease of over 66,500 pounds
(73%) in releases and transfers of 1,1,1-tri-
chloroethane between 1988 and 1992. A
biodegradable cleaner was substituted for 1,1,1-
trichloroethane.
Glin
Olin Corporation is a Fortune 200 company,
headquartered in Stamford, CT, with 103 facilities
nationwide. Twenty-three of its facilities report
33/50 Program releases and transfers. The company
manufactures a wide variety of products, including
specialty chemicals, metals, and other materials, as
well as products for the defense, aerospace, and
sporting ammunition industries. The Olin
Corporation has reduced its total releases and
transfers of 33/50 Program chemicals (including
dichloromethane, lead and compounds, 1,1,1-
trichloroethane, xylenes, nickel and \compounds,
mercury; methyl ethyl ketone, ^}amk carbon
atetfachldride) by 67% from 1988:tb*1992 as a result
of its reduction activities. Major reduction activities
include:
REDUCTION HIGHLIGHTS
Page 6
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33/50 PROGRAM
» Installation of scrubber and process vent
collection system. At the Rochester, NY facility
over 60 different types of specialty chemicals are
produced—relatively low volume products tai-
lored to the specific needs of individual
customers. In order, to recover carbon tetrachlo-
ride from air vents, the plant installed a scrubber
and additional process vent collection equipment,
and now reuses the reclaimed material in several
of the facility's production processes. 1992 air
emissions of carbon tetrachloride were reduced
to 3,437 pounds at this facility, a reduction of
70%. This facility is also investigating the
substitution of carbon tetrachloride and other
33/50 Program chemicals with non-toxic raw
materials.
*• Identification of chemical substitution options
and modification of degreaser chiller. At the
Red Lion, PA facility, 1,1,1-trichloroethane is
used as a multi-purpose cleaner and degreaser.
A number of steps to reduce the use of this
chemical were undertaken including: restricting
access and requiring employees to justify their
use of the material; identifying material substitu-
tion options for products not required to use the
chemical (e.g., by military procurement specifica-
tions); and modifying the chiller on a solvent
degreaser to enhance vapor capture. As a result
of these efforts, air emissions of 1,1,1-trichlo-
roethane were reduced to 21,700 pounds in 1992,
a reduction of over 80% from 1988 levels. The
facility is currently investigating two additional
actions to further reduce the use of 1,1,1-
trichloroethane: installing a parts washer that
will use water-based cleaners instead of
chlorinated solvents, or altering the overall
production process to completely eliminate the
cleaning process.
*• Conversion to water-based soaps. At the
Indianapolis,' IN facility, air emissions of 37,000
pounds of 1,1,1-trichloroethane and
dichloromethane were reported, that were used as
degreasers. By 1990, the facility had completely
eliminated its use of these two chlorinated sol-
vents by switching to the use of water-based
soaps and hot water rinsing in its metal
processing and maintenance operations.
Recycling of lead waste. The East Alton, IL
Main Plant facility used to landfill large
quantities of lead wastes (off-site disposal of
815,853 pounds in 1988), primarily from bullets
test-fired into sand traps at the Winchester sport-
ing ammunition plant. The facility used to
screen as much lead as possible out of the sand
for reuse in their own production processes, and
landfill the remaining lead-contaminated sand
off-site. The facility began selling unscreened
material to a battery manufacturer, and more
recently began selling it to a lead smelter. The
sand/lead mixture is used directly as a recycled
raw material in the smelting process. The
landfilling of lead wastes has thus been dramati-
cally reduced to 39,673 pounds in 1992, for an
overall reduction of 95%.
Parker
Parker Hannifin Corporation manufactures a broad
array of motion control products for industrial and
aerospace applications. As a result of Parker's
reduction efforts releases and transfers of 33/50
Program chemicals (14 chemicals including
dichloromethane, tetrachloroethylene, 1,1,1-
trichloroethane, trichloroethylene, methyl ethyl
ketone, toluene, xylene, carbon tetrachloride, and
methyl isobutyl ketone) decreased by more than
1,350,000 pounds between 1988 and 1992 — a 71%
reduction. The company is headquartered in
Cleveland, Ohio and operates 143 manufacturing
plants worldwide. Fifty-two of Parker Hannifin's
facilities report the use of 33/50 Program chemicals.
Major reduction activities include:
> Elimination of 756,000 pounds of releases and
transfers of dichloromethane, tetrachloroethylene,
1,1,1-trichloroethane, and trichlorethylene by
switching to aqueous cleaning systems for
degreasing operations. As a result of the
agitation required in the aqueous cleaning
process, the racks used to hold parts during
cleaning were redesigned to accommodate agita-
tion.
*• Elimination of 453,000 pounds of releases and
transfers of methyl ethyl ketone and toluene by
substituting water-based solutions for solvent
REDUCTION HIGHLIGHTS
Page?
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33/50 PROGRAM
solutions used to carry cements in the
manufacture of rubber hoses. This substitution
required: the addition of a drying step because of
the relatively slow evaporation rate of water.
Elimination of 109,000 pounds of releases and
transfers of carbon tetrachloride, methyl isobutyl
ketone, and xylene by substituting water-based
adhesives and paints for solvent-based adhesives
and paints.
Elimination of 30,000 pounds of releases and
transfers of chromium and chromium compounds
used in coloring processes that are part of the
metal finishing operations. This reduction was
achieved through waste minimization techniques
such as counter-current rinsing, reduced drag-out
rates, and improved quality control.
PRinTED
CIRCUIT
corporation
of completed circuit boards, in place of
dichloromethane and 1,1,1-trichloroethane.
Printed Circuit Corporation manufactures printed
circuit boards. As a result of the efforts of this
company, total releases and transfers of 33/50
Program chemicals (dichloromethane and 1,1,1-
trichloroethane) have been reduced by 100% from its
1988 levels. The company is headquartered and
located in Woburn, Massachusetts. Major reduction
activities involved a two-step substitution process:
+ Implementation of the use of a water-based
cleaner to strip away excess polymer from the
etched circuit boards. Further, all solvent clea-
ning operations were switched to 1,1,1-
trichloroethane, resulting in an elimination of the
use of dichloromethane. As a result of the
process change, the company also was able to
minimize its use of methanol, a non-33/50
Program TRI chemical.
*• Replacement of its use of 1,1,1 -trichloroethane as
a developing agent with a water-based sodium
carbonate solution. As a result of the
substitution efforts, the company now uses a
mild detergent with water for the final cleaning
Raytheon
Raytheon Company is a diversified organization
whose major interests include manufacturing of
aircraft, residential and commercial appliances,
electronics, and energy/environmental services. As
a result of the efforts at its facilities, Raytheon's
releases and transfers of 33/50 Program chemicals
(11 chemicals including, trichloroethylene,
dichloromethane, tetrachloroethylene, 1,1,1-
trichloroethane, lead, chromium, toluene, and xylene)
decreased over 2.5 million pounds between 1988 and
1992 — a 65% reduction. The company is
headquartered in Lexington, Massachusetts and has
323 facilities across the United States. Twenty-five
of its . facilities. report 33/50 Program chemical
releases ^and 1 transfers. Major reduction activities
include: **V» - •
* Reduction or elimination of ozone depleting
substances and suspect carcinogens.
Dichloromethane, 1,1,1 -trichloroethane, tetrachlo-
roethylene, trichloroethylene, and CFC-113 were
all targeted by the company's ozone depleting
substances and suspect carcinogen phaseout
goals. In 1988, these solvents were used at 18
facilities for electronics cleaning and metal
degreasing, and as general solvent cleaners.
Terpene-based cleaners and mildly alkaline
aqueous solutions were identified as alternatives
to these solvent cleaners. As a result of the
development of these alternate cleaners, the use
of dichloromethane, tetrachloroethylene, and
CFC-113, was successfully eliminated and the
use of 1,1,1-trichloroethane and trichloroethylene
was significantly reduced.
• .. . *;. . ;..
*• Implementation of dry media blasting system.
At the Wichita, KS facility, dichloromethane was
used to strip paint from aircraft. The company
implemented a dry media (wheat starch) blasting
system for paint stripping that completely elimi-
nated the need for dichloromethane at this
facility.
REDUCTION HIGHLIGHTS
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33/50 PROGRAM
>• Implementation of powder paint system. Lead,
chromium, toluene, and xylene are used in
painting and soldering operations. Identification
and implementation of a powder paint system in
some facilities has resulted in a reduction of
releases and transfers of these chemicals. For
applications in which powder painting is not
technically feasible, the company is working with
its coating suppliers to reduce the amount of
solvent used in its coatings.
Modification of coke quenching process. After
the coke is removed from the coke ovens, it must
be cooled rapidly. Previously, the Clairton
Works used contaminated water to quench the
coke. Use of contaminated water, however,
resulted in releases of 33/50 Program chemicals
such as benzene and toluene. The facility
switched to clean quench water 100% of the
time, thus eliminating the releases of benzene
and toluene from the quenching operations. The
contaminated water is currently treated at the
facility's wastewater treatment plant where
contaminants are removed to permitted levels.
U.S. Steel Group is a large, integrated steel
manufacturer and also includes several smaller
diversified businesses. The company is
headquartered in Pittsburgh, Pennsylvania, and
operates nine wholly-owned plants located in six
states in the middle and eastern United States, six of
which report releases and transfers of 33/50 Program
chemicals. U.S. Steel Group's reduction activities
have resulted in a reduction in releases and transfers
of 33/50 Program chemicals (benzene, chromium and
compounds, cyanide, lead and compounds, nickel and
compounds, toluene, 1,1,1-trichloroethane, and
xylene) of 87% from 1988 to 1992. Major reduction
activities include:
•• Installation of an inert gas blanketing system at
the Gary, IN and Clairton, PA plants. Typically,
nitrogen is used to confine air emissions of
volatile toxic chemicals such as benzene,
cyanide, toluene, and xylene in tanks or
containers. By maintaining a layer of inert gas
over an open tank or container, toxic chemical
vapors are unable to escape from the tank.
*• Implementation of dust pelletizing process. In
the Steel making operations, pollution control
dusts containing iron units and various metallic
compounds are produced. Under normal
circumstances, these dusts are landfilled.
Because of the recoverable iron units in the
dusts, the Edgar Thomson plant in PA, U.S. Steel
Mon Valley Operations has implemented a
pelletizing operation whereby pellets are recycled
back into the steel making operations.
REDUCTION HIGHLIGHTS
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