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Shipbuilding & Ship Repair

Shipbuilding & Ship Repair

, onmental onmental TUNITIES TUNITIES epair sector PPOR O . AL educing air emissions, and emissions, and educing air tunities for envir tunities for e in managing and minimizing and minimizing e in managing NVIRONMENT eatest oppor E ovement ar ovement oving water quality EY K r and ship For the the gr impr waste, r toxics and impr s 2 3 orea, 1 7 5 346 $16 billion 92,400 . 6 oland. om the damage the , and P epair has epair industry has , Italy ecover fr 2,000 to 92,400. 0 ime will tell whether these d. T Over the past four years, the Over the past four s shipbuilding leaders such as South K ds har elatively stable. Appropriations for of new military ships Appropriations for construction (6%) from 2000 to 2006, showed a modest increase over the last year but declined by 35% employment within the Between 2000 and 2004, sector fell from 1 the world’ The U.S. now has less than a 1% share of vessels of new construction market for commercial the more than 1,000 gross tons, lagging behind world’ Japan, China, Germany alue of Contracts: alue of Contracts: RENDS Number of Employees: Number of Sector At-a-Glance At-a-Glance Sector Facilities: Number of V T ■ ■ ■ Coast In the fall of 2005, hurricanes hit Gulf shipyar facilities will fully r storms inflicted. shipbuilding and ship r shipbuilding and been r cial pair e epair epair ships, ges, and ds do only r

e oil and gas well drilling e oil and gas well epairs ships, bar epairs ships, fshor

e of The shipbuilding and ship r and ship The shipbuilding ge vessels for military and commer for military and ge vessels builds and r builds and t or alter ships, as well as facilities that ships, as well as facilities t or alter oduction platforms. Most facilities that oduction platforms. 4 ROFILE sector P . other lar operations that sector also includes clients. The conver manufactur and pr the ability to r build ships also have yar although some smaller 2006

Shipbuilding & Ship Repair 71 Shipbuilding MANAGING AND MINIMIZING TOXICS As shown in the Total TRI Disposal or Other comparison does not take into account the Given the diversity of their industrial processes, Releases line graph, the annual normalized relative toxicity of each chemical. Chemicals shipbuilding and ship repair facilities use a quantity of chemicals disposed or released by vary greatly in toxicity, meaning they differ in variety of chemicals and report on the release this sector decreased by more than half (58%) how harmful they can be to human health. and of many of those materials from 1994 to 2003, with one-third of this decline To account for differences in toxicities, each through EPA’s Toxics Release Inventory (TRI). occurring between 2000 and 2003. From 2000 to chemical can be weighted by a relative 2003, there was a similar decline of 37% in the toxicity weight using EPA’s Risk-Screening In 2003, 41 facilities in the sector reported 10.5 sector’s normalized quantity of chemicals Environmental Indicators (RSEI) model. million pounds of chemicals released (including released to air and water. disposal) or otherwise managed through The TRI Air and Water Releases line graph & treatment, energy recovery, or . Of In 2003, the chemicals disposed or released presents trends for the sector’s air and water

this quantity, 80% was managed, while the by the sector were dominated by n-butyl releases in both reported pounds and toxicity- Ship Repair remaining 20% was disposed or released to alcohol and xylene, which accounted for 42% weighted results. When weighted for toxicity, the environment, as shown in the TRI Waste of the total pounds. Zinc, , and 1,2,4­ the sector’s normalized air and water releases Management pie chart. Of those chemicals trimethylbenzene accounted for another 26% show a 73% decline from 1994 to 2003, with disposed or released to the environment, 24% of the sector’s total.8 little overall change from 2000 to 2003, despite were disposed and 76% were released into air an increase in 2001. The spike in 2001 is Data from TRI allow comparisons of the total or water. attributable to an increase in manganese releases quantities of a sector’s reported chemical releases to air, with one facility accounting for 68% of across years, as presented below. However, this those releases.

TRI Waste Management Total TRI Disposal or Other Releases TRI Air and Water Releases by the Shipbuilding & Ship Repair Sector by the Shipbuilding & Ship Repair Sector by the Shipbuilding & Ship Repair Sector 4 Energy Recovery Treatment 3.5 3.5 6% 34% Water Releases 3.0 3.0 2% 3 Disposal 2.5 2.5 24% 2 2.0 2.0 Releases 20% 1.5 1.5

1 1.0 1.0 Pounds (millions)* Pounds (millions)* 0.5 0.5 Air Releases 0 0.0 0.0 74% 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 Recycling Toxicity-Weighted Results (billions)* 40% Year Year Disposal or Releases, total Air and Water Releases, only Pounds Toxicity-Weighted Results * Normalized by annual value of shipments. * Normalized by annual value of shipments. Source: U.S. EPA, 2003. Sources: U.S. EPA, U.S. Census Bureau. Sources: U.S. EPA, U.S. Census Bureau.

72 gely epair ge ships e lar ve the ve the steel eser Most lar ocesses ar der to pr eleases discussed above, eleases discussed formance characteristics formance MISSIONS MISSIONS ticulate matter (PM), volatile ticulate matter (PM), E eparation and the application of eparation and the IR A face pr face. The shipbuilding and ship r shipbuilding and face. The eleases par ovide specific per ovide specific ed in the TRI air r ganic compounds (VOCs), and air toxics ganic compounds EDUCING EDUCING e built of steel and must be periodically steel and must be e built of R ar coated in or cleaned and and pr to the sur sector r or during sur Although emissions of VOCs and coatings. these pr and air toxics during captur a closer look at PM and these this section takes chemical categories. e, efor 9 espect , ther ith r omium). ds. Thus, RSEI elative harmfulness elative harmfulness 10 . vatively assumes that assumes vatively omium (the most toxic form, omium (the most eleased in the form associated the form associated eleased in eleases to air and water eleases to estimate the r e r eleases by shipyar ch indicates that the hexavalent form of ch indicates that the RSEI model conser RSEI omium r omium in the sector s ’ omium does not constitute a majority of total omium does not constitute omium r A e hexavalent chr P the model assumes that 100% of these emissions of these emissions assumes that 100% the model ar higher oral and inhalation with significantly trivalent chr toxicity weights than E ar chemicals W highest toxicity weight. with the to chr Resear chr chr analyses over of chr A s (<1%) ecent eleases, e driven omium s toxicity- tunity for Source: U.S. EP eased Lead s Copper educing the omium. In r esulted in little TER RELEASES esults wer A W eatest oppor eleases incr ess in r eleases to air and water eleases to

eighted Results eighted Results ogr e attributable to air r e attributable esents a list of the chemicals the chemicals a list of esents (99%) educing air emissions of these educing air emissions eleases. ges to water accounted for less than ges to water accounted e than 99% of the sector’ e than 99% e, r esents the gr e than tripling. One facility

esults wer oxicity-W efor Nickel op TRI Chemicals Based on op TRI Chemicals T , mor T Chromium Manganese AIR RELEASES eleases to air fluctuated but r eleased that accounted for 90% of the sector’ accounted for eleased that years, normalized manganese and chr r During overall change between 1999 and 2003. this time period, nickel r steadily accounted for 69% of the industry’ emissions in 2003. toxicity of its r In 2003, toxicity-weighted r by manganese, nickel, and chr The table below pr table below The r r total toxicity-weighted Mor in 2003. r weighted while dischar 1%. Ther chemicals pr pr the sector to make 2006 2006

Shipbuilding & Ship Repair 73 Shipbuilding

Particulate Matter Surface preparation is As shown in the PM & VOC Emissions bar chart, PM & VOC Emissions from between 1996 and 2001, normalized PM and critical to the coating life cycle, since it provides 10 the Shipbuilding & Ship Repair Sector both the physical and chemical requirements for PM2.5 emissions from this sector increased by long-term coating adhesion. To prepare surfaces approximately 31% and 74%, respectively.11 6 However, these emissions estimates may not for coating applications, shipyards predominantly 5 use a dry- blasting process. This reflect the shipyards’ efforts in the last five years 4 dry- is typically performed to contain PM emissions from abrasive blasting 3 by using shrouds, shrink-wrap, and other forms 2 outdoors, as the sheer size of a ship makes & enclosure difficult and expensive. of containment. In addition, many shipyards Tons (thousands)* 1 0

have switched blasting materials from slag PM10 PM2.5 VOC Ship Repair The blasting operation generates PM emissions 1996 2001 and steel shot to garnet, high-pressure water, and * Normalized by annual value of shipments. from both the breakup of the abrasive material PM = Particulate Matter; VOC = Volatile Organic Compounds other lower emission . The following Sources: U.S. EPA, U.S. Census Bureau. and the removal of the existing coating. Over case study highlights one shipyard’s success in Case Study: Ultra-High Pressure Water Blasting the past 10 years, shipyards have developed reducing PM emissions by adopting an at Atlantic Marine In an effort to reduce its PM several methods to reduce PM emissions to alternative blasting . the environment, including: emissions, Atlantic Marine in Jacksonville, FL, has stopped all open-air abrasive blasting in favor of ultra-high pressure ■ Temporary containment of blasting operations; (UHP) water blasting. This technology uses high-pressure ■ Material substitutions; and streams of water, instead of grit, to remove the coatings from ■ Alternative surface preparation technologies. ships. Unlike abrasive blasting, there are no PM emissions from the water stream, and the flakes of paint are larger Early attempts at temporary containment so they do not end up in the air. Over the last six years, consisted of hanging curtains from scaffolding, Atlantic Marine has avoided more than 460 tons of PM wires, dock-arms, and other structures around emissions through the adoption of the UHP technology, as the ship. Generally, these temporary structures shown in the following table.12 were open at the top and reduced PM emissions by reducing the wind speed in the blasting area. PM Emissions Avoided by This practice has evolved to include the Atlantic Marine construction of temporary shrink-wrap YEAR TONS AVOIDED enclosures of entire ships in drydock. 1999 32.0 2000 43.1 EPA’s National Emissions Inventory (NEI) 2001 121.7 estimates that, in 2001, the sector released 2002 83.2 2003 76.0 1,963 tons of PM10 and 1,257 tons of PM2.5. 2004 104.4 Total 460.4 74 e oducts d e than 16 ecor eplaced mor onic r eviews of all new eview of mor placements for these e eater than 3.5 pounds per eater than 3.5 pounds ol equipment, Electric Boat in ol equipment, Electric educing VOC emissions educing VOC onic catalog system to identify onic catalog system to esult, Electric Boat has r oduction and maintenance work. oduction and maintenance der to lower VOC emissions and der to lower VOC emissions In or oduct substitution. oduct substitution. onmental data and r , Electric Boat initiated an electr , conducted an exhaustive r , conducted an exhaustive s success in r s success oducts listed in its inventory system to identify oducts listed in its inventory d’ ough pr oton, CT

system to collect air emissions data associated with boilers system to collect air emissions data associated and generators. As a r with pr than 100 , glues, fillers, and sealants gallon. that do not exceed 3.5 pounds of VOCs per The following case study highlights one one highlights case study following The shipyar thr Reductions at VOC Emissions Case Study: Electric Boat contr eliminate the need for Gr 10,000 pr gr those materials with VOCs gallon, developed an electr specific envir stringent r materials, and implemented materials for use in pr Additionally Toxicity-Weighted Results (billions)* (billions)* Results Toxicity-Weighted 3.0 2.5 2.0 1.5 1.0 0.5 0.0 d due ficult 2003 eased line 2002 e than esults for air esults for oving the eformulated ed by 2001 Toxicity-Weighted Results ers, working in 2000 quir eleases decr e 1999 Ship Repair Sector oxics Releases Releases oxics e viscous and dif ds, have r Year & eformulation of marine eformulation of marine ease occurring between ease occurring 1998 formance characteristics. 1997 oxicity-weighted r oxicity-weighted educe VOC and air toxics educe VOC and air T TRI Air T TRI Air 14 15 1996 TRI Air Toxics Releases 1995 Pounds om 1994 to 2003, with mor om 1994 ter of this decr ter of this , these low-VOC, high-solids content , these low-VOC, high-solids content 1994 eleases showed a similar decline over the eleases showed a similar 1.5 1.0 0.5 0.0 2.5 2.0

formance characteristics r by the Shipbuilding (millions)* Pounds Sources: U.S. EPA, U.S. Census Bureau. * Normalized by annual value of shipments. 2000 and 2003. 2000 and in both VOC and air toxics Much of the decline the r emissions is due to manufactur coatings. Coatings shipyar cooperation with r many coatings to or impr content while maintaining per customers. Although mor to apply standar coatings have become the industry to their excellent per As shown in the in As shown r air toxics graph, normalized by 72% fr one-quar toxics r 10-year period. ds ol the 13 ds, eleased evious onmental ol operly esented om shipyar t on the pr e applied indoors, e applied indoors, onment during dous air pollutants, face is pr e included in TRI) eleases of 730,000 e applied outdoors. e applied outdoors.

s sur bar char onment. ted air toxics r

eleased to the envir Once the ship’ Once the , most coatings ar epor d. These coatings may contain chemicals d. These coatings e r ed, coatings can be applied. The type of can be applied. ed, coatings NEI estimates that, in 2001, the sector NEI estimates that, in 2001, the sector esult, VOCs and air toxics may be r s ’ A epar e a subset of the TRI chemicals pr fects as air toxics. In 2003, 38 facilities in the fects as air toxics. In 2003, 38 facilities olatile Organic Compounds & Air & Air Compounds Organic olatile P oxics elease of VOCs and air toxics. At shipyar elease of VOCs and in the eleased 3,333 tons of VOCs. As shown declined by 36% between 1996 and 2001. declined by 36% between 1996 and it is possible to utilize contr it is possible to utilize spray booths, to contr equipment, such as r however As a r into the envir E r PM & VOC Emissions page, normalized VOC emissions fr pr level down to the be applied (typically coating to by the customer brand) is specified of a specific rather than the (i.e., the ship owner/operator) shipyar that ar coatings ar application. When Air toxics, also called hazar ar 188 above. The Clean Air Act designates chemicals (182 of which ar that can cause serious health and envir ef sector r pounds.

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Shipbuilding & Ship Repair 75 Shipbuilding MANAGING AND MINIMIZING WASTE Over the past decade, the shipbuilding and ship Case Study: Eliminating Stormwater Discharges EPA data on large quantity repair sector has made progress in reducing at Todd Pacific Shipyard Before Todd Pacific Shipyard generators, as reported in the National Biennial waste generation and increasing reuse and Corporation could effectively remediate the contaminated RCRA Hazardous Waste Report, indicate that the recycling rates. Improvements in hazardous sediment that had accumulated around its facility over the shipbuilding and ship repair sector accounted for waste management at shipyards can be attributed past century, the shipyard needed to prevent future releases less than 1% of the hazardous waste generated to several practices, including: of contaminants to the water. Located on Harbor Island in nationally in 2003. Seattle, WA, Todd Pacific’s various construction, repair, and ■ Development of improved coating application maintenance operations take place on a 10.5-acre paved technologies, such as in-line plural component mixers In 2003, 63 facilities in the sector reported industrial yard. In the past, rainwater that fell on the 12,000 tons of hazardous waste generated. Half that only mix the amount of coating necessary, as it pavement was discharged to surrounding waters via outfalls & is required, to avoid the waste of excess paint; of the sector’s waste was generated through and served as a major source of sediment contamination. To ■ wastewater treatment, and another 21% was Use of paint waste for fuel blending, rather than prevent future contamination, the company has implemented Ship Repair generated from painting and coating processes. solidifying it for land disposal; and a system that collects the stormwater runoff from the The waste management methods most utilized ■ Reclamation of spent solvents from spray paint primary yard pavement and discharges the water into the by this sector were chemical precipitation, fuel equipment. sewer so it can be treated at the Seattle Public Utilities blending, and or surface impoundment. treatment plant. Key features of this system include MPROVING ATER UALITY Releases of I W Q the following elements: When reporting hazardous wastes to EPA, chemicals into water account for a small fraction quantities can be reported as a single waste code of the TRI toxicity-weighted results for this ■ Industrial runoff from the paved yard is channeled (e.g., lead) or as a commingled waste composed sector. However, pollutants generated by through catch basin sumps for solids removal and then of multiple types of wastes. Quantities of a shipyards can be released into the environment passes through a second-stage treatment method for specific waste within the commingled waste are through stormwater runoff. additional solids removal as well as oil and grease not reported. The shipbuilding and ship repair Over the last several years, a group of Gulf separation. sector reported 68% of its wastes as individual Coast shipyards led an effort with EPA to ■ Runoff from roofs and the employee parking lot is waste codes. Of the individually reported wastes, develop best management practices for separated from the industrial runoff and discharged the predominant hazardous waste types reported stormwater.18 Additionally, many shipyards on through existing outfalls. by the sector in 2003 included corrosive waste the West Coast capture and treat stormwater ■ New 450,000-gallon detention tanks are large enough (6,000 tons), lead (1,000 tons), ignitable waste, before discharging it. to handle runoff from a 10-year storm event. and chromium. Additional quantities of these ■ Discharges from the detention tanks to the Seattle Public wastes also were reported as part of commingled Utilities sewer are metered so as not to exceed the 17 wastes. capacity of the sanitary system. This new stormwater control system at Todd Pacific exceeds regulatory requirements and eliminates all routine industrial stormwater discharges to adjacent waters.19 76

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