Toxics Use Reduction Institute

TURA and Tech Diffusion in the Plating and Food Industry

Buenos Aires

September 31, 2009

Janet Clark, Senior Associate DirectorJanet Clark, Senior Associate Director

Toxics Use Reduction Act Goals

• Reduction in use of toxic chemicals and generation of wastes – source reduction

• Establish TUR as the preferred means of regulatory compliance

• Sustain and promote the competitive position of Massachusetts industry

• Enhance and coordinate state agency enforcement of environmental laws

1998-2008 Progress• TUR -- 40%

• Emissions Reduction -- 91%• TUR Planning

– 70% of firms identified TUR options

• Implementation– 81 % of the firms that identified TUR options in their plans

reported implementing at least some of them– 67% of firms reported cost savings– 66% of firms reported health and safety benefits

• Materials accounting was rated the most valuable component of TUR planning

4

Fees Pay for TURI Services

How to Design effective services for industry?

• Technology Diffusion Tools can help agencies

• TUR Planning is the best practice for industry

• TURI Laboratory is unique and effective

Technology Diffusion

• Everett Rogers classic model of diffusion of technological innovation (Rogers, 1995)

“Diffusion is the process by which an innovation is communicated through certain channels over time among members of a social system”

1. Show economic or social advantage

2. Help connect the concept to values, beliefs, experiences

3. Address Complexity

4. Make it easy to do small scale testing

5. Offer demonstrations

6. Remove barriers ($, research, training)

Toxics Issues are Complex

Core Technology to Advance -- TUR Planning

Companies with skills in

planning and evaluating innovations

will be more effective than

promoting a particular innovation.

ProcessCharacterization

ProcessCharacterization

Pre-PlanPre-Plan

Identify TUROptions

Identify TUROptions

Develop orUpdate PlanDevelop or

Update Plan

Certify PlanCertify Plan

Screen & Evaluate TUR

Options

Screen & Evaluate TUR

Options

ImplementPlan

TUR Planning CycleMeasureSuccess

Green boxes are what TUR Planners do

Definition of TUR

TUR Techniques: Improve processes Reformulate Substitute a safer material Redesign process, product, or

service Improve operations and

maintenance In-process recycling

Reduce use of toxic chemicals or generation of waste at the source

by using…

Technology Diffusion of TUR

Difficult to advance because they are about “prevention”; market opportunities are easier

Drivers of change play key role

• Regulatory: bans, phase outs, emission or use restrictions, fees

• Market: Customer “green” goals and brand protection, labeling, government Environmentally Preferable Purchasing (EPP) programs

Change Agents

Change agents play a crucial role• Technical assistance programs

Must be funded!• Researchers and universities

Must be funded!• Consultants to industry

Must prove their value!• Opinion leaders in industry

Must be recruited

Identify Issue or Need

Develop or Identify Innovative Solutions or Materials or Technologies

Assess Alternatives

Identify and work with Supply Chain

Identify Industry Leaders

Prove & Demonstrate Technology/Materials

Provide Assistance: Testing, information, workshops, more R&D at Companies and Universities,

on-site assistance, grants

At a “critical mass” number of companies, adoption becomes self-sustaining

Con

tin

uou

s

Imp

rovem

en

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TURA Industry Programs

1. On-site Technical Assistance2. University Research on Technical

Problems (Grant program)3. University Laboratory Testing Program4. Technology specific Workshops and

Seminars5. Training and Conferences for TUR

Planners6. Peer Mentoring and collaboration

TUR Planning Example - Electroplating

Plating Tank Rinse Tanks

A 1

= Evaporation

D = Dragout 1

W = Tank Dumps W = Rinse Overflow 1 2

S = Floor Spills 1

(To Scrubber)

C = Chemical In 1

H = Hazardous Waste Disposal 1

I = In Process 1

TUR Planning: Options Identification and Evaluation

EvaluateEvaluate

ScreenScreen

IdentifyIdentify

Evaluate remaining TUR Options•Technical evaluation• Economic evaluation

Brainstorm TUR Options• Consider techniques• Generate lots of ideas

Eliminate TUR Options• Technically or economically infeasible• Not TUR

For each toxic in each production unit,

TUR Planning: Cost Categories

Production

Material handling

Inspection

Recordkeeping

Reporting

Monitoring

Labeling

Manifesting

Stocking

Training

Raw materials

Solvents

Cleaners

Process water

Cleaning water

Office supplies

Training materials

Safety materials

Parts

Production

Cleaning

Degreasing

Material handling

Storage

Waste treatment

Water treatment

Air pollutn control

Painting

Protective

Safety

Depreciation

Maintenance

Waste disposal

Insurance

Taxes

Utilities

Regulatory fees

Lab fees

Health & Safety

Liability

LABOR MATERIALS EQUIPMENT OTHER

Lightolier Changes

• Increased drip time to allow acids to return to chemical baths• Installed still-rinse tanks • used countercurrent rinsing.•Looked at hidden costs of using TCE•Switched from petroleum coolants to a water soluble formula•Replaced an old vapor degreaser and reduced use of TCE by 98% (from 125,000 pounds per year)•Switched to a brightner with 90% less copper to protect local wastewater treatment facility

• Increased drip time to allow acids to return to chemical baths• Installed still-rinse tanks • used countercurrent rinsing.•Looked at hidden costs of using TCE•Switched from petroleum coolants to a water soluble formula•Replaced an old vapor degreaser and reduced use of TCE by 98% (from 125,000 pounds per year)•Switched to a brightner with 90% less copper to protect local wastewater treatment facility

Attended program workshopsVisited by OTAAttended program workshopsVisited by OTA

Doing Planning Alternatives

After several cycles of TUR planning, firms can choose to report on

–Resource Conservation Planning – energy, water, materials

–Integrating TUR Planning into Environmental Management Systems (EMS)

Lightolier

• 44 Million Gallons per Year Reduction

• $ 181,715 per year annualized savingsWater Usage by Month Avg GPD

100,000

150,000

200,000

250,000

300,000

350,000

Jun-07Jul-07Aug-07Sep-07Oct-07Nov-07Dec-07Jan-08Feb-08Mar-08Apr-08May-08Jun-08Jul-08Aug-08Sep-08Oct-08

Gallons

Inner TiteInner Tite

LightolierLightolier

VH BlackingtonVH Blackington

Olympic MnfOlympic Mnf

• 97% reduction of TCE• Zero Discharge to air• 98 % reuse of plating chemicals • $12,000 saved annually

• 97% reduction of TCE• Zero Discharge to air• 98 % reuse of plating chemicals • $12,000 saved annually

•1.2 million pounds TCE eliminated• $2,000,000 saved•1.2 million pounds TCE eliminated• $2,000,000 saved

• Eliminated TCE• 85% reduction in Copper and Zinc• 95% reduction in Cyanide

• Eliminated TCE• 85% reduction in Copper and Zinc• 95% reduction in Cyanide

• 75% reduction in coolant• $38,000 saved annually• 75% reduction in coolant• $38,000 saved annually

TURATURA

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Many Successful Stories

• Tri-Star Technologies of Lowell produces printed wiring boards

• TUR planning identified the option of installing a electrolytic regeneration system to the cupric etch line, resulting in:– fully eliminating the use of hydrogen peroxide– a 90% reduction in the use of hydrochloric acid– recovery of 42,000 pounds of copper each year– a two-year pay-back of the $110,000 investment for

the regeneration unit

Continuing Education Examples

Innovative Coating Techniques

National and Int’l Policy

MaterialDeclarations

IMDSEIA Guide

EU Directives

WEEERoHSELV

USPolicies

CA Prop 65MP&M RuleChem Policy

Organizational change workshops

Toxicology

Integrating Lean & Clean Manufacturing

Industrial Energy Efficiency2

Green ChemistryTheory and Practice

Research and Technical Support

– Research: collaboration through Industry Supply Chains (lead-free electronics)

– Research: Applied Green Chemistry, Biomaterials, Nano-materials

– Workgroup: Environmental Management Systems Peers

– TURI Laboratory

TURI Laboratory

Pilot Cleaning in Lab Setting

– Using client specific operating conditions

– Using client supplied parts

– Compare with current solvent (if possible)

– Client assessment of results to confirm

Alternatives to TCE

TURI Laboratory

• Assists industry and communities in the search for safer cleaning processes– Tests the performance of

alternatives to hazardous solvents– Extensive database of results at

www.turi.org

• Janitorial cleaning• Industrial parts cleaning

0

0.5

1

1.5

2

2.5

1990 1996 2001 2002 2003millions of pounds

TCE Cleaning Use Data

Atlantic Ocean

Atlantic Ocean

Pacific Ocean

Pacific Ocean

XX

XX