TURA and Tech Diffusion in the Plating and Food Industry


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Por Janet Clark, Senior Associate Director of Toxic use Reduce Institute

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  • Why we are here. This is the Charles River, recovered from several centuries of abuse. If you fell into the Charles 30 years ago, you were rushed to the hospital and given several injections and monitored in case you became sick. Like many rivers in our area, this one received waste from industries and towns. Industries included manufacturers and finishers of textiles, metals, leather, felting and hats, paper, printing, electronics and medical research. Today the Charles is swimable, which means it is clean enough to drink. Its waterfront is alive with activity, contributing to the quality of life of its human and wild communities.
  • 2/3 of firms reported savings - $ and/or EH&S We look forward to seeing if companies are still finding value in the process, in particular materials accounting. Expect that they might feel differently 10 years later – e.g., now that the low hanging fruit has all been plucked. In fact, it was in response to industry complaints about diminishing returns on TUR planning that led to a significant amendment to the Act in 2007.
  • Humbling picture
  • Examples of TUR Solvent substitution in washing and degreasing Cyanide replacement in electroplating baths Hydrocarbon-based inks replaced with water-based inks Dry-process coatings replacing wet-process coatings Installing energy- and water-conserving pumps and motors Installing automated pressure and temperature controls to reduce leaks and spills
  • Chemicals: Phosphoric Acid Sulfuric Acid Nitric Acd Sodium Hydroxide TCE VOC in paints (Butyl alcohol,MEK, Toluene,Acetone) Water soluable nitrates produced during neutralization of nitric acid Refrigerants CFC – 12, CFC-22
  • Why be interested in the Massachusetts TURA Program? Here is a quick look at what firms have achieved under this program. (details will be part of tomorrow’s session) INNER TITE Makes: Fabricated metal prouducts INNER-TITE Corp. is the world's largest manufacturer of the highest quality meter locking devices, meter seals and a host of mechanical accessories sold exclusively to utility companies TUR Technique: replaced its existing parts degreasing equipment with two entirely enclosed Forenta ョ degreasing units. LIGHTOLIER MAKES: Lamps, fabricated metal, metal finishing See handout VH BLACKINGTON MAKES badges, service pins TCE cleaning operations were replaced with an aqueous cleaning system using 都 imple green crystal cleaner. � Approximately 45 gallons of water-based cleaner is used annually, achieved by carefully monitoring the bath chemistry and ultra-filtering the cleaner weekly for reuse. In addition, a small in tank filter, an oil skimmer, and conversion to compatible water-based pressing and stamping oils, made the new aqueous cleaning system more efficient. Changes were then made to the company 痴 bright dip operations reduced the copper and zinc loading to the wastewater by 85 percent. These changes include chemistry, metal recovery, improved process management, and the installation of drag-out tanks and a closed-loop system for rinsing operations. reducing the size of the plating tanks (from 60 gallons to 10 gallons), decreasing the concentration of cyanide used in the plating bath, and replacing the cyanide used in one specific process with less toxic sulfuric acid and phosphoric acid. These changes, along with switching from a 2-stage to a single stage cyanide desamount of sodium hypochlorite (bleach) used by 75 percent. The new Nitrogen/Hydrogen furnace system was paid for in 3 years from savings in fees, chemical disposal costs and other operating costs . OLYMPIC MNF MAKES: Screws
  • One industry supply chain workgroup is… 10 million lbs of lead and lead comp used in MA in 2000 more than 8 mill in plastics and resins – PVC etc. 3-1/2 mill used in coating of wire and cable In add’n, industry uses phthalates, BFRs, antimony, other heavy metals as stabilizers, FR, pigments, etc.
  • Hello I come a long way. Many similarities: ocean harbors,
  • TURA and Tech Diffusion in the Plating and Food Industry

    1. 1. TURA and Tech Diffusion in the Plating and Food Industry Buenos Aires September 31, 2009 Janet Clark, Senior Associate Director
    2. 3. Toxics Use Reduction Act Goals <ul><li>Reduction in use of toxic chemicals and generation of wastes – source reduction </li></ul><ul><li>Establish TUR as the preferred means of regulatory compliance </li></ul><ul><li>Sustain and promote the competitive position of Massachusetts industry </li></ul><ul><li>Enhance and coordinate state agency enforcement of environmental laws </li></ul>
    3. 4. 1998-2008 Progress <ul><li>TUR -- 40% </li></ul><ul><li>Emissions Reduction -- 91% </li></ul><ul><li>TUR Planning </li></ul><ul><ul><li>70% of firms identified TUR options </li></ul></ul><ul><li>Implementation </li></ul><ul><ul><li>81 % of the firms that identified TUR options in their plans reported implementing at least some of them </li></ul></ul><ul><ul><li>67% of firms reported cost savings </li></ul></ul><ul><ul><li>66% of firms reported health and safety benefits </li></ul></ul><ul><li>Materials accounting was rated the most valuable component of TUR planning </li></ul>
    4. 5. Fees Pay for TURI Services <ul><li>How to Design effective services for industry? </li></ul><ul><li>Technology Diffusion Tools can help agencies </li></ul><ul><li>TUR Planning is the best practice for industry </li></ul><ul><li>TURI Laboratory is unique and effective </li></ul>
    5. 6. Technology Diffusion <ul><li>Everett Rogers classic model of diffusion of technological innovation (Rogers, 1995) </li></ul><ul><li>“ Diffusion is the process by which an innovation is communicated through certain channels over time among members of a social system” </li></ul><ul><ul><li>Show economic or social advantage </li></ul></ul><ul><ul><li>Help connect the concept to values, beliefs, experiences </li></ul></ul><ul><ul><li>Address Complexity </li></ul></ul><ul><ul><li>Make it easy to do small scale testing </li></ul></ul><ul><ul><li>Offer demonstrations </li></ul></ul><ul><ul><li>Remove barriers ($, research, training) </li></ul></ul>
    6. 7. Toxics Issues are Complex
    7. 8. Core Technology to Advance -- TUR Planning <ul><li>Companies with skills in </li></ul><ul><li>planning and evaluating innovations </li></ul><ul><li>will be more effective than </li></ul><ul><li>promoting a particular innovation. </li></ul>
    8. 9. TUR Planning Cycle Green boxes are what TUR Planners do Process Characterization Pre-Plan Identify TUR Options Develop or Update Plan Certify Plan Screen & Evaluate TUR Options Implement Plan Measure Success
    9. 10. Definition of TUR <ul><li>TUR Techniques: </li></ul><ul><li>Improve processes </li></ul><ul><li>Reformulate </li></ul><ul><li>Substitute a safer material </li></ul><ul><li>Redesign process, product, or service </li></ul><ul><li>Improve operations and maintenance </li></ul><ul><li>In-process recycling </li></ul>Reduce use of toxic chemicals or generation of waste at the source by using…
    10. 11. Technology Diffusion of TUR <ul><li>Difficult to advance because they are about “prevention ” ; market opportunities are easier </li></ul><ul><li>Drivers of change play key role </li></ul><ul><li>Regulatory: bans, phase outs, emission or use restrictions, fees </li></ul><ul><li>Market: Customer “green” goals and brand protection, labeling, government Environmentally Preferable Purchasing (EPP) programs </li></ul>
    11. 12. Change Agents <ul><li>Change agents play a crucial role </li></ul><ul><ul><ul><li>Technical assistance programs </li></ul></ul></ul><ul><ul><ul><ul><ul><li>Must be funded! </li></ul></ul></ul></ul></ul><ul><ul><ul><li>Researchers and universities </li></ul></ul></ul><ul><ul><ul><ul><ul><li>Must be funded! </li></ul></ul></ul></ul></ul><ul><ul><ul><li>Consultants to industry </li></ul></ul></ul><ul><ul><ul><ul><ul><li>Must prove their value! </li></ul></ul></ul></ul></ul><ul><ul><ul><li>Opinion leaders in industry </li></ul></ul></ul><ul><ul><ul><ul><ul><li>Must be recruited </li></ul></ul></ul></ul></ul>
    12. 13. 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 Continuous Improvement
    13. 14. TURA Industry Programs <ul><li>On-site Technical Assistance </li></ul><ul><li>University Research on Technical Problems (Grant program) </li></ul><ul><li>University Laboratory Testing Program </li></ul><ul><li>Technology specific Workshops and Seminars </li></ul><ul><li>Training and Conferences for TUR Planners </li></ul><ul><li>Peer Mentoring and collaboration </li></ul>
    14. 16. TUR Planning Example - Electroplating
    15. 17. TUR Planning: Options Identification and Evaluation Evaluate Screen Identify <ul><li>Evaluate remaining TUR Options </li></ul><ul><li>T echnical evaluation </li></ul><ul><li>Economic evaluation </li></ul><ul><li>Brainstorm TUR Options </li></ul><ul><li>Consider techniques </li></ul><ul><li>Generate lots of ideas </li></ul><ul><li>Eliminate TUR Options </li></ul><ul><li>Technically or economically infeasible </li></ul><ul><li>Not TUR </li></ul>For each toxic in each production unit,
    16. 18. TUR Planning: Cost Categories
    17. 19. Lightolier Changes <ul><li>Increased drip time to allow acids to return to chemical baths </li></ul><ul><li>Installed still-rinse tanks </li></ul><ul><li>used countercurrent rinsing. </li></ul><ul><li>Looked at hidden costs of using TCE </li></ul><ul><li>Switched from petroleum coolants to a water soluble formula </li></ul><ul><li>Replaced an old vapor degreaser and reduced use of TCE by 98% (from 125,000 pounds per year) </li></ul><ul><li>Switched to a brightner with 90% less copper to protect local wastewater treatment facility </li></ul>Attended program workshops Visited by OTA
    18. 20. Doing Planning Alternatives <ul><li>After several cycles of TUR planning, firms can choose to report on </li></ul><ul><ul><li>Resource Conservation Planning – energy, water, materials </li></ul></ul><ul><ul><li>Integrating TUR Planning into Environmental Management Systems (EMS) </li></ul></ul>
    19. 21. Lightolier <ul><li>44 Million Gallons per Year Reduction </li></ul><ul><li>$ 181,715 per year annualized savings </li></ul>
    20. 22.     Inner Tite Lightolier VH Blackington Olympic Mnf     <ul><li>97% reduction of TCE </li></ul><ul><li>Zero Discharge to air </li></ul><ul><li>98 % reuse of plating chemicals </li></ul><ul><li>$12,000 saved annually </li></ul><ul><li>1.2 million pounds TCE eliminated </li></ul><ul><li>$2,000,000 saved </li></ul><ul><li>Eliminated TCE </li></ul><ul><li>85% reduction in Copper and Zinc </li></ul><ul><li>95% reduction in Cyanide </li></ul><ul><li>75% reduction in coolant </li></ul><ul><li>$38,000 saved annually </li></ul>TURA     { { { {
    21. 23. Many Successful Stories <ul><li>Tri-Star Technologies of Lowell produces printed wiring boards </li></ul><ul><li>TUR planning identified the option of installing a electrolytic regeneration system to the cupric etch line, resulting in: </li></ul><ul><ul><li>fully eliminating the use of hydrogen peroxide </li></ul></ul><ul><ul><li>a 90% reduction in the use of hydrochloric acid </li></ul></ul><ul><ul><li>recovery of 42,000 pounds of copper each year </li></ul></ul><ul><ul><li>a two-year pay-back of the $110,000 investment for the regeneration unit </li></ul></ul>
    22. 24. Continuing Education Examples Industrial Energy Efficiency2 Green Chemistry Theory and Practice Innovative Coating Techniques National and Int’l Policy Organizational change workshops Toxicology Integrating Lean & Clean Manufacturing
    23. 25. Research and Technical Support <ul><ul><li>Research: collaboration through Industry Supply Chains (lead-free electronics) </li></ul></ul><ul><ul><li>Research: Applied Green Chemistry, Biomaterials, Nano-materials </li></ul></ul><ul><ul><li>Workgroup: Environmental Management Systems Peers </li></ul></ul><ul><ul><li>TURI Laboratory </li></ul></ul>
    24. 26. TURI Laboratory
    25. 27. Pilot Cleaning in Lab Setting <ul><ul><li>Using client specific operating conditions </li></ul></ul><ul><ul><li>Using client supplied parts </li></ul></ul><ul><ul><li>Compare with current solvent (if possible) </li></ul></ul><ul><ul><li>Client assessment of results to confirm </li></ul></ul>
    26. 28. Alternatives to TCE
    27. 29. TURI Laboratory <ul><li>Assists industry and communities in the search for safer cleaning processes </li></ul><ul><ul><li>Tests the performance of alternatives to hazardous solvents </li></ul></ul><ul><ul><li>Extensive database of results at www. turi .org </li></ul></ul><ul><li>Janitorial cleaning </li></ul><ul><li>Industrial parts cleaning </li></ul>TCE Cleaning Use Data
    28. 31. Atlantic Ocean Pacific Ocean X X