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Pollution Prevention and Green Chemistry

Making Our Industries and Communities Safer, Healthier, and More Competitive (I’m serious)

[email protected] www.turi.org

Pollution Prevention

Massachusetts’ Toxics Use Reduction Act

(TURA)

Green Chemistry and Design for Environment Career Possibilities

A little history of toxics and pollution prevention


10

Evolution of Pollution Laws


Earl Blumenauer asks the FDA to recall Brazilian Blowout Published: Wednesday, September 28, 2011

Toxics – still newsworthy

EPA Releases Final Health Assessment for TCE Release date: 09/28/2011 WASHINGTON – The U.S. Environmental Protection Agency (EPA) today released the final health assessment for trichloroethylene (TCE) …The final assessment characterizes the chemical as carcinogenic to humans and as a human noncancer health hazard.


End-of-the-pipe Pollution Control


Reactionary En

d-of

-the-

pipe

rem

edia

tion

4. Prevention

3. Recycling

2. Treatment

1. Disposal

Anticipatory

1. Prevention

3. Treatment

2. Recycling

SHIFT

4. Disposal


Source Reduction

TUR • Energy Conservation • Cleaner Production

• Resource Conservation

Treatment

Recycling

Waste Disposal Minimization

Energy Recovery

Pollution Control = end of pipe mediation

Pollution Prevention = greater efficiency with less or no toxic material

Pollution Prevention vs Pollution Control


Treatment

Storage and Disposal

Eliminate Hazards

Personal Protective Equipment

Administrative Controls

Reduce exposure to toxic substances by “control at the

source”

Eliminate or Reduce toxic substances and processes

Engineering Controls

Pollution Prevention- P2 Workplace Health and Safety

Least Effective for H&S and P2

Best H&S and P2

Hierarchy for Preventing Pollution &Workplace Illnesses, Injuries, & Fatalities

Recycling: Processing waste for reuse

Treatment


Reduce exposure to toxic substances by “control at the

source”

Eliminate or Reduce toxic substances and processes


Eliminate Hazards

Treatment


Reduce exposure to toxic substances by

“control at the source”

Eliminate or Reduce toxic substances and

processes



Toxics Use Reduction Act (TURA)

• Users of large amounts of toxics must:

– Report toxics use

– Pay fees

– Plan toxics reduction

• 2006 Amendments: – Designates higher and lower hazard substances

– Resource Conservation Planning – energy, water, materials

– Integrates Environmental Management Systems into TUR

Adopted 1989 Effective 1990

Expanded 2006


Required data collection points

Production Unit

In-plant treatment or recycling

Byproduct

Raw Material

Product

Emission


TURA Overview

• Massachusetts competitiveness • Toxics reduction • Technical analysis • Financial analysis • Report toxics use


Did We Achieve the Goals?

19

Total Use Production Adjusted

0.0

200.0

400.0

600.0

800.0

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

Year

Mill

ions

of P

ound

s

Byproduct

0.020.040.060.080.0

100.0120.0

1990

1991

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

Year

Mill

ions

of P

ound

s


Toxics Use Reduction Planners

• Only professionals able to certify MA TUR Plans

• 48-hour intensive course

• Certified by exam

TURA 20th Anniversary Video at www.turi.org

“[Becoming a TUR Planner] was a whole new career path….we have new credibility; people listen to us; we became part of the business planning process.”

Jack Bailey, TUR Planner, Bose Corp.


TUR Plans

FINANCIAL ANALYSIS

Draft Project Parameters

Send RFP’s to Vendors

Analyze Proposals for Technical Feasibility

Choose Equipment Based on Technical Merits

Collect Cost Information

Determine Incremental Cash Flows

Apply Measures of Profitability

List Qualitative Issues

Develop Comparative Information

Interpret Results

Prepare Justification Package

Evaluate Performance

TECHNICAL ANALYSIS

QUALITATIVE ANALYSIS

Assess Impacts

Prepare Assessment Map


TUR Technical Analysis


TUR Financial Analysis


TUR Input substitution


TUR Product Reformulation


TUR Production Unit Redesign

X-ray inspection – ball-grid array


TUR Modernization


TUR Improved Operations & Maintenance


Integral recycling


Alternatives Assessment

Risk Assessment

Better Solutions

Problem-based approach Debates delay prevention Toxicity data limited Risk shifting Game nobody wins

Focus on solutions & opportunities Greater stakeholder participation Promotes innovation, enterprise creation Multi-risk consideration


Green Screen

• Developed by Clean Production Action

• 17 environmental, health and safety criteria

http://www.cleanproduction.org/library/Green_Screen_Report.pdf

http://www.cleanproduction.org/library/Green_Screen_Report.pdf

[email protected] www.turi.org 32

Car

cino

geni

c

Mut

agen

ic

Rep

rodu

ctiv

e

Dev

elop

men

tal

Endo

crin

e D

isru

ptio

nN

euro

logi

cal

Met

abol

ites

Deg

rada

tion

Prod

ucts

DecaBDE 1163-19-5 97 M L L M M M L L L nd L L nd L L vH Mpenta- to nona-BDE

tri- to nona-BDE

PentaBDE 32534-81-9 nd L M M H M L H L L M M nd H H vH vH

OctaBDE 32536-52-0 nd L M H M M L H L nd L L nd L L vH M ndlower

PBDEs

Human Health Effects Ecotox. Fate

Chr

onic

Pers

iste

nce

Bioa

ccum

ulat

ion

Breakdown Products

Decabromodiphenyl ether (decaBDE) - CAS# 1163-19-5

Bold text = based on experimental data. Black italics text= based on analog data or expert judgment.

Breakdown ProductsPriority Effects

Acut

e To

xici

tySy

stem

ic/O

rgan

Effe

cts

Sens

itiza

tion

(ski

n)

Sens

itiza

tion (

resp

irato

ry)

Irrita

tion/

Cor

rosi

on (s

kin)

Irrita

tion/

Cor

rosi

on

(eye

s)Im

mun

e Sy

stem

Effe

cts

Acut

e

Chemical CAS#%

in F

orm

ulat

ion

Green Screen Benchmarking DecaBDE


TUR Planning Process

• Planning viewed as a continual improvement cycle

33

Implement

Evaluate

Review

Continual Improvement…

Modify

Evaluate

Review Plan (year 0)

Update (year 2)


Green Chemistry Design for Environment


Great Philosophical Dilemmas of the 21st Century

Plastic? (polystyrene)

OR

Paper?


Hocking paper in Science (Feb. 1991): Paper vs Polystyrene, a Complex Choice

• Wood product use: 33g • Petroleum material: 4.1g • Steam: 9-12 tonne/T • Electricity: 980 KWh/T • Cooling water: 50 m3/T

• Water effluent: 50-190 m3/T • H2O solids: 35-60 kg/T • Metal salts to H2O: 1-20 kg/T • Low recycled use (coating removal) • Biodegradable with BOD* lechate

and CH4 to air • Clean incineration

• Wood product use: 0 • Petroleum material: 3.2g • Steam: 5 tonne/T • Electricity: 120-180 KWh/T • Cooling water: 154 m3/T

• Water effluent: 0.5-2 m3/T • H2O solids: trace • Metal salts to H2O: 20 kg/T • High recycled use (resin re-use) • Inert, non-biodegradable • Clean incineration

Paper Cup Polystyrene Cup

* Biological Oxygen Demand


Criticisms of Hocking

• No consideration of human toxicity • No consideration of eco-toxicity • Styrofoam not economical to recycle • Some quantities double-counted


Framework for Sustainable

Products

What makes a product ‘green’?


DfE Definitions • “…product contains only those

ingredients that pose the least concern [regarding human health and environmental effects] among chemicals in their class.”

• “Ecodesign aims at reducing the environmental impact of products, including the energy consumption throughout their entire life cycle.”


“The DfE program has three priorities: • Energy efficiency - reduce the energy needed

to manufacture and use our products

• Materials innovation - reduce the amount of materials used in our products and develop materials that have less environmental impact and more value at end-of-life

• Design for recyclability - design equipment that is easier to upgrade and/or recycle”

DfE Definitions


From Take-Make-Waste….


…to Cradle-to-Cradle


Drivers: Legislation

REACh RoHS TURA ToSCA

EU Energy CA Appliance Efficiency

MA “Stretch Codes”

Energy

Toxics Resource Conservation

WEEE ELV

EU Ecodesign Directive: all 3


Drivers: Labeling and Certification


Drivers: Consumer Preference


Examples of DfE factors

Low power logic family vs standard logic families Design Choice

Recycled pulp inserts vs styrofoam Packaging

Gold circuit board traces vs copper Material Recovery

Improved Design for Disassembly Recyclability

‘Always on’ power adaptor vs ‘Smart’ power adaptor Energy Consumption

Plastic housing vs metal Material Choice

Inkjet vs laser Product Concept


Life Cycle Analysis (LCA)

Fossil Fuel Depletion Mineral Depletion

Land Use Water acidification / eutrophication

Eco-toxicity Climate Change

Ozone Layer Depletion Carcinogenic Substances

Organic Respiratory Effects Inorganic Respiratory Effects

Ionizing Radiation

Ecosystem Resources

Ecosystem Quality

Human Health

Impact Categories (“Midpoints”) Typical Groupings Endpoints

Ecosystem Resources

Ecosystem Quality

Human Health

Processing Chemicals: • Reduce hazardous processes (3) •Energy Efficiency (6) • Safer Solvents (5) • Reduce Derivatives (8) •Catalysis (9) •Real-time Analysis (11) • Accident Prevention (12)

The Product : • Designing Safer Products (4)

End-of-Life: •Recycle (1) • Reuse (1) • Regeneration (1) • Compost/Biodegradable (10) • Land Fill (Pollution)

Pollution to Avoid: • By-products • Unused reagents & raw materials • Spent Solvent • Wasted Energy

Pollution Prevention: • Reduce by-product formation (2) (8) • Use less/safer reagents and raw materials (3) • Use less/safer solvents(5) • Reduce Energy Use (6) • More efficient processes (9)

Raw Materials and Feedstocks: • Atom Economy (2) • Renewable Feedstocks (7)

12 Green Chemistry Principles – In Action


Making DfE Happen Total Quality Management Focus on identifying defects and waste in every step

Continuous improvement = The Better Mousetrap:

• Higher quality • More reliable • Better focused on customer

need • Cheaper

Total Quality Environmental Management Consider non-compliance and adverse environmental impact to be defects

Existing TQM practices

= The Greener Mousetrap:

• Environmentally compliant • Designed for the

Environment • ISO Life cycle oriented


TUR & 6-sigma Quality Management

>$1M in efficiency improvements

$100K scrap

reduction

70% VOC reduction

$15K saved by reducing VOCs


Quality Costs

Supplier Inspection

Incoming Inspection

Fabrication Inspection

Sub-product Test

Final Product Test

Field Service

0.003 0.03

0.30

$3

$30

$300

Quality costs escalate as value is added to a product or service

Cost of finding and correcting a defective electronic component

P. Crosby & Associates, 1979


Environmental Quality Costs

Product concept

Landfill, incineration, etc.

Environmental cleanup

Manufacture

Design

Use

Life Cycle Costs escalate at later stages of the Life Cycle

Life Cycle Cost of a toxic material

“Most environmental costs are incurred on the first day of product development”


Environmental Quality Costs

Product concept


Environmental cleanup – landfill toxics remediation

Manufacture

Design

Use

Life Cycle Cost of Mercury battery

One ‘button battery’ per kg of soil renders cost of soil remediation virtually

infinite


Theoretical Environmental Quality Costs

Product concept


Environmental cleanup – landfill remediation

Manufacture

Design

Use

Life Cycle Cost of rechargeable alkaline and Lithium-ion batteries

Relatively expensive to purchase, these batteries last much longer, are less

toxic, are rechargeable, and can be recycled easier.


Theoretical Environmental Quality Costs

Product concept


Environmental cleanup – landfill remediation

Manufacture

Design

Use Self-powered windup devices minimize the

problem of battery disposal

Life Cycle Cost of windup flashlight


Life-Cycle Analysis (LCA)

• Consider products or product options which deliver equivalent function

• Model chains of engineering unit processes, their resource/pollution flows

• Sum resource/pollution flows over chain (inventory analysis – LCIA)

• Determine damage potentials – impact analysis • Optimize environmental performance throughout

the product’s entire life


Modeling unit functions

Extractions from the environment • Fuel • Materials • Land, water, air, etc.

Could be from biosphere or technosphere

Emissions to the environment • To air • To water

Product or service

From previous unit

process(es)

To next unit process(es)


Example Life Cycle Inventory hierarchy


Life Cycle Analysis (LCA)

Fossil Fuel Depletion Mineral Depletion

Land Use Water acidification / eutrophication

Eco-toxicity Climate Change

Ozone Layer Depletion Carcinogenic Substances

Organic Respiratory Effects Inorganic Respiratory Effects

Ionizing Radiation

Ecosystem Resources

Ecosystem Quality

Human Health

Impact Categories (“Midpoints”) Typical Groupings Endpoints

Ecosystem Resources

Ecosystem Quality

Human Health


Summing resource and emission flows, calculating impact results

Inventory results (LCI) Impact Assessment results


Impact group results – comparing alternatives


Impact group results – comparing weighted alternatives


Career Considerations

• Toxics Use Reduction Planner • Alternatives Assessment

– Product design – Process design – Service design

• Clean Production • Lean / 6 Sigma “Black Belt” • Design for Environment

We can't solve problems by using the same kind of thinking

we used when we created them. Albert Einstein

[email protected] +1 978.934.3298

mailto:[email protected]

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