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Proven Profits from Pollution Prevention PROVEN PROFITS FROM POLLUTION PREVENTION: CASE STUDIES IN RESOURCE CONSERVATION AND WASTE REDUCTION Donald Huisingh, Ph.D. Larry Martin Helene Hilger Neil Seldman, Ph.D. Institute for Local Self-Reliance 2425 18th Street, NW Washington, D.C. 20009 (202) 232-4108 Since 1974, the Institute for Local Self-Reliance (ILSR), a research and educational organization, has provided technical information and assistance to city, county, and state governments, and citizen and neighborhood organizations. ILSR focuses on energy and waste utilization from a common sense economic development perspective, PLSR works exclusively in urban areas. Current ILSR projects are located in Philadelphia, Pennsylvania; Saint Paul, Minnesota; Newark, Trenton, and Edison, New Jersey; Cleveland, Ohio; Fayetteville, Charlotte, Durham, and Asheville, North Carolina; Providence, Rhode Island; Boston, Cape Cod, and New Bedford, Massachusetts; New Haven, Connecticut; Washington, D.C,; and Gainesville, Florida. Staff of the Institute for Local Self-Reliance: Co-directors: David Morris, Ph.D. Neil Seldman, Ph.D. Energy and Economic Development Waste Utilization/Economic Development David Morris, Ph.D. John Plunkett Neil Seldman, Ph.D. Jack Gleason, M.S. Larry Martin David Peterson, L.L.B., M.A. Ken Woodruff, M.E. Rick Anthony, M.A. Don Huisingh, Ph.D. Mary Appelhof, M.S. Donald Rowe Administration David Bardaglio Jan Simpson Copyright @ 1986 by Donald Huisingh and Institute for Local Self -Reliance 2425 18th Street, NW Washington, D.C. 20009 (202) 232-4108 All rights reserved. No part of this document may be reproduced in any form or by any electronic or mechanical means, including information storage and retrieval systems without permission in writing from the Institute for Local Self-Reliance. Library of Congress Catalog Number: 85-82638 ISBN: 0-917582-47-0 Cover design by James True Printed in the United States of America ements. e (I e B e * 0 8 * * * e * * r e e e e e i Foreword. * * e e e B 0 e e * * 0 B 0 * e * B B * * * e s * ii Historical. Perspective a e e a e e a 1 Types and Quantities of Hazardous Waste Generated e 4 The Cost of Hazardous Waste Generation to Industry, Society, and the Environment e e 9 Pollution ~~~~ent~on-~ast~~in~mi~a~ion~ Essential for Economic and Human Health e e e e e 13 Overview of Pol%ution Prevention and Waste Minimiiation e 16 Review of Individual Components and Processes Applicable for Pollution Prevention and Waste Minimization 17 CHAPTER 3: WASTES TO RESOURCES I) e e e e e e 24 Characterization of astes Not Produced, Recovered, or Recycled as a Consequence of Strategies Documented in the Case Studies e e e e a a 24 Waste Reduction Projections e e e 26 CHAPTER 4: CASE STUDIES ORGANIZED BY STANDARD INDUSTRIAL CODE e e..... e* 27 0100 & 0200 Case Study 1: The Choplin Farm *e*** 28 inina and Extractive Industries 1000 .d Case Study 2: Climax Molybdenum Company eo.** 33 Food And Kindred Products 2000 Case Study 3: California Canners and Growers =, e 37 Case Study 4: Dunbar Foods e e II . e e 41 se Study 5: Milles Brewin Company e e e e e 45 ill Products 2200 Case Study 6: Hampshire Hosiery e e e e (I e e 49 Furniture 2500 Case Study 7: United Globe Corporation . e e 53 Paper and Allied Products 2600 Case Study 8: West Point Pepperell . e . e . e . 58 Printing and Publishing 2700 Case Study 9: Rexham Corporation . e 62 Chemicals and Allied Products 2800 Case Study 10: Exxon Chemicals America e . e . 67 Case Study 11: Allied Chemical . e e e e . a . e 71 Case Study 12: Borden Chemical Company . 74 Case Study 13: American Enka Company . e . 79 Case Study 14: Minnesota Mining and Manufacturing (3M) . 82 Case Study 15: The Coty Division of Pfizer, Inc. 85 Case Study 16: USS Chemicals . 88 Case Study 17: Industrial and Agricultural Chemicals, Inc. 92 Case Study 18: IC1 Americas, Inc. e 95 Case Study 19: Daly-Herring Company . e e . e . 99 Case Study 20: Texasgulf . e . 102 Rubber Plastic Products 3000 Case Study 21: Nebraska Small Farms Action Group 105 Metals 3300 Case Study 22: Florida Steel Corporation . e e . 109 Case Study 23: Waupaca Foundry . e . e e e e e e e 112 Fabricated Metal Products 3400 Case Study 24: Stanadyne, Inc., Moen Group . e . 117 Case Study 25: Elkhart Products Division, Inc. 130 Case Study 26: Pioneer Metal Finishing, Inc. e . 133 Non-Electric Machinery 35 00 Case Study 27: Deere and Company e e a e e . - 136 Case Study 28: Emerson Electric Company (Also 3600) . 141 Electrical and Electronic Equipment 3600 Case Study 29: Hamilton Beach Division of Scovill, Inc. 149 Case Study 30: GTE Sylvania . 154 Case Study 31: Data General Corporation e . 158 Case Study 32: Minnesota Mining and Manufacturing (3M) . 165 Case Study 33: Digital Equipment Corporation . 168 Transport Equipment 3700 Case Study 34: Modine Manufacturing e e . e e e e e e 171 Instruments and Related Products 3800 Case Study 35: Rexham Corporation e . e . e - 175 Electric. Gas & Water 4900 Case Study 36: Carolina Power and Light Company e a e . 182 Case Study 37: Duke Power Company .............186 Case Study 38: Natural Power ...............196 Case Study 39: Hickory/Newton/Conover Complex .......200 Case Study 40: City of Morganton. North Carolina a a e 204 Case Study 41: San Diego Regional Water Reclamation Agency ...................213 Wholesale Trade Non-Durable Goods 5100 Case Study 42: Chevron USA. Inc ..............221 Service Industries 7000 Case Study 43: Minnesota Mining and Manufacturing (3M) . e 226 Case Study 44: PCA International. Inc ...........229 Case Study 45: American Fotokemi. Inc ...........235 Case Study 46: Vulcan Automotive Equipment Ltd .......239 CHAPTER 5: ABSTRACTS CROSS-REFERENCING CASE STUDIES BY MATERIALS ..............243 Agriculture/Food Processing Wastes .............244 Fly Ash and Bottom Ash ...................245 Low-Level Radioactive Wastes ................246 Metals and Other Inorganic Chemicals ............247 Municipal Wastes ...................... 254 Process Water ....................... 256 Rubber and Plastics .................... 260 Solvents. Oils. and Other Organic Chemicals ........261 CHAPTER 6 : ABSTRACTS CROSS-REFERENCING CASE STUDIES BY PROCESS ...............268 Adsorption ......................... 269 Distillation ........................ 270 Electrolytic Reactions ...................272 Equipment Design and Operation ...............275 Filtration ......................... 282 Housekeeping ........................ 283 Incineration/Heat-Energy Recovery .............285 IonExchange ........................ 287 Land Application ...................... 289 Management Initiatives ...................290 Materials Substitution ...................293 Recycling. Recovery. and Reuse ...............295 CHAPTER 7: INCREASING THE RATE AT WHICH INDUSTRIES AND INSTITUTIONS IMPLEMENT POLLUTION PREVENTION AND WASTE MINIMIZATION POLICIES AND TECHNOLOGIES . 304 Goals and Objectives for Waste Minimization Throughout Society ...................304 A Discussion of Impediments to the Implementation of Pollution Prevention-Waste Minimization (PP-WM) Approaches ...................305 Proposed Strategy for Overcoming the Barriers and Accelerating the Global Implementation of PP-WM Approaches e e e e e e e e e e e e 308 GONCLUSION .~...s.....*....0...0e..s311 LITERATURE CITED a e e e e , e e e e e 312 APPENDIX 1: The Questionnaire Used in Gathering Data 313 The authors gratefully acknowledge the cooperation of industrial leaders who have provided informtion about the ways they have reduced the quantities of hazardous and non-hazardous waste they produce, while simultaneously increasing net profitability. Our thanks to the North Carolina Board of Science and Technology for a grant to perform the first portion of this study and for their permission to utilize some of the North Carolina case study materials in this present volume. Also, our grateful appreciation to Sven Thesen who contributed much to the first edition. Our thanks to the Institute for Local Self-Reliance for providing timely assistance to the project. Our thanks to our families who, with understanding and patience, have encouraged us to devote the time and effort necessary to develop this volume in the very short time allotted. Our gratitude also to all who build upon the examples included here, and thereby help to make the world a safer and more healthy place to live. i Since 1974, the Institute for Local Self-Reliance has worked to make communities more efficient, and to increase the amount of work derived from local resources., Higher efficiency makes for a healthier local economy. It also makes communities more self- reliant. The concept of local self-reliance has broad application. Rather than import all our materials from outside sources and dump the used materials in waste repositories, the self-reliant community embraces closed-loop systems that minimize the use of materials and maximize recycling. Rather than base the health of a local economy on its ability to attract jobs from remote corporations, the self-reliant community generates employment by nurturing its native entrepreneurialism and inventiveness. Rather than allow remote governments to make decisions that destabilize the local economy, the self-reliant community assumes the authority and responsibility for its own future. The Institute works with interested communities and provides technical information to the general public on innovative, locally based solutions to the problems facing our society. Proven Profits from Pollution Prevention is one in a series of such b ooks. Twenty years
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