12/8/2010

1

Cleaner and Greener Manufacturing Seminar

The business value of toxics reduction and

pollution prevention planning

Breakfast Seminars Fall 2010

Mississauga, September 21

Guelph, September 28

Kingston, September 30

Chatham, October 5

Welcome!

12/8/2010

2

Agenda • Welcome 5 minutes

– Fred Granek, VP Sustainability, OCETA

• Benefits of Focusing on Sustainability 20 minutes – Blake Smith, Director, Environment, Energy and Vehicle Safety,

Ford Motor Company of Canada

• Toxics Reduction Act Summary 10 minutes – Nancy Coulas, Director Environmental Policy, CME

• Lean and Green 15 minutes – Peter Corbyn, Project Manager

• Pollution Prevention & Toxics Reduction – The Business Case 15 minutes – Fred Granek

• Panel Q&A 10 minutes – Fred, Peter, Nancy, Blake

• Next Steps 5 minutes

Sustainability

Blake Smith Director, Environment, Energy and Vehicle Safety Ford Motor Company of Canada

12/8/2010

3

Toxics Reduction Act

Requirements

1. Track and quantify the listed substances used or created at the facility (Toxic Substance Accounting)

2. Prepare a plan to reduce the use and creation of each of these substances (Toxic Substance Reduction Planning)

3. Plan is certified by highest ranking employee at the facility

4. Provide summaries of their plans to the public and notify employees the same day as summaries are made public

5. Report to the Ministry and the public on their progress in reducing listed substances

6. Review plans on a regular basis

Plans

12/8/2010

4

Are you subject to the Act?

Yes

• Use or create one of the 47 priority toxic substances in Table A - 2010; remainder of NPRI and acetone – 2012

Yes • Report under Reg. 127/01 or NPRI

Yes • NAICS code starts with 31, 32, 33 (manufacturing),

212 (mining except oil and gas)

Yes • Stick around – this affects you

12/8/2010

5

Key Dates

Phase I

Jan 1, 2010: Start tracking and quantifying priority substances

Jun 1, 2011: First report to MOE for 2010

Dec 31, 2011: Complete plan for each substance and summary to public and Ministry by this date

Phase II

Jan 1, 2012: Same as above + current NPRI list + acetone

June 1, 2013: Same as Jun 1, 2011 for all substances

Dec 31, 2013: Same as Dec 31, 2011 for all substances

Steps to comply I

1. Toxic substance accounting Account for the listed substances used, created, transformed, destroyed, released, disposed of, transferred and contained in the product at your facility by tracking and quantifying them. Requires process flow diagrams and methodology.

2. Develop a plan to reduce toxics Establish a team (recommended) / identify costs / identify reduction methods / assess options and feasibility / choose best options / map out implementation timeline

Option types include: 1. Material or feedstock substitution

2. Product design or reformation

3. Equipment or process modifications

4. Spill and leak prevention

5. On-site reuse or recycling

6. Improved inventory management or purchasing techniques

7. Training or improved operating practices

12/8/2010

6

Steps to comply II

3. Provide summary Tell the public why your facility uses or creates a substance and whether you intend to reduce use and creation and how to achieve reductions, or not.

4. Report on your progress Report to Ontario government and public each year. Details on specific information to be shared are on their way.

5. Review your plans to reduce toxics Review processes, methods, options and trends. First review is required by Dec 31, 2018, then 2023, 2028, etc.

Additional Notes

• Additional information coming soon from Ministry that provides more details on the overall process

• Individual fines up to $25k/day for first offence, $50k/day for second offence, corporate fines $50k/day and $100k/day

• Further information at http://www.ene.gov.on.ca/en/toxics/index.php

• Toxics Reduction Act is at http://www.e-laws.gov.on.ca/html/statutes/english/elaws_statutes_09t19_e.htm

• Reg. 455/09 is at http://www.e-laws.gov.on.ca/html/regs/english/elaws_regs_090455_e.htm

12/8/2010

7

Lean and Green

12/8/2010

8

PFD/EnVSM

12/8/2010

9

12/8/2010

10

Soft

war

e

12/8/2010

11

12/8/2010

12

12/8/2010

13

Toronto Region Sustainability

A one-stop pollution prevention (P2) & energy efficiency technical assistance program with funding incentive for small-to-medium sized (SME) manufacturers in the Greater Toronto Region

12/8/2010

14

Reducing the Environmental Footprint Through Integrated Process Improvements

Bowne of Canada

203-person document management & lithographic printing company

“OCETA and EcoSafe have been instrumental in helping us re-align our goals. We now have a solid action plan in place which will pay dividends and assist us on the road to true environmental sustainability.”

Brian Arrol, Environmental Health & Safety Manager

Bowne’s Press Room

Toronto Region Sustainability:

Case Study – Printer

12/8/2010

15

• Installation of wash water recirculating unit

PRE-PRESS Computer-to-Plate

Processor

Processes

Targeted Pollutants/ Waste

P2 Options

Water Consumption

• Installation of ultra membrane filtration • Centralized fount dosing system

Results

• 29.3 Tonnes/yr of VOCs • 51.6 Tonnes/yr of Process Wastes, 25.4 Tonnes/yr of Hazardous Waste • 2.7 Kilotonnes/yr of Water & 8,265 m3/yr of Natural Gas • 22.9 Tonnes/yr of Greenhouse Gases (GHGs) • Total Savings upon full Implementation: $ 136 K • Overall Payback = 0.6 Yr

PRESSROOM

Waste Fountain Solution (Process Waste and VOCs)

Press Wash &

Rags and Wipers (VOC-generating Solvents)

•Vacuum distillation (re-use solvents) •Improved Operating practices

Toronto Region Sustainability:

Case Study – Printer

Anonymous

95-person chemical specialty manufacturer of glycerine, oleic and stearic acids

Main Processes: Raw materials split into fatty acid and glycerine

intermediate products Glycerine is concentrated, purified and sold in

liquid bulk drums Fatty acids are separated into oleic and stearic

acid fractions, hydrogenated, distilled, and sold in liquid bulk, drums and powdered products

Participation Drivers: Toronto sewer use by-law Hazardous waste management and product loss

costs

Toronto Region Sustainability:

Case Study – Chemical Specialty

12/8/2010

16

• Precipitation of Nickel waste from modifier condensate • Improved process efficiency

FATTY ACID & GLYCERINE PRODUCTION

Processes

Targeted Pollutants/ Waste

P2 Options

Zinc, Nickel & Hazardous Waste

•Retrofit transfer lines •Install line pigging system

Aggregated Results

• 6.7 kg/yr of Metals • 17 kg/yr of Toxics • 120 tonnes/yr of Hazardous Wastes (Annual savings $ 140K, Payback <1 month) • 68.2 tonnes/yr of Process Wastes & 39.2 kilotonnes/yr of water • Total savings upon full implementation: $270 K with Overall Payback of 5 months

MATERIAL TRANSFER

Oleic Acid, Stearic Acid & Glycerine Wastes

Nonyl Phenol Ethoxylates,

Water Consumption

•Reuse air compressor cooling water • Reduce Ammonia compressor water consumption • Material Substitution

BUILDING SERVICES

Toronto Region Sustainability:

Case Study – Chemical Specialty

Anonymous

100-person paint and resin manufacturer

Two Main Processes: Manufacture of liquid paints

Manufacture of epoxy phenolic resins

Participation Drivers: Municipal sewer use by-law & MOE

Regulation 127

Process optimization

Minimizing impact on environment

Toronto Region Sustainability:

Case Study – Paint Manufacturer

12/8/2010

17

• Chill mixing tanks

Paint Mixing Tanks

Processes

Targeted Pollutants/ Waste

P2 Options

Solvents (VOCs)

• Use pelletized form of bisphenol • Eliminate fugitive releases • Recycle & re-use srubber water

Aggregated Results

• 30.5 tonnes/yr of VOCs • 13 tonnes/yr of Particulate Matter/Toxics • 4.7 kg/yr of Metals • 38,324 tonnes/yr of Water consumption • 70.5 tonnes/yr of GHGs • Total savings upon full implementation: $97 K with Overall Payback of 2.1 Years

Resin Plant Loading and Scrubber

Bis-phenol (Toxic) GHGs, Water

Chromium, Zinc, Lead

Toluene, Xylene

• Cleaning process change • Efficient use • Equipment modification

Cleaning

Toronto Region Sustainability:

Case Study – Paint Manufacturer

Cost Avoidance & Profitability Cost savings Payback period Operational Efficiencies

Business Risks Reduction Hidden costs of non-compliance Workers Health & Safety Spills, fines, high remediation costs Changing regulations

Competitive Advantage

Green marketing Access to Global markets

Company Value

Non-financials / Reputation

Financials

Pollution Prevention & Toxics Reduction – The Business Case

12/8/2010

18

Toronto Region Sustainability: Financial Results

Totals Savings (Annualized) $5.1 million

Capital Investment $4.4 million

Return on Investment 10 Months

90% of program clients are implementing “all” or “most” of the P2 projects recommended in the assessment reports.

Toronto Region Sustainability: Key Program Outcomes

Implementation rate: 90%

Payback < 1 year

Clients with public P2 case studies: 50%

12/8/2010

19

Panel Q&A

Next Steps

Presentations will be available on the Cleaner and Greener Manufacturing Program web portal www.cme-mec.ca/clean

Cleaner & Greener Manufacturing two day workshops:

Mississauga – October 19/20

Kitchener-Waterloo – November 2/3

Chatham – November 16/17

Kingston – November 30/December 1

Toxics reduction/pollution prevention technical assistance

16 confidential toxics reduction/P2 assessments through the Toronto Region Sustainability Program with $7K cost share.

First come, first serve! Register early!

Please fill out the evaluation forms

THANK YOU!