ENVIRONMENTAL BENCHMARKING FOR IPC INDUSTRIES FINAL REPORT Prepared for the Environmental Protection Agency by Clean Technology Centre, Cork Institute of Technology Authors: Noel Duffy, Colman Mc Carthy and Matthias Zoehrer ENVIRONMENTAL PROTECTION AGENCY An Ghníomhaireacht um Chaomhnú Comhshaoil PO Box 3000, Johnstown Castle, Co.Wexford, Ireland Telephone: +353-53-60600 Fax: +353-53-60699 Email: [email protected] Website: www.epa.ie © Environmental Protection Agency 2002 ACKNOWLEDGEMENTS This report has been prepared as part of the Environmental Research Technological Development and Innovation Programme under the Productive Sector Operational Programme 2000-2006. The programme is financed by the Irish Government under the National Development Plan. It is administered on behalf of the Department of the Environment and Local Government by the Environmental Protection Agency which has the statutory function of co-ordinating and promoting environmental research. DISCLAIMER Although every effort has been made to ensure the accuracy of the material contained in this publication, complete accuracy cannot be guaranteed. Neither the Environmental Protection Agency nor the author(s) accept any responsibility whatsoever for loss or damage occasioned or claimed to have been occasioned, in part or in full, as a consequence of any person acting, or refraining from acting, as a result of a matter contained in this publication. All or part of this publication may be reproduced without further permission, provided the source is acknowledged. ENVIRONMENTAL BENCHMARKING FOR IPC INDUSTRIES FINAL REPORT Published by the Environmental Protection Agency, Ireland PRINTED ON RECYCLED PAPER ISBN:1-84095- to come 06/01/300 Price: IR£5/E6.35 Contents Executive Summary……………………………………………………………………i 1 INTRODUCTION............................................................................................... 1 1.1 Objectives of Part 1....................................................................................... 1 1.2 Project Team................................................................................................. 2 1.3 Methodology ................................................................................................. 2 1.4 Report Structure............................................................................................ 3 2 REVIEW OF INTERNATIONAL PRACTICE .............................................. 4 2.1 Literature Review.......................................................................................... 4 2.1.1 Scope of literature examination 4 2.1.2 Background 5 2.1.3 What is environmental performance? 7 2.1.4 How can environmental performance be measured? 7 2.1.5 What kind of performance is comparable? 16 2.1.6 How can one build performance into a company’s EMS? 18 2.1.7 Related initiatives, case studies, organisations 19 2.2 EMS Software Tools Assessment ............................................................... 24 3 INDUSTRIAL PRACTICE.............................................................................. 28 3.1 ENVIRONMENTAL MANAGEMENT .................................................... 32 3.1.1 Status and Outlook 32 3.1.2 Use of Software 33 3.2 REPORTING .............................................................................................. 37 3.3 INDICATORS............................................................................................. 40 3.3.1 Number of Indicators Used by Licensees 41 3.3.2 Which EPIs do IPC Licensed Companies Use? 42 3.3.3 Level of Detail 44 3.4 BENCHMARKING .................................................................................... 47 4 NEEDS AND WANTS ...................................................................................... 60 4.1 EPA needs and wants .................................................................................. 60 4.1.1 Existing Reporting Requirements 60 4.1.2 AER Report Structure 61 4.1.3 Recurring Reporting Requirements 62 5 REPORTING RECOMMENDATIONS......................................................... 63 5.1 Introduction ................................................................................................. 63 5.2 Data reported by licensees........................................................................... 63 5.3 Generic Key Indicators................................................................................ 64 5.4 Quantitative data presentation and interpretation methods:........................ 67 5.4.1 Eco-efficiency Indicators 68 5.4.2 Environmental Performance Indicators 71 5.5 Management Performance Indicators.......................................................... 72 6 SOFTWARE SPECIFICATION ..................................................................... 75 6.1 Introduction ................................................................................................. 75 6.2 Alternatives ................................................................................................. 75 6.2.1 Site Tool – Central Tool 76 6.2.2 Browser – Central Tool 77 6.2.3 Comparisons 78 6.3 Functional Requirements - Site tool............................................................ 80 6.3.1 Open System 80 6.3.2 Quantitative Information 81 6.3.3 Scheduling –Targets - Thresholds 81 6.3.4 Classification and Grouping 81 6.3.5 Data Quality 82 6.3.6 Reports and Analysis 83 6.3.7 Documentation 83 6.3.8 User Interface 84 6.3.9 Templates 84 6.4 Technical Requirements.............................................................................. 84 6.4.1 Data Storage 85 6.4.2 Physical network 85 6.4.3 Operating system 85 6.4.4 Programming platform 85 6.5 COST – Site Tool........................................................................................ 85 6.6 Risk Analysis............................................................................................... 86 6.7 Check list..................................................................................................... 87 7 DISCUSSION .................................................................................................... 93 8 CONCLUSIONS & RECOMMENDATIONS ............................................. 100 BIBLIOGRAPHY…………………………………………………………………102 Appendix I Existing AER Electronic Reporting Requirements..........................104 Appendix II EPA IPC Licence Recurring Reports...............................................110 Appendix III Proposed Additional Electronic Reporting Requirements ...............111 Appendix IV Examined Software Tools ................................................................127 Appendix V Survey of Industrial Practice – Questionnaire..................................152 Executive Summary This project had the goal of developing the specification for a software tool that could facilitate a process of benchmarking and internal development of an environmental management system among licensees, in addition to assisting electronic reporting, taking into account the needs of companies and the EPA, the scope for performance indicators and the reporting obligations. A detailed examination of reporting requirements was conducted. International literature on the use of environmental indicators and benchmarking was examined, along with existing software for environmental management systems. A response rate of 35% was achieved with a comprehensive survey of IPC licensed companies to determine current practice and attitudes. There is merit in developing software to facilitate the mandatory reporting of data. This should be based on the model of a site tool for preparation of data to be subsequently uploaded to the EPA central system. The software should be relatively simple, to encourage rapid acceptance by licensees. Along with templates for environmental records and reporting an environmental management programme (EMP), there should be a scheduling tool and report generator. There is no benefit in developing extensive environmental management system support software. There are numerous commercial products available, yet the majority of licensees have installed or are maintaining a system without recourse to such software. A detailed specification is provided. The cost of developing a prototype site-tool, from scratch, is estimated at 3115 hours, equivalent to €185,000, assuming certain software and hardware pre-conditions at the test site. Adaptation of an existing commercial system is likely to be less expensive and involve less risk. A more detailed estimate and specification of the software could be achieved at a cost of approximately €20,000. While the vast majority of licensees use environmental indicators, the average number of indicators used is 6, and these are generally the result of specification in the IPC licence. The existing level of indicator use and benchmarking practice is relatively modest among licensees. A few generic Operational Performance Indicators should be used across IPC industries: global warming contribution, contribution to ozone depletion, contribution to acidification, non-renewable primary energy input, total water use and total waste disposal. In view of the existing level of indicator usage, these should be introduced on a site-wide basis rather than by process or product, though process or product-specific values are more useful for management. Licensees should be encouraged to combine these with economic values to derive eco- efficiencies. A small number of generic Management Performance Indicators should be used: number of complaints on