GREEN PROFITS The Managers Handbook for ISO 14001 and Pollution Prevention

GREEN PROFITS The Manager's Handbook for ISO 14001 and Pollution Prevention Nicholas P Cheremisinoff, Ph.D Avrom Bendavid-Val S UTTERWORTH E I=-N E M A 'N 1~ An Imprint of Elsevier Boston Oxford Auckland Johannesburg Melbourne New Delhi Butterworth-Heinemann is an imprint of Elsevier Copyright 2001, Elsevier All rights reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher Permissions may be sought directly from Elsevier's Science and Technology Rights Department in Oxford, UK Phone: (44) 1865 843830, Fax: (44) 1865 853333, e-mail: permissio.n s@e!sevier.co.uk You may also complete your request on-line via the Elsevier homepage: h_tt.p-/Lwww.elsevier.c o_m by selecting "Customer Support" and then "Obtaining Permissions" Recognizing the importance of preserving what has been written, Elsevier Science prints its books on acid-free paper whenever possible Library of Congress Cataloging-in-Publication Data Cheremisinoff, Nicholas E Green Profits: the manager's handbook for ISO 14001 and pollution prevention / Nicholas P Cheremisinoff, Avrom Bendavid-Val p cm Includes indexes ISBN-13 978-0-7506-7401-0 ISBN-10 0-7506-7401-6 (all paper) I ISO 14000 Series Standards Manufacturing industries Environmental aspects I Bendavid-Val, Avrom II Title TSI55.7.C454 2001 658.4;08 dc21 2001025366 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library The publisher offers special discounts on bulk orders of this book For information, please contact: Manager of Special Sales Elsevier 200 Wheeler Road Burlington, MA 01803 Tel: 78 I-313-4700 Fax: 781-313-4882 For information on all Butterworth-Heinemann publications available, contact our World Wide Web home page at: http://www.bh.com 10987654 Printed in the United States of America CONTENTS Preface vii Acknowledgements xm Abbreviations xiv ~176176 ROAD MAP TO PART I: ENVIRONMENTAL MANAGEMENT SYSTEMS CHAPTER EMS" PRINCIPLES AND CONCEPTS The Basics of an EMS: What Is It, and Why Do It What the ISO 14001 Standard Is All About Essential Elements of the ISO 14001 EMS One More Time Questions for Thinking and Discussing 12 15 16 CHAPTER EMS: APPLIED MODELS 18 ISO 14001 and Implementation Overview Environmental Policy (Clause 4.2) Planning: Environmental Aspects (Subclause 4.3.1) Planning: Legal and Other Requirements (Subclause 4.3.2) Planning: Objectives and Targets (Subclause 4.3.3) Planning: Environmental Management Programs (Subclause 4.3.4) Implementation and Operation: Structure and Responsibility (Subclause 4.4.1) Implementation and Operation" Training, Awareness, and Competence (Subclause 4.4.2) Implementation and Operation: Communication (Subclause 4.4.3) Implementation and Operation: EMS Documentation (Subclause 4.4.4) Implementation and Operation: Document Control (Subclause 4.4.5) Implementation and Operation: Operational Control (Subclause 4.4.6) Implementation and Operation: Emergency Preparedness and Response (Subclause 4.4.7) Checking and Corrective Action: Monitoring and Measurement (Subclause 4.5.1) Checking and Corrective Action: Nonconformance and Corrective and Preventative Action (Subclause 4.5.2) 18 22 29 36 37 45 50 iii 54 58 60 63 66 69 71 75 Checking and Corrective Action: Records (Subclause 4.5.3) Checking and Corrective Action: EMS Audit (Subclause 4.5.4) Management Review (Clause 4.6) One More Time Two Exercises Questions for Thinking and Discussing CHAPTER TOOLS AND TECHNIQUES 79 81 87 92 93 99 101 Using this Chapter Before Policy Environmental Policy (Clause 4.2) Planning: Environmental Aspects (Subclause 4.3.1) Planning: Legal and Other Requirements (Subclause 4.3.2) Planning: Objectives and Targets (Subclause 4.3.3) Planning: Environmental Management Programs (Subclause 4.3.4) Implementation and Operation: Structure and Responsibility (Subclause 4.4.1) Implementation and Operation: Training, Awareness, and Competence (Subclause 4.4.2) Implementation and Operation: Communication (Subclause 4.4.3) Implementation and Operation: EMS Documentation (Subclause 4.4.4) Implementation and Operation: Document Control (Subclause 4.4.5) Implementation and Operation: Operational Control (Subclause 4.4.6) Implementation and Operation: Emergency Preparedness and Response (Subclause 4.4.7) Checking and Corrective Action: Monitoring and Measurement (Subclause 4.5.1) Checking and Corrective Action: Nonconformance and Corrective and Preventative Action (Subclause 4.5.2) Checking and Corrective Action: Records (Subclause 4.5.3) Checking and Corrective Action: EMS Audit (Subclause 4.5.4) Management Review (Clause 4.6) One More Time Exercises Questions for Thinking and Discussing 101 103 105 109 118 119 124 CHAPTER EMS" FIRST STEPS 175 The Benefits of an EMS Initial Environmental Review (IER) and Gap Analysis EMS Lite One More Time Exercises iv 126 128 131 135 141 146 148 149 153 156 157 171 172 173 173 175 177 185 191 193 R O A D M A P T O P A R T II: P O L L U T I O N P R E V E N T I O N 194 C H A P T E R P O L L U T I O N P R E V E N T I O N : P R I N C I P L E S AND CONCEPTS The Basics of P2: What Is It, and Why Do It What Pollution Prevention is All About Essential Elements of Pollution Prevention What About Material Waste and Energy? How are P2 and EMS Related? One More Time Questions for Thinking and Discussing 196 196 199 202 205 209 210 211 C H A P T E R I N D U S T R Y - S P E C I F I C P O L L U T I O N PREVENTION PRACTICES Defining P2 One More Time Hierarchy of Pollution Management Why and How Is P2 Done? The P2 Benefits Matrix Industry Specific Guidelines and Practices Questions for Thinking and Discussing 213 213 214 215 229 233 258 C H A P T E R T H E P O L L U T I O N P R E V E N T I O N A U D I T Introduction The Pre-assessment (Phase I) The In-plant Assessment (Part of Phase II) Working with Material Balances The In-plant Assessment (Part of Phase II) Synthesis, Benchmarking, and Corrective Actions (Phase III) One More Time A Summary of All the Steps Questions for Thinking and Discussing 259 C H A P T E R F I N A N C I A L P L A N N I N G T O O L S Introduction Total Cost and Cost Accounting Establishing Baseline Costs Revenues, Expenses, and Cash Flow Interest and Discount Rates Income Taxes Application of Total-Cost Assessment 321 321 321 326 331 336 337 339 259 262 273 286 300 304 317 318 319 The Life-Cycle Analysis Final Comments Glossary of Important Terms 347 356 360 Appendix A: ADDITIONAL ISO 14001 AND POLLUTION PREVENTION RESOURCES 362 Index to Tables 371 Subject Index 375 PREFACE Environmental management systems, or EMSs, are planned and organized means that an enterprise can use to manage its interactions with the environment ~ in particular, those interactions that contribute to resource consumption, environmental degradation, and human health risk An EMS is a structured program of continual environmental improvement that follows procedures drawn from established business management practices EMS concepts are straightforward, and EMS principles can be easily applied if supported by top management The best known EMS worldwide is ISO 14001 ISO 14001 is an international standard for EMSs that embodies essential elements of other EMSs, such as Britain's BS7750 and the European Union's EMAS, and clearly is becoming universally recognized among industry and the public as the standard for an EMS A proper EMS is a program of continual improvement in environmental performance that follows a sequence of steps based on established sound businessmanagement practice Accordingly, it allows an enterprise to understand and track its environmental performance, and provides a framework for identifying and carrying out improvements that may be desirable for financial or other corporate reasons, or that may be required to meet regulatory requirements Under the best conditions, an EMS is built on an existing quality-management system A typical sequence of planning and management steps that structure an EMS is: 1) Establish an environmental policy for the enterprise 2) Review the environmental consequences of enterprise operations 3) Establish environmental performance goals 4) Develop and carry out an action plan to achieve the goals 5) Monitor performance 6) Report the results 7) Review the system and the outcomes and strive for continual improvement As this sequence of steps suggests, perhaps the most important characteristic of an EMS, and one that can yield significant long-term benefits, is that it represents a systematic strategic management approach through which an enterprise deals with environmental issues The opposite of strategic management is reactive decisionmaking m when something breaks, fix it; when markets fail, scramble for new ones; when the public clamors for greater corporate responsibility, figure out what to Winners in the marketplace today are increasingly those with good strategic planning and management systems Environmental regulators m certainly in Western countries m are slowly but definitely moving from media-based to systems-based compliance enforcement approaches that reward enterprises for engaging in strategic environmental management through an EMS For recent evidence of this see the U.S Environmental Protection Agency's new National Environmental Performance Track program (www.epa.gov/perftrac/program/program.html) The public also is demanding that corporations deal with environmental, quality, health and safety, and social-justice issues in a systematic, integrated, and strategic way, under the overall heading of "corporate social accountability" or similar terms vii Already, corporations at the leading edge are exploring ways to integrate their quality, environmental, and occupational health and safety (OHS) management systems System-based strategic management is good management, and a sound EMS complements and reinforces a systematic strategic approach to managing an enterprise An EMS helps management identify and address environmental priorities in terms of their ecological and health implications, as well as in terms of the strategic requirements of the enterprise, rather than just checking and enforcing compliance with a collection of unrelated and unprioritized standards This makes an EMS an instrument for promoting enterprise sustainability and long-term prosperity A key feature of ISO 14001 is its specification of the elements of a system that can be independently audited and certified as conforming to an internationally accepted EMS standard The question of certification underlies much of the discussion about environmental management systems, and the real or hoped-for benefits of certification have provided the principal motivation for implementing ISO 14001 in many enterprises But the benefits associated with certification represent only a small portion of overall benefits gained by implementing an EMS Enterprises need not focus on certification when they begin the process of implementing an ISO 14001based EMS An enterprise can use ISO 14001 either as guidance for implementing a very simple EMS as the first step on a long road that may ultimately involve seeking certification, or as a set of precise specifications for setting up an EMS that can be certified relatively soon The greatest direct benefits to an enterprise of implementing an EMS usually come from the savings generated by pollution prevention (P2) practices and technologies About 50 percent of the pollution generated in a typical "uncontrolled" plant can be prevented with minimal investment by adopting simple and inexpensive process improvements In industrial countries, increased discharge fees and wastedisposal charges provide much of the incentive for cost-effective pollution reduction A major consequence of implementing an EMS is the identification of wasteminimization and cleaner production opportunities for the enterprise The process of introducing the EMS can be a catalyst for worker support for environmentalperformance improvements (including the simple changes that make up "good housekeeping"), and also for making the best use of existing P2 and control equipment Pollution prevention diverts attention away from pollution controls and posttreatment practices (that is, treatment of pollution after it has been generated), and focuses instead on replacing technologies that generate pollution and undesirable byproducts with those that not, or that generate them at greatly reduced levels Ultimately, P2 through waste minimization and cleaner production is more costeffective and environmentally sound than traditional pollution control and posttreatment methods P2 techniques apply to any manufacturing process or business operation, and range from relatively easy operational changes and good housekeeping practices to more extensive changes, such as finding substitutes for toxic substances, investing in clean technologies, and using state-of-the-art materials-recovery equipment Pollution prevention can improve plant efficiency, enhance the quality and quantity of natural resources for production, and make it possible to invest more financial resources into enterprise competitiveness To illustrate: viii The EPA, through its voluntary Green Lights program, introduced the concept of using low life-cycle-cost lighting systems rather than the lowest first-cost lighting systems Pollution prevention activities under the energy-efficiency program include reducing wattage per square foot; changing from incandescent to fluorescent bulbs; changing ballast materials; using sodium- and mercury-vapor lamps; and installing motion detectors to detect when an area is occupied, and activate lights only then Based on a survey of 200 participating companies, on average each enterprise was able (through decreased electricity demand) to reduce their emissions of carbon dioxide (CO2) by 826 metric tons (kkg) per year; to reduce their emissions of sulfur dioxide (SO2) by 6.5 kkg per year; and to reduce their emissions of nitrogen oxides (NOx) by 2.7 kkg per year This is equivalent to burning about 2,100 barrels of oil per year But the participants did much more than reduce air-pollution emissions Over the life of the program, participants have saved more than 380 million kilowatt-hours annually This is enough electricity to run 42,000 Americanhouseholds for a full year The cost savings for the representative group of companies is impressive The average total cost for such P2 activities per company was $245,550; the average annual savings per company was $113,431 In other words, on average, a one-time investment of $245,550 returned $113,341 for every year thereafter Payback periods ranged from less than one year to more than four years (source m EPA doc # 742/96/002) Motorola Inc.'s Government Systems and Technology Group, in an effort to eliminate ozone-depleting chemicals (ODCs), developed a soldering process for circuit-board manufacturing that is so clean that the chemical fluxes normally used to remove oxides prior to soldering was no longer necessary The fluxes leave corrosive residues, which must be removed with chemical rinses Freon 113 and trichloroethane (TCA), both ODCs, were commonly used as part of these chemical-rinse activities Old-style soldering machines use up to 8,000 pounds of cleaner per month (i.e., 48 tons of cleaners per year) The newer technology has eliminated the need for a rinsing stage and, therefore, has eliminated the use of Freon 113 and TCA c l e a n e r s - and their associated air emissions Each machine that employs this new soldering process saves between $50,000 and $245,000 per year in chemical use alone Conventional wave solder machines can be retrofitted for $40,000 to $100,000, thereby providing very attractive payback periods (source- EPA doc # 742/96/002) A recent study of the Polish chemical industry identified 43 pollution prevention projects among manufacturers of fertilizers, pesticides, synthetic rubber, plastics, dyes and pigments, coke chemicals, inorganic chemicals, and pharmaceuticals P2 activities ranged from simple housekeeping practices, to materials substitutions, to technology changes The table below summarizes the results of the study Total investment for all 43 projects amounted to $1,439,075 In just the first year, these projects in combination yielded a return of $7,184,490 - - or nearly 500 percent! The payback periods for these P2 investments ranged from less than month to more than years, and the projects will continue to generate savings in both pollution and money in the years to come What is important to note from the ix 366 GREEN PROFITS 9) http://www.getf org/projects/enviromgmt.cfm Global Environment and Technology Foundation Contains information on municipal EMS pilot projects completed in partnership with the U.S EPA 1O) http://www.globalreporting.org Global Reporting Initiative (GRI) Strives to establish a generally accepted global framework for sustainability-reporting at the organization level Provides draft June 2000 guidelines for preparing, communicating, and requesting information about corporate environmental, social, and economic performance 11) http://www.inem.org International Network for Environmental Management (INEM) Includes case studies, general information on ISO 14000, publications, interactive check-lists, downloadable how-to guides, related links, calendar of conferences and events 12) http://www.iso.ch International Organization for Standardization Includes basic information on what ISO is, what ISO does, the members of ISO, ISO's organizational structure, and information on ISO's publications and long-range strategies 13) http://www.iso.clt/presse/presse 12.html Clarifies the implications of ISO management systems, rather than productperformance standards, and what certification to ISO management-system standards really means 14) http://www.isol4OOO.com The ISO 14000 Information Center Contains news releases, ISO 14000 supporting companies and organizations, a discussion group, overviews of the standard, EMS articles, resources, links and an aid to finding training on implementation, auditing, or promoting ISO 14001 15) http://www.iso14000.net GlobeNet Includes news briefs, case studies, databases for EMS accrediting bodies, registrars, and registered companies Contains a "Status of ISO 14000 Documents" link 16) http://www.mgmt14k.com MGMT Alliances, Inc Contains the "ISO 14001 Pizza," which includes guidance for setting environmental policy, planning, implementation and operation, checking and corrective action, and management review 17) http://www.ncedr.org/guides/iso/htm National Center for Environmental Decisionmaking Research (NCEDR) Provides downloadable ISO 14001 guidance manual, to help organizations develop an EMS that is consistent with ISO 14001, achieve ISO 14001 registration, and improve environmental performance Provides a list of related links ADDITIONAL RESOURCES 367 18) http://www.eli.org/isopilots.htm National Database on Environmental Management Systems Contains information on an ISO 14001 Pilot Project study, which evaluates the performance of U.S enterprises implementing ISO 14001-style EMSs Provides links to ISO 14001 implementation, training, and resources sites 19) http://www,worldbank.org/nipr New Ideas in Pollution Regulation (NIPR) Targeted at individuals and organizations interested in public-policy issues relating to the cost-effective control of pollution Maintained by the World Bank's Economics of Industrial Pollution Control research team Contains ISO 14001-related articles and links 20) http://www.nsf-isr.org/html/body_iso_14000,html NSF International Strategic Registrations, Ltd (NSF-ISR) Contains basic information on ISO 14000, the registration process, ISO 14001 auditors, ISO 14001 training services, EPA/NSF EMS pilot projects, EMS articles and publications, FAQs, and ISO 14000 links 21) http://www.pri.sae.org Performance Review Institute Discusses the standard in general terms, trends in regulation, advantages of implementation, common problem areas found during an audit, and the relationship between ISO 9001/2 and ISO 14000 22) http://www.quality.org//lists/quest.list.txt QUEST (Quality in Environmental and Safety Training) ISO 14000 information e-mail discussion list Provides Internet forum for research and information exchange on harmonization of standards like ISO 14001, ISO 9001/2, OSHA standards, etc 23) http://www.rabnet.com Registrar Accreditation Board (RAB) Provides information on RAB-approved ISO 9000 and ISO 14001 registrars, training course providers, individual auditors, how to select a registrar or auditor, directories of companies currently certified to ISO 14001, and directories of accredited ISO 14001 auditors Discusses requirements for QMS and EMS certification 24) http://susdev.eurofound.ie European Foundation, sustainable development theme Searching for "ISO 14001" under the "tools" heading produces a set of hyperlinks to other Web sites that together offer a wide array of practical tools related to ISO 14001 implementation 25) http://www.trst.com/iso-14OOl-pages.htm Transformation Strategies Contains links to pages of smaller, less well-known companies that have registered to ISO 14001 Contains articles, benefits of implementation, books, case studies, keys to success, and steps to take 368 GREEN PROFITS SECTION II: ADDITIONAL RESOURCES POLLUTION PREVENTION Author's note: We've listed the resources in this section to correspond to the chapters to which they relate The following references will help readers of Chapter gain further information on pollution prevention case studies 1) 2) 3) 4) 5) 6) 7) 8) 9) Ahmed, Kulsum Renewable Energy Technologies: A Review of the Status and Costs of Selected Technologies, World Bank Technical Paper No 240 Washington: World Bank Group, 1994 Bernstein, Janis D Alternative Approaches to Pollution Control and Waste Management: Regulatory and Economic Instruments Washington: The World Bank, 1993 Cheremisinoff, Nicholas P Handbook of Pollution Prevention Practices New York: Marcel Dekker Inc., 2001 Pollution Prevention and Abatement Handbook 1998 - Toward Cleaner Production Washington: The World Bank Group, 1999 Profile of the Petroleum Refining Industry, EPA 310-R-95-013 Washington: U.S Environmental Protection Agency, 1995 A Planner's Guide for Selecting Clean Coal Technologies for Power Plants, Technical Paper No 387 Washington: The World Bank, 1997 Guide to Accessing Pollution Prevention Information Electronically Boston: U.S Environmental Protection Agency m Northeast Waste Management Official's Association, 1997 Profile of the Motor Vehicle Assembly Industry EPA 310-R-95-009 Washington: U.S Environmental Protection Agency, 1995 Prototype Study of hldustry Motivation for Pollution Prevention, EPA 100-R-96-001 Washington: U.S Environmental Protection Agency, 1996 Readers of Chapter can use the following references for information, examples, and procedures useful in working with material and energy balances, and general process calculations 10) ll) Azbel, David, and Nicholas P Cheremisinoff Fluid Mechanics and Unit Operations Ann Arbor, Mich.: Ann Arbor Science Publishers, 1983 Chopey, Nicholas P., and Tyler G Hicks, editors Handbook of Chemical Engineering Calculations New York: McGraw-Hill Book Co., 1984 Readers of Chapter can use the following references as background reading materials on equipment specifications criteria for unit operations and processes ADDITIONAL RESOURCES 12) 13) 14) 15) 16) 17) 369 Cheremisinoff, Nicholas P Handbook of Chemical Processing Equipment Boston: Butterworth-Heinemann, 2000 Cheremisinoff, Nicholas P Chemical Engineer's Condensed Encyclopedia of Process Equipment Houston: Gulf Publishing Co., 2000 Peters, Max S., and Klaus D Timmerhaus Plant Design and Economics for Chemical Engineers New York: McGraw-Hill Book Co., 1968 Cheremisinoff, Nicholas P Liquid Filtration ~ 2nd Edition Boston: Butterworth-Heinemann, 1998 Cheremisinoff, Nicholas P., and Paul N Cheremisinoff Compressors and Fans Englewood Cliffs, N.J.: Prentice-Hall Inc., 1992 Cheremisinoff, Nicholas P., and Paul N Cheremisinoff Carbon Adsorption for Pollution Control Englewood Cliffs, N.J.: Prentice-Hall Inc., 1993 Readers of Chapter will benefit from the following references Shim, Joe K., and Joel G Siegel Managerial Finance Schaum's Outline Series (067306-9) This instructional text, which describes financial analysis, includes sections on the time value of money and on capital budgeting 18) Shim, Joe K., and Joel G Siegel Managerial Accounting Schaum's Outline Series (067303-0) This instructional text, which describes management accounting, includes sections on cost concepts, terms and classifications, cost allocation, and capital budgeting 19) Purcell, A.H Hazardous and Solid Waste Minimization, ISBN/ISSN: 0865871361 Government Institutes Inc This document, which describes waste minimization and resource recovery, includes the whys and wherefores of waste minimization; considers the economics of waste-management decisions; and covers waste-minimization planning, auditing, and implementation 20) Waste Minimization Manual ISBN/ISSN: 0865877319 Government Institutes Inc This document discusses waste minimization, economic imperatives, legal and regulatory incentives, and how to conduct waste-minimization audits It also contains waste-minimization case histories for Dow, DuPont, Chevron, Hewlett Packard, and the U.S Navy 21) Wittman, Marlene R Costing and Financial Analysis of Pollution Prevention Projects Massachusetts Office of Technical Assistance This text provides a curriculum that is intended to familiarize environmental professionals with basic business terms, and to increase professionals' awareness of the factors that influence an investment in P2 options 22) This Page Intentionally Left Blank Index to Tables Chapter Table 10 11 12 13 14 15 16 17 18 19 20 21 22 Title Page The ISO 14001 Framework Activities, Aspects and Impacts Aspects, Objectives and Targets Three Types of Environmental Management Programs Objectives, Targets, and Programs Template for Checklist of ISO 14001 Requirements Activities, Aspects, Impacts, Objectives, Targets, and Environmental Programs 18 33 41 46 Structure for an Environmental Policy Statement Staring the Analysis with Activities and Environmental Interactions Starting the Analysis with Activities and Specific Types of Aspects Starting the Analysis with Known Environmental Impacts Matrix for Assessing Environmental Significance Assessing Strategic Importance of Significant Environmental Aspects Establishing a Rating System for Strategic Importance Factors Elements of an Environmental Management Program Work Plan Table of EMS Responsibilities and Resources Analytical Matrix for EMS Training Needs, Planning, and Tracking Analytical Matrix for EMS Training Needs, Planning, and Tracking Internal Top-Down Communication Log External Enterprise-Out Communication Log Required and Other Possible ISO 14001 EMS Documentation Worksheet for EMS Document Control Procedure Example of an EMS Document Control Matrix Example of an EMS Document Header Structure for an EMS Procedure Structure for Work Instructions and Standards for an EMS Procedure Elements of an EMS Emergency Preparedness and Response Plan Example of an EMS Record Header Plain English Checklist of ISO 14001 Requirements 371 48 94 98 108 112 113 115 116 122 123 125 127 129 131 132 134 136 142 145 146 147 147 148 157 160 372 GREEN PROFITS Chapter Table 4 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Title Page IER Information Collection Form ISO 14001 Gap Analysis Findings and EMS Implementation Needs A Limited-Scope Initial EMS 179 187 Environmental Management Hierarchy Examples Polish Chemical Companies Included in an Analysis Pollution Prevention Matrix of Company-Specific Case Studies Generalized Pollution Prevention Benefits Matrix P2 Practices in the Chemical Processing Industries P2 Practices in Fertilizer Manufacturing Plants P2 Practices in the Coking Industry P2 Practices in Pharmaceuticals Manufacturing P2 Practices in Oil Refineries P2 Practices in Iron and Steel Making P2 Practices in Mini Steel Mills P2 Practices in Zinc and Lead Smelting P2 Practices in Copper Smelting P2 Practices in Pulp and Paper Manufacturing P2 Practices in Sugar Manufacturing P2 Practices in Tanning and Leather Finishing P2 Practices for Breweries P2 Practices for Cement Factories P2 Practices for Vegetable Oil Processing P2 Practices for Wood Preserving P2 Practices for Electronics Manufacturing P2 Practices for Electroplating P2 Practices for Foundries P2 Practices for Fruit and Vegetable Processing P2 Practices for Meat Processing and Rendering P2 Practices for the Printing Industry P2 Practices for the Textile Industry P2 Practices for the Mining Industry U.S Auto P2 Case Studies 215 218 219 Various Types of Audits and Their Subsets An Initial Checklist of Unit Operations Sample Index to File Organization Example of Recording Raw Materials Storage and Handling Losses Sample Questions for Identifying Raw Materials Savings Sample Spreadsheet for Input Materials 189 232 234 234 235 236 237 239 242 243 244 245 246 246 248 248 249 249 250 250 251 252 252 253 254 255 256 260 267 269 274 275 276 INDEX TO TABLES Chapter Table 10 11 12 13 373 Title Page Sample Spreadsheet for Water Balance Sample Spreadsheet for Tabulating Process Outputs Example of Spreadsheet for Tabulating Wastewater Flows Example of Spreadsheet for Tabulating Off-Site Disposal Sample Spreadsheet for a Preliminary Material Balance Common Waste Reduction Hints Summarizing Annual Process and Waste Treatment Operating Costs 278 280 282 Current Yearly Costs for Bottle-Cleaning Operation Present Value Calculations for a Vodka Bottling Plant Effect of Changes in Revenues and Expenses on PreTax and Net Profits Partial Inventory of Potential Capital-Cost Items Partial Inventory of Potential Operating Costs Pollution Prevention Project (P3) Analysis Worksheet Present Value Factors for Nominal Discount Rates Example of a Life-Cycle Checklist Example of a Life-Cycle Worksheet 284 301 306 315 329 330 338 341 342 344 346 351 354 This Page Intentionally Left Blank Subject Index accident prevention 260 accident statistics 260 action plans 315 air-quality impact 260 ammonia plant 298 annual benefits 343 annual costs 343 audit 203,259 audit focus 262 audit objectives 264 audit team 262 audits, types of 260 awareness 128 Azovstal 229 chemical energy 208 chemical industry 217 chemical oxygen demand 281 chemical reaction 290, 302 Chrysler Warren Stamping plant 257 citizen groups 29 clean technologies 308 coal 235 coal burning 283 coal combustion 198 coal-fired power plants 199 Code of Environmental Management Principles coke by-products 240 coke oven emissions 239 cokeless technologies 239 coke-oven gas 236 coking industry 235 cold-extrusion 309 communication 131, 134 competence 54 Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) 331 computer hardware 74 condensation 299 contingent costs 357 control variables 263 cooling water 300 copper 256, 257 copper smelting 243 copper wire 310 Corex process 239 corrective action 10, 79, 81,149, 153, 156, 157, 304 cost accounting 321 cost savings 191 cost-accounting (see cost-accounting tools) 203 cost-accounting tools 195 cost-saving categories 231,356 baseline costs 326 batch operations 294 benchmarking 304 benefits 357 benefit-to-cost ratio 324 best available control technologies (BACT) 259 biochemical oxygen demand 281 birth defects 226 block painting 216 boiler modifications 200 breweries 248 business practices 205 cancer 226 capital cost items 341 carbon dioxide 291 cash flow 331 cash flow consideration 336 catalyst preparation stage 265 cement factories 248 central nervous system disorders 226 certification audit 105 certification auditors 52, 57, 74, 78, 84, 107 certification mechanisms 11 375 376 GREEN PROFITS cyanide 257 Davy Still Auto-process 239 demo expenses 335 dependent variables 263 depreciation 333 depreciation expenses 333 direct costs 206 direct iron-ore smelting 239 discount rate 336, 343,360 distillation columns 208 document characteristics 63 document control 63, 84, 92, 141 document control procedure 142 documentation 135, 140 documentation directions 140 due diligence 260 Eco-Management and Auditing scheme 59 economic evaluation 314 effluent discharge points 280 electric arc furnace (EAF) 242, 243 electric arc furnace dust 240 electricity production 208 electronics manufacturing 250 electroplating 250 emergency preparedness 69, 92, 148, 155 emission reduction 217 employee buy-in 265 EMS assignments 51 EMS audit techniques 159 EMS auditing 83 EMS audits 10, 81, 82, 85, 89, 157, 159, 260 EMS Committee 15, 19, 20, 30, 34, 37, 46, 47, 62, 68, 78, 101-106, 110, 115, 128, 129, 144, 152, 155, 156, 178, 187 EMS coordination 51 EMS coordinator 52 EMS document control procedure 144 EMS documentation 64, 82, 157 EMS documents 63, 65, 84, 127, 141 EMS implementation 102 EMS implementation process 46, 89, 101 EMS improvement 53 information management 79 maintenance 159 management reviews and procedures 53, 86, 89 nonconformance 86 operational control procedures 73 operations 13, 76, 126 procedures 75, 81 programs 58 records 151 reference book 60 review 88 role 170 standard training 55, 129, 130 training programs 26, 73 work instruction 76 end-of-pipe measures 25 energy 33, 111,205,275, 313 energy audits 208 energy efficiency 207,260 energy inputs 276 enterprise operations 66 environmental action plans 190 environmental affairs 197 environmental aspects 29, 31, 34, 59, 68, 92 environmental audits 185 environmental awareness 54 environmental awareness program 22 environmental compliance 197 environmental emergency 69, 71 environmental ethics 54 environmental health risk assessment 117 environmental impacts 28, 32, 109, 115, 120, 260 SUBJECT INDEX environmental laws (see CERCLA, RCRA, and environmental regulations) 23, 43 environmental management 55, 104, 214 environmental management practices 186 environmental management programs 14, 30, 45, 47, 48, 50, 63, 66, 67, 92, 98, 124 types of 46 environmental management system (EMS) 8, 197 environmental objectives 28, 39, 40 environmental performance 22, 74, 90, 113, 186 environmental policy 2, 22, 62, 67, 92, 102, 105, 106, 145 environmental policy statement 107 environmental records 80 environmental regulations 43, 190 environmental significance 32 environmental standards 15 environmental survey 104 environmental targets 42, 43, 47 equipment calibration 74 evaporation 295 expected value 330 expenses 321, 331,332 external communication 59, 60 fertilizer manufacturing 234 filtration 289 financial analysis factors 323 financial analysis term 343 financial tools 215 finishing stages 241 fire prevention 260 fixed ammonia content 236 flammable gas 228 floor space expenses 335 flues gas 292 fly-ash disposal 33 Ford Assembly plant 257 377 Ford Motor Company 226 Ford Norfolk Assembly Plant 257 foundries 251 four-way communication 58 fugitive emissions 227 fugitive particulate matter 40 full cost environmental accounting 340 future costs 357 future liability costs 326 gap analysis 104, 159, 177, 186 gaseous emissions 282, 286 gas-fired facility 200 global sustainability 199 glycol ether 256 GM Fairfax Assembly Plant 257 GM Technical Center 257 graphic representations 135 graphite recovery 229 grease 281 Green Globe 21 gross domestic product 197 groundwater 358 hazards 213 hidden costs 204, 326 hierarchy of pollution management 214 Hlsmelt process 239 human health risk 32, 33 hurdle rate 334, 360 impact assessments 348 implementation needs 187 implementation planning 120, 187, 192 improvement assessment 348 income tax 337 indoor air quality 260 industry sector 233 industry-specific P2 practices 194 initial environmental review (IER) 378 GREENPROFITS 104, 177, 178, 192, 260 in-plant assessment 273, 300 input materials 276 inspection 213 interest expense 333 interest rate 336 internal audit 87, 170 internal EMS audit 83 internal rate of return (IRR) 314,324, 360 International Organization for Standardization inventory analysis 348 investment evaluation 348 ISO 14000 standards ISO 14001 accreditation 11 certification 35, 73 certification audit certification auditors 44 EMS standard 16, 56, 93 framework 18 policy 29 requirements of 49, 52, 62, 64, 68, 70, 74, 159 standard 34, 77, 175 standards, descriptions 80, 112, 151 ISO 14001-based EMS 11 ISO 14004 descriptions 8, 107, 121 life cycle assessment 360 life cycle costing 361 life cycle-based worksheet 353-354 life-cycle checklist (LCC) 350, 351 life-cycle cost assessment 340 life-cycle costing (LCC) 321 life-cycle stages 349 low-cost/no-cost investments 210 lowest achievable emission rate (LAER) 259 low-NOx burners 47 lubrication oils 33 kidney disease 226 maintenance activities 74 management commitment 12, 230 management objectives 40 management programs 105 management review 11, 87, 171 management systems 6, 175 manpower costs 334 material balance information sheet 301,303 material balance system 300 material balances 286- 303 material waste 205 materials substitution 242 measurement 36, 71,149, 150 meat processing 252 minimization 206 monitoring 36, 71,149, 150, 204 monitoring data 80 monitoring parameters 263 labor expenses 334 labor organizations 37 LCA concepts 349 lead smelting 243 leak detection 238 leather finishing 246 less tangible costs 204, 326 Life cycle analysis (LCA) (see Life Cycle Assessment) 206, 216, 211, 347, 348, 350 natural gas 200 net benefits 325 net present value (NPV) 314, 361 net present value analysis 345 new-source standards 200 nickel 256, 257 nitric acid 256 nonrecovery coke battery 239 normal costs 204, 326 NOx-reduction technology 200 SUBJECT INDEX O&M costs 198 off-site wastes 284, 286 oil 281 oil refinery 237 operating costs 191,327, 342 operating criteria 69 operational control 92, 146 operational control procedure 66 operator manual 74 opportunity cost 333 overall material balance 287 P2 activity, definition 215 P2 audit 34, 259, 261, 316 P2 benefits matrix 229 P2 improvement 123 P2 investment 321 P2 measures 25 P2 opportunity 215 P2 solutions 195 paint solvents 257 paper manufacturing 245 payback analysis 345 payback period 323, 343, 361 pharmaceuticals manufacturing 236 Phase I environmental audit 260 Phase II environmental audit 260 pig iron 240 pipestill unit process 271 policy requirements 107 policy statement 108 pollution control 25, 206 pollution prevention benefits matrix 217, 231,232 pollution prevention matrix 217 pollution prevention, definition 198 pollution treatment 25 pollution, definition of 196, 201 polymerization reactors 228 post incident (accident) 260 preliminary assessment 273 present value 322, 325, 330 present worth 322 prevention 198, 213,214 379 preventive action 75, 77, 153, 154 printing industry 253 proactive management 176 process flow sheets 269, 273, 276, 286 process output 279 process safety 260 process substitution 308 procurement 327 profit 321,331 project review 352 proof of principle 195 property transaction 260 public health 213 pulverized coal injections 239 PVC resin 227 quality 213 raw materials savings 275 Raynaud's phenomenon 227 RCRA storage equipment 285 recording 72 records 62, 156 recovery 206 recurring costs 357 recycle stream 298 recycling 206, 214, 242, 279 refinery pipestill operation 270 regulatory compliance 44 regulatory compliance audit 114 regulatory penalties 16 regulatory requirements 185 rendering 252 Resource Conservation and Recovery Act (RCRA) 285, 326, 311 response plan 148 return on investment 336 reuse 206 revenues 321,331,332 scleroderma 227 scoring system 83 self-declared environmental practices 28 380 GREEN PROFITS software 74 solid waste 33 solid-liquid filtration 288 SOx-emissions control 237 start-up costs 343 steel manufacturing 241 steel mill 229 steel-making process 235 stormwater-runoff 285 strategic factors 35, 39, 44 strategic management 87 strategic planning 29 sugar manufacturing 246 sulfuric acid 243,294 suspended solids sustainability 176, 210 textile industry 254 textile-preservation chemicals 254 thresholds of investment 223 total cost 321 total cost accounting (TCA) 321,339 total cost assesment 339, 361 Total Quality Environmental Management (TQEM) 230, 237 toxic chemicals 33 toxic effluents 40 toxic materials packaging 237 training 54, 128 training expenses 335 training programs 49, 54 training records 80 treatment 214 trichloroethylene (TCE) 225 turbidity 281 U.S Agency for International Development (USAID) 217, 229 umbrella procedures 67 unit operations 265,267,274 VCM vapor 228 VCM-monitoring 228 vegetable oil processing 249, 252 vinyl chloride monomer (VCM) 227 VOC emissions 257 VOCs 256, 281 voluntary conformance 11 waste adhesive 257 waste minimization 205, 214, 260 waste minimization opportunities 266 waste reduction 247 waste treatment operating costs 315 waste-exchange bureau 309 waste-reduction options 308, 314 wastes 307 wastewater 257 wastewater flows 280 wastewater treatment 40, 114 water balance 278 water conservation 247 water usage 277 Western standards 329 wire-drawing 309 wood preserving 249 work instructions and standards 67 work plan 124, 125 zinc 257 zinc smelting 243 [...]... legal environmental performance standards on the other hand, is a concern of governmental agencies, and is considered by the ISO 14001 standard to be a matter apart from voluntary conformance to ISO 14001 But not completely apart, because if an enterprise EMS truly conforms to the requirements 12 GREENPROFITS and spirit of the ISO 14001 standard, its environmental performance and level of regulatory... heart of ISO 14001, then the enterprise's commitment to regulatory compliance, continual improvement, and pollution prevention are its soul The 52 explicit requirements of ISO 14001 represent the letter of the standard; these three overarching commitments set the tone for the way the enterprise meets the requirements, and thus A productive EMS represent the spirit of the standard What these three commitments... series - - the ISO 14000 series ISO 14001 is the ISO standard for EMSs, and this is the ISO 14000 standard that we are concerned with here Other ISO 14000 standards, including some still under development, deal with such subjects as auditing EMSs, environmental considerations in life cycles of products, and environmental labeling One of the last steps in the ISO 14001 EMS cycle is a self-audit When the self-audit... have to be conducted all environmental at one time One point about ISO 14001 that is very important performance to understand: ISO 14001 is an international standard for environmental management systems It is not a standard for environmental performance Conformance to the ISO 14001 standard is voluntary, and the ISO 14001 accreditation and certification mechanisms are (or should be) operated completely... students and others who just want to be well-informed on the subjects of EMS and ISO 14001 Chapter I starts with a short overview of the basic principles and concepts of EMSs, what ISO 14001 is all about, and the core elements of ISO 14001 As with all chapters in this book, the last section of Chapter 1 contains a brief review of the main points At the end of the chapter are some questions for individual... implementing, d) monitoring and correcting, and e) reviewing and revising This brings us to ISO 14001 The basic steps in the ISO 14001 EMS are a) environmental policy, b) planning, c) implementation and operation, d) checking and corrective action, and e) management review One could quibble with the choice of words and the particular way the steps are broken out, but what the authors of the ISO 14001 EMS did is... both the environmental performance of the enterprise under the EMS, and the performance of the EMS as a management system Obviously, the EMS audit required under Clause 4.5 provides much of the information for the management review Clause 4.6 of ISO 14001 requires top management to carefully consider every element of the EMS and consider changes that would improve it in light of its performance and. .. containers, symbols for automobile controls, and screw threads There is a reason why the International Organization for Standardization goes by the acronym "ISO, " but we will leave it for readers to find elsewhere After a successful experience developing and encouraging international standards for quality management (the ISO 9000 series), in late 1996 the ISO issued the first few standards in the environmental... the outline of ISO 14001, which is organized as a series of clauses and subclauses that each represent a distinct element of the EMS Except for the introductory and review sections, the sections of Chapter 2 correspond to the elements of ISO 14001 Though the material stands on its own, enterprises concerned with ISO 14001 certification will benefit most by reading Chapter 2 with a copy of the ISO 14001. .. (Clause 4.2) of the ISO 14001 EMS are "Top management " The first words in the last step (Clause 4.6) of the ISO 14001 EMS are "The organization's top management " Because many of the people who helped formulate ISO 14001 came from industry, they knew that an EMS begins and ends with the top management of the enterprise For an EMS to be effective, top management has to be committed to improving the environmental