IEPA’s Pollution Prevention Internship Program

Kevin GreeneIllinois EPAGGCC Green Universities and Colleges Subcommittee Monthly MeetingAugust 17, 2011

Presentation Objectives

Provide background information on the program

Describe the components Highlight intern projects

at higher education institutions

Share “lessons learned”

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Background Pollution Prevention (P2)

Internship Program launched in1989

Evolved from discussions between IEPA and State Chamber of Commerce Improve relations between

IEPA and business community Provide a non-regulatory

approach to help facilities reduce environmental impacts

Encourage environmental innovation and leadership-type projects

Purpose: help facilities improve environmental performance, while providing practical work experience for college students

P2 Focus: Avoid generation of waste and

emissions Decrease use of toxic

substances Use materials, equipment,

energy and water more efficiently

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Key Components

Place student interns at 15-20 facilities each year, primarily in the manufacturing sector

Recruit students from public and private universities in the state Junior/senior undergrad and graduate level college students Background in engineering, chemistry or environmental

management Train students on energy efficiency, waste auditing, processing

mapping and other process improvement techniques Students work for 12 weeks in the summer (includes 11 weeks in

the field and one week of training) Provide a salary of $2,500 a month Depending on funding availability, IEPA will pay entire student

salary or negotiate a cost-sharing agreement with the host facility

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What are the benefits for host facilities? Technical resource

provided at a relatively modest cost

Fresh perspective with a focus on process improvement

Reduced waste, emissions, energy losses and potential environmental liabilities

Cost savings related to materials, operations, treatment and disposal

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Student Benefits Gain “hands-on” experience in

industrial and other workplace settings

Opportunity to make a difference in protecting the environment

Gain project management skills

Improve communication and presentation skills

Earn a salary Build resume and professional

contacts

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Illinois Institute of Technology University of Illinois at

Chicago University of Illinois at Urbana-

Champaign Bradley University Southern Illinois University

Edwardsville Southern Illinois University

Carbondale Northern Illinois University Northwestern University

Which state universities have provided intern students?

IEPA’s role in the intern program Recruit qualified students Review facility project proposals Match interns with host facilities Establish contracts with students Train interns on P2 technologies and practices Conduct initial on-site visit with student Review intern progress reports and periodically consult with the facility

supervisor Provide project support (technical advice, resource leads, problem-solving,

etc.) Publicize the project results

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Intern Responsibilities

Attend one-week training class in Springfield Adhere to a work schedule (typically a 40-hr. work week) Follow company policies and regulations (e.g., safety,

personal protection, operating procedures and confidentiality)

Work with management and staff Submit bi-weekly progress reports

Reports are reviewed by facility supervisor before submittal to IEPA

Present project results at half-day seminar Deliver a final report at end of project

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Facilities Must Provide: Well-defined project

Student supervision

Work space

Safety training

Employee cooperation

Workers’ compensation

Cost-sharing fee and misc. expenses, where appropriate

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Program Timeline September & October – attend job fairs and work with career service

offices to recruit students November – review student applications and interview qualified

candidates (intern application deadline is October 25 for following summer)

November & December – review project proposals (project application deadline is October 25)

January – select host facilities and student interns May – conduct one-week training class (typically the week before

Memorial Day weekend) June to August – place students in the field for 11 weeks August – host two seminars for students to present project results

(typically second week of the month) October – post a summary of the student projects on agency web site

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A sampling of facilities that have participated in the program Industry

Caterpillar Motorola Abbott Laboratories Nalco Company Honeywell Case New Holland (Goodfield) Illinois & Midland RR (Springfield) Harris Corp. (Quincy) Innertech (Nashville) Carlisle SynTec (Greenville) Rhodia Inc. (Blue Island) Prairie Farms Dairy (Carbondale) J & M Plating (Rockford) Roe Machining (Johnston City)

Local Government City of Du Quoin Wilmette Water Plant Village of Algonquin Public Works Tazewell County Health Department

Institutions University of Illinois at Chicago Southern Illinois University -

Carbondale Rock Island Arsenal St. Mary’s Hospital (East St. Louis) U.S. Penitentiary Marion Industrial Council of Nearwest

Chicago Joliet Public Schools District 86

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What type of projects have past interns implemented or recommended? Lighting/motor upgrades

Air compressor usage Solid waste reduction Process efficiency Material substitution Equipment cleanup Waste segregation Heat recovery Boiler replacement Improved inventory control Container reuse/recycling Laboratory chemicals/solvents Training/awareness building Environmental management systems

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2009 Intern Project: University of Illinois at Chicago

Project Focus: identify opportunities for decreasing laboratory wastes and make recommendations for improving the management of medical and pharmaceutical wastes at the medical center

Results: The intern made the following recommendations: Establish a program to recycle acetone and hexane solvents from the organic chemistry

labs and xylene from hospital pathology . Recommended that the university evaluate the use of on an on-site fractional distillation unit, which has the potential to save $14,000 a year in disposal costs

Determined that a large percentage of hazardous waste could be reduced through source reduction or in-house recycling. The intern developed a reusable container program for sharps disposal that will be introduced in early 2011. This program has the potential to reduce the amount of plastic waste by one ton a year. The sharps can also be treated as medical waste

The reusable sharps container program and reclassification of the waste stream have the potential to save $485,000 a year in disposal costs

Improve inventory methods and redistribute expired, unused flush medications (e.g., saline and dextrose) to university labs for use in research projects. This project has the potential to reduce disposal costs by up to $15,000 a year

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2009 Intern Project: Illinois Central College Project Focus: investigate opportunities to reduce energy use in campus buildings Results: The student made the following recommendations:

Install occupancy sensors in 62 bathrooms. This project could save $2,800 annually, with a payback period of 1.5 to 2 years

Apply a reflective coating to extend the life of roof at two buildings. This project could save the college $900,000 in avoided replacement costs and reduced energy usage

Replace existing boilers with high efficiency units. This project has the potential to save $100,000 in reduced natural gas usage, with a payback period of less than 4 years

Replace the windows in the Academic Building with double-pane Energy Star windows and improve insulation around all metal panels

Install energy controls on beverage and snack machines. This project could save $10,000 annually, with a payback period of 11 months

Power down computers at night and during weekends. This project could save $80,000 annually

Install day-lighting controls on the library skylight. This project could save over $2,800 annually, with a payback period of less than 1 year

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2008 Intern Project: Southern Illinois University -Carbondale Project Focus: Identify energy efficiency opportunities in the university

laboratories and research buildings Results: the student completed the following tasks:

Collected data on over 300 separate chemical fume hoods, including electrical usage for the exhaust fan motors. A baseline energy consumption profile was calculated for each system

Identified several strategies to reduce energy use, including occupancy-based, variable air volume exhaust and automatic sash positioning systems

Recommended a decommissioning program for unused hoods based on air change requirements

Calculated that four buildings could save over $67,000 by reducing supply and exhaust air volumes with variable speed fans and new controls based on occupancy and sash position

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1999 Intern Project: John A. Logan College Project Focus: Provide on-site technical assistance to small businesses in the region Results: The student completed the following tasks:

Conducted waste reduction assessments and follow-up consultation at six facilities, including a screen-printer, sandblaster, metal welder, fiberglass fabricator, manufacturer of connectors and drill manufacturer

Identified several projects for the screen printer, including a screen reclamation system using high-pressure washers without volatile solvents, cleaner bath reuse, silver recovery and prolonged ink shelf-life practices

Recommended that the sandblasting facility use a solidification/vitrification process to convert waste bottom ash into a marketable product. This process is expensive and would require a large investment

Proposed that the fiberglass fabricator consider an industrial chopper or grinding machine to reuse waste fiberglass and also convert to an alternative cleaning solvent. A list of possible contacts for the industrial grinders and potential solvent alternatives were given to the facility

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2009 Program Results

Activity & Outcome Measures ResultsNumber of intern host facilities reporting

8

Number of student recommendations implemented

25

Gallons of water reduced N/A

Tons of hazardous material reduced

N/A

Metric tons of carbon dioxide reduced

2,301

Kilowatt hours of energy reduced 2,667,550

Dollars saved (capital costs, operating costs, one-time savings)

$1,379,035

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Lessons Learned Primary driving force for implementing P2 opportunities is reduced

operating costs Over the last several years, energy use has been the major focus of

intern projects With the down economy, facilities are seeking shorter payback periods

(e.g., less than 1 year) in selecting P2 projects for implementation Plenty of “low-hanging fruit” is still available for improving

environmental performance (e.g., lighting upgrades, waste heat reuse and tag/repair leaks in compressed air systems)

Host facilities are interested in having interns calculate reductions in carbon emissions from energy efficiency projects

Facilities that have multiple departments/staff involved in the intern project tend to produce the greatest results

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For more information: Rick Reese, P2 Intern Program Coordinator

richard.reese@illinois.gov (217) 557-8671

Illinois EPAOffice of Pollution Prevention (#34) 1021 N Grand Ave. East P.O. Box 19276Springfield, IL 62794-9276

www.epa.state.il.us\p2\internships

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Questions

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