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

A little history of toxics and pollution prevention Massachusetts’ Toxics Use Reduction Act (TURA)

Pollution Prevention

Green Chemistry and Design for Environment Career Possibilities

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Evolution of Pollution Laws

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Toxics – still newsworthy Earl Blumenauer asks the FDA to recall Brazilian Blowout Published: Wednesday, September 28, 2011 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.

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End-of-the-pipe Pollution Control

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End-of-the-pipe remediation

Reactionary

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Anticipatory

4. Prevention

1. Prevention

3. Recycling

2. Recycling

SHIFT 2. Treatment

3. Treatment

1. Disposal

4. Disposal

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Pollution Prevention vs Pollution Control Pollution Control = end of pipe mediation Pollution Prevention = greater efficiency with less or no toxic material Energy Recovery Source Reduction TUR

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• Cleaner Production • Energy Conservation • Resource Conservation

Treatment Recycling Waste Disposal Minimization

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Hierarchy for Preventing Pollution &Workplace Illnesses, Injuries, & Fatalities Workplace Health and Safety

Pollution Prevention- P2 Eliminate or Reduce

Eliminate or Reduce toxic toxic substances and substances and processes

processes

Eliminate Hazards Eliminate Hazards

Best H&S and P2

Reduce exposure Reduce exposure to toxicto substances by “control at the toxic substances by source” “control at the source”

Engineering Controls

Recycling: Processing waste for reuse

Recycling: Processing waste for reuse

Administrative Controls Treatment Treatment Storage and Disposal

Storage and Disposal

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Least Effective for H&S and P2

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Personal Protective Equipment

Toxics Use Reduction Act (TURA) • Users of large amounts of toxics must:

– Report

toxics use Adopted 1989 Effective 1990 Expanded 2006

– 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

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Required data collection points Emission

In-plant treatment or recycling Byproduct Raw Material

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Production Unit

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Product

TURA Overview • • • • •

Massachusetts competitiveness Toxics reduction Technical analysis Financial analysis Report toxics use

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1995

1994

1993

1992

1991

1990

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2002 2003 2004 2005

2002 2003 2004 2005

0.0

2001

20.0

2001

60.0 40.0

2000

80.0

2000

100.0

1999

Year

1999

1998

1997

1996

Byproduct

1998

120.0

1997

1996

1995

1994

1993

1992

1991

1990

Millions of Pounds

Millions of Pounds

Did We Achieve the Goals? Total Use Production Adjusted

800.0

600.0

400.0

200.0

0.0

Year

19

Toxics Use Reduction Planners • Only professionals able to certify MA TUR Plans • 48-hour intensive course • Certified by exam

“[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.

TURA 20th Anniversary Video at www.turi.org [email protected]

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TUR Plans TECHNICAL ANALYSIS

FINANCIAL ANALYSIS

QUALITATIVE ANALYSIS

Draft Project Parameters

Collect Cost Information

List Qualitative Issues

Send RFP’s to Vendors

Determine Incremental Cash Flows

Prepare Assessment Map

Analyze Proposals for Technical Feasibility Choose Equipment Based on Technical Merits

Apply Measures of Profitability Interpret Results

Prepare Justification Package Evaluate Performance [email protected]

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Develop Comparative Information Assess Impacts

TUR Technical Analysis

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TUR Financial Analysis

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TUR Input substitution

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TUR Product Reformulation

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TUR Production Unit Redesign

X-ray inspection – ball-grid array

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TUR Modernization

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TUR Improved Operations & Maintenance

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Integral recycling

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Alternatives Assessment Risk Assessment Problem-based approach

Better Solutions Focus on solutions & opportunities

Debates delay prevention Toxicity data limited Risk shifting

Greater stakeholder participation Promotes innovation, enterprise creation

Game nobody wins Multi-risk consideration

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Green Screen • Developed by Clean Production Action • 17 environmental, health and safety criteria

http://www.cleanproduction.org/library/Green_Screen_Report.pdf [email protected]

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Green Screen Benchmarking DecaBDE

L

vH M to nona- nona-

Degradation Products

L

Metabolites

nd

Bioaccumulation

Persistence

L

Chronic

nd

Acute

Irritation/Corrosion (skin)

L

Breakdown Products

Immune System Effects

Sensitization(respiratory)

L

(eyes)

Sensitization (skin)

Endocrine Disruption Neurological

Developmental

Reproductive

Mutagenic

Carcinogenic

% in Formulation

CAS#

Irritation/Corrosion

Systemic/Organ Effects

L

Priority Effects

Chemical

Ecotox. Fate

Acute Toxicity

Human Health Effects

Decabromodiphenyl ether (decaBDE) - CAS# 1163-19-5 penta- tri- to DecaBDE

1163-19-5

97

M

L

L

M

M

M

L

BDE

BDE

Breakdown Products 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

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

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vH M

nd

lower PBDEs

TUR Planning Process • Planning viewed as a continual improvement cycle Continual Improvement…

Review

Update (year 2) Modify Evaluate

Review

Plan (year 0)

Evaluate

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Implement

Green Chemistry Design for Environment [email protected]

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Great Philosophical Dilemmas of the 21st Century

Paper?

OR Plastic?

(polystyrene)

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

Polystyrene Cup

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

• • • • • • • • • • •

* Biological Oxygen Demand [email protected]

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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

Criticisms of Hocking • • • •

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

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What makes a product ‘green’?

Framework for Sustainable Products

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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.”

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DfE Definitions “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”

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From Take-Make-Waste….

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…to Cradle-to-Cradle

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Drivers: Legislation REACh RoHS TURA ToSCA

WEEE ELV

Toxics

Resource Conservation

Energy

EU Ecodesign Directive: all 3 [email protected]

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EU Energy CA Appliance Efficiency MA “Stretch Codes”

Drivers: Labeling and Certification

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Drivers: Consumer Preference

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Examples of DfE factors Product Concept

Inkjet vs laser

Design Choice

Low power logic family vs standard logic families

Material Choice

Plastic housing vs metal

Energy Consumption

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

Recyclability

Improved Design for Disassembly

Material Recovery

Gold circuit board traces vs copper

Packaging

Recycled pulp inserts vs styrofoam

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Life Cycle Analysis (LCA) Impact Categories (“Midpoints”) Fossil Fuel Depletion Mineral Depletion Land Use

Typical Groupings

Endpoints

Ecosystem Resources

Water acidification / eutrophication Eco-toxicity Climate Change Ozone Layer Depletion

Ecosystem Quality

Carcinogenic Substances Organic Respiratory Effects Inorganic Respiratory Effects Ionizing Radiation

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Human Health

12 Green Chemistry Principles – In Action Raw Materials and Feedstocks:

• Atom Economy (2) • Renewable Feedstocks (7)

• Designing Safer Products (4)

End-of-Life:

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 :

•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)

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

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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

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TUR & 6-sigma Quality Management >$1M in efficiency improvements $100K scrap reduction 70% VOC reduction $15K saved by reducing VOCs

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Quality Costs Quality costs escalate as value is added to a product or service Supplier Inspection Incoming Inspection Fabrication Inspection Sub-product Test

0.003 0.03

Cost of finding and correcting a defective electronic component

0.30 $3

$30

Final Product Test

$300

Field Service

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P. Crosby & Associates, 1979

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Environmental Quality Costs Life Cycle Costs escalate at later stages of the Life Cycle Product concept Design Manufacture

Life Cycle Cost of a toxic material

Use Landfill, incineration, etc. Environmental cleanup

“Most environmental costs are incurred on the first day of product development” [email protected]

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Environmental Quality Costs Life Cycle Cost of Mercury battery

Product concept

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

Design Manufacture Use Landfill, incineration, etc.

Environmental cleanup – landfill toxics remediation

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Theoretical Environmental Quality Costs Life Cycle Cost of rechargeable alkaline and Lithium-ion batteries Product concept Design Manufacture Relatively expensive to purchase, these batteries last much longer, are less toxic, are rechargeable, and can be recycled easier.

Use Landfill, incineration, etc. Environmental cleanup – landfill remediation

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Theoretical Environmental Quality Costs Life Cycle Cost of windup flashlight Product concept Design Manufacture Use Landfill, incineration, etc.

Self-powered windup devices minimize the problem of battery disposal

Environmental cleanup – landfill remediation

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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

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Modeling unit functions Emissions to the environment • To air • To water From previous unit process(es)

Product or service

To next unit process(es)

Extractions from the environment • Fuel • Materials • Land, water, air, etc. Could be from biosphere or technosphere [email protected]

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Example Life Cycle Inventory hierarchy

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Life Cycle Analysis (LCA) Impact Categories (“Midpoints”) Fossil Fuel Depletion Mineral Depletion Land Use

Typical Groupings

Endpoints

Ecosystem Resources

Water acidification / eutrophication Eco-toxicity Climate Change Ozone Layer Depletion

Ecosystem Quality

Carcinogenic Substances Organic Respiratory Effects Inorganic Respiratory Effects Ionizing Radiation

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Human Health

Summing resource and emission flows, calculating impact results Inventory results (LCI)

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Impact Assessment results

Impact group results – comparing alternatives

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Impact group results – comparing weighted alternatives

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Career Considerations • Toxics Use Reduction Planner • Alternatives Assessment – Product design – Process design – Service design

• Clean Production • Lean / 6 Sigma “Black Belt” • Design for Environment [email protected]

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We can't solve problems by using the same kind of thinking we used when we created them. Albert Einstein

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