United States Office of Research and EPA/825/2-90/001
Environmental Protection Development September 1990
Agency Washington, DC 20460
USER'S GUIDE:
Process Analysis for
Pollution Prevention
Strategic
WAste
Minimization
Initative
Version 1.2
\\V
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USER'S GUIDE FOR
SWAMI
Strategic WAste Minimization Initiative
Version 1.2
Prepared for:
•>
U.S. Environmental Protection Agency
Center for Environmental Research Information
Cincinnati, OH
Prepared by:
PEER Consultants, P.C.
4134 Linden Ave.
Dayton, OH 45432
and
University of Dayton Research Institute
300 College Park
Dayton, OH 45469-0120
April 1990
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NOTICE
This user's guide describes software which was developed as a tool for
demonstrating concepts of process analysis following a waste minimization audit. The
software and this guide have been field tested, peer reviewed, and approved for
publication by the U.S. EPA. Information obtained through the use of this software
system should not be presumed to represent U.S. EPA policy and official endorsement
should not be inferred. Mention of trade names or commercial products does not
constitute endorsement or recommendation for use.
111
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FOREWORD
The Strategic WAste Minimization Initiative (SWAMI) Software, Version 1.2 is a
tool for using process analysis for identifying waste minimization opportunities within
an industrial setting. The software requires user-supplied information for process
definition, as well as material inputs and products for each unit operation and outputs
associated with waste streams. SWAMI provides a scheme for identifying and
prioritizing (on a cost or volume basis) waste reduction opportunities in process units
and treatment operations, and directs the selection of candidate waste minimization
strategies. This software system was developed in conjunction with the U.S. EPA
publication "Waste Minimization Opportunity Assessment Manual" (EPA/82S/7-88/003).
The use of that manual can provide the information necessary for input to this software.
IV
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TABLE OF CONTENTS
Section Pace
Notice iii
Foreword iv
Tables vi
Figures vi
Acknowledgments vii
1.0 INTRODUCTION 1
2.0 THEORETICAL CONSIDERATIONS 2
2.1 PROCESS ANALYSIS 2
2.2 PRIORITIZATION 3
2.3 STRATEGIZING 5
3.0 USING THE SWAMI SOFTWARE 7
3.1 INSTALLING SWAMI 7
3.2 GETTING STARTED WITH SWAMI 10
4.0 DETAILED DISCUSSION OF SWAMI CAPABILITIES 12
4.1 USING SWAMI FOR PROCESS DEFINITION 12
Unit Operations 12
4.2 WASTE STREAMS 13
4.2.1 Input Materials 14
4.2.2 Products 14
4.2.3 Treatments 15
4.3 PRIORITIZATION WITH SWAMI 15
4.3.1 Assign Responsibility 16
4.3.2 Priority Reports 18
4.4 STRATEGIZING WITH SWAMI 18
5.0 SAMPLE SESSION WITH SWAMI 20
APPENDIX A A-l
APPENDIX B B-l
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TABLES
Number Page
3.1 Summary of Important Keys Recognized by SWAMI 9
3.2 Definition of Terms 11
FIGURES
3-1 SWAMI main menu 10
4-1 Prioritization menu 16
4-2 Example of responsibility assignment 17
5-1 Sample process for SWAMI 20
5-2 SWAMI main menu 22
5-3 A completed process description form 23
5-4 Prioritization report sorted by cost 43
5-5 Prioritization report sorted by volume 43
5-6 Strategy report for the sample problem 50
VI
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ACKNOWLEDGMENTS
This software and user's guide were prepared under Contract No. 68-03-3312 by
PEER Consultants, P.C., and the University of Dayton under the sponsorship of the
U.S. Environmental Protection Agency. H. Douglas Williams of the U.S. EPA, Office of
Research and Development, Center for Environmental Research Information was the
project officer responsible for the preparation of this software. Participating in the
development of the engineering aspects of the software for PEER Consultants, P.C.,
were Joseph T. Swartzbaugh, Donovan Duvall, Edward J. Martin, and
Andrew W. Weisman. The software development was principally the work of
Clarence W. Cross, Jr., and Timothy K. Medlock of the University of Dayton Research
Institute. Thanks is given to the thousands of attendees of the Waste Minimization
Workshops who tested the software for their own applications. Special acknowledgment
is given to those who specifically tested earlier versions of the software and made
suggestions for its improvement, specifically Chuck Beckerdite of Gates Rubber
Company, Reuben A. McDavid of the University of Southern California, Robert Pojasek
of Geraghty and Miller, Incorporated, Thomas Blewett of the Iowa Department of
Natural Resources, Myles E. Morse of The U.S. EPA, Donald L. Brosky of 3M, and
Christopher Messner of SAIC.
Vll
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SWAMI
USER'S GUIDE FOR SWAMI
SECTION 1.0
INTRODUCTION
The purpose of the SWAMI software is to help the user
identify waste minimization opportunities, set up a
procedure to prioritize those opportunities, and devise a
strategy to take advantage of those opportunities that rate
the highest.
The Strategic WAste Minimization Initiative software
package known as SWAMI (including program, source code,
and documentation) was developed by PEER Consultants,
P.C., and the University of Dayton.
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SWAMI
SECTION 2.0
THEORETICAL CONSIDERATIONS
Before describing the mechanics of SWAMI, it is
necessary to explain the theoretical basis from which
SWAMI was developed. This section explains three such
topics: process analysis, opportunity prioritization, and
preliminary strategy identification.
2.1 PROCESS ANALYSIS
The software is based on standard systems analysis
concepts in which the entire process is looked upon as a
system of interacting unit operations (unit ops) or
components. In fact, an entire production line can be
considered an integrated process or system and this can
include such operations as material purchase, inventory
control, production, maintenance, waste collection and
mixing, waste treatment, and storage. If you use the
process flow diagram approach for an entire production
line, the software can lead you to specific opportunity
points within the plant. The software aids you in
generating a complete and realistic process flow diagram
for your plant (if one does not already exist).
Once the process flow diagram is completed, the
opportunity points become obvious. For example, every
waste flow emanating from a unit op defines a unit where
opportunities exist to affect that waste stream. Strategies
in that case include process modifications at that and
preceding unit ops to change the quantity or character-
istics of that stream. Other examples include:
(1) every material input stream identifies oppor-
tunities for material substitution (and for
possible changes in inventory control
methodologies);
(2) every connection point between unit ops (in fact,
every flow line) is an occasion for spillage to
occur (and thus an opportunity to control
spillage); and
(3) every point at which waste streams are joined is
an opportunity for waste segregation in order to
enhance recyclability of waste streams.
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SWAMI
2.2 PRIORITIZATION
Once the realistic opportunity points are identified,
the next step is to prioritize the opportunity points—
eventually winding up at the unit op from which the highest
priority waste emanated. Criteria to be used in setting up
a priority rating scheme can be chosen from any
combination of 3 criteria: volume of waste, hazardous
nature of waste, and cost to manage the waste. Further,
you can evaluate each unit operation directly from the
inputs and outputs associated with it if you have the
information needed for prioritization. SWAMI allows you
to start at the final waste streams leaving the plant, and
work backward (keeping track of which waste streams
cause certain costs and volume changes through any
treatment 'plants, blend points, etc.) until you arrive at the
unit op at which the waste originates. Then you can
properly assess the "contribution" of that unit op to the
final volume of waste streams leaving the plant as well as
the "contribution" of that unit op to the cost of treating,
storing, and disposing of the final waste streams leaving
the plant.
Two similar algorithms are used to compute the
volume and cost contributions of waste emanating from a
unit op. The "volume" of waste is traced from a final
waste back to its primary waste (a waste emanating from a
unit op) keeping a running product of responsibilities (as
decimal fractions) times the volume of the final waste.
When all such paths in the process have been traced, the
computed products of like primary wastes are combined
(summed). The result is the total amount of waste
attributed to a particular unit op. The mathematical
formulation for the volume contribution is:
V unit op
n
J-l
A
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SWAMI
where:
i = an index for the number of blend
• points or treatments passed
when tracking a final waste back
to a unit op.
j = an index for the number of paths
between a final waste and a unit
op.
kj = the number of blend points or
treatments on the jtn path.
n = the total number of final wastes
that the unit of interest
contributes to.
ri = the responsibility value (assigned
by you) at the ith blend (or
treatment).
v(j) = the volume of the final waste on
the jtn pathway to the unit op
of interest.
Similarly, one can estimate a total "cost" of
managing the wastes emanating from the unit op.
At any treatment or blend point, < each
incoming waste stream will be "responsible" for
some share of the cost of operating that treatment
or blend point and also responsible for a share of
the subsequent costs of managing and disposing of
the waste stream leaving that point. If we track
backward from final disposal, then the steps in the
logic process for this accumulation of costs and
responsibilities can be envisioned using the
following logic:
1.
2.
Set Cj equal
output waste.
to final cost of jth
Let the index i be a counter for the
number of treatment or blend points
encountered in following a waste flow
path back to the original unit op and k be
an index which keeps track of the
pathway being followed.
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SWAMI
3. Let Cj = RDi(k)Cj + RT^kJFj where RDj(k)
is the share or the output waste cost
borne by the k^ input waste at the
jth treatment or blend point, RT j(k)
is the share of the operating cost borne by
the kth input waste at the j"1
treatment, RTj(k) is the share of the
operating cost borne by the ktn input
waste and Fj is the operating cost of
the itn treatment or blend point.
4. Repeat step 3 for each treatment or blend
point encountered.
Note that for any treatment operation, there may be more
than one output waste stream and so the subsequent costs
of managing and disposing of those wastes must be included
in the volume responsibility assignments and cost tracking.
Once these values have been calculated for each of
the individual streams emanating from process unit ops, it
is a simple matter to list the results on a basis of
decreasing volume "responsibility" and by decreasing cost
responsibility.
2.3 STRATEGIZING
The next step in the logic process—once a unit op has
been picked as a prime candidate for waste minimization
activities—is to devise a strategy for alternatives to the
present operation. Such alternative strategies can be as
simple as resetting one control in a process, to as complex
as making major equipment modifications, or making a
complete change in the type of unit op used in a process.
At this stage, the software package can prove helpful in
identifying a strategy to be considered. The program,
through a sequence of questions and answers, will aid in
identifying generic waste minimization strategy concepts.
The output from this exercise is a statement of relevant
facts and a list of keywords. This statement and keyword
list will guide you to sources of more specific information
for developing alternatives. For example, with these
keywords, you can access existing literature and case study
databases to find specific information about strategies
used in your (and similar) industry.
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SWAMI
Note that SWAMI's usefulness does not end here. When an
alternative has been designed, you can, with the aid of the
program, evaluate the effects of waste minimization in
light of the proposed alternative by entering the proposed
modifications to your process as a new process to be
analyzed with SWAMI.
Certain types of information must be gathered to
proceed with the evaluation and selection of these waste
minimization opportunities. Most of this infor- mation is
specific to the strategies to be evaluated. For example,
specific strategies under consideration for implementation
at a particular unit operation point in a process must be
sized to meet the demands of the process and unit op.
Furthermore, many process modifications will require
installation of several pieces of equipment. Obviously, the
capital cost for implementing such strategy will then
depend upon the equipment list, and the specific size of
equipment necessary (to match the existing process at that
point and time), while operating costs will depend on the
labor, maintenance, supplies, and utilities requirements to
operate and maintain the equipment. All these are cost
factors about which information must be garnered for this
specific application and specific size range necessary for
the proposed strategy. It is imperative, then, that when
you search any database using the keywords that SWAMI
generates, you should look for information about factors
such as equipment size, capital cost factors, operating cost
factors, equipment lifetime, reduced production costs,
reduced waste disposal costs, and intangibles such as
reduction of potential liability, ease of operation, and
other factors to which it is difficult to assign a dollar value.
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WAMI
SECTION 3.0
USING THE SWAMI SOFTWARE
SWAMI is an acronym for "Strategic WAste
Minimization Initiative." The following paragraphs explain
procedures for installing and using SWAMI on your
personal computer. Important keys recognized by SWAMI
are given in Table 3.1. If you press an invalid key, SWAMI
warns you with a beep. (For example, try pressing the
key when the main menu appears on the screen.)
3.1 INSTALLING SWAMI
SWAMI was designed to operate on IBM personal
computers (or compatibles) with 640K memory, a 286 or
386 processor, a hard disk, and MS-DOS version 2.0 or
higher. (If your system does not meet all these
requirements, you should still try to install it; it may
work.) Five steps are needed to install SWAMI.
(1) Insert your floppy diskette into drive "A". Then,
to copy the contents of your SWAMI diskette to
your hard disk, type "a:installa" in response to
the DOS prompt as shown below:
C:\>a:installa
You may instead insert your floppy diskette into
drive "B" and type "b:installb."
To fit all of SWAMI on one diskette, a
compression program has packed all the files
into one large file. The install procedure
unpacks the SWAMI files and puts them in your
new SWAMI directory. You should check
C:\SWAMI (type "dir C:xSWAMI") to make
sure you have the following files:
MAINMENU.EXE
SWAMI.HLP
TEXT.DAT
TEXT.K01
RELATE.DAT
RELATE.K01
KEYWRDS.DAT
KEYWRDS.K01
KEYWRDS2.DAT
KEYWRDS2.K01
SWAMI1.BAT
SWAMI2.BAT
SWAMI3.BAT
SWAMI4.BAT
SWAMI5.BAT
SWAMI6.BAT
SWAMI7.BAT
SWAMI8.BAT
SWAMI9.BAT
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SWAMI
(2) The install program creates a SWAMI dir-
ectory. Add your new SWAMI directory to
the PATH statement in your OAUTOEXEC.BAT
file. The following examples show how you
would add SWAMI to an existing PATH
statement. (These are examples only; the exact
contents of your PATH instruction will probably
vary.)
Example 1:
BEFORE
PATH=C:\DOS;\BATCH
AFTER
PATH=C:\DOS;\BATCH;\SWAMI
Example 2:
BEFORE
PATH=C:\DOS;\TEXT;\BATCH
AFTER
PATH=C:\DOS;\SWAMI;\TEXT;SBATCH
You can use the EDLIN line editor (or other text editor)
to make this change.
(3) Add or modify the FILES statement in the
C:CONFIG.SYS file. The new instruction should
read "FILES=60" as in the example below:
BEFORE
FILES = 20
AFTER
FILES = 60
(Note: If the existing FILES instruction is greater
than or equal to 60, no change is needed.)
Again, use the EDLIN (or other) editor to do this.
(4) Reboot your system. Do this by holding down the
and keys and pressing .
(5) Make sure the new SWAMI directory is in the
PATH definition. Type "SET" and press .
If NSWAMI does not appear in the path
definition, consult your local computer guru.
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SWAMI
TABLE 3.1. SUMMARY OF IMPORTANT
KEYS RECOGNIZED BY SWAMI
& arrows: moves the selector bar up and down
& arrows: moves the cursor left and right
within a data field
or : selects an item from a list or menu.
Also used to complete a data field and advance to the next
data field or screen.
: displays help information relevant to activity in
progress.
: a back-up key. Backs up 1 field or 1 screen. Also
used to exit the HELP screen.
: when entering data into a field, this key can
be used to delete 1 character immediately to the left of
the cursor.
: used when a list appears on the screen. This key
notifies SWAMI that you wish to add a data item to the list.
: used when a list appears on the screen. This key
notifies SWAMI that you wish to delete the highlighted
data item from the list.
: a process definition key which activates the
treatment list.
: a process definition key which activates the
materials list.
: a process definition key which activates the waste
list.
: a process definition key which activates the master
waste list.
: a process definition key which activates the
products list.
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SWAMI
3.2 GETTING STARTED WITH SWAMI
The SWAMI program is started by executing one of the
batch command files in the \SWAMI directory. Since
SWAMI is intended to assist you in analyzing processes in
your plant (production processes, treatment processes,
etc.), you may wish to define (and store for future use)
several different processes. Batch files in your SWAMI
directory (SWAMI1.BAT through SWAMI9.BAT) activate
one of the subdirectories within the SWAMI directory, then
start the SWAMI program. Since each process is stored in
its own subdirectory, this method of starting SWAMI also
selects the process you wish to access. For example, if you
wish to define or access the process in C:\SWAMI\1
type "SWAMU". SWAMI2.BAT can be used to access the
process in C:\SWAMI\2. Separating the process data
files by subdirectories, simplifies your back-up procedure.
Simply type:
C:\>copy C:\SWAMI\1\*.* a:
to copy all of your process #1 data to the floppy diskette in
the A: drive.
SWAMI begins by displaying
Figure 3-1) consisting of six options.
a main menu (see
Strategic WAste Minimization Initiative
(SWAMI)
Version 1.2 March 9, 1890
SWAMI MAIN MENU
Select one of the following ateps:
1} Nam* the process
2) Process definition
3} Prioritize opportunities
4} Strategy development
6) Feasibility study HELP
6) Cost analysis HELP
Available Keys:
- exit SWAMI
& arrows move selector bar
• activate menu Item
Developed by:
PEER Consultants
and
University of Dayton
Sponsored by:
United States
Environmental
Protection Agency
Figure 3-1. SWAMI main menu.
10
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SWAMI
Use the arrow keys to move the selector bar up and down
and the key to select the highlighted option. The
key labeled is the SWAMI help key. Pi ess it any time
you need additional information. You may also wish to
study the definition of terms in Table 3.2.
TABLE 3.2. DEFINITION OF TERMS
Cursor: a small box or line, sometimes blinking, indicating
the screen position of the next typed character.
Data entry Form: a screen containing labels and data
fields. SWAMI data entry forms are analogous to
traditional paper forms you are familiar with.
Data field: an area of the screen where typed values (data)
appear.
Lists: data items organized in rows or columns which can
be selected like menu items.
Menu: program options displayed on the screen. These
options can be chosen by positioning the selector bar on the
desired item and pressing the key.
Selector bar: a highlighted rectangle on the screen for
choosing items in a list or marking the maximum number of
characters in a data field.
Waste: a waste emanates from a unit op or treatment as a
substance which is classified as unsalable and therefore
must be disposed of or treated and recycled.
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SWAMI
SECTION 4.0
DETAILED DISCUSSION OF SWAMI CAPABILITIES
This section describes the features of SWAMI and
specific keys used to activate them. Because the
information is presented in a sequence consistent with
anticipated usage you may wish to try using the program as
you proceed through Section 4.0.
4.1 USING SWAMI FOR PROCESS DEFINITION
The two menu options are used to define your process.
"Initial Description" presents a data entry form for
defining parameters that identify your process, including
company name, plant name and location, process name, and
major products. Some of these parameters appear as
header information in SWAMI reports.
"Process definition" uses a series of lists and data
entry forms to define the components (unit operations,
wastes, treatments, blends, products, and materials) of
your process. Lists summarize the process components
which have been defined; forms are used to define, modify,
and delete components. When an empty list is activated,
SWAMI automatically displays the correct form for
defining the first item in that list.
Unit Operations
Defining the process flow begins at the unit op. The
order of the unit ops in the unit op list should reflect the
logical order of the process. For example, the top unit op
in the list represents the first unit op in the process.
Similarly, the bottom unit op is the final unit op in the
process.
• You can define a new unit op by pressing the
key when the unit op list is active.
• You can modify an existing unit op by moving the
selector bar to highlight your choice and pressing
.
• Finally, you can delete a unit op by highlighting
it, pressing the key, and pressing
.
Once a unit op has been defined, you can activate the
materials, wastes, and products lists by pressing ,
, and respectively.
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SWAM
The items defined at this time will "belong" to the unit op
that was highlighted when you activated one of these lists
(i.e., they will be those entering or exiting the process at
that unit op). Notice that SWAMI only displays the
materials, wastes, or products belonging to the highlighted
unit op. To define materials, wastes, or products for a
different unit op, return to the unit op list and select
another unit op (with or ). Then, activate one
of the other lists.
4.2 WASTE STREAMS
The waste list shows which waste streams
emanate from the highlighted unit op or treatment.
Wastes can be added, modified, or deleted when this list is
active (by pressing when the particular unit op is
highlighted). A special waste lists shows all wastes in
your process. Wastes can only be modified or deleted when
the waste list is active. You can return to the unit op
or treatment list by pressing .
To define a new waste, press the key. To edit
an existing waste, use the and arrow keys to
move the selector bar, then press . To remove a
waste, move the selector bar, press the key, and
press to return to the unit op or treatment list.
Remember, these activities are available only when one of
the waste lists is active.
The waste description form is used to add, modify, or
delete a process waste. SWAMI automatically displays this
"Waste description form" if you activate an empty waste
list. After defining your first waste, you can select it
again by pressing , , or when the
waste list is active. "Record will be Added," "Record will
be Changed," or "Press Enter to Delete" appears beneath
the title to indicate how the waste will be processed.
The following fields appear in the waste definition
form:
Waste name - name which appears in the
waste list to identify the
waste.
Description - an optional field for expanding
the waste name.
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SWAMI
Fate type -
Fate name -
identifies the type of destination
of the waste (e.g. a treatment
operation within your plant; a
blend point such as a common
sump; a recycling operation in
your facility; or "exit," i.e., a
Treatment, Storage, and Disposal
Facility (TSDF) outside of the
generating plant.)
name of the treatment or blend
point. You must either select a
treatment from the treatment
list appearing on the right of the
screen or add a new treatment
to the list and then select it
from the list (e.g., your plant's
industrial wastewater treatment
plant; the "acid sump"; solvent
still No. 3; the Harrison Landfill;
etc.).
4.2.1 Input Materials
The materials list shows which materials are used by
the highlighted unit op or treatment. Materials can be
added, modified, or deleted only when this list is active.
To add a new material, press the key. A blank
material description form will appear with the message
"Record will be Added." To edit an existing material, use
the and arrow keys to move the selector bar,
then press . This time the material description
form will contain the current data and the message
"Record will be Changed." To remove a material, move
the selector bar, press the key, and press
in response to the message. Again, the material
description form (with current data) will be displayed. The
message "Press Enter to Delete" tells you to press
to complete the deletion. Finally, when you finish editing
the materials list, press to return to the unit op or
treatment list.
4.2.2 Products
The products list shows which products are generated
by the highlighted unit op or treatment. Products can only
be added, modified, or deleted when this list is active. To
define a new product, press the key. To edit an
existing product, use the and arrow keys to
move the selector bar, then press .
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WAMI
To remove a product, move the selector bar, press the
key, and press in response to the
message. Finally, when you finish editing the products list,
press to return to the unit op or treatment list.
4.2.3 Treatments
A treatment is similar to a unit op except it has one or
more input wastes and appears in an alphabetized
treatment list. You can define a new treatment (or blend)
when one of two treatment/blend lists is active. The first
list is accessed by pressing when the unit op list is
active. You can add a treatment by pressing .
Existing treatments can be changed by moving the selector
bar to your choice and pressing . You can remove a
treatment by highlighting it and pressing the key.
The second treatment (or blend) list appears
automatically when you define a waste's fate as
"treatment" or "blend." When this new treatment list is
active you can press to add a new treatment or
to select one as the fate of the current waste.
When a treatment appears in the list, you can
define its input materials, output wastes, and products by
pressing , , and respectively. (The input
waste list cannot be modified directly through the
treatment fields. This can only be done by defining a
treatment as the destination (fate) of a waste. The items
defined at this time "belong" to the treatment that was
highlighted when you activated one of these lists. Notice
that SWAMI only displays the materials, wastes, and
products belonging to the highlighted treatment. To define
materials, wastes, or products for a different treatment,
return to the treatment list and select another treatment.
Then reactivate one of the other lists.
4.3 PRIORITIZATION WITH SWANfl
"Prioritization" helps you select wastes which offer
the best opportunities for waste minimization. A precise
process definition must be completed to ensure an accurate
prioritization. Selecting "prioritization" presents the menu
shown in Figure 4-1.
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SWAMI
Strategic UAite Ninloiitation Initiative |
I
Version 1.2 •• -or M»rch 9. 1990 |
SWHI HAIM MEW
Select one of the folloulng ct
1) Dane the process
2) Process definition
3) Prloritlie opportunities
<) Strategy development
5) Feasibility Study HELP
6) Cost Analysis KELP
PRIORITIZATIOM MENU
ASSIGN RESPONSIBILITY
PRIORITIZATION REPORTS
• KELP
•j • selects nenu option
-j • HELP I
arrows watt selector bsr |
• activate ami Itea I
Figure 4-1. Prioritization menu.
4.3.1 Assign Responsibility
During the "Assign Responsibility" operation you will
estimate the share of responsibility an input waste has for
the treatment cost and the cost and volume of the wastes
emanating from that treatment. For example, if a
treatment has 2 input wastes and 1 output waste, you
probably want the percentages assigned to each input
waste to total 100% with respect to the output waste and
treatment cost (unless there are other processes in your
plant which "feed" wastes to the same treatment
operation).
In Figure 4-2 there are two waste pairs: (1) input
waste #1 and the output waste and; (2) input waste #2 and
the output waste. This selection of waste pairs provides
the foundation for the "Assign Responsibility" operation.
You will be asked to tell what share of the treatment
costs, what share of the output waste's volume, and what
share of the output waste's subsequent treatment and
disposal costs are there because of the need to treat and
dispose of each of the two incoming wastes. For example,
suppose that input waste #1 were a high-volume, dilute
waste stream, while input waste #2 has a small volume of
highly hazardous material.
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SWAMI
Then you might decide that most of the cost of disposing of
the output waste is because of waste #2, while most of the
tankage in the treatment existed because of the need to
handle waste #1. These are decisions you must make,
based on your knowledge of your plant.
INPUT WASTE **_!_
50%$ 25% V
67% T$
INPUT WASTE
50%$ 75%V
33% T$
TREATMENT
OUTPUT
WASTE
SYMBOLS
$ • WASTE DISPOSAL COST
V-OUTPUT WASTE VOLUME
T$-TREATMENT COST
Figure 4-2. Example of responsibility assignment.
The treatment list displayed in "Assign Responsibility"
appears to the left of the waste pair list. To proceed,
select a treatment from the treatment list. (Use the arrow
keys to move the selector bar, then press .)
The waste pair list shows all combinations of input and
output waste pairs for the treatment highlighted in the
treatment list. (Remember that establishing the rela-
tionship of input waste to output waste is a requirement
for assigning responsibility.) To proceed, select a waste
pair from the waste pair list. SWAMI will ask you the
following:
(1) What percentage of the treatment cost is
attributable to the input waste?
(2) What percentage of the volume of output waste
is attributable to the input waste?
(3) What percentage of the final disposal costs of
the output waste is attributable to the input
waste?
17
-------
SWAMI
Your responses to the responsibility questions are
recorded in the waste pair list. (SWAMI assigns 100% when
only one input waste exists for a treatment. Note that if
other processes should share these costs and volumes, you
must correct the numbers appropriately.) You can then
check the list to ensure that the information is correct.
4.3.2 Priority Reports
"Priority Reports" presents a menu allowing you to
choose the type of report: screen, print, or disk file.
There are three options in this menu; each will generate a
prioritization report. The difference is the destination of
the report. If you wish to view the report on the screen,
select the first option. Option two causes a printed
report. If you are not connected to a printer, this option
may lock-up your computer. (Note: To recover from a
computer lock-up, you must reboot. To accomplish this,
hold down the and keys while pressing
.) The third option, "File," is not yet available.
4.4 STRATEGIZING WITH SWAMI
Begin the strategizing process by selecting "Strate-
gies" from the main menu. Next, select a waste from the
strategy waste list. This waste list shows all wastes in the
process. Presumably, you have used SWAMI's prioritization
or some other methodology to identify the best waste
opportunity points. To select one of these waste
opportunities, use the and arrow keys to move
the selector bar, then press .
Next, SWAMI displays the strategy menu. There are
two options in the strategy menu, each pertaining to the
waste you just selected. The first, "Identify Strategies,"
presents several questions you must answer to determine
the waste cause and lead to a set of candidate waste
minimization strategies. The "Print Report" option sends
the strategy report to your printer. If no printer is
connected to your computer, selecting this option may
lock-up your computer. (See reboot requirements in
Section 3.1.)
Answering the set of questions presented in this step
will lead to a set of possible strategies for reducing or
eliminating the selected waste. (To answer the question,
position the selector bar to your choice using the and
arrow keys.
18
-------
SWAMI
Then press the or key. You can back up
1 question by pressing the key.) This step helps you
rule out any strategies which absolutely do not apply to the
chosen waste opportunity point. For these, type 'N';
otherwise, type '¥'. The temptation might be to rule out
strategies which, on the surface, seem unlikely candidates.
However, if you are not sure, keep them until additional
research proves them infeasible or undesirable.
19
-------
WAMI
SECTION 5.0
SAMPLE SESSION WITH SWAMI
SWAMI is best learned by using it. For this reason,
Section 5.0 gives a detailed step-by-step account of a
sample problem for you to try. Each step includes an
action, a short explanation of the action, and a description
or picture of the results. If this is not enough, you can
press any time during the session for additional
information. When you complete the example, you will be
ready to put SWAMI to use. Figure 5-1 shows the sample
process you will be working with. This section assumes you
are working the example for the first time (using empty
data files).
WATER £ WASH
1
WATER -j * 1
RINSE
pc:
HEAT
CURING
I
WIDGET
DIRTY ACIDIC WATER
U_... .
NEUTRAL
TAN
5% ACIDIC WATER
(ZING SLUDGE ^
> 15000 TSDF«
VAS9 1 •= 3VJUVS
MASS = 1200
KILN RESIDUE ^
TSDF«
COST = 250
MASS = K)
Figure 5-1. Sample process for SWAMI.
20
-------
S.WAMI
Steo #1
Step #2
Action:
type: SWAMI1
and press:
Result:
The screen goes blank for a few seconds and a title
screen appears.
Explanation;
You will both select a process and begin executing
SWAMI with this one instruction. If you wish to
access the process defined in subdirectory
C:\SWAMI\1 type the instruction "SWAMI1" and
press the key. Likewise, "SWAMI2" will
select the process in C:\SWAMI\2 and execute
SWAMI. Altogether, there are nine SWAMI
commands (SWAMI1 through SWAMI9) meaning you
can have nine processes on your system at one time.
For this sample we will assume you are starting a
new problem.
Action:
Read this screen then press .
Result:
SWAMI displays the main menu as shown in
Figure 5-2.
Explanation:
This title screen shows that SWAMI can be used to
perform three steps of a waste minimization
analysis. It also identifies software available for
performing two additional steps.
21
-------
SWAMI
Strategic WAste Minimization Initiative
(SWAMI)
Version 1.2 March 9, 1990
SWAMI MAIN MENU
Select one of the following steps:
1) Name the process
2) Process definition
3) Prioritize opportunities
4) Strategy development
5) Feasibility study HELP
6) Cost analysis HELP
Available Keys:
= HELP
» exit SWAMI
& arrows move selector bar
= activate menu item
Developed by:
PEER Consultants
and
University of Dayton
Sponsored by:
United States
Environmental
Protection Agency
Step #3
Figure 5-2. SWAMI main menu.
Action:
Press the key.
Result:
A blank process description form appears like the one
shown in Figure 5-3.
Explanation:
The first thing you should do is define the identifying
parameters of the process. Some of this information
will appear in the strategy report.
22
-------
SWAMI
Step #4
Action:
type: Curing
press:
type: XYZ Widget Manufacturing Corporation
press:
type: Eastside plant
press:
type: Department of Redundancy Department
press:
type: Building 200
press:
type: 1424 E. Fourth Street
press:
type: Dayton, OH 45410
press:
type: Small atomic widgets
press:
Result:
The data is entered onto the form. When you press
from the last field, the process description
data is saved and the main menu is redisplayed.
Explanation:
Each time you complete a SWAMI data entry form,
the contents are saved on your disk.
| Strategic UAsle mmaitatlon Initiative |
I I
| Version 1 2 lurch •>. 1990 |
I 1
Process Description Fora
Record mil be Changed
PROCESS :Curing
HUM :XTZ tlldgef Manufacturing Corporal Ion
PL/ml -Eastsioe plant
OEPMtHEm .deportment of Redundancy Department
•SEA .Building 200
SHEET -UZ4 E. fourth SI
Cllr.SI 2IP:Oayton. OH 45410
PRODUCTS :Snall atonic uidgets
— «M> for HELP
| • HELP |
| «1C> • exit SVAHI |
| «up» a «down> arrows move selector bar |
| B activate nenu Itea |
returns to svln Menu -J
Figure 5-3. A completed process description form.
23
-------
WAMI
Step #5
Step #6
Action:
Press 2, then press the key
Result:
The process definition screen appears and the "Unit
Operation Description Form" (also called a worksheet
or a data entry form) appears on top of it.
Explanation:
The next step for a new problem is to define the
process components including all unit operations,
input materials, wastes, products, treatments, and
blends. Pressing 2 moves the selector bar to the
second menu option, "Process Definition"; pressing
activates it. Futhermore, since no unit ops
exist for the new process, SWAMI displays the "Unit
Op Description Form" to define your first unit
operation.
Action:
type: ACID WASH
and press:
Result;
Your first unit op is defined. SWAMI removes the
data entry form and "ACID WASH" appears as the
first unit op in your process.
Explanation:
A name is the only data item needed for a unit
operation. If you make a mistake while entering the
name, use the key to go back and fix it.
The left and right arrow keys, , and
also work. The key switches between
overstrike and insert modes. Experiment with these
keys while the worksheet is visible. If you decide to
exit the form without saving the data, press .
24
-------
SWAM
Step #7
Step #8
Step #9
Action:
Press the key
Result:
SWAMI pops up a box for choosing if you want to
insert the unit op before or after "ACID WASH," the
unit op which is highlighted.
Explanation:
Try using the left and right arrow keys to switch
between the words "Before" and "After." If you use
the key to return to the process screen, no new
unit op is added.
Action:
Use the left or right arrow keys to move the selector
bar between "After" and "Before." Select "After."
Then, press .
i
Result:
SWAMI displays the unit op data entry form.
Explanation;
Once again, a name is the only data item on the unit
op worksheet. Pressing at this time will return
you to the process 'screen without adding a new unit
op.
Action:
type: SPRAY RINSE
and press:
Result:
Your second unit op is defined. SWAMI removes the
data entry form and "SPRAY RINSE" appears below
"ACID RINSE" as the second unit op in your process.
Explanation;
SWAMI makes the worksheet data permanent when
you complete the name field and press .
Remember, you can use , the arrow keys,
, and when completing a data entry
form.
25
-------
WAMI
Step #10
Step #11
Step#12
Press the key then,
press the key.
Result:
Again, SWAMI pops up the box for choosing if you
want to insert the unit op before or after the unit op
which is highlighted. "After" is chosen and SWAMI
displays the "Unit Op Description Form."
Explanation:
You are ready to enter the name of your third and
final unit op. If you use the key to return to
the process screen, no new unit op is added.
Action:
type: HEAT CURING
and press:
Result:
Your third and final unit op is defined. SWAMI
removes the data entry form and "HEAT CURING"
appears in the process list.
Explanation:
The data becomes permanent when you complete the
name field and press .
Action;
Press
Result:
The waste list is activated and the "Waste
Description Form" appears.
Explanation;
The only way to define a new waste is from the
waste list. This list shows all wastes defined for the
highlighted unit op, "HEAT CURING." Since no
wastes have been defined for "HEAT CURING,"
SWAMI displays the "Waste Description Form."
26
-------
WAM
Step #13
Step #14
Step #15
Step#16
Action:
type: KILN RESIDUE
and press:
Result:
The cursor advances to the field labeled
"Description."
Explanation;
A waste name can be up to 25 characters in length.
Because the waste name is what you use to reference
a .waste stream, SWAMI will not let you proceed to
the next field until you type at least one character
into the "Waste Name" field.
Action:
type: Brown flaky stuff that smells real bad!
and press:
Result:
The cursor advances to the field labeled "Hazardous?"
Explanation:
The description field is optional.
Action:
Use the left or right arrow key to select "Yes" or
"No," then press .
Result:
The cursor advances to the field labeled "Fate Type."
Explanation:
The only way to proceed to the next field is by
selecting "Yes" or "No" in response to the hazardous
question.
Action:
Use the right or left arrow key to highlight "Exit,"
then press the key.
27
-------
WAMI
Step #17
Step #18
Result:
SWAMI displays two new fields called "Annual cost to
outside TSDF! and "Annual volume (mass) rate to
outside TSDF" and advances the cursor to the former.
Explanation;
Select "Exit" as the fate type when a waste "goes out
the gate" or when a waste leaves the process.
Presumably, it is this point when the process
personnel have knowledge and records of costs to
treat, store, and/or dispose of the waste stream.
Action:
type: 250
and press:
Result:
The cursor advances to the "TSDF volume" field.
Explanation:
The TSDF cost represents the annual expenses for
disposing of a waste leaving the plant including labor
and shipping expenses and fees paid to outside
agencies to store and treat the waste.
Action:
type: 10
and press:
Result:
SWAMI removes the "Waste Description Form" and
puts "KILN RESIDUE" into the waste list for "HEAT
CURING."
Explanation:
The TSDF volume (or mass) represents the annual
amount of waste. To generate a meaningful volume
prioritization report you must use the same units for
all TSDF waste volumes.
28
-------
SWAMI
Steo #19
Step #20
Step#21
Action:
Press the key.
Result:
SWAMI returns to the unit op list.
Explanation:
Among other things, returning to the unit op list
allows you to select another unit op to work with.
The material, waste, and product lists describe
components of the highlighted unit op and therefore
must be activated after highlighting the desired unit
op.
Action:
Move the selector bar to "ACID WASH" by pressing
the up arrow key twice. Then, press the key.
Result:
The empty waste list for "ACID WASH" is activated
and the "Waste Description Form" appears.
Explanation:
The waste worksheet appears because no wastes are
present in the waste list for "ACID WASH."
Action:
type: DIRTY ACIDIC WATER
press:
type: Green and stinky
press:
Result;
The cursor advances to the field labeled
"Description," then to the "Hazardous?" field.
Explanation:
So far, completing the waste worksheet is just as you
did before.
29
-------
SWAMI
Step #22
Step #23
Step #24
Action:
Press the key.
Result:
The waste is identified as hazardous and the cursor
advances to the field labeled "Fate Type."
Explanation:
The only way to proceed to the next field is by
responding "Yes" or "No" to the hazardous question.
Action:
Press the key.
Result:
The waste destination is a treatment. SWAMI
displays an empty treatment list and a "Treatment
Description Form."
Explanation:
When you identify a waste's fate (destination) as
treatment, SWAMI displays a list of the defined
treatments and waits for you to select one. Since
none have been defined, SWAMI gives you the
"Treatment Description Form."
Action:
type: NEUTRALIZING TANK
and press:
Result;
The cursor advances to the "Annual Operating Cost"
field.
Explanation:
"Treatment Name" is a required field.
30
-------
SWAMI
Step#25
Step #26
Step #27
Action:
type: 15000
and press:
Result:
The worksheet disappears and "NEUTRALIZING
TANK" appears in the treatment list highlighted by
the selector bar.
Explanation;
Be sure to include all costs associated with operating
the treatment. Among other things, this includes
input materials, labor, utilities, and amortized
equipment and maintenance costs. Remember,
defining the treatment is only an intermediate task
required to complete the waste definition.
Action: ,
Press the key.
Result:
"NEUTRALIZING TANK" becomes the fate name of
"DIRTY ACIDIC WATER." The treatment list and
"Waste Description Form" go away. "DIRTY ACIDIC
WATER" is highlighted in the waste list. The
message "Press ESC when finished" blinks at the
bottom of the waste list.
i
Explanation;
The waste definition is complete.
Action:
Press the key.
Result;
The blinking message disappears. The unit op list is
reactivated.
Explanation;
Remember, since the process is defined around the
unit op, you will constantly return to the unit op list.
31
-------
SWAMI
Step #28
Step #29
Step #30
Action:
Press the key.
Result:
The
empty materials list for "ACID WASH" is
activated and the "Material Description Form" pops
up.
Explanation;
The material worksheet appears because no materials
are present in the material list for "ACID WASH."
NOTE: Version 1.2 of SWAMI does not use the
material data in any calculations or reports.
However, it is advisable to define the process
materials for completeness of the process definition.
Action:
type: WATER
and press:
Result:
The cursor advances to the "Supplier" field.
Explanation:
"Material Name" is required. SWAMI will not
proceed until the "Material Name" field is filled in.
Action:
type: Gotham City Water Works
and press:
Result:
The cursor advances to the first line of the
"Chemical Component" field.
Explanation:
You may wish to include an address in the "Supplier"
field.
32
-------
SWAMI
Step #31
Step #32
Step#33
Action:
Press the key four times.
Result:
The cursor advances to the "Hazardous?" field.
Explanation:
For this example, we are skipping the "Chemical
component" field because water is water, right?
Actually, you may wish to indicate concentrations of
chlorine or other chemicals in your city water. Use
the four lines (forty characters each) as you see fit.
Action;
type: N
and press: A
Result:
The cursor advances to the "Annual Usage Rate" field.
Explanation:
The "Hazardous?" field in the material worksheet is
just like the one for wastes. In previous steps you
used the left and/or right arrow keys to move the
selector bar. This step shows that typing the first
character of a menu option is another way to move
the selector bar.
Action:
type: 650
and press:
Result:
The cursor advances to the "Shelf Life" field.
Explanation:
The annual usage rate must be an integer.
33
-------
SWAMI
Step #34
Step #35
Step #36
Step #37
Action:
type: n/a
and press:
Result:
The cursor advances to the "Delivery mode" field.
Explanation:
"Shelf Life" is a 10-character field for entering
information like "30 days" or "5 years."
Action;
type: pipeline
and press:
Result:
The worksheet disappears and "WATER" appears in
the material list. The message "Press ESC when
finished" blinks at the bottom of the list.
Explanation;
The material definition is complete for "WATER."
Action:
Press the key.
Result:
The "Material Description" form appears again.
Explanation:
is the key used to add a new item to a
nonempty list.
Action:
Enter data for the other input material of "ACID
WASH." Use the actions similar to those in steps
29-35.
34
-------
SWAMI
Step #38
Step #39
Step #40
Result:
"HCL" is defined and added to the material list for
"ACID WASH." The message is still .blinking at the
bottom of the material list.
Explanation:
You have finished defining the input materials for
"ACID WASH."
Action:
Press the key.
Result:
The blinking message disappears and the unit op list
is reactivated.
Explanation:
All materials and wastes have been defined for
"ACID WASH."
Action:
Press the down arrow key to "SPRAY RINSE" then,
press .
Result:
The empty waste list for "SPRAY RINSE" and a blank
waste worksheet appear.
Explanation:
Remember, each waste list pertains to a particular
unit op. Even though two wastes have already been
defined, these were for different unit ops. That is
why this waste list is empty.
Action:
type: 5% ACIDIC WATER
press:
type: Tinted green and barely stinky
press:
press:
press:
35
-------
WAMI
Step#41
Step #42
Result:
The first four field blanks are filled in and a
treatment list appears with "NEUTRALIZING TANK"
as the only defined treatment.
Explanation:
SWAMI is waiting for you to select a treatment.
When the waste "goes to" one of the listed
treatments, use the arrow keys and press to
select the correct one. Otherwise, press to
define a new treatment.
Action;
press:
press:
Result:
"NEUTRALIZING TANK" becomes the fate name of
"5% ACIDIC WATER." The treatment list and
"Waste Description Form" go away. "5% ACIDIC
WATER" appears in the waste list. The unit op list is
reactivated.
Explanation;
The definition of "5% ACIDIC WATER" is complete.
Action:
Press the key.
Result;
A new screen appears with a treatment list in the
center flanked by two waste lists, a material list, and
a product list.
Explanation:
The treatment screen is used to define the path of
wastes until they leave the plant or process as "Exit"
wastes. Primary wastes (from unit ops), which are
already defined, appear in the input waste list. You
will begin defining output wastes using the same
procedures followed earlier.
36
-------
SWAM
Step#43
Step#44
Step #45
Action:
Press the key.
Result:
The empty waste list for "NEUTRALIZING TANK" is
activated and the "Waste Description Form" appears.
Explanation;
The waste worksheet appears because no wastes are
present in the output waste list for "NEUTRALIZING
TANK."
Action:
type: SLUDGE
press:
type: Black gooey slime
press:
type: N
press:
type: E
press:
Result:
After selecting "Exit" for the fate type, SWAMI adds
two more fields and the cursor moves to the "Annual
Cost to Outside TSDF" field.
Explanation:
SWAMI only asks for these values when the waste is
an "Exit" waste.
Action:
type: 5000
press:
type: 1200
press:
Result:
The waste worksheet disappears and "SLUDGE"
appears, highlighted, in the output waste list. "Press
ESC when finished" blinks at the bottom of the waste
list.
37
-------
SWAMI
Step #46
Step #47
Step #48
Explanation:
The "Exit" waste is now part of the process.
Action:
Press the key three times.
Result:
SWAMI builds a prioritization file, then takes you
back to the main menu.
Explanation:
You are now finished defining the sample process. If
you wish to expand the process definition, you can
come back to it when you finish the rest of Section
Three.
Action;
type: 3
and press:
Result:
SWAMI displays the "Prioritization Menu." The
selector bar is positioned on the first option, "Assign
Responsibility."
Explanation:
You are now ready to begin the prioritization process.
Action:
Press the key.
Result;
The screen for assigning responsibility appears.
"NEUTRALIZING TANK" is highlighted in the
treatment and blend list.
38
-------
SWAMI
Step #49
Step #50
Step #51
Explanation:
Responsibility assignments are simply percentage
estimates of a waste's contribution to the cost of
operating a treatment, cost of each of the
treatment's output wastes, and volume (mass) of the
treatment's output wastes. For each treatment,
SWAMI displays a list of all possible pairs of waste
where one waste is an input to the selected
treatment and the other is an output of the same
treatment. In this sample, there is only one
treatment and it has two waste pairs.
Action:
Press the key.
Result:
The selector bar highlights the first waste pair.
Explanation:
Remember, these waste pairs represent an input
waste and an output waste of the selected treatment.
Action:
Press the key.
Result:
Three responsibility questions appear
where the treatment list used to be.
on the left
Explanation:
The first two questions pertain to the selected waste
pair. The third is relevant for the input waste and
the treatment.
Action;
type: 75
press:
type: 90
press:
39
-------
SWAMI
Step #52
Result:
The cursor moves to the field following the third
question.
Explanation:
In this sample, we have decided that "DIRTY ACIDIC
WATER" is 75% responsible for the TSDF cost of
"SLUDGE" and 90% responsible for the volume of
"SLUDGE" emanating from the "NEUTRALIZING
TANK."
Action;
type: 100
press:
Result;
SWAMI redraws the waste pair
completed waste pair highlighted.
list with the
Step #53
Explanation:
In this hypothetical example, we decided that since
we have another process in the plant that is able to
use slightly acidic water, the "NEUTRALIZING
TANK" is necessary only as long as we have the
"DIRTY ACIDIC WATER." Therefore, "DIRTY
ACIDIC WATER" is 100% responsible for the
treatment operating costs.
Action:
Press the down arrow key, then press .
Result;
Again, the responsibility questions appear. This time
they refer to the other waste pair.
Explanation:
Again, the first two questions pertain to the selected
waste pair. The third is relevant for the input waste
and the treatment.
40
-------
SWAMI
Step #54
Step #55
Step #56
Action:
type: 25
press:
type: 10
press:
Result:
The cursor moves to the field following the third
question.
Explanation:
You will notice that the percentages add up to 100%.
For example, it follows logically that if "DIRTY
ACIDIC WATER" is 75% responsible for the TSDF
cost of "SLUDGE," then "5% ACIDIC WATER" is
responsible for the remaining 25% of the cost.
Although there are cases when this isn't true, it is
still a good way to check your numbers. If the
percentages total more than 100%, SWAMI displays
an error message and will not let you proceed until
the problem is corrected.
Action:
Type a zero, then press the key.
Result:
SWAMI returns to the waste pair list.
Explanation:
Because "DIRTY ACIDIC WATER" already accounts
for 100% of the treatment cost, "5% ACIDIC
WATER" is responsible for none of it.
Action:
press:
press:
Result:-
SWAMI computes the prioritization results and
returns you to the "Prioritization Menu."
41
-------
SWAMI
Step #57
Step #58
Explanation:
Since there are no more treatments, we are finished
with the responsibility assignment.
Action;
Press the down arrow key, then press .
Result:
SWAMI displays a menu of three ways to receive your
prioritization report: screen, printer, and file.
Explanation;
The option "File" has not been developed for version
1.2 of SWAMI. Also, never select the option
"Printer" when using a computer that doesn't have a
printer. Doing so may lock-up your keyboard.
Action:
Press the key.
Result;
SWAMI displays the
shown in Figure 5-4.
first prioritization report as
Explanation:
Each waste report lists the primary wastes and
source unit ops, 'Y1 or 'N1 indicating if the waste is
hazardous or not, and the computed cost and volume
of the waste. The first report sorts the wastes from
highest to lowest cost. Notice that "DIRTY ACIDIC
WATER" heads this report.
42
-------
WAMI
Step #59:
PRIMARY WASTE
PRIMARY WASTE REPORT
by
COST
April 20. 1WO
SOURCE UNIT OP HAZARDOUS
TSOF
COST VOLUME
DIRTY ACIDIC WATER
5X ACIDIC WATER
KILN RESIDUE
ACID WASH
SPRAY RINSE
MEAT CURIKG
Y (18750.00 1080.00
Y S1Z50.00 120.00
V (2SO.OO 10.00
Figure 5-4. Prioritization report sorted by cost.
Action:
Press the key.
Result:
SWAMI displays the second prioritization report as shown
in Figure 5-5.
Explanation:
The second report includes the same information as the
first but is sorted by volume. In this example, the only
difference is in the report title.
PRIMARY WASTE
PRIMARY WASTE REPORT
by
VOLUME
April 20. 1990
SOURCE UNIT 0? HAZARDOUS
TSOF
COST VOLUME
DIRTY ACIDIC WATER
5X ACIDIC WATER
KILN RESIDUE
ACID WASH
SPRAY RINSE
HEAT CURING
Y S187SO.OO 1080.00
Y $1250.00 120.00
V 1250.00 10.00
Figure 5-5. Prioritization report sorted by volume.
43
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SWAMI
Step #60
Step #61
Step #62
Action:
press:
press:
Result;
SWAMI returns to the main menu.
Explanation:
You are ready to begin the strategy portion of the
analysis.
Action:
press: 4
press:
Result:
SWAMI shows an alphabetical list of the wastes
defined in your process.
Explanation:
Remember, the prioritization reports indicated that
"DIRTY ACIDIC WATER" was judged responsible for
the greatest amount of waste in terms of both cost
and volume.
Action:
Press the down arrow, then the key.
Result:
"DIRTY ACIDIC WATER" is selected and SWAMI
displays the strategy menu.
Explanation:
For this sample problem we have elected to go after
the biggest generator. In actual use, you may have
reasons to start with a different waste.
44
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SWAMI
Step #63
Step#64
Step#65
Action:
To begin the strategy selection process, press the
key.
Result;
SWAMI displays a question and two valid responses.
The question reads "Why do we have this waste? The
waste is:."
Explanation:
After choosing a waste stream, you must select
"Identify Strategies." Remember that all questions,
answers, and candidate strategies pertain to the
waste chosen in the previous step ("DIRTY ACIDIC
WATER").
Action:
To select "process-related or a process requirement,"
press the key.
Result:
SWAMI presents the next question: "What type of
process waste is it?"
Explanation:
You have selected "process-related or a process
requirement" as the best answer to the question.
Now, study the next question and the available
choices. If you decide to back up a question, press
the key. However, make sure you return to
this point before continuing with the sample problem.
Action;
To select "physical change of precursor," press the
down arrow key. Then press .
Result:
SWAMI presents the next question: "What type of
physical change occurs to the precursor?"
45
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SWAMI
Step#66
Step #67
Explanation:
You have selected "physical change of precursor" as
the best answer to the question.
Action:
To select "physically contaminated (dirty)," press the
down arrow key 3 times. Then press .
Result:
SWAMI displays four candidate strategies for
reducing "DIRTY ACIDIC WATER."
Explanation:
You have selected "physically contaminated" as the
cause for "DIRTY ACIDIC WATER." In the next step
you will determine which strategies can be ignored
(with 100% certainty) because they are not applicable
or not feasible. If not ignored, a strategy will appear
in the strategy report and should be considered for
additional study.
Action:
press: Y
press: Y
press: N
Result:
Each of the
'Y1 or 'N1 keystrokes expands to a 'YES1
or 'NO* on the screen and advances the cursor to the
next strategy.
strategy.
The selector bar highlights the fourth
Explanation:
For this example we arbitrarily chose "Change
process to prevent contamination" as an invalid
strategy concept. Of course there are legitimate
reasons for dropping a strategy concept from
consideration. Just be careful NOT to restrict your
options too early in the waste minimization process.
46
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SWAMI
Step #68
Step #69
Step #70
Action:
press: Y
Result:
SWAMI completes the fourth strategy field and
removes the list of candidate strategies. The
question "What type of physical change occurs to the
precursor?" reappears.
Explanation;
This is when your strategy selections for "DIRTY
ACIDIC WATER" are saved. The strategies
presented on the screen are the only ones which can
be saved for "DIRTY ACIDIC WATER." If you back
up, answer the questions differently, and complete
the strategy selection, your previous answers are
erased. Of course each waste can have its own
unique strategy set.
Action:
Hold down the key and press .
Result:
SWAMI brings you all the way back to the strategy
menu.
Explanation;
You could also have pressed by itself several
times to back out one question at a time.
Action:
Press the arrow key and press .
Result:
A list of additional keywords appears on the screen.
47
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SWAMI
Steo #71
Step #72
Step #73
Explanation;
These keywords can be used in a literature search
with the Pollution Prevention Information Exchange
System (PIES) Case Study Database.
Action;
Use the and arrow keys to position the
selector bar on "Metal," then press .
Result:
Metal changes color and the selector bar advances.
Explanation:
You have marked "Metal" as a keyword to appear in
your strategy report.
Action:
Press
Result:
"Metal finishing" turns color and the selector bar
advances.
Explanation;
You have marked another keyword.
Action:
Hold down the key and press .
Result:
The marked keywords are written to a file and the
next list appears.
Explanation:
The keywords selected apply to the current waste
selected during Action #62 ("DIRTY ACIDIC
WATER").
48
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SWAMI
Step #74
Step #75
Steo #76
Action:
Press several times until the strategy
menu reappears.
Result:
Additional lists appear.
menu is displayed.
Eventually the strategy
Explanation:
In actual use, you would want to select other
keywords from the other lists. If not, press to
return immediately to the strategy menu.
Action:
type: R
press:
Result;
The strategy report destination menu appears.
Explanation;
Of the three options, "File" has not been
implemented and "Printer" will lock-up your
keyboard if a printer is not attached.
Action:
Press the key.
The strategy report, as shown in Figure 5-6, appears
on the screen.
49
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SWAMI
WASTE MINIMIZATION STRATEGY REPORT FOR
XYZ Uidget Manufacturing Corporation
April 20. 1990
PLANT: Eastside plant
PROCESS: Curing
PRODUCTS: Small atomic uidgets
WASTE: DIRTY ACIDIC WATER
SOURCE: ACID WASH
CAUSE: PHYSICALLY CONTAMINATED (DIRTY)
STRATEGY: Modify process to isolate contaminant
TYPE: Source reduction
KEYWORDS: operator training, temperature control, process modification.
process rate, segregation
STRATEGY: Treat waste to remove contaminant and recycle
TYPE: Recycle
KEYWORDS: recycle, reuse, distillation, filtration, evaporation, settling,
Iiquid-liquid extraction
STRATEGY: Find use/user for the dirty waste
TYPE: Recycle
KEYWORDS: recycle, reuse, waste exchange, contaminated
MORE KEYWORDS (for use with EIES Case Study Database):
Metal, Metal finishing
Figure 5-6. Strategy report for the sample problem.
50
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SWAMI
Step #77
Step #78
Explanation:
The header of a strategy report identifies the
process, the waste name, the waste's source, and the
cause of the waste. The body of the report lists the
selected strategy concepts each followed by a list of
keywords you might find useful when doing your
research. Also consider as keywords important words
from the name and description fields of your unit ops,
products, materials, wastes, and treatments (or
blend).
Action:
press twice, then press .
Result:
SWAMI returns to the waste list.
Explanation:
In a real application you might wish to identify
strategies for another waste stream. At this point
you could select another waste and start the strategy
and keyword selection procedures all over again.
Action:
Press the key twice to exit SWAMI.
Result:
Your system exits SWAMI and displays the "C:\"
prompt.
/Explanation:
You have completed the sample problem. More
importantly, you now understand some of the
fundamental activities for performing waste
minimization in your plant. They are:
(1) Define your process to identify waste
minimization opportunities.
(2) Rank the opportunities by cost and volume.
(3) Identify strategy concepts for reducing or
eliminating selected waste streams.
51
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APPENDIX A.
PROBLEMS AND SOLUTIONS
If you are having trouble making SWAMI work properly, you may find
the information in this section helpful. Included are solutions to
several of the common problems encountered by SWAMI users.
PROBLEM: Typing SWAMI1 (or SWAMI2 thru SWAMI9) does not start the
program.
EXPLANATION: If you are certain you typed the instruction
correctly, several other causes are possible:
(1) You may not have directory "C:/SWAMI" properly identified in the PATH
instruction of your AUTOEXEC.BAT file. Type the DOS command "PATH" to
check it.
(2) SWAMI may not be properly installed on your C: drive.
(3) Your system may not have the necessary hardware or DOS version to work.
(4) Your hard disk might be full.
Review the installation procedures and computer system manuals as needed. You
might also reboot and try again.
PROBLEM: SWAMI aborts with the message "TOO MANY OPEN FILES."
EXPLANATION: The FILES instruction in your CONFIG.SYS file does not
specify at least 60 or you have not rebooted since the change was
made.
PROBLEM: The , , and arrow keys don't work.
EXPLANATION: This is usually because the numeric keypad
feature is active. Press once to deactivate it and try
again.
PROBLEM: SWAMI beeps when some keys are pressed.
EXPLANATION: Certain keys are deactivated during some operations. The
menus, forms, and lists indicate which keys you should use.
PROBLEM: Data entered on the forms is not saved and does not appear in
the list.
EXPLANATION: Data is saved when the last field of a data entry form is
completed and is pressed. If you leave a data entry form by
way of the key, the new and changed entries are lost.
A-l
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APPENDIX B.
VERSION 1.2 MODIFICATIONS
This section lists the modifications made for version 1.2 of SWAMI. Many of these
changes are a direct result of your suggestions made during and after the Waste
Minimization workshops in 1989. More SWAMI updates are planned, so please continue
sending in your comments.
Much testing was done to make sure that important data files created with version
1.1 would still be usable with Version 1.2. There is one exception. The first time you
attempt to use Version 1.1 files with Version 1.2 SWAMI, you must first delete PRI
RPT.DAT and PRI.RPT.KOl. Since these are created each time you exit "ASSIGN
RESPONSIBILITIES," there is no other work required by you. If something else was
overlooked, please (with our apologies) delete the offending file(s) and reenter that data
with SWAMI. If this is unsuccessful, you will have to enter the entire process from
scratch.
Enhancements:
(1) The strategy questions and responses were reviewed. As a result, the wording has
been greatly improved and new choices are now available.
(2) The keyword database was expanded.
(3) A database of additional keywords was added. The keywords selected from this
database appear in the strategy report and can be used with the PIES.
(4) A new form was added to record process identification information. The strategy
report was expanded to show some of this information.
(5) Help messages were edited and new messages were added. Color was added to some
to dress them up.
(6) Names of keys were made more consistent in lists, menus, and help messages.
(7) A number of error messages were rewritten and the user-friendliness of some error
handling was improved. For example, some error conditions now return you, more
appropriately, to the main menu. In addition, error messages now appear in red.
(8) The four options in the prioritization menu have been reduced to two. "Build
Prioritization" is now performed as you exit "Process Definition" if changes were
made to any wastes, treatments, or blends. "Perform calculations" happens
automatically each time you exit "Assign Responsibilities."
(9) A title screen was added to explain the purpose of the software and offer suggestions
for supplementary material and software.
B-l
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Enhancements (cont.):
(10) Color was added to the data entry forms to make them stand out from the lists.
(11) Another installation file was added for systems with a floppy drive identified as "B:."
(12) Processes with no treatments or blends will allow prioritization calculations to
occur even though the results are somewhat trivial.
(13) SWAMI no longer activates the key on the numeric keypad. This should
eliminate confusion about why the arrow keys sometimes didn't work.
Corrections:
(1) Previously, it was possible to delete a treatment (or blend) and leave a waste with no
source. Subsequent attempts at prioritization would fail. Three features were added
to correct this problem. First, help messages were added to explain the ramifications
of deleting certain elements in a process. Second, deleting a unit-op, treatment, or
blend automatically deletes the waste streams emanating from that part of the
process. However, the entire waste stream is not traversed to delete additional
obsolete treatments and their output wastes. Third, a new function, F5, makes it
possible to view (and edit or delete) all wastes in the process from a single list.
(2) Upon completion of a unit-op, treatment, or blend deletion, SWAMI sometimes
displayed the wrong lists (materials, wastes, and products) with the newly highlighted
unit-op.
(3) The beta test versions displayed debugging information which cluttered the screen
and created confusion. This information is no longer displayed.
(4) A bug kept some primary wastes from appearing in the prioritization report. This
occurred if a 0% cost responsibility was entered along with a nonzero volume
responsibility.
(5) Treatments in the waste flow path beyond the initial treatment were not included in
the calculated primary wastes cost.
(6) Treatment cost fractions (the cents) were being lost.
B-2
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