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Pollution Prevention Opportunity Assessments

B-004-OPP-P-XX-08-S-R1 Standard Operating Procedure

Office: Office of Pollution Prevention and Technical Assistance Branch: Pollution Prevention

Section: N/A

Revised: September 15, 2008. Revision Cycle: 2 years Effective date: July 31, 2007

Scope of operations This SOP shall be the guidance document for conducting on-site Pollution Prevention Opportunity Assessments. Scope of applicability Pollution Prevention Environmental Engineer shall use this SOP when conducting on-site Pollution Prevention Opportunity Assessments. Authorizing Signatures

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Pollution Prevention Opportunity Assessments B-004-OPP-P-XX-08-S-R1

Table of Contents 1.0 Overview “work-flow” flowchart ........................................................................................................3 2.0 Definitions ........................................................................................................................................3 3.0 Roles ................................................................................................................................................4

3.1. Responsibilities:...........................................................................................................................4 3.2. Training and Experience requirements:.......................................................................................5

4.0 Description of equipment, forms, and/or software to be used .........................................................5 5.0 Procedure.........................................................................................................................................6

5.1. Procedural Flowchart...................................................................................................................6 5.2. Procedure ....................................................................................................................................6

6.0 Records Management......................................................................................................................8 7.0 Quality Assurance / Quality Control .................................................................................................8 8.0 References.......................................................................................................................................8 9.0 History of Revisions .........................................................................................................................9 10.0 Appendices ......................................................................................................................................9

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1.0 Overview “work-flow” flowchart

2.0 Definitions Assistant Commissioner: An Assistant Commissioner in the Indiana Department of Environmental Management.

Branch Chief (BC): A second-level Agency supervisor responsible for managing Section Chiefs and non-supervisory Agency staff.

Environmental Engineer: A Staff level position within the Office of Pollution Prevention and Technical Assistance in the Indiana Department of Environmental Management..

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Material Safety Data Sheets (MSDS): A form containing data regarding the properties of a particular substance.

Net Present Value: A standard method for the financial appraisal of long-term projects, measures the excess or shortfall of cash flows, in present value (PV) terms, once financing charges are met.

Northeast Waste Management Official’s Association (NEWMOA): NEWMOA is an interstate association that has a membership composed of the hazardous waste, solid waste, waste site cleanup, and pollution prevention programs in the northeast states. Its mission is to develop and sustain an effective partnership of states to explore, develop, promote, and implement environmentally sound solutions for the reduction and management of materials and waste, and for the remediation of contaminated sites, in order to achieve a clean and healthy environment.

Office of Pollution Prevention and Technical Assistance (OPPTA): The Office of Pollution Prevention and Technical Assistance is a division of IDEM housing the Compliance and Technical Assistance Program (CTAP), the Pollution Prevention Branch (P2), the Source Reduction and Recycling Branch (SR&R), and the Community Environmental Health and Education Branch.

Pollution Prevention (P2): Pollution prevention is the reduction or elimination of pollution at the source (source reduction) instead of at the end-of-the-pipe or stack.

Pollution Prevention Opportunity Assessment (P2OA): A pollution prevention opportunity assessment is an evaluation of the processes at a facility to identify ways to; use fewer raw materials, conserve energy, reduce wastes and emissions, and meet and reduce regulatory requirements.

Project Payback Period: The length of time required to recover the cost of an investment, usually expressed in months or years.

Quality assurance (QA): Quality assurance refers to planned and systematic processes that provide confidence of a product's or service's effectiveness.

Quality control (QC): Quality control is developing systems to ensure products or services are designed and produced to meet or exceed customer requirements.

Quality Manager, OPPTA: Staff within the Office of Pollution Prevention and Technical Assistance in the Indiana Department of Environmental Management responsible for the implementation and maintenance of the Agency quality assurance system.

Toxic Release Inventory Environmental Manager: A first-level Agency supervisor responsible for managing non supervisory Agency staff

3.0 Roles

3.1. Responsibilities:

Environmental Engineer: Performs outreach, conducts site visits, analyzes ideas generated, prepares and mails P2OA report, follows up visit with results inquiry, and reports results in the National P2 Measurement Database. Toxic Release Inventory Environmental Manager: Reports results in the National P2 Measurement Database. Branch Chief: Reviews P2OA report and SOP.

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Quality Manager, OPPTA: Reviews P2OA SOP. Assistant Commissioner, OPPTA: Reviews P2OA SOP. Quality Assurance Manager, IDEM: Reviews P2OA SOP.

3.2. Training and Experience requirements: N/A

4.0 Description of equipment, forms, and/or software to be used P2OA Information Request Sharepoint P2OA Information Request.doc P2OA Self Assessment Checklist Sharepoint P2OA Self Assessment.doc P2OA Field Assessment Checklist Sharepoint P2OA Field Assessment

Checklist.doc P2OA Report Template Sharepoint P2OA Report Template.doc Performance Measures for P2OAs Spreadsheet

Sharepoint P2OAs Database for Performance Measures.xls

P2OA One Month Feedback Survey Sharepoint P2OA One Month Feedback Survey.doc

P2OA Follow Up Template (6 month and 1 year)

Sharepoint P2OA Follow Up Template.doc

P2OA Results Spreadsheet Sharepoint P2OA Results Spreadsheet Net Present Value calculation http://en.wikipedia.org/wiki/Net_present_value

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5.0 Procedure 5.1. Procedural Flowchart

5.2. Procedure

The following steps are taken when an Environmental Engineer performs P2OA outreach through telephone cold calls, inspection referrals, e-mailed information, public speaking events, initial introductory visits, trade association contacts, P2OA informational flyer/brochure and other marketing opportunities.

1. Upon attaining a site visit request, the Environmental Engineer requests the facility fill out the Pollution Prevention Opportunity Assessment Information Request. This form contains basic information about the facility to assist the Engineer with site visit preparation, including but not limited to the facility layout and MSDS of materials used at the facility.

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2. If the company provided the information requested, move on to step 3. If the information was not provided, the Environmental Engineer may need to conduct a pre-assessment visit to fully understand the specific facility and processes. 3. The Environmental Engineer researches the facility and processes via the internet or other resources to create a P2OA Assessment Checklist for the specific facility and processes. 4. During the site visit, the Environmental Engineer meets with the facility’s Health, Safety and Environmental (HS & E) Coordinator (or other representative) to walk through the plant. While touring the plant, the Environmental Engineer evaluates facets of the business asking questions whenever clarification or comprehension is needed. Areas to be evaluated by the Environmental Engineer may include but are not limited to the following:

a. Production Lines. b. Shipping & Receiving. c. Inventory Control (warehouses, stockpiles, chemical storage…etc.) d. Material Handling Areas. e. All waste treatment and storage areas including wastewater treatment

equipment, treatment lagoons or retention ponds, air control equipment, dumpsters and waste drums.

f. Maintenance and Machining Areas. g. All Plant and Process Ovens, Furnaces and Boilers. h. Compressed Air System. i. Scrap Material Areas. j. All emissions points of environmental releases. k. LEAN seven “deadly wastes” (transportation, overproduction, motion, defects,

waiting, inventory, and processing). 5. Before exiting the facility, the Environmental Engineer conducts a brief wrap-up session with the facility representative. The site visit summary includes discussion on possible pollution prevention ideas and continuous improvement ideas. 6. The Environmental Engineer reviews pollution prevention and continuous improvement ideas generated from the site visit for technical merit and feasibility. Web resources for evaluating pollution prevention ideas are listed as follows:

a. Southwest Network for Zero Waste http://www.zerowastenetwork.org/P2Options/index.cfm

b. NEWMOA P2Rx Topic Hub http://www.newmoa.org/prevention/topichub/toc.cfm c. Iowa Waste Reduction Center http://www.iwrc.org/ d. U.S. EPA Metal Finishing Pollution Prevention

http://www.epa.gov/region09/waste/p2/projects/metal.html e. Toxic Use Reduction Institute Cleaner Solutions Database

http://www.cleanersolutions.org/?action=contaminant_search f. Green Chemistry Resource Exchange

http://www.greenchemex.org/?module=search.list g. U.S. EPA Environmental Technologies Verification Program as listed on the U.S.

EPA website h. U.S. EPA Waste Reduction http://oaspub.epa.gov/npep/npep_pkg.query_main

i. NEWMOA Innovative P2 Technologies Profile http://www.newmoa.org/prevention/p2tech/

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j. Great Lakes Regional Pollution Prevention Roundtable http://www.glrppr.org/search

k. National Pollution Prevention Roundtable http://www.p2.org/ If possible, the Environmental Engineer calculates project payback periods or net present values. 7. The Environmental Engineer drafts a P2OA report, proofreads and forwards to the Branch Chief for review. The report may contain information on P2 suggestions, waste stream mapping, and reductions in costs, pollutants, wastes (to include the “seven deadly wastes” from Lean), natural resources, and regulatory requirements from P2 suggestions (if possible). When waste stream mapping is appropriate, it shall contain both current state mapping and future state mapping. 8. After review, the report shall be sent to the company. The report shall include estimated release reductions and payback periods of the IDEM recommendations. The Environmental Engineer will use the P2OA Report Template as a guide for the report format. The Environmental Engineer creates the one month, six month, and one year mailings, and files them appropriately in a tickler filing system. The Environmental Engineer enters the activity in the CTAP database. 9. One month after mailing the P2OA report, the Environmental Engineer or other OPPTA staff sends the P2OA Feedback Survey to the business. The Environmental Engineer shall maintain a tickler file system based on the month when each mailing is to be sent. 10. Three to six months after mailing the written report, the Environmental Engineer mails the six month follow up letter to the company. If the company does not respond within one week, the Environmental Engineer will call the company. The Environmental Engineer records any measurable results from the site visit and P2OA report. Measurable results include reduced water consumption, solid or hazardous waste generation, air emissions, wastewater discharged, energy consumed, and raw materials usage. The source will be asked if any suggestions have been implemented or are scheduled to be implemented. The Environmental Engineer shall maintain a tickler file system based on the month when each mailing is to be sent. 11. Results are logged into the P2OAs Results Spreadsheet. 12. One year after mailing the written report, the Environmental Engineer mails the one year follow up letter to the company. If the company does not respond within one week, the Environmental Engineer will call the company. The Environmental Engineer records any measurable results from the site visit and P2OA report. Measurable results include reduced water consumption, solid or hazardous waste generation, air emissions, wastewater discharged, energy consumed, and raw materials usage. The Environmental Engineer shall maintain a tickler file system based on the month when each mailing is to be sent. 13. Results are logged into the P2OAs Results Spreadsheet. 14. Close out case.

6.0 Records Management The Environmental Engineer will file all aforementioned documents on Sharepoint.

7.0 Quality Assurance/Quality Control The Environmental Engineer will complete the QA/QC work with assistance of other OPPTA staff and P2 resources.

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8.0 References 1. Southwest Network for Zero Waste http://www.zerowastenetwork.org/P2Options/index.cfm 2. NEWMOA P2Rx Topic Hub http://www.newmoa.org/prevention/topichub/toc.cfm 3. Iowa Waste Reduction Center http://www.iwrc.org/ 4. U.S. EPA Metal Finishing Pollution Prevention

http://www.epa.gov/region09/waste/p2/projects/metal.html 5. Toxic Use Reduction Institute Cleaner Solutions Database

http://www.cleanersolutions.org/?action=contaminant_search 6. Green Chemistry Resource Exchange http://www.greenchemex.org/?module=search.list 7. U.S. EPA Environmental Technologies Verification Program as listed on the U.S. EPA website 8. U.S. EPA Waste Reduction http://oaspub.epa.gov/npep/npep_pkg.query_main 9. NEWMOA Innovative P2 Technologies Profile http://www.newmoa.org/prevention/p2tech/ 10. Great Lakes Regional Pollution Prevention Roundtable http://www.glrppr.org/search 11. National Pollution Prevention Roundtable http://www.p2.org

9.0 History of Revisions Date Month/day/year

Revision Number

Description

09/15/2008 1

10.0 Appendices 10.1 Appendix A - Clean Manufacturing & Pollution Prevention Opportunity Assessment Information

Checklist 10.2 Appendix B - Clean Manufacturing & Pollution Prevention Opportunity Assessment 10.3 Appendix C -P2OA Field Assessment Checklist 10.4 Appendix D - Pollution Prevention Opportunity Assessment Report For (name and mailing

address of company) 10.5 Appendix E - Database for Performance Measures 10.6 Appendix F - Pollution Prevention Opportunity Assessment Survey For (name and mailing

address of company) 10.7 Appendix G - P2OA Results

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Appendix A

Clean Manufacturing & Pollution Prevention Opportunity Assessment Information Checklist

Please provide as many of the following items as possible in order for us to best serve your needs:

Plant/Facility Layout

Pollution Prevention Opportunity Assessment Information Request Sheet

MSDS or Certified Product Data Sheets for materials used in the Processes being evaluated

Copies of permits and technical support documents

Facility contact person and phone number

Any additional information that you feel would be necessary for this assessment

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Clean Manufacturing & Pollution Prevention Opportunity Assessment Information Request

This questionnaire is designed to help identify where you are having the most difficulty with environmental issues and to provide the best customer service possible. Please answer the questions to the best of your knowledge. What process or environmental waste do you want assistance with? What environmental issue is causing you the most problems? What processes are being used at your facility? In the process identified, which of the seven Lean “deadly wastes” are you the most concerned with at this time? What is the SIC or NAICS code for your facility? Do you have any permits from IDEM (e.g. air, land, or water)? What are the permit numbers?

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What are the top three regulated chemicals used in the process identified? What are the chemicals used for? Does your facility have an environmental management system (EMS)? Approximately, how much waste (solid, liquid, and hazardous) does your facility produce (per year or month)? Where do you send this waste? How much waste is sent to a landfill, is recycled and/or reclaimed? Estimate the amount of electricity (kWh), water (gallons), and natural gas, No.2 fuel oil, etc. (Btus, therms, or gallons) used per month in the process identified? What is the average cost of each? Do you have a wastewater treatment facility? Additional information you feel is necessary for this assessment.

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Do you currently have plans to implement any pollution prevention projects? What personal protection equipment is required for the engineer visiting your facility?

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Appendix B

Clean Manufacturing & Pollution Prevention Opportunity Assessment

What environmental concerns are causing you the most problems? Process Control List the production processes that would be enhanced by process controls, such as:

• Tracking scrap/reject rates; • Implementing a statistical process control system; • Tracking waste generation rates; • Quantifying the costs associated with the wastes generated; • Planning production schedules to reduce the generation of hazardous and

nonhazardous waste; • Preparing and posting written operation procedures.

Process 1. Process 2. Process 3. Process 4. Process 5.

Alternative Materials/Production Equipment List the production processes that could use alternative materials or production equipment, such as:

• Materials with low to no volatile organic compound (VOC) content; • Materials that contain no hazardous air pollutants (HAPs); • Alternative production processes that would reduce air emissions; • Alternative production processes that generate less solid wastes; • Production equipment that reduces air emissions; • Production equipment that generates less solid wastes. s . Proces 1

Process 2. Process 3. Process 4. Process 5.

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Material Storage and Handling List the production processes that would be improved by material storage and handling procedures, such as:

• Storing raw materials in a manner that protects them from damage; • Tracking material usage in your production processes; • Organizing production processes to minimize material handling; • Monitoring raw material inventories to ensure that products do not exceed

their expiration date. Process 1. Process 2. Process 3. Process 4. Process 5.

Purchasing and Inventory Management List the production processes that would be improved by purchasing and inventory management systems, such as:

• Establishing a centralized purchasing program; • Utilizing a “just-in-time” purchasing program; • Implementing a “first in – first out” policy for materials purchased; • When feasible and practical, purchasing materials in bulk or larger containers; • Maintaining an inventory of unused materials that could potentially be used in

other departments or divisions of the company; • Requesting suppliers to take back used shipping containers, totes, and pallets

for reuse. Process 1. Process 2. Process 3. Process 4. Process 5. Shipping and Receiving

List the production processes that would be improved by implementing shipping and receiving practices, such as:

• Inspecting materials before accepting a shipment; • Dating material containers when received; • Improving the packaging of the final product to better protect it from damage

Process 1 during transport. .

Process 2. Process 3. Process 4. Process 5.

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Employee Training List the production processes that would be improved by implementing employee training programs, such as:

• Training employees in the proper handling of chemicals; • Training employees in proper work practices to optimize production, reduce

scrap rate, and minimize material usage; • Periodically reviewing employee work practices to optimize production,

reduce scrap rate, and minimize material usage. Process 1. Process 2. Process 3. Process 4. Process 5.

Leak Prevention/Spill Control List the production processes that could implement a system to prevent chemical leaks and control chemical spills, systems such as:

• A written schedule for inspecting production equipment and storage containers for leaks;

• A written chemical spill prevention plan and written procedures for containing a spill;

• A written procedure for managing raw and waste materials in a manner that minimizes the possibility of a release into the environment and worker exposure.


Equipment Calibration List the production processes that could be enhanced by scheduled equipment calibration, such as:

• Scheduled calibration of pollution control devices and monitoring equipment in accordance with the manufacturer’s recommendations and permit requirements;

• Scheduled calibration of quality control monitoring and measurement equipment.


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Housekeeping and Maintenance Practices List the production processes that would be improved by housekeeping and maintenance practices, such as:

• A written schedule for the cleaning of production equipment; • A written maintenance schedule for production equipment; • A written procedure for cleaning of production areas and equipment.


Recycling List the production processes that could implement a recycling program, including:

• Reusing all possible wastes and scrap; • Segregating all recyclable wastes from non-recyclable wastes; • Recycling all recyclable materials.


Energy Efficiency List the production processes that could improve energy conservation, through methods such as:

• Conducting energy audits addressing heating/cooling systems, lighting, steam systems, and electric motors;

• Scheduling inspections of compressed air systems; • Developing a written service schedule for all heating/cooling systems and

industrial process heaters; • Tracking utility costs and considering alternative energy sources.


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Environmental Management System List the production processes that could implement elements of an environmental management system, such as:

• Preparing a written environmental/pollution prevention policy; • Establishing written pollution prevention goals; • Creating a pollution prevention team.


Management Practices and Commitment

List the production processes that could be improved by management practices and commitment, such as:

• Management stressing the importance of pollution prevention to all employees;

• Management establishing facility-wide pollution prevention goals; • Management requiring the facility to conduct periodic pollution prevention

opportunity assessments; • Management promoting employee suggestions concerning potential pollution

prevention practices and measures. Process 1. Process 2. Process 3. Process 4. Process 5. Use the worksheets on pages 6 – 8 to prioritize the identified opportunities and associated processes.


Worksheet 1. Production Processes and Identified Opportunities

List each production process you identified in the previous section. Place an X in the corresponding column for each opportunity identified for that process. Then total the number of X’s for each process. Go to worksheet 2.

Identified Opportunities

Production Process Pro

cess

Con

trol

Alte

rnat

ive

Mat

eria

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Pro

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Equi

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t

Mat

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l Sto

rage

&

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Pur

chas

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& In

vent

ory

Man

agem

ent

Shi

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g &

Rec

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ng

Em

ploy

ee T

rain

ing

Leak

Pre

vent

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Spi

ll C

ontro

l

Equ

ipm

ent C

alib

ratio

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Hou

seke

epin

g &

Mai

nten

ance

Pra

ctic

es

Rec

yclin

g

Ene

rgy

Effi

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cy

Env

ironm

enta

l M

anag

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t Sys

tem

Man

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ent P

ract

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&

Cor

pora

te C

omm

itmen

t

Tota

l Num

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f O

ppor

tuni

ties

Iden

tifie

d

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Worksheet 2. Clean Manufacturing and Pollution Prevention Opportunity Assessment Ranking

Identify the five production processes with the highest scores from worksheet 1 and list them in the table below along with the opportunity associated with each process. A process may have more than one opportunity, so a production process may be listed multiple times. To help you prioritize the processes and associated opportunities identified, assign a score to the column heading for each opportunity using a scale of 1 to 5 (5 indicating the most beneficial such as those with the highest potential for waste/emissions reductions, cost savings, regulatory burden relief, and reducing employee exposure). Total the scores for each process and associated opportunity. Go to worksheet 3.

Production Process Opportunity

Potential Reduction in Waste / Emissions

Potential Cost Savings

Potential Reduction in Regulatory Burdens

Potential Reduction in Employee Exposure Total Score

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Worksheet 3. Priority Production Process Opportunities Identify the top three scoring production processes and associated opportunities from worksheet 2 and list them in the order of the total score assigned, with the process and associated opportunity having the highest score listed under Priority 1. Assign a goal (i.e. what you intend to achieve and the proposed completion date) and specify the employee within your facility responsible for overseeing the achievement of that goal. Priority Production Process Opportunity Facility Goal Responsible Employee

1 2 3

If you have questions or would like assistance in completing the worksheets, contact Robert Henry at (317) 232-8188.

Fact Sheets on specific pollution prevention and clean manufacturing opportunities are available at www.in.gov/idem/oppta/p2/assessments/ for the following industry sectors:

• • • • •

Structural Wood Product Manufacturers Miscellaneous Chemical Manufacturers Metal Products Manufacturers Plastic and Rubber Product Manufacturers Transportation and Miscellaneous Product Manufacturers


Appendix C

P2OA Field Assessment Checklist (Check the identified opportunities) Process Control

A system to track the scrap/reject rate of production processes. A statistical process control system to monitor production processes. A system to track the waste generation rates of production processes. Quantify the costs associated with the wastes generated in production processes. Prepare and post written operation procedures for each production process. Plan production schedules to reduce the generation of hazardous and nonhazardous waste.

Alternative Materials/Production Equipment

Materials with low to no volatile organic compound (VOC) content. Materials that contain no hazardous air pollutants (HAPs). Alternative production processes that would reduce air emissions. Alternative production processes that generate less solid wastes. Production equipment that reduces air emissions. Production equipment that generates less solid wastes.

Material Storage and Handling

Store raw materials in a manner that protects them from damage. A system to track material usage in production processes. Organize production processes to minimize material handling. Monitor raw material inventories to ensure that products do not exceed their expiration date.

Purchasing and Inventory Management

A centralized purchasing program. A “just-in-time” purchasing program. A “first in – first out” policy for materials purchased. Purchase materials in bulk or larger containers, when feasible and practical. A running inventory of unused materials that could potentially be used in other departments or divisions of the company. Request that suppliers take back used shipping containers, totes, and pallets for reuse.

Shipping and Receiving

Inspect materials before accepting a shipment. Date material containers when received. Improve packaging of the final product to better protect it from damage during transport.

Employee Training

Train employees in the proper handling of chemicals. Train employees in work practices that optimize production, reduce scrap rate, and minimize material

usage. A program to periodically review employee work practices to optimize production, reduce scrap rate,

and minimize material usage.

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Leak Prevention/Spill Control

Scheduled leak inspections of all production equipment and storage containers. A written chemical spill prevention plan and written procedures for containing a spill

if one does occur. A written procedure for managing raw and waste materials in a manner that

minimizes the possibility of a release into the environment and worker exposure.

Equipment Calibration

Scheduled calibration of pollution control devices and monitoring equipment in accordance with the manufacturer’s recommendations and permit requirements.

Scheduled calibration of quality control monitoring and measurement equipment.

Housekeeping and Maintenance Practices

A written schedule for the cleaning of production equipment. A written maintenance schedule for production equipment. A written procedure and schedule for cleaning of production areas.

Recycling

Reuse all possible wastes and scrap. Segregate all recyclable wastes from non-recyclable wastes. Recycle of all recyclable materials.

Energy Efficiency

Conduct energy audits addressing heating/cooling systems, lighting, steam systems, and electric motors.

Regularly scheduled inspections of compressed air systems. A written service schedule for all heating/cooling systems and process heaters. Track utility costs and consider alternative energy sources.

Environmental Management System

A written environmental/pollution prevention policy. Written pollution prevention goals. A pollution prevention team.

Management Practices and Commitment

Management stressing the importance of pollution prevention to all employees. Management establishing facility-wide pollution prevention goals. Management requiring the facility to conduct periodic pollution prevention

opportunity assessments. Management promoting employee suggestions concerning potential pollution

prevention practices and measures.

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Air Emissions

Type of air permit? Title V Federally Enforceable State Operating Permit (FESOP) Minor Source Operating Permit (MSOP) Source Specific Operating Permit (SSOA) Registration Exemption Permit by Rule

No permit required

Does the company have a good understanding of their permit requirements? Yes No

Are there other state or federal air regulations not specified in the facility’s air permit that it must comply with? (e.g. regulations such as National Emissions Standards for Hazardous Air Pollutants (NESHAPs) or other rules that have been promulgated since the issuance of the permit) Yes No If yes, list the regulation(s) and indicate if the company has a good understanding of the requirements associated with the regulation. What emissions are generated from the facility’s manufacturing processes?

(chemical/compound and associated processes): Volatile Organic Compounds (VOCs)/ Hazardous Air Pollutants (HAPs):

Particulate Matter (PM):

Nitrogen Oxides (NOx):

Sulfur Oxides (SOx):

Carbon Monoxide (CO):

Other:

Solid Waste (including hazardous waste)

Hazardous Waste Does the facility generate hazardous waste? Yes No (if yes identify the wastes) Does the facility have a good understanding of the hazardous waste regulations? Yes No Universal Waste Does the facility generate universal wastes? Yes No (if yes identify the wastes) Does the facility have a good understanding of regulations pertaining to universal waste? Yes

No Used Oil Does the facility generate used oil? Yes No Does the facility have a good understanding of the regulations pertaining to used oil? Yes No

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Wastewater/Storm Water

Is industrial process wastewater being generated at the facility? Yes No Is a National Pollutant Discharge Elimination System (NPDES) permit required? Yes No

If yes, is the facility familiar with the requirements of your NPDES permit? Yes No Is the facility required to have a storm water permit? Yes No If not, why not?

All storm water associated with industrial activities is discharged to a combined sewer system.

All storm water associated with industrial activities is retained on-site. The facility is operating under the “No Exposure” exemption.

If the facility does have a storm water permit, do they have a good understanding of the storm water permit requirements? Yes No

Toxic Release Inventory

Was the facility required to file a Toxic Release Inventory (TRI) report for the last reporting year? Yes No

If not, why not? The facility did not use, manufacture, or process reportable quantities of TRI chemicals. The facility employs fewer than 10 employees. The facility operates under a Standard Industrial Classification Code (SIC) that is exempt

from the TRI reporting requirements. Does the facility have a good understanding of the TRI reporting requirements? Yes No

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APPENDIX D

Pollution Prevention Opportunity Assessment Report

For

(name and mailing address of company) At: (location of facility) By: (name of IDEM staff, title) Pollution Prevention Branch Office of Pollution Prevention and Technical Assistance (800) 988-7901 Date: Month, day, year Process and Site Visit Summary: On (date), the Environmental Engineer conducted a pollution prevention opportunity assessment at (company name) in (facility location), Indiana. This facility manufactures (list what they manufacture). The facility’s manufacturing processes include (list processes). The Environmental Engineer researched pollution prevention and energy conservation opportunities for the processes at this facility and created value stream maps for these same processes. The specific opportunities will be identified, and the estimated savings or reductions from those opportunities will be quantified (if possible) in this report. Pollution Prevention and Energy Conservation Opportunities: The Pollution Prevention Opportunity Assessment revealed several opportunities for (company name) to decrease releases and conserve energy. Opportunity #1: (detailed description of opportunity)

Pollution Prevention Opportunity

Estimated Savings (or Reductions)

Estimated Capital

Investment

Payback Period

Brief Description $XX,000/year (or tons per year)

$XX,000 - $XX,000

years

Potential Environmental Impacts:

Opportunity #2: (detailed description of opportunity) Pollution Prevention Opportunity


Estimated Capital

Investment

Payback Period


$XX,000 - $XX,000

years


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Estimated Capital

Investment

Payback Period


$XX,000 - $XX,000

years, months




Estimated Capital

Investment

Payback Period


$XX,000 - $XX,000

years, months




Estimated Capital

Investment

Payback Period


$XX,000 - $XX,000

years, months


Disclaimer: I have no experience with any of the above listed products. In compliance with state regulations, I do not promote or condone any of these products nor do I intentionally exclude other products. I act in no interest to any of the enclosed entities. These products are results of a brief web search and I provide the enclosed articles for educational purposes only. If you are interested in the technology, I recommend an expanded inquiry into products and vendors. These suggestions as drafted by IDEM’s Office of Pollution Prevention and Technical Assistance are meant to serve as a guide to reduce pollutants and waste streams and do not constitute regulatory requirements. The above suggestions will not work in all situations and their successes are contingent upon factors inherent to each individual facility. Proposed project cost and savings are estimates made with minimal data and may have significant error factors. They are presented to serve as a guide only. A complete cost and savings analysis with thorough data collection is recommended. References

(1) Energy Star Wise Rules for Industrial Energy Efficiency; U.S. Environmental Protection Agency; Washington D.C., September 2003.


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P2OA & Site Visits

Made Contact

Self ssess-ment

ed

Total time (hrs)

Completed

Total time (hr

P2OA Promo Location Contact Phone Number DateStart Time

End Time

Time (hrs) Follow Up

Plant Layout

Received

A

Receiv& Follow Up Calls and/or Email

Site Visits (hrs) 0.000.00 Phone calls (hrs) 0.00

Emails (hrs) 0.00

SEP Review Time Date Start Time End Time Time (hrs)

s) 0.00

APPENDIX E

Database for Performance Measures


Appendix F

Pollution Prevention Opportunity Assessment Survey

For (name and mailing address of company)

At: (location of facility) By: (name of IDEM staff, title) Pollution Prevention Branch Office of Pollution Prevention and Technical Assistance (800) 988-7901 Date: Month, day, year On (date), the Environmental Engineer conducted a pollution prevention opportunity assessment at (company name) in (facility location), Indiana. To follow up on the assessment, please fill out this survey and return it via mail or email. Check the box of the opportunities that have been implemented, and state any results realized after implementation. Check

all that

apply

Opportunity Number

Description of Opportunity Suggested in the P2OA Report

Saving or Reductions

Tons per year, kWh, gallons per minute, etc




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Did you implement any other Pollution Prevention projects that were not suggested by the Environmental Engineer? What are the realized savings or reductions from those projects? How do you feel about the Pollution Prevention Opportunity Assessment? Did you find it to be helpful and useful? Would you recommend it to another person or company? Please return to: Name Attn: P2 Engineer Office of Pollution Prevention and Technical Assistance Indiana Department of Environmental Management 100 North Senate Avenue Wo41 MC64-00 IGCSW041 Indianapolis, IN 46204-2251 Thank you for helping us improve our assistance and measure our performance.


Appendix G P2OA Results

Project Description Measure Unit Pollutant, Energy, or Waste Reduced Quantity Date Estimate or Confirmed

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

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Pollution Prevention Opportunity Assessments B … Opportunity... · Pollution Prevention...

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