WASTE
REDUCTION
THE
HURDLES AHEAD
June 3 — 5, 1987
National Academy of Sciences
Conference Center
Woods Hole, Massachusetts
Sponsored By:
Center for Environmental Management
Tufts University
Co-Sponsors:
League of Women Voters of
Massachusetts
U.S Environmental Protection Agency
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On June 3-5, 1987 The Center for Environmental Management sponsored a
conference - "Waste Reduction — The Hurdles Ahead".
During this third waste reduction conference, speakers focused on the waste
reduction activities of government at the national and state level, industry and
public interest groups. Representatives of major U.S. corporations filled out a
questionnaire prepared by the Center documenting their waste reduction
accomplishments. This book is a collection of all of the questionnaires and
summaries.
A final report summarizing the presentation at the meeting will be available in
the near future.
The Center for Environmental Management wishes to extend special thanks
to:
The League of Women Voters of Massachusetts
Susan Shaer, President
The Office of Solid Waste of the U.S. Environmental Protection Agency:
Elaine Eby, James Berlow, Robert Dillenger, Joseph Carra, Marsha
Williams
The Office of Environmental Engineering and Technology of the U.S.
Environmental Protection Agency: Kurt Jakobson, Fred Lindsey and
John Skinner
National Academy of Sciences, Bob, Chet, Johan, Chris and Sal
Dana Duxbury
Barbara Friedman
All the Speakers
Nancy and Ralph at E-Z Copy, Inc., Dedham, Massachusetts
The League of Women Voters of Falmouth
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INDEX
Allied Signal Inc.
American Cyanamid Company
Amoco Chemical Company
AT&T
Chevron Corporation
Digital Equipment Corp.
Department of Defense
Dow Chemical
E.I. Du Pont de Nemours & Co., Inc.
Exxon Chemical Americas
General Electric
Hewlett Packard
ICI Americas Inc.
Eastman Chemicals Division,
Eastman Kodak Co.
3M
Monsanto Company
Occidental Chemical Corporation
Olin Corporation
Polaroid Corporation
Public Service Electric
And Gas Company
Rohm and Haas Company
Shell Oil Company
Texas Instruments Inc.
Union Carbide Corporation
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Allied Signal Inc
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Allied Signal Inc.
Address p-°- Box 2332R, Morristown, NO 07960
Contact Person, Title R- J- Ford, Manager Pollution Control
Telephone #(201)455-4947
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit)
Net Worth 1985 1,608,000,000
Sales 1985 9,115,000,000
Major Products by Divisions Aerospace Electronic Systems and Components;
Automotive Components; Engineered Plastics and Fibers.
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste #
Waste solvents - F001-005 Sludges - D006-8
Ignitable Fluids - 0001 Acidic Wastewater - D004,
Corrosives - D002 D002
Number of plants which generate hazardous wastes 200+
Location of plants which generate hazardous wastes 38 States
Number of Employees 137,000
Please return to: DANA DUXBURY
CBMTJSK FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
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'Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.) '
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
Guidance Document Attached
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
The program 1s undergoing modification now, but was not changed in the
last year.
c) What were the leading factors that caused you to alter your
waste reduction efforts during thec|«W year?
. Cost and increasing difficulty in disposing of waste
. Anticipation of expansion in regulatory requirements
. Reduction of future Corporate liabilities.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Changes will be made up to level of Corporate Vice-President.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Waste reduction includes source reduction, recycle plus any treatment prior to
disposal which reduces volume or toxicity of waste.
Wastes covered are those defined as RCRA hazardous waste.
RETURN BY MAY 4, 1987
Page 2
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
£) Does each Division or plant in your corporation have its
own specific program or plan?
Yes, although some of the newly acquired business units are still in the process
of complying with the guideline.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
All levels—the guidance was fssued as a Corporate Policy.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
We are presently exploring the use of consultants to provide additional
expert resources.
i) Does your corporate waste reduction program or plan include
goals? If so/ describe them - including the nature of the goal
and the time frame in which the goal is to be met.
No
j) Does each plant or Division establish its own particular
goals?
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Corporate Director
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
The waste reduction program is almost fully implemented at its present level
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
A variety of methods will be used to expand:
. Videotape and written materials to upper management
. Centralized accumulation of data and development of performance statistics.
. Communication of waste reduction technologies
. Inclusion of waste reduction program into environmental assurance review process.
. Potential use of waste technology audits.
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
No
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
A variety of indices are presently used because of the wide diversity in business
operations.
What is your base year?
Principally 1984, but this also varies.
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Performance statistics have not yet been accumulated on a Corporate basis; this 1<
underway now.
Do you also keep this information on a plant and or
process stream basis?
Most waste data is compiled on a plant basis.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how pan they be overcome?
There are problems, but no absolute barriers have been identified. Problems are:
. Regulations which discourage recycling
. Contracts & specifications which limit the use of reclaimed material
. Small waste streams which are difficult to justify spending money on.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
This is a likely outgrowth of our present efforts to develop performance data.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
In general, a plant basis seems most logical.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
The Corporate guideline was communicated through the business areas to the
individual plants. The guidance stipulates the development of a multi-disciplinary
waste minimization committee, a minimum acceptable level of activity and a
method of documenting activity and results.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
It was not changed last year.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes
How did you accomplish this?
This is done through the involvement of manufacturing and engineering staff on
the waste minimization committee.
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
This is being evaluated now.
Have you computerized this waste stream audit data?
e) Have you established a process to identify: your process
losses/ opportunities and costs for further waste reduction,
prioritization of waste reduction methods/ and implementation,
documentation and communication, of results, etc?
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
This is presently being considered.
g) If so, what elements are included in your waste reduction
Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next _ years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
RETURN BY MAY 4, 1987
Page 6
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474 Boston Avenue, Curtis Hall
Tufts university, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10, 1987
Question III: Hhat have your waste reduction acccnplishments been in the past year since Hoods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or refomulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
SAHPUE Ftaxmcrs
WASTE REDUCTION
METHOD
(see above)
B
A
A
A
A
WASTE REDUCED
EPA HAZARDOUS
HASTE 8
007,0008
D008
D001
0002
TYPE OF
HASTE
Paint
rinse
water
Cool f ng
Oil
Paint
Sludge
Caustic
Solution
Water
Soluble
Oil
PLANT LOCATION
DATE
1986
1986
1985
1986
1985
PER CDFT
REDUCTION
63%
(73.000 lb<
100Z
(5800 gal)
361
(11.7 ton!
100«
(248 tons)
31.075 gal
LOCATIOM
CN-SITE
)
)
OFF-SITE
X
X
X
X
X
DESCRIPTION
Modified cleanout
procedure on process
equipment.
Substituted material
Changed from solvent
paint system to ponder
paint.
Replaced chemical dip
with burn-off oven.
Oil separator Installed
to remove the 951 water.
ADDITIONAL
INFORMATION
Page 7
PLEASE RETURN BY MAY 4, -1987
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
A questionnaire was not completed for 1985.
RETURN BY MAY 4, 1987
Page 8
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Section IV Pollution Control
IV - E4 Hazardous Waste Minimization Program
IV - E4 - I INTRODUCTION
Under Che 1984 RCRA Amendments, hazardous waste generators must
certify the following on all hazardous waste manifests prepared
after September 1, 1985:
(1) "the generator has a program In place to reduce the volume or
quantity and toxicity of such waste to the degree determined
by the generator to be economically practicable:" and
(2) "the proposed method of treatment, storage or disposal is that
practicable method currently available to the generator which
minimizes the present and future threat to human health and
the environment."
EPA has issued a revised Hazardous Waste Manifest form which con-
tains the required generator certification* A copy of this form
is Attachment I.
Additionally, there is a requirement to submit a biennial report
to the appropriate regulatory Agency, which provides the
following:
• the quantity and nature of hazardous waste generated during
the year;
e the disposition of this hazardous waste;
• the efforts made during the year to reduce the volume and
toxicity of the waste generated;
• the changes in volume and toxicity of waste achieved in
comparison to previous years.
IV - E4 - 2 PURPOSE
This guideline is to provide an outline for the written program of
hazardous waste minimization, which is required at every Allied
location generating hazardous waste, as a basis for the cer-
tification made on the waste manifest. The program outlined
herein reflects segments of programs already implemented by
Sector/Company organizations. This guideline is not intended to
restrict program development based on sice specific conditions.
Rather, it is to serve as a baseline model for those elements
which all programs should address in order to assure a consistent
• and technically sound approach.
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IV - E4 - 3 PROGRAM ELEMENTS
In complying with these regulations, four primary areas should be
addressed in developing individual location programs for hazardous
waste minimization. These are local organization, baseline data
development, system evaluation and documentation/reporting.
Prior to examining these individual items, it must be emphasized
that the "practicable" achievement standard set out in the regula-
tion is based on a variety of factors including economics, tech-
nology and geographic location. The performance objective to be
expected of any location is therefore variable according to both
individual plant circumstances and the passage of time. This
means that a waste minimization program is not a "one-shot"
effort, but must be a continuing evaluation of facility opera-
tions, technology, applicable regulations and cost/risk alter-
natives. The principal objective is to reduce hazardous waste;
therefore methods to recycle/reclaim wastes should be evaluated
prior to consideration of any disposal methods.
A. Local Organization
A plant committee, appropriate in size to the facility, is needed
to develop, Implement and manage the plant program. Primary
program responsibility lies within the manufacturing group, with
input and guidance from technical, financial, operations and
environmental staff. A multi-disciplinary approach is essential
to proper identification and study of waste reduction and disposal
•alternatives. An example of committee make-up would be:
Director of Operations, Manufacturing Supervisor, Plant Engineer,
Accounting Supervisor, and Pollution Control Coordinator.
This group must meet on some regular basis, but at least semi-
annually. A record of these meetings, with progress reports, must
be prepared and maintained in a binder, to document the existence
of the location program and provide the basis for periodic reports
Co the regulatory agency and internal organizations.
B. The regulations state that an assesment must be made of the
achievements of the waste minimization program. This requires the
development of a benchmark for comparison purposes.
1) The baseline period should be at least one year, but may be
longer if the hazardous waste generation rate at a facility is
irregular. It is recommended that this period be either the
calendar year 1984, or the year preceeding the RCRA reauthoriza-
tlon (11/8/83 - 11/8/84), in order to reflect current waste
generation races. Other periods may be selected if local cir-
cumstances make these an inappropriate base at some facility, but
this decision should be reviewed with the Sector/Company pollution
control manager.
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-3-
2) The unlcs of measure selected nay be quancteles (gallons, cu.
ft) or ratio, I.e. waste generation to manufacturing rate. The
key is to define the baseline in a manner that is appropriate for
the individual location and reflects a true measure of production
levels and hazardous waste generation rates.
3) Disposal methods and sites must also be identified for the
baseline period. The environmental soundness of the disposal
method and location is given equal weight in the statute with
actual reduction of waste volumes.
The Corporate Waste Disposal Information System should provide all
required data to develop Individual facility baselines. In addi-
tion, this system should be referenced in location waste minimiza-
tion programs inasmuch as it represents a general management tool
for monitoring and controlling waste generation and disposal.
C. Systems Evaluation
The waste minimization/risk reduction programs must, by their
nature, be individually designed to fit local circumstances.
Certain basic steps however, should be common to the program acti-
vities at all locations.
1) Each hazardous waste stream at a facility must be identified
by both type and source.
2) Following identification, the local committee can develop a
list of potential options for reducing waste volume and/or mini-
mizing disposal risks. Items for consideration could include:
• manufacturing changes to eliminate a waste stream
• changes in raw material or treating agents which result
in less waste or less toxic waste.
• potential recycle or reclamation of wastes*
• pretreatment to eliminate or reduce waste toxicity.
Disposal methods utilized should also be examined and ranked
according to their degree of present and long-term risk to human
health and this environment. The ranking order will vary from
plant to plant according to wastes generated and disposal options
available, but an example list In decreasing preference would be:
a) eliminate waste generation
b) recycle/reclaim wastes
c) pretreat to eliminate/reduce toxicity
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-4-
d) iaeineracion
e) outside recovery with hazardous residue
f) stabalizacion with land disposal
g) land disposal
Another element in evaluating the risk associated with waste
disposal is the soundness of the management of the disposal fact"
lity or site, no matter what disposal technology is employed.
Attachment II, is a descriptive outline of the Corporate Waste
Site Inspection Program, which was designed to help assure the
Corporation that waste disposal is conducted in an environmentally
sound manner. Location waste minimization programs oust include
this Corporate inspection activity as this is a significant effort
toward reducing present and future threat to human health and the
environment.
0. Documentation/Reporting
Minutes or other written record of each committe meeting must be
made. Efforts to investigate waste reduction/disposal options,
projects initiated and results achieved must also be documented.
Attachment III, is a multipurpose form developed by Chemical
Sector which provides both meeting and project documentation.
This form or another locally developed document should be used.
W. M. Reiter' R. J. Ford
ad
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location:
ATTACHMENT III
Project No.
Haste Volu«* and Disposal Risk Reduction Program
A - individual waste Stream Review
1. (tone or short description of waste:
2. EPA X.O. No. (if hazardous waste)
3. source of waste:
4. Supervisor(s) responsible for minimization:
5. Base generation rate;
(from 11/8/83 to 11/8/84)
6. Present treatment (if any) and purpose:
7. Present disposal method (and location):
8. Running chronological summary* of volume and disposal risk reduction
efforti
Date(s) Aetivities/Results/Out-of-Peelcet Costs or Savings
•Notes Attach additional pages of chronological sv try as needed.
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American Cyanamid Company
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, Ha 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987'
General Information
name of Company American Cyanamid Company
Address One Cyanamid Plaza, Wayne, HJ 07470
Contact Person, Title R. A. Dennis, Manager of Environmental Affairs
Chemicals Group
Telephone # 201-831-3996
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 2816, 19, 21, 22, 24, 31, 33, 34,
41, 42, 43, 61, 65, 69, 73, 74, 79, 91, 99.
Ret Worth 1986 $1,720,600,000 (from 1986 Annual Report to Shareholders)
Sales 12&& $3,815,900,000" (from 1986 Annual Report to Shareholders)
Major Products by Divisions:
See attached
Major Hazardous Waste Streams by Division and EPA Hazardous Waste #:
Corrosive (D002), Ignitable (D001), Solvents (F001-F005), and production
wastes (K011-K013)
Number of plants which generate hazardous wastes: Cyanamid has 33 plants
which generate hazardous waste; 6 generating 0-1 ton; 10 generate 1-100 tons;
4 generate 100-1000 tons; and 13 generate more than 1000 tons per year.
Location of plants which generate hazardous wastes:
Cyanamid RCRA plants operate in 9 EPA regions and 21 states.
Number of Employees - Approximately 34,000
Please return to: DANA DUXBUR7
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
Page 1
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Major Products by Divisions:
Medical Group: vaccines, anticancer agents, antibiotics, Pharmaceuticals,
parenteral products, surgical sutures, disposable
hospital products, surgical instruments
Shulton Group: fragrances, toiletries, household cleaners and pesticide
products, haircare products
Agricultural Group: animal nutrition and health products, pesticides,
herbicides, fertilizer
Chemicals Group: acrylonltrile, acrylamide, methyl methacrylate, melamine,
ammonia, paper and water treatment chemicals, alum,
mining chemicals, resins, textile specialties, adhesivea,
fibers, dyes, rubber chemicals, catalysts, acrylics,
sulfuric acid, vulcanized vegetable oils, electronic
chemicals, personal safety products, chemical light
products.
Page 2
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Hedford, MA .02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate waste reduction
program or plan. (Such as: guidance, goals, routine reporting mechanisms,
yearly recognition of employees, a newsletter, video, yearly review to
corporate management, technology seminars, included in performance reviews,
waste reduction project competition for capital, etc.)
If you have not previously included a copy of your corporate waste
reduction program or plan, please do so.
As stated in 1984 and 1985, executive general procedure memoranda lead to
implementation and compliance, which require monitoring, auditing, technical
assistance and periodic reporting throughout the corporation.
b) Please note how your corporation has modified or expanded its corporate
waste reduction program or plan in the past year, if indeed you have modified
or expanded it.
Computerized waste tracking systems commenced operation.' Formal plant
committees on waste reduction and monthly reporting within divisions and
business groups were established to meet RCRA waste minimization requirements.
c) What were the leading factors that caused you to alter your waste
reduction efforts during the past year?
The desire to reduce waste disposal costs and additional regulations requiring
more organization and formality of ongoing programs.
d) At what management level in your corporation, during the past year, were
changes, if any, made in your waste reduction program or plan?
The corporate (executive) level had previously established a policy on
regulatory compliance, so no action was necessary in 1986. Plant management
established formalized waste reduction committees as noted in item (b) above.
e) How does your corporation define waste reduction? What media and wastes
or emissions are covered in your definition?
Waste reduction is reduction in the mass or volume of waste generated or
needing disposal, and therefore, addresses source to terminus. In addition,
hazardous waste may be treated to remove, reduce, alter or destroy those
materials or properties which render it hazardous.
RETURN BY MA? 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Hedford, HA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its own specific
program or plan?
Each of the four Business Groups in Cyanamid has its own program. The group
plans specify Division and plant requirements. A corporate environmental
committee coordinates the groups.
g) To what level in your corporation has your waste reduction program or plan
been communicated?
From top to bottom.
h) Have you found the need for additional waste reduction expertise in the
last year? If so, new staff or consultants?
There have been minimal staff increases at operating plant and Divisional
levels. More research and development staff time is being devoted to waste
minimization for new products and manufacturing processes.
i) Does your corporate waste reduction program or plan include goals? If so,
describe them - including the nature of the goal and the time frame in which
the goal is to be met.
The corporation sets objectives and policy. Each Business Group establishes
its own goals, programs, amd organization.
J) Does each plant or Division establish its own particular goals?
Plants and Divisions detail plans, procedures, staffing and budgets, including
specific goals.
k) At present, what is the highest management level in your corporation that
is responsible for waste reduction?
Division Presidents of each operating division sign RCBA permit documents and
are responsible for implementation of corporate policy.
1) What stage has your corporation reached in implementing your corporate
waste reduction program or plan?
The program was started in 1982 and operates as a continuous ongoing project
at all levels in the company. We have been in the implementation stage since
1982.
m) How are you going to maintain or accelerate the momentum and awareness of
your waste reduction program in the year ahead?
The program has built-in impetus since waste reduction leads to cost savings
which are included in each manager's personal goals and rewarded through
incentive compensation. Failure would lead to monetary loss, personnel shifts
in responsibility and career upsets. New computerized tracking systems will
improve accountability and acknowledge accomplishment.
RETURN BY HAT 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost accounting procedures to
ensure that waste reduction is encouraged to a greater extent? If so, how
have you done this? (i.e., placing additional charges on things such as total
volume, method of waste management, potential long term liability, or
recharges to specific plants for environmental management.)
Cost accounting for waste disposal was started in 1974. We already have
adequate means of measuring achievement in this area.
o) Bow do you measure your waste reduction^accomplishments (by sales,
employees, pounds/unit production)?
Accomplishment is measured by costs saved or recovered plus pounds per unit of
production or service provided.
What is your base year?
1982
p) When accounting for production variations, did your corporation's
hazardous waste generation rate change from the previous year? If so, how?
Cyanamid has undergone some major production changes, both increases and
decreases, and we have achieved some significant reductions in waste loads.
Final analysis is not complete, but will be provided for the annual CMA waste
reduction survey.
Do you also keep this information on a plant and or process stream basis?
Waste generation and reduction data is recorded on both plant and process
stream basis. The new computerized waste tracking system will improve
data analysis and reporting.
4) Are there any specific barriers to achieving significant waste reduction
levels that your corporation, particular divisions or process streams face?
If so, what are they and how can they be overcome?
Achievement is a function of people, time and money and the driving forces to
expend them in order to overcome existing manufacturing process and/or
facility limitations. Cyanamid applies people, time, and money to reduce
waste.
r) Have you begun to identify how far and how fast your corporation can move
to attain the maximum benefits of waste reduction?
Each project ultimately is funded by products or product lines, whether they
be costs o'r recoveries, and will be subject to corporate standards of
profitability.
Should this identification of maximum benefits be done on a corporate,
plant or process waste stream basis?
All three.
BETDBR BY MAY 4, 1987
Paae 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Hedford, HA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation implements its
vaste reduction program or plan at the plant or division level.
Each plant has a committee on vaste reduction which seeks, identifies,
analyzes technical feasibility, evaluates alternatives and costs, projects
timing, schedules and investments relative to goals, requests division and
group approval and implements specific projects in a manner similar to other
engineering Jobs. Waste minimization is also an integral part of research and
development for new products and manufacturing processes.
b) Please note where your corporation has changed its plant or division level
waste reduction implementation scheme in the past year.
As stated above, formalizing committees and their activities for compliance
with 'corporate and regulatory policies.
c) Assuming that your corporate waste reduction plan or program began in your
environmental division, have you Integrated this program or policy with your
division or plant level manufacturing personnel?
Yes, implementation is by manufacturing personnel.
How did yon accomplish this?
Corporate mandates are carried out through line management and coordinated by
committees at all levels. Manufacturing personnel function on both.
d) Do you conduct a waste TTr*""^ (OT process loss) audit? If so, how
frequently do you conduct the audit?
Corporate requirements are semiannual, but higher frequencies are attained as
a function of waste source, magnitude, hazard, exposure, etc.
Have you computerized this waste stream audit data?
Bach Business Group is implementing computerized tracking systems.
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prioritization of
waste reduction methods, and implementation, documentation and
communication, of results, etc?
Yes. It's done at the plant level as described above. Each plant manager is
responsible for implementing his own environment protection program, with
assistance from service groups as needed.
Please detail this process. (If you accomplish this process through a waste
reduction audit, please proceed to the next question)
RETURN BY MAY 4, 1987
Page 6
-------
Tufts University Center for Environmental Management (617)381-3486
47.4 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit? Yes
b) If so, what elements are included in your waste reduction audit? Do you:
Yea or No
Identify and quantify sources of all process losses to all media. If
not all, which ones?
Identify opportunities for future cost effective reductions?
Establish goals for the next 3 years?
Yea Identify resource requirements for attainment of goals?
Yes Identify techniques to attain goals?
Yea Interview plant employees to ascertain training needs and levels of
awareness? To within reasonable limits.
Yea Require sufficient data so that progress can be reported relative to
output?
Yea Document and report accomplishments and problems to management?
Yea Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Yes Identify resource requirements for the future?
Yes Project expected future returns?
Yea Other elements?
Maintain compliance with several regulatory authorities requiring
similar information to varying degrees and with conflicting formats.
Is your waste reduction audit computerized?
It is being developed as part of new computerized waste tracking
systems initiated in 1986.
RETURN BY MAY 4, 1987
Page 7
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Hedford, MA 02155 March 10, 1987
•Question IV
a) What new waste reduction efforts have you underway? Have you followed
through on those mentioned in 1985's questionnaire as yet?
Cyanamid's responses to the 1985 questionnaire included only those projects
which had been initiated prior to or during 1985. All waste reduction
projects identified were begun or implemented in the period stipulated. All
the 1985 projects reported have become continuing waste reduction programs,
except where the production process or generating source has been discontinued.
Similarly, the 1986 projects reported were initiated during the course of the
year. There are many more reduction projects in the development and/or
evaluation stage, which will be reported in subsequent years as implemented.
RETURN BY MAY 4, 1987
0141I/0587J
Page 8
-------
QUESTION III What have your hazardous waste reduction accomplistaents been In the past five years? PLEASE TELL ALL
taste Reduction
Method
Waste Reduced Plant Location Date Per Cent Location Description
Reduction
Additional Information
EPA Hazardous Type of On Site Off-Si to
Process
Modification
Waste
Compaction
Waste Reuse
Waste No. Waste
State Contaminated drum Azusa. 1986 SOX X
Hazardous liners California
Only
State Empty Waste Azusa. 1986 7SX X
Hazardous Drum California
Only
State Extruder Scrap Azusa. 1986 100X X
Hazardous (Netal Catalyst) California
Only
Switched to lighter
PE liners for temp-
orary storage of
finished catalyst.
Oruns with contamin-
ated liners formerly
disposed as contain-
erized waste.
Now crushed to 1/4
volume and bulk
disposed.
Waste stream
formerly sent to
landfill.
Reduced the number of
drums of contaminated
liners needing
disposal.
Reduced volume of
waste stream.
Reuse eliminates
this waste stream.
ST:0141I/0585J-1
-------
QUESTION III What have your hazardous waste reduction accomplishments been in the past five years? PLEASE TELL AH,
rfaste Reduction Waste Reduced Plant Location
Method
EPA Hazardous Type of
Waste No. Watte
Raw Material F001 TCE Waste Bound Brook,
Change F002 New Jersey
New Waste 0001 Ignitable filter Bound Brook,
Management cake New Jersey
Process
•
Process N.A. NH3 content in Bound Brook,
Modification NPOES discharge New Jersey
Data Par Cent Location
Reduction
On Site Off-Site
1986 100X X
(8,300 Ibs
per year)
> 1986 100* X
(50,000
pounds
per year)
1986 10* X
(16.000
Ibs per
year)
Description
Utilities Oept.
discontinued use
of TCE for solvent
cleaning.
Ethanol and isoprop-
anol removed by
water wash.
Reduction of raw
material use of
NH4OH in prod-
uction process.
Additional Information
.
Eliminated hazardous
waste stream.
Wash renders filter
cake non-hazardous.
•
Process modification
reduces cost.
preserves product
Integrity and reduces
NH3 in effluent.
ST:0141I/058SJ-2
-------
QUESTION III What have your hazardous waste reduction accomplishments been In the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Par Cent
Reduction
Location
Description
Additional Infornatlon
EPA Hazardous
Waste No.
Type of
Waste
On Site Off-Site
Raw
Material
Change
D006
Liquid waste
containing
chroniuB
Danbury,
Connecticut
1986
lOOt
(200.000
gallons
per year)
Process change elln- Pilot demonstration
Inated use of completed. Cost
chromium and this savings of $50,000
hazardous waste per year.
stream.
Raw Material
Change
F001
Spent nethylene
chloride solvent
Danbury,
Connecticut
1986
100X
Changed to a
different solvent
which is recycled.
Waste stream
formerly disposed
now recycled.
ST:0141I/0585J-3
-------
QUESTION III What have your hazardous waste reduction accompli shMnts been in the past five years? PLEASE TELL ALL
Waste Reduction
Method
Process
Modification
Waste Reduced Plant Location
EPA Haiardous Type of
Waste No. Watte
K013 Process waste Fortier.
fron acrylonltrlle Louisiana
production
Date Per Cent Location Description
Reduction
On Site Off-Site
1986 33* X Process revisions
(SO 6PM to product filtrat-
Reductlon) ion step reduced
waste generation.
Additional Information
•
Process change also
improved product
quality and yielded
cost savings.
ST:0141I/0585J-4
-------
QUESTIOH HI What have your hazardous waste reduction accomplishments been in the past five years? PLEASE TELL ALL
laste Reduction
Method
'rocess
Modification
Waste Reduced Plant Location
EPA Hazardous
Waste No.
Wide Range
Type of
Waste
Solid Hazard Wastes Hannibal.
Missouri
Date Per Cent Location Description Additional Information
Reduction
On Site Off-Site
1986 Not X Modification of Produced significant
Quantified existing liquid reduction in amount of
waste incinerator
with new feed and
scrubber capabilit-
ies to handle solid
and containerized
liquids.
drummed waste shipped
for disposal.
ST:0141I/0585J-5
-------
QUESTION III What have your hazardous waste reduction accomplishments been In the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Per Gent
Reduction
Location
Description
Additional Information
EPA Hazardous
Waste No.
Type of
Waste
On Site Off-Site
Energy Recovery 0001
Waste alcohols
Kalanazoo.
Michigan
1986
100*
Installing new plant
boiler - will burn
all waste alcohols
to recover fuel
value.
Eliminates off-site
shipping and Incin-
eration costs
and hazards.
Process
Modifications
and
Administrative
Control s
U154. U031
0001
Raw material,
product and
process spills
Kalamazoo,
Michigan
1986 Not quant- X
ifled
Process interlocks Process modifications.
and sequence controls
installed to reduce
upsets and losses.
Installed alarms.
piping changes and
shut offs to reduce
spills.
All potential spill
areas paved and
curbed to contain
spills.
Raw material unload-
ing rescheduled to
daylight hours
to reduce spill
Incidents.
Emergency systems.
Waste segregation and
containment.
Management practices.
ST-.01411/05853-7
-------
QUESTION III What have your hazardous watte reduction accomplishments been in the past five years? PLEASE TELL ALL
Waste Reduction Waste Reduced Plant Location
Method
EPA Hazardous Type of
Waste No. Waste
Process 0002 Corrosive filter Marietta.
Modification cake Ohio
Waste Segregation Non-haiardous Trash Marietta,
watte Ohio
Waste Segregation Non-hazardous Non-contaminated Marietta.
waste run off Ohio
Date Per Cent Location
Reduction
On Site Off-Site
1986 lOOt X
1986 Not X
Quantified
1986 * unknown X
< 125 .000
gallons per
year)
Description
Introduced process
modifications that
changed corrosive
clarification cake
to a non-hazardous
waste.
Segregation of
trash from
hazardous solid
waste for separate
disposal.
Diverted run off
from hazardous
waste treataent
inpound.
Additional Information
Cake eliminated as
hazardous waste
stream.
Significant reduction
of hazardous waste
stream.
Significant reduction
of hazardous waste
stream.
ST:0141I/0585J-8
-------
QUESTION III What have your haiardoin waste reduction accomplichnent* been in the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Per Cent
Reduction
Location
Description
Additional Information
EPA Hazardous
Waste No.
Type of
Waste
On Site Off-Site
Waste Reuse
Non-Hazardous Fines
Michigan City. 1986 100X
Indiana
Waste stream shipped Waste strean totally
as produced to new reused.
company process at
another location.
Waste Reuse Non-Hazardous Nuller Waste #1 Michigan City. 1986 100*
Indiana
Waste Reuse Non-Hazardous Nuller Waste « Michigan City. 1986 5t
Indiana
Fresh waste Isned-
lately returned to
process extruder.
Eliminates streact by
quick reuse.
Process
Modification
and
Waste Reuse
Non-Hazardous Spent CSI
Solution
Non-Hazardous Off Grade
Substrate
Michigan
Indiana
Michigan
Indiana
City. 1986 30* X
City. 1986 lOOt X
Combined streams
used in new addit-
ional process step
to produce saleable
product.
This is waste reuse
via process modific-
ation.
Stream Is slurried. Reduces waste stream
blended with product by recycle.
slurry and spray
dried into product.
ST:014II/0585J-9
-------
QUESTION III What have your hazardous waste reduction accomplishments been In the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reuse
Process
Modification
Raw Material*
Change
Waste Reuse
Waste Reduced Plant Location
EPA Hazardous Type of
Waste No. Waste
F003 Spent Nethanol Pearl River.
Solvent New York
N.A. Ethyl one Oxide Pearl River.
Process Entsslons New York
Emissions
0002 Potassium dichron- Pearl River.
0006 ate lab cleaning New York
solution
"D" & "U" Waste Lab Pearl River,
Reagents New York
Date Per Cent Location Description
Reduction
On Site Off-Site
1986 100X X In solvent recovery.
•ethanol forecuts
sent off site for
reuse.
1986 100* X Catalytic systen
Installed and
operated to abate
Ethyl ene Oxide
missions.
1986 100X X Potass tun Oi chroma te
solutions discontin-
ued for washing lab-
oratory glassware.
1986 100X X Unused lab reagents
formerly were dis-
posed as hazardous;
now returned to
supplier.
Additional Information
-
To be used
as gasoline
additive.
Waste stream
eliminated.
Significant hazardous
waste stream at RftO
center totally
eliminated.
Waste stream at R&D
center significantly
reduced .
ST:0141I/0585J-10
-------
QUESTION III Wh»t have your haiardous waste reduction accomplishments been in the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
EPA Haiardous
Watte No.
Type of
Waste
Plant Location Date Per Cent
Reduction
Location Description
On Site Off-Site
Additional Information
Waste Reuse
F003
Spent solvent
Pearl River.
New York
1986
100X
(320 tons
per year)
Spent methyl alcohol
solution previously
Incinerated now
sent to fuel blender
for energy recovery.
Transposed waste
stream Into reuse
stream to recover
heat value and obtain
cost reduction.
Waste Reuse 0001
Spent solvent Pearl River.
New York
1986 10W
(582 tons
per year)
X Spent Isopropanol
solution previously
a hazardous waste
now sold as comer-
clal product.
Transposed waste
stream Into product
stream to reduce
waste volume and
recover cost.
>T:0141I/058SJ-11
-------
QUESTION III What have your hazardous waste reduction accomplishnents been in the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
EPA Hazardous
Waste No.
Type of
Waste
Plant Location Date Per Cent
Reduction
Location
On Site Off-Site
Description
Additional Information
•
Administrative
Controls
"F", "0". and
"U" Listed
Haiardous RtD
lab wastes
Princeton.
New Jersey
1986
15*
Research Facility
centrallied
purchasing of lab
reagents. Now
order only when
necessary with
Purchasing Oept.
oversight.
Improved utilization
of laboratory reagents
and supplies.
Waste Management -F", "D", and Hazardous RID
Change "U" Listed lab wastes
Princeton.
New Jersey
1986 SOX X
(94 tons
per year.)
Changed containers
to allow incinerat-
ion of wastes
previously land-
filled.
Eliminated landfill
disposal of this
waste stream.
ST:0141I/0585J-12
-------
QUESTION III What have your haiardous watte reduction accompli shmnts been In the past five years? PLEASE TELL ALL
Waste Reduction
Method
Watte Reduced
Plant Location
Date
Per Cent
•eduction
Location
Description
Additional Inforaatlon
EPA Hazardous
Waste No.
Type of
Watte
On Site Off-Site
Waste Recycling 0001
Ignltable liquid
watte
Sanford,
Maine
1986
43.5*
Inprovenent
In ratio
» Waste
» Product
over 1982
baseline
Wiped flin evap-
orator Installed
In 1985.
Methyl Mathacrylate
returned to
production.
Recycled amount. 1985
was 12X greater than
1984.
1986 was 89X greater
than 1985.
ST:0141I/0585J-13
-------
QUESTION III What have your hazardous waste reduction accomplishment* been In the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Per Cent
Reduction
Location
Description
Additional Information
EPA Hazardous
Waste No.
Type of
Waste
On Site Off-Site
Waste Reuse
F003. F005 Spent solvent
Saugus.
California
1986
100X
Formerly recycled
solvent continually
to exhaustion, then
disposed.
Now use solvent
once-through and
send off site for
recovery.
Eliminated waste
stream and reduced
cost of solvent use
for cleaning.
ST:0141I/0585J-14
-------
QUESTION III What have your hazardous waste reduction accomplishments been In the past five years? PLEASE TELL ALL
Waste Reduction Waste Reduced Plant Location Date
Method
EPA Hazardous Type of
Waste No. Waste
Waste Recovery 0001 Ignl table Stanford Research. 1986
liquid Connecticut
waste
Waste Segreation "F" and "D" Spent solvents * Stanford Research. 1986
and Recycling listed process wastes Connecticut
.
Waste Segregation Various Misc. waste Stanford Research. 1986
and Reuse stream Connecticut
New Waste D001 Hazardous Stanford Research. 1986
Management 0002 filter cake Connecticut
Process
Per Cent Location Description
Reduction
On Site Off-Site
75* X Waste ethyl accetate
strean being dis-
tilled with new
systen (cost 1.0M$)
X Segregated recover-
(75,000 able wastes for off-
gallons in site recycling vs.
si* Months) previous incinerat-
ion.
76* X 1. Waste con-
solidation.
2. Separation of
non-hazardous
trash.
3. Return to stock
of partially -
used reagents
and supplies.
1001 X Cake packed in lined
fiber packs and
incinerated.
Additional Information
•
El Ini nates hazardous
stream - savings
300k$ per year.
Increased recycle
strean and decreased
disposal strean plus
cost savings.
Landfill disposal
decreased signific-
antly by through
use of these methods.
Totally eliminated
waste stream going to
landfill.
ST:0141I/05B5J-1S
-------
QUESTION III What have your hazardous waste reduction accomplishments been In the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Per Cent
Reduction
Location
Description
Additional Information
EPA Hazardous
Waita No.
Type of
Waita
On Site Off-Site
Energy Recovery 0001
Ignitable
liquid waste
Stamford Research,
Connecticut
1986
lOOt
(29.000
gallons)
Streams formerly
incinerated now
blended into fuel
for energy recovery.
Eliminated incinera-
tion of these waste
streams.
ST:0141I/0585J-16
-------
QUESTION III What have your hazardous waste reduction accomplishments been in the past five years? PLEASE TELL ALJ
Waste Reduction
Method
Waste Reuse
Waste Reuse
Process
Change
Process Change
Waste Reduced
EPA Hazardous Type of
Waste No. Waste
0001 Off Grade Products
F006 Nickel Hydroxide
Sludge
State Empty Product
Hazardous Bags
Only
State Ash fron sludge
Hazardous Incineration
Only
Plant Location
Wallingford.
Connecticut
Wallingford.
Connecticut
Wallingford.
Connecticut
Wallingford,
Connecticut
-
Date Per Cent Location
Reduction
On Site Off-Site
1986 Not X
Quantified
1986 100X X
1986 Not X
Quantified
1986 28* X
(129 tons
reduced)
Description
Expanded sales of
off-grade polymer
and products.
Nickel hydroxide
sludge sent to
reclamation.
Using 1,300 Ib.
"Super Sacks" in
place of 13 -
100 Ib. bags.
Biological waste
treatment sludge
dewaterlng system
improved by reduc-
tion In use of lime
through using
polymers.
Additional Information
•
Significant reduction
in waste stream from
Thermoplastics Oept.
Complete elimination
of wastestream from
Coated Fibers Oept.
Change in containers
reduces waste loads
from Thermosetting
Dept.
Improves incineration
efficiency and reduces
quantity of ash for
disposal. Also reduces
amount of lime raw
material used.
Reduces raw material
and hauling cost.
ST:0141I/0585J-17
-------
QUESTION III What have your hazardous watte reduction aeeonolisnnents been in the pact five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Per Cent
Reduction
Location
Description
Additional Information
EPA Hazardous
Was to No.
Type of
Wait a
On Site Off-Site
Raw Material
Change
Process
Modification
"F" Listed "F" Listed
solvents
D001 Ignl table
liquid waste
Warners. 1986 1001 X
New Jersey
Warners. 1986 15* X
New Jersey (64.000 IDS.
per year)
Maintenance Oept.
discontinued use of
these solvents.
Installed drain on
overhead condenser
for wiped file evap-
orator. Facilitates
removal of weekly
caustic wash sol-
ution which Is a
haiardous waste.
This action totally
eliminated this
waste stream.
Improves recovery of
overheads, reduces
amount of purge water.
saves $42.400 per year
in raw material and
Incineration costs.
ST:0141I/058SJ-18
-------
QUESTION III What have your haiardous waste reduction accHpllchnents been in the past five years? PLEASE TELL ALL
Waste Reduction
Method
Waste Reduced
Plant Location
Date
Per Cent
Reduction
Location
Description
Additional Information
EPA Hazardous
Watte Mo.
Type of
Watte
On Site Off-Site
Raw Material
Change
0006
Liquid waste
containing
chromium
Walland, Ontario
Canada
1986
100X
Changed cooling
water treatment to
cease using
chromium
based product.
Eliminated chromium
discharge.
ST:0141I/0585J-19
-------
QUESTION III What have your hazardous waste reduction acconpltshnents been In the past five years? PLEASE TELL ALL
f
Waste Reduction Waste Reduced Plant Location Date Per Cent Location Description Additional Information
Method \ Reduction '
EPA Hazardous Type of On Site Off-Site
Waste No. Watte
New Waste 0010 Hazardous West Springfield, 1986 95X X Hash-dry waste Reduced waste
Management liquid Massachusetts (1.000 to solid vs. volume significantly.
Process waste gallons) previous decanting.
ST:0141I/05B5J-20
-------
QUESTION III What have your haiardoui waste reduction accomplishments been In the past five years? PLEASE TELL ALI
Waste Reduction
Method
Waste Abatement
New Waste
Treatment
Process
Process
Modification
New Waste
Management
Process
Waste Reduced Plant Location
EPA Hazardous
Waste No.
0009
F003. F005.
K002, K003.
K005, K007.
K103. K104.
0001, D002.
0003. 0007.
U019
F003, F005.
K002. K003.
K005. K007.
K103, K104,
0001, 0002,
0003, 0007,
U019
F003. FOOS.
K002. K003.
K005, K007.
K103. K104,
0001. 0002.
0003. 0007.
U019
Type of
Waste
Catalyst dust Willow Island,
containing West Virginia
mercury
Bological Waste Willow Island.
Treatment Plant West Virginia
Sludge
Bological Waste Willow Island,
Treatment Plant West Virginia
Sludge
Sludge Incinerator Willow Island.
ash. West Virginia
Date Per Cent Location
Reduction
On Site Off-Site
1986 70S X
(Reduced
fro* 114
to 34 Ibs
per day)
1986 100X X
(10,000
tons per
year)
1986 SOX X
(1.000
tons per
year)
•
1986 100X X
Description
Installed auto-
mated blending
system for Cat-
alyst products
Installed Fluidized
Bed Incinerator to
handle biological.
sludge and waste
solvents.
Substituted poly-
electrolyte for
line In sludge
filtration.
Install new land-
fill system for
ash disposal.
Additional Inform.at.ibn
Significantly reduced
amount of dust assoc-
iated with prior sys-
tem and thus waste
stream.
Eliminates landfill
disposal for sludge.
Reduced lime content
of ash for disposal.
Have exchanged ash
disposal meeting
minimum technology
requirements for
wet sludge disposal.
ST:0141I/058SJ-21
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Amoco Chemioal Company
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March.10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name Of Company Amoco, Chemical Company
Address 200 Ease Randolph Drive, Chicago, IL 60601
Contact Person, Title Raymond C. Vaseleski, Director-Environmental Conservation
Telephone # (312) 856-6827
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) varies
Net Worth 1985 (See attachment)
Sales 1985 (total chemicals) - $2905 million 1986 • $2928 million
Major Products by Divisions (See attachment) '
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # various ignitable (D001), corrosive (D002), and rea:tive (D003) and
EP toxic (D007) wastes; spent organic solvents (F003) and spent halogenated
solvents (F001, F002) and product spills (U239).
Number of plants which generate hazardous wastes: out of 44 facilities coca:
16 "large quantity generators" and 15 small quantity generators (two of large quantity';
Location of plants which generate hazardous wastes (See Attachment#3.1
Large quantity Generators (Texas, Illinois, Indiana, Ohio, S. Carolina, Mississippi,
California)
Small Quantity Generators (Georgia, Indiana, S. Carolina, California, Iowa, Arkansas,
Ohio, Virginia, Alabama, New Jersey)
Number of Employees
17,169 worldwide (13865 domestic)
Please return to: DANA DUXBURY
CKm'V-H FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4. 1987
-------
Attachment
1. Net Worth 1985
Amoco Chemical Company is wholly-owned subsidiary of Amoco
Corporation, an integrated oil, gas, chemicals, and minerals
company. The net worth of the subsidiary companies are not
reported. Amoco Chemical Company's worldwide assets totaled
$2,334 million in 1985 and $2,545 million during 1986. The parent
company, Amoco Corporation's net worth for the year ending
December 31, 1986 was $11324 million. ($11588 million for 1985).
2. Malor Products by Divisions
Amoco Chemical Company - Industrial organic chemicals,
intermediates, polymers and resins.
Amoco Fabrics Company - Polypropylene carpet backing and face
yarns.
Amoco Foam Products - Polystyrene foam food containers and
insulation products.
Amoco Container Company - Polyester containers for beverages,
health products, etc.
Amoco Petroleum Additives Company - Oil, gasoline and lubricant
additives.
Amoco Performance Products, Inc. - Engineering resins and carbon
fibers and composites.
Welchem - Chemicals for oil production.
3. Number of plants generating hazardous wasted during 1986
3.1 - generate only state restricted wastes.
3.2 - 27 of 35 manufacturing operations generated
4 of 6 lab/R&D facilities generated
_0 of _3 blending/storage terminals generated
31 of 44 total facilities generated
of these 31 facilities that "generate", 11 are small quantity
generators (SQG's). Many of the 31 facilities "recycle" (both on-site
and off-site), the majority of the "waste" generated.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
SEE ATTACHMENT
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
There were no major changes to our program during 1986.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
N/A
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
President of Amoco Chemical Corporation
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Waste reduction or minimization is defined as the process of reducing
the amount of waste material that must be subjected to disposal techniques.
Such reduction can be achieved through source reduction, process improvements,
recycling and treatment.
RETURN BY MAY 4, 1987
Page 2
-------
(Question l.a)
Corporate Waste Reduction Program
Plant managers report to Amoco Chemical Corporate management on waste
generation, disposal, recycling, and reuse practices for all wastes
(hazardous and non-hazardous) on a semi-annual basis. This
information is summarized and analyzed by the Corporate Environmental
Staff for presentation to senior management. Based on this
information* and corporate and management recommendations, the
divisional and plant managers establish goals for improving
performance for the coming year.
(Question l.m)
Maintenance and Acceleration
The Corporate Environmental Affairs Group will provide the individual
plant personnel with additional assistance in the following areas:
1. identification of additional recycle opportunities
2. identification of all sources of losses
3. identification of technical assistance and training
requirements
4. assistance in justifying capital expenditures for waste
reduction projects
(Question l.q Continued)
Barriers in Achieving Waste Reduction
contain no "product" for which a market exists or that can be further
extracted at a price that a customer is willing to pay. This
technology and economic barrier, which is by no means static, exists
.for the entire industry.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Each plant has primary responsibility for identifying methods of
reducing their wastes, but the auditing of progress and technical
assistance is provided by the Corporate Environmental Staff.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
To senior management including President.
h) Have you found the need for additional waste reduction
expertise in the last year? If so,, new staff or consultants?
There was no perceived need for additional "outside" expertise or
consultants assistance but the corporate "consultant" staff grew by about 5!
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
-and the time frame in which the goal is to be met.
Plant managers and plant personnel with environmental responsibilities
at most of the "large quantity generator" locations have a annual goal
to reduce by 10% the quantity of waste inquiring disposal.
j) Does each plant or Division establish its own particular
goals?
The goals are established at the plant based on input from divisional
managers and/or senior management.
Jc) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
President
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Corporate plan was initiated during 1983 and is fully operational.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
SEE ATTACHMENT
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume/ method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
No cost accounting procedural changes were Implemented during 1986, but during
1987 we have formally incorporated potential long term liability into cost
accounting and waste disposal decision making.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
pounds/unit production and total tons.
What is your base year?
1983
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Overall, the pounds of waste per unit production has decreased each year since
the program was formalized in 1983. However, some individual plant's rates may
increase due to shifts in the types of chemicals produced and due to non-routine
activities (i.e. closures, maintenance activities).
Do you also keep this information on a plant and or
process stream basis?
"Bates" are calculated for the total plant only but data is reported for each
process stream.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Amoco Chemical Company has achieved an 87Z reduction in hazardous waste requiring
disposal since the 1983 base year. Waste reduction gains will become increasing!:,
difficult to achieve as the more obvious and resource effective projects will have
already been implemented. As the chemical industry continues to extract more and
more "products" from raw materials and residues, the "leftovers" eventually (Acta<
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Such identification efforts have thus far been limited to the major waste
streams, so comphrehension of the maximum or ultimate benefits for the
entire company not available at this time. _. . .
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Ideally, this identification process would begin at the plant level with an
in-depth review of each process waste stream and this information would be
conveyed to the corporate level to help in establishing goals, timetables and
resource requirements.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Each plant has slightly different procedures for administering programs but
most plants dovetail it into their overall "profitability improvement program"
(PIP). Under the PIP program, all plant employees are encouraged to submit
written suggestions for improving profitability.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
There were no program changes during 1986.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
yes
How did you accomplish this?
The corporate program was introduced to the plant managers via correspondence
from the divisional vice president. This vice president routinely reviews
program'status during plant manager's meetings.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
Waste stream reductions are audited semi-annually.
Have you computerized this waste stream audit data?
No
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
This process is conducted by the individual plants but it is not formally
documented. The results are routinely documented and repqrted.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAT 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall/ Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit? Yes
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
x Identify opportunities for future cost effective
reductions?
Establish goals for the next 1 years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
_X Note problems and corrective actions undertaken?
JE Document costs and return on reduction efforts?
_x Identify resource requirements for the future?
_X Project expected future returns?
Other elements?
Is your waste reduction audit computarized? No
RETURN BY MAY 4, 1987
Pace 6
-------
474 Boston Avenue. Curtis Ball
Tufts University. Medford, MA 021S5
CQOER FOR ENVUCmENBO. MANKSMENr (617) 381-34B6
Much 10, 1987
Question IIIi Uiat have your waste reduction acccnplishnents been In the past year since Hoods Bole XI? (PI£ASE TEH, ALL)
METHODS: A) Inprovenents in technology t equipment; B) Inprovements in plant operational C) Substitution of raw materials;
D) Redesign or refbnnilation of end products; E) Recycling in-plant tastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
see above)
Equipment
improvement
recycling of
materials.
reformulation of
end products
Reuse via sale
Recycled
Internally
Recycling
off-site
Substitution of
taw material
VA5XE pmrm
EPA HAZARDOUS
HASTE C
D001
D003
D002
FOOI
•
FOOI
TYPE OF
HASTE
Solvent-
contamtd.
polypro-
pylene
Aluminum
chloride
solution
Caustic
solution
Spent
chlorlntd
solvent
degreaser
Spent
chlorlnnd
solvent
degreaser
PUNT IOCKTICW
Texas
Texas
Indiana
Several States
Several States
DATE
1987
1986
1986
1986
1986
PER CENT
PHXCTION
icovncN
CH-SITE
X
'
X
X
OFF— SITE
X
X
DESCRIPTION
Installed equipment to
permit recovery of solvenl
contaminated polypropylen
for blending with a
different grade of poly-
propylene to formulate
a new comnerclal product
Material sold to original
manufacturer for reuse
as a raw material.
Material used in waste-
water treatment process
for pH control (replacing
commercial grade caustic)
Encouraged several plants
to utilize services of
an Integrated solvent
service contractor
Encouraged several planti
to replace FOOI solvents
with non-hazardous
petroleum solvents for
maintenance degress ing
ATJOmCNAL
INFORMATION
purposes.
Pane 7
PLEASE RETURN BY MAY 4.-1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV /
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
Proposed Projects
1. Burning of a 261.33 (f) listed waste for fuel value In an on-site boiler.
2. Substitution of materials in a neutralization process to eliminate generation
of a non-hazardous sludge.
3. Substitution of catalyst to reduce frequency of catalyst disposal and to
eliminate characteristic of EF toxicity.
RETURN BY MAY 4, 1987
Page 8
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AT&T
-------
, Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3,4,5- 1987
General Information
Name of Company : AT&T
Address 650 Liberty Ave., Union, NJ 07083
Contact Person, Title: Walter S. Boyhan, Sr. Staff Engineer
Telephone # (201) 851-3391
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 3661
Net Worth 1985 - $ 40,500,000,000
Sales 1985- $34,909.5 million
Major Products by Divisions-Telecommunications Equipment
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # F006 - Industrial Wastewater Treatment Plant Sludge
F001 - Spent Halogenated Solvents
F002 - Spent Halogenated Solvents
F003 - Spent Non-halogenated Solvents
D002 - Corrosive
Number of plants which generate hazardous wastes- Approx. 30 major locations
Location of plants which generate hazardous wastes- Throughout the U.S.
Number of Employees - 337,600
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire (
Question 1
• ,
Corporate Waste Reduction Policy i
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews/ waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
Corporate Policy Statement
Cost Reduction Program
Centralized Env. Eng. Organization Guidance
Technology Transfer Conferences
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
No change - continued emphasis on reducing
generation of wastes
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Vice Presidential Level: Staff environmental functions
have been centralized for all AT&T entities.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Any reduction in quantity and/or potentially harmful
nature of waste.
RETURN BY MAY 4, 1987
Page 2
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
£) Does each Division or plant in your corporation have its
own specific program or plan?
Each location develops its own waste reduction plan.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
>
Facility manager through production workers.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Waste reduction is an on-going activity - there is never
enough staff to perform the work that could be done.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
No specific goals, but a hierarchy of disposal methods
has been established.
j) Does each plant or Division establish its own particular
goals?
Yes
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Facility Manager (Vice President)
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Continued emphasis by centralized Env. Eng. organization.
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
Locations are urged to consider the long term potential
costs of various disposal methods.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
Determined by each facility
What is your base year?
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Yes, down.
Do you also keep this information on a plant and or
process stream basis?
Centralized Hazardous Waste Manifest Accumulation by Plant.
g) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
This is a continuing effort - there is no specific goal to be
obtained - we can always do better.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Rapid changes in technology make the concept of
"maximum benefit" meaningless.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Corporate Env. Eng. Staff Organization provides guidelines
and overall objectives.
Plant Personnel initiate specific programs. Information on
effective programs distributed to other facilities.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
How did you accomplish this?
Waste reduction is an inherent activity in manufacturing,
The Corporate Staff Organization provides overall
objectives and direction.
Cost reduction is a manufacturing personnel activity.
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
Pone locally
Have you computerized this waste stream audit data?
Possibly, at some locations.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Possibly, at some locations.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
No
g) If so, what elements are included in your waste reduction
Do you:
Yes or Ho
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computarized?
RETURN BY MAY 4. 1987
-------
474 Boston Avanue, Curtis
Tufts University, Madford, HA 02155
CENTER FOR ENVUXXMEKZAI. MANAGEMENT (617) 381-3486
• March 10. 1987
Question IHt Wiat have your uaste redaction accaiplishnents been in the past year since Hbods Hole H? (PLEASE TELL ALL)
ME3ODS: A) Inpxovanents in technology I equirment; B) Inprovenents in plant operations; C) Substitution of raw materials;
0) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE REDUCTION
METHOD
(see above)
A
B
C
B
WASTE BEntrrn
EPA HAZARDOUS
WASTE I
F007
F009
D008
F002
Various
TXPE OF
WASTE
Plating
Solution
PUB drll
dust
Chlorin-
ated
Solvents
Do
.
PLANT LOCATION
DATE
PER CENT
IXDUUIMUH
951
601
lOOt
Varies
LOCATION
ON-SXTE
X
X
X
X
•
1
OFF-SITE
'
LU^XJU-tM'lON
Chemical precipitation
unit reduces hazardous
from 3,000 gaL/day to
30 gal ./month.
Segregated solder-free
drill dust from drill-
Ing of printed wiring
boards to reduce the
volume that must be
treated as hazardous.
Continued development
of aqueous processed
cleaners, fluxes, photi
resists, etc. to
replace solvent pro-
cessed materials.
Aggressive use of sur-
plus material exchange
within facility and
corporation, donation
of consumer type
materials to charltabli
groups for sale to
general public.
ADDITIONAL
INFORMATION
-
Strong resistance co
declaring a material
surplus. Discourage
purchase oE excess
materials.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
RETURN BY MAY 4, 1987
Page 8
-------
Chevron Corporation
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Chevron Corporation
Address P.O. Box 7924, San Francisco, CA 94120
Contact Person, Title W. J. Mulligan - Manager, Environmental Affairs
Telephone #415-894-3252
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 2843,2869,2873,2874,2879,2911
Net Worth 1985 29.5 billion
Sales 1985 43.8 billion
Major Products by Divisions
Petroleum products, Oil and Fuel additives. Agricultural Chemicals. Fertilizers, geothermal
energy, minerals
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # API Separator Sludge (K051). Slop Oil Emulsion Solids (K049), DAP float (K048),
leaded tank bottoms (K052). Heat Exchanger Cleaning Sludge (K050), acids, caustics,
amine sludge, cooling tower sludge, off spec pesticides, solvents (F002, P003), waste
water (D001. DO 13, D016) containers.
Number of plants which generate hazardous wastes 15 major facilities
account for 99% of the hazardous waste generation
Location of plants which generate hazardous wastes
California, Louisiana, Texas, Missouri, New Jersey, Iowa, Pennsylvania, Hawaii
Number of Employees
51.000
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
In 1981, Chevron Corporation completed a hazardous waste survey which determined
what types of wastes were being generated, disposal methods and costs. As a result
of that survey, several OpCos developed formal waste management programs.
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Corporation Environmental Policy was amended to show that Company efforts to
support and practice positive conservation measures will include 1) Minimizing the
generation of hazardous wastes to the extent that Is technically and economically
feasible, and 2) Establishing Internal procedures, plans or programs to encourage
the conservation of resources through recycling or reuse wherever practical. (See Enclosure I)
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
0 Long term liability costs of disposal becoming more evident
0 Development of cost-effective recycling alternatives
0 General disposal cost increases
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
The Vice Chairman of the Board signed a memorandum beginning the SMART program.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Chevron defines waste reduction as: generating less waste (Le. source control or process
change), finding a use for the waste (Le. recycling, fuel use), or changing the wastes
characteristics to become less hazardous (Le. treatment so waste becomes non-hazardous).
All emissions are covered in our definition.
RETURN BY MAY 4, 1987
Page 2
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medfbrd, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Goal is to have plant programs revised or developed by October 1987.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
We have communicated to an levels (Le., the field, middle management and upper management).
h) Have you found the need for additional waste reduction
expertise in.the last year? If so, new staff or consultants?
Yes; support staff from Chevron Corporation, Engineering Technology Department,
Chevron Research Company, Chevron Oil Field Research and the operating companies
have increased efforts in the waste reduction area. Chevron participated with the (Enclosure I)
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
To establish the most cost effective (Including long term liability) combination of
source reduction, recycling and treatment options. A review of each facilities waste
management plan are being incorporated within the one and five year business cycle.
j) Does each plant or Division establish its own particular
goals?
Yes
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
To the Executive Board Level
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Initial stages
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
1) Articles in following publications: Chevron World, Chevron Focus and Management
Newsletter
2) Video
3) Recognition of employees
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
For capital projects, charges may be placed on certain methods of waste management
(Le. varying cost of disposal depending on level of hazard of waste as disposed). This
increases the cost-effective number of options that could be implemented.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
This win be facility specific.
What is your base year?
1986
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
This will be calculated company-wide in 4th Quarter 1988.
Do you also keep this information on a plant and or
process stream basis?
Generally on a plant or regional basis.
q) Ars there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
0 Permitting of facilities linked with corrective action
. ° Regulation barriers to recycling from facility to facility within one Company
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Yes; we may know in 1988 our rate of change.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
On a plant/regional basis.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Currently only in draft form. It IB evolving as our knowledge increases.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past y e a r. Plants or regions are incorporating the following elements of a waste
minimization/management plan:
0 Inventory ° Prioritize wastes
0 Alternatives (Le. source reduction, recycling, treatment)
0 Schedule and Targets to reduce volumes or degree of hazard
• Monitoring and Evaluation
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
How did you accomplish this?
Corporate program was sanctioned by the Health, Environmental, Safety Advisory
Committee which includes manufacturing personnel.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
Yes; we plan to revise or plan annually by reviewing the opportunities In each plant
or region.
Have you computerized this waste stream audit data?
No
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Yes
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question) This process is currently only in draft form and is evolving.
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit? Yes; our waste reduction
process includes a yearly review for capital expenditures for environmental projects.
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Yes Identify and quantify sources of all process losses to
all media. If not all, which ones?
Yes Identify opportunities for future cost effective
reductions? ,
Yes Establish goals for the next 1 65 years?
Yes Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computarized?
Not yet on a corporation wide basis.
RETURN BY MAY 4, 1987
Page 6
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474 Boston Avenue, Curtis Hall j
Tufts University, Hedford, MA 02155
CXMIGR FOR ENVIRONMENTAL MANAGEMENT (617) 381-3486
March 10, 1987
Question IIIi What have your waste reduction acccnplishments been in the past year since Hoods Hole II? (PIZASE TELL ALL)
METHODS: A) Improvements in technology & equipment j B) Inprovements in plant operations; C) Substitution of raw materials;
D) Redesign or refoundation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE REDUCTION
METHOD
(see above)
Cbev
IIASTE rnnrm
EPA HAZARDOUS
HASTE (
on U developli
TYPE OP
HASTE
I lororraatl
PLANT LOCATION
a to refpond Co tbl
OKIE
Quectlon 1
PERCENT
PEDUCTICN
1988.
10CATION
CN-SITE
•
OFF-SITE
DESCRIPTION
ADOmCNAL
INFORMATION
PLEASE RETURN BY MAY 4, -1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a-) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
See Question la. Chevron Chemical Company completed 1985's questionnaire and
has followed through on the waste reduction efforts mentioned.
RETURN BY MAY 4, 1987
Page 8
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ENCLOSURE I
Question 1
b) In addition, Chevron developed the SMART program which is described in Che attached
documents 1) March 12, 1987 Memorandum on "Comprehensive Response to Land
Disposal Ban and Waste Minimization Requirements", and 2) Recent newsletter article
(see insert).
h) American Petroleum Institute and Western Oil and Gas Company in funding consulting
expertise.
-------
Memorandum . - . -A
Son Francisco, CA
March 12, 1987
A COMPREHENSIVE RESPONSE TO
LAND DISPOSAL BAN AND WASTE
MINIMIZATION REQUIREMENTS
HEADS OF OPERATING COMPANIES:
The 1984 Hazardous and Solid Waste Amendments (HSWA) to the Resource
Conservation and Recovery Act have caused the Corporation to consider changes in its
approach to hazardous waste management. Upon enactment of HSWA, Congress
'legislated requirements that preclude or severely restrict the continued land disposal
of untreated hazardous wastes and have established a national policy to minimize the
future generation of such wastes. As a result, significant investments or procedural
changes in Chevron facilities may be necessary to achieve compliance.
It is essential that Chevron's operations organize well engineered programs to
minimize the cost of waste management. In addition, the next few years are a test
period during which the legislators and regulators will observe how well industry meets
waste minimization requirements. The degree of future legislation will depend on our
action now.
I am requesting each Operating Company with wastes potentially subject to land
disposal ban and waste minimization requirements to prepare a waste management
plan by September 30, 1987. These plans should include target dates and technology
options to meet source reduction, recycling and treatment goals set by each operating
company. We have chosen "SMART" as the acronym for the program which stands for
Save Money And Reduce Toxics.
To assist your organizations in this endeavor, a steering committee consisting of
HE&LP, CRC, ETD, COFRC, Legal, Government Affairs and OpCo representatives
will be established to coordinate the effort. The committee will work through its
OpCo representatives to obtain scoping information on the OpCo plans as they are
developed. Resources from Corporate support functions will be made available at the
request of the Operating Company.
In addition, Environmental Affairs Policy #502 will be amended to show that Company
efforts to support and practice positive conservation measures will include:
I. Minimizing the generation of hazardous wastes to the extent that is
technologically and economically feasible.
2. Establishing internal procedures, plans or programs to encourage the
conservation of resources through recycling or reuse wherever practical.
Congress has charged the EPA with the responsibility to ascertain the "desirability and
feasibility" of new legislation to accomplish the national policy of waste minimization.
How well we respond could ultimately determine the extent to which we will be
regulated.
K.
ccs Officers and Department Heads - Corporation
-------
Digital Equipment Corp.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 Jterch 10, 1987
HASTE REDUCTION: THE HURDLES AHEAD
General Information
Name of Company DIGITAL EQUIPMENT CORP.
Address 146 MAIN ST, MAYNARD MA 01754
Contact Person, Title James K. Rogers, Corp. Mgr., Energy & Environmental
Affairs.
Telephone # (617) 493-3837
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 2513
Net Worth 1985 $6-1 Billion
Revenues
•9BBT 1985 (July 85 _ July 86) $7-6 Biilion
Major Products by Divisions COMPUTER SYSTEMS INCLUDING PERIPHERALS AND
ASSOC. EQUIPMENT.
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # F001 — Halogenated Solvents
F003 — Flamable Solvents
F006 — Metal Hydroxide Sludge
D002 — Corrosive Liquids
Number of plants which generate hazardous wastes over 40 at last count.
Location of plants which generate hazardous wastes MASS, NH, VT, ME, CT,
CO, SC, AZ, NM, PR, CA, WA, and more than 10 foreign countries.
Number of Employees 105,000 worldwide
Please return to: DANA DUXBURT
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole 111 Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital/ etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
1) Part of corporate policy. 2) Subject of training videos. 3) In-
cluded in annual environmental seminar. 4) Subject of many information
memos.
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
1) Added corporate policy statement.
2) Included in annual environmental meeting.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
1) Increaseflliability for wastes.
2) Fewer "satisfactory" waste sites.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Mostly middle management and plant level.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Any activity which reduces the quantity or toxicity of waste or improves
its recycle/reuse potential. Generally any activity that reduces our
present and future costs and risks would be considered "waste reduction."
RETURN BY MAY 4, 1987
Page 2
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Each plant which generates hazardous waste has a waste minimzation plan.
However, their detail and sophistication varies greatly.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
Up through the V.P. of manufacturing.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Not from external sources.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
No specific goals. Our business is so dynamic that reliable baselines
are mot available.
j) Does each plant or Division establish its own particular
goals?
Some do and all are encoured to when applicable.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Plant managers plus the corporate environmental affairs group.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
You tell me.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
1) More training and education.
2) More management awareness.
3) More emphasis on process engineering decisions.
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
Have begon discussions with risk management and plan to allocate
environmental insurance costs to waste generators.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
No metrie,our business changes too much.
What is your base year? NOt applicable
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Not applicable
Do you also keep this information on a plant and or
process stream basis?
We keep absolute quantities only.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
The people who generate the waste aren't responsibile for it. We
try to change that with education and accounting changes .
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
No-Tin a meaningful way and we could waste all our time on figuring
out metrics rather than reducing wastes.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Plant and process waste stream.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
We! have no divisons. Each plant must develop its own waste reduction
program.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
Plant level implementation schemes hatf?not changed significantly in
the past year.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes.
How did you accomplish this?
Our Environmental Division is in Corporate Manufacturing which helps
in implementing programs in manufacturing.
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
NO.
Have you computerized this waste stream audit data?
No.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
No.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit? No.
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
Not Applicable.
RETURN BY MAY 4, 1987
Page 6
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985 's questionnaire
as yet?
1. Further substitution to reduce volumes of solvents.
2 . Presentations to meddle and upper management about the
benefits of waste reduction to them and their facilities.
3. More meetings and training sessions for plant environmental
people to help them sell waste minimization at their facilities.
4. We send out copies of new waste reduction ideas to everybody who
could possibly benefit from
Installing new photofixer purifiers which double the life
of photoprocessing chemicals.
RETURN BY MAY 4, 1987
Page 8
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Department of Defense
-------
Tufts University Center Cor Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Department of Defense
Address Pentagon, Washington, DC
Contact Person, Title Carl J. Schafer Jr,
taputy ftul*t*it Swat*ry of 0*f«nw GrwIronMnt
Telephone « (202) 695 7820
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 9?11
Net Worth 1985 Roughly $3 Trillion
BMVailUCS
Jfi«itt6X1985 $245 Billion
Major Products by Divisions
Land Defense
Sea / Amphibious Defense
ftir Defense
Major Hazardous Haste Streams by Division and EPA Hazardous
Waste #
IMU9MLE mfUTlOWi KOM. 049. 046 md CHMUCTBI1ST1C
OFF SPEC MO USED FUEL. OIL RM> LUBRICANTS: DWVCTGMSTJC, SPECIFIC OR F001 - 009 CONTPH1NRTBO
JMXJSTR1M. XfiSTWOTW (WO SLUOM FROH KTM. VBKXlMsCWm&lOK CONTROL OP6RPT10HS: CHfWBCTERJSTJC OR FOOB
SPSHT SOLUEMrS, OPTEM MIXED KITH PMMT. F001 - DOS . CNWDCTERISTIC
Number of plants which generate hazardous wastes.
Approximately 500 installations Tmilitary bases)
Location of plants which generate hazardous wastes
Nationwide
Number of Employees
Roughly 3 million
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
Military S«rvlM« and Oefanae Loglntlce Pqanoy Ml TE RCSOURCC!! ON RCTURL REDUCTION
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Effort that started with DoD's logistics commands C
(major industrial generators) has been extended to operation
force bases.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
Part of strategic plan
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
CEFUTV ASSISTAKT SECRCTMtV OF OCFCNSE ISSUED FOWL POL1CV
K1L1TMV SarvlOM / OEFEME LOB2ST1CS MENCV OCUGLOPINO ' ISSUING fOOUL POLICV FOR OPEKPTINO OWWWS
uOOISTJCS COWMOS COXTIMJE IHPUHENT'MG POLICY ISSUED IN 1983
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
No restrictions are placed on innovation. Anything that reduces
hazardous uudsie quantity or to
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
That is the goal.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
Likening each DoD installation to a private 'plant,'
then the level is at least this far.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Ves. Both have been used.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
The ultimate goal is to eliminate hazardous waste. This
will be approached through interim goals and comprehensive
process examination which is an ongoing requirement.
j) Does each plant or Division establish its own particular
goals? ves. Each Military Service or Major Command sets
goals. Subordinate installations are encouraged to exceed
expectations.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Policy is that all personnel are responsible. The Deputy
fisst Sec Def provides policy and certain funding and oversight.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Largely investigatory, discovering where possibilities lie,
except for a few notable process changes, identified before
formal plans, which are in various stages of test & evaluation,
budgeting or implementation.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Information exchange, perhao? in the form of a vidio that
«.hou*s actual imDrovemffnifi, . n GOG rat j on.
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
\
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability/ or recharges to specific plants for environmental
The cost of disposal has been changed from
central budgeting to increasingly lower levels of command
to effect awareness of reduction benefits.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
Total quantity is serving at present, but some form of
unit or commodity specific measure may be deueloped.
What is your base year?
Generally 1985
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
We are still experiencing an increase from increased
environmental awareness. Figures for 1986 are not
available for realistic trend analysis at this time.
Do you also keep this information on a plant and or
process stream basis? flt .pjant. Qr inslallation lewel§
both are kept. Headquarters receives only combined rollups.
g) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
fff> PeRPITTJHO - BY PEKSISTENCC
UlL.'TflftY REPOIHESS OEMNO.'NO HIGHEST QUPUTV - TESTING OF INNOU0T1UE PRODUCTS ' PROCESSES
TIMING SNO MMJLM1LJTV OF CflPITM. - NULTJVEMt FIM3 APPRCPM M ! OMS
COKPCT:TION IN COKTIWCTJHO - KORC USE OF NEOOTJOTEO WJSRS SEM.CO Bio PROCUREHENT
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction? ye na(je no limits; adjustments are a continuous
sr identification i-s underuov.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
I;^:TBHV :NST«LU»::CSS RO"<:ib*T -M-. BEST nccoi*"T:«, wCJU.. BUT WKTL STKUVI imnajrf txxsss IN
aaunonRj=s is RECORDED PS t> H-'TER ww T3 M-TC TO BRIPS MTU sair *>sTe STKUWS
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level. .... . , , ^
Attached are synopses of Army, Air Force
and Defense Logistics Agency programs and a draft "Notice"
outlining the Nauy program.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
Increase in formal recognition of hazardous
waste reduction as a specific program.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufaeturino personnel?
In progress. An example is Army Material Command Plan - attend
How did you accomplish this?
Through command directed •formal communication: committees,
briefings, training, etc. In the case of DoD's logistics
commands which operate fiscally similar to priuate industry,
the chance of Increasing competitiveness is a motiuator.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
Different Commands establish process control reporting to
fit their needs. (See AP1C Plan, Navy 'Note1 for examples.)
Have you computerized this waste stream audit data?
The leuel of automation uaries considerably throughout DoD.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc? Surveys or
reports are cona'jC'eo in uarious Uii^s . (.See si'cha highlights
of an Air ^orce Systems Command cTudy of one of its installaiions)
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Dp you conduct a waste reduction audit?
Jns.t3li3~.iOP Ic^i1 ae'ud)] dk: P TO \^\ i $ procrr^c !<•• cond-ictea but not
kepT =>~ Ooij h€ddqjaTieri ie^e^.
g) If so, what elements are included in your waste reduction
Aliflli? Do you: Numerous variations ujould occur throughout
„ „ OoD's 500 generating installations.
Yes or Ho 3 3
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
RETURN BY MAY 4, 1987
Page 6
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
COTTER FOR ENvTPCNMEMTAL MANAGEMENT (617) 381-3486
March 10, 1987
Question III: Wat have your waste reduction acconplishments been in the past year since Moods Hole 117 (PLEASE TELL ALL)
METHODS: A) Irprovements in technology I equipment; B) Inprovements in plant operations; C) Substitution of raw materials;
D) Redesign or refornulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE KhUULTlON
METHOD
(see above)
1
HASTE unurn)
EPA HAZARDOUS
HASTE «
TYPE OF
HASTE
PLANT LOCATION
DATE
PER CENT
MUH.-iiW!
LOCATION
CN-SITE '
OFF-SITE
DESCRIPTION
•
ADDITIONAL
INFORMATION
fD o'ol D 15 IT
C L.I 00 Q_^-
fD "^ r-*-*-'-CO
•-•"0 QJ C
o f]^. r-- i 'I — '-(—»-
QJ i— -ox:
Q A"Qj CT)
Q fi) r-«-Q; (D
C"D '-J-^
H' r+-O O
,-'«-'jj
(1) r-'-O
I Dj"
CO
PLEASE RETURN BY MAY 4, -1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
Attached excerpts from Navy's Draft Technical Memorandum
outline its actions.
Attached Air Force Logistics Command's briefing of its
incinerator project is an example of a specific action.
Defense Logistics Agency's Plan (attch'd, referenced earlier)
prouios examples of other e'f •forts underway.
RETURN BY MAY 4, 1987
Page 8
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Dow Chemical
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company The Dow Chemical Company
Address 2030 Willard H. Dow Center, Midland, Michigan 48674
Contact Person, Title Ryan Delcambre, Issue Manager, Waste Reduction
Telephone # (517) 636-2953
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 2800-Chemical Manufacturing
Net Worth 1986 Approximately $4.5 billion total assets
Sales 1986 Approximately $11 billion net sales
Major Products by Divisions (See Attachment)
i
Major Hazardous Waste Streams by Division and EPA Hazardous Waste ft
Number of Plants which generate hazardous wastes All
Location of plants which generate hazardous wastes All
Number of Employees 28,000 U.S. Area
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Attachment #l
MAJOR PRODUCTS
EASTERN DIVISION! SIC
Plastic Resins
Miscellaneous Plastic Products 3079
LOUISIANA DIVISION;
Organic Chemicals 2869
Plastic Resins 2821
Inorganic Chemicals 2812
MICHIGAN DIVISION;
Inorganic Chemicals 2812
Organic Chemicals 2869
Pesticides 2879
Plastic Resins 2821
TEXAS OPERATIONS;
Organic Chemicals 2869
Inorganic Chemicals 2812
Plastic Resins 2821
Non-Ferrous Metals 3339
WESTERN DIVISION;
Plastic Resins 2821
Organic Chemicals 2869
Pesticides 2879
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
(See Attached)
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Program was formalized under W.R.A.P. (Waste Reduction
Always Pays).
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
Goals & Plans for formalization were established in 1985
and implemented in 1986.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Program review, approval & communication occurred at the
vice president of manufacturing level.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
(See Attached)
RETURN BY MAY 4, 1987
Page 2
-------
Attachment #2
(Page 1 of 2)
ANSWER FOR QUESTION l.a.t
W.R.A.P. INFORMATION (WASTE REDUCTION ALWAYS PAYS)
The program is a long term plan to formalize our past, present and
future efforts in a form that can be used to establish our progress
and future directions. The goals of the program are to reduce waste
to the environment, provide incentives for waste reduction projects,
provide recognition for those who excel in waste reduction and
re-emphasize the need for continuous improvement by recognizing
opportunities in waste reduction. We believe by actively pursuing
waste reduction opportunities we will reduce our waste management
cost, improve operations productivity, and demonstrate to the public
our commitment to environmental protection.
The program has 3 main objectives from the U.S. Area perspective:
1) data base for tracking progress; 2) a compendium of projects
implemented or proposed that reduces waste; and 3) recognition of
facilities/employees that make significant contributions to waste
reduction.
Specific details of the objectives are:
1. Data base requires that each plant should develop an inventory of
all process losses to the environment (air, water and solids). This
inventory should be both quantitative and qualitative and source
specific. These losses should then be a ratio of production rates to
account for production variances and allow for calculating a weighted
average for each division. This waste index (#waste/#product) can
then be tracked and evaluated by each site at some frequency.
2. Projects that qualify must have a measurable reduction of waste to
the environment. The projects can be capital, maintenance or
operational/administrative changes. We would like these projects to
save Dow $ (including avoided cost) where possible but, some projects
may not have a ROI that can be quantified. The use of a form to
document projects was suggested. The reason we encourage this type of
documentation is due to the many improvements that can occur within
the process area that require no capital and would otherwise go
unrecognized. This will also assist in advocacy support of Dow and
more specifically our local operation, as states become more active in
this area of environmental concern.
3. Selection of projects/efforts that are recognized for waste
reduction occur at the local level. Projects are reviewed by a
committee of manufacturing and environmentalist management and
selected for recognition. In 1986, 10 awards were presented in the
U.S. Area. These awards are presented by U.S. Area Management.
-------
Attachment #2
Page 2 of 2
Question l.a.3., continued;
Reviews of data and reporting vary from each division. Many
divisions require quarterly tracking and reporting of plant waste
reduction indices to monitor progress. From a U.S. Area requirement,
yearly reports are required which include weighted average index for
the division and a list of projects that have been implemented and the
results of the project (see attachment) are reviewed with U.S. Area
Manufacturing Management.
Employee awareness and motivation is accomplished in a myriad of
ways. Brochures, stickers, awards and video tapes are used as tools
to educate and motivate our employees.
ANSWER FOR QUESTION I.e.;
Any in-plant process (including some forms of treatment) that
avoids, reduces, or eliminates waste that would have otherwise entered
the environment. All process losses to all media (air, water & land)
are included and tracked in our programs.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION 1 CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Each division incorporates the U.S. Area plan as their minimum
requirements but have the flexibility to expand this plan to meet
their specific locational needs. See attached sheets from each
division as they explain individual programs.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
Top management through operations personnel.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
See attached network sheet. These committees are not new staff,
but are primarily manufacturing personnel having experience in waste
reduction.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Corporate goals are continuous improvement in the waste
reduction indices.
j) Does each plant or division establish its own particular
goals?
Yes - each plant.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
At all levels - this is a measure of all employees'
job performance.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
The program is essentially implemented. Waste inventories in
some divisions are not complete but are expected to have complete by
August 1987.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Through W.R.A.P. program recognition, newsletters, fact sheets
and videos.
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION 1 CONTINUED)
n) During the past year, have you modified your cost accounting
procedures to ensure that waste reduction is encouraged to a greater
extent? If so, how have you done this? (i.e., placing additional
charges on things such as total volume, method of waste management,
potential long term liability, or recharges to specific plants for
environmental management.)
No. Dow has a long history of recharging & surcharging of all
waste management activities to the generating plants.
o) How do you measure your waste reduction accomplishments (by sales,
employees, pounds/unit production)?
(Ibs of waste air, water or land/lbs of product)
What is your base year?
1982
p) When accounting for production variations, did your corporation's
hazardous waste generation rate change from the previous year? If so,
how?
Overall waste generation has decreased due to project
implementation.
Do you also keep this information on a plant and or process stream
basis?
Plant basis.
q) Are there any specific barriers to achieving significant waste
reduction levels that your corporation, particular divisions or
process streams face?
If so, what are they and how can they be overcome?
No, just the 2nd Law of Thermodynamics.
r) Have you begun to identify how far and how fast your corporation
can move to attain the maximum benefits of waste reduction?
Each plant is responsible for "imagineering" the maximum
theoretical reduction and examine methods, resources and capital
requirements to reach the theoretical.
Should this identification of maximum benefits be done on a
corporate, plant or process waste stream basis?
Plant.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
QUESTION II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
See Attached from Division Coordinators.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the past year.
c) Assuming that your corporate waste reduction plan or program began
in your environmental division, have you integrated this program or
policy with your division or plant level manufacturing personnel?
How did you accomplish this.
d) Do you conduct a waste stream (or process loss) audit? If so, how
frequently do you conduct the audit?
Have you computerized this waste stream audit data?
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prioritization of
waste reduction methods, and implementation, documentation and
communication, of results, etc.?
Please detail this process. (If you accomplish this process through a
waste reduction audit, please proceed to the next question).
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
(See Attachments #3, #4, #5, and #6 from Division
Coordinators)
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
How did you accomplish this?
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
Have you computerized this waste stream audit data?
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the nezt
question)
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computarized?
RETURN BY MAY 4, 1987
Page 6
-------
Attachment #3
QUESTION II; Plant or Division Implementation!
a) Eastern implemented from the top of the organization down.
B. Weaver made a presentation at plant managers staff meeting.
Eastern Division General Manager made a video tape directed to plant
managers and their staff.
Site Responsibilities: 1,
3
4
5
Develop waste reduction history for
each process.
Identify all non-products leaving
the plant.
Identify where the losses occur.
Ratio the losses to production units.
Set goals.
6. Track & report quarterly.
b) Formal kickoff in 1987.
c) Yes.
Items 1 through 6 in Question a) are the responsibility of the
plant (process) supervision.
d) Yes. This is to be an integral part of Eastern's program. The
audit will be conducted by process plant personnel. This is the mass
balance requirement.
No.
e) Yes.
See Attachment #7 - Road Map Suggestions.
-------
Attachment 14
QUESTION II; Plant or Division Implementation:
a) The program in the Michigan Division has been on going for many
years but under different headings. Raw material utilization
improvements and yield improvement programs have been and continue to
be part of the operating procedures for the Division. Because each of
the divisions are different in their product make up, the local
program is tailored for each Division's needs. In the Michigan
Division, the U.S. Area sponsored program is blended into an existing
program in the Quality and Productivity area.
b) The program has become more formalized in its approach. The
Division will require that each plant calculate a "waste index" and
report this number to upper management at regular intervals. This
waste index will be used to reward those who show sustained and
significant reduction and also to indicated processes where
opportunities for improvement exist.
c) The formal program has not been initiated as of this writing.
When started the program will be carried to all levels of
manufacturing personnel. This will be accomplished through training
programs and public relation type efforts.
d) We do conduct an annual audit of our emissions to the air. This
audit is computerized. We are beginning the process of auditing
emissions to the other media. This annual audit will also be
computerized as it is developed.
e) We conduct periodic environmental reviews with each processing
plant. At that time we discuss most of the elements outlined in
Section (f).
-------
Attachment 15
QUESTION II; Plant or Division Implementation;
a) Texas Operations management implements a number of its programs by
formulating key objectives for the Division. One of the ke.y
objectives in 1986 called for the continuous reduction of wastes to
the air, water and land by an average of 10-20% per year for the next
five years.
b) Texas Operations has not changed its basic waste reduction
implementation scheme in the past year.
c) Yes.
The program began in 1985 with management creating an
Environmental Management Support Team. This group became the focal
point for the conduct of all activities in carrying out waste
reduction policy. This group, consisting of managerial members from
the Environmental Department and manufacturing personnel, then set the
priorities for carrying out the key objective mentioned in Ila
(above).
d) We do not conduct specific waste stream (or process loss) audits
as such within each plant facility. Texas Operations instead conducts
extensive, detailed inventories of all waste streams emitted to the
atmosphere, water streams, and land. This includes specific chemicals
and daily rates or annual tonnages being emitted. Solid wastes are
characterized in a similar fashion. These inventories are conducted
plant by plant, and includes all manufacturing, research, maintenance
and service facilities within the divisional organization. Texas
Operations is currently going through this inventory process for the
2nd year in a row.
i
All data from these inventories is set up in computer data bases.
e) Through the inventory process described above (d), it has been
possible to establish which chemicals are being emitted to the
greatest extent, individual plant wide, and also division wide. After
prioritizing these emissions by type and plants involved through
classical graphical and statistical techniques, the "top ten"
chemicals or plants are identified and one can then set the basis for
the best, cost-effective projects for effecting waste reduction. The
general premise is that the largest quantity of chemicals being
emitted or those plants contributing the largest emission amounts
offer the best possibility of effecting the greatest amount of waste
reduction in the shortest length of time. Implementation of methods
for reduction or the priorities are generally carried out by personnel
at the individual plants involved. Progess is measured by successive
inventories taken yearly and conventional reporting and documentation
procedures.
-------
Attachment |
(Page 1 of 2)
QUESTION II: Plant or Division Implementation;
The Louisiana Division has encouraged waste minimization in the past
through formal programs such as "energy contests", industrial hygiene
reviews, and environmental awards and recognition. We are presently
emphasizing a formal waste minimization program at the plant level
called W.R.A.P. - Waste Reduction Always Pays.
Waste minimization awareness is accomplished through education at the
division level and emphasis at the plant level. A waste minimization
team was formed to develop a W.R.A.P. booklet which describes the
waste minimization philosophy, benefits, and details the formal
W.R.A.P. Program requirements. A division W.R.A.P. coordinator was
named to chair the team and organize the program efforts.
The W.R.A.P. Program "kickoff" to the division consists of the
following:
1. Describing the program in an edition of our Dow Louisiane, a
monthly division-wide newsletter sent home to the families of
Louisiana Division employees.
2. Presenting the specifics of the'program to the division
management.
3. Each individual manufacturing plant then assigns a W.R.A.P.
contact. The W.R.A.P. coordinator, W.R.A.P. contact and plant
superintendent meet to discuss specific data collection and
calculations required from the plant by the program.
4. Progress reports on the program kickoff are presented to differer
levels of division management. A newscast with the Division General
Manager supporting the program is available for division employees to
view.
The program itself is basically a documentation of past waste
minimization performance, data collection and trending, and goal
setting. Specifics of the W.R.A.P. program include:
1. Collect data of water, air, and solid waste.
2. Calculate a waste minimization ratio (# waste/Mi) product) for ai;
water, and solid wastes.
3. Trend these ratios for 1985, 1986, and for each quarter starting
in 1987 for each meda.
-------
Attachment #6
(Page 2 of 2)
4. Set individual goals for waste reduction efforts based on these
ratios.
5. Review and document past waste minimization projects to help
quantify our previous waste reduction effort.
6. Document waste minimization ideas for future waste minimization
projects.
7. An award and recognition are given to the plant with the most
significant waste minimization project for that year.
Specific capital money for future waste minimization projects will be
provided as waste minimization categories are intergrated into our
established "energy content" and capital budget programs.
A preliminary review of past waste minimization projects since 1984
show waste reductions of all types amounting to over 285 million
pounds of materials reduced. More projects are on the books waiting
for completion.
-------
474 Boston Avenue, Curtis Hall
Tufts University, Modford, MA 02155
CLWrER FOR ENVIKOtWENTAL MANAGEMEWr
(617) 381-3486
March 10, 1987
Question III: What have your waste reduction aocanplishmcnts been in the past year since Moods Hole II? (PLEASE TELL ALL)
PARTIAL LIST
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WRSTE REDUCTION
MC1U1D
(see above)
A
A, C
A,B,E
£
B
HASTE REDUCED
EPA HAZARDOUS
WASTE (
TYPE OF
HASTE
VOC
VOC,MeCl2
VOC.DMSO
solid
solid
PLANT LOCATION
Midland. MI
II
II
11
II
DATE
1986
1986
1986
198C
1986
PER CENT
PFIXCTION
871
92%
30%
501
721
IOCATION
ON-SITE
X
X
X
X
X
OFF-SITE
DESCRIPTION
1ETHOCEL*-Sc rubber installe
-Fuaitives %
material balance.
DURSBAN*-Removed solvent
from process
RARLON*- Improved olant oner
plus DMSO recovery still.
Herbicide "roduction -reuse
of catalyst
VBC Research - develon new
method to clean column
reducinn waste by 70+55.
*Trademark of The Dow Chera
ADDITIONAL
INFORMATION
. OOWANOL* P»
MeOH, Prooylene alycol
MeCl2
tions
OMSO
cal Comnanv
-------
QUESTION fill, continued:
DOW CHEMICAL USA
-3-
Waste
Reduction
Method Plant
Date
Description
Glycol II 2Q, '86
Chlorine 3Q, '86
Chlorine
E/A
Solvents/
EDC I
Solvents/
EDC I
A/E
A/B
Vinyl II
Vinyl II
Methanes
LH:sb
4/87
1Q, '87
1984
1984
4Q, '85
3Q, '85
HQ, '85
Provide a closed loop absorber water
cooling system by installing heat
exchangers and associated equip-
ment. This eliminated 250 M
gallons/year bottoms stream
requiring biological_treatment and
recovered another 1 M f/year pro-
duct loss.
Recycle 37 M f/year of waste
effluent as a raw material which
previously required treatment.
Intall process equipment and
improve plant operation to reduce
freon lost to the atmosphere by
901.
Modified existing process equipment
to reduce organic losses to the
water by 60%.
Install a process modification to
reduce byproduct waste to the inci-
nerator by 10 M f/year and recycle
as a raw material to the process.
Recovered 225,000 f/year of an
incinerator feed as a product by
installing new process equipment.
Recycle 500,000 f/year of an
incinerator feed to the process as
a raw material.
Improved production yield 21 and
reduced organic losses to the water
by 991 by installing new process
equipment and better process
control.
-------
PLANT
SIMMRY OF WASTE REDUCTION PROJECTS
MICHIGAN DIVISION
PROJECT DESCRIPTION
ANNUAL COST
SAVINGS
ANNUAL TONS
OF WASTE
REDUCED
MEDIA
METHOCEL
DURSBAN
INSTALLATION OF WATER
SCRUBBER AND DETAILED
MONITORING OF FUGITIVES
CONVERSION OF PLANT TO
SOLVENTLESS TECHNOLOGY
1,431
765
AIR
AIR
DOWFAX
VARIETY OF PROJECTS
INVOLVING YIELD IMPROVE-
MENT ON ALL RAW MATERIALS
20*
MULTI
GARLON
INSTALLATION OF IMPROVED
WASHING TECHNOLOGY AND A
SOLVENT RECOVERY SYSTEM
35Z
MULTI
BUTYLENE
OXIDE
PLANT STUDIES OF TOD AND
IDS GENERATION
135
10%
Ml'LTI
-------
PLAKT
SUMMARY OF WASTE REDUCTION PROJECTS
EASTERN DIVISION
PROJECT DESCRIPTION
ANNUAL COST
SAVINGS
ANNUAL TONS
OF WASTE
REDUCED
MEDIA
ALLYN'S PT.,
CT
STYROFOAM PLANT, REPLACE
CONVEYOR FEED SYSTEM TO
SCREW FEED SYSTEM
35
13.6
SOLID
DALTON, GA LATEX PLANT, INSTALLED
VENT SCRUBBER/RECOVERY
SYSTEM
175
500
AIR
RIVERSIDE. POLYSTYRENE PLANT, NEW
MO OPERATING PROCEDURE FOR
POWER FAILURE
45
60 DRUMS SOLID
WESTERN DIVISION
LATEX PLANT
WHITE WATER ELIMINATION
THROUGH PROCESS AND
PROCEDURAL CHANGES
26
873
WATER
-------
SUMMARY OF HASTE REDUCTION PROJECTS
TEXAS DIVISION
ANNUAL COST
PLANT
FREEPORT HG.
DEPT.
LIGHT HYDRO-
CARBON NO. 6
OCD- PHENOL/
ACETONE
LIGHT HYDRO-
CARBON NO. 7
GLYCERINE II
ETHYL-
BENZENE A
POLYCARBONATE
ETHYL-
BENZENE A
LATEX PLANT
EPOXY II
BISPHENOL
EPOXY I
EPOXY I
MAG-
CHLORIDE A
PROJECT DESCRIPTION
CL2/HCL REDUCTION PROGRAM
LEAK DETECTION AND REPAIR
PROGRAM
CARBON BED/CUMENE VENT
RECOVERY
LEAK DETECTION AND REPAIR
RCLS- INSTALL VACUUM PUMPS
LARGER VENT GAS COMPRESSOR
METHYLENE CHLORIDE PILOT
PLANT CONDENSER
REPAIR FLOATING ROOF TANK
SEAL
STRIP STYRENE BIOPOND STREAM
ACETONE VENT RECOVERY
POND CLOSURE PROJECT (TOLUENE)
SOLVENT TANK PROJECT
REPAIR AND INSTALL NEW DEMISTER
IN T-2 SEAWATER TOWER
SAVINGS
($M)
ND
36
ND
13
ND
ND
4
ND
ND
ND
1
ND
ND
ANNUAL TONS
OF WASTE
REDUCED
630
449
223
85
7.7
37
35
49
25
5
2
1
34.6
MEDIA
AIR
AIR
AIR
AIR
AIR
AIR
AIR
AIR
AIR
AIR
AIR
AIR
AIR
GLYCERINE II T-307 ACETONE STRIPPER
57
20
AIR
-------
-2-
TBEAS DIVISION (CONT'D)
PLANT
CMP DEFT.
CMP DEPT.
GLYCERINE
DEPT.
TDI PLANT
CHLOR-ALKALI
MAG DEPT.
PROJECT DESCRIPTION
CHLORINATED METHANE
HEAVIES RED
CHLORINATED HEAVIES FROM
TRICHLOR PROD
PROPYLENE BICHLORIDE
REDUCTION
CHLORINATED LIGHTS
REDUCTION
SCRUBBER WATER REDUCTION
RECYCLE OF WASTE STREAMS
(LOST 4 MO/$ 1985)
ANNUAL COST
SAVINGS
($M)
ND
ND
ND
ND
ND
ND
ANNUAL TONS
OF WASTE
REDUCED
601
75Z
4*
UZ
91Z
5,400
MEDIA
^^^^•^^^
SOLID
SOLID
SOLID
SOLID
WATER
WATER
-------
Waier ireaimeni Plant tor Latex
requires
Pieri explained that introducing a
manpower-intensive operation while
meeting Oow's "leaner and
meaner" goals created an
interesting challenge.
A series of surveys showed that
operators lacked the free time
necessary to monitor the new
system. This finding led to a brain-
storming session which resulted in
the suggestion to restructure jobs.
versus looking at operations as they
currently existed.
"A little light bulb in everybody's
head came on at the same time,"
Pieri said.
Delegating some of the operators'
previous work to others and making
slight mechanical changes in
procedures will allow the new facility
to function utilizing existing
manpower.
While Dalton's efforts focused on
introducing a new system. Riverside
recently increased production
capabilities and profitability in their
existing STYRON* polystyrene
plant. Hot strands of polystyrene
were plugging up the pellet cutter.
creating fusion and large chunks of
product in the silos.
To improve the strand cooling
process, operators increased the
length of the existing water bath
and refined work activities
surrounding it. Addition of a bigger
hydraulic motor also allowed more
material to be forwarded into the
bath.
According to Dave Sextro.
production engineer, these efforts
resulted in increased production
capacity of 25 million pounds of
Styron polystyrene each year. Unit
production costs are now lower, and
longer requires manual arum
CoiilinuuJ on
Gallon — lottie Conner and David Dyer work
on the collection basin sump pump, which
transfers waste water to storage tanks. Team
members in Dalton include: Paul Pieri, Jim
Geammn. David Dyer. Lottie Conner. Jim
Black. Sue Hall. Rocky Davis, LeeHoy Peeler,
Glenn Prine. Wayne Ray. Tom Patterson. Gail
Nonnemacher. Jimmy Gotote, Handy Gumn.
Dennis Stone, and Ron Ingle
the plant is benefiting in terms of
profitability.
Operators at both the Findlay and
Hanging Rock plants also increased
the efficiency of existing operations.
The Findlay Graphic Arts Problem
Solvers (GAPS) recognized that
equipment used to fill orders for
DOWETCH- plates created a
productivity problem. To fill orders of
less than ten pallets, two employees
would get one pallet for each type
of requested plate out of inventory,
spread them across the warehouse
floor, then hand group and package.
As part of the problem-solving,
warehouse personnel were surveyed
on details of repacking. Their
solution was a roller conveyor with
dual lift tables and a power bander.
Racks were also installed behind
the conveyor to store the Dowetch
materials. The new system allows
different sizes and gauges of
Dowetch to be consolidated, versus
the previous method of using an
individual pallet for each size and
gauge requested. This new program
resulted in total savings to the plant
of $18,000, and reduced a two-
Tom Smolarek
General Manager's
Report
This issue of Eastern Scene features some of the "thinkers"
and "doers" who made 1986 a year to be proud of. These
are the kind of people who achieved over $13 million in cost
savings, most of which came from personal ingenuity and
dedication. If you think that you, as an individual, can't make
a difference in Dow's profitability, just glance at some of the
people and ideas pictured in the center spread on pages 2
and 3. You are the difference between a mediocre or spec-
tacular performance, and we should all try for the spectacular!
Eastern Division's Fourth Quarter Sales of over $135 million
were the best ever experienced, breaking our 1983 record.
Our total 1986 sales (over $575 million), and our profit before
tax, approached previous records and reflected strong de-
mand for our STYROFOAM* plastic foams and STYRON*
polystyrene product lines. Our plant operating rates continued
to improve over previous years and our cost containment pro-
gram was a huge success. We exceeded our savings goal by
58% and these cost savings accounted for 22% of our 1986
profit.. . and this is just the beginning.
In 1987. we will be seriously applying our experience with The
Right Way to Manage* and various QSPP techniques to an
additional challenge — waste reduction. By creating less
waste and reducing our costs for treatment and disposal, we
will again be improving Dow's competitiveness. We will also
be helping our communities address one of our most serious
social problems — where to put society's wastes.
So. to all of you, I ask that you keep on thinking and keep on
doing. Your ideas, your efforts, and your loyalty are not just
important, they are essential. .-^
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WRAP program kicks off
B\ Leslie Hollis
Ent'iTonmencal Serrices
Waste reduction means minimizing or
eliminating the generation of waste. This
is often accomplished through process
improvements that reuse or recycle waste
materials in the plant.
Examples of waste generated in the div-
ision include general trash and scrap,
spilled or otherwise lost raw materials,
fugitive emissions, byproducts, bad
runs...so many opportunities!
Companies like Dow have every incen-
tive to reduce their own wastes. If waste
is not generated, then it doesn't have to
be disposed of or treated. Both treatment
and disposal require energy, time, and
money. Lost or off-spec products cannot
be sold at full market price. These con-
siderations don't even touch on the most
important factor—the impact that these
wastes have on present and future
generations!
The new waste minimization program
within Dow is appropriately called
Waste Reduction Always Pays, or
WRAP. The Louisiana Division can
attest to the fact that it does pay! By
reviewing past capital projects since
1984, the division has reduced waste by
over one-fourth of a billion pounds. Sav-
ings amount to over $5,250,000. There
are projects on the books worth another
$6 million in savings that haven't been
completed!
The division has been minimizing waste
all along, but hasn't done a very good job
of telling the story. That's what WRAP is
all about. During the next two months,
each plant will be putting together a
waste minimizing ratio of pounds of
waste divided by pounds of product.
Ratios will be calculated and trended for
the plant's air, water and solid wastes for
1985, 1986, and for each quarter begin-
ning with 1987.
This will allow each plant to set goals to
continue waste reduction and tell the
story of its waste minimization accomp-
lishments. An award will be given to the
plant with the best waste minimization
project.
The efforts of many employees will result
in a program that makes employees
proud to be doing things the right way.
WRAP will help to reduce costs and to
continue to conduct business in an
environmentally sound matter.
WASTE
REDUCTION
ALWAYS PAYS
Good news for engineers
What is GLOBAL PE? It is a VAX-based, menu-driven system of computer pro-
grams for chemical engineering calculations. GLOBAL PE has been instituted at 12
locations, including the Louisiana Division, throughout Dow's process engineering
community.
The purpose of the system is to eliminate duplication of effort and to increase the
quality and consistency of chemical engineering calculations. The system presently
contains 36 applications and 13 utility programs. More programs are under review
and updates to the system will be issued at least semi-annually.
An additional benefit of GLOBAL PE has been the establishment of a system to
manage Dow-developed and purchased software. A goal is to eventually include all
chemical engineering programs of common interest to various sites.
The new system culminates a two-year effort by the 10-member, multi-site Process
Engineering Computerized Calculations Committee. John Monroe was the initial
representative from the Louisiana Division and has since turned those responsibili-
ties over to Paul Roux. More information is available from Paul at 8153 in Process
Engineering.
PACE 3
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The Do» Chemical (ompany
and Subsidiaries
Synopsis of Significant Events
From: 1986 Annual Report
A Strong Safety
Performance
Dnu's Fine safety record for 198fi was second »nl\
to chat or 1985 m Company history The Company'*
frequency rate for lost time injuries per 1 million
work hours was 0 13, compared to 0 11 in 1985.
That record is well below the average for major
U.S. chemical companies and represents perform-
ance dramatically better than that of all industry.
The severity rate of employee injury was reduced
to an all-time low. In addition, Dow employees:
at Texas Operations, achieved 21.8 million hours
worked with no lost time injuries, setting a new
standard for manufacturing units; in US , sales
offices established the best non-manufacturing
record of any industry in the U S by working
more than 28 million safe work hours; in Dow
Canada and Dow Pacific, both won the President's
Award for working 10 million work hours without
a lost time injury.
• • • Property damage was also at an all-time low
in 1986, excluding the effect of a September flood
in Midland, Michigan.
A Good Health
Environment
A new Dow study showed employees continue to
experience lower mortality rates than the general
population from all major causes of death,
including cancers.
• • • Involving 37,000 Dow employees at Michigan
Division and U.S.A. headquarter units (between
1940 and 1982), the study was the most compre-.
hensive employee health survey yet completed by
the Company. It represented a major expansion of
earlier research, involving about 8,000 men,
which showed Dow employees to have had lower
mortality rates than the general population.
Both studies were conducted as part of Dow's
medical/epidemiology program to evaluate the
health experience of employees. Such research is
a key element of a continuing Company-wide
emphasis on employee good health and safety in
the workplace.
Increased Dividends
In the third quarter, Don's board of directors
voted to raise the quarterly dividend to $.50 per
share, an increase of 105 per share. In an-
nouncing the dividend, Paul F Oreffice said the
new rate reflected the improved nature of Dow's
business and management's confidence in the
sustained earnings power of the Company for the
balance of 1986 and the future.
Key Officer Changes
Robert W Lundeen, chairman of the board of
directors of The Dow Chemical Company, retired
May 30, capping a 40 year career that he began
as a researcher in Pittsburg, California. Paul F.
Oreffice. Dow president and chief executive
officer assumed the additional role of chairman
of the board following Lundeen's departure
• • • Robert E. Naegele retired from the board of
directors.
• • • Andrew J. Butler and Herbert H. Dow were
elected vice presidents of the Company. Butler is
president of Dow Chemical Europe and a member
of Dow's board of directors Dow is also a
director of the Company.
• • • Donna J. Roberts was named to succeed
Herbert Dow as secretary of the Company. She
will retain her responsibilities as an assistant
general counsel for Dow.
Increased Coamitment to
Environmental Priorities
Dow has had a continuing commitment to
environmental protection for more than half a
century. Since 1970, in the US. Area losses to the
air have been reduced by approximately 90
percent while losses to water have declined by
more than 95 percent. Today the amount of
organic material in landfill disposal is approach-
ing zero as a result of DOM'S use of incineration.
Similar reductions have occurred in other Dow
geographic locations. In 1986, Dow established
the Combustion Technology Research Group to
expand its emphasis in this area and ensure the
Company maintains its leading edge in waste
management technology.
• • -Additionally, in 1986 the U.S. Area created a
new issue management team and a recognition
program for environmental waste reduction. Com-
munity environmental information and awareness
programs were also stepped up. Total Dow capital
expenditures associated with environmental
control were increased to $101 million in 1986
..J
18
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DOW U.S. AREA WASTE REDUCTION NETWORK
Louisiana Division
Coordinators
Plant
Texas Operations
I
Eastern Div. Coordinator
Waste Reduction Committee
U.S. Area Coordinator
/
\
western Div. Coordinator
Waste Reduction Committee
I
Michigan Division
Plant Coordinators
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E.I. Du Pont de Nemours & Co., Inc.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
HASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company E. I. du Pont de Nemours & Co., Inc.
Employee Relations Department, N-11543
Address 1007 Market Street, Wilm., DE 19898
Contact Person, Title Dr. J. R. Cooper, Director of Environmental Affa
Telephone # (302)774-3788
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 28:13
Net Worth 1985 $31 Billion
Sales 1985 $27 Billion
Major Products by Divisions (See Attachment B)
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste #
There are over 1200 waste streams. The important information on all
these waste streams has been entered into a computer data base.
Number of plants which generate hazardous wastes (See Attachment B)
Location of plants which generate hazardous wastes(See Attachment B)
Number of Employees 141,268
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
The following are essential ingredients: 5% waste reduction goal for
1987, Wasteline Newsletter, Corporate Symposium, video which explains
the program, annual reports to senior managements, computer data base,.,
and strong support from the business units and Engineering Department
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
The business units better understand the economics associated with
waste management and are driving the waste reduction goals.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
The program has been altered, but it has become more encompassing,
including more segments of the Company.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
N/A
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
We support a multimedia waste reduction program in that waste cannot
reduced by simply transferring it from one medium to another. We hav
targeted RCRA solid waste now as the primary waste for reduction. A
definition of our waste reduction targets was submitted in 1986
(Question Il-b).
RETURN BY MAY 4, 1987
Page 2
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Yes. The plant programs were developed using the Corporate
definitions and outline.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
All levels
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
NO
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Yes, an eight-year goal from 1982-1990 of 35% reduction has been
established. To continue meeting this goal, a 5% reduction was set
for calendar year 1987.
j) Does each plant or Division establish its own particular
goals?
Yes
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Executive Committee oversees program policy. Same answer as last
year for Question I-d.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
The program has certainly been communicated and now the business
units are driving to reduce the waste while technical support comes
from a knowledgeable Engineering Department.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
A stronger internal communication effort is underway. Wasteline
Newsletter will be issued with a greater frequency. In addition,
another waste reduction symposium is scheduled for the Spring of 1988.
The last symposium in October, 1986 attracted over 300 Du Pont employee
and over 60 papers were presented. Also, financial incentives in the
form of cash awards will be given.
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
Total cost records associated with "tabulated" wastes targeted for
reduction are being maintained by each plant site. Tnis information
is in the Corporate data base.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
In most cases (>90%) it is normalized by pounds of production.
What is your base year? 1982
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
A list of comparisons between the 1982 and 1985 'generation rates has
been developed for over 1200 waste streams. There is no simple answer-
or trend. Each waste stream must be reviewed based on startup conditd
growth, shutdowns, or unusual circumstances.
Do you also keep this information on a plant and or
process stream basis?
Yes
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Barriers are limited by resources to implement programs and not all
reduction approaches are cost effective.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
No, our goal is subject to change based upon new data that were
established based on past experience. Waste reduction is a primary
focus of the Company and will continue as a part of our business cult
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
The maximum benefit is to the entire Company but this total benefit i
the sum of plant-by-plant and waste-by-waste stream reduction efforts.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
The Corporate waste reduction program has been established to support
line organization programs. The information for the economics associat<
with waste management and the technical resources have been supplied
by the Corporate Committee. It is the line organization that implements
the program. Plant sites have designated person(s) to track and
coordinate waste reduction.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
N/A
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
How did you accomplish this?
The program started in the Corporate Manufacturing Committee which is
responsible for all manufacturing and production within the Company.
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
Yes, annually.
Have you computerized this waste stream audit data?
Yes
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Yes
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)38-1-3486
474 Boston Avenue, Curtis Hall, Hedford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computarized? yes
RETURN BY MAY 4, 1987
Page 6
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DUPONT QUESTION III
PLANT A
Ethylene glycol is used in several of Du Pont's fiber
manufacturing processes. The ethylene glycol after use is
"contaminated" with low- and high-boiling impurities and polyester
solids. A 32-tray continuous refining column separates water/
acetic acid/ and high-boiling impurities from the ethylene glycol.
A recent modification to the existing glycol refining column piping
and its operation resulted in a reduction of carbon waste at a
savings of $400,000/year.
PLANT B
A technique has been developed for rejuvenating carbon
beds in aqueous waste service and increasing the carbon life by a
factor of four. This practice has decreased waste carbon
generation by 380,000 Ibs./yr. at a savings of $300,000/yr.
PLANT C
In an effort to reduce the amount of methylene chloride
used on site, a unit was installed to remove solids from the spent
solvent and allow reuse of the methylene chloride. Startup
difficulties with temperature controls were- eventually overcome and
the unit now reduces the off-site shipment of waste solvent by
150-2000 gpd at a savings of 5300,000-$500,000/year.
PLANT D
Du Pont's Petrochemicals Department produces
11 intermediates" used by other departments within Du Pont to make
end products. The Department has a very successful program to
transform non-primary streams into high value specialty chemicals
by identifying customers who can make good use of the material.
Various "waste streams" have become the basis of profitable
businesses. Some markets have been so attractive that we
deliberately produce products that we previously considered
non-primary streams or by-products. Sales resulting from these derived
from this effort now exceed $3,000,000/year.
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PLANT E
Du Pont supplies paints for several markets. As colors .__
change, obsolete paint is disposed of as a hazardous" waste. We
have developed a system to return the obsolete paint to a
manufacturing site, separate the paint from the metal can, and
blend it to make a salable product. This will save Du Pont and'its
customers money and eliminate the need to dispose of the paint as a
waste.
PLANT F
One of the largest and most complex Du Pont plants makes
six completely independent products at the,site, which means that
there are, in effect, six separate manufacturing facilities. In
1985, these six facilities produced over 230 million pounds of
finished product.
From the year 1981 to 1985, the site increased the total
pounds of finished product produced by 51 percent. During that
same period, the site generated 51 percent ,less hazardous waste.
The plant credits this dramatic progress to a strong commitment by
site management and educational efforts at all levels.
PLANT G
Du Font's New England Nuclear Products has reduced the
volume of its lab-generated low-level radioactive waste by 76
percent in the past seven years. This has been achieved by
eclectic volume-reduction awareness programs targeting elimination
of waste at its point of origin, coupled with upgraded waste
management programs to improve processing efficiency.
The programs succeed by tapping the lab workers' creative
talents via attention-getting mechanisms, and have been effective
in significantly modifying the generation of waste.
PLANT H
At one plant site, a solvent used for cleaning accounted
for approximately 95% of all hazardous waste generated on-site. In
an effort to minimize this waste solvent, a commercially available
solvent distillation unit was installed. The solvent is now
recovered and the site waste generation rate has been reduced by
90%/year, at an annual savings of $150,000.
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PLANT I
A new innovative process for recycling silver has. recently
been patented. This process allows for the rapid identification
and then eventual separation of silver from a polyester matrix. - -
Approximately $20,000,000 worth of silver waste is now being
recovered and recycled in-house. • .
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474 Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II"
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw mater:
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
See 1
held
exam]
WASTE Kl
EPA HAZARDOUS
WASTE #
ttachment C
in Wilmingt
les of wast
ujuusu
TYPE OF
WASTE
- The A
on, Dela
e reduct
PUNT LOCATION
renda for the
rare in Octobe
on at Du Pont
DATE
«
aste Rec
, 1987 I
PER CENT
PEDUCTION
action Syi
as sever a
LOCATION
ON-SITE
posium
OFF-SITE
i
DESCRIPTION
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
RETURN BY MAY 4, 1987
Page 8
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ATTACHMENT A
DESCRIPTION OF MAJOR PRODUCTS
-------
aurketed widely ia On aetlth tut industry, products in ads segment include»bntd liae otx-ny
products; diagnostic Idts, instruments, repeats, tad imaging agents; prescription Pharmaceuticals; sad i
wide tuft of rsdiolsbeled chemicsls, biologies! msterisli, sad instruments used in biologies! research.
BIOMEDICAL PRODUCTS: Consolidating internal
resources and initiating many collaborative ventures yielded
a strengthened focus on worldwide health care markets.
IIJ ILO IU
M M M
Sesuted to Include
18 million charge (or
Urly Retirement
Program
Tut In Review In a move toward more customer
focused and Industry-aligned marketing. Du Poms »L2
billion health can business was consolidated by merg-
ing medical X-ray products with other medical diag-
nostic, research, and therapeutic businesses
The company* Pharmaceuticals business was
strengthened In the hospital market by the purchase of
the assets of American Critical Can. which has a con
of acute-can products used primarily in hospital emer-
gency, Intensive can. and surgical procedures Based
in Waukegan. III. the unit was renamed Du Pont Crit-
ical Can. Inc At year end. "Bnvibloc.* a short-acting
prescription drug classified as a beta blocker. was
given approval for marketing by the Food and Drug
Administration. It will be used to moderate certain
abnormal heart activity In critical-can situations
Collaborative ventures announced during 1986 wen
a flve-yeac IS million joint medical research project
with Duke University, and the formation of On-
cogenetlcs Partners with Applied biotechnology Inc. of
Cambridge. Uass. for cancer research. Du Pont also
purchased a minority equity position in Laserscope
Blomedlcal Corporation, a Santa Clara. Calif., company
that manufactures surgical laser systems: acquired the
marketing rights to "Coumatrak.' an anticoagulant
monitoring system from Blotrack Inc. of Sunnyvale.
Calif.: and entered into a research and distribution
agreement Involving DNA and peptide synthesizer In-
struments and chemicals with Vega Biotechnologies of
Tucson. Ariz.
•Analyst,' a new clinical chemistry analyzer for use
In physicians' offices and small clinics, was Introduced
during the year, and shipment began of 'Dimension'
clinical chemistry analyzers for high-volume testing.
The company* extensive line of research and blood
screening products associated with the AIDS virus and
Its antibodies gained market acceptance worldwide
fertormsnee Sales for 1986 wen II 2 billion. 13 per-
cent ahead of last year, primarily due to Increased
volume and higher U S dollar-equivalent selling prices,
reflecting the weaker dollar overseas The segment also
Includes Du Pont Critical Can results since the Sep-
tember acquisition
After-tax operating Income was 188 million, up 44
percent from 1985. largely reflecting gains on sales of
technology and certain non-strategic International
Pharmaceuticals businesses. Pharmaceuticals results
also improved due to higher sales and a successful
comarkeUng program with Hoffmann-La Roche for
•Versed" midazolam. a preoperattve sedative Interna-
tional results for medical X-ray and biotechnology sys-
tems Improved, reflecting business strength, an
effective cost containment program, and the weaker
dollar in Europe. Results for diagnostics wen about
equal to 1985 as Income from new product sales was
oflset by market Introduction expenses Sales of con-
sumables for the 'aca' discrete clinical analyzer re-
mained strong, and demand for the HTUMII (AIDS)
antibody blood screening test was particularly strong
at year end.
Cspitsl Sxpenditures Capital expenditures wen 195
million venus »82 million in 1965. In addition, during
1986 the assets of American Critical Can wen acquired.
Outlook Continued strong growth in medical diag-
nostics Is expected as new clinical chemistry analyzers
and tests an Introduced and marketed. Demand for
•Dimension' and 'Analyst* analyzers Is high, and the
market for tests for the 'aca' analyzer remains strong.
Global acceptance of the expanded line of blood
screening products, particularly AIDS-nlated tests.
should strengthen the company* presence In these
markets. New electronic imaging and information-han-
dling equipment should continue to build Du Fonts
overall role In medical X-ray and other Imaging
modalities A new radlopharmaceutical for heart imag-
ing that has excellent growth potential will be Intro-
duced in Europe during the second quarter.
In Pharmaceuticals, both existing and new hospital-
oriented drugs should show strong sales growth. Mar-
keting programs for new products such as •Bnvibloc'
and •Coumatrak' should enable the strong growth
trend of recent yean to continue.
An Increasing focus on customer needs should ex-
pand the number and scope of business relationships
with large multi-hospital chains and buying groups
Dtffu Sillt, jccout nprmautin ia tai atilalf rarficti dtftrtmiat, mitwi lapartat tntara tl tht urn "Uauaiiia" cltaial
tatlfur IU nittmtr Or. Trot turn. Oinctor if CUaiul Ltbtntttiu it tbt ntnnitf tl Wliaatia Bufitil la tttHm. Sbipmiau
tl -Hauuilia, • tntpti ta Ugh-Hltat UtUai if tint at Haw totf/ ttaiit, ttfia ia Ou fill.
-------
Thli segment includes photographic products tad systems tot printing, engineering reproduction, data
recording, and miemgnphle markets; products for electronic circuits; electronic components, including
connectors and microelectronic packages; information storage media for the milt, video, tad data markets;
finishes tor the automotive tad other industries; nonstick coatings; analytical instruments for research ana
industrial process monitoring; building materials; eiplosives; and sporting goods, including Remington
sporting firearms and ammunition.
INDUSTRIAL AND CONSUMER PRODUCTS: Business units,
technologies, and products were realigned to better meet needs of
global markets for electronic, imaging, and automotive products.
Aftv-tu
Optima*
MM iiir UN
• Restated to include
113 million charge for
Early Retirement
Program
Tear in Review Businesses in this segment were re-
organized to Identify them more closely with the global
markets they serve
ElectronicsAJolnt venture. BTtD Technologies Ltd.
was formed with British Telecommunications pic. to pro-
duce optoelectronic components for flber optic systems
used In telecommunications and data communication.
During the year, the company acquired Tau Labora-
tories Inc of Poughkeepsie. N Y.. the largest U S mer-
chant manufacturer of photomask products used by
the semiconductor industry to make integrated cir-
cuits The company also purchased the assets of Elite
Circuits. Inc. of San Diego. Calif., a producer of molded
circuit Interconnects, and the ceramic packaging assets
of Bourns Inc.. of Riverside. Calif
The opening in 1986 of the previously announced
Research Triangle Park facility near Raleigh. N.C. and a
technical center In Yokohama, Japan, expanded the oom-
paoyfe electronics research and development capability
while providing a major advance in customer service
Philips and Du Pont Optical Company (PDO). began
operation of a world-scale compact disc plant at Kings
Mountain. N.C PDO also established a smaller compact
disc venture with STET. the state-owned telecom-
munications company In Italy, and announced plans to
convert a vinyl record and cassette plant into a com-
pact disc facility at Louvters. France.
Imaging Systems To accelerate Its development of elec-
tronic Imaging technology, the company purchased mi-
nority equity positions in Perceptive Systems Inc.. a
Houston. Texas, digital imaging firm, and In ImaglTez
Inc.. a Nashua. N H. manufacturer of electronic Imag-
ing systems. In addition, an agreement was signed with
Xerox Corporation for Joint development of an electro-
photographic color proofing system.
Automotive Products The company purchased the
assets of Ford Motor Company* North American auto-
motive paint operations, including Ford's Mt Clemens.
Mich. paint plant A facility under construction in
Kansas City. Mo. will enable the company to paint and
supply complete front and back automotive sub-assem-
blies, called fascia, to General Motors Laboratories for
full-scale automobile coatings applications and engi-
neering polymers will open In 1987 In Troy. Mich.
Fabricated Products The "Teflon' coatings business
was strengthened by the introduction of a superior new
nonstick coating for cookware, -Silver-Stone SUPRA.'
The company signed an agreement with Schock & Co. of
West Germany to manufacture 'Corlan' building mate-
rials for the European market.
i Segment sales were $2.8 billion, up 2
percent from 1985. Prices wen up 6 percent, partly
offset by a 4 percent decline In volume.
After-tax operating Income was $189 million, down 7
percent from 1985. primarily due to decreased demand
for some domestic automotive products, costs associated
with BT4D Technologies, and the Impact of petroleum
industry spending cuts on maintenance finishes. De-
clines were partly offset by higher specialty products
earnings, particularly for "Corlan* building products
and 'SllverStone* *""* Teflon* flninhnn, *nd by improve-
ment In electronic products and printing systems. The
segment also benefited from gains associated with the
withdrawal from the commercial propellants business.
Capital Sipenditures Capital expenditures were 1263
million versus $257 million In 1985. Major projects
Included the auto fl""*!* painting facility in gflngfla City
and completion of the Yokohama technical center. Addi-
tional expenditures were made for the Ford and Tau
Laboratories acquisitions, and the BT&D and PDO
Joint ventures.
Outlook Despite current weakness in the electronics
Industry, the electronics business Is well positioned
with Its new research and development and manufac-
turing facilities to realize substantial worldwide
growth In areas of rapid technological change such as
data and entertainment storage media Imaging sys-
tems should benefit from new product Introductions.
and penetration of the worldwide automotive Industry
should increase as the company aligns its technologies
and resources to meet growing demands
tttirt Ttihn
-------
Du Pont has the world's most extensive family of man-nude fiber products, with leading positions in tS»
markets served. The segment includes t broadly diversified mix of speeitity fibers serving end uses
ranging from high-strength composites to protective appanl, packaging, tad tetin sportswear. It also
include* high-volume fibers far apparel and home fabrics, carpeting, and industrial applications. These
products an sold directly to the textile and other industries for processing into products used in coniuat*
and industrial markets.
FIBERS: An outstanding year was marked by quality leadership, productivity
improvement, reduced costs, and strong demand In many markets.
M.1 MJ MJ
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Restated to include
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Air In Jtorieir Continuing focus on quality improve-
ment contributed to significant increases in productiv-
ity, development of new customer partnerships, and
advances In product quality that led to an outstanding
performance for the segment Major Investments In ad-
vanced technology facilitated direct electronic link-ups
with many customers' plants to speed flow of informa-
tion about product requirements, specifications.
quality, and shipping. Additionally, hundreds of the
company* production employees learned firsthand at
customers' plants the Importance of flber quality and
put that Insight to work in their dally Job activities
Carpet fibers performed at excellent levels Strong
overall demand was complemented by the U S Introduc-
tion of Du Font-certified "Stalnmaster" carpet, using the
largest advertising and promotion campaign in the Indus-
trys history. In commercial carpets, sales expanded
strongly for Du Font-approved •Antran Precedent" car-
pet which provides exceptional soil and stain release
and superior texture retention In high-traffic areas.
Performance of apparel fibers Improved, but con-
tinued to be negatively impacted by the growth of Im-
ports. "Lycra* spandex continued as the preeminent
elastomerlc flber worldwide in hosiery, swlmwear. and
a broad range of actlvewear markets Fiber-fill products
and Du Font-certified "Thermal* and "Coolmax" fabrics
of Du Pont polyester filled special market niches for
thermal Insulation and warm-weather comfort in pre-
mium sportswear.
Specialty products such as ' Kevlar" and "Nomex'
aramld fibers and •Tyvek" spunbonded olefln, which
serve many Industrial markets, experienced significant
worldwide growth In volume and earnings. Fueled by
economic expansion and new end-use applications. For
example. "Kevlar* has found widespread application in
Japan. Europe, and the United States as a replacement
for asbestos in such key end uses as automotive brakes
and clutches, gaskets, and sealants •Tyvek" continues
In high demand in all world markets in a variety of
uses ranging from overnight courier envelopes to air
infiltration barriers used to improve efficiency of home
insulation
A new composites business organization combines
expertise in polymers and fibers in the development of
new advanced materials systems for aerospace, de-
fense, and automotive applications. Department of De-
fense research contracts obtained during the year will
enable the company to participate In the development
tary aircraft, technology that ultimately wUl be ex-
panded for use In commercial aircraft and other r*u
Performance Segment sales were 14 8 billion in l.-5c.
up 7 percent from 1985, principally as the resu.:.:
higher volume In carpet and specialty fibers. V;:_r;
was up 5 percent, and worldwide U S. dollar-*;-"^*:
selling prices were up 2 percent, reflecting the T=^_-
dollar overseas. Domestic selling prices were ^:T: 1
percent.
After-tax operating Income was 1542 mill;;- r.r-
than double 1985. The Improvement Is attribute.- -
business growth, cost reductions, strong Interim ~=.
results, and a more favorable product mix. Sfp=r~
results also include gains from the sale of tt; • =*&.-
and U S.-based "Typar" businesses in Decent
Capital Sipeaditures Capital expenditures T=> —
million, compared with 1351 million in the ;:.- ^-~
Expendltures were made primarily for pro;?:-1 -
nounced in 1985. including a new facility - "—*•-
bourg to produce "Tyvek". a plant In May
-------
Thii segment mm t wide spectrum at industries, Including packaging, transportation, chemictl
processing, electrictl and electronics, piper, tad textile, with a diversified product Oat Out includes
plastic resins, elastomers, films, membranes, and fabricated products.
POLYMERS: New products for automotive, industrial,
construction, and packaging industries, supported by cost and
productivity improvements, resulted in good performance and
a positive outlook.
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Restated to include
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Early Retirement
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Jtar in Jbvfar The segment had good results In 1986
because of new product introductions, growth of spe-
cialty markets, cost reduction and productivity im-
provements, strengthened International results, and a
greater focus on customers
Mora than 125 new or Improved products were In-
troduced In 1986 Examples include "ftrylon' polyary-
late resin, a new generic engineering polymer with
broad applications, "Valan* cable Jacketing, a new win
insulation classified by Underwriters Laboratories as
low-smoke- and low-flame-producing; new adherable
grades of "Mylar" polyester film for reprographic ap-
plications; high-performance grades of "Surlyn"
lonomer for industrial and pyk^ng applications, and
a hydrogen gas separator, the first of a series of gas
and liquid separator systems based on proprietary
polymer membranes.
Demand for products In the automotive. Industrial.
and construction Industries was strong, ftrylon," In-
troduced In October, has excellent heat resistance.
weatherabillty. and dimensional stability, and Is well
positioned for electrical electronic, and appliance ap-
plications Market interest in this new product Is high.
Significant growth In the packaging Industry had an
impact on segment results Coated 'Mylar* film is now
being used for the lid of frozen entrees suitable for
microwave cooking, and •Surlyn* lonomer resins con-
tinued rapid penetration In snack food and convenience
meal products. "Bynel." a family of coextrudable ad-
hesive resins. Is finding Increased application as the
binder for multi-layer structures that are replacing
metal cans and glass bottles •Selar" polymers have
excellent barriers to oxygen and solvents and an being
Introduced into glass and metal replacement markets
t Segment sales totaled 13 7 billion in 1986.
up 8 percent from 1985 Volume was up 4 percent, and
prices were up 4 percent mainly reflecting higher U S
dollar-equivalent selling prices in overseas markets
due to the weaker dollar
After-tax operating Income for this segment was
1266 million In 1986. up 54 percent from 1985 Engi-
neering polymers made a substantial contribution to
this performance with significant increases in volume
and earnings Earnings improvements also were
achieved in the elastomers and ethylene-based
polymers businesses, netably packaging and Industrial
products, mainly as a result of lower costs. High-
performance films and fluoroproducts contributed to
segment performance, despite a slowdown In the elec-
tronics Industry
Capital Sipenditures Capital expenditures were 1399
million in 1986, compared with 1392 million In 1985.
Major projects Included the expansion of fluonpolymer
and fluoromonomer (acuities and a new "Vlton* fluoro-
elastomers plant at Dordrecht, the Netherlands; expan-
sion of "Mylar* capacity In Luxembourg; a major facil-
ity for reducing energy costs at the Maydown.
Northern Inland, site; expansion of market develop-
ment capacity at Chattanooga. Tena. for 'Bexloy* auto-
motive engineering resins and "Arylon"; and expansion
of high-performance fli™ capacity at Clrcleville. Ohio.
On too* Growth is anticipated for the segment, despite
weakness In certain sectors of the domestic economy
and the uncertain outlook for energy and feedstock
costs. The driving forces of cost quality, functionality.
and performance assure ongoing replacement of tradi-
tional materials with polymer products. Continued
focus on both domestic and International markets
should open up new market opportunities in flexible
and rigid rafflrafl1ngi electrical and electronic, and gas
and liquid separation applications.
tvtm Sftttiimtcdt. muM
-------
Agricultunl product! businesses include worldwide manufacture tad silt of fungicides, heroicides, ua
insecticides for crop protection and products tor Industrie! weed control. Industrie! cbemicsJs comprise t
wide rafe of commodity md specialty products such is white pigments, organic chemiesls, tluoro-
chemictls, petroleum additives, mineral acids, and other inorganics. These ate used mainly in the
construction, transportation, petroleum, agricultural, piper, and textile industries.
AGRICULTURAL AND INDUSTRIAL CHEMICALS: A
strong new role in the corn herbicide market and continued growth
of the white pigments business highlighted the year.
l*.f M.4 IM
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Aftu-IU
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•Restated to include
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losi on restructuring of
Investments and Early
Retirement Program
lear la Review In 1986. Du Pont registered eight new
agricultural products, a record for the industry All are
based on proprietary chemistry — "Classic." "Canopy.'
and 'Gemini' soybean herbicides. "Ally' and 'Finesse'
cereal herbicides, and "Escort* Industrial weed control
herbicide, registered In the United States, and "Punch"
and 'Nustar" fungicides in France and parts of Latin
America. All were well accepted and should contribute
substantially to the agricultural products business.
The acquisition of the U S. crop protection assets of
Shell Agricultural Chemical Company gives Du Pont a
strong position in the U S. corn herbicide market with
•Blades.' a leading corn herbicide, and strengthens Its
position in the Insecticide market. The company is al-
ready well established in the soybean, wheat, fruit.
vegetable, and industrial weed control markets
Du Pont also acquired a 50 percent Interest In Nor-
dlsk Alkali Blokemi A/S. a leading distributor of crop
protection products In Scandinavia, to strengthen its
position In key International markets.
In Industrial chemicals, the whits pigments busi-
ness had Its third successive year of record sales To
meet Increasing needs of its customers around the
world, the company announced plans to locate plants
In the growing Far East and South American markets
During the year. Du Pont Japan Ltd. announced plans
to build a 'Krytoz' Quorocarbon lubricant plant In
Utsunomlya to supply growing demands in the elec-
tronics market Construction of the Du Pont Canada
hydrogen peroxide plant at Maltland. Ontario, is on
schedule to meet the needs of paper market customers
for pulp bleaching agents.
Efforts to streamline the segment^ operations In-
cluded the sale of the sodium silicates business Also.
certain 'Kel-Chlor.' chlorocarbons. and chloralkall fa-
cilities at the Corpus Christ!. Texas, plant wen shut
down and are In the process of being dismantled as
favorable long-term supply contracts for intermediates
for "Freon' fluorocarbons were negotiated.
Performance Sales for 1986 were $3 4 billion, about
equal to 1985. reflecting a 2 percent Increase In prices.
offset by a 2 percent decline in volume, due to restruc-
turing and discontinuance of certain businesses
After-tax operating Income was 1241 million, com-
pared with a loss of *33 million in 1985. The Increase
Is attributable to continued strong performance In
white pigments, and Improved performance for spe-
cialty chemicals. "Freon* fluorocarbons. and industrial
chemicals Agricultural products earnings were also up
despite continued weakness in the domestic farm econ-
omy, due to strong International sales and excellent
market acceptance of new products. The segment also
benefited from lower fixed costs due to restructuring In
1985 of ethylene and methanol operations
Results for 1986 Include charges associated with the
dismantlement of the facilities at Corpus Christ!, dis-
cussed previously, partly offset by gains from the sale
of the company* 50 percent interest in Condea Chemie
GmbH, a German *
-------
Upstream operations include exploration, development, tad induction at crude ait ad nttunl gee.
exploration activities in contacted worldwide. Crude oil is produced in toe United States, Canada, tne
United Kingdom, Bonny, the Setherlands, Dubai, Egypt, tad Indonesia. Sttnnl get i» eold in the
United States, Canada, too United Kingdom, end Sonny, primarily to companies tor distribution to
residential end industrial customers end to electric utilities.
PETROLEUM EXPLORATION AND PRODUCTION:
Projects to strengthen the company* position long-term continued
while some programs were curtailed in response to price declines.
MtiMnbiBSilM
111.1 I1M IM
MUM
IIM uar KK>
M 99 M
• Restated to include
114 million credit for
Early Retirement
Program
tear In Beviow Exploration and development programs
wen cut back in 1986 because of the sharp decline in
crude oil and domestic natural gas prices However.
work continued on projects that remain attractive at
currant costs and prices and will place the company
In a strong position as prices improve In interna-
tional upstream activities during the year, explora-
tory acreage was acquired in Norway, the United
Klngdoa Ecuador. Australia. Angola, and Somalia. In
the United States, the company obtained eight tracts
offshore Louisiana. Also, an agreement for a joint do-
mestic exploration venture was signed with Nippon
Mining Company.
In Egypts Western Desert, four additional discov-
eries were made. In the United Kingdom, the company
announced an onshore oil discovery, favorable results
from an onshore appraisal well and successful ap-
praisals of two earlier discoveries in the North Sea.
In the United States, a gas discovery was reported
in California, and oil discoveries were made offshore
Louisiana on Green Canyon Block 228, and In Utah.
Production commenced In the Ula Field, offshore
Norway, in the Kepiting Field, offshore Indonesia, and
In the Salam Field In the Khalda concession of Egypts
Western Desert. In the United Kingdom sector of the
North Sea. the company began development of three
natural gas fields that are expected to supply 5 percent
of Brttalns natural gas needs by the early 1990s.
In the Gulf of Mexico, a new field and two additional
production platforms wen brought onstream. and an-
other field Is scheduled to begin production in early
1987 An engineering contract was awarded for a float-
ing tension-leg production platform for the deep-water
Green Canyon Block 184. A decision was made to sus-
pend temporarily production at the Milne Point Field in
Alaska until crude oil price levels Improve
Performance Combined revenues for the Petroleum Ex-
ploration and Production segment and the Petroleum
Refining. Marketing and Transportation segment wen
19 8 billion in 1986.24 percent lower than in 1985 as a
result of lower prices
The Petroleum Exploration and Production segment
recorded an after-tax operating loss of $59 million.
compared with Income of 1324 million In 198S Results
for 1986 Include a benefit from the adjustment of
prior-year tax provisions partly offset by the write-off
of an Investment In a petroleum concession In the Gulf
of Suez. Losses In the United States totaled 1104 mil-
lion, compared with Income of 1151 million In 1985.
reflecting lower production Income caused by substan-
tially lower prices.
The company's crude oil and condensate production
in the United States averaged 113.354 barrels dally, up
3 percent from 1985. The average selling price of the
company v domestic crude oil and condensate was
113 86 per barrel versus *2S 89 per barrel In 1985.
Natural gas deliveries from leases (befon removal of
natural gas liquids) In the United States averaged 678
million cubic feet dally In 1986. up 7 percent from 1988.
The gas sold for an average of SL81 per thousand cubic
feet, compared with 12.49 in 1985.
Income from International operations decreased
1128 million to 145 million, mainly due to lower prices.
International crude oil and condensate production
averaged 308.715 barrels daily, up slightly from 1985.
reflecting Increases in the North Sea and other produc-
ing anas, nearly offset by the cessation of operations
in Libya In June Natural gas deliveries Increased 25
percent to 274 million cubic feet dally in 1986. reflect-
ing Increased production from North Sea fields.
Capital expenditures Capital expenditures were 1781
million, compared with 11.113 million in 1985. Major
U S. expenditures were for offshore development pro-
jects In the Gulf of Mexico and development drilling in
onshore fields Major International expenditures In-
cluded the further development of the Southern Basin
gas and Statfjord fields in the North Sea and the S.W
Fatah Field In Dubai and new development of the
Khalda concession In Egypt
OutlooM Prospects for earnings In 1987 are heavily
dependent on petroleum price levels Exploration and
development programs are based on the assumption of
continued depressed prices in the short-term and sub-
stantial price improvement in the long-term
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DowoMtnam letiritiu ianlvt applying crude? oil, oitnnl gas, ana otiur Mdstoot to tat company t
nttnuiu ud attvtl fit proctssing plants; manufacturing high-value, high-quality petroleum products;
ud distributing OHM products to coapuy facilities tad to i wide witty of distrieuton ud consumers.
fetnlnm products an sold mainly in the United States ud northwestern Europe.
PETROLEUM REFINING, MARKETING AND
TRANSPORTATION: Competitive refining capability, combined with
expansion of aggressive marketing, resulted in strong performance.
Afia-iu
1900
M u at
•Restated to Include
113 million credit for
Early Retirement
Program
You in Xeriew The strong performance of the com-
pany* downstream operations continued In 1986. par-
ticularly during the first half of the year
A number of projects to Improve the companyB com-
petitive position were completed In 1986. The start-up
of the fluid catalytic cracking unit at the Humber refin-
ery In the United Kingdom enables production of larger
volumes of gasoline and heating oil from less expensive
feedstocks. A new calciner at the Lake Charles. La..
refinery started producing finished coke for use in the
manufacture of graphite electrodes. The completion of
several smaller projects at both the Lake Charles and
Fonca City, Okla. refineries has increased the com-
pany* capability to process additional lower-cost
sour crudes.
Production of natural gas liquids for use as fuels
and chemical feedstocks began at the new company-
operated natural gas processing plant in the San Juan
Basin of northwestern New Mexico. This facility, one of
the nations largest, is a Joint venture with Tenneco
More than 300 miles of pipeline and other related
assets wen acquired to strengthen the company*
crude oil supply and product distribution network in
the Rocky Mountain area.
An aggressive marketing expansion in the United
States continued in 1986 The number of Conoco-
branded retail outlets increased by nearly 500 to a
total of approximately 5.400 This expansion was sup-
ported by a comprehensive advertising and merchan-
dising program to promote the company's •Powerscrub"
detergent gasoline additive and by a drive to increase
the number of Conoco credit card holders.
In Europe, the company acquired 32 gasoline sta-
tions at supermarket sites in northern West Germany
as part of a continuing program to Increase selectively
the company? European retail gasoline market share.
A successful campaign boosted unleaded gasoline sales
to 89 percent of the companyB total gasoline volume in
West Germany, and marketing of this new product com-
menced In Denmark and Sweden The company signifi-
cantly Increased Its Jet fuel sales in the United Kingdom
In 1986. following its entry into the market In 1985
fortoTttunco After-tax operating income was $414 mil-
lion, up SI percent from 1985. reflecting improved re-
fined product margins and higher sales volumes. The
segment also benefited from an adjustment of prior-year
tax provisions related to international operations.
Income In the United States totaled 1184 million, up
3 percent from 1985. primarily reflecting higher refined
product volumes and Improvements in efficiency. Sales
volumes of refined products in the United States In-
creased to 452.983 barrels daily from 425.646 barrels
daily in 1985. largely as a result of strong demand for
distillates and gasoline.
Crude oil and other feedstocks processed at the com-
pany's refineries In the United States increased 4 per-
cent to 377.421 barrels dally. Company crude oil
capacity utilization In 1986 was 92 percent, compared
with 83 percent for toe Industry. The average cost of
crude oil and condensate processed at the companyB
domestic refineries was 114.36 per barrel down from
126 83 per barrel In 1985
Income from International operations totaled $230
million, up from 197 million In 1985 The increase
mainly reflects higher refined product margins and
volumes.
Sales volumes of International refined products In-
creased to 237126 barrels per day. up 10 percent from
1985. mainly due to increased demand in the United
Kingdom and West Germany Crude oil and other
feedstocks processed at the company* two European
refineries Increased 10 percent to 190.188 barrels daily.
Capital Eipendituns Capital expenditures were 1233
million, compared with 1289 million In 1985 Major U S.
expenditures Included those for the completion of the
San Juan natural gas processing plant and the coke
calciner at the Lake Charles refinery. Major Interna-
tional expenditures Included those for the completion
of the fluid catalytic cracker at Humber and the ac-
quisition of marketing outlets In West Germany.
Outlook Downstream operations will be strongly Influ-
enced by worldwide petroleum markets, presently
characterized by keen competition and volatility in crude
oil and petroleum product prices. The company expects to
continue to be a strong competitor because of its sophisti-
cated refineries and effluent, innovative marketing
17
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........ ......... --- ..
OpertOont count pnaapuif 01 aumag JMUU CMU,
urf Giuda, and metallurgical coal, uld to itetl producers in Uu United Statei and enratu.
COAL: Significant acquisitions of low-sulfur coal reserves and con-
tinued productivity accomplishments through longwall mining
enhanced ability to meet market needs effectively.
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Tut in Jtori«r The company made two important
property acquisitions In 1986. Both advanced the goals
of obtaining a significant reserve base of low-sulfur
coal and enhancing the company* ability to serve the
growing Southeast and Midwest markets
In July, the company acquired Sierra Coal Company
from Utah International Inc. Sierra has 2 6 million
tons per year of production capacity and a reserve
base of almost 250 million tons of medium- to low-
sulfur coal primarily in eastern Kentucky
In November, the acquisition of the Inland Steel Coal
Company was completed A low-sulfur coal reserve
base of almost 300 million tons and two large under
ground mines In southern Illinois were acquired, along
with a contract to supply Inland Steel with high-
volatile metallurgical coal and steam coal for Its steel
manufacturing facilities at the Indiana Harbor Works
In East Chicago. Ind. Additional agreements were nego-
tiated for steam and metallurgical coal sales from the
properties. Present production capacity of the two
mines Is 3.5 million tons per year.
In Its first full year of production, the Bailey Mine In
southwestern Pennsylvania exceeded forecasts for ton-
nage and productivity. Total production from the mine
In 1986 was 31 million tons. A second longwall mining
system was Installed In June, and new long-term con-
tracts for 1S million tons per year wen signed during
the year
The development of the Buchanan Mine in Buchanan
County. Va., continued throughout the year. Production
of 940.000 tons of high-quality, low-volatile metal-
lurgical coal was sold to both domestic and export
customers. A longwall mining system will be installed
during the first quarter of 1987. and full production of
2 2 million tons per year should be achieved by the
first quarter of 1988.
Negotiations are in progress with the Environmental
Protection Agency and the Department of Energy to
demonstrate flue gas humldiflcaUon and 'Coolslde" sor-
bent Injection technology on a full-scale utility boiler at
the Ohio Edison Edgewater Station. The technology
demonstrates the cost-effective reduction of sulfur diox-
ide emissions for burning high-sulfur coal In retrofit
utility applications
ferformanet Sales in 1986 were II5 billion, and after-
tax operating income was 1130 million, both essentially
unchanged from 198S.
Production volumes totaled 41 million tons, an In-
crease of 3 percent versus 198S. Steam coal production
was up 6 percent to 34 million tons, and metallurgical
coal output decreased 13 percent to 7 million tons.
CtyiUI Sxpesditum Capital expenditures totaled
1136 million, compared with 1129 million In 1983. Ma-
jor expenditures Included the continued development of
the Buchanan Mine Additional expenditures for the
acquisition of the Sierra Coal Company and the Inland
Steel Coal Company totaled 1155 million.
Outlook Demand for U 3. coal In 1987 is expected to
Increase slightly. The two-year pattern of Inventory
drawdowns Is forecast to change In 1987 when both
steam and metallurgical coal consumers are expected
to increase their stockpiles as a precaution against a
supply disruption In early 1988.
Exports of U.S. coal are expected to decline slightly
because of reduced demand from PJUUUHM electric util-
ities and Increased competition from other coal-produc-
ing countries.
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ATTACHMENT B
MAJOR PLANT SITES AND PRODUCTS OP DU PONT
-------
wr tar i4r ur
CHEMICAL & SPECIALTY
PRODUCTS
MAJOR GLOBAL SITES
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OHUdCAL AND SPECIALTY PRODUCTS
MAsIOB GLOBAL SITES AMD PRIHOIBAL PRODUCTS
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Finishes. -SllvorSlona' coatlnfi. com-
poundliif ream. -UBpsr
engineered putt. -Kalra* fluoro-
i)
' -I Ufll AMBBIOA
I m BAM
ftufflaik
Copenhagen
E B. Ow BUT
Hannover
llunsur
Ncu Issnburf
Uenirop
rrasce
Benlcarlo
BwltawlaU
Cernay
Chalampe
Louvurs
Pail
!Ulf
Bolzano
Rome
luiabeuf
Conurn
Hespennfc
Bsthsiluds
Dordnchi
* Henopnboacb
Oosurbout
Crap protacuoo chemicals
Optical dues
Crop praucUoD cnenlcals
Medical i-ray awl graphic aria flloi.
alflctronlc producu
Nylon and -Duron* polyaoir ntan.
lyu/T nylon realm
Connociara. ibcmnlo nauriala
Crap proucUon dumlcali
Nylon Inunudlaut
Optical discs
OlaCDOMcliMNaianliaiid
OdlK Uajiua
Blackbura
Bristol
HikMa
Ipswich
Haydmn.
Londonderry
Suvsaaje
nnlsbes
Rajlonal IwadQiianen. ouiuuur
semes eentsr
Optical discs
Connscum
•Aldyl-polyethylene pipe
OptnlsciFonlc cooponsnts
Haopnne and -HypataT
lyntheuo rubber. 'Lycra' apu-
Hex noer. -Ksdar* anold fiber
(under construction)
Electronic matsrlals
Arfutlna
Bsraiataiul
ysrcsdea
Nylon flbere -Freon* nuorocarbon.
•Aldyr pipe, entuserlnf poly-
mers. Inner polypropylene Dim
Nylon apparel and 'Lycra' spandsi
fibers, connectors
.AutnUa
Sydney
Multiple
Puerto Uadryn riuonpar mill
InsU
Baflneerlnf plastics (under
constnicUon)
Graphic arts flnlsblnf. connscutrs.
electronic materials
"Freon" nuorocarbontCrop protscuon
VauPraU)
1 I Mm AslUIOA
Hulupto
Crap protection chemicals
Optical discs
•yylar'and-Cronar'poly-
ester aims, lypar' spunbondsd
polypropylene 'Hylnl' polyester
elastomer, lyvek' spunbonosd
olsfln (under oonslrucUon)
•Oeinn' acsul resin. -Lycra" span-
dex fiber. •Fnon* nuorocarbon.
-IMloo- nuoropolymer, -Vitan'
Ajai
Kingston
North Bay
Sarnla
Whltby
nnlsbes
Nylon apparel, carpel and industrial
fibers
Hyton Inisrinedlaus. enflnserlnf
polyowrs. hydrogen peroxide.
•Lycra1 spandei fiber, •moo*
nuorocarbon
Eiploslves
•Sclair' polyetbylene realm
•Daruf nyton Him. 'Wxar' plastic
Barnnoullls
nuorspar mine/mill
'Lycra' epsjidex fiber, etocuonle
Draducu (iiodsr oonstmdlon)
nmsbes
Crop protection chemicals
Gasoline additives
Vital lutes
(SMmapfolbwlnipaie)
Cuernaiaca
La Linda
Urma
Ualamoras
Msm».Dr
Honterrqr
aullanin
Tamplco
Connectors
Audio praducts. Ylrlnomagnetlr tape
Pluorepar mine/mill
Crop protscllon chemicals
Hydrojsn fluorlds
Crop protection chemicals. tn|U)str-
ln| polymere. finlsbss. •Pnon*
nuoNcarbon, pbarmaceutlcala
Nylon. -Lycra* ipsodex and poly-
ssisr fibers
Sodium cyanide (under oonstnwUon)
WhIM ptfmeiils
Bxploelvas
Cblba
Kawasaki
Ubaiahloa
Najoya
Otaks
Sblfa
Shuolzu
Total
Toyama
Uuunomlya
Itokahama
•siss
Seoul
Cabuyao
Bbujepen
Juronf
Nelll
UnfTknf
tmaliaad
Banipoo
Crop pnucuon cbemicals
Exploaivas
Explosives
Buunediol. -Freon' nuorocarbon
Naopnne eymheuc rubber
Pyramelliuc dianbydrlde
•Hytrel' polyester elastomer
•Surlyn' nnorner -Nucrel* acid
copolymera •Elvax'copolymers
•Lycra' spandei fiber
•Preon' nuorocarbon 'Teflon'fluoro
polymer i-ray and -Kisun' pbo-
umist finishuu]
•Kaplan' polyimioe film
'Conan' buildinj producu
Eiuoneenni polymers. 'Vesper enp
neerinf plastic. •Kalrai* Ouoro
elaauour 'Krytoi' nuorocarbon
lubricant
Customer service and research cen-
ter connectors and electronic
materials
Connectors
Crop protection chemicals
Connectors
Connectors i ray finishing
Crop prelection chemicals
Crop prauciion chemicals
-------
"1/V£S3« ' «T£g
« Yr»^L^^r\*£l#
— « P55^! n-^X;
CHEMICAL & SPECIALTY
PRODUCTS
7« ep
***
MAJOR DOMESTIC SITES
-------
CHEMICAL A1
MAJOB BOMB
MuucbiHlU
1 N Billsrlca
2 Bosion
Cennactlsit
3 Bridgeport
4 Newtown
•a> Ttark
S Garden City
6 PoufbkeepGie
7 Ilion
6 Rochester
10 Buffalo
BesiJaiaef
11 Gibbsuwn
12 Deepwaur
13 Linden
14 Parlin
IS Pompum Lakas
reusyliaale
16 Philadelphia
17 Glenoldan
18 Towanda
19 Camp Hill
20 EmicsnUe
21 New
Cumberland
22 Claarfleld
Delaware
23 Sune-Haskell
Lab
24 Glufow
25 Edgemoor
IB SPECIALTY PRODUCTS
STIC SITES AMD PBIHCTEAL
AAffluolUoo
Ccnirlfuies
PharmacauUcalB
Semiconductor i>*"*^***i«
firearms
Graphic an* and enfuuennj rapro
mm
•Terathana* polyatnar (lyeou. so-
dium, electronic maurlals
•Conan* bulHln| products, •Tndlar*
polyvlnyl Ouortde and adhaalvss
Sulfunc and mine adds, sodium
nitrite
Gasollns addnivee fluore-
cheDlcal refruerutfl. surfac
tints polymers and lubricants
aromatic Intermediates utnsr BUT*
factanta. •*•**•' complazas
Sulfunc acid
Graphic arts and i-ray fllms.
•SUverSuns* coaUnfs
BlpkWlVBB
finishes research
PhotorsBlst fllms and i-ray Intenslfy-
uu] screens
Connector systtoa HI)
Connecton
Cc mature
Connectors
BesaaKh
-aca* and "rjunsnalnn' Instrumente
and rainminyiMm. •Peroaasp* per-
mealars, analytical Immimenui
PBODUCTS
26 Experimental
Station.
Wilmington
27 Pencader.
Newark
28 TralsePark.
Wllmlrujton
29 Willow Bank.
Newport
SO Chestnut Run.
Wilmington
31 Bafla Run.
Newark
32 Holly Run.
Newport
33 Sealord
MlcUfu
34 Flint
SB MonUfue
38 Mount Clemens
37 Troy
lULula
38 BIPaso
39 Seneca, Morris
Indians
40 EaslCnlcato
4J Xnkooo
•antacky
42 LouisvUIS
OUs
43 Clrclavllle
44 Toledo
46 Cleveland
•ftatVlffUa
46 Fwaenbunj
47 llaruniburf
48 Bella
Rssaucb
•Vaaper enjlneered parta. advanced
conpoBll68
"Kalrez' enfmeand pana
"Lucita" shaeUnf
ChfoniuD dioiuto
Nylon fiber
Finishes
•Freon' nuorocarbons
Finishes
Automotive HQ, finishes
development laboratory
Crop prolscuon chemicals
Bxploslvaa
"Ludox* colloidal alttca
fiamirfliuliifftep maumala
Neoprana synthetic rubber. 'Freon'
fluorocaitons
•Mylar* polyester and 'Kapton*
polyumdeftlma
FinlahaB
"ZHcloo* zinc ACUBootun oblorlds
•Zylsl* nylon. -Dalrin* aceul and
•Rynlte* polyester en(1nearln|
polymer resins. Tenon' fluoro-
polymera. •Luclte* acrylic resins
Explosives
Crap praucuve chemicals.
fomaldBbydB
Virginia
49 Richmond 'Tyvek* spunbonded olafin. 'Kevlar*
and 'Nomei' aramld fibere,
•Mylar* polyester film
SO MarUnsnllB Nylon fiber
61 Waynesboro 'Orion* acrylic. "Lycra* epandei and
nylnnflbtn
62 Front Royal Finishes
•sittOsnUns
63 Klnaton 'Dacroa' polyeslor fiber
64 Research Electronics research
Triangle Park.
Durham
66 Faystuvllls 'Bulaciu* safety ahesllruj. 'Naflon*
ion sxchan|e membranes
66 WllmuujUMi 'Dacron' polyeslsr fiber, polyasuir
Intermediates
67 Klnja Mountain Compact discs
61 Brevard X-ray film
69 Chauanoofa Nylon fiber. -Arylon* polyarylata
resin
60 Old Hickory •Sontara* apunlaced products, poly-
esiar Interaedlatea
61 New Johnson While pumenu)
mile
.62 Memphis Hydntfen cyanide, sodium cyanide.
methyl oalnacrylats monomera.
•Luclta' aheet
•alheacellaa
63 Savannah River US Dept of Energy
64 Camdan Nylon. •Dacran* polyasur. 'Lycra*
apaadei and 'Orion' acrylic fibers
66 Charleston 'Dacron* polyester fiber
68 Florence -Mylar* polyester Aim
Oetrlla
67 Atnens Tertlla baamlru] faclllUes
neiiia
68 Uwtay llmemteore
tietteUM
69 AjMadllla PbarmaomUcals
TO Manatl PhafmaneiiUoals, crop protection
'hflB.Krf'ff
^lafcalM
71 Mobile
Mississippi
72 De Lisle
Aruras
73 Jonesbora
74 Hazsn
78 Lonoke
InbUae
76 La Place
77 Burnslde
lues
78 Oranfe
78 Beaumont
80 Vicuna
81 Bay City
82 Corpus Cnrtstl
83 Alvu
84 La Porte
OUefceae
88 TUlia
Wsaemrl
88 Mobsrly
Ism
87 Fort Madison
68 Clinton
Oallbnb
89 Anuoch
Crop protection chemicals
Whits pifnenu
•aca* packs
Ammunition
Ammunition
Biasiomere, -Kevlar' Intermediates
Sulfunc acid
Nylon Intermediates.
etbylene polymers
Acrykmurilc -Horde!'
hydrocarbon rubber -Nypalon'
aynthstic rubber aniline
meihanol
Nylon Intermodule ethylene
polymers
Polyethylene
'Freon' nuorocarbons
Olaflna and aronuulcB
Polyvlnyl alcohol vinyl acetate
crop protection chemicals acety
Isnlc cbamicals sulfunc and
hydrofluoric acid
•AUyl' polyethylene pipe
Finishes
Finishes
Packaging Alms
Whits pi{menis>. -rreon'
nuorocarbons
-------
NORTH AMERICAN
EXPLORATION & PRODUCTION
UNDEVELOPED ACREAGE
AT DEC. 31.1986
(Thousands ol Acres)
Canada
U.S. Onshore
(Excluding Alaska)
U.S. Offshore
(Excluding Alaska)
Alaska
-------
Mr iw
CUT AHA
\«***l^u»*
nUKMGUUM
-40-
INTERNATIONAL
EXPLORATION & PRODUCTION
CONOCO OPERATING LOCATIONS
L~Z) Undeveloped Petroleum Acreage
* Active Production Operations
0 4,000
L^-^V^BVH^^^—^^^^^^_^^^^
Mites
nr
100-
r
I
IW
-------
See Map, Page 48
For Detail,
Set Map, Page
IRELAND {J33
UNITED KINGDOM
AMSTERDAM
NETHERLANDS
INTERNATIONAL
EXPLORATION & PRODUCTION
NORTH SEA/U.K. ONSHORE
CELTIC SEA OVERVIEW
I I Conoco Interest
0 100
-------
ATTACHMENT C
THE AGENDA FOR THE CORPORATE WASTE REDUCTION
SYMPOSIUM INCLUDES SEVERAL EXAMPLES OF WASTE
REDUCTION AS WELL AS BETTER APPROACHES TO
MANAGE WASTE.
-------
WASTE
REDUCTDN
DU PONT
WORKSHOPS
Workshop Session 1 Wednesday October 15,1986 1:30-3:00 P.M.
1
REDUCTION OF
AQUEOUS WASTE
Waasswater Reduction
m Uwal Fabrications
Operations
H L Marim et al PO
Savannan River
Recycle and Recovery
id Reduce AON
Aquaeui Waataa
3 M Williams PO
Sabne River
CONVERTING
BY-PRODUCTS TO
NEW PRODUCTS
Convening Dilute
HjSO4 Into Saleable
Byproducts
J W Robinson TF
Spruance
Segregation at
Non-Hazardous Carbon
Material lor Reuse
E 0 wans C&P
T D vanOometen C&P
Niagara
Fraorr* Waste
Reduction through
Mute Ac* Sato*
T W Hn C&P
0 L Morns C&P
Antioeh
NUUCTION OF
WAST* BY
RECLAMATKW
Paint Reciainfication
Pro|0ci
J M Gibbs APO
Wilmington
The Ortnn- Ingredient
' Recovery Facilities
R W Ouaries Jr PPO
Wasnington Works
Waste Recovery and
Recycle MI a Reactor/
Distillation Tram
Pfoceas
G M voiker AG
Belie
BIOTECHNOLOGY TO
DETOXIFY
In SjjuBtorectsmatKxv
PnnoptM. Practices.
and Potential Uses
C D LitcMiaM CR4D
HaskeiiLab
BKxecnnotefly in tno
C B Fhermans PO
Savannah River
BttMctmotogy to
Dana* Cyan*
Wastes
M Hanson PO
N-6537
TRACKING WASTE
FOR REDUCTION
OPPORTUNITIES
Computerization and
Tracking el Waste
Streams
H 1 Shade TF
Cooper River
Comoutenzed Tracking
System lor Large
Number ot Small Waste
Streams
H J Dorsman CR4D
Experimental Station
E 315204
Con Reductions
Through Du Pont
Control of Waste
Activities
D J Orgeron PO
Sabine River
SPECIAL PROBLEMS
IN WASTE
HANDLING
Cape Fear Drum
Control Program
C T Bl.ck PO
H 0 Oe Haas PO
Cape Fear
Strategy lor New
Disposal Capacity lor
Savannah River Plant
E L Aibenesus PD
E L Wiinne PO
Savannah River Plant
A System tar Chemical
Cleaning of Process
Contaminated
Equipment
Bruno Furini Jr PO
J P Songy PD
Pontcnanram
(ThciRM Me Keen
Room)
(Caesar Rodney
NOOM)
C
(New Ark Room)
(Now Amatol ROOM)
Workshop Session 2 Wednesday October 15,1986 3:30-5:00 P.M.
AQUEOUS WASTE
REDUCTION VIA
MEMBRANE
SEPARATION
An Overview Ou Pom's
Approach to Practical
Membrane Separation
Systems
W F Weber PPO
Glasgow
Membrane Technology
Ultrafiitration and
R A Butz a a! ENGG
E 304218
Membrane Technology
EletroryM Processed
L L Burton PPO
W G F Grot PPO
Experimental Station
MARKETING
BY-PRODUCTS
Converting Waste Iron
cnunde into a
Profitable Co*Product
A Ch«sa C&P
Chestnut Run 709
New Marketing
By-Product Streams at
T K AnanthattriShnan
C&P Louisville
HecovQty o*
By^Products ffont the
Manufacture of
G 0 Sheonerd P&EP
Brevard
REDUCING WASTE
BV CHANGING
THE PROCESS
New Process Routes
Achieve Waste
Reduction in
Manufacture ot HFPO
J R Lawson PPO
E 3536M
Waste Reduction
improvement
J C LOy APO
Moberty
DETOJQFVINa
AQUEOUS WASTE
The 'Pact" Process
towaneMier
Treatment at
ChenbefB Wortts
H w Heam Jr C&P
Chambers Works
AON .AqueOBS Waste
TnMmliini***1
B M W*ams.PO
Sabine River
NeuvwesflBon wtfi cuv
P B Budai. ENGG
Beaumont
SITE MINUMZATON
STRATEGV
General Sue waste
Minimization Plan
0 M Schwartz TF
Spruance
Strategy for Hazardous
^^
A H NckcUuS PO
veona
FeedHtoawALRus
and Put H on 1 C E
Low Level Radioactive
K Bennert NEN
Bcmed 1617) 671 8670
SPECIAL PROBLEMS
IN WASTE
HANDLING
Charactenzing and
Testing of Mixed Waste
for Volume Reduction
W M Wierzr>CKi PO
Savannan River
waste Oil Management
Drum Handling
F B Pack PPO
Florence
Recycle and
Reclamation of
Tetra Ethyl Lead
0 E Cregar C&P
Chambers Works
A
(New Ark Room)
B
(Caeaar Rodney
Room)
(Thomas Me Keen
(New Castle Room) (George Reed Room)
-------
WASTE
REDUCTION
DU PONT
WORKSHOPS
Workshop Session 3 Thursday October 16, 1986 8:30-10:00 A.M.
3
REDUCTION OF
SOLID WASTE
Novel. Modem Waste
Dewatenng Techniques
E Mayer ENGG
LOU viers- 1373
Waste Reduction in
Proieci Design
T R Bass PD
W E Ehren PD
Victoria
Reducing Wastewater
Treatment Plant Solids
E 0 Wans CAP
C Zuber CAP
Niagara
REDUCTION OF
ORGANIC WASTE
Detoxification ol
Adiponrmie Wastes
J C Caton PO
W E Ehren PD
Vcona
Modification* ol Glycol
Column Operation
N B Amory AQ
Belle
Handling Organic Wastes
via Distillation/Chill Roil
Flaker
R J Woods PO
Saftne River
ONE SITE'S BYPRODUCT •
ANOTHER SITE'S RAW
MATERIALS
Saleable CaCi2 from Waste HCI
Al Washington Works
W L Mncneil PRO
Washington Works
Use of CO, SHU Bottoms As
A Feedstock to Produce TiCI«
J E Harris C&P Corpus Chnsi
R P Bernard C&P OeLiSle
FPO • Specialty Services m
waste Reduction Activities
T S Govmdan FPO
F A Gershman FPO
Barley Mill 19 1206
REDUCTION OF WASTE
BY RECOVERY AND
RECYCLE • 1
Keviar* Solution
Recycle
G R Hamilton TF
Spruance
Reclamation and Recycle
of Unreacted TiO> and
Coke
0 H Eaanam C&P
Deusle
Extraction and Disposal
of Polynnropnenols
E A Krasovec CAP
0 H Bjrtey C&P
Beaumont
INCINERATION .
TODAY AND
TOMORROW
Incineration Technology •
Where is Ou Pont
Headed?
T A Fiscner ENGG
Louviers-1386
Gulf Coast Regional
Incineration
S H Jackson PD
Choc Bayou
Incineration of Low
Level Radioactive
Wastes
J R Buco PD
Savannah River
(Oeorg<
A
i Read Room)
B
(New Ark Room)
(Caesar Rodney
Room)
(New Amatel Room)
(New Castle Room)
Workshop Session 4 Thursday October 16, 1986 10:30-12:00 Noon
4
REDUCTION OF
SOLID WASTE
Paint wastewater
Management
F Wfltty, APO
Marshall Labs
On-Site Separation and
Treatment to Reduce
Waste
H I Shade TF
Cooper River
Reduction of Sohd
Waste and Recovery of
Valuable Materials
M Henson PD
N-6537
SOLVENT
RECOVERY
Wiped Film Evaporator
for Recovering Waste
Solvent
G f Cretekos P&EP
Towanaa
Solvent Recovery from
Paint Waste
O B Wheat PD
Savannah River 703 H
Recycling
0 E Ardary ED
Cleartieia PA
NEW TECHNOLOOY
Computer Prediction of
Gaa-Liquid-Solid Solubility
in Water
N C Scnvnet ENGG
Lowers 13S6
Controlling the Dispersion
and Coagulation ol Metal
Fines
R 0 Nelson ENGG
LOuviers 13W7S
New Methodology to Reduce
Emissions and Pollution from
Flare Stacks and Submerged
Combustion incinerators
P G GeitHum ENGG
Louwers 13W51
REDUCTION OF WASTE BY
RECOV. AND RECYCLE • II
Recovery and Disposal of
SbClj Catalyst from Freon*
Processes
v K Guota C&P
Chambers Works
Rejuvenation Technique
for Waste Carbon Using
Nitrogen and Water
A Monge PO
Pontcnanrain
Via Waste Tar Conversion
and Recovery
0 N Dike PPD
LaPorte
GETTING S'S BACK
FROM INCINERATION
Burning Waste Solvent for
Energy Recovery
R Crockett Jr APD
Flint
Vendor Built and Owned
On-Site Refuse Denved
Fuel Steam Plant
B 0 Hoffman P&EP
Towanaa
Higher Monomers Waste
Burning in Spent Acid
Recovery unit
R N Shah FPO
Belie
(New Castle Moon)
B
(George Read Room)
C
(Caesar Rodney
Room)
(Thomas Me Kean
Room)
(New Ark Room)
-------
Vendor Workshop Session 1 Thursday October 16, 1986 1:30-2:30 P.M.
INNOVATIVE
TECHNOLOGY FOR
WASTE REDUCTION • 1
Critical Fluid Systems.
Inc
Critical Fluid E«liaci.on
ot Aqueous Hazardous
Waste
CRS Sirrme. Inc
E>liacnve Recovery ol
Aqueous Ogamc
Wastes w.lh Super
Critical Liquid Carbon
BIORECLAMATION
Btosyslems. Inc
In Situ BIO reclamation
Groundwater
Technology
In situ Enhanced
Natural Degiedaiion
ol Organic Compounds
CHEMICAL ENOINEERINO
APPROACHES TO
WASTE REDUCTION
SCADA Systems
Implementation ol a
Zero Discharge Wdsie
Management System In
Ihe Punted Circuit
Boaid Indusliy
International
Technology
Waste Reduction
Ihionnh Effective
Chemical Engineering
THERMAL
DESTRUCTION OF TOXIC
WASTE • 1
G A Technologies. Inc
TiansportaMe denial
ing Bed Combustor Iw
Hazardous Waste
Destruction
Shirco Infrared
Systems
Mobile and In Plant
Inlra Red Waste
Desiiuclion The
technology and
C>|iciicnce
REDUCINO THE VOLUME
OF AQUEOUS WASTE • 1
Bechlel National. Inc
Watei Balance A Key
In Waste Minimization
Camp Dresser &
McKee. Inc
Liquid Waste Redama
lion Using Membrane
Processes
SPECIAL WASTE
HANDLING PROBLEMS
Chemical Wasle
Management. Inc
Suspending Sohds/
Sludges lor Reducing
Waste and Maniminng
Energy Recovery
Roy F Weslon. Inc
Low Temperature
Thermal Slripivng ot
Volatile Compounds
horn Sor!
WASTE REDUCTION IN
THE ELECTRONICS AND
PIGMENTS INDUSTRIES
GCA Corp
Technology Division
Waste Reduction in [he
Printed Ciicun and
Semiconductor
Manufacturing Industry
Versar. Inc
Methods lor Recovering
Usable Products in
Place ol Generatrix)
Hazardous Wasle
(Caessr Rodney
Room)
B
(George Read Room)
c
(New Ark Room)
(New Caille Room) •
(Thomas Me Kean
Room)
(New Amstel Room) (Wllllngtown Room)
Vendor Workshop Session 2 Thursday October 16, 1986 2:40-3:40 P.M.
INNOVATIVE
TECHNOLOGY FOR
WASTI REDUCTION • a
Ecology 4 Environment.
Inc
Inno/ali.'S He*
Ha/itirluus W3r.te
tieaiiiicni lechnoioo'es
Batielle
(Columbus Drv )
Eteci'oaroiKiic
Owalunng Twl.nokxjy
A Novrt Apixaacli to,
Wasrp Treatment and
Recovery
RECOVERY OF
VALUABLES FROM
WASTE
OH Materials Corp
Chemical Engineering
Appioaches lo Wasle
Cleanup and Recovery
Black & Vealch
ftecnvery of Itatjle
Material Ironi Hd/arUous
W.1SIP Usirif) Inn
F«rlianrjo
ECONOMICS OF WASTE
REDUCTION
Millelhauser Corp
Review nl Technologies
Available to Reduce
votume/Tmicily nl Oly
Sludties
Jacobs Engineering
Group. Inc
Ju-jiiic.iiiori oi Wasle
(Vxlnclirxi Pnijerls by
i>juinirhcinive OKI
nenrlil AnnlysiS
THERMAL DESTRUCTION
OF TOXIC WASTE • H
Westinghouse
Pyroplasma Oeslruclion
of Hazardous Wastes
Waste-Tech Services.
Inc
Options lor On Sue
Ha/nrdous Wasle
Thermal Oxidation
REDUCmO. TNE VOLUME
OF AOUEOU WASTE • a
Morrison A Knudson
Engineers. Inc
Slate ot Ihe Art
Techniques lor Process
Waslewaier Reduction
ERT
Reducing Vokimo nl
Waste horn Chemical
Cleaning ol Process
tqtiipmenl
REDUCINO TOXICITV OF
HAZARDOUS WASTE
Radian Corp
The Radian Cyanide
Conversion (CMC)
Process
Engineering Science.
Inc
Toxcrty Reduction
(Caesar Rodney
Room)
B
(Oeofge Read Room)
C
(New Ark Room)
D
(New Cettte Room)
(Thomas Me Kean
Room)
(New Amtlel Room)
§<
10
O33
-------
WASTE
REDUCTION
LIST OF VENDOR PRESENTATIONS
Battelle (Columbus Dlv.)
Electroacouslic Dewatering Technology -
A Novel Approach for Waste Treatment
and Recovery
Bechtel National, Inc.
Water Balance • A Key in Waste
Minimization
Blosystems, Inc.
In-situ Bio-reclamation
Black & Veatch
Recovery of Usable Material from
Hazardous Waste Using Ion Exchange
Camp Dresser & McKee, Inc.
Liquid Waste Reclamation Using
Membrane Processes
Chemical Waste Management, Inc.
Suspending Solids/Sludges for Reducing
Waste and Maximizing Energy Recovery
Critical Fluid Systems, Inc.
Critical Fluid Extraction of Aqueous
Hazardous Waste
CRS Slrrine, Inc.
Extractive Recovery of Aqueous Organic
Wastes with Super Critical Liquid Carbon
Dioxide
Ecology and Environment, Inc.
Innovative New Hazardous Waste
Treatment Technologies
Engineering-Science, Inc.
Toxicity Reduction
ERT
Reducing Volume of Waste from Chemical
Cleaning of Process Equipment
G. A. Technologies, Inc.
Transportable Circulating Bed Combustor
for Hazardous Waste Destruction
GCA Corp. Technology Division
Waste Reduction in the Printed Circuit and
Semiconductor Manufacturing Industry
Groundwater Technology, Inc.
In-situ Enhanced Natural Degredation of
Organic Compounds
International Technology Corp.
Waste Reduction through Effective
Chemical Engineering
Jacobs Engineering Group, Inc.
Justification of Waste Reduction Projects
by Comprehensive Cost-Benefit Analysis
Mittelhauser Corp.
Review of Technologies Available to
Reduce Volume/Toxicity of Oily Sludges
Morrison-Knudsen Engineers, Inc.
State of the Art Techniques for Process
Wastewater Reduction
O. H. Materials Corp.
Chemical Engineering Approaches to
Waste Cleanup and Recovery
Radian Corp.
The Radian Cyanide Conversion (CNC)
Process
SCADA Systems
Implementation of a Zero- Discharge
Waste Management System for the
Printed Circuit Board Industry
Shirco Infrared Systems
Mobile and In-Plant Infra-Red Waste
Destruction - The Technology and
Experience
Versar, Inc.
Methods for Recovering Usable Products
in Place of Generating Hazardous Waste
Waste-Tech Services, Inc.
Options for On-Site Hazardous Waste
Thermal Oxidation
Westinghouse
Pyroplasma Destruction of Hazardous
Wastes
Roy F. Weston, Inc.
Low Temperature Thermal Stripping of
Volatile Compounds from Soil
-------
Exxon Chemical Americas
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Exxon Chemical Americas
Address 13501 Katy Freeway, Houston, TX 77079
Contact Person, Title R. M. Cardillo
Telephone f (713) 870-6524
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit)
Net Worth 1985: NA
Sales 1985: $3 Billion
Major Products by Divisions
Basic Chemicals
Polymers
Solvents, Intermediates, and Specialty Products
Major Hazardous Waste Streams by Division and EPA Hazardous Waste f
Contaminated Wastewater
Amorphous Solvents
Wastewater Treatment Sludges
Number of plants which generate Hazardous Wastes 7
Location of plants which generate Hazardous Wastes
Bayway, N3; Bayonne, NJ; Baton Rouge Chemical Plant, Baton Rouge, LA;
Houston Chemical Plant, Houston, TX.; Baytown Chemical Plant, Baytown
Olefins Plant, Baytown, TX.; Mont Belvieu Plastics Plant, Mont Belvieu.
TX.
Number of Employees: Approximately 7000
Please return to: DANA DUXBURY
CENTER FDR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: MAY 4f 1987
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
Woods Hole III Questionnaire
Question I
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate waste
reduction program or plan. (Such as: guidance, goals, routine reporting
mechanisms, yearly recognition of employees, a newsletter, video, yearly
review to corporate management, technology seminars, included in performance
reviews, waste reduction project competition for capital, etc.)
If you have not previously included a copy of your corporate waste
reduction program or plan, please do so.
o Complete yearly inventory of all wastes generated
o Focus on major risks or waste volumes
o Routine stewardship to management
b) Please note how your corporation has modified or expanded its corporate
waste reduction program or plan in the past year, if indeed you have modified
or expanded it.
o Intensifying efforts to achieve waste minimization.
o Increased planning to anticipate effects of 1984 RCRA Amendments.
o Exxon has set up regional waste management teams to draft plans and
transfer technology between neighboring manufacturing units.
c) What were the leading factors that caused you to alter your waste
reduction efforts during the past year?
o High cost of waste disposal
o Future Regulatory Impact
o Significant potential liability
d) At what management level in your corporation, during the past year, were
changes, if any, made in your waste reduction program or plan?
o Plant Management
o Corporate Environmental
e) How does your corporation define waste reduction? What media and wastes
or emissions are covered in your definition?
o Waste reduction includes reduction in volume or hazard of solid
wastes, air emissions, and wastewater discharges.
RETURN BY MAY 4, 1987
Page 2
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Hedford, HA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its own specific
program or plan?
Yes, where appropriate.
g) To what level in your corporation has your waste reduction program or
plan been communicated?
Has been reviewed with the President (Exxon Chemical Americas).
h) Have you found the need for additional waste reduction expertise in the
last year? If so, new staff or consultants?
o Increased efforts at plant level.
o Temporary additional HQ effort to increase focus.
o Use of consultants on membrane separation technology.
i) Does your corporate waste reduction program or plan include goals? If
so, describe them - including the nature of the goal and the time frame in
which the goal is to be met.
Progressive reduction of untreated land disposal of solid wastes over
next 5-10 years.
j) Does each plant or Division establish its own particular goals?
Yes
k) At present, what is the highest management level in your corporation that
is responsible for waste reduction?
President (Exxon Chemical Americas)
1) What stage has your corporation reached in implementing your corporate
waste reduction program or Plan?
Waste management is a mature program and has been in the implementation
stage for the last 5 years.
m) How are you going to maintain or accelerate the momentum and awareness of
your waste reduction program in the year ahead?
o Effective use of regional waste management teams.
o Close attention to economic losses sustained through waste.
o Employee training and involvement.
o Involvement of technical resources.
o Planning emphasis to anticipate future needs and focus on
opportunitites.
RETURN BY HAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost accounting procedures
to insure that waste reduction is encouraged to a greater extent? If so, how
have you done this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term liability, or
recharges to specific plants for environmental management.)
We have not. We feel such changes are neither desirable nor necessary
and would hurt waste management in the long run by providing inaccurate
information. Emphasis is placed on reinforcing accountability by
insuring that waste related costs are booked against the operations
responsible for them being incurred.
o) How do you measure your waste reduction accomplishments (by sales,
employees, pounds/unit production)?
o tons of waste and tons waste per ton production
What is your base year?
1982
p) When accounting for production variations, did your corporation's
hazardous waste generation rate change from the previous year? If so, how?
Data not available at this time.
Do you also keep this information on a plant and or process stream
basis?
It is usually done on a product (business) line basis at HQ and at the
plants including process stream basis where appropriate.
q) Are there any specific barriers to achieving significant waste reduction
levels that your corporation, particular divisions or process streams face?
If so, what are they and how can they be overcome?
o Mature, highly complex plant processes are difficult to modify and
subject to only slow changes.
o Over regulation conflicts with optimum use of resources - overcome by
adjusting resources over time to respond to economic optimization
opportunities.
r) Have you begun to identify how far and how fast your corporation can move
to attain the maximum benefits of waste reduction?
Not completely, more of an evolutionary process.
Should this identification of maximum benefits be done on a corporate,
plant or process waste stream basis?
Optimum basis is plant or manufacturing facility. Corporate basis is
also useful. Implementing the plan will naturally deal with individual
processes or waste streams.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Enviroi ntal Managenent (617) 381-3486
474 Boston Avenue, Curtis Hall, Hedford, HA 02155 March 10, 1987
(QUESTION II)
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation implements its
waste reduction program or plan at the plant or division level.
o Plant environmental coordinator works with department operating
personnel to develop and implement the plan with site management
overview and periodic HQ stewardship.
b) Please note where your corporation has changed its plant or division
level waste reduction inplemention scheme in the past year.
Use of regional teams.
c) Assuming that your corporate waste reduction plan or program began in
your environmental division, have you integrated this program or policy with
your division or plant level manufacturing personnel?
Yes.
How did you accomplish this?
Plant sites have accepted responsibility for reduction plan development,
execution and stewardship.
d) Do you conduct a waste stream (or process loss) audit? If so, how
frequently do you conduct the audit?
Yes. Once per year.
Have you computerized this waste stream audit data?
Yes.
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prioritization of waste
reduction methods, and implementation, documentation and communication, of
results, etc?
Yes.
Please detail this process. (If you accomplish this process through a waste
reduction audit, please proceed to the next question)
RETURN BY HAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a taste reduction audit? Yes.
g) If so, what elements are included in your waste reduction audit? Do you:
Yes or No
Yes Identify and quantify sources of all process losses to all media. If
not all, which ones?
Yes Identify opportunities for future cost effective reductions?
Yes Establish goals* for the next 1-3 years?
Yes Identify resource requirements for attainments of goals?
Yes Identify techniques to attain goals?
No Interview plant employees to ascertain training needs and level of
awareness?
Yes Require sufficient data so that progress can be reported relative to
output?
Yes Document and report accomplishments and problems to management?
Yes Report progress on waste reduction relative to goals?
Yes Note problems and corrective actions undertaken?
Yes Document costs and return on reduction efforts?
Yes Identify resource requirements for the future?
- Project expected future returns?
Other elements?
*Goals are in terms of projected programs and projects.
Is your waste reduction audit computerized? Yes.
RETURN BY MAY 4, 1987
Page 6
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, HA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
Question III: Mhat have your waste reduction accomplishments been in the past year since Woods Hole II?
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw material;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
A
WASTE REDUCED
EPA HAZARDOUS
WASTE I
I gni tables
TYPE OF
WASTE
Spent
Solvents
PLANT LOCATION
Baytown, TX
DATE
1986
PER CENT
REDUCTION
20%
LOCATION
ON-SITE
X
OFF-SITE
DESCRIPTION
Improved Catalyst System
reduced waste generation
RMC(13)
Page 7
-------
Tufts University Center for Environmental Hanagenent (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have you followed
through on those mentioned in 1985's questionnaire as yet?
o Regional Waste Management groups are focusing on increasing recycle
and reclaim opportunities.
o New source reduction programs are underway to further reduce
hydrocarbon emissions to air and water.
o Small plants have increased the use of reliable contract reclaimers
for used oil and obsolete product recovery.
o Project at major site to recover and recycle hydrocarbon from
wastewater treatment sludge followed by fluid bed incineration.
o Implementing CMA air quality control program with speciated
inventories and community impact assessment.
o Continuing to follow through on programs mentioned in 1986 Woods Hole
Survey response.
RETURN BY HAY 4, 1987
Page 8
-------
General Electric
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company: GENERAL ELECTRIC
Address: 3135 Easton Turnpike
Falrfleld, Connecticut 06431
Contact Person, Title: Richard MacLean, Manager Environmental Protection
Telephone: (203) 373-3077
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-dlgit)
GE has diversified manufacturing and many SIC classifications.
Net worth 1985 13.7 Billion
Sales 1985 29.2 Billion
Major Products by Division
See Note 1
Major Hazardous Waste Streams by Division and EPA Hazardous Waste #
See Note 2
Number of plants which generate hazardous wastes 300 (approximately)
Location of plants which generate hazardous wastes
See Note 3
Number of employees Domestic: 170,000 (approximately)
(Including RCA) Worldwide: 359,000
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02154
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate waste reduction
program or plan. (Such as: guidance, goals, routine reporting
mechanisms, yearly recognition of employees, a newsletter, video, yearly
review to corporate management, technology seminars, Included in
performance reviews, waste reduction project competition for capital, etc.)
If you have not previously included a copy of your corporate waste
reduction program or plan, please do so.
See note 4
b) Please note how your cooperation has modified or expanded its corporate
waste reduction program or plan in the past year, if Indeed you have
modified or expanded it.
See note 5
c) What were the leading factors that caused you to alter your waste
reduction efforts during the past year?
Three Is a growing awareness at every management level that disposal of
hazardous wastes can present serious long term liability issues,
especially to "deep pockets" companies.
d) At what management level in your corporation, during the past year, were
changes, if any, made in your waste reduction program or plan?
The commercial waste facility qualification program had to be reviewed by
the Chief Executive Office since It is one of the few programs in GE in
which a Corporate staff operation has direct review authority over the
specific vendors used by the company.
e) How does your corporation define waste reduction? What media and wastes
or emissions are covered In your definition?
Waste reduction has not been formally defined by Corporate. Business
components generally use waste reduction and minimization
interchangeable. Treatment and recycling are considered waste reduction
efforts at the plant site level
RETURN BY MAY 4. 1987
Page 2
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its own specific
program or plan?
The majority have their own programs. These tend to be specific at the
plant level (e.g. individual waste streams are targeted for reduction) and
general at the higher levels within the organization.
g) To what level in your corporation has your waste reduction program or plan
been communicated?
Board of Directors
h) Have you found the need for additional waste reduction expertise in the
last year? If so, new staff or consultants?
Yes. No staff has been added, however, consultants have been utilized for
information newsletters, our financial handbook and the computer database.
1) Does your corporate waste reduction program or plan include goals? If so,
describe them - Including the nature of the goal and the time frame in
which the goal 1s to be met.
Goals have not been established at Corporate.
j) Does each plant or Division establish its own particular goals?
Where goals exist they are generally site specific with targets for
certain waste streams.
k) At present, what is the highest management level in your corporation that
Is responsible for waste reduction?
Vice President, Corporate Environmental Programs
1) What stage has your corporation reached in implementing your corporate
waste reduction program or plan?
All of the programs listed in (a) have been Implemented.
m) How are you going to maintain or accelerate the momentum and awareness of
your waste reduction program in the year ahead?
See Note 6
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost accounting procedures to
ensure that waste reduction Is encouraged to a greater extent? If so, how
have you done this? (I.e., placing additional charges on things such as
total volume, method of waste management, potential long term liability,
or recharges to specific plants for environmental management.)
The majority have not, however, those that have now place waste disposal
charges In functional operating budgets rather than a central fund.
o) How do you measure your waste reduction accomplishments (by sales,
employees, pounds/unit production)?
Generally by volume or pounds per "unit" of production. A "unit" can be
many things e.g. ton of plastic or a jet engine. Some have a base year.
Others track by Individual waste stream and focus on trend.
p) When accounting for production variations, did your corporation's
hazardous waste generation rate change from the previous year? If so, how?
No central records are assembled at Corporate or at major business groups
and a quantitative answer to this question cannot be obtained. The
general response by the businesses reviewing this questionnaire was that
waste generation is decreasing per unit of production based on their
knowledge of the individual plant site activities.
Do you also keep this information on a plant and or process stream basis?
Where records are kept they generally are kept on major categories at a
plant unless a specific process stream is being tracked.
q) Are there any specific barriers to achieving significant waste reduction
levels that your corporation, particular divisions or process streams face?
If so, what are they and how can they be overcome?
See Note 7
r) Have you begun to identify how far and how fast your corporation can move
to attain the maximum benefits of waste reduction?
No
Should this identification of maximum benefits be done on a corporate,
plant or process waste stream basis?
This should be done at all levels especially in highly decentralized and
diversified corporations like GE.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston AVenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation Implements Its
waste reduction program or plan at flfve plant or division level.
See Note 8
b) Please note where you corporation has changed its plant or division level
waste reduction Implementation scheme in the past year.
The Increasing awareness of long-term liabilities, escalating waste
disposal costs, and new regulations such as land bands has elevated priorities
on waste reduction plans.
c) Assuming that your corporate waste reduction plan or program began in your
environmental division, have you integrated this program or policy with your
division or plant level manufacturing personnel?
How did you accomplish this?
Programs have historically been at the plant level rather than originating
out of Corporate. Manufacturing personnel have lead the effort, Initially
driven by easily recognizable cost savings opportunities.
d) Do you conduct a waste stream or (process loss) audit? If so, how
frequently do you conduct the audit?
Corporate does not; some components do.
Have you computerized this waste stream audit data?
The vast majority of sites do not have a computerized data base.
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, pr1or1t1zat1on of waste
reduction methods, and implementation, documentation and communication, of
results, etc.?
This Is done on a waste/process specific basis.
Please detail this process. (If you accomplish this process through a
waste reduction audit, please process to the next question)
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
This is not done on a formalized basis.
g) If so, what elements are included in your waste reduction audit? Do you:
Although formal systems are not in place elements of some or all of the
Items listed below are in place.
Yes or No
Identify and quantify sources of all process losses to all media. If
not all,which ones?
Identify opportunities for future cost effective reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals/
Interview plant employees to ascertain training needs and level of
awareness?
Require sufficient data so that progress can be reported relative to
output?
Document and report accomplishments and problems to management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
No
RETURN BY MAY 4, 1987
Page 6
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT (617) 381-3486
March 10, 1987
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
F
rt/3/C
C/E
F
A
HASTE REDUCED
EPA HAZARDOUS
HASTE C
All I tastes
F001
M001
D008
D007
D001
F006.D006
D007, D008
TYPE OF
HASTE
Liquid/
Solid
TCE
(Degreasin
solvent)
Screw
machine
oil
Cleaning
Solvent
Metal
Hydroxide
Sludge
PLANT LOCATION
Shreveport, LA
Gomer sworth , NH
Sancrvorth,trs to the punch presses to
ication
in the rino operation
il specs, the above
te need to degrease rinas.
stock used to produce rivets
stem, added a polishinn filter
ed oils.
methane to tho safety Uc-in
be recycled off site.
reduce the ZnCl, that enters
uasbe treatment plant, i
i; 9
Dfc-ncr DPTIIRN RV MAY 4 10H"7
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford. MA 02155
COTTER FOR ENVIRONMENTAL MANAGEMENT (617) 381-3486
March 10, 1987
Question III: fctiat have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TEH, ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(S6C dbOVB)
A&B
F
F
E
E
F
F
L.
F
p
F
F
C
C
F
C
SEE NOTE 9
V1ASTE REDUCED
EPA HAZARDOUS
HASTE (
D0002
D001
F001
0001
F001
F001
0011
D002
D001
F001
D001
P001
F001
D007
D011
D001
F001
D002
TYPE OF
HASTE
Coustics
Fuel/Oil
Solvent
Oil Coola
Solvent
Solvent
ifaste Mate
Acids
Oil
Solvent
Oil
Solvent
Solvent
Process Ba
Wastewate
Oil/Fuel
Solvent
Caustic
Cleaner
PLANT LOCATION
Arkansas City, KG
n
n
t Ontario, CA
n
M
: Albuquerque, M'
M
•1
a
Madisonville.irY
H
Evendale.OH
h
M
If
n
Hickory, NC
DATE
1936
M
n
1986
M
II
II
II
M
M
M
•1
II
II
«
M
«
•
PER CENT
PEDUCTION
59
100
100
90
75
100
100 "
67
100
100
100
100
100
100
100
100
100
50
LOCATION
ON-SITE
X
X
X
X
X
X
X
OFF-SITE
V
X
X
X
X
X
X
X
X
.X
X
DESCRIPTION
Improved Etpjipnent & Traini
Fuels Program
uomrercial recycle
)n-site Recycle for fteuse
Dn-site Recycle for Reuse
Dortnercial Recycle
Silver Recovery
Operations Inrirovenents
Fuels Program
Gomuercial Recycle
Fuels Program
Cormercial Recycle
Less toxic Solvent Used
Less toxic material Used
Silver Recovery
Fuels Prooram
Commercial recycle
Replaced caustic wire clear
with biodegradable detergei
ADDITIONAL
INFORMATION
a
;r
IJT ri\cr Dt-nrprvj nv MAV a 1 9R7
-------
474 Boston Avenue, Curtis Hall
Tufts University. Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10, 1997
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Inprovements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE REDUCTION
METHOD
(see above)
F
F
F
F
F
F
F
A
B
B
B
A
F
SEE NOTE 9
HASTE Rl
EPA HAZARDOUS
HASTE (
D001
F001
D001
F001
D001
F001
D001
F003
F005
F001
D007
D001
D003
D001, F003
EDUCED
TYPE OF
HASTE
Oil /Fuel
Solvent
Oil
Solvent
Oil
Solvent
Oil
Paint
Solvent
Liquid
Liquid
Solid
Cyanide
Liquid
PLANT IOCATICN
Pebbles, OH
Seattle, HA
Cincinnati, OH
N
Wilmington ,NC
M
ttojeve, CA
waukesha, WI
n
Ft. Edward, NY
Ft. Edward, NY
Hudson Falls,
Vieques, PR
aireveport, LA
DATE
1986
II
n
1935
II
It
1986
PER CENT
REDUCTION
100
100
100
100
100
100
100
•ao
22
30
90
iJas Genera-
tinn 6 dr/
>*. Ma;
2 dr/wk.
100
LDCAT]
ON-EITE
X •
X
X
X
X
EON
OFF-SITE
X
X
X
X
X
X
X
DESCRIPTION
ruels Program
Conmerciai Recycle
Fuels Program
Commercial Recycle
Fuels Program
Conmerciai Recycle
Fuels Proaram
High Otec Paints
"bdified the operation of a
facility and reduced the a
generated.
Reduced the frequency of ch
ore-paint treatment bath.
Initiated the segratation o
from hazardous (flaimable)
Improvements in the design
and operation of the
process pumping system.
ne-cyclinn of solvent paint
related wastes
ADDITIONAL
INFORMATION
Can be refrigerated & used
:he following day instead of
disposal.
large vapor degroasing
twnt of spent trichlorootJiylene
inging a chromium containinn
non-hazardous paint solids
aint solvents & thinner.
Material substitution is being
investigated in 1987.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
QUESTION IV
a) What new waste reduction efforts have you underway? Have you followed
through on those mentioned in 1985's questionnaire as yet?
t Corporate programs are described in note 6 In question I(M)
t The majority of site programs fall within the definition of waste
minimization (i.e., treatment) rather than reduction. Several reduction
examples are listed below:
- Change from chrome to chrome-free phosphate process. Now that EPA
changed the F006 listing to exclude phosphate processing, going to
chrome-free will no longer make this waste a characteristic D007
waste either.
- The R&D facilities are negotiating agreements with local universities
to donate reagent chemicals to their research efforts rather than
discarding them as hazardous waste.
- Purchasing departments are negotiating no charge samples for R&D
activities rather than allowing chemists and development scientist to
order minimum quantity purchase orders that usually result In excess
chemicals being accumulated and later disposed of.
- Installation of carbon absorption system on FREON TF process.
- Installation of wire drawing fluid recycle system.
- Conversion from solvent based paint to "dry" system
- Conversion from chlorinated solvent cleaning to aqueous based system
- Investigate product/process changes to eliminate freon degreasing
- Investigate IVD-A1 as a substitute to Cd-Sn plating
RETURN BY MAY 4, 1987
Page 8
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NOTE #1
Aircraft Engine Business
Aircraft (military & commercial) engines
gas turbines for marine & Industrial application
Calma Company
Computer-aided engineering, testing, design; manufacturing
Construction Equipment Business
Power distribution equipment protection devices, switchgear products,
transformers, power-conditioning equipment, power supplies
Factory Automation
Robots & factory automation systems (electric vehicle controls)
Carboloy Company
Carboloy cemented carbide and ceramic metal
Drive Operations
AC DC Drive Systems
Automation Controls Operations
Programmable controls, numerical controls, general purpose control, vision
systems, robots
General Electric Information Services
Applied telecommunications and remote processing services
Ladd Petroleum
Exploration, production of oil/gas
Lighting
Fused quartz tubing, rod, crucibles, and ingot. Glass (tubing, bulb
blanks, pressed ware), bases formed metal parts wire, powders, pressed;
sintered tungsten, molybdenum, metal 1 zed colls, filaments, cathodes lead
wires, chemical Lucalox ceramic
Electrical supplier; wire device products
Lamps (incandescent, photographic, miniature, sealed beam, quartz)
Lighting systems utilizing high-intensity discharge light sources
Fluorescent lamp products
Major Appliance
Clothes dryer, refrigerators, gas; electric ranges, dishwashers
Medical Systems
CT, ultrasound, MR diagnostic medical products. Nuclear cameras;
associated equipment
-------
Motors
AC Induction motors, vertical AC motors, DC motors, Hermetic motors,
automotive accessory motors; electro-mechanical systems
Plastics
LEXAH; LOMOD, VALOX, XENOY, polycarbonate resins, NORYL, GELOX,
thermoplastic resins ortho, cresol; mesitol, acetone, phenol
Electro materials
copper clad; muiti-layer systems for electronic printed circuit boards
Rubber & Fluid Products
51ITcone elastomers, fluids and specialty products
Insulating Materials
Electrical insulating materials
<
Power Systems
Steam turbines generators, generator control systems, associated component
gas turbines, turbo machinery
GE Environmental Services
Utility & Industrial boiler fuel gas emission control devices
Nuclear
BoTTing 1^0 reactor fuel, nuclear detectors, sensors and other
associated equipment
Power
Transformers, power capacitors,insulators for electrical distribution and
transmission lines substations, semiconductors, locomotives
-------
NOTE 2
Aerospace
D002
F007
Aircraft Engine
D001
D002
FOOT
F006
Components Products Operation
F006
D001
Construction & Engineering Services
D001
F001
F006
Corporate RAD
D001
D007
D003
D002
Engineered Materials
D001
D001, F003, F005
FOOT, F002, F003, F005
F003
D001
D001, D003
GE Credit
D001
U051
F006
F007
F008, D003, D002
-------
- 2 -
Lighting
D004
D005, D006, D008
D005
0008
Major Appliance
F001, F006, D002
F002, 0001
F003, D007
F005
Medical Systems
FOOT
F002
F003, F005
Nuclear
D002
F006
Plastics
F004, 0118. U052
F005
F005, 0001, U220
Power Delivery Division
F001, 0001
F002
F003, 0002
F004, 0007
F006, 0008
RCA
F001, 0001
F002, 0002
F003, 0003
F005, 0005
Semiconductor
FOOT, F003
-------
- 3 -
Static Power
FOOT, F003
Transportation Systems Business Operations
F005, D001, F017
F006
Turbine
D001
F001
D007
-------
NOTE 3
Manufacturing facilities are located 1n 245 plants in 149 U.S. cities 1n 32
U.S. states. This does not include RCA that was merged In June, 1986, one of
the largest non-oil mergers in history. RCA adds approximately 18
manufacturing sites. Many service shops and non-manufacturing facilities
generate small quantities of hazardous waste and that is why the'total plant
figure given In the preceding question is higher than the number of
manufacturing sites. Major facilities (defined primarily by plant employee
population) are located in:
Albuquerque, New Mexico
Bloomington, Indiana
Burlington, Vermont
Camden, New Jersey
Cicero, Illinois
Cleveland, Ohio
East Windsor, New Jersey
Erie, Pennsylvania
Evendale, Ohio
Flndlay, Ohio
Fort Wayne, Indiana
Indianapolis, Indiana
Louisville, Kentucky
Lynchburg, Virginia
Marlon. Indiana
Milwaukee, Wisconsin
Moorestown, New Jersey
Mountalntop, Pennsylvania
Mt. Vernon, Indiana
Philadelphia, Pennsylvania
Pittsfleld, Massachusetts
Rutland, Vermont
Salem, Virginia
Schenectady, New York
Scranton, Pennsylvania
Somersworth, New Hampshire
Syracuse, New York
Utlca, New York
West Lynn, Massachusetts
Wlllmington, North Carolina
-------
NOTE #4
The Corporate waste management program consists of the following individual
elements:
o Commercial waste facility qualification program. Commercial treaters,
storers, disposers and transporters of hazardous waste (includes "GE"
and RCRA defined hazardous wastes) must be inspected and qualified by
Corporate before business components are allowed to use them.
o Financial analysis. Business components are encouraged to conduct
financial analysis of waste management alternatives. A workbook has
been prepared to assist them in including long term liability costs.
See attached literature article.
o Information seminars. Waste reduction was the theme of the last company
wide environmental meeting held in November, 1986.
o Information newsletters. These primarily deal with the Implementation
of hazardous waste regulations
The above programs are directed at encouraging and supporting better methods
of waste management. Waste reduction 1s encouraged above all other forms of
waste management. For example, in the financial analysis handbook no long
term liability costs are associated with waste reduction, however, other forms
of waste treatment, Including Incineration, are Identified with specific
liability costs that must be factored into the financial analysis.
NOTE #5
Major strides have been taken over the past year to support waste
reduction at the Corporate level. Prior to 1986, all efforts were focused
at the plant level with very little Corporate Involvement. In November,
1986 the financial analysis workbook was Introduced and 1n March, 1987 the
cut point for the use of only Corporate qualified commercial waste
facilities was implemented. Both of these programs favor waste reduction
as the option of first choice.
-------
NOTE #6
• The handbook for financial analysis of waste management alternatives has
been made available to the environmental organizations but has not been
distributed to the financial community. We plan to elevate the
awareness of long term liability issues by distributing and promoting
this approach within the finance organization.
f Corporate Environmental Programs is also expanding their involvement In
company run management training courses. This cuts across all
businesses and focuses on middle and upper level management. Waste
reduction will be one of the topics covered.
t Corporate Is negotiating a national contract with a computer software
firm to enhance a commercially available environmental database manager
system for plant operations. A module of this system will allow sites
to track their waste generation activities and also assist Corporate in
consolidating Information. This will help to focus resources and set
waste reduction priorities.
NOTE #7
1. Manpower resources - All projects must compete for limited
resources.Just because a waste reduction program saves money, it
will not obtain resources unless it is of greater benefit to the
business than other competing projects. Corporate Is shifting the
finance picture by assisting plants in factoring in long-term
liability costs.
2. Government specifications - Business component doing contract
military work must pass government specifications that require
requalification of process changes. These can make changes lengthy
and expensive. Can priority be given within the military
specification system?
3. Process control - The uniqueness of some processes restrict the
variety of chemicals that can be used and the hardware and process
conditions that are available. Technical resources are necessary to
do the required research. Manpower (as 1n 1 above) Is the Issue.
-------
NOTE #8
The programs are based on common sense, standard environmental engineering
approaches consisting of:
• Waste stream identification
- Analyzing characteristic wastes
- Verifying the accuracy of listed wastes
• Waste stream segregation
- Separating hazardous/non-hazardous
- Separating listed/characteristic
• Reviewing manufacturing process for environmental risks/impacts
• Investigation of treatment/recycle options
• Investigation of process changes/material substitution
• Development of waste specific management plans
• Prioritization and funding within business plans
-------
NOTE 9
Plant site activities vary tremendously within GE. There are sites that have
made no progress towards waste reduction and sites that have made tremendous
advances. An example of the latter is GE's Nuclear Fuel and Corporate
Manufacturing facility In Wilmington, N.C. that was awarded the 1986
Governor's Award for Waste Management. Other examples for the Evendale
Production and Aviation Service, Power Delivery and Medical Systems Divisions
are listed in the table for Question III. The examples indicate that when
successes are achieved they result in substantial Improvements. This probably
reflects the point on the learning curve that GE businesses generally are at.
Programs are in the early development stages and the achivements tend to be
the major, more obvious ones.
-------
Financial Analysis of Waste Management Alternatives
Richard W. MacLean
Corporate Environmental Programs
General Electric
Fairfield, Connecticut
ABSTRACT
Sound business decisions on waste program management can-
not be made without the consideration of long-term liability
issues. History has shown that today's inexpensive disposal op-
tion can be far more expensive in the long-term than the initially
more expensive route. It is difficult, however, to predict precisely
the liabilities which may be incurred in the future for specific
waste management practices. The problem is two-fold. First,
there is very little information available on which to evaluate the
technical and legal issues that impact future liability costs. Se-
cond, existing information has not been structured in an organ-
ized format from which costs can be derived.
Recognizing this. General Electric has developed a workbook
and companion computer software program to help their divi-
sions estimate these future liability costs. The program presently
being implemented, while based on technology considerations, is
structured to reflect both corporate policy and sound en-
vironmental practice. Business managers can readily understand
and act on the output from the analysis which is presented. Thus,
environmental engineers are provided with a tool that allows them
to address in financial terms the liability and technical issues that
otherwise would be extremely difficult to quantify to manage-
ment.
INTRODUCTION
Business executives are faced almost daily with reminders of the
enormous cost, liability and public concerns for the generation
and disposal of waste. How do these individuals put their com-
pany on a sensible track to reduce waste? How can they do that is
right, both from an environmental and a cost-effectiveness stand-
point? Glowing policy statements on the merits of waste reduc-
tion may appear to enhance the company's image but do almost
nothing to attack the real issues. The middle managers who are in
the best position to take action do not need general policy state-
ments; they need the knowledge and tools to implement specific
programs. Agency hazardous waste regulations are sometimes
specific, but they provide little assistance for organizing a waste
reduction program. A policy based on "letter of the law" com-
pliance may lessen short-term liabilities but does very little to ad-
dress long-term issues or to establish cost-effective leadership.
Because of these difficulties some companies have established
"5-year plans" that have overall reduction targets for waste mini-
mization. Others have opted for waste end taxes as a policy tool
to force business components to reduce waste generation. For
some companies, policies such as these can be very effective,
especially for small firms or for large homogeneous firms, if they
have internal environmental technical resources. For large, highly
decentralized and diversified Firms, these policy approaches are
extremely difficult to administer. For example, how do you main-
tain fairness between corporate divisions; differentiate among
treatment options and waste toxicity?; shift resources to the mou
significant long-term needs?; and provide environmental
technical assistance at those plants where none may be available1
CORPORATE POLICY
Considering all of the above. General Electric elected a funda-
mentally different approach. First, the policy had to be specific.
technically defensible and capable of being implemented at a
plant level. Second, the policy guidelines had to be written in
language that engineers (not necessarily environmental engineers)
and managers in highly diversified businesses could understand
and implement. Simply stated, the policy is this:
"Business components are to determine both short- and
long-term costs, including future liabilities, when
evaluating waste management plans. Those programs that
reduce all liabilities and are the best according to estab-
lished financial procedures are to be implemented."
The theory behind this policy is straightforward. If the total
costs are known, managers can implement better, more cost-
effective long-term waste reduction programs. However, from a
corporate responsibility standpoint, if long-term liabilities are
considered, the best, most environmentally sound decisions will
be made today, and the company and the community will win in
the long-term.
So much for theory. How do you turn this into workable im-
plementation guidelines? General Electric's approach has been to
develop a financial analysis workbook and companion computer
software program which will allow plant personnel to determine
total waste management costs including future liability considera-
tions. The mechanics of this are discussed in the next sections of
this paper. It is important to mention that the techniques, while
they are based on a foundation of technology, do involve a signif-
icant amount of judgment in establishing the "weighing factors"
used in the calculations. Depending on the values selected, certain
waste management practices can turn out significantly better than
others. It is. thus, possible to establish sound environmental prac-
tices by means of a financial technique simply by establishing fac-
tors that drive long-term liability costs to unacceptable present
value costs for less desirable environmental practices. In General
Electric's program corporate establishes these factors and, in so
doing, establishes environmental policy.
Concurrent with this policy are two other activities that, in
total, define General Electric's corporate program for hazardous
waste reduction. First, beginning in 1987 all commercial treat-
ment, storage and disposal firms will be reviewed and qualified by
corporate to do business with the company. This review will con-
318 WASTE MINIMIZATION
-------
sist of a financial screening in addition to an on-site technical in-
spection conducted by outside consultants or by a team of in-
ternally trained inspectors drawn from divisions. The data obtain-
ed from these inspections, as will be shown later, will be used to
estimate the liabilities associated with these commercial firms
Second, an internal audit program (called the "PULSE" self-
appraisal program) will be used to insure that divisions are com-
plying with internal policies and applicable local and federal
requirements for waste management.
TOTAL COSTS FOR WASTE MANAGEMENT
For the purposes of financial analysis, waste management costs
can be divided into two categories: (1) direct costs and (2) future
liabilities. Direct costs include the out-of-pocket costs routinely
associated with waste management and disposal. Examples of
direct costs include:
• Payments to vendors, including waste-end taxes
• Investment in waste management equipment
• Waste collection and transportation costs
• Raw material and labor costs associated with on-site waste
treatment, storage and disposal
• Production costs affected by waste management decisions
(e.g., raw material usage, energy or productivity penalty)
These costs usually are readily identifiable by standard finan-
cial and engineering techniques. In addition, there are numerous
reference handbooks on waste minimization and disposal that can
help engineers identify possible options.'•' Waste reduction pro-
grams that go back further into the manufacturing operations
generally require the expertise of process engineers and are often
so site-specific that "universal" handbooks are of limited value.
Future commercial treatment and disposal costs and especially
long-term liability costs are much more difficult to quantify.* For
do this, the types of wastes that are generated and those that
suit from intermediate treatment processes must be identified
and their quantities and constituents characterized.
The next step is to determine all the technically feasible alter-
Mives to these current waste generation, treatment, storage and
•sposal practices. Particular focus should be placed on process
changes that would eliminate the generation of waste entirely
The present direct costs for these alternatives are then calculated.
itre again, there are numerous references that can assist manu-
ring personnel in doing these steps, since this is standard
textbook environmental and process engineering.
At this stage in the analysis, it is worthwhile to assemble the in-
formation into an organized format that will lend itself to the
financial analysis that will be described later. One approach is il-
lustrated in Figs. 1, 2 and 3.
o
0
Currtnt Wastes at point of generation, after subse-
quent management steps, when combined with other
wastes, and at ""end of pipe."
Alternative Quantities or Types of Wastes that
would result from proposed waste management
changes such as source reduction or more broadly,
waste minimization.
Current Waste Management Steps including genera-
tion and any on-site storage, treatment or reclama-
tion which would result in the generation of a waste.
Boxes also represent any on-site disposal or reuse,
and any off-site management steps.
Alternative Waste Management Steps to those
designated by boxes, for proposed changes to gen-
eration and management based on quantity or type
of waste and on different technology approaches to
generation or management.
Figure 1
Symbols for the Waste Flow Diagrams
Figure 2
Current Waste Practices
Figure 3
Alternative Waste Practices
WASTE MINIMIZATION 319
-------
These waste flow diagrams are especially useful in analyzing
complex processes since costs for each step must be identified.
Note that both on-site and off-site management practices are in-
cluded as well as all on-site generation practices One must ac-
count for all costs because some treatment options such as recycl-
ing, may have positive cash flow.
Generally this is as far as most waste management reviews go:
the present cost for the existing program is compared against the
alternatives and the lowest present cost option wins. An
enlightened manager or an environmental engineer may "in their
heart" know that an alternative practice is better than current
practice, but the cost is greater In the absence of a company
policy, lower costs options usually win. It is at this traditional
"end" point that our analysis begins.
Liability Costa
It is possible to view future liability costs as the price of an "in-
surance policy." An insurance company determines the pnce for
your life insurance policy (not knowing when or how you will die)
based on well-established actuarial tables. The General Electric
financial analysis workbook serves a similar function; it estimates
liability costs for specific types of facilities based on past history
and corporate policy. Just like the life insurance costs for a cer-
tain occupation, say a stuntman, are high, the liability costs of
certain types of disposal activities are high, even though the cur-
rent pnce may be low.
Actuarial tables on which insurance costs are determined are
very precise statistical tools since they are based on literally
millions of bits of information spanning decades of data.
Remedial costs, liability and regulatory issues on which one can
evaluate case histories are few and span only a decade or so. The
net result is that even the most complex, sophisticated technical
and legal analysis of a specific waste management program will
not guarantee that the cost estimates are an accurate predication
of what will happen in the future. With time, this situation will
improve, but for now a relatively straightforward analysis is all
that can be practically done. Remember also that the desired end
product of the analysis is the implementation of sound en-
vironmental policy as will be shown later.
From an overall standpoint, the two key determining factors in
estimating liability are the type of treatment, storage or disposal
activity and the type of waste involved. Furthermore, a financial
analysis must include two measurements: liability dollar amount
and the time at which this future expenditure is incurred. Both of
these measurements are dependent on the type of facility and the
nature of the waste handled. For the sake of simplicity, however.
these parameters are separate for financial analysis according to
the matrix presented in Table 1. As illustrated it is assumed that
liabilities are incurred sooner for those wastes that are highly toxic
and mobile. In addition, it is assumed that the dollar amount
depends on key facility characteristics, specifically proximity to
local residents and water supplies, prior history of problems and
the treatment or disposal technology employed at the facility.
T«Wtl
Fatal* Liability Baste
Foclor
Waste
Facility
Parameter
• Toxicity
• Mobility
• Technology
• Population
• Water Supply
• Leak History
Input
Waste
Constituents
Site
Inspection
Program
Onlpat
Time
Amount
Since most of the available information on liability cost is
on remedial cleanup issues at land disposal facilities the
book uses this as the base case. All other casts are exiraoola,
from this "average landfill." Using this base case, the long-term
"excess" liability is estimated to be $350/ton In other »ordi »i
some time in the future a company will face an additional ,.o« Of
$350 for each ton of waste disposed in a typical landfill to pay for
the three liability issues listed previously. This dollar amount »u
based on analysis of hazardous waste landfills meeting Part :M
requirements.1 The costs associated with inactive National
Priorities List (NPL) sites could be substantially higher, however
this analysis is for facilities now in operation. Obviously some
landfills are better than others and some treatment and disposal
technologies present lower risk. In order to adjust the base case to
account for this, facility rating factors are determined next.
The rating factors shown in Fig. 3 are determined as follows:
• Population: Serves as an indicator for the number of people
who could consider themselves harmed by the release from the
facility. Estimates of injury claims, economic loss claims and
property claims depend on the affected population.
Score Description
I low for a rural location
2 medium for an industrial location
3 high for an urban location
• Proximity to Water Supply: The workbook assumes that near-
by wells or surface water are sources for drinking water. Esti-
mates of natural resources damage, personal injury claims and
fluid removal and treatment costs depend on the proximity to
water supply. The workbook evaluates the proximity to water
supply as:
Score Deserlptlra
1 low for a well more than 10 mi away or a
groundwaier table more than SO ft below
2 medium for a well between 1 and 10 mi away
or a groundwaier table between 10 and 30 ft
below
3 high for a well less than 1 mi away or a
groundwater table less than 10 ft below
• History of Leaks: This measure serves as an indicator to de-
termine the probability of a leak. The total amount of future
liabilities is the expected value of these costs and equals the
amount incurred when the leaks occur multiplied by the proba-
bility of occurrence. The workbook calculates the probability
of leaks as:
Score Description
1 low for no leak, spill or discharge
2 medium for any leak, spill or discharge that
has not harmed human health and/or the en-
vironment and for any potential leak, spill or
discharge
3 high for any leak, spill or discharge that has
harmed human health and/or the environ-
ment
The score for the base case or average landfill is 6 (i.e.
2+2+-2). Specific facilities (either company-owned or off-site
are adjusted by totaling their score (from a low of 3 to a high o
9), dividing by 6 (the score of the base case) and multiplying b;
the base case dollars per ton. In the case of General Electric, thi
information required to determine facility rating factors is ob
tained as part of the corporate audit program mentionet
previously. Since facilities are qualified by corporate for use b1
320 WASTE MINIMIZATION
-------
livisions the resultant scores are typically low.
Even at this stage in the analysis the utility of the liability cost
es imates becomes obvious. For example, it is much easier to ex-
plain to a general manager that long-term liability costs will be cut
,y X dollars per ton and this is the justification for switching to a
ugher priced disposal facility that provides an environmentally
oeiter service. Discussions involving geohydrology comparisons
between facilities are stimulating to technical people but are in-
omprehensible to most business managers.
The facility-adjusted dollar amount is next modified to account
lor the type of technology employed. Table 2 lists examples of
multipliers that are used to either increase or decrease the liability.
~"hese factors vary by more than 100-fold because technology is
irobably one of the most significant determining parameters.
Note also that waste reduction is the best situation of all; no
waste, no waste liability!
Table 2
WdgUof Factors Baaed en Technology
Technology Example
Multiplier
Treatment
Surface Impoundment 1.00
Chemical Treatment 0.01
Stabl11zatlon/Sol 1dlf1catlon 0.10
Incineration 0.01
Biological Treatment 0.01
Other Land-based Treatment 1.00
Other Tank-based Treatment 0.10
Surface Impoundment 1.0
Haste Pile 1.0
Tank 0.1
Other Land-based Storage 1.0
Other Tank-based Storage 0.)
Disposal
Landfill 1.0
Surface Impoundment 1.0
Injection Well 2.0
Land Farm 0.5
Ocean 0.8
Other Off-stle Disposal 1.0
Other On-site Disposal 0.5
Consider two examples to illustrate how the above works.
A well-run incinerator with a rating score of 3 and a multiplier
of 0.01 would have a future liability cost of SI .75 per ton (3+6
x $330 x 0.01). On the other hand, a poorly operated deep well
ijection unit that is inexpensive by today's market price could
ive liability costs as high as SI,050 per ton—and one must
remember this amount is only for liability costs! One also must
consider direct costs. The liability costs can increase or decrease
spending on the specific weighing factors selected as a result of
>mpany policy decisions and/or additional technical informa-
tion. Some companies may consider, for example, deep well injec-
tion safer than landfilling. They may change the 2.0 factor to,
ly. 0.5.
The workbook assumes that these liability costs will be in-
curred. Thus, it is not a question of if, but when and how much.
't has been shown how to estimate how much. What follows is a
lethod to estimate when.
As mentioned previously, mobility and toxicity of the waste are
the parameters used to determine when. The mobility of the waste
measures the speed at which the primary waste constituent moves
through the ground. The higher the mobility, the faster the consti-
tuent moves and the sooner the corrective action and claims will
occur. The differences in the mobility of various chemicals re-
leased to similar hydrogeologic environment are due to dif-
ferences in their chemical properties. Chemical-specific retarda-
tion factors measure soil attenuation and, for organic chemicals,
are primarily a function of the partitioning characteristics of the
chemical in soils.
The toxicity of the constituent also effects the timing of future
claims. Some very mobile constituents might not trigger any cor-
rective action or claim because people do not perceive them as
dangerous. Based on experiments conducted with animals, tox-
icologists establish dose-response relationships. These relation-
ships correlate the response or number of animals affected within
a sample population to the dose of hazardous constituent that was
ingested or inhaled by these animals.
For the sake of simplicity the toxicity and mobility of a waste
constituent are independently ranked as being high, medium or
low. The time span corresponding to low toxicity. low mobility
constituents was selected somewhat arbitrarily at 20 yr and for
highly toxic, highly mobile constituents at 4 yr. Examples are in-
cluded in Table 3. For mixtures, the most significant (i.e., in
terms of both concentration and toxicity) waste constituent is
used in the evaluation. Here again, in the absence of more
technical data, the rationale is some science, some crystal ball and
lots of policy.
Table 3
Number of Yean for Liability Oain* lo Occur by Chemical
Hiiardout
ConjtHutnt
Mobility ToitcUy
H)qti~He3T5iLo» High Mtualon
r of
tactic Acid
Chlorine
Foruldeftyde
Gttoltn*
Hydrochloric Acid
Ntrcury
Mttkyl Ctllauln
Ntthylen* ChloHd*
Phenol
Patitilui CjrMldt
Sod tin Nydroilde
Sulfurlc Acid
Tolucnt
N
N
H
N
H
N
L
H
N
N
N
N
H
16
8
4
6
12
4
20
16
12
At this stage, we have determined both total dollar amount per
ton plus the time at which these costs will be incurred. A straight-
forward financial analysis flows from this point and is described
in the next section. It is, of course, possible to add or subtract
levels of complexity to or from the liability cost estimation de-
pending on the availability of additional information and the skill
and background of the workbook user. For example, one addi-
tional factor that is useful is to add a multiplier for those treat-
ment or disposal units that are almost exclusively used by a single
"deep pocket" company. In the event of future liability, the com-
pany may end up with a disproportional share of the cost of
cleanup.
Financial Analysis
Financial indices can be used to identify and rank order alter-
native waste generation and management practices which are
preferred to the current practice. The results depend on the rule a
company uses and whether real (i.e., start-year) dollars or
nominal (i.e., reported) dollars are applied. Example rules:
• Discounted Cashflow Rate of Return (DCRR)
Accept an alternative waste generation and management prac-
tice if the DCRR based on incremental cashflows is greater
WASTE MINIMIZATION 321
-------
than cost of money or discount rate
• Net Present Value (NPV)
Accept an alternative waste generation and management prac-
tice if its net present value based on the incremental cashflows
is positive
• Break-Even Point
Accept an alternative waste generation and management prac-
tice if the break-even point based on incremental cashflows
falls within X years of the project's start year
• Return on Investment (ROl)
Similar to the DCRR rule; i.e.. accept an alternative waste
generation and management practice if the return on invest-
ment based on the incremental cashflows is greater than the
cost of money or discount rate
Finance staff and most engineers have access to computer soft-
ware programs that turn the drudgery associated with these
calculations into a simple exercise. Abbreviated example financial
input and output formats are illustrated in Tables 4,5,6 and 7 for
the alternative waste management case presented in Fig. 3. These
calculations were made using a standard Lotus 1-2-3* financial
software package that has been adapted to meet the specific needs
of the workbook. Table 7 demonstrates a preference for the alter-
native waste management program in Fig. 3.
Table 4
Input Parameters
Table 6
Incremental After-Tax Cashflows of Alternative Practice
Relative lo Current Practice (Real Dollars)
m 01ff»rtiK« BHn»«n Currym titt llt«rnit*»«
l Utal Bqllirtl
«[«. S
28-Oct-at
clMl Colt or NOW* III
Imtttmt lu Crtdll Uu It)
FfMrtl Til UU It)
Otprwlicloi Sen***!*:
rtir-
Fvrcmt.
1987
llnpyl
5.001
17 001
10.091
41 001
in m
It CIPlUI I «T I »U» M IMCtl)
1
lit
6
01
• 10
01 01
tioned previously, these can be significantly above the normal in-
dustrial price indices. Table 8 includes example increase. These in-
creases in market prices reflect changes that have occurred be-
tween 1985 and 1986. In the past 5 yr, there have been wide fluc-
tuations. For example, the market price for incineration went up
20«* between 1984 and 1983.
Table 5
Cajartowi Associated with Alitrudve Practice (Real Dollars)
euutir mcnci
il-Oct-
t/ i
ct
Op
Fu
i I I i ... n
1987 1991 IM4 I Mi 1006
00060
10000 10000 10000 IOOM 10000
00060
Tibia 8
i In Market Prices by Type of CommerciaJ Treatment.
Storage and Disposal Facility
Type Of TSOF
Increase
In Market
Price (Percent)
Treaeeent
tctldqr I
CIDIUI Com
Owntli* In
r»t«n llttlUtlM
•etf.itj I
Cititil Com
o*oni<*8 Iipmn
F*un LlMllitln
Cnlul Cml*
Opti-itOf In
ruuf* KMiutin
Ciplul Com
OwltlDf CIPMIM
riitof* LIlollUlM
icitiitr t
ClflUI ClIU
Owratmi Iipmn
Fiun liointiii
CiplUI Coitl
OptritlHf I«M«UI
Futirt IIMIHIIM
0
0
00
0
0
00
0
0
•
0
0
0
0
0
1000
0
0
1000
0
0
1000
0
0
1000
0
0
MOO
0
1000
0
0
1000
0
0
1000
6
0
1000
0
0
MOO
0
1000
0
0
ION
1171
0
1000
0
0
1000
1
0
MOO
0
loot
0
0
1000
0
0
1000
0
0
1000
0
0
MOO
0
1000
0
0
1000
0
0
1000
0
0
1000
0
0
1000
0
0 ...
0
19000
1411
0 ...
Surface Impoundment
Choxolcal Treatment
Stabilization/Solidification
Incineration
Biological Treatment
Other Land-bated Treatment
Other Tank-based Treatment
Storioje
Surface Impoundment
Matte PIla
Tank
Other Land-bated Storage
Other Tank-bated Storage
Ottpotal
Landfill
Surface Impoundment
Injection Hell
Land Far*
Ocean
Other Disposal
IS
15
IS
30
IS
15
15
20
20
15
20
15
20
20
25
15
10
20
Other important considerations are the projected cost increases
for commercial storage, treatment and disposal services. As men-
Cost increases for on-site waste management activities in many
cases can be less than those for commercial treatment, storage or
322 WASTE MINIMIZATION
-------
disposal services (i.e., more in line with other site operational cost
increases) This situation may give the company an incentive to
construct its own waste management facilities. This is particularly
true if manufacturing process changes that eliminate waste
generation and avoid the regulatory permit process are im-
plemented In addition, a company also may feel that it will exer-
nse greater control over us own facilities and further reduce the
likelihood of liabilities. After all. it has already assumed certain
risks because it generated the waste in the first place. Commercial
disposal firms would strongly disagree with this position and
x>int out that the company now will assume 100% of the liability
issociated with future disposal issues. Furthermore, they would
point out that their facilities are larger and most cost effective. By
performing the financial analysis, at least a company will be in a
position to better understand the issues.
CONCLUSIONS
Future liability costs need to be considered when evaluating
nazardous waste management plans. Unless this is done, a com-
pany may select waste management practices that can later prove
o be both environmentally and economically inferior. Although
uture liability costs cannot be predicted precisely, it is possible to
structure estimation techniques. General Electric's approach has
been described in this paper.
The specific methodology employed by General Electric is
escribed in a workbook and a computer software package de-
signed to guide users through the financial analysis steps. Other
methodologies are possible and they may be more suitable to the
eeds of some companies.
The important consideration is that the system described can
act as a policy by which company environmental organizations
can guide business components toward better waste management
radices—and do this by utilizing a Financial analysis technique.
This method offers several advantages over company policies
such as an end-tax on waste or a five-year waste reduction plan
The primary benefits are that the method addresses the most
significant, long-term environmental issues and that the output of
the analysis is expressed in financial terms that upper manage-
ment can readily understand and utilize.
REFERENCES
I Campbell, M.E. and Glen, W.M , Profit from Pollution Prevention:
A Guide to Industrial Waste Reduction and Recycling. Pollution
Probe Foundation, Litpak, B.C., Ed., Toronto, Ont., Canada, 1982.
2. Environmental Engineers' Handbook, 3 Volumes, Chilton Books,
Radner, PA, 1974.
3. Regan, R.W and Craffey, P W. "Assessment of the Hazardous
Waste Practices in the Paint and Allied Products Industries." Penn-
sylvania State University, Institute for Research on Land and Water
Resources, University Park, PA, Dec. 1984.
4. Monsanto Research Corporation, "Alternative Treatments of Organic
Solvents and Sludges from Metal Finishing Operations: Final Re-
port." Prepared for U.S. EPA. Dayton, OH. Sept. 1983.
5. Gupta, A.. Johnson. E.R.. Mindler, A.B. and Schlossell. R.H.. "A
Central Metal Recovery Facility: A Preliminary Appraisal of Feasibil-
ity for the Treatment of Electroplating Job Shop Wastes," Prince-
ton University, Princeton, NJ, Oct. 1983.
6 U S. Congress, Office of Technology Assessment, "Serious Reduc-
tion of Hazardous Waste: For Pollution Prevention and Industrial
Efficiency." OTA-ITE-317, U.S. Government Printing Office, Wash-
ington, DC, Sept. 1986.
7 U.S. EPA, "Remedial Action at Waste Disposal Sites (Revised).
EPA-42J/6-8J/006. Washington. DC.
8. ICF Technology, "A Comparison of the True Costs of Landfill Dis-
posal and Incineration of DOD Hazardous Wastes," Prepared for
Environmental Policy Directorate. Office of Secretary of Defense.
Defense Environmental Leadership Project Office, Washington, DC,
Sept. 21. 1984
WASTE MINIMIZATION 323
-------
Hewlett Packard
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Hewlett-Packard
Address 1819 Page Mill Road Bldg. 18, Palo Alto, CA 94304
Contact Person, Title cliff Bast, Corp. Environmental Control Mgr.
Telephone # 415-857-3925
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 3600,3573
Net worth *$6& 1986
Sales IOT6C 1986 $7.10 Billion
Major Products by Divisions Computer Products (53%)
Electronic Test & Measurement Products (37%)
Medical Electronic Equipment (6%)
Analytical Instrumentation (4%)
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # see attached
Number of plants which generate hazardous wastes See attached
Location of plants which generate hazardous wastes See attached
Number of Employees 84,000
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD; MA 02155
by: May 4, 1987
-------
Number of plants which generage Hazardous Wastes: 28
Location of plants which generate Hazardous Wastes:
CALIFORNIA: Cupertino, Mountain View, Palo Alto (5),
Rohnert Park, Roseville, San Diego, San Jose,
Santa Clara, Santa Rosa, Sunnyvale
COLORADO: Colorado springs, Fort Collins, Greeley,
Leveland
IDAHO: Boise
MASSACHUSETTS: Andover, Waithan
NEW JERSEY: Rockaway
OREGON: Corvallis, McMinnville
PENNSYLVANIA: Avondale
WASHINGTON: Lake Stevens, Spokane, Vancouver
-------
HEWLETT PACKARD COMPANY
MAJOR HAZARDOUS WASTE STREAMS
Waste Stream
Generation (tons)
1983 1984
% of Total
(19841
I• Acid and Metal Bearing Liquids 4772 3970
42
2,. Inorganic Sludges
4122
3425
36
3 • Organic Sludges
670
659
Waste Solvents
597
529
Waste Oils
392
175
All Other
702
680
Total
11,255 9438
100
1983 - 1984 Change: 16% Reduction
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees, a
newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your corporate
waste reduction program or plan, please do so.
As a company with a decentralized management structure, HP's
manufacturing divisions are responsible for their own waste
reduction programs. Division performance with respect to waste
reduction is monitored by means of an annual corporate survey of
division hazardous waste management practices. Additionally,
HP's Corporate Environmental, Health and Safety (EHS) department
conducts periodic audits of division environmental programs.
Waste Reduction/Recycling is one of the eleven audit categories
among HP's audit criteria. The essential elements of HP's audit
criteria for waste reduction include requirements for divisions
to:
- factor cost-benefit and risk management considerations into
waste management decisions
- inform Manufacturing regarding the costs and liabilities
associated with waste disposition and the need for increased
efforts to reduce the hazardous waste generation.
- provide summaries of hazardous waste quantities and costs to
functional areas that generate hazardous waste
- minimize land disposal of hazardous waste (employ
alternatives like recycling or incineration)
- maintain a centralized record of all waste reduction efforts
and accomplishments
- charge back the cost of waste disposition to areas that
generate waste
-------
- estaoiisn goals lor tne reduction ot specific waste streams
- issue an internal annual report summarizing program
performance
Promoting technology transfer and information exchange among HP's
division is an important element of HP's environmental program.
At HP's national environmental conference in November 1986, a
technology transfer program was initiated.
HP's 28 domestic manufacturing locations have been divided into
four Technology Transfer Groups:
(1) Printed circuit Facilities
(2) Integrated Circuit Facilities
(3) Mixed Operations (Machine Shops, Painting etc.)/ and
(4) Light Assembly Facilities
The purpose of HP's technology transfer program is to provide a
mechanism for HP divisions with common operations to routinely
exchange information on environmental control procedures and
technologies, especially those relevant to waste minimization.
Additionally, HP has operated a regional environmental program
since 1983. HP divisions are divided into four regions:
California, Pacific Northwest, Colorado and the East Coast.
The technology transfer group program is expected to complement
the existing regional program and further promote the transfer of
waste reduction technology throughout HP.
b) Please note bow your corporation has modified or expanded its
corporate waste reduction program or plan in the past year, if
indeed you have modified or expanded it.
No major modifications have been made to HP's waste reduction
program during the past year.
e) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
Not applicable.
d) At what management level in your corporation/ during the past
year/ were changes/ if any/ made in your waste reduction program
or plan?
Not applicable
e) How does your corporation define waste reduction? What media
and wastes or emissions are covered in your definition?
At HP, waste reduction is defined as:
-eliminating/reducing the quantity of waste that employs land
-------
disposal as a means or waste disposition, ana
- eliminating/reducing the quantity of waste generated as
result of HP's manufacturing and/or waste treatment operations
Although the intent is multi-media, HP's annual hazardous waste
survey presently does not include tabulation of air emission
reductions being achieved. It is clear, however, that many of
the waste minimization techniques being employed also yield
reductions in air emissions.
f)Does each division or plant in your corporation have its own
specific program or plan?
Each HP division is required to establish a waste minimization
program and waste reduction goals for their facility.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
HP's waste reduction program is communicated throughout the
organization. Articles regarding the program have been included
in a number of internal newsletters which are circulated among
key manufacturing and corporate management. Also, a review of
each division's waste minimization program is included in audit
reports which are circulated to corporate and division
management.
h) Have you found the need for addition waste reduction
expertise in the last year? If so new staff or consultants?
The results of audits indicate that HP divisions are devoting
increased resources to waste minimization. These additional
resources include involving HP engineering personnel outside of
the environmental staff in waste minimization projects and, in
some cases, obtaining outside assistance from consultants and
equipment vendors.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
HP divisions are required to develop individual waste
minimization goals for their facility. Corporate EHS reviews
division programs and goals during the audits.
j) Does each plant or Division establish its own particular
goals?
Yes, as required under corporate audit criteria.
fc) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Responsibility for for each division's waste reduction program
resides with the division general manager, who has overall
responsibility for site environmental management.
-------
1) What stage has your corporation reached in implementing your
corporate waste reduction program or plan?
HP's program is at the stage of continuing transfer of waste
reduction technologies throughout the organization. Survey
results for 1986 indicate that this stage will continue for
several more years before technology transfer will have been
maximized.
m) How are you going to maintain or accelerate the momentum and
awareness of your waste reduction program in the year ahead?
During 1987, we will issue a report which summarizes progress
achieved since 1983 and the current and future direction of the
program. This report will be given wide distribution throughout
the company to further publicize the program.
n) During the past year/ have you modified your cost accounting
procedures to ensure that waste reduction is encouraged to a
greater extent? If so, how have you done this? (i.e./ placing
additional charges on things such as total volume/ method of
waste management/ potential long term liability/ or recharges to
specific plants for environmental management.)
Our review of division programs during 1986 indicates that almost
all divisions are charging disposal costs directly to waste
generators. Off-site disposal costs are charged as direct costs
and costs for on-site waste treatment are allocated to each waste
generating area based on an estimate of their contribution of
waste to the treatment system. HP does not employ artificial
accounting procedures such as adding surcharges to actual
disposal costs to account for potential future liability.
o) How do you measure your waste reduction accomplishments (by
sales/ employees, pounds/unit production)?
Some HP divisions have begun to track waste generation against
selected production parameters although we have yet to do this on
a large scale throughout the company. Some operations are
integrated and it is therefore difficult to normalize the data
against a single production measure.
It is recognized that measurement relative to production will
become more critical when waste reduction begins to level off as
technology transfer is maximized. Corporate EHS is encouraging
our divisions to evaluate this question through their respective
technology transfer groups. We are also engaging in discussions
with other companies in the electronics industry in an effort to
identify an effective means for tracking waste reduction relative
to production.
What is your base year?
-------
HP's base year is 1983, the first year of our corporate
hazardous waste survey.
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Overall, during 1986, total hazardous waste production at HP's
domestic U.S. divisions decreased by an estimated 17 percent(
data for 1986 were still being compiled at the time of this
survey). During 1986, HP's U.S. sales increased by 3 percent.
Do you also keep this information on a plant and or process
stream basis?
Each division is required to track waste reduction for each waste
stream generated at their facility. The companywide totals
represent a summary of individual facility data which are
developed by HP divisions.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
Yes. These barriers have been discussed at length at past Woods
Hole and other conferences on this issue. Some of the barriers
include regulatory obstacles such as delays in permitting new
technologies, more burdensome regulatory requirements for on-site
treatment, and difficulties encountered by HP facilities that do
not generate high volumes of hazardous waste.
If so, what are they and how can they be overcome?
HP would encourage this issue to be addressed on a state or in
some cases, regional level. For example, EPA recently sponsored
a conference in Seattle entitled: "Challenges and Opportunities:
Managing Hazardous Waste in the Pacific Northwest". The
conference provided the first opportunity to bring together the
key policy makers who need to examine how their respective
programs either promote or discourage waste reduction in their
region. It is hoped that, by sponsoring this type of program,
EPA and pertinent state and local agencies can coordinate more
effectively in developing realistic strategies for effective
waste management in the region.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
On an overall basis, technology transfer should continue for the
next several years. Once technology transfer has been maximized,
waste reduction will be a function of new technology changes
within the industry. The trends toward "dry" processes in some
areas will favor waste reduction whereas the necessary
continuation of certain wet processes (unless alternate
technologies are forthcoming) will inhibit waste reduction.
-------
Should this identification of maximum benefits be done on
corporate, plant or process waste stream basis?
All three.
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Attached is a two-part article that describes how HP's waste
minimization program is administered at HP's division in Waltham,
Massachusetts. The article appeared in the "Hazardous and Solid
Waste Minimization and Recycling Report published by Government
Institutes, Inc., Rockville, MD
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the past
year.
HP's audit criteria for 1987 includes a new requirement for HP
divisions to establish waste minimization goals for their
facility.
c) Assuming that your corporate waste reduction plan or program
began in your environmental division, have you integrated this
program or policy with your division or plant level manufacturing
personnel?
Our audits during the past year indicate that Manufacturing is
becoming more involved in waste minimization. Environmental
specialists at HP division are doing a more effective job of
directing information about the need for waste reduction directly
to the manufacturing areas that generate significant quantities
of waste.
How did you accomplish this?
HP's requirement for divisions to set waste reduction goals
should help achieve greater involvement by key manufacturing
managers in the waste reduction program. This effort to make
manufacturing the focal point for waste reduction is a key part
of HP's long term strategy.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
Corporate EHS conducts an annual survey of division hazardous
waste management practices and reviews divisions hazardous waste
management program during the audits.
Have you computerized this waste stream audit data?
-------
•rne results 01 tne annual survey are consolidated into a
companywide data summary by computer. Several of HP's larger
divisions are evaluating computerization of their waste streams.
e) Have you established a process to identify: your process
losses/ opportunities and costs for further waste reduction/
prioritization of waste reduction methods, and implementations/
documentation and communication, of results, etc?
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
guestion)
f) Do you conduct a waste reduction audit?
Yes.
g) If so/ what elements are included in your waste reduction
audit? Do you:
Yes or No
X Identify and quantify sources of all process losses
to all media. If not all, which ones? Hazardous
Waste
X Identify opportunities for future cost effective
reductions?
X Establish goals for the next (varies) years?
X Identify resource requirements for attainment of goals?
X Identify techniques to attain goals?
X Interview plant employees to ascertain training needs
and level of awareness?
Being
Developed Require sufficient data so that progress can be
reported relative to output?
X Document and report accomplishments and problems to
management?
X Report progress on waste reduction relative to goals?
X Mote problems and corrective actions undertaken?
X Document costs and return on reduction efforts?
X Identify resource requirements for the future?
X Project expected future returns?
See Q I- Other elements?
Is your waste reduction audit computerized?
No.
-------
Question III
What have your vaste reduction accomplishments been in the past
year since Woods Hole II?
HP's response to Question III will be distributed at the Woods
Hole Conference, June 3,4 and 5, 1987.
-------
Question IV
a) What new waste reduction efforts have you underway? Have you
followed through on those mentioned in 1986's questionnaire yet?
HP is continuing to follow through with our basic waste reduction
strategy outlined during our presentation at the first conference
in 1985. We have the following new waste reducion efforts
underway:
(1) Converting soldering technology from wave solder machines to
surface mount technology.
(2) Converting degreasing technology from vapor degreasers to
bio-degradeable detergent/water rinse systems.
(3) Changing from sheet metal plenums and cabinets to plastic.
(4) Expand use of onsite treatment facilities to treat waste
streams formerly landfilled. ;
(5) Replace chromic acid in brite dip process (surface
passivation of aluminum).
(6) Consolidate manufacturing processes (improve overall
efficiency of chemical use and treatment).
We have continued to implement the following measures, which were
mentioned in previous questionnaires:
(7) Metals reclamation from waste treatment sludge by smelter.
(8) Improved waste treatment process for plating operations.
(9) Conversion to water-based paints.
(10) Replace water-wall paint booths with dry-filter booths.
-------
Page 14
Waste Minimization & Recycling Report
Case Study
WASTE MINIMIZATION AT HEWLETT PACKARD
(Part One of a Two-Part Series)
by: Paul L. Dadak
Environmental Health & Safety Specialist
Hewlett Packard Co. - Waltham Division
Waltham, MA
Editor's Note: Paul Dadak is presently
the divisional CHS specialist for
Hewlett Packard's Waltham Division
and Eastern Regional Environmental
Coordinator for HP's divisions in And-
over, Massachusetts, Avondale, Penn-
sylvania, and Rockaway, New Jersey.
This article is the first of a two-part
series to be concluded in the next issue.
Minimizing waste is an integral part of
the HP Way. The extent of our commitment
can be seen by:
I. Giving you a brief perspective of
Hewlett Packard Company — specifically
Waltham Division's waste generating pro-
cesses, the general categories of wastes
resulting from these operations, and volumes
produced. This will give you a feeling of the
relative scale of this issue at HP-Waltham;
secondly,
2. Describing in some detail the rela-
tionship between the divisional responsibility
and corporate policy. Note here that I am
representing my own perspectives based on
experiences during my tenure at HP-Waltham
Division. AH of my comments regarding
company policy are based on information
supplied to me by our Corporate Environ-
mental Health and Safety office and are used
to describe one of the "driving forces" and
the "yardsticks" by which a divisional mini-
mization program is promoted and presently
evaluated; and
3. Outlining administrative procedures
and modifications initiated to control exist
ing waste problems and curtail introduction
of new disposal problems if at all possible.
Some of the information I share with you
may be already in a similar form at your
plant or within your company; some may
not. Hopefully, as you see it in an overall
program, all of the information will be of use
in establishing or modifying your own
programs.
"Hewlett Packard Company is a world-
wide leader in the manufacture of
electronics for industry, science and
medicine." That's how public radio describes
HP. How does that translate in waste
minimization? To be a high tech leader one
must fabricate electronic and mechanical
components; assemble and test equipment,
and possibly produce chemical by-products.
Waltham Division is somewhat typical of
larger sites for Hewlett Packard Company, in
terms of manufacturing processes involved:
printed circuit board manufacture; sheet
metal fabrication, including metal forming,
degreasing and painting; plastics extrusion
and forming; engineering R&D lab; clean
room; solder wave and washing; waste-water
pretreatment, and facilities maintenance.
Liquid Wastes Produced
All of these functions can produce vary-
ing amounts of liquid wastes in the form of
spent plating baths, miscellaneous solvents,
waste paints, unused vendor samples, and
metal hydroxide pretreatment sludges.
Although, compared to a chemical manufac-
turer or other large chemical handler, our
volumes are low, enough material is produced
to give HP-Waltham Division "large genera-
tor" status. Why raise the issue of relative
(Continued on next page)
-------
Waste Minimization & Recycling Report
Page 15
Waste Min. at Hewlett Packard (Cont'd)
scale? Two reasons: if volumes produced
are low, alternatives for minimizing waste
transported off-site may be limited, and
secondly, very large percent reductions in
volume can be more difficult to achieve in
the so-called high-tech industry.
What part does HP-Corporate play in
waste minimization? As most of you know,
HP's management is based on individual
initiative, and waste minimization is a case
in point. How then does corporate EHS get
involved? It does so by implementing a
national policy applicable to individual
divisions, acting as a consultant, and by being
a "driving force" through annual audits and
corporate waste surveys. Let me expand on
the last function.
At least annually, our corporate EHS
office schedules a two-and-one-half day EHS
audit of the Waltham Division. "Waste
Reduction/Recycling" is one of 11 major
environmental audit criteria reviewed. As
part of the audit agenda, a closing confer-
ence is held with the division general manag-
er, management staff, and the division EHS
staff to review audit results. This takes the
form of a "meets/does not meet" rating sheet
and discussion of relative findings from
which the final scores were determined. This
is based on the following general criteria:
• Potentials for waste recycling:
Evaluated;
Implemented where feasible.
* Division management made aware of:
Costs;
Potential liabilities; and
Need to reduce overall quantity of wastes
produced.
* Division has minimized the quantity of
waste going to landfill.
Audits at Division Level
What does the audit do at the divisional
leveP
1. It helps raise the level of awareness,
increase involvement, and foster support of
waste minimization at the divisional man-
agement level;
2. It sets performance expectations by
which the divisional program is measured;
3. It provides a written measure of per-
formance for the division EHS office and
divisional management.
The audit program also goes further than
a communication between Palo Alto and Wal-
tham. The final audit results enjoy wide dis-
tribution and review, including several levels
of upper management. This aspect of the
audit has special importance when talking
about waste minimization. It is another way
of maintaining a level of awareness among
management and of making my job easier, as
I'll mention later. Lastly, the audit criteria
is a dynamic tool; as requirements change, so
does the criteria to reflect these changes.
Another tool used by Corporate Environ-
mental Health and Safety is an annual com-
pany-wide survey of divisional hazardous
waste practices. The data gathered includes
disposal methods involved, unit disposal
costs, and increases/decreases in volumes
generated. It is summarized in a report and
also distributed within the company. The
two benefits of this program are that it
establishes (1) a baseline by which future
performance can be measured in a way that
management can understand and (2) it pro-
vides another yardstick by which local man-
agement can measure performance.
Controls on New Chemicals
How does one ensure that waste genera-
tion (and its attendant costs, liabilities and
headaches) is minimized at HP-Waltham?
Actually in two general ways, both working
together to be an effective program. The
first way is actually administrative and
affects the introduction of new regulated
materials into the picture. Limiting new
chemical introductions can be equally as
important as evaluating existing opportuni-
ties. All chemicals, whether «amples, for
experimental use, or for a new process, etc.,
must be reviewed according to an established
format by the "initiator" and by the division-
al Environmental, Health and Safety Office
prior to introduction—actually prior to deliv-
ery to the facility.
(Continued on next page)
-------
Page 16
Waste Minimization & Recycling Report
Hewlett Packard (Ccnt'd)
The format uses basic questions to raise
certain issues regarding the proposed mate-
rial. Who produces it? Is there a substitute
that is easier to handle and is not considered
hazardous, in terms of disposal? Is it col-
lected for disposal? How much must be kept
on hand and what is its shelf life? Is the
Material Safety Data Sheet useful? This
format helps the initiator and EHS office to
thoroughly evaluate a product and, specifi-
cally in the waste minimization context,
determine if a new disposal problem could be
created.
You must be cautioned that even though
this procedure may sound obvious, logical and
even necessary, it may unfortunately take
some time to convince certain parties in your
organization of the need to follow the proce-
dure in all, cases. As part of the review/
approval format, the EHS divisional office
after discussion with the initiator and/or
vendor can identify specific storage/or dis-
posal considerations that the initiator
acknowledges by his or her signature.
Capital Equipment Purchase Review
Another aspect of administrative control
that often works hand-in-hand with the
chemical review procedure is the Capital
Equipment Purchase Review procedure
(CEPR). Wet process equipment is the issue
here. Originators in this area may not know
or feel they must get involved with chemi-
cals — maybe their job is mechanical engi-
neering, so their focus, then, is mechanical,
not chemical. While the form is being com-
pleted, the originator and DEHS office work
together to determine (1) if any new chemi-
cal combinations may be produced as a by-
product and (2) if having this equipment is a
necessity or are there other materials that
can be substituted.
In summary, these two review formats
can be used as tools to minimize new waste
production, manage chemical inventory, and
ensure that people ordering new chemicals
are thoroughly aware of the potential safety
and disposal problems involved in new and
existing chemical uses. It's really a matter
of education.
Chemical Disposal Cost Allocation
The third administrative tool presently
being expanded at Waltham Division involves
Chemical Disposal Cost Allocation—i.e.,
charging-out costs for preparing, transport-
ing and disposing of chemicals to the using
area. Traditionally the costs for disposing of
chemicals were centralized in one account
and charged to one area. Unfortunately the
immediacy of rising costs and liabilities for
unit disposal costs was sometimes difficult to
relate to by area management, because it
wasn't in their budget. However, allocation
of costs is a way to raise the level of aware-
ness directly. Once the awareness is there,
it becomes much less difficult to discuss or
understand the need for review of existing
and proposed units with waste reduction as
the goal.
The last aspect of this program is charg-
ing of hourly time to the generating area,
which is a consulting fee in a way. This
serves as an internal tax and economic
incentive to reduce the amount of wastes
generated. //
Part Two, in the March issue of WM&RR,
will focus on the evaluation of waste
minimization opportunities.
Recovery - U.K. (Cont'd from pg. 8)
technologies, including continuous st^am for
aqueouv solutions, fractionation,/and dry
distillation^ with the use of thin film or
scraped surface evaporators./ Because of
fouling problernsv^and still/bottoms with a
high proportion Dissolvents still present,
Soiree has developeox^a scraped surface
evaporator which *#roducM an excellent
yield of solventlesa residue, processes all the
difficult residues, including PVC, and can
process material containing sou^s up to
about 70 o^rcent solids."
modified system has, in Dtjwd's
"been the basis of our rapid growth
35*0 success." //
AHP
-------
Waste Minimization & Recycling Report
Page 15
Case Study
WASTE MINIMIZATION AT HEWLETT-PACKARD
(Part two of two-part series)
by: PaulL. Dadak
Environmental Health & Safety Specialist
Hewlett Packard Co. - Waltham Division
Waltham, MA
Editor's Note: Paul Dadak is presently
the divisional EHS specialist for
Hewlett Packard's Waltham Division
and Eastern Regional Environmental
Coordinator for H-P's divisions in
Andover, Massachusetts, Avondale,
Pennsylvania, and Rockaway, New
Jersey. This article is the second and
final part of a two-part series.
Evaluation of Opportunities
I have discussed with you so far the
individual players, their parts, their goals,
their methods in the management system,
and how they communicate. Now I would
like to share with you two specific instances,
both positive, with regard to evaluation of
possible waste reduction opportunities.
The first involves segregation of
wastes. A small clean room degreaser was
involved. Since operation began, spent
alcohols and a chlorinated solvent were
regularly mixed in the same collection
container and disposed of as a mixed waste.
Until recently this practice remained
unquestioned—the relative volumes were low;
disposal cost was not great. Upon more
careful consideration, the decision was made
to purchase an additional safety container
and establish separate collection stations.
Now both chlorinated and non-chlorinated
solvents can be reused. Through this simple
procedure, we realized a 50 to 70 percent
decrease in cost for disposal based on
$/gallon fee.
The second example involved an effort to
reduce substantially the amount of solvent
generated by our paint shop by the purchase
and operation of a small package still. I will
preface my remarks here by saying relative
volumes to be handled in this experience
seem only to affect cost but not the total list
of other environmental, health and safety
considerations that must be reviewed.
Handle Two Solvents
The initial investigation involved evalua-
tion of the practicality of operating a unit
that would have reasonable initial costs, be
able to handle possibly two solvents (one
chlorinated and one non-chlorinated), and
have approximately 15 gallons capacity
(twice per week use). The goals of economi-
cal waste minimization and employee/oper-
ator safety had to be balanced here as well
as property protection—the wastes being
distilled, in the case of the non-chlorinated
solvent (toluene), was a'material with a rela-
tively low flash point. In addition, approval
would have to be granted by the Massachu-
setts Department of Environmental Quality
prior to initiation of any recycling operation.
We met with our Factory Mutual Loss Pre-
vention Representative and discussed our
proposal in-depth.
The end result was FM's recommenda-
tion: "Due to lack of several safety features
and interlocks on the proposed units, we do
not recommend that they be used unless they
are away from the main building". In short,
at the time this option was reviewed based
on volume, location, initial cost, safety
considerations, and existing disposal alter-
natives, the decision was made to shelve the
idea.
(Continued on next page)
-------
Page 16
Waste Minimization & Recycling Report
Waste Minimization at H-P. (Cont'd)
Converting Paint Shops
An additional factor (one that could be
considered a waste minimization technique)
should be noted here. At about the same
time these units were being discussed, a
corporate initiative was begun to convert all
remaining paint shops to the use of water-
based paints, replacing a "hazardous"
material with a relatively non-hazardous
waste-producing product.
In summary, HP recognizes that waste
minimization—the reduction of wastes gen-
erated and minimization of the use of haz-
ardous materials in general—is the present
and the future of industry. This is a neces-
sity due to the significant human and
economic resources presently required to
manage hazardous wastes, including:
Management & Administrative
Control/Procedures
Facilities and Engineering Controls
Records Management
Emergency Response Programs
Training
Monitoring Activities
UST Realities
Branding Regulatory Controls
Employee Exposure Potential/Hazard
Communication. //
GLASS PLANT INSTALLS NEW
RECYCLING PROCESSING UNIT
The Owens-Illinois Glass Container Plant
in Clarion, Pa., has installed a new $1 million
processor that will make use of recycled
glass at the plant more economical. Accord-
ing to Ted McGrath, plant manager, the
processor is expected to facilitate glass
recycling within 300 miles of the plant by
making it easier and more profitable for
recycling organizations to handle waste
glass.
The new processor crushes whole bottles,
removes label scrap, and extracts metal caps
and neck rings. It can handle 80,000 color-
sorted bottles and jars per hour.
The Clarion plant is the 14th Owens-
Coming glassmaking facility to have an
automatic glass processor. Other Owens-
Illinois plants have experienced as much as
300 percent increases in glass recycling after
installing the new processors. //
AHP
REDUCTION COMPENDIUM
AVAILABLE
The Toxibs Coordinatina/Pfoject of the
Coalition on Envkpnmerrtafand Occupational
Health Hazards has^dftogether a 68-page
compendium on^x^asteirmnimization. The
coalition alsp^publishes thelnqnthly "Toxics
Watchdog^ For more information, contact:
ToxicX^Coordinating Project, C.E.O.H.H.,
Capitol Avenue, Sacramento, CA 95816.
Hazardouo A Solid
Waste Minimization A Recycling Report
Publisher
Thomas F.P. Sullivan
Technical Editor
Arthur H. Purcell. Ph.D.
Director, Waste Reduction
Information & Consulting Services/
Resource Policy Institute
Managing Editor
Martin L Heavner
The Hazardous & Solid Waste Minimization &
Recycling Report is published monthly by
Government Institutes. Inc.. 966 Hungerford
Drive. #24, Rockville, MD 20850. USA. 301-251-
9250. Subscriptions are $192 for 12 issues. ISSN
0890-5509 This publication is designed to pro-
vide accurate and authoritative information with
regard to the subject matter covered. It is provided
with the understanding that the publisher is not
engaged in rendering legal, accounting, or other
professional services. If legal advice or other
expert assistance is required, the services of a
competent professional should besought.—From
a Declaration of Principles jointly adopted by a
Committee of the American Bar Association and
a Committee of Publishers Material m this publi-
cation may not be reproduced in any form without
permission Copyright Government Institutes.
Inc . 1986
-------
",4 Boston Avenue, Curtis Hall
1\.Ets University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3-486
Mirch 10, 1987
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipm-nt; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
D
F
A
C
A
A
A
WASTE REDUCED
EPA HAZARDOUS
WASTE {
P006
K001
F002
D002
F006
F006
F003
F003
F003
F001
TYPE OF
HASTE
Sludge
Solvents
Acids
Metal
Sludge
Metal
Sludge
Paint
Sludge
Paint
Sludge
Solder-
Flux
Tnchloro
ethane
PLANT LOCATION
Sunnyvale, CA
Palo Alto, CA
Cupertino, CA
Co. Springs, CO
Lovoland, CO
Palo Alto, CA
Co. Springs, CO
Loveland, CO
Loveland, CO
NcMinnville, OR
Sunnyvale, CA
Spokane, WA
San Diego, CA
DATE
1986
1986
1986
1986
1986
1986
1986
PER CENT
REDUCTION
20-100
100
30
30
100
100
100
LOCATION
ON-EITE
X
X
X
X
X
X
OFF-SITE
X
X
1
DESCRIPTION
Consolidate manufacturing
activities - improves
efficiency of chemical
use and treatment
Sludge formerly landfilled
now sent to smelter for
metals reclamation
Switch to sodium borohydrid
to reduce plating sludge
vo 1 ume
Conversion to water based
paints
Convert water wall paint
booth to dry filters
Replacement of wave solder
machines with surface
mount technology.
Replacement of solvent
dcgrcasers by detergent
ADDITIONAL
INFORMATION
Effects printed circuits.
intcgiatcd circuits, painting
and machine stops.
Also eliminates solder dross
(lead/lead oxido)
Page 7
PLEASE RETURN BY MAY 4,1987
-------
I'M Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FDR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10, 1987
Question III: What have your waste reduction accomplishments been in the past year since Hoods Hole II? (PLEASE TELL ALL)
METHODS- A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products: E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
D
B
A
HASTE REDUCED
EPA HAZARDOUS
WASTE {
DO01
D002
F019
TYPE OF
WASTE
Oils
Acids
Sludges
Chrome
Sludge
PLANT LOCATION
San Diego, CA
San Jose, Oi
kvondale, PA
tanner t Park, CA
DATE
1986
1986
1986
PER CENT
PEIXCTION
27
70-1OO
SO
IOCATION
ON-EITE
X
X
X
OFF-SITE
1
DESCRIPTION
Replacement, of sheet metal
cabinets by plactic cabine
Treat waste on-site that
was previously landfilled
Replacement of hrite dip
tanks with conveyor i zed
system
ADDITIONAL
INFORMATION
Also eliminates use of caustic.
sulfuric acid and TCA
Page 7
PLEASE RETURN BY MAY 4 , -1987
-------
ICI Americas Inc.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
HASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name Of Company ICI Americas Inc., a subsidiary of Imperial Chemical Industries
PLC, London, England
Address Wilmington, Delaware 19897
Contact Person, Title Dr. V. J. Marchesani, Director, Environmental Quality Dept
Telephone * (302) 575-4505
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 2300, 2321, 283*. 2^65, 2.°.69,
2879, 2899
Net Worth 1985
Sales 1985 Not published
Major Products by Divisions Pharmaceuticals, Agricultural Chemicals, Plastics,
Polyester Films, Petrochemicals, Specialty Chemicals, Electronics, Fibers, Dye and
Textile Chemicals, Security Devices, and Aerospace Components
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste #
Ignitable waste streams (D001), Corrosive waste streams (D002), Reactive waste
streams (D003)
Number of plants which generate hazardous wastes 6
Location of plants which generate hazardous wastes
Bayonne, NJ; Atlas Point, DE; Fairfax, DE; Dighton, MA; Goldsboro, NC;
Bayport, TX
Number of Employees Approx. 8,000
Please return to: DANA DUXBURT
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
Previously described.
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
N/A
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
N/A
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
N/A
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Previously defined.
RETURN BY MAY 4, 1987
Page 2
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Yes
g) To what level in your corporation has your waste reduction
program or plan been communicated?
All levels
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
No
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Yes, continuing reduction.
j) Does each plant or Division establish its own particular
goals?
Yes
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
The manager of each business area.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Program implemented.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
The program assures this.
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
No
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
Founds/units of production.
What is your base year?
1984
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Yes, lower.
Do you also keep this information on a plant and or
process stream basis?
Yes, both as appropriate.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
No
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
No
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Variously within business area, plant and process waste stream as
appropriate.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
The individual business areas are responsible for Che development
of appropriate programs.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year. (
N/A
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes
How did you accomplish this?
See above.
No
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit? N/A
Have you computerized this waste stream audit data?
N/A
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
No, but this is done within individual business areas.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
No
g) If so, what elements are included in your waste reduction
audit? Do you:
N/A
Yes or Ho
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
N/A
RETURN BY MAY 4, 1987
Page 6
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MAN/CEMENT
(617) 381-3486
March 10, 1987
Question III: that have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology 6 equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant tastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
see above)
WASTE fa*if ^A"1*38
EPA HAZARDOUS
WASTE ft
COMPANY 1
TYPE OF
WASTE
ONFIDENTI/
PLANT LOCATION
. - Computer Izat:
net reductloi
DATE
in of wasl
In both 1
PER CENT
PEDUCTION
> generatloi
IB rate of ,
LOCATION
ON-SITE
by site
enerat Ion
OFF-SITE
ind waste
and In to
DESCRIPTION
tream shows an overall
al waste generated.
ADDITIONAL
INFORMATION
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
(1) Program assures new efforts on a continuing basis.
(2) Yes.
RETURN BY MAY 4, 1987
Page 8
-------
Eastman Chemicals Division,
Eastman Kodak Co.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company: Eastman Chemicals Division, Eastman Kodak Company
Address P. 0. Box 511, Kingsport, Tennessee 37662
Contact Person, J. C. Edwards, Manager, Clean Environment Program
Title
Telephone # (615)229-2444
Description of U. S. Company Activities
Standard Industrial Code Numbers (4-digit) 2860
Net Worth 1985
Sales 1986 $2.4 Billion
Major Products by Divisions
Chemicals, Fibers, Plastics
Major Hazardous Waste Streams by Division and EPA Hazardous Waste #
F003, F005, D001, D002
Number of plants which generate hazardous wastes 4
Location of plants which generate hazardous wastes
Kingsport, Tennessee; Longview, Texas; Columbia, South Carolina;
Batesville, Arkansas
Number of Employees Approximately 17,300
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees, a
newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your corporate
waste reduction program or plan, please do so.
Waste reduction concepts are integrated into a variety of
programs within the Eastman Chemicals Division. Beginning in the
Research Division where new manufacturing techniques and products
are developed, environmental and waste management personnel are
included in the product development decision making process. The
objective of this early involvement is the optimization of a
waste management strategy with emphasis on waste minimization.
The new manufacturing processes which result from these efforts
receive a waste audit and must obtain authorization for any
wastes generated from a computerized waste management system. In
a similar way existing processes are reviewed at least once per
year to evaluate waste reduction opportunities and to document
progress which was made in the previous year.
The waste management review of new and existing processes forms
the core of the waste reduction program within the Eastman
Chemicals Division. Other contributing elements include a sales
group devoted to finding markets for process streams which would
otherwise require treatment or disposal and an incentive program
which rewards employees for providing workable suggestions which
result in waste reductions or prevention. All of these elements
combine to make a comprehensive and effective waste reduction
program.
b) Please note how your corporation has modified or expanded its
corporate waste reduction program or plan in the past year, if
indeed you have modified or expanded it.
NA
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
NA
RETURN BY MAY 4, 1987
Page 2
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
d) At what management level in your corporation, during the past
year, were changes, if any, made in your waste reduction program
or plan?
NA
e) How does your corporation define waste reduction? What media
and wastes or emissions are covered in your definition?
Waste reduction encompasses all activities which result in
reductions in the release of pollutants to the environment. At
the process level these activities include waste elimination and
waste recovery and at the treatment level these activities
include energy recovery and waste volume reduction.
f) Does each Division or plant in your corporation have its own
specific program or plan?
No. All divisions conform to the corporate plan.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
The waste reduction plan was developed at a high corporate level
and applies to all divisions of the corporation.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
No
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Yearly objectives are formulated at the process and/or
department/division level.
j) Does each plant or Division establish its own particular
goals?
Objectives are established in the manufacturing areas for
specific processes.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
The Company's waste management directive was formulated and
issued by the Company's Chairman and Chief Executive Officer
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
1) What stage has your corporation reached in implementing your
corporate waste reduction program or plan?
Waste reduction has been integrated into existing waste
management policies.
m) How are you going to maintain or accelerate the momentum and
awareness of your waste reduction program in the year ahead?
Momentum will be maintained through the annual waste reduction
review of all manufacturing processes and employee awareness will
be increased through awards granted by the waste reduction
incentive program.
n) During the past year, have you modified your cost accounting
procedures to ensure that waste reduction is encouraged to a
greater extent? If so, how have you done this? (i.e., placing
additional charges on things such as total volume, method of
waste management, potential long term liability, or recharges to
specific plants for environmental management.)
No. Existing accounting procedure include environmental changes.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
Ib waste/lb production
What is your base year?
Comparisons are made to previous year.
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Yes. Records indicate a significant reduction for many
individual process streams. Examples are discussed in
Question 3. Other waste stream showed increases in volume due to
increase in production rate, changes in the definition of
hazardous waste, etc.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Additional incentives for waste reduction could be provided by
modifications of state and federal regulations to encourage
recovery and reuse operations by exempting these operations from
compliance with hazardous waste regulations.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Records on each process waste stream are maintained and evaluated
at least once per year.
Should this identification of maximum benefits be done on a
corporate, plant or process waste stream basis?
These records are maintained at the division level with overall
benefits compiled by corporate environmenal staff.
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10. 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
1. Early involvement of environmental and waste management
personnel in process research efforts
2. Requirements for waste authorization for new processes
3. Waste reduction audit of all processes conducted at least
once per year
4. Marketing function devoted to sales of process streams which
would otherwise require treatment or disposal
5. Promote awareness through employee waste reduction awards
program
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the past
year.
NA
c) Assuming that your corporate waste reduction plan or program
began in your environmental division, have you integrated this
program or policy with your division or plant level manufacturing
personnel?
Yes
How did you accomplish this?
Waste reduction concepts were already represented in existing
company manufacturing policies and programs. Special emphasis
was placed on these concepts and the employee suggestion
incentive program was initiated to increase awareness.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
Yes. At a minimum audits are conducted once per year.
Have you computerized this waste stream audit data?
Yes. All waste streams must receive authorization and are
included in a computerized waste management inventory.
RETURN BY MAY 4, 1987
Page 6
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc.?
Yes
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question).
f) Do you conduct a waste reduction audit?
Yes
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Yes Identify and quantify sources of all process losses to all
media. If not all, which ones?
Yes Identify opportunities for future cost effective reductions?
Yes* Establish goals for the next years?
Yes Identify resource requirements for attainment of goals?
Yes Identify techniques to attain goals?
No • Interview plant employees to ascertain training needs and
level of awareness?
Yes Require sufficient data so that progress can be reported
relative to output?
Yes Document and report accomplishments and problems to
management?
Yes Report progress on waste reduction relative to goals?
Yes Note problems and corrective actions undertaken?
Yes** Document costs and return on reduction efforts?
Yes Identify resource requirements for the future?
Yes Project expected future returns?
? Other elements?
* Goals for improving process efficiency
** In some outstanding cases
Is your waste reduction audit computerized?
No
RETURN BY MAY 4, 1987
Page 7
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT (617) 381-3486
March 10, 1987
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE REDUCTION
METHOD
(see above)
n
A
B
B
A
B
A
E
C
E
C
A
WASTE REDUCED
EPA HAZARDOUS
WASTE (
D001
D001
1)009
D004
D003
U190
D002
D001
DOOI
F003
1)001
F003
TYPE OF
WASTE
Liquid
Solid
Solid
Solid
Liquid
Solid
Solid
Liquid
Solid
Liquid
Solid
Liquid
PLANT LOCATION
Kingsport, TN
(Ingsport, TN
(Ingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
Kingsport, TN
DATE
1986
1986
1986
1986
1986
1986
1986
1986
1986
1986
1986
1986
PER CENT
REDUCTION
52
67
78
34
17
87
49
28
8
100
17
12
LOCATION
ON-SITE
X
X
X
X
X
X
X
X
X
X
X
OFF-SITE
X
DESCRIPTION
Sold as conmierc1.il chemli a
ADDITIONAL
INFORMATION
Page 7
PLEASE RETURN BY MAY 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have you-
followed through on those mentioned in 1985's questionnaire as
yet?
Waste reduction opportunities are identified through process
audits. A compilation of accomplishments for 1987 will be
available early 1988.
RETURN BY MAY 4, 1987
Page 8
-------
3M
-------
Tufts University Center for Environmental Management (617)38]-i-;?
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10. ]-?•
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company 3M
Address 900 Bush Ave., St. Paul, Minnesota 55144
i
Contact Person, Title John Pilney
Telephone « 612-778-4451
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) Numerous
Net Worth 1985 $4.5 billion (worldwide)
Sales 1985 $5.26 billion (U.S.); $8.6 billion (worldwide)
Major Products by Divisions
40 major product lines with tens of thousands of products.
Major Hazardous waste Streams by Division and EPA Hazardous
Waste # Majority is solvent and solvent-containing wastes.
Number of plants which generate hazardous wastes about 135
Location of plants which generate hazardous wastes 26 states
•
Number of Employees U.S. 48,000; Worldwide 81,800
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts Univpxs.ity Center loi fcnvi ronmt nt al Kunagenit nt (t.]7)3f.l-
474 Boston Avenue, Curtis Hall, Medford, MA 02151* March 10,
Moods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter) video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
The corporate waste reduction program is based upon 3H's overall
Corporate environmental policy established in 1975 (copy attached
to the 1985 questionnaire) and is implemented through the 3P
program (Pollution Prevention Pays). The 3P program documents
achievements in all form pollution reduction (including hazardous
waste) and includes quarterly reporting and individual recognition
by division management at formal departmental functions. Videos
and special presentations are used to inform and encourage
employees throughout the company to actively participate in the
program. An update on the 3P program is contained in a
"Environmental Report" routinely circulated to division management
and plant people.
b) Please note how your corporation has modified or expanded
its corporate .waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Formed a corporate staff waste minimization committee and have
been in the process of modifying the 3P Program to improve the
quantity and quality of the information to meet the Federal
reporting requirements.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
The new Federal waste minimization requirements and a need to
improve overall control of wastes..
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Staff Vice President.
-1-
-------
Tufts University Center for Environmental Management (617)30 J •_•,
474 Boston Avenue, Curtis Hall, Medford, MA 02155 Mdrrh 10, I'
(QUESTION I CONTINUED)
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Waste reduction is elimination or reduction of waste generation at
the source, recovery and reuse of the waste as a raw material
either on-site or off-site, and reduction in the volume and/or
toxicity of wastes up to the point of final disposal
f) Does each Division or plant in your corporation have its
own specific program or plan?
Each facility has a corporate plan tailored for its operations
and the large generators have specific plans. Additionally, each
facility has a cost of quality program that is primarily directed
at lowering costs through waste reduction.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
Throughout all levels of the corporation.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
No. However, members of our environmental group do participate in
various trade associations and attend numerous seminars and
thereby are able to exchange and gain information on waste
reduction practices and technologies.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Yes. As part of the 3P program, goals for annual savings due to
pollution prevention (including waste) are established. The goal
for 1986 of $56 million was exceeded with a total first year
savings of $58 million. Also, the cost of quality program, which
relies largely upon waste reduction, has a goal of 35% reduction
over 5 years.
j) Does each plant or Division establish its own particular
goals?
No.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Staff Vice President of Environmental Engineering and Pollution
Control is responsible for insuring that waste reduction is
implemented.
-------
luftr. University Ctntei (en 1 nvi lonnnTit dl Nnn«,grr • M ((.17)3(1 , ;
474 Boston Avenue. Curtit Hall. Mediord, KA 021!.'. Knic-h 10, J t
(QUESTION I CONTINUED)
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
We believe that our overall pollution prevention program (3P),
now in its eleventh year, is entering a mature stage.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Plan to: continue to modify the existing 3P program reporting
procedures to improve the quality and quantity of information;
modify the 3P project submittal form to clarify the hazardous
waste sextion; and expand the 3P review committee membership to
include a member from Corporate Process Engineering. Also, we are
conducting an annual waste management survey for all generating
facilities.
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long tern.
liability, or recharges to specific plants for environmental
management.)
Instituted a departmental recharge accounting system for all
hazardous waste (over 95% of the company total) handled at our
centralized TSD (incinerator) facility, including surcharges for
special classes of wastes. This system readily identifies the
charges by types and amounts of wastes per month and provides a
means to identify and target the major waste generating
departments for waste reduction evaluation.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
What is your base year?
By dollars saved and by tons of pollution prevented. Current year
only; not referenced to a base year since the large number of
product produced and the processes at a typical facility are
constantly in a state of change.
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Don't know. As noted above, processes and products are
continuously being modified and replaced, as new or improved
products are being introduced and as products are being shifted
among sites to utilize available equipment and technologies. Hence
a production basis for comparison purposes from year to year it
meaningless for our facilities.
Do you also keep this information on a plant and or
process stream basis?
Mn
-------
TuJtJ Univi-i j.ity Ci-ntri lei l.nvi ionn,i nt a) Kiinage-nK nt (( J 7) 3HJ -*•*!»
474 Boston Aveiiw. Curtit Hall, Mi-diord. KA 021bi, Kitich 30. ll-f
(QUESTION I CONTINUED)
q) Aze there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Maintaining product quality and containing production costs often
are barriers to implementing product re-formulations, process
modifications and equipment changes aimed at reducing waste.
Hopefully, long-term product and process research and
developmental work should overcome these barriers.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Recently initiated a major effort on a waste management survey to
identify and quantify all non-regulated and regulated wastes
generated at each facility. This should assist in focusing efforts
to maximize waste reduction benefits and in transferring waste
minimization technology among divisions and plants.
Should this identification of ma A mum benefits be done on
a corporate, plant or process waste stream basis?
Currently the identification is being done on an overall
corporate basis and on some of the larger generators with major
waste streams to gain maximum benefit.
Question XI
Plant or Division inmliini»nHiHftn
a) Please provide a detailed outline Of how your corporation
implements its waste reduction program or plan at the plant o;
division lev-
Waste reduction at the plant and laboratory levels is being
implemented through our existing 3P program. As noted previously,
the program is being modified to improve the quantity and quality
of the information on wastes, especially hazardous wastes.
b) Please note where your corporation has changed its plant er
division level waste reduction implementation scheme in the
past year.
2b. Emphasized technology transfer to reduce waste by creating a
second tier of recognition in the 3P program that awards
recognition for implementing demonstrated technologies.
-------
lull:. Univri «.i ly CiTitfi loi triv j i onmt-nt a } Mmidgcmriil « J 7 ) 3 f< 1 •
474 Lc.i.U.n AVLMUI , Curtis Hall, MidforcJ, KA 021l>!, Kinch 10,
(QUESTION II CONTINUED)
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes.
How did you accomplish this?
Through the use of videos, training seminars and prograns,
newsletters and nemos, and recognition ceremonies.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
No, but because of our knowledge of the processes, we generally
know the nature and amount of process losses and the company has
instituted a cost of quality program to reduce production costs
through waste reduction over the next 5 years.
Have you computerized this waste stream audit data?
Not applicable.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
i
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
Yes, for the larger generating facilities.
Identify those waste streams from disposal and survey records
by type and department number and then target the ones with the
largest disposal costs and/or having the highest environmental
risk for further study.
f) Do you conduct a waste reduction audit?
No, however, we are in the process of conducting a waste
management survey as noted above to identify types and amounts of
wastes for each facility.
-5-
-------
lulls Uiiivfi M t y CrnU i fm tnvj i OMiiicr.t dJ rniincjri:i« i.t ((.]7)3fU
«74 Boston Avenue-, Cuitu: Hull. MedlcuO, K'. OI'l'V.. MdicJ. H>. i
(QUESTION II CONTINUED)
g) If BO, what elements ere included in your waste reduction
fiiiiil? Do you:
Yes or No Not applicable.
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
-------
474 Boston Avenue, Curtis Hall
Tofts University, Medford. MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMBrr
(617) 381-3486
March 10. 1987
Question III: What have your waste reduction acccnplishments been in the past year since Hoods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Inprovements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
One following are all 3P programs awarded recognition in 1966 for hazardous waste prevented.
^STC hHMki k 1^ jl
METHOD
»e above)
B
A
C
E
A
HASTE HCTtr-m
EPA HAZARDOUS
WASTE (
D001
D001
D009
F001
D011
TYPE OF
HASTE
Liquid
Seini-
liquid
Solid
Liquid
Liquid
PLANT LOCATION
BPA Region 1
3
4
5
4
4
DATE
Fall, 86
Simmer.
1986
Summer,
1986
Spring,
1986
Spring,
1986
PER CENT
REDUCTION
>80%
5 ton
first year
100%
8.8 tons
first year
100%
11.6 tons
first year
100%
60 tons
1 ton
first year
LOCATION
ON-SITE
X
X
X
-
X
X
OFF-SITE
DESCRIPTION
More closely matched produc
tion to usage to minimize
scrap.
Modified equipment to allow
direct return of production
samples into the system for
ultimate use.
Developed proprietary
process technology to permit
[or raw material substi-
tution.
Developed and implemented
technique to separate
solvent from oil mixture.
deduced contamination and
lowered amount of scrapped
product.
ADDITIONAL
INFORMATION
Requires closer comfor-
mance to production
specifications.
Saved on transportation
and disposal costs, better
yield and product quality.
Page 7
PLEASE RETURN BY MAY 4. 1987
-------
Tufti University Cinti-i loi I MVI icmnu nt (. 1 Koiiucjc: n nl (t J 7 ) .
«74 Boston Avenue, Curtis Hall, Mi-dlord. VJ 021!>S Kunr). J
Question IV
a) What new waste reduction efforts have you underway? Havt
you followed through on those mentioned in 1985's questionnaii
•s yet?
Improve the quantity and quality of information on all types wastes
(i.e., regulated and non-regulated) particularly through the newly
created corporate staff waste minimization committee, an annual waste
survey, and improvements in the 3P submittal form. Also, through the
cost of quality program, reduce the costs and liabilities associated
with the handling, treatment and disposal of hazardous wastes.
Regarding last years efforts, monthly amounts and costs for hazardous
wastes incinerated for each operating department are being tracked,
recovery and.reuse of wastes have increased, and the data base for
those wastes*not incinerated at the company owned facility, which are
largely non-regulated wastes, has been greatly improved.
-------
Monsanto Company
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Monsanto Company
Address 800 North Lindbergh Blvd.
St. Louis, MO 63167
Contact Person, Title Dennig B. Redington, Director, Regulatory Management
Telephone # 314-694-6503
Description of U.S. Company Activities
<
Standard Industrial Code Numbers (4-digit) 2800
1986
Net Worth MftB $3.8 Billion
Sales XSS6 $6.9 Billion
Major Products by Divisions
See Attachment 1.
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste #
See Question I(p)
Number of plants which generate hazardous wastes
26
Location of plants which generate hazardous wastes
Distributed throughout the U.S.
Number of Employees
37,000
Please return to: DAHA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
See Attachment 2.
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
No substantial changes were made during 1986.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
N/A
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
N/A
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Waste reduction is defined as reducing the quantity of process wastes
generated which require waste treatment or disposal. The disposal
methods include all the traditional methods of responsible waste
treatment and/or disposal.
RETURN BY MAY 4, 1987
Page 2
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Yes, see Attachment 2.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
See Attachment 2.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
No.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Each operating unit sets its own annual goals as indicated in
Attachment 2.
j) Does each plant or Division establish its own particular
goals?
Yes, consistent with the operating unit's program or plan, and waste
reduction potential.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
General Managers of Manufacturing.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
The program is fully implemented.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
An assessment of program results to date Is planned and may lead
to minor redirection of emphasis and structure to achieve implementation.
RETURN BY MAY. 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater eztent? If so, how have you done
this? (i.e./ placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
No.
o) How do you measure your waste reduction accomplishments (by
sales employees, pounds/unit production)? Our most reliable corporate
indicator is pounds of waste produced. However, in evaluating individual waste str«
or unit results, we utilize pounds of waste per unit of production.
What is your base year?
1982
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Calendar 1986 statistics are not yet available. During 1985, overall hazardous
waste generation (on a total pounds basis) decreased by 11.6% over 1984. See
Attachment 3.
Do you also keep this information on a plant and or
process stream basis?
Yes.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
See Attachment 4.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Our program is aimed at reducing waste to Che extent possible with our given
resources.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Once a waste reduction program has been established for a few years, such as
Monsanto1s, continued major waste reductions are the result of process research and
application of major capital expenditures The allocation of these resources is
best directed from the corporate level.
RETURN BY MAY 4, 1987
Paae 4
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Individualized, case specific, implementation is carried out at each site
consistent with the corporate program outlined in Question I.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
None.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes.
How did you accomplish this?
See Attachment 2.
d) Do you conduct a waste stream (or process loss) audit? If
so/ how frequently do you conduct the audit?
At least annually, a detailed waste reduction review is conducted.
Have you computerized this waste stream audit data?
Yes, we have a computerized data base covering each waste stream.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Yes, as shown under the Program description of Attachment 2.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit? We conduct annual reviews of
individual operating unit performance on waste reduction goals which can inclui'
many of the elements listed below.
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective
reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management? ' •
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
We have a computerized stream-by-stream waste disposal data base which was implemen
in 1981. Calendar year 1982 is the first complete calendar year data contained
in our data base.
RETURN BY MAY 4, 1987
Page 6
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4'i sti ran Cm Ha
Tufts University, Medford, MA 02155
CH FC \TL\ NT ftNJ
NT
M If
I | •••»-" |f I
Question III: What have your waste reduction accomplishment a been in the past year since Woods Hoie
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw ma
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
WASTE REDUCED
EPA HAZARDOUS
WASTE j?
rHE FOLLOWING
CORPORATE PROC
JASTEUATERS AI
Landfilled
Wastes
Incinerated
Wastes
Wastes to
Boiler Feed
as Fuel
Wastes to
Recovery or
Sale
TYPE OF
WASTE
RESULTS SU
RAMS. IND
E NOT INCL
*Major par
PLANT LOCATION
IHARIZE CORPORATE
VI DUAL PROJECTS ,
DEI).
Several
Several
Several
Several
t of reductlondue
DATE
RESULTS FC
RE NOT DEI
1986
1986
19 86
1986
to discon
PER CENT
REDUCTION
R 1986, VS.
\ILED OR AV4
35
10
33
97 *
Inuatlon of
_ i
LOCATION
ON-SITE
A BASE YEU
ILABLE AT
s
t/
V
a busine*
OFF-SITE
R OF 1982
THE CORPOR
y
ER MONSANTO 'a
HE' LEVEL.
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, MR 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10, 1987
METHODS: A)
D)
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
A few specific examples are provided below:
Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
B
A
E
B
F
WASTE REDUCED
EPA HAZARDOUS
HASTE f
RCRA
261.33(e)
Toxic
Toxic.
DOOI
U001
TYPE OF
HASTE
Solid
Residue
Lab
Solids
Liquid
Liquid
PLANT LOCATION
South
Midwest
Midwest
Midwest
Midwest
DATE
'85
'86
'86
'86
'86
PER CENT
REDUCTION
100
20
50
95+
100
IOCATION
ON-SITE
S
S
/
s
OFF-SITE
1
DESCRIPTION
Novel method to detoxify
scrap and dismantled
equipment so It can be
sold for scrap value
rather than landfllled.
Improved column efficiency
by repacking with Koch
packing.
Return lab samples to
departments.
Added recycle step to
recover solvent which u.is
previously destined for
Incineration.
Recycle used oil Instead
of incineration.
ADDITIONAL
INFORMATION
The scrap Is placed into
specially constructed baskets
and lowered into the plant
biological treatment basins.
After anywhere from 2 days to
4 weeks, the material Is
removed, analyzed to assure
complete detox, and sold
for scrap value.
Page 7
PLEASE RETURN BY MAY 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
Waste reduction efforts and considerations are ongoing with literally all of our
waste streams on a continual basis. We did not submit a 1985 questionnaire.
RETURN BY MAY 4, 1987
Page 8
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ATTACHMENT 1
Major Products by Divisions;
Agricultural Products: Herbicides, Insecticides, and other Ag chemicals.
Nutrition Chemicals: Food Ingredients, Food and Feed Preservatives,
Animal Feed Supplements.
Fibers and Intermediates: Synthetic Fibers, Textile Industry Chemical
Intermediates.
Industrial Chemicals: Detergent Chemicals, Pharmaceuticals, Water
Treatment Chemicals, Specialty Chemicals.
Polymer Products: Plastics, Resins, Rubber Chemicals, Instruments
and Equipment for Rubber Industry.
Electronic Materials: Silicon - Wafer Products.
Engineered Products: Enviro-Chem Environmental Systems, Prism
Separators, Astroturf, Fabricated Products,
RDI Electron Beam Accelerator.
Fisher Controls: Process Control Instrumentation.
-------
ATTACHMENT 2
Monsanto
HAZARDOUS WASTE MANAGEMENT
INTRODUCTION
The general order of preference for managing hazardous
waste will be:
1 Reduce the generation of hazardous waste
through process improvement.
2. Recovery or upgrading of hazardous waste for
raw materials, resale or energy use.
3. Biological, chemical or physical treatment of
the waste to convert it to innocuous material.
4. Thermal destruction or separation of
hazardous constituents in the waste with
energy or raw material recovery where
feasible.
5. Deep-well disposal, limited to individual
process waste streams approved by the EPC.
6. Land and ocean disposal of wastes not
amenable to practical alternatives, in
accordance with Program No. #4 of this
Guideline.
Operating companies will use the most cost effective mix
of Monsanto owned or approved contractor facilities with
proper regard for long-term security and liability.
PROGRAM
The following action program applies only to Monsanto's
U.S. operations. The specific program for Europe-Africa
is set forth in the "Management Plan for Process Related
Waste" of Mav. 1983. published by Monsanto
Europe-Africa Environmental Operations. The latter
provides strategic direction for the management of process
related wastes in Europe-Africa over the next 5-10 years.
Overall policy direction to this plan is provided by this
Guideline. Specific programs for other ex-U.S. operations
will be developed later after more expenence has been
Minimize the quantities of hazardous waste generated
and emphasize upgrading to co-product status those
wastes which cannot be eliminated. For the remaining
wastes, select treatment/disposal practices taking into
consideration: cost effectiveness, compliance with
regulations, risk evaluation and long-term product
strategies. Establish Monsanto monitored and/or
controlled disposition of all solid wastes. Reduce
Monsanto's dependency on landfill and deep-well
injection of wastes.
gained with the U.S. program. In the meantime, ex-U.S.
operations will continue to dispose of their wastes in
conformance with host country regulations, [he dictates of
social responsibility and the intent of the above order of
preference of treatment/disposal methods.
1. Waste Management Plans
Each operating company will prepare annual
waste management plans beginning in 1983 as
pan of the long-range environmental and
long-range business plans. Operating
companies will include hazardous waste plans
in 1984 results.
2. Hazardous Waste Reduction
Each operating company assigns an individual
with prime responsibility for coordinating the
hazardous waste reduction effort in
accordance with the approved Hazardous
Waste Management study of November 15.
1982.
Specific numerical goals will be set by end of
1983 for each operating unit.
3. Waste Treatment/Disposal Practices
Unless excluded with the approval of the EPC,
hazardous waste streams will be treated or
disposed of in accordance with the following
guidelines:
a. Eliminate by January 1. 1984. where
alternates are available, the land disposal
of "acutelv" hazardous wastes, by either
governmental or Monsanto definition,
through detoxification prior to land
disposal or an approved alternate
disposal method.
MONSANTO ENVIRONMENTAL POLICY STAFF
Pace 1-4
-------
ATTACHMENT 3
A. Absolute total hazardous waste generation volume decreased by 9% from
our base year 1982 through 1985.
B. For the period 1982 through 1985:
use of landfill disposal has decreased by 38%.
use of deepwell disposal has decreased by 4%.
treatment by incineration has increased by 14%.
C. For reasons of confidentiality, Monsanto waste volumes are not listed
here. The reader is referred to the Chemical Manufacturers Association
1985 Hazardous Waste Survey Report which 'provides trend data back
through 1981. The 1986 survey is underway.
-------
ATTACHMENT 4
We have Identified three issues which can be temporary obstacles to
reduction efforts.
Obstacle Corrective Action
Limited Technical Resources Concentrate waste reduction efforts
on major waste streams and those whose
waste generation rate (pounds waste/
pound production) are disproportionately
high.
Economic Constraints Many of our economic decisions had
been based on current and projected
near-term disposal costs. We have
begun to look more closely at the
future cost of potential site
remediation liability, and projected
waste disposal costs.
Employee Awareness We are working hard to get total
commitment all the way down through
the manufacturing organization to the
individual chemical worker. Our
success depends on grass-roots
realization that waste reduction is
in the same class as productivity,
quality, and safety.
-------
Occidental Chemical Corporation
-------
WASTE REDUCTION: THE HURDLES AHEAD
General Information
Name of Company - Occidental Chemical Corporation
Address - 360 Rainbow Blvd. S.
Niagara Falls, NY 14302
Contact Person, Title - Harold F. Dubec, Manager - Solid Waste
Telephone - 716-286-3104
Description of U. S. Company Activities
Standard Industrial Code Numbers (4-digit) - 2812, 2819, 2821, 2869, 2873,
2874, 2879, 29116-12, 29116-13
Net Worth 1985 - 31,234,000,000 for Occidental Chemical Holding Corporation
Sales 1985 - $1, 616, 000, 000 for Occidental Chemical Holding Corporation
Major Products by Divisions -
Electrochemicals, Detergents & Specialty Chemicals - Chlorine, Caustic
Soda, Halogenated Organic & Inorganic Compounds, Elemental
Phosphorous, Inorganic Phosphates & Phosphorous Compounds, Phosphoric
Acid, Chrome Compounds, Slicates & Silica Compounds
Plastics & Polymers - Phenyl Formaldehyde Resins & Molding Compounds,
Polyvinyl Chloride Resins & Compounds, Polyvinyl Chloride Film &
Sheeting
Agricultural Products - Superphosphoric Acid, Phosphoric Acid, Triple
Superphosphate, Diammonium Phosphate, Animal Feed Supplements
Major Hazardous Waste Streams by Division and EPA Hazardous Waste # -
Electrochemicals, Detergents, & Specialty Chemicals - D001, D002, D003,
D009, D004, K071, K106
Plastics & Polymers - D001, D002, F005, U1S8, U122
.Agricultural Products - D001, F003
Number of plants which generate hazardous wastes - 29
Location of plants which generate hazardous wastes - Ashtabula, OH;
Battleground, TX; Belle, WV; Burlington, NJ (2); Castle Hayne, NC;
Chicago, IL; Convent, LA; Dallas, TX (2); Deer Park, TX; Delaware
City, DE; Grand Island, NY; Jeffersonville, IN; Jersey City, NJ;
Kenton, OH; Lake Charles, LA; Mobile, AL; Muscle Shoals, AL; Niagara
Falls, NY; N. Tonawanda, NY; Oxnard, CA; Pasadena, TX; Pottstown, PA;
Salisbury, MD; Savannah, GA; Tacoma, WA; Taft, LA; White Springs, FL
Number of Employees - 9, 132
-------
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate waste
reduction program or plan. (Such as: guidance, goals, routine
reporting mechanisms, yearly recognition of employees, a newsletter,
video, yearly review to corporate management, technology seminars,
included in performance reviews, waste reduction project competition
for capital, etc.) If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
The QxyChem waste reduction program is supported by a Corporate
Objective, signed by the Pre'sident, as follows:
"Substantially reduced generation of hazardous wastes achieved
primarily through process innovation.*
All facilities activities in this area are reviewed on an annual basis
by members of the QxyChem Environment & Safety Group. As needed,
guidance and assistance are provided the facilities. Reporting is
conducted on an annual basis, and is included in the Annual Report of
the Environment & Safety Group.
A copy of the QxyChem program was submitted in 1985.
b) Please note how your corporation has modified or expanded its
corporate waste reduction program or plan in the past year, if indeed
you have modified or expanded it.
The QxyChem program has been expanded to new facilities which have
been acquired within the past year.
c) What were the leading factors that caused you to alter your waste
reduction efforts during the past year?
The waste reduction efforts were altered in that they were expanded tc
additional facilities.
d) At what management level in your corporation, during the past year,1
were changes, if any, made in your waste reduction program or plan?
No changes were made in the program.
-------
e) How does your corporation define waste reduction? What media and
wastes or emissions are covered in your definition?
Waste reduction is defined as the elimination or reduction of waste
generation through segregation, process change, or application of
physical methods; the reuse or recycle cf waste streams; and the
in-company detoxification of waste streams. All media are covered,
however, the emphasis has been placed on land disposal streams.
£) Does each Division or plant in your corporation have its own specific
prdgram or plan?
Each plant is responsible for generating and implementing its own
plan. Where waste reduction activities may aid more than one plant.
Division or multi-plant task groups are created for developing and
implementing activities.
g) To what level in your corporation has your waste reduction program or
plan been communicated?
The Corporate Objectives which form the basis for the program have
been signed by the President, and communicated throughout all levels
of the corporation.
h) Have you found the need for additional waste reduction expertise in
the last year? If so, new staff or consultants?
When additional waste reduction expertise is needed, consultants are
utilized on a project basis.
i) Does your corporate waste reduction program or plan include goals? If
so, describe them - including the nature of the goal and the time
frame in which the goal is to be met.
At the present time, goals are project specific and plant specific.
During annual Environmental Assessments of all facilities, waste
reduction efforts are reviewed, and plans for activities to be carried
out for the next year may be established. Host projects are designed
to be completed within a one year period.
J) Does each plant or Division establish its own particular goals?
Yes, in consultation with the OxyChem Corporate Environmental & Safety
Croup.
-------
k) At present, what is the highest management level in your corporatio-
that is responsible for waste reduction?
While all employees are responsible for waste reduction efforts,
through his signing of the Corporate Objective, the President is the
highest responsible level.
1) What stage has your corporation reached in implementing your corporate
waste reduction program or plan?
OxyChem has reached the stage where all of the "easy* waste reductions
have already been accomplished, and those being designed/implementec
are at a significant cost for relatively small reductions.
m) How are you going to maintain or accelerate the momentum and awareness
of your waste reduction program in the year ahead?
Additional informational mailings to the facilities will be used to
maintain awareness and momentum in the program.
n) During the past year, have you modified your cost accounting
procedures to ensure that waste reduction is encouraged to a greater
extent? If so, how have you done this? (i.e., placing additional
charges on things such as total volume, method of waste management,
potential long term liability, or recharges to specific plants for
environmental management. )
There have been no cost accounting changes implemented within the past
year.
o) How do you measure your waste reduction accomplishements (by sales,
employees, pounds/unit production)?
Currently, waste reduction accomplishments are measured on a pounds of
waste/pound of production basis.
What is your base year?
For this purpose, the base year is 1984. For total waste reduction
efforts, the base year is 1979.
-------
p) When accounting for production variations, did your corporation's
hazardous waste generation change from the previous year? If so, how?
Waste generation from 1935 to 1986 decreased by 12. 5%.
Do you also keep this information on a plant and/or process stream
basis?
The information is kept on a plant specific basis, but not a process
specific basis.
q) Are there any specific barriers to achieving significant waste
reduction levels that your corporation, particular divisions or
process streams face? If so, what are they and how can they be
overcome?
(
At the present time, there are barriers to achieving significant
reductions in waste generation. They are primarily caused by our
program being approximately eight years old, and having achieved all
of the "simple" reductions. We are nov in a position of looking for
reductions which may require redesigning processes and plants. The
barriers nov faced, are both technological and monetary.
r) Have you begun to identify how far and how fast your corporation can
move to attain the maximum benefits of waste reduction?
No identification beyond current activities has been conducted.
Should this identification of maximum benefits be done on a corporate,
plant or process waste stream basis?
From the activities conducted and benefits achieved to date, it
appears the most beneficial identification of benefits should be
carried out on a process stream basis.
-------
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how ycur corporation implements.
its waste reduction program or plan at the plant or division level.
At the plant level. the corporate waste reduction program is
implemented primarily by the local management, with guidance from the
Corporate Environment & Safety Group. First, the Corporate Objectives
apply to all facilities, without exception. One of the Objectives is
the reduction of hazardous waste generation. For the past several
years, it has been the responsibility of the individual facility to
set its own goals in this area. The goals/projects are reviewed by
the corporate Group during the annual Environmental Assessment. At
this time, the progress achieved is discussed, and further activities
to enhance waste reduction are agreed upon. With the issuance of the
Assessment Report, the activities (Action Plans with agreed upon
target dates) are entered into the corporate computer system for
tracking. As Action Plans are completed, it is the responsibility of,
the individual facility to "close" them in the computer. These
activities are tracked on a corporate basis by the Corporate Group,
with quarterly reports issued. In addition members of the Corporate
Group responsible for providing assistance to specific divisions track,
the completion of Action Plans for the plants for whom they are the
contact.
b) Please note where your corporation has changed its plant or division
level waste reduction implementation scheme in the past year.
No changes have been made in the past year.
c) Assuming that your corporate waste reduction plan or program began in
your environmental division, have you integrated this program or
policy with your division or plant level manufacturing personnel? How
did you accomplish this?
The program has been integrated at the manufacturing level at all
facilities by ensuring environmental goals and results are made a part
of all pertinent Job descriptions within the corporation. Once this
has been accomplished, manufacturing personnel are measured against
the goals they have agreed to with their management.
d) Do you conduct a waste stream (or process less) audit? If so, how
frequently do you conduct the audit?
On an annual basis, the waste generation data is collected from all
-------
facilities, and used to prepare the annual report. In this way, waste
stream specific information is gathered.
Have you computerized this waste stream audit data?
The information collected is maintained in a data base on a personal
computer. It is not currently stored on a mainframe computer.
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prioritization of
waste reduction methods, and implementation, documentation and
communication, of results, etc? Please detail this process. (If you
accomplish this process through a waste reduction audit. please
proceed to the next question)
Identification of process losses, opportunities and costs, and
prioritization of waste reduction methods are the responsibility of
the individual facilities. They are made a part of the noemal ongoing
evaluation of processes and products. Implementation is likewise the
responsibility of the individual facility. Documentation and
communication is accomplished through the computer tracking of Action
Plans as described above.
f) Do you conduct a waste reduction audit?
No.
g) If so, what elements are included in your waste reduction audit?
No to all parts of this question.
Is your waste reduction audit computerized?
No.
-------
Question III
What have your waste reduction accomplishments been
in the past year since Woods Hole II?
Belle. WV
Waste Reduction Method - F
Waste Reduced - EPA * K01S
Type of Waste - Carbon Tetrachloride heavy ends
Plant Location - Belle, WV
Date - 1986
Percent Reduction - 100%
Location - Off-site - Deer Park, TX
Description - This material is now shipped to another company plant as a
raw material, and is no longer a waste.
Burlington (N). NJ
Waste Reduction Method - B
Waste Reduced - EPA # - None - State Hazardous Waste
Type of Waste - Waste oil/water mixture
Plant location - Burlington, NJ
Date - 1986
Per Cent Reduction - S55C
Location - on-site
Description - Through improved plant operations, the volume of this waste
was reduced because it was no longer generated.
Salisbury. MD
Waste Reduction Method - E
EPA Waste » - F005
Type of Waste - Spent wash solvents
Plant Location - Salisbury, MD
-------
Date - Nov, 1986
Per Cent Reduction - 36V.
Location - On-site
Description - The site installed a vacuum distillation unit which allows it
to sufficiently clean the spent solvents so they may be
re-used.
-------
Question IV
a) What new waste reduction efforts have you underway? Have you followed
through on those mentioned in 1985's questionnaire as yet?
Currently, there is a multi-plant project underway to reduce volumes
and concentrations of heavy metals in sludges which should allow foi
the de-listing of these waste streams entirely.
A single plant project involves vacuum drying of WWTP and othei
sludges which allows for recovery of solvents, re-use of catalysts,
and possibly de-listing of the various waste streams.
Through the installation of process and/or WWTP tanks, three locations
are delisting themselves as TSD's, and eliminating the hazardous waste
streams.
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Olin Corporation
-------
Tufts University Center for Environmental Management (617)381-3485
474 Boston Avenue, Curtis Hall, Hertford, MA 02155 March 10, 1957
HASTE REDUCTIOH: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company : Olin Corporation
Address: 120 Long Ridge Road, P. 0. Box 1355, Stamford, CT 06904-1355
Contact Person, Title : Robert D. Bradford, Jr., Director, Environment,
Health & Safety
Telephone # : (203) 356-2832
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) : There are over 40 four digit
SIC //'s. Most products are under 28, 33, 34 prefixes. Others are 30, 35, 37, 38.
Net Worth 19896 :$654,048,000.
',
Sales 1989*6 : $1,707,261,000.
Major Products by Divisions : Commodity. Organic & Specialty Chemicals;
Brass & Stainless Strip & Mill Products; Ammunition & Related Defense Products;
Rocket Propulsion Devices & Electronic Chemicals.
Major Hazardous Haste Streams by Division and EPA Hazardous
Haste t : Color Alkali Plant Brine Sludge (K071) Corrosives Non-Wastewater (D002)
Acidic/Basic Wastewater (D002) Ignitables (D001)
Toluene Diisocyanate Sludge (K027) Lead Contaminated Wastes (D008)
Mercury Contaminated Wastes (D009) Methanol Residues (K112)
Wastewater Treatment Plant (Various)
Number of B&Bftfcfi which generate hazardous wastes : 40
facilities
Location of Bd&ftfeGcwhich generate hazardous wastes :
facilities
AL, CA, CT, FL, GA, IL, IN, KY, LA, MA, MI, MO, NJ, NY, OH, PA, RI, TN, TX,
WA, WI, WV.
Number of Employees : 13,200
Please return to: DANA DUXBURY
CENTER POR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
The Group Presidents appoint an individual who reports annually to the
Corporate Director, Environment, Health & Safety, who in turn reports to
the CEO on Olin's progress in reducing the quantity and hazard level of
waste generated and disposed of and reviews the disposition of each hazardous
waste stream at Olin's plants in the United States.
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Essentially, the plan is unmodified. Started to evaluate by stream, evaluating
disposal technique - moving toward recycle as preferred method. Reducing
treatment storage for disposal units. Evaluating disposal sites.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
Federal regulations, costs of disposal, and concern for the environment.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Group and Corporate Vice President level.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Waste reduction is defined as the current year's liquid and solid waste reduction
compared with the rate at which waste would have been produced at the efficiency
existing in the base year (Olin calculates from 1981) in order to display a
percentage Improvement factor.
Air Emissions are covered by an Air Quality Program modeled on the CMA Air
Toxics Program.
RETURN fiy
Page
-------
Tufts University Center for Environmental Management (617)381-3456
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1967
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Yes.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
Top level management.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Internally, staff has strengthened themselves. We have used vendors on waste
fixation, in-situ biological treatment.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Yes, at individual plants.
j) Does each plant or Division establish its own particular
goals?
Yes.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Top level Group Manufacturing management.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Collection of data and reporting on progress versus base year annually.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Modification of the Waste Reduction Program to separate one-time waste from
production-related waste. Monitor those wastes we can control against goals.
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3466
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1967
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
Accounting procedures have not been modified. We have established and encouraged
the use of a permitted, in-house incinerator.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
Total pounds and pounds/unit using RCRA methodology and RCRA methodology
uses previous two years as base.
What is your base year?
1981
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, bow?
Yes. Production related waste generation rate was decreased. When corrected
for one-time waste, and non-production related waste such as RCRA site clean-up
or plant shutdown clean-up.
Do you also keep this information on a plant and or
process stream basis?
Both.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Yes. Rainfall and other non-production related wastes-such as river water silt,
paint waste, et al.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Yes.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
All three, depending on the situation.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3*;ci
474 Boston Avenue, Curtis Hall, Medford, HA 02155 March 10, is = ~
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
* Streams are identified, characterized and quantified.
* Objectives to reduce waste are formulated meeting all regulatory requirements.
* Manufacturing, process research, engineering and environmental affairs
formulate projects to reduce waste.
* Projects scoped and authorized.
* Performance monitored.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
Augusta. GA, Los Angeles, CA, Mclntosh, AL, Livonia, MI all reduced waste.
We went out of some waste generating businesses. Recycling has increased.
Raw Material changes.
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes.
How did you accomplish this?
Started with manufacturing. Environmental Affairs is a service function.
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
Yes, annually.
Have you computerized this waste stream audit data?
Yes, all hazardous waste streams are Included in a computerized data base.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
On going, per above.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management <617)381-34fce
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10,
f) Do you conduct a waste reduction audit?
Yes.
g) If so, what elements are included in your waste reduction
Do you:
Yes or No
Yes Identify and quantify sources of all process losses to
all media. If not all, which ones?
Yes Identify opportunities for future cost effective
reductions?
Yes Establish goals for the next 5 years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Yes Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
Partially.
RETURN BY MAY A, 1987
Page 6
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•I /•! Uu:*lon Avuiuiu, i.In 11i> lull
University. MuUiurd, MA 0215i
< KJK
(017) 3B1-34BG
March 10, 1987
III: Mv»t have your wjbtc reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Inprovunents in tt_chnolc»jy t. ix|uinnujit; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or refomuldtion or end proOucts; E) Kucycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
HASTE Bmirm
EPA HAZARDOUS
WASTE (
TYPE OF
WASTE
PLANT LOCATION
DATE
PER CENT
PEDUCTION
LOCATION
ON-SITE
OFF-SITE
-
DESCRIPTION
ADDITIONAL
INFORMATION
Page 7
PLEASE RETURN BY MAY 4.1987
n
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1967
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
The 1985 efforts are either completed or ongoing. Some of the new efforts
in 1986 are:
1. Reevaluating all waste streams to insure the wastes listed as hazardous
still are hazardous and are properly characterized.
2. Initiated a program for waste paint and solvent recycle and reuse.
Paint left over from maintenance programs was a large hazardous waste
problem.
3. We are changing our source of salt as a raw material to improve salt
purity and to reduce brine sludge generation.
A. The high pH wash water from cleaning caustic tanks and equipment will
be shipped to our acid plants for use in neutralization. This will
save the cost of neutralization and disposal at both caustic handling
and acid handling plants.
5. We have Internally provided a permitted incinerator at one of our locations
to burn qualifying wastes from all of our locations which reduces our
use of more costly and less environmentally favorable forms of disposal.
6. Segregation of hazardous waste streams for separate treatment so non-
hazardous streams remain non-hazardous.
7. Evaluate function and in-situ biological treatment processes.
RETURN BY MAY 4, 1987
Page 8
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Polaroid Corporation
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Polaroid Corporation
Address 549 Technology Square, Cambridge, Massachusetts 02139
Contact Person, Title Harry Fatkin, Director of Health, Safety &
Environmental Affairs
Telephone # (617)577-4105
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 3861
Net Worth 1985 $922,000,000.
Sales 1985 §1,295,000,000.
Major Products by Divisions Manufactures & markets products primarily in
instant imaging recording fields including instant photographic cameras and films,
magnetic media, light polarizing filters, lenses and optics.
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # Proprietary Chemicals: D001; F003; F005; F002; D002
Photographic Coatings: D001; F005; D002
Other: 0002; F003
Number of plants which generate hazardous wastes
13
Location of plants which generate hazardous wastes
Eastern Massachusetts
Number of Employees
14,765
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue. Curtis Hall. Medford. MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients In your corporate waste reduction
prograa or plan. (Such as: guidance, goals, routine reporting mechanisms, yearly
recognition of employees, a newsletter, video, yearly review to corporate
management, technology seminars, included in performance reviews, waste reduction
project competition for capital, etc.)
If you have not previously included a copy of your corporate waste reduction
program or plan, please do so.
This is the first year Polaroid has been invited to participate in this
survey. At this time the company is involved in a complete restructuring of its
waste reduction program. See question IV for an outline of this effort.
b) Please note how your corporation has modified or expanded its corporate waste
reduction program or plan in the past year, if Indeed you have modified or
expanded it.
During 1986 the company began to reconstruct data for the entire year of 1986
along the lines of the new plan (see question IV) so that 1986 would be the base
year for future activities.
c) What were the leading factors that caused you to alter your waste reduction
efforts during the past year?
Recognition of limitations due to regulatory focus of the previous program and
insights gained from participating in the OTA study. A more comprehensive waste
reduction approach, when tested within Polaroid, was found to be workable and more
consistent with the Company's objective of anticipating environmental needs.
d) At what management level in your corporation, during the past year, were
changes, if any, made in your waste reduction program or plan?
The President of Polaroid and senior officers meet monthly to review Health,
Safety and Environmental matters and this has been a recurring agenda item over
the past 18 months.
e) How does your corporation define waste reduction? What media and wastes or
emissions are covered in your definition?
Historically we have tracked RCRA definitions. The new program will be
multi-media.
Page 2
-------
f) Does each Division or plant in your corporation have its own specific
program or plan?
Yes. historically in those areas with waste minimization obligations
related to annual report and manifest certifications.
g) To what level in your corporation has your waste reduction prograa or
plan been communicated?
Polaroid's President and C.E.O.
h) Have you found the need for additional waste reduction expertise in
the last year? If so, new staff or consultants?
Existing staff has been spending increasingly more time on waste
reduction activities. A Program manager is now assigned to the newly
restructured program.
1) Does your corporate waste reduction program or plan include goals?
If so, describe them - including the nature of the goal and the,time
frame in which the goal is to be met.
See question IV.
j) Does each plant or Division establish its own particular goals?
See question IV.
k) At present, what is the highest management level In your corporation
that is responsible for waste reduction?
It is a line management responsibility at all levels.
1) What stage has your corporation reached in implementing your
corporate waste reduction program or plan?
Recycling of hazardous waste has been a major historical focus and,
in 1986, 36% of all 'RCRA Reportable* waste company wide was recycled,
including 24% at Polaroid facilities.
m) How are you going to maintain or accelerate the momentum and
awareness of your waste reduction program in the year ahead?
See question IV.
n) During the past year, have you modified your cost accounting
procedures to ensure that waste reduction is encouraged to a greater
extent? If so, how have you done this? (i.e., placing additional
charges on things such as total volume, method of waste management,
potential long term liability, or recharges to specific plants for
environmental management.)
No. Waste management costs have historically been charged to the
Division generating the waste.
Page 3
-------
o) How do you aeasure your waste reduction accomplishments (by sales, employees,
pounds/unit production)?
'RCRA reportable1 waste per sales dollar was 14% lower in 1986 than in 1985
although that is an "after the fact" index.
What is your base year?
The base year for the newly restructured system will be 1986. the index will
be per unit of product which will also be used as a performance measure.
p) When accounting for production variations, did your corporation's hazardous
waste generation rate change from the previous year? If so, how?
Production levels overall are generally related to sales. See question 'o1
above.
Do you also keep this information on a plant and or process stream basis?
The newly restructured system will use normalization factors specifically
related to waste generation activity for each division.
q) Are there any specific barriers to achieving significant waste reduction
levels that your corporation, particular divisions or process streams face? If
so, what are they and how can they be overcome?
We believe that major reductions from conservation and "best management
practices" have already been realized. A future challenge is in the research and
design of Polaroid's unique proprietary processes.
r) Have you begun to identify how far and how fast your corporation can move to
attain the maximum benefits of waste reduction? Should this Identification of
maximum benefits be done on a corporate, plant or process waste stream basis?
We have identified the need for interdisciplinary efforts among Research,
Engineering and Manufacturing and this has begun. Maximum benefits will be
achieved to the extent these technical teams can impact individual process
streams which are at the core of our program.
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation Implements its
waste reduction program or plan at the plant or division level.
Company-wide performance derives from waste reduction programs at the
Divisional level which are linked. Divisional waste performance derives from
waste generation rates of Individual processes. Waste accounting for each
process assigns waste generation to major causes which are typically a) inherent
in process design, b) deviations from the process design, c) result from
additional consumption of materials because of losses in downstream operations.
Page 4
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Waste reduction priorities are established by divisions and different
interdisciplinary teams are formed for each of categories a, b, or c.
b) Please note where your corporation has changed its plant or division
level waste reduction implementation scheme in the past year.
The answer to question 'a1 describes the program which is now being
put into place. Additional information is provided in Question IV.
c) Assuming that your corporate waste reduction plan or program began in
your environmental division, have you integrated this program or policy
with your division or plant level manufacturing personnel?
Yes.
How did you accomplish this?
A series of workshops and meetings involving manufacturing,
research and engineering management at every organizational level in the
company have been conducted to fine tune the framework of this program.
This is an ongoing activity.
d) Do you conduct a waste at re*** (or process loss! audit? If so, how
frequently do you conduct the audit?
Priority setting described in the answer to question 'a* results from
audits, the frequency of which varies by division.
Have you computerized this waste stream audit data?
Only partially.
e). Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prloritization of
waste reduction methods, and implementation, documentation and
communication, of results, etc?
See answer to question 'a' and 'd1: Performance against goals are to
be communicated through publication of results.
Please detail this process. (If you accomplish this process through a
waste reduction audit, please proceed to the next question)
f) Do you conduct a waste reduction audit?
Yes
Page 5
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g) If so, what elements are included in your waste reduction audit? Do
you: """""""""""""""""""""""""^
The program outlined in Question IV includes waste reduction audits
which will utilize most of the elements listed below.
Yes or No
Identify and quantify sources of all process losses to all Media.
If not all, which ones?
Identify opportunities for future cost effective reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs and level of
awareness?
Require sufficient data so that progress can be reported relative
to output?
Document and report accomplishments and problems to management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
only partially
Page 6
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474 Boston Avenue, Curtis Hall
Tufts University, Medford, MR 02155
(617) 381-3486
March 10, 1987
CENTER FOR ENVIRONMENTAL MANAGEMENT
Question III: What have your vraste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
IASTE REDUCTION
METHOD
«e above)
E
B
E
B
B
WASTE REDUCEtl
EPA HAZARDOUS
HASTE f
D001
D001
F003
D002
D001
D008
TYPE OP
HASTE
LIQUID
SOLID
LIQUID
LIQUID
LIQUID
PLANT LOCATION
WALTHAM
WALTHAM
WALTHAM
WALTHAM
WALTHAM
DATE
1986
1986
1986
1986
1985-
1986
PER CEMT
REDUCTION
100
90
50
50
90
IOCATION
ON-SITE
X
X
•
X
X
X
OFF-SITE
DESCRIPTION
ISOPROPANOL DISTILLED FROM
WATER AMD REUSED FOR
CLEANING
REDUCED SOLVENT SOAKED
FILTER WASTES DUE TO
CHANGE IN PROCEDURES.
STRIP OFF METHANOL FROM
CAUSTIC, BURN METHANOL AND
USE CAUSTIC/WATER FOR
NEUTRALIZATION
IMPROVED CLEANUP METHODS
TO REDUCE SOLVENT USAGE
CHANCED COATING PROCESS
TO REDUCE AQUEOUS LEAD
SULFIDE WASTE.
ADDITIONAL
INFORMATION
Paqe 7/(
PLEASE RETURN BY MAY 4, -1987
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
Question III: W»t have your waste reduction accomplishments been in the past year since Vtoods Hole II? (PLEASE TELL ALL)
(617) 381-3486
March 10, 1987
METHODS: A) Irprovements in technology & equipne.it; B) Inprove-nents in plant operations; C) Substitution of raw materials;
D) Redesign or refomulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
IASTE REDUCTION
METHOD
ee above)
B
WASTE REDUCED
EPA HAZARDOUS
WASTE (
D011
TYPE OF
HASTE
LIQUID
PLANT LOCATION
NEW BEDFORD
DATE
1986
PERCENT
REDUCTION
100
LOCATION
ON-SITE
X
•
OFF-SITE
DESCRIPTION
CAPTURED SILVER RICH DYE
SOLUTION FOR SILVER
RECLAMATION.
ADDITIONAL
INFORMATION
Paqe
PLEASE RETURN BY MAY 4, 1987
-------
474 Boston Avenue, Curtis Hall
TUfts University, Medford, MA 02155
CENTEX FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10, 1987
Question III: What have your waste reduction accomplishments been in the past year since Hoods Hole II? (PLEASE TELL ALL)
METHODS: A) Inprovements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or refoundation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
IASTE REDUCTION
METHOD
«e above)
E
E
A
E
E
WASTE REDUCED
EPA HAZARDOUS
WASTE C
NON-
REGULATED
F002
D001
D001
D001
TYPE OF
HASTE
LIQUID
LIQUID
LIQUID
LIQUID '
LIQUID
PLANT LOCATION
WALTHAM
UALTHAH
WALTHAM
UALTHAH
FREETOWN
DATE
1980
1980-
1981
1981-
1986
1981-
1986
1981-
1986
PER CENT
REDUCTION
95
90
100
100
100
LOCATION
ON-SITE
X
X
X
X
X
OFF-SITE
DESCRIPTION
RECOVERY/RE-USE OF NON-
REGULATED ORGANIC SOLVENT
RECOVERY/RE-USE OF
CHLORINATED SOLVENT
ELIMINATED RESLURRY
PURIFICATION STEP AND.
THUS, ALL SOLVENTS USED
IN THAT STEP.
MODIFIED SPARE EQUIPMENT
TO PERFORM STRIP OF
ALCOHOL CLEANING SOLUTION
FOR RE-USE
BEGAN OPERATION OF NEW
ALCOHOL RECOVERY UNIT
HANDLING - 600.000 GAL.
PER YEAR OF WASTE.
ADDITIONAL
INFORMATION
Paqe 7C
PLEASE RETURN BY MAY 4, 1987
-------
474 Boston Avenue, Curtis Hall
Tufts University, Medford, Mft 02155
(617) 381-3486
March 10, 1987
CENTER FOR ENVIRONMENTAL MANAGEMENT
Question Ills Wiat have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology s equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
RSTE REDUCTION
METHOD
see above)
C & E
F
F
F
F
F
WASTE REDUCED
EPA HAZARDOUS
HASTE S
D001
F002
F002
D001
F005
NON-
REGUIATED
TYPE OF
WASTE
LIQUID
LIQUID
LIQUID
LIQUID
LIQUID
LIQUID
PLANT LOCATION
FREETOWN
NORWOOD
WALTHAM 4
FREETOWN
WALTHAM
WALTHAM !
WALTHAM
DATE
1982-
1986
1980-
1986
1980-
1986
1980
1980-
1986
1981-
1986
PER CENT
REDUCTION
95
100
100
75
50
95
IOCATION
ON-SITE
X
OFF-SITE
X
X
X
X
X
DESCRIPTION
SUBSTITUTED ISOPROPAHOL
FOR ANOTHER ALCOHOL TO
ALLOW RECOVERY OH-SITE.
EXTERNAL RECOVERY OF
HALOCENATED SOLVENT.
EXTERNAL RECOVERY OF
HIXED HASTE OF ALCOHOL
AND HALOCARBONS.
EXTERNAL RECOVERY OF
ISOPROPANOL.
EXTERNAL RECOVERY OF
SIGNIFICANT PORTION OF
TOLUENE CONTAINING
WASTES.
TOLL RECOVERY OF HIGH
BOILING NON-IGNITABLE
ORGANIC SOLVENT.
ADDITIONAL
INFORMATION
Paqe
PLEASE RETURN BY MAY 4, 1987
-------
474 Boston Avenue, Curtis Hall
Tufts University. Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10, 1987
Question III: Nhat have your waste reduction accomplishments been in the past year since Hoods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
lASTE REDUCTION
METHOD
ee above)
E
E
E
E
WASTE REDUCED
EPA HAZARDOUS
WASTE f
D001
FOOS
F002
F002
TYPE OF
HASTE
LIQUID
LIQUID
LIQUID
t
LIQUID
PLANT LOCATION
WALTHAM
WALTHAM
WALTHAM
FREETOWN
DATE
1982-
1986
1982-
1985
1983-
1986
1983-
1986
PER CQfl*
PHXCTION
100
80
95
100
IOCATION
ON-EITE
X
X
X
OFF-SITE
X
DESCRIPTION
BEGAN SHIPPING ALCOHOL
WASTE TO ANOTHER POLAROID
FACILITY FOR RECOVERY/
RE-USE
BEGAN USING NEW
DISTILLATION SYSTEM TO
RECYCLE WASTE TOLUENE.
RECOVERY/RE-USE OF NEW
WASTE CONTAINING
CHLOROBENZENE
USED PROCESS EQUIPMENT
TO DISTILL METHYLENE
CHLORIDE WASTE FOR
RECYCLE.
ADDITIONAL
INFORMATION
Paqe 7g
PLEASE RETURN BY MAY 4, 1987
-------
4~M Boston Avenue, Curtis Hall
Tufts University, Medford, MA 02155
CENTER FOR ENVIRONMENTAL MANAGEMENT
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
(617) 381-3486
March 10, 1987
b
METHODS: A) Inprovenents in technology 4 equipne.it; B) Inprovenents in plant operations; C) Substitution of raw materials;
D) Redesign or refonmlation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
IASTE REDUCTION
METHOD
«e above)
F
F
F
F
F
WASTE REDUCED
EPA HAZARDOUS
WASTE {
F002
D001
F002.
F003
F002
NON-
REGULATED
TYPE OF
WASTE
LIQUID
LIQUID
LIQUID
LIQUID
LIQUID
PLANT LOCATION
WALTHAH
UALTHAH
UALTHAN
FREETOWN
FREETOWN
DATE
1982-
1986
1983-
1984
1985-
1986
1986
1986
PER CENT
PHXCTION
90
80
100
100
95
LOCATION
ON-SITE
OFF-SITE
X
X
X
X
X
I
DESCRIPTION
TOLL RECOVERY OF
0-DICHLOROBENZENE WASTES
EXTERNAL RECOVERY OF
BENZENE/ISOPROPANOL
UNTIL PHASE OUT OF
BENZENE USE.
EXTERNAL RECOVERY OF
HETHYLENE CHLORIDE AND
ETHYL ACETATE WASTE FROM
NEW PROCESS.
EXTERNAL RECOVERY OF
HALOCENATED SOLVENT
DESIGNED NEW PROCESS
WITH NON-REGULATED
SOLVENT WHICH COULD
BE RECOVERED EXTERNALLY.
ADDITIONAL
INFORMATION
Paqe If
PLEASE RETURN BY MAY 4, 1987
-------
Question IV
a) What new waste reduction efforts have you underway? Have you
followed through on those Mentioned in 1985's questionnaire as yet?
Polaroid has restructured its 1986 waste generation information
along the lines described in previous answers. The company is in
the final stages of developing a new management information system
to support a world-wide program to achieve three parallel
environmental objectives: virtual elimination of 'toxic'
emissions; reduction of all generated chemical waste per unit of
product; and, maximized recycling prior to use of on-site liquid
incineration or other technologies on a preferential waste
management hierarchy. The base year will be 1986 against which
performance in 1987 and beyond can be evaluated. This information
system will be designed so that results can be audited by
qualified, independent third-parties prior to publication.
Subject to final modification based on consultation with such
independent experts, the waste generation framework now contains
the following features. It will be 'multi-media' and account for
all chemical wastes leaving a process after any 'closed loop'
recycling which is Inherent to the process. Hater will not be
included in waste accounting for the air and sewer media; water
which is inherent in a process waste will be included in such waste
which is collected for recycling and other waste management. All
chemical waste will be included regardless of current regulatory
status. Haste reduction can be reported for all multi-media
generated waste, but the system will also have the flexibility to
report reductions using various regulatory criteria as well. Haste
generation will be 'normalized' for each division's production
activity for the purpose of waste accounting, goal setting and
management performance reporting. However, each division's
performance will be based on a company-wide waste accounting system
designed to facilitate interdisciplinary waste reduction efforts.
This world-wide system will also allow for development of a
Polaroid waste generation 'bottom line'.(such as a waste generation
index based on 'chemical waste per million pictures') which could
be calculated and reported. The system will have a 'degree of
toxicity1 capability to assist management in setting waste
reduction priorities and in achieving the 'toxic emission1
reduction goal.
Page 8
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Until the framework is finalized later this summer waste reduction
goalsetting is tentative, but the intent is to do so in the context
of a five-year plan since much of Polaroid's future waste reduction
Mill require research, development and (probably) invention. The
final framework must be designed to provide the correct Incentives
to set goals which will maximize environmental benefit. Examples
of framework/goal issues which must be thought through so as to
provide the desired envoronmental results are: Where water is
included in collected (e.g. manifested) wastes, a reduction in
water is a reduction in waste volume (is this appropriate?); Where
presence of a low concentration of a toxic ingredient
"contaminates" a large bulk, a large reduction of the "volume and
toxicity of the bulk can be achieved by eliminating that small
toxic ingredient concentration (is this the best way to encourage
on the "toxic reduction" objective?); where an increased volume of
a less toxic material replaces a lesser volume of a more toxic
material the total waste volume increases (will this discourage the
desirable substitution of less toxic alternatives?) Setting aside
such framework issues for the moment, and using 1986 as the base,
internal goal setting exercises at Polaroid for year end 1991 are
testing the reality of a goal of 41* reduction in the volume and
toxicity of chemical waste generation per unit of product (an
average of 10% reduction per year over the next five years).
Page 9
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Public Service Electric
And Gas Company
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name Of Company Public Service Electric and Gas Company
Salem and Hope Creek Generating Stations
Address Environmental Licensing, P.O. Box 236
Hancocks Bridge, NJ 08038
Contact Person, Title
Albert Fralinger III, CHMM, Environmental Engineer
Telephone ff
See attached annual report for Public Service Enterprise
Group Incorporated
(609)
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 4931
Net worth 1985
Sales 1985
Major Products by Divisions
Electric Utility
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste # DOOl x725 - N.J. waste type waste oil spill debris
D002 x726 - N.J. Waste Type waste oil
P001
PQQ3 (Waste oil is the major waste stream
generated at the plants under review)
Number of plants whicn generate hazardous wastes
This questionnaire addresses 2 plants.
Location of plants which generate hazardous wastes
PSE&G - Salem Generating Station PSESG-Hope Creek Gen. Station
Foot of Buttonwood Road-P.O. Box 236 Foot, of Buttonwood Road,
Hancocks Bridge, Salem County, NJ P.O. *Bpx 236
08038 Hancocks Bridge, Salem County, NJ
Number of Employees 2,000 08038
(Both Stations and Support Groups combined)
• Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
* NOTE: Asterisk indicates the information in this form addresses only the
Salem and Hope Creek Generating Stations. Time did not allow other
company facilities to be included.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
Presently the Corporate waste reduction program or plan that exists consists of
essentially training and improved housekeeping. The driving forces to begin lookine
closer at waste minimization are disposal costs an'* reaulatory requirements to reduce
waste at t.he-seurce. See attached NJDEP 1986 annual reports for hazardous waste
and waste minimization activity. . .... - , ,
b) Please note now your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
The bulk of our waste reduction program has consisted of improved operations due to
housekeeping and training of employees. Although waste volume reduction has not been
great we have attempted to reduce toxcity/hazards of wastes through less toxic/
hazardous product substitutes.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
High costs of hazardous waste disposal and increased company liability for generated
hazardous waste.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan? staff Environmental Engineer level. These changes consisted of
primarily improved housekeeping and hazardous waste awareness training. Also physic
mechanical changes to address oil/water waste mixtures due to waste oil being
classified as hazardous waste in N.J.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
No real corporate definition exists.Corporate efforts have been directed at burning
waste (oils) in a boiler at an existing plant facility. Haste minimization "on-papei
has been difficult because many non-hazardous wastes are generated and handled/disposed
of as hazardous waste due to potential liabilities and Superfund litigation. Therefc
our volumes are artificially inflated.
RETURN BY MAY 4, 1987
Pan«> ")
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Yes, although the plans are not presently formalized. The goal is for proper and
environmentally sound disposal practices and toxicity reduction through product
substitution rather than volume reduction.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
To the Corporate Hazardous Waste Task Force (General Manager - Environmental Affairs)
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Mo, however legislation introduced into the state senate and assembly may mandate
the need for such services. See attached N.J. Bills.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
No
j) Does each plant or Division establish its own particular
goaiSf No> waste volumes a function of plant operations, i.e. unplanned outages.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Presently from a regulatory point of view the corporate Environmental Affairs
General Manager. Actual implementation remains with middle management at each
rffpe w&\ psfage has your corporation reached in implementing
your corporate waste reduction program or plan?
N/A
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
•Through placing accountability of waste generated and associated disposal costs
on each operating department. Also the responsibility of overall hazardous waste •
management for the Salem and Hope Creek Stations has been given to a central group
so that waste minimization efforts can be increased.
RETURN BY MAY 4, 1987
Paqe 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.) Efforts have started to identify each department generating
waste, the volumes, types, disposal costs and other performance indicators.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
See attached NJDEP waste minimization report. This is our only present measure of
waste reduction.
What is your base year? This is the first year a measure of reduction
was required.
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
Yes, typically during a planned or unplanned outage various construction projects,
repairs and modifications occur on the operating units which greatly increase
hazardous waste volumes. If unplanned outages do not occur volumes of waste are
normally substantial less.
Do you also keep this information on a plant and or
process stream basis? yes
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face? Yes
If so, what are they and how can they be overcome?
Unplanned outages of the electric generating units, better housekeep and reduction
of in plant spills.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction? No
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Once and if an identification operation occurs.
RETURN BY MAY 4, 1987
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Rohm and Haas Company
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1937
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Rohm and Haas Company
Address Independence Mall West, Philadelphia, PA 19105
Contact Person, Title Ronald F. Black, Corporate Environmental Manager
Telephone # (215) 785-7578
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 2821, 2869, 2879
Net Worth 1986 1,002,000,000
Sales 1986 2,067,000,000
Major Products by Divisions
Acrylic emulsions for latex paints, surfactants, biocides, acrylic monomers,
Plexiglas sheet, motor oirartditlves, ion exchange resins, electronic chemicals,
agricultural chemicals, acrylic coatings, membrane systems.
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste #
A number of small volume streams which the largest volume is ignitable characteristic
waste. Corrosive, reactive, EP toxic and listed wastes in smaller ammounts.
Number of plants which generate hazardous wastes
Location of plants which generate hazardous wastes
Bristol, Spring House and Philadelphia, PA; Louisville, Ky; Knoxville, Tenn;
Hayward and Redwood City, CA; Bayport and Deer Park, Tx.
Number of Employees 12,060
Please return to: DANA DUXBURY
CKNTUtt FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees,
a newsletter, video, yearly review to corporate management,
technology seminars/ included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
Guidance comes from the Corporate Environmental Affairs Group to each plant location
in form of expertise with respect to interpretation of rules and regulations which
would impact on their operation. <
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Intensified efforts within the scope of plan previously submitted.
c) what were the leading factors that caused you to alter your
waste reduction efforts during the past year? None
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
Although no changes did occur in the program if they had it would be reviewed at
CEO level.
e) How does your corporation define waste reduction?
media and wastes or emissions are covered in your definition?
"In a strict sense, we define waste generation/reduction to be the elimination
of the production waste. We also recognize recycling (resue) use of waste or
waste reduction. We agree with the definition of waste reduction used by the
Massachusetts League of Women voters in their information package." We include
solid, air and water.
RETURN BY MAY 4, 1987
Page 2
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Tufts University Center for Environmental Management (617)381-3-136
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Plant managers have been given guidelines to follow which encompass the elements
of our waste reduction program. These elements are those defined under RCRA
in addition to Corporate requirements.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
To all Corporate levels and within all facilities.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Current staff within Corporate and facility levels are focusing more attention
to waste reduction.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
No numerical goals have been set. Our primary objective is to reduce reliance
on landfill disposal.
j) Does each plant or Division establish its own particular
goals?
Yes
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Vice President of Operation
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Fully implemented
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Through training and audit functions.
RETURN BY MAY 4, 1987
Page 3
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Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
No! Me have not modified cost accounting procedures. Cost incentives are
developed at the facility level.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
What is your base year? 1985
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
% reduction based/unit production.
Do you also keep this information on a plant and or
process stream basis?
We do it on a plant basis.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Cost of necessary research in relationship to the value of the process. RCRA
provisions that may require permit modifications.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
No. This is a dynamic process and difficult to predict.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Plant basis because our approach could resolve problems of other processes.
RETURN BY MAY 4, 1987
Page 4
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Tufts University Center for Environmental Management (617)381-3485
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Each plant defines its own waste reduction program based on our Corporate guidelines.
The progress is monitored through Corporate audits. The driving force for the
program 1s primarily economics but internal requirements also force us to reduce
land disposal usage.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
No change
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
How did you accomplish this?
The Corporate Waste Reduction Policy is administered through regional directors.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
For each new or modified process the waste stream is part of Safety, Health
and Environmental Review.
Have you computerized this waste stream audit data?
Waste disposal quantities are computerized but not audits.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Yes
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
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Tufts University Center for Environmental Management (617)381-3435
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit;?
Not uniformly but under several programs.
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or Ho
Yes Identify and quantify sources of all process losses to
all media. If not all, which ones?
Yes Identify opportunities for future cost effective
reductions?
Yes Establish goals for the next years?
Yes Identify resource requirements for attainment of goals?
Yes Identify techniques to attain goals?
Yes Interview plant employees to ascertain training needs
and level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waate reduction audit computerized?
Yes! See previously submitted examples.
*Not Applicable
RETURN BY MAY 4, 1987
Page 6
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4V-I l.istim nuc. On Us Hall
•nifts Univi.isity, Medford, MA 02155
CENTER FOR ENVIRC»«ENTAL MANAGEMENT
(617) 381-3486
March 10, 1987
Question III: What have your waste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
Me continue to focus our emphasis on waste reduction throtiqh process innrovenonts. Internally reuse or
recycle of solvents and raw material used In research (see previously submitted examples).
METHODS: A) Improvements in technology 6 equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
WASTE REDUCTION
METHOD
(see above)
F
r
WASTE REDUCED
EPA HAZARDOUS
WASTE (
TYPE OF
HASTE
Still
bottoms
Prims
PLANT LOCATION
Bristol
All location
DATE
1W.P
pne
PER CENT
REDUCTION
inn
._
10CATICN
ON-SITE
__
__
OFF-SITE
X
w
n
DESCRIPTION
3rd stage distillation
bottoms
Drums (steel i finer.
polynpr)
ADDITIONAL
INFORMATION
These bottoms are incineratrd for
enerqy recovery
I'.Y M,\V i. 1'IH7
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10. 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
Those mentioned in 1985 questionnaire have been fully Implemented. We are
now focusing specifically on high volume waste and liquid solvents.
RETURN BY MAY 4. 1987
8
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Shell Oil Company
-------
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company: Shell Oil Company
Address: One Shell Plaza, Houston, TX 77001
Contact Person, Title: R. R. Kienle, Manager Environmental
Affairs - HS&E
Telephone #: (713) 241-6236
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit): 12, 13, 28, 29, 46
Net Worth, 1986: $14,312 Million
Sales and Other Revenues, 1986: $18,222 Million
Major Products by Divisions: Crude oil, natural gas, natural gas
liquids, automotive gasoline, jet fuel, kerosene, heating and
diesel oils, heavy fuel oils, propane and other LPG, petro-
chemical feedstocks, asphalt, petroleum coke, lubricants, wax,
olefins, aromatics, chemical intermediates, detergent and
ethylene oxide products, solvents, plastics, and elastomers
and resins.
Major Hazardous Waste Streams by Division and EPA Hazardous Waste #:
RCRA listed wastes associated with petroleum refining, chemical
manufacturing and product distribution systems. For example
(and in numerical order), we generate:
D001 - Ignitable wastes, not otherwise listed.
D002 - Corrosive wastes, not otherwise listed.
D003 - Toxic wastes, not otherwise listed.
D007 - Chromium containing wastes, not otherwise listed.
F002 - Spent halogenated solvents.
K022 - Tars from phenol/acetone distillation process.
K048 - Dissolved air flotation float.
K049 - Slop oil emulsion solids.
K050 - Heat exchanger bundle cleaning sludge.
K051 - API separator sludge.
Number of plants which generate hazardous wastes: Eleven manufac-
turing plants in seven states. Additionally, Shell has crude
oil and gas exploration and production operations, and pro-
duct marketing and distribution system and support facilities
throughout the U.S.
Location of plants which generate hazardous wastes: California,
Illinois, New Jersey, Louisiana, Texas, Washington and Ohio
— other facilities essentially nationwide.
Number of Employees: 1986: 32,641
CR8711001
-------
Woods Hole III Questionnaire
Question I
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals, routine
reporting mechanisms, yearly recognition of employees, a newsletter,
video, yearly review to corporate management, technology seminars,
included in performance reviews, waste reduction project competition
for capital, etc.)
If you have not previously included a copy of your corporate
waste reduction program or plan, please do so.
Guidance is developed by Shell's corporate environmental organi-
zation, utilizing both internal and external information sources.
For larger facilities, the intent is that fundamental goals be estab-
lished with representatives from operating functions and others who
either generate wastes or provide assistance in minimization efforts.
More specific goals are to be set by location management. Progress
reports are to be made to location and corporate management annually,
from which a corporate report will be prepared for broad distribution.
For smaller locations, the plan is similar but somewhat less formal.
Waste minimization is specifically addressed at annual environmental
conferences in both plenary and workshop formats. Functional and
corporate memoranda addressing specific aspects of waste minimization
are developed as necessary and appropriate.
b) Please note how your corporation has modified or expanded its
corporate waste reduction program or plan in the past year, if indeed
you have modified or expanded it.
Shell's corporate plan has not been modified. As the program
has developed, additional corporate and functional staff time has been
directed to specific program elements. Emphasis has been placed on
establishing baseline data from which waste minimization progress can
be measured. From this, more specific goals have been and will con-
tinue to be developed. One additional staff member has been assigned
to the corporate environmental group and is devoting 15-20% of his
time on waste minimization to provide stronger focus on the program.
Later this year an additional Head Office process engineering staff
member will be assigned specifically to study processes and process
streams to identify and evaluate waste reduction opportunities.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
Our program has matured to the point that previously recognized
needs for additional staff time had to be satisfied.
PAGE 2
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(QUESTION I CONTINUED)
d) At what management level in your corporation, during the past
year, were changes, if any, made in your waste reduction program or
plan?
The staff additions discussed previously required concurrence of
senior management.
e) How does your corporation define waste reduction? What media
and wastes or emissions are covered in your definition?
Shell considers waste reduction to be the minimization of both
the quantity and toxicity of materials disposed either off-site or
on-site, with emphasis on the latter and in consideration of all
media -- air, land and water. Inherent in this consideration is our
premise that true minimization, or avoidance, of wastes includes
treatment, reduction and recycling or reuse. In this latter regard,
recycling/reuse of materials, particularly for energy recovery, is
normal good resource conservation practice and only those efforts to
further recover or reuse materials from current "wastes" are "waste
reduction" in our view. We would add that a principal goal is waste
self-sufficiency, or the elimination of dependency upon outside
entities and locations to accommodate our wastes.
f) Does each Division or plant in your corporation have its own
specific program or plan?
It will. In following corporate guidance and achieving corporate
goals, each manufacturing location is in the process of developing its
own specific plan and program. Such plans will embrace the corporate
environmental premises which set forth the corporate goals. We have
also begun to require larger locations to develop an environmental
long-range plan which will emphasize these goals in a more formal
manner and which will require approvals at high location, functional
and corporate levels.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
All levels, from location operators to functional and corporate
vice-presidents and Shell's General Executive Office. It is pertinent
to note here that significant reduction opportunities have been
identified by operating personnel. Many of these have been low in
capital requirements and high in innovation and ingenuity.
h) Have you found the need for additional waste reduction expertise
in the last year? If so, new staff or consultants?
Yes; though this is a function of our program maturity rather
than a suddenly recognized need for staff.
PAGE 3
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(QUESTION I CONTINUED)
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the .goal and
the time frame in which the goal is to be met.
Yes. Directional goals are set forth as shown in the attached
"Directions for Future Solid Waste Management." More specific goals
are established in the corporate environmental premises from which
locations or functions develop their own plans and goals. Examples
of the manufacturing premises include: reduce waste* volume one to
five percent annually; complete planning and begin implementation to
minimize need for deep well disposal within the next few years;
complete steps to minimize dependence on deep well disposal by early
1990"s; continue capital investment and process changes to meet waste
minimization goals. As an example of our progress in achieving these
goals, one of our Louisiana plants has already reduced its need for
deep well injection and should eliminate it almost entirely by the
end of 1987. This reduction will amount to 296,000 tons per year of
non-hazardous waste.
j) Does each plant or Division establish its own particular goals?
This is our intention. See I.f.
Jc) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
We consider such responsibility to be primarily a line function
for which location or operating managers are responsible. Functional
managers are obviously required to ensure that their functions meet
established corporate goals. Corporate goals are established by the
corporate Environmental Affairs manager; functional goals are set by
the appropriate corporate functional environmental manager. All of
these managers audit progress in goal achievement.
1) What stage has your corporation reached in implementing your
corporate waste reduction program or plan?
We have completed data gathering and initial reviews to establish
our waste reduction baseline, and have called for additional data for
the 1986 calendar year. A corporate report establishing the baseline
and 1986 progress will be developed; data and information from earlier
years (1980-1985) will be included.
*Both hazardous and nonhazardous wastes. Reduction is determined
in the context of our response to question I.e.
PAGE 4
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(QUESTION I CONTINUED)
m) How are you going to maintain or accelerate the momentum and
awareness of your waste reduction program in the year ahead?
Staff additions to both the corporate environmental and process
engineering groups have been approved. These additions have been
identified in earlier responses and are an outgrowth of Shell's plan
maturation. The assignees will provide focus for guidance and infor-
mation (in and out) regarding both the corporate program and waste
reduction opportunies.
n) During the past year, have you modified your cost accounting
procedures to ensure that waste reduction is encouraged to a greater
extent? If so, how have you done this? (i.e., placing additional
charges on things such as total volume, method of waste management,
potential long term liability, or recharges to specific plants for
environmental management.)
Shell will not modify cost accounting procedures to artificial-
ly favor waste reduction. Rather, we depend upon senior corporate
management to acknowledge those needs and to support the development
and implemention of plans to satisfy them as established by environ-
mental and functional management at all levels. We have, however,
identified and emphasized the necessity to ensure that accounting
procedures properly reflect the true costs of waste generation and
handling. We have not yet determined how to allocate long-term/
liability costs. Except for this, costs are generally allocated to
appropriate cost centers and are becoming readily identifiable.
(Superfund costs, for example, are charged to functions that may
have contributed to the site. Actual disposal costs are allocated
to the generating location.) This approach ensures that waste reduc-
tion projects and programs are properly represented in both the
identification of problem areas and the competition for capital.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
At present, accomplishments are measured by quantification of
both volume and toxicity reductions and assessment of avoided costs.
Careful consideration is being given to other forms of measurement;
however, we confess having difficulty in developing a denominator
(sales, employees, production, etc.) appropriate to our organization.
At present, we favor either intake or product volumes as a denomina-
tion, although this may not be best for all situations.
What is your base year?
1985.
PAGE 5
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(QUESTION I CONTINUED)
p) When accounting for production variations, did your corporation's
hazardous waste generation rate change from the previous year? If
so, how?
Yes. However having no "universal" denominator, we cannot as
yet specifically state how it changed in terms of rate. We do know
that significant reductions were made in both the volume and toxicity
of wastes during 1986, as well as in previous years.
Do you also keep this information on a plant and/or process
stream basis?
On a plant basis for the present.
g) Are there any specific barriers to achieving significant waste
reduction levels that your corporation, particular divisions or
process streams face? If so, what are they and how can they be
overcome?
Yes. At present in our industry the economic barrier is a
significant one which will persist for at least the near term. Thus,
funding for staff, capital and research and development projects is
highly competitive. We have been successful in adding staff to
further our waste management efforts in keeping with our corporate
plan. Process engineering and research and development approaches
to waste reduction'techniques (process modifications, material
substitutions, equipment changes) are being investigated. Where the
results of these investigations must compete for capital, an addi-
tional barrier may arise: recapitalization costs associated with
changes to mature processes, complex and interrelated facilities
and large plants can be immense. Until specific projects have been
identified, however, we cannot determine how this barrier might be
overcome.
r) Have you begun to identify how far and how fast your corporation
can move to attain the maximum benefits of waste reduction?
Yes, we have begun but such determinations are incomplete and
will remain so for the near term. As time passes, we anticipate
changes to occur in our plans since we view them as dynamic and
continuous.
Should this identification of maximum benefits be done on a
corporate, plant or process waste stream basis?
For our company, the process waste stream basis appears to be
the most appropriate. We are continuing to consider other bases,
however.
PAGE 6
-------
QUESTION II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Functions and locations follow the corporate plan in developing
and implementing their own program. Guidance documents and environ-
mental planning premises are adapted and included as appropriate.
Discussions are held among location representatives, functional
business center management, corporate environmental groups and other
appropriate organizations. Location personnel attend and partici-
pate in annual environmental conferences and periodic coordinating
meetings in certain areas. Annual reports are prepared by locations
for evaluation and incorporation in the corporate report. There is
interchange among corporate, functional, support and field represen-
tatives. Ideas, successes, failures and developments are discussed.
i
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the past
year.
There have been no such changes. Although not a change in plan,
it is worth noting here that the process stream study commencing this
year (with a staff addition) will likely lead to changes in the on-
coming several years.
c) Assuming that your corporate waste reduction plan or program
began in your environmental division, have you integrated this
program or policy with your division or plant level manufacturing
policy?
Yes.
How did you accomplish this?
By distributing "Directions for Future Solid Waste Management*'
with accompanying guidance for its interpretation and implementation.
We develop long-term environmental planning premises which are amended
and updated annually. Wide-ranging discussion is held at various
meetings during the year, and in plenary and work group sessions at
the annual environmental conference. Progress is discussed and
evaluated during location environmental reviews. See II.a.
d) Do you conduct a waste stream (or process loss) audit? If so,
how frequently do you conduct the audit?
No. This is expected to be one of the results of the process
engineering study to be conducted by the staff addition. The design
and implementation of such audits will require time.
PAGE 7
-------
(QUESTION II CONTINUED)
Have you computerized this waste stream audit data?
We have no waste stream audit; however, other waste reduction
data is computerized.
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prioritization
of waste reduction methods, and implementation, documentation and
communication of results, etc.?
Yes, but it is not yet fully developed. In conjunction with the
process engineering staff addition and subsequent stream studies,
we plan to develop and implement a computerized waste tracking system
for each waste stream.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next question.)
Process losses are quantified by process yield methods. Inven-
tory losses are included as well as off-specification, damaged and
lost or otherwise unaccounted for materials.
Opportunities and costs of further waste reduction will be
identified by: process studies; costs of treatment, disposal or
other means of waste handling; and cost estimates of identified
waste reduction projects.
Prioritization of waste reduction methods is determined by
needs for the protection of the environment and public health,
regulatory requirements and deadlines and economic evaluations
addressing costs vs. benefits.
Implementation, documentation and communication of results is
accomplished through means described in several previous responses.
f) Do you conduct a waste reduction audit?
No.
-------
(QUESTION II CONTINUED)
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Identify and quantify sources of all process losses to
all media. If not all, which ones?
Identify opportunities for future cost effective reductions?
Establish goals for the next years?
Identify resource requirements for attainment of goals?
Identify techniques to attain goals?
Interview plant employees to ascertain training needs and
level of awareness?
Require sufficient data so that progress can be reported
relative to output?
Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Note problems and corrective actions undertaken?
Document costs and return on reduction efforts?
Identify resource requirements for the future?
Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
PAGE 9
-------
Tufts University, Medford, MA 02155 March 10, 1987
Question III: Mhat have your vasts reduction accoip^ishrents been in the past year since Hoods Hole H? (PLEASE TFT.T. ALL)
NOTE: our listings here are in the context of our response to Item I.e on Page 3. Methods C. E and F are, in our view, waste avoidance.
METHODS: A) Inprovements in technology & equirns.it; 3) Inprovenents ir. plar.t operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling i--.-pla.nt wastes; F) Recycling off-site.
1986 Data Being Processed. Examples of Some 1986 and Earlier Efforts ftre Listed Below.
'iASXE REDUCTION
METHOD
sea above)
A
B
E
E
E
E
E
E
E
E
WASTE 9
EPA KAZARDCUa
WASTE f
K050
None
K048
None
D007
0002
0003
D001
None
None
EDUCED
TYPE OF
HASTE
Toxic
~
Toxic
-
EP
toxicity
Corrosive
Toxic
Igni table
-
-
PLANT LOCATION
Illinois
Louisiana
California
California
California
California
California
California
California
California
DATE
1986
1986
1984-86
1984-86
1980-86
1983-86
1986
1986
one-time
1986
one-tune
1986
one-time '
PER C3ZI
?EDUCTICN
H/A
25%
11,000 TPY1
30,500 TPY
15 TPY
1,100 TPY
100%
1.5 TPY
43 T
21 T
171 T
IOCATICN
GI'-EITS
X
X
X
X
X
X
X
X
X
X
OFT-SITi
(
DESCRIPTION
Reduced toxicity.
Source control, unproved
pretreatment, increased
sludge aging.
Reused as CO boiler fuel.
Reused as CO boiler fuel.
Burned in reforming
furnace.
Used for effluent treat-
ment pH control.
Recycled contaminated
containers. •
Reprocessed waste.
Reprocessed waste product.
Reprocessed waste.
ADDITIONAL
INFORMATION
Heat exchanger bundle cleaning
sludge.
Effluent treater biosolids.
DAF float.
Effluent treater biosolids.
Sulfinol reclaimer bottoms.
Spent caustic.
-
-
-
-
•Includes reuse in same or other process/product
1TPY = T0ns per year. Percentage not available.
Page io(a)
PLEASE RETURN BY MAY 4, -1987
-------
Itifts University, Bedford, MA 02155 March 10, 1987
Question IH: VJhat have your waste reduction accoiplisrrrants been in the past year since Woods Bole H? (PLEASE TTT.T. ALL.)
NOTE: Our listings here are in the context of our response to Item I.e on Page 3. Methods C, B and F are. in our view, waste avoidance.
METHODS: A) Inprovements in technolccv & esuipns.it; B) Inprovenents ir plant operations; C) aistitution of raw materials;
D) Redesign or reformulation"of end products; E) Recycling ir.-pla.it wastes; F) Recycling off-sita.
ViASTE REDUCTION
METHOD
see above)
E
E
E
F
F
F
F
F
F
F
F
WASTE REDUCED
SPA HAZARDOUS
WASTE £
D002
KOSO
K051
D001 (?)
D003
D003
D001
CA Hazardous
Waste
CA Hazardous
Waste
Various
various
Not listed
TYPE Of
HASTE
Corrosive
Toxic
Ignitable
(?)
TOXiC
Toxic
Ignitable
-
-
-
~
PLANT LOCATION
California
California
California
Washington
Washington
Washington
California
California
California
California
California
DATE
1967-86
1976-86
1986
1986
1986
1985
one-time
1984-86
1984-86
1984-86
1984-86
1986
one-time
PER CECT
pmucnox
31. 500 TPY
1.300TPY
9 TPY
175 TPY
47 TPY
2,3007
la 500 TPY
4, 700 TPY
110 TPY
550 TPY
0.6 T
IOCATION
s:-£:n:
X
X
X
OrT-SnE
X
X
X
X
X
X
X
X
I
DESCRIPTION
Neutralized.
Converted to product.
Remove metal filter frame
for reuse.
Sold as raw material.
Sold for regeneration.
Sold for heat value and
aggregate.
Sold as product.
Sold.
Burned in CO boiler.
Burned in CO boiler.
Returned to supplier.
ADDmCNAL
INFORMATION
Spent caustic.
Heat exchanger bundle cleaning
sludge.
-
Spent metal catalyst.
Spent metal catalyst.
Tank bottoms.
Wet coke process fines.
Dry coke fines.
Machine shop wastewater.
Plant sump water.
Cobalt acetate solution.
Page 10 (b)
PLEASE RETURN BY MAX 4,-1987
-------
University,Medfora, MA 02155 harcn 10,
Question in: What have your waste reduction accoipliSnents been in the past year since Woods Hole n? (PLEASE TPTT. ALL)
NOTE:. Our listings here are In the context of our response to Item I.e on Page 3. Methods C, E and P are, in our view, waste avoidance.
T *
METHODS: A) Inpiovaienta in technology & equionent; B) Imaioveuents in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation" of end products; E) 'Recycling in-plant wastes; F) Recycling off-site.
XASTE REDUCTION
METHOD
see above)
F
F
F
F
F
WASTE navjrm
SPA HAZARDOUS
WASTE $
Not listed
D002
D003
Various
Not listed
TXPE OF
WASTE
Corrosive
Toxic
-
HANI LOCATION
California
California
California
California
California
DATE
1986
one-tine
1981-86
1980-86
1980-86
1986
PER con*
REDUCTION
0.3 T
57,000 TPY
550 TPY
35 TPY
1,500 TPY
LOCATION
OS-SITE
OFF-SITE
X
X
X
X
X
1
DESCRIPTION
Returned to supplier.
Sent to supplier for
recycling.
Sent to metals reclaimer.
Sent to reconditioner.
Sold for alternate use.
ADDITIONAL
INFORMATION
Cobalt nitrate solution.
Spent sulfuric acid.
Spent/off-spec catalyst.
Hazardous materials drums.
Non-hazardous catalyst.
m
Page 10(c)
PLEASE RETURN BY MAX 4,1987
-------
QUESTION IV
a) What new waste reduction efforts have you underway? Have you
followed through on those mentioned in 1985's questionnaire as yet?
The efforts mentioned in our 1985 response have been, and
continue to be, active. As to new efforts, we are focusing on the
process waste stream studies mentioned in I.b, I.m and I.g.
PAGE 11
-------
SHELL OIL COMPANY
DIRECTIONS FOR FUTURE
SOLID WASTE MANAGEMENT
CONDUCT OPERATIONS IN A MANNER TO MINIMIZE WASTE PRODUCTION.
WASTES WHICH ARE PRODUCED WILL BE DISPOSED OF CONSIDERING
BOTH SHORT- AND LONG-TERM IMPACTS. TO CONTINUE IMPROVING ON
THE DISPOSITION OF WASTE CONSTITUENTS WHICH POSE A THREAT TO
THE ENVIRONMENT BY:
• WHERE PRACTICAL, DETOXIFY WASTES PRIOR TO DISPOSAL
USING METHODS SUCH AS CHEMICAL TREATMENT, INCINERA-
TION AND BIODEGRADATION.
• USE LAND DISPOSAL ONLY WHEN THERE IS NO REASONABLE
ALTERNATIVE, AND WHERE GROUNDWATER CAN BE PROTECTED.
• LIMIT USE OF DEEP WELL INJECTION TO NONTOXIC BRINES
AND WATERS AND OTHER WASTES ASSOCIATED WITH OIL AND
GAS PRODUCTION.
• WHERE PRACTICAL, BECOME SELF-SUFFICIENT IN WASTE
MANAGEMENT BY TREATING AND DISPOSING AT SHELL
FACILITIES.
• WHERE SELF-SUFFICIENCY IS IMPRACTICAL, USE OUTSIDE
CONTACTORS WHOSE PRACTICES ARE COMMENSURATE WITH
THOSE ACCEPTABLE TO SHELL.
-------
Texas Instruments Inc.
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Texas Instruments Inc., Materials § Controls Group
Address 34 Forest Street, Attleboro, MA 02703
Contact Person, Title Francis J. Veale, Jr., Environmental Engineering
Manager, Environmental Attorney
Telephone # 617-699-1804
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit) 3613, 3471, 3399
Net Worth 1985 $93M\
j* Materials Division Only
Sales 1985 $180M/
Major Products by Divisions
CPD - Motor Controls, Motor Protectors and Electronic Controls
MMD - Clad Metals, Connector Systems, Thermostat Bimetals
EPD - Precious Metal Plated Lead Frames
Major Hazardous Waste Streams by Division and EPA Hazardous
Waste #
Photo Etch D002
Waste Treatment F006
Materials § Controls M001, F001
Number of plants which generate hazardous wastes 6
Location of plants which generate hazardous wastes Attleboro, MA,
Europe, Far East, United States. Major facility in United
States is Attleboro.
Number of Employees 9» 5,000 at Attleboro
Please return to: DANA DUXBURY
CENTER FOR ENVIRONMENTAL MANAGEMENT
TUFTS UNIVERSITY
474 BOSTON AVENUE (CURTIS HALL)
MEDFORD, MA 02155
by: May A, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Woods Hole III Questionnaire
Question 1
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate
waste reduction program or plan. (Such as: guidance, goals,
routine reporting mechanisms, yearly recognition of employees/
a newsletter, video, yearly review to corporate management,
technology seminars, included in performance reviews, waste
reduction project competition for capital, etc.)
If you have not previously included a copy of your
corporate waste reduction program or plan, please do so.
See Attachment #1. All capital projects must be reviewed and
approved by Environmental Engineering.
b) Please note how your corporation has modified or expanded
its corporate waste reduction program or plan in the past year,
if indeed you have modified or expanded it.
Placing greater emphasis on allocating costs of waste disposal to
individual manufacturing cost centers. By directly impacting
profits, the manufacturing departments are motivated to generate
less waste.
c) What were the leading factors that caused you to alter your
waste reduction efforts during the past year?
A combination of factors including: environmental awareness,
awareness of the impact of waste disposal on all media within the
environment, potential liability.
d) At what management level in your corporation, during the
past year, were changes, if any, made in your waste reduction
program or plan?
It has always been recognized and espoused by upper management,
the thrust now is to implement programs through operations
managers.
e) How does your corporation define waste reduction? What
media and wastes or emissions are covered in your definition?
Though not the purest form of source reduction, TI's definition
includes some forms of treatment such as incineration, recovery
of heat value in industrial boiler. Emphasis, however, is placed
on true source reduction.
RETURN BY MAY 4, 1987
Page 2
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
f) Does each Division or plant in your corporation have its
own specific program or plan?
Yes.
g) To what level in your corporation has your waste reduction
program or plan been communicated?
Waste reduction is communicated by technology transfer on the
corporate level during quarterly council meetings.
h) Have you found the need for additional waste reduction
expertise in the last year? If so, new staff or consultants?
Source reduction concepts are well understood. The actual
engineering and implementation require additional resources at
the production level.
i) Does your corporate waste reduction program or plan include
goals? If so, describe them - including the nature of the goal
and the time frame in which the goal is to be met.
Specific goals are being formulated. It is recognized that the
goals must be quantifiable so that true progress can be measured.
One goal is the total elimination of Trichloroethylene by 1995.
j) Does each plant or Division establish its own particular
goals?
Yes.
k) At present, what is the highest management level in your
corporation that is responsible for waste reduction?
Department Manager.
1) What stage has your corporation reached in implementing
your corporate waste reduction program or plan?
Corporation has set high goals, therefore we are still in early
stages.
m) How are you going to maintain or accelerate the momentum
and awareness of your waste reduction program in the year ahead?
Education, training, and interaction between environmental and
manufacturing. Ultimately, source reduction, in order to
succeed, must be implemented by manufacturing.
RETURN BY MAY 4, 1987
Page 3
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
(QUESTION I CONTINUED)
n) During the past year, have you modified your cost
accounting procedures to ensure that waste reduction is
encouraged to a greater extent? If so, how have you done
this? (i.e., placing additional charges on things such as
total volume, method of waste management, potential long term
liability, or recharges to specific plants for environmental
management.)
Yes - We incorporated hazardous waste disposal costs into existing
division accounting database. This is the most significant action
toward distributed the costs of waste generation directly to the
manufacturing profit centers.
o) How do you measure your waste reduction accomplishments (by
sales, employees, pounds/unit production)?
By weight or volume per year. Emphasis is being placed on
normalizing, values against production rates.
What is your base year?
Different waste streams have different base years, but generally
it is 1980.
p) When accounting for production variations, did your
corporation's hazardous waste generation rate change from the
previous year? If so, how?
For trichloroethylene, hazardous waste generation has decreased.
Do you also keep this information on a plant and or
process stream basis?
On a plant basis.
q) Are there any specific barriers to achieving significant
waste reduction levels that your corporation, particular
divisions or process streams face?
If so, what are they and how can they be overcome?
Lack of engineering resources; difficulty of technology transfer
for diverse processes; regulatory structure emphasizes end-of-pipe
treatment.
r) Have you begun to identify how far and how fast your
corporation can move to attain the maximum benefits of waste
reduction?
Yes.
Should this identification of maximum benefits be done on
a corporate, plant or process waste stream basis?
Most meaningful at the process level.
RETURN BY MAY 4, 1987
Page 4
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
On the Division level, we have formulated a committee consisting
of environmental and key manufacturing personnel. The committee
convenes monthly under the direction of environmental, and it
discusses the ongoing and future projects. Actual implementation
occurs at the manufacturing level.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
N/A
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
Yes.
How did you accomplish this?
Through a waste reduction council described above, and charge-out
allocation. In each Department, manufacturing managers have appointed
champions to accomplish the specific activities.
d) Do you conduct a waste stream (or process loss) audit? If
so, how frequently do you conduct the audit?
Yes, monthly accounting for waste generation; and annual site
audits.
Have you computerized this waste stream audit data?
Yes.
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Yes, with respect to prioritization, implementation, documentation
and communication.
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question)
RETURN BY MAY 4, 1987
Page 5
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
Yes.
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
Yes Identify and quantify sources of all process losses to
all media. If not all, which ones?
For major'waste generation processes.
Identify opportunities for future cost effective
reductions?
es Establish goals for the next 5 years?
Yes
Identify resource requirements for attainment of goals?
Yes Identify techniques to attain goals?
Interview plant employe*
and level of awareness?
No
Interview plant employees to ascertain training needs
Yes
Require sufficient data so that progress can be reported
relative to output?
Yes Document and report accomplishments and problems to
management?
Y » e
Report progress on waste reduction relative to goals?
es Note problems and corrective actions undertaken?
Yes Document costs and return on reduction efforts?
Yes Identify resource requirements for the future?
es Project expected future returns?
Other elements?
Is your waste reduction audit computarized?
No, not entirely.
RETURN BY MAY 4, 1987
Page 6
-------
474 Boston Avenue, Curtis Hall
Tufts University. Nedford, MA 02155
(617) 381-3486
March 10, 1987
OUTER FOR ENVIRONMENTAL MANAGEMENT
Question III: ttiat have your vaste reduction accomplishments been in the past year since Woods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology 6 equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
STE 1 -DUCTION
METIiOO
see above)
E
C
E
B
B
HASTE REDUCED
EPA HAZARDOUS
HASTE «
D011
M001
F001
TYPE OF
WASTE
Spent
Hack-
strip
iolution
Ind.
Waste
Water
trawing
Oil
TCE
«
'umice
PLANT LOCATION
Attleboro
Attleboro
Attleboro
Attleboro
Attleboro
DATE
1/86
3/86
7/86
1/84
8/86
PER CENT
kdXJCTlOrt
90t
1992000
Gallons
9000
Gallons
56t
95t
LOCATION
ON-SITE
X
X
X
X
X
OFF-SITE
<
DESCRIPTION
Electrolytically
recover silver.
Jltra-filtration of
Alkaline cleaning
solution on electric
furnace lines * 2
and IS.
Centrifuge Emulsified
wire drawing oil
TCE Elimination and
TCE Replacement with
Aqueous based
detergents .
Elimination of pumice
abrasive in the metal
strip cleaning
process.
I
ADDITIONAL
INFORMATION
Destroy cyanide by industrial
waste treatment.
Extend life of solution
Extend life of oil.
On-going program to eliminate
all TCE usage by 1995.
Paoe 7
PLEASE RETURN BY MAY 4. 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) What new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
as yet?
1. Sitewide elimination of TCE by 1995 is an ongoing effort.
2. Eliminate 150,000 gal/.yr of Spent Ferric Chloride Etch
solution:
1.) Modify material handling so that most resistant metals
are etched first while solution is strong, and least
resistant materials are etched later as solution weakens -
Double life of solution.
2.) Re-cycle ferric chloride solution.
3.) Implement closed-loop, totally recycling etching system
based on Cupric Chloride solution for compatible materials,
3. Install fabric pre-filtration system for high quality
lubricating oil on the metal rolling mills. Reduce generation
of voluminous, high spec filters'.
RETURN BY MAY 4, 1987
Page 8
-------
ATTACHMENT 1
-------
"S - COUTRO'° 6PrtMP
FACILITIES & SERVICES
ENVIRONMENTAL ENGINEERING
HAZARDOUS HASTE MANAGEMENT POLICY
THE MANAGEMENT OF TI GENERATED HAZARDOUS MATERIALS WILL BE IN
COMPLIANCE WITH ALL APPLICABLE LAWS AND REGULATIONS. PRACTICES
WILL MINIMIZE TI's LONG-TERM LIABILITY AT THE MOST PRACTICAL COSTS,
TI's MANAGEMENT OF HAZARDOUS MATERIAL WILL COMPLY WITH THE
FOLLOWING STEPS IN RANK ORDER:
- REDUCE USAGE OF CHEMICALS THAT WILL BE CLASSIFIED AS HAZARDOUS
AFTER USE.
- RECYCLE OR REUSE MATERIALS PRIOR TO CLASSIFICATION AND DISPOSAL
AS A HAZARDOUS WASTE.
- TREAT OR NEUTRALIZE INDUSTRIAL BY-PRODUCTS WHENEVER PRACTICAL
TO PRODUCE NON-HAZARDOUS MATERIAL.
- THERMAL DESTRUCTION SHOULD BE USED TO DISPOSE OF WASTE WHERE
REDUCTION, RECYCLING. TREATMENT, OR NEUTRALIZATION IS NOT
PRACTICAL.
- HAZARDOUS WASTE LANDFILLING AT TI APPROVED HAZARDOUS WASTE
DISPOSAL SITES WILL BE THE LAST ALTERNATIVE.
4 NOV 86 FJV/sx 050-0525
-------
MATERIALS & CONTROLS GROUP
FACILITIES & SERVICES
WASTE MANAGEMENT PRACTICES
0 EFFORTS FOR HASTE MINIMIZATION PROGRAMS MUST BEGIN AT THE
LEVEL OF THE PRESIDENT AND BOARD OF DIRECTORS.
0 IMPERATIVE THAT INTERNAL SITE AUDITS BE PERFORMED AT LEAST
ANNUALLY TO IDENTIFY MAJOR PROCESS TECHNOLOGIES AND DISCOVER
POTENTIAL SOURCE REDUCTION TECHNIQUES.
0 DEVELOP A COMPUTRIZED WASTE TRACKING SYSTEM OF ALL WASTE
STREAMS - INSURE COSTS ARE DIRECTLY REFLECTED IN INDIVIDUAL
MANUFACTURING AREAS, RATHER THAN SPREAD OUT.
0 IMPROVE AWARENESS AND ALLOW PARTICIPATION TO BE WITH THE
INDIVIDUAL MANUFACTURING AREA.
4 NOV 86 FJV/SK 050-0525
-------
MaitRk/U-S & COuiitOLo GRuuP
FACILITIES & SERVICES
HASTE MANAGEMENT PRACTICES
THE POSSIBILITY OF COMPANIES DEVELOPING A JOINTLY OWNED
INCINERATOR SHOULD BE INVESTIGATED.
INCREASE ON-SITE HASTE RECOVERY.
HASTE STREAMS SHOULD BE REVIEHED FOR APPLICATION IN NEH
TREATMENT TECHNOLOGIES RATHER THAN SIMPLY RECYCLING BACK TO
ORIGINAL USE.
ALL SOURCE REDUCTION IMPLEMENTATIONS SHOULD BE CONSIDERED IN
LIGHT OF:
RCRA
CLEAN HATER ACT (H20 QUALITY)
CLEAN AIR ACT
NOV 86 FJV/SR 050-0525
-------
FACILITIES & SERVICES
WASTE MINIMIZATION
ESTIMATES PREDICT 40-50X REDUCTION IN HAZARDOUS HASTE GENERATION
THROUGH COMPREHENSIVE APPLICATION:
HOUSEKEEPING
PROCESS CHANGE
DIRECT REUSE/RECYCLING
4 NOV 86 FJV/SK 050-0525
-------
Union Carbide Corporation
-------
Tufts University Center for Environmental Management (617) 381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
WASTE REDUCTION: THE HURDLES AHEAD
June 3, 4, 5 - 1987
General Information
Name of Company Union Carbide Corporation
Chemicals & Plastics Group
Address 39 Old Ridgebury Road - P2606
Danbury, CT 06817-0001
Contact Person/ R.T. Jackson
Title Director, Environmental Affairs
Chemicals & Plastics Group
Description of U.S. Company Activities
Standard Industrial Code Numbers (4-digit)
2869 (Inorganic chemicals)
Net Worth 1985 Data not available on C&P basis
Sales 1985 $4.7 billion
Major Products by Divisions
Polyolefins Polyethylene
Specialty Chemicals Silicones, Urethane Intermediates
Solvents & Coatings Mtls Alcohols, Glycol Ethers/Esters, Vinyl, Phenoxy,
and Phenolics Resins
Industrial Chemicals Ethylene Oxide/Glycol, EO Derivatives
Number of plants which generate hazardous wastes
Approximately 30
Location of plants which generate hazardous wastes
AL, CA, IL, LA, MD, NJ, NY, PR, IX, WA WV
Number of Employees Approximately 12,000
Please return to: DANA DUXBURY
Center for Environmental Management
Tufts University
474 Boston Avenue (Curtis Hall)
Medford, MA 02155
by: May 4, 1987
-------
Woods Hole III Questionnaire
Question I
Corporate Waste Reduction Policy
a) Please outline the essential ingredients in your corporate waste reduction
program or plan. (Such as: guidance, goals, routine reporting mechanisms,
yearly recognition of employees, a newsletter, video, yearly review to
corporate management, technology seminars, included in performance reviews,
waste reduction project competition for capital, etc.)
If you have not previously included a copy of your corporate waste
reduction program or plan, please do so.
A Guidance for waste reduction program comes from corporate policy and
continuing emphasis from top management. Each division, as well as
manufacturing/distribution location within a division, has a waste management
strategic plan that is used as a basis for goal-setting and resource
allocation. This plan is an integral part of the annual business planning
process and is reviewed and updated at that time. Specific items used in the
program include:
0 Review of new processes and projects at an early phase.
0 Written directions from the CEO and C&P business group
president specifying:
- Air emissions reduction goals.
- Reducing dependence on land disposal as quickly as
possible.
- Capital set aside for reduction projects.
- Defined waste minimization programs at division and
plant levels.
-------
b) Please note how your corporation has modified or expanded its corporate
waste reduction program or plan in the past year, if indeed you have modified
or expanded it.
A This year, a consistent format for waste management strategic planning has
been implemented to facilitate the planning and management process, and to
simplify review and control of the program by senior management.
Efforts to move away from land disposal as rapidly as practical have
intensified and have been the subject of directives by the C&F Business Group
President.
Increment II of the Emissions Reduction Program has been defined.
Increment II capital of $35MM, added to &45MM for Increment I, brings the
total authorized since 1985 to $80MM for emissions reduction expenditures over
and above normal programs.
c) What were the leading factors that caused you to alter your waste
reduction efforts during the past year?
A A combination of factors that include:
- Smaller, more focused company.
- Improved understanding of escalating costs that illustrates where
waste minimization efforts should be focused.
- The near and longer term costs associated with waste disposal.
- Sensitivity to the public perception that reduction is preferable
to treatment, no matter how environmentally safe the treatment
method may be.
d) At what management level in your corporation, during the past year, were
changes, if any, made in your waste reduction program or plan?
A As noted above, the increased emphasis on waste reduction has been
emphasized at all management levels, starting with the CEO.
-------
- 2 -
e) How does your corporation define waste reduction? What media and wastes
or emissions are covered in your definition?
A Waste reduction is the decrease in process materials which are not
consumed in the manufacturing process, as well as reduction in losses in
distribution and handling. It includes all media: air, water and land.
Design of new processes and facilities to minimize waste formation, at-source
reduction in existing facilities, environmentally sound conversion of wastes
into usable products, and recycling are the top priorities. Where waste
treatment is the only practical alternative, the most environmentally sound
method is sought.
f) Does each division or plant in your corporation have its own specific
program or plan?
A Yes. Currently, emphasis is being given to provide uniform formats for
data and program planning to facilitate understanding and control at all
management levels. Goals must be location-specific, but the overall goal is
to have uniform emphasis and program quality at all locations.
g) To what level in your corporation has your waste reduction program or plan
been communicated?
A C&P Business Group President has issued directives to division
Presidents. Each division president has communication throughout his
organization, which includes all manufacturing/distribution locations as well
as Engineering and R&D centers.
h) Have you found the need for additional waste reduction expertise in the
last year? If so, new staff or consultants?
A Yes. Additional staff has been added at the division and plant level.
Outside consultants are being used where technical expertise or additional
people are needed to support waste reduction/management activities. Waste
reduction programs in other companies are monitored, and UCC is an active
participant in the Chemical Manufacturer's Association (CMA) waste
minimization efforts.
-------
- 3 -
i) Does your corporate waste reduction program or plan include goals? If so,
describe them - including the nature of the goal and the time frame in which
the goal is to be met.
A C&P reduction goals of 301 per year for 3 years in process air emissions
and episodic environmental incidents were set in 1985. Continuous process
emissions have been reduced 36%, and accidental releases were reduced 30% in
1986.
For other wastes, goals are set at the plant level, and are reviewed and
agreed to with division management. Items such as concerns of local
communities, environmental impact, and near and longer term liability are used
to set priorities.
Goals are set annually, except as noted above, and progress is monitored
monthly or quarterly. Waste reduction goal setting includes day-to-day
operations as well as reductions obtained by process changes and capital
projects.
j) REFER TO ANSWER FOR li) ABOVE.
k) At present, what is the highest management level in your corporation that
is responsible for waste reduction?
A CEO - For example, he is the person who set the emission reduction goals
noted in the answer to (i) above. Even more important, however, is the thrust
to integrate management of waste reduction into the annual business planning
process. This requires each divison president to address the issue, and
involve the appropriate people in each division. The C&P Environmental Group
staff monitors this activity and reports on implemention progress to the C&P
Business Group President.
-------
- u -
1) What stage has your corporation reached in implementing your corporate
waste reduction program or plan?
A The process air emission and episodic incident reduction programs are well
defined, understood, and being implemented with continuing management
emphasis. Likewise, recycling of wastes and burning of liquid wastes have
been practiced for more than 20 years with good success. Transition to the
next level of waste reduction is being facilitated by:
- Continuing senior management emphasis.
- New, more comprehensive and uniform planning formats as mentioned
earlier.
- A more comprehensive waste management information system
utilizing a state-of-the-art computer system that will be placed
in service later this year.
The ultimate goal is to institutionalize waste reduction as an inherent
part of the corporate culture where it is viewed in a manner comparable to
personnel and operational safety.
m) How are you going to maintain or accelerate the momentum and awareness of
your waste reduction program in the year ahead?
A The items noted in the answer to II will make it possible to better
identify reduction opportunities and facilitate management control and
performance evaluation. Also, each division has implemented, or is
implementing, a "total quality" program that is intended to impact on every
aspect of business and functional performance. Waste reduction is an integral
part of these programs.
-------
n) During the past year, have you modified your cost accounting procedures to
ensure that waste reduction is encouraged to a greater extent? If so, how
have you done this? (i.e., placing additional charges on things such as total
volume, method of waste management, potential long term liability, or
recharges to specific plants for environmental management.)
A Waste costs are well understood at the plant level. However, the new
management information system noted earlier will more specifically relate
waste costs to specific business units, and will make it easier for management
to monitor reduction performance.
As noted earlier, corporate commitment for reductions in air emissions and
in use of land disposal is being actively pursued. Several of the incentives
mentioned in the question are under consideration, but they are not considered
necessary at this time.
o) How do you measure your waste reduction accomplishments (by sales,
employees, pounds/unit production)?
A Waste treatment costs, amount of material recycled and burned in boilers,
air emission volumes, and the number of accidental releases to the environment
are all used as measures. While all of these factors are treated with
importance, reduction in accidental releases is treated as a critical priority.
What is your base year?
A For the Air Emissions Reduction Program - 1985. For solid wastes,
year-to-year comparisons on a location-by-location basis have been used for
performance evaluation. The new management information system noted earlier
will facilitate organization of data in a C&F-wide basis and make base-year
comparisons more practical.
-------
- 6 -
p) When accounting for production variations, did your corporation's
hazardous waste generation rate change from the previous year? If so, how?
A At present, there is not a computerized C&P-wide report. Last year's
results have not been compiled yet since the varying plant reporting formats
must be consolidated manually. The new management information system under
development will facilitate more timely reporting.
Do you also keep this information on a plant and or process stream basis?
A This information is maintained on a process stream basis.
q) Are there any specific barriers to achieving significant waste reduction
levels that your corporation, particular divisions or process streams face?
If so, what are they and how can they be overcome?
The barriers are technical in nature.
- Assessing environmental impact accurately and determining
improvement benefits vs resource requirements.
- The impact of environmentally related process changes on product
quality.
r) Have you begun to identify how far and how fast your corporation can move
to attain the maximum benefits of waste reduction?
A Yes. The air emission and accidental release goals of 30% per year for 3
years were noted earlier. These are extremely aggressive goals, and the rate
of reduction beyond the third year cannot be predicted with accuracy at this
time.
Goals for other waste reduction activities are set on a year-by-year
basis, and the issues involved are too complex to allow estimation of
longer-term reduction rates at this time.
"Maximum benefits" will be a changing term that will be defined by
continually increasing understanding of environmental issues, process
chemistry, equipment, etc.
-------
- 7 -
Should this identification of maximum benefits be done on a corporate,
plant or process waste stream basis?
A Benefits are assessed using guidance provided from the Corporation and
Business Group. However, a meaningful reduction program requires benefits
analysis on a stream-by-streao basis.
-------
- 8 -
QUESTION II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation implements its
waste reduction program or plan at the plant or division level.
A Most locations focus their waste reduction efforts on the high volume or
most toxic waste streams. Within categories, more emphasis would be placed on
wastes going to land disposal, for example, than on wastes going to
incineration. Most locations schedule reviews with the generating departments
to discuss opportunities for reducing, recycling or eliminating the waste
streams targeted for minimization. In most cases, process R&D and Engineering
personnel must become involved where steps such as raw material substitution,
changes in process operating conditions, or in process recycling possibilities
are to be evaluated.
On an annual basis, the results of•• these efforts are summarized and
reported as required to EPA and/or state agencies, as well as internally.
b) Please note where your corporation has changed its plant or division level
waste reduction implementation scheme in the past year.
A The answer to this questions has been provided in the answers to earlier
questions.
c) Assuming that your corporate waste reduction plan or program begin in your
environmental division, have you integrated this program or policy with your
division or plant level manufacturing personnel?
A Yes, as noted in the answers to earlier questions.
How did you accomplish this?
A By receiving top level management support and direction.
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- 9 -
d) Do you conduct a waste stream (or process loss) audit?
frequently do you conduct the audit?
If so, how
A Operating conditions are monitored continually for changes that might
indicate an environmental release. Process efficiencies are computed at least
daily, and in the case of some units, every few minutes via computer
monitoring. Also, plant sewer and cooling water systems have sampling systems
that provide rapid indication of a process leak.
Audits are periodically, and frequencies vary depending on conditions
existing at the location.
Have you computerized this waste stream audit data?
A Waste stream data are available via computer at many locations. C&P is
moving to a uniform format at all locations using the management information
system noted earlier.
e) Have you established a process to identify: your process losses,
opportunities and costs for further waste reduction, prioritization of waste
reduction methods, and implementation, documentation, and communication, of
results, etc?
A Yes, as noted in the answers to earlier questions. Although no formal
process currently exists on a Corporation-wide basis, efforts are undertaken
to communicate success scories which have allowed plants to reduce waste
generation, or identify generic waste reduction opportunities (e.g., methods
for reducing waste due to sampling of residue streams, reducing lab wastes via
improved purchasing procedures, etc).
f) Do you conduct a waste reduction audit?
A See the answer to Question II d) above.
Also, waste identification and reduction is an integral part of all new
process evaluations as well as process revisions resulting from day-to-day
operations changes or capital projects.
-------
- 10 -
g) If so, what elements are included in your waste reduction audit?* Do you:
Yes or No
Yes Identify and quantify sources of all process losses to all media. If
not all, which ones?
Yes Identify opportunities for future cost effective reductions?
Yes Establish goals for the next 1 to 5 years.
Yes Identify resource requirements for attainment of goals?
Yes Identify techniques to attain goals?
Yes Interview plant employees to ascertain training needs and level of
awareness?
Yes Require sufficient data so that progress can be reported relative to
output?
Yes Document and report accomplishments and problems to management?
Yes Report progress on waste reduction relative to goals?
Yes Note problems and corrective actions undertaken?
Yes Document costs and return on reduction efforts?
Yes Identify resource requirements for the future?
Yes Project expected future returns?
Other elements?
Is your waste reduction audit computerized? - Partly.
*Audit as defined here defines many of the elements of a waste reduction
program and the answers were given on that basis.
-------
- 11 -
QUESTION IV
a) What new waste reduction efforts have you underway? Have you followed
through on those mentioned in 1985's questionnaire as yet?
A New efforts are noted above. Questionnaire was not completed in 1985.
-------
474 Boston Avenue. Curtia Hall
Tufts University, Medford. MA 02155
OUTER FOR ENVIRONMENTAL MANAGEMENT
(617) 381-3486
March 10. 1987
Question III: What have your waste reduction accomplishments been in the past year since Moods Hole II? (PLEASE TELL ALL)*
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials?
D) Redesign or raforaulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE REDUCTION
METHOD
(See Above)
C
B
B
E
HASTE PBT^KTH'
EPA
Hazardous
Haste »
U-028
—
F-001
Various
Type of
Haste
Residue
Liquid
Residue
Spent
Solvent
Liquid
Residues
PLANT LOCATION
Taft, LA
Seadrift, TX
Bound Brook. MJ
Texas City. TX
DATE
1986
PER CENT
REDUCTION
loot
100%
sot
37*
LOCATION
On-Site
X
X
X
X
Off-Site
DESCRIPTIOK
Less toxic compound was
substituted for U-028,
resulting in reduced
toxicity of waste.
Recycled sample.
Plush back to process.
Partially replaced
1.1. 1-tr ichloroetnane
with KEK. a less tome
solvent.
Burned a total of
12,345 tons of hazard-
ous waste in boilers
for fuel value.
ADDITIONAL INFORMATION
Approximately 200 tons
per year of waste are
involved.
3 tons per year reduc-
tion in waste.
This reduced the use of
1.1, 1-trichloroethane
and the amount of F-001
spent solvent generated
by 50*.
This represented an
increase of 37* in the
amount of hazardous
waste recycled in this
fashion. '•
•These are only some examples of waste reduction at specific plants as time limitations did not permit preparation of a complete list of accomplishments
throughout the CfcP Business Group.
-------
SZCTICN
SHERWIN-WILLIAMS DECORATING WORLD
•ail Mni\»'ju. Cr IM W
Hunisviile 35801 533-2292 Emo '1-.5
JO Peitia Gen Mgr Yr Est 1949
2899 Industrial And Chemical Coatings
2391 Drapnes Curtains Cornices Ana Swags
2591 Blinas And Woven Wmaow Shaaes
SOUTHERN LITHOGRAPHING CORP
80 Si Michael Street P 0 Box 2065
Mobile 36652 433-5930 Emp 6-10
Earl Grube Pros Yr Est 1920
2752 Commercial Printing
2B99 Foil Stamping
2753 Embossing
THOMASSON COAL AND COKE. INC.
3100 35tti Ave N
Birmingham 35207 8414132 Emp 11. IS
Tom Pruitt V-Prei /Mgr Yr Eai 1980
2899 Foundry Products
UNITED CIRCUITS
Oiv Of Untied Plating. Inc
2400 Ml Lebanon Rd P O Box 207
Meridianville 35759 828-3737 Emp 51-75
Ouane A Black General Mgr Yr ESI 1983
3679 Fabrication Of Printed Circuit Boards
2899 Commercial And Military Assemblies
3357 Cable Assemblies
WESLEY INDUSTRIES. INC.
P 0 Box 727
Oemopolis 36732 289-4750 Emp 16-20
Mr JE Megraw V-Pres Yr Est 1983
2899 Water Treatment Products
WESLEY INDUSTRIES. INC.
PO Box490
Montrose 36559 626-2040 Emp 51-75
Jack W Boykm Pros Yr Elt 1982
2879 Agricultural Chemical Pesticide*
2869 Speciality Organic Chemicals
2899 Water Treatment Products
2077 Animal Oil Derivatives
2911 PETROLEUM REFINING
ALABAMA GASOHOL, INC.
P 0 Box 387
Ashford 36312 899-3361 Emp 11-15
Tom Shirley Pres Yr Est 1979
2911 Gasohol
2048 Came Feed
2879 Commercial Chemicals
HUNT OIL CO . INC.
Oiv Of Dallas Tx
2900 interfirst One Bank Bldg
Dallas 75202 758-6675 Emp 201-250
JW Marcum Mgr Yr Est 1946
2911 Fuel Oils
2911 Asphalt
2911 Gasoline
2869 Solvents
LOUISIANA LAND AND EXPLORATION CO.. INC.
Mobile flednwy
PO Drawer 306
Saraland 36571 675-7040 Emp 76- ICO
Wayne J Oberdmg Refinery Mgr Yr f si 1975
2911 Gasoline
2911 «2 Fuel Oil
2911 Aviation Turbine Fuel
1321 Liquid Propane Gas
M ft M CHEMICAL CO . INC.
US 11 N PO Box 291
Gadsdan 35902 538-3800 Emp 21-30
Jimmy Mceiendon V-Pres Yr Est 1975
2869 Solvent Distillation
2911 Fuel From liquid irjnito'jia Wastn
MONSANTO CO INC
A .- cultural 3")UJc s Di
Birmingnam Hwy P 0 Bo* 2-19
4nn,s«jn 3S202 236 S381 Emrj 251-300
E J Jurevia Plant Mgr Yr Est 935
2911 Paratnion
2879 Paranuro Phenol
2869 Phosphorous Pentasulhde
2869 Biphenyl
PHILLIPS PETROLEUM CO . INC.
Chatom Field
P 0 Box 4S8
Chatom 36518 Emp 21-30
J 0 Beach Plant Supt Yr Est 1973
1321 Condensele And Propane
2911 Gasoline Refining
2819 Sulfur
1311 Natural Gas Production
QUAKER SUPREME CHEMICAL CORP
2820 Fairlane Or P 0 Box 77
Montgomery 36101 277-2676 Emp 21-30
Jake Mendel Pres Yr Est 1949
2992 Brake And Automatic Transmission Fluid
2911 Motor OH
SKELTON OPERATING CO . INC.
PO Box 16169
Jackson 39206 468-3383 Emp 1-5
Oenise Skelton Parker Pres Yr Est 1972
2911 Gas Production
2911 Oil Production
VULCAN ASPHALT REFINING CO . INC.
P 0 Box 388
Cordova 35550 251-0033 Emp 21-30
Ed J Webb. Jr Sr V-Pres Yr Esl 1952
2911 Asphalt
2911 Fuel Oil
2911 Jet Fuel
29B1 PAVING MIXTURES & BLOCKS
ANNtSTON CONCRETE CO.. INC.
P 0 Box 1088
Annuton 36202 236-2519 Emp 1-5
E Mcgmnis Chmn Of Bd Yr Est 1965
2951 Asphalt Plant Mix
LABAMA. INC.
PO Box 818
Birmingham 35201 252-3456 Emp 201-250
T S Malhiesen Oiv Pres Yr Est 1900
2951 Asphalt Paving Mixtures
1442 Sand And Gravel
APAC-ALABAMA. INC.
Oiv Of Tuscaioosa. AI
PO Box 1937
Tuscaioosa 35401 349-1278 Emp 6-10
John Brown Branch Mgr Yr Est 1976
2951 Asphalt Plant-Mix
APAC-ALABAMA. INC.
PO Box 460
Anmston 36202 831-7130
Paul Bradahaw Pies Yr Est 1941
29S1 Asphalt Plant Mix
1442 Crushed Stone
Emp 101-150
ASHBURN AND GRAV. INC.
2315 Bob Wallace Ave P 0 Box 48
Huntswlle 35804 881-3451 Emp 6-10
J Tapscot! Plant Mgr Yr Est 1056
2951 Asphalt Plant Mix
BALLEW & ROBERTS CONSTRUCTION CO INC
Civ. Of S> = t.«ic ii
PO Sox '57
Sheffield 35660 383 598' E-c -
jonn A Harawav v Pres
2951 Bituminous Paving Materials
CALHOUN ASPHALT CO, INC
PO Box 1890
Gadsden 35902 547-6387 Emp T :
M H McCartney Sr Pres
2951 Aspnait Paving Mix
CAPITAL CITY ASPHALT CO INC
Mitylane Plant
PO Sox 9126
Montgomery 36108 272-0752 EmpS-X
W A Hughes Praa Yr ESI 1976
2951 Asphalt
1442 Sand And Gravel
CENTRAL ALABAMA PAVING. INC.
Spring Creek Rd P 0 Box F
Calera 35040668-1911 Emp 31—
Jamas L Cardan Pres Yr Est 1964
2951 Asphalt Plant Mix
CHEVRON USA.. INC.
Southern Oiv
P 0 Box 1069
Mobile 36633 438-1641 Emp 51-7'
R L Nunezy Refinery Mgr Yr Esl 1950
2951 Paving Asphalts
2952 Roofing Asphalts
2952 Industrial Asphalt Emulsions
CHEVRON USA. INC.
Star Rt Box 2130
Mulga 35118 436-3661
E E Gossett Supv Yr Est
2951 Psving Asphelts
1930
COUCH INC
1020 Twitched Hd PO Box 7106
Dothan 36302 794-2631
Charles Owens Mgr Yr Est 1908
3273 Ready-Mix Concrete
2951 Hot Mix Aaphalt
Emp 1-
Emp 51-7'
ASPHALT CONTRACTORS. INC
PO Box b 152
Montgomery 36106 264-8012
Charles Brassed Pres Yr Est 1973
2951 Asphalt
Emp 31-40
COUCH. INC.
1020 Twchell Rd P 0 Box 7106
Oothan 36301 794-2631 Emp 76-Id
Wayne Eidsen v-Pres Yr Est 1932
29B1 Hot-Mix Asphalt
3273 Reedy Mix Concrete
1442 Send Mining
DUNN CONSTRUCTION CO.. INC.
P 0 Box 247
Birmingham 35201 592-S927 Emp 51-~r
Borden H Burr h V-Pres Yr Est 1878
2951 Plant Mix Asphalt
OUNN CONSTRUCTION CO.. INC
PO Box 11961
Birmingham 35202 663-0776 Emp 1-
Borctan H Burr, li V-Pres
2951 Plant Mix Aaphalt
EAST ALABAMA PAVING CO.. INC.
Old Columbus Rd Box 11
Opalika 36801 7494865 Emp 16-2
JB Taium Pres Yr Esl 1971
2951 Asphalt Products
GARDNER ASPHALT CO
Gardner Industries Ine
199 Mum Si PO Box 299
SpringvtlMi 35146467-6187 Emp 21-3
RW Brown Mgr Yr Est 1978
2951 Coannos
343
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question II
Plant or Division Implementation
a) Please provide a detailed outline of how your corporation
implements its waste reduction program or plan at the plant or
division level.
Haste reduction programs (efforts) are implemented through the production or
environmental support organizations at each facility.
b) Please note where your corporation has changed its plant or
division level waste reduction implementation scheme in the
past year.
N/A
c) Assuming that your corporate waste reduction plan or
program began in your environmental division, have you
integrated this program or policy with your division or plant
level manufacturing personnel?
N/A
How did you accomplish this?
d) Do you conduct a waste stream for process loss) audit? If
so, how frequently do you conduct the audit?
NO
Have you computerized this waste stream audit data?
N/A
e) Have you established a process to identify: your process
losses, opportunities and costs for further waste reduction,
prioritization of waste reduction methods, and implementation,
documentation and communication, of results, etc?
Yes
Please detail this process. (If you accomplish this process
through a waste reduction audit, please proceed to the next
question) interviews with plant personnel and unannounced inspections of plant
waste handling and waste generating activity. Also reviews of manifests and spill
reports to identify problem areas responsible for generating excessive volumes of
waate. RETURN BY MAY 4, 1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
f) Do you conduct a waste reduction audit?
Yes, although informal and not on a routine basis
g) If so, what elements are included in your waste reduction
audit? Do you:
Yes or No
NO Identify and quantify sources of all process losses to
all media. If not all, which ones?
Yes
Identify opportunities for future cost effective
reductions?
NO Establish goals for the next years?
Yes Identify resource requirements for attainment of goals?
Yes Identify techniques to attain goals?
Yea interview plant employees to ascertain training needs
and level of awareness?
NO Require sufficient data so that progress can be reported
relative to output?
Yea Document and report accomplishments and problems to
management?
Report progress on waste reduction relative to goals?
Yea Note problems and corrective actions undertaken?
NO Document costs and return on reduction efforts?
Yes Identify resource requirements for the future?
No Project expected future returns?
Other elements?
Is your waste reduction audit computerized?
No
RETURN BY MAY 4, 1987
-------
474 Boston Avenue, Curtis Hall
Tufts university, Hedford, MA 02155
OUTER FOR ENVHOWEMTAL MANAGEMENT (617) 381-3486
March 10. 1987
Question III: ttiat have your waste reduction accaiplishments been in the past year since Hoods Hole II? (PLEASE TELL ALL)
METHODS: A) Improvements in technology & equipment; B) Improvements in plant operations; C) Substitution of raw materials;
D) Redesign or reformulation of end products; E) Recycling in-plant wastes; F) Recycling off-site.
HASTE REDUCTION
METHOD
(see above)
HASTE R
EPA HAZARDOUS
HASTE f
EDUCED
TYPE OF
WASTE
PLANT LOCATION
•8BB ATTACBBD 1
WORT FOB THE
PBOTBCTIOB, Ti
GBBBBATIBG STJt
DATE
86 HAIABD
BIB JBBSB
SB RBFORT
IOBS.
PER CENT
REDUCTION
OS HASTB Gl
DBPAjmOBI
COVBfc THB
IOCATICN
ON-SITE
UBATOB H
OF BBVIB
IALBN ABD
OFF-SITE
BIHIIATIOI
BMBMTAL
BOPB CBBBI
DESCRIPTION
ADDITIONAL
INFORMATION
Page 7
PLEASE RETURN BY MAY 4,1987
-------
Tufts University Center for Environmental Management (617)381-3486
474 Boston Avenue, Curtis Hall, Medford, MA 02155 March 10, 1987
Question IV
a) what new waste reduction efforts have you underway? Have
you followed through on those mentioned in 1985's questionnaire
33 yet? N/A
A 1985 Questionnaire was not completed. The questions answered in this questionnaire
address hazardous waste management per New Jersey regulations. (This includes waste
oils, oil and water and oil spill cleanup debris) . Until legislation is passed the
policy practiced at the Salem and Hope Creek Stations is directed at primarily disposa
practices, that is using the best available technology regardless of costs, to
minimize liabilities and future Superfund involvement. Also our position many times
is overly conservative in treating/disposing of waste as hazardous while pursuant to
state and federal regulations the material is non-hazardous. Treating waste under thi:
condition many times gives an inflated volume of hazardous waste being generated.
This waste disposal position is taken primarily due to the fact the federal govern-
ment has not classified waste oils as a hazardous waste. Therefore neighboring states
have less stringent standards for the management/recycling of waste oils. Under
present regulatory conditions the only waste reduction practice is through education
and improved housekeeping practices.
RETURN BY MAY 4, 1987
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