NIPSCO Energy Symposium The 4 R s of Sustainability October 10, 2012 2012 Purdue Research Foundation 1
Sustainability Meeting the needs of the present without compromising the ability of future generations to meet their own needs. 2012 Purdue Research Foundation 2
Sustainability Core Concepts 1. 4R WASTE Hierarchy 2. WASTE Inputs & Outputs 3. Environmental WASTE Categories 4. Sustainability Triple Bottom Line 2012 Purdue Research Foundation 3
4R WASTE Hierarchy Most desirable Least desirable Refuse Reduce Reuse Recycle Energy Recovery 4Rs Disposal 2012 Purdue Research Foundation 4
Environmental WASTE Categories Water Air Solids Toxicity (Chemicals) Energy 2012 Purdue Research Foundation 5
Sustainability Global Impact 2012 Purdue Research Foundation 6
Sustainability Triple Bottom Line Profit (Economic) Improves efficiency & lowers costs Reduces regulatory compliance costs Creates revenue enhancement opportunities Planet (Environmental) Reduces demand for resources and energy from nature Reduces waste to nature People (Social) More resources and energy become available for others Closing the loop (cradle-to-cradle) generates new jobs Planet 2012 Purdue Research Foundation 7
Water Module Topics Water Quantity & Quality Point Source & Non-Point Source Pollution Water Regulations Wastewater Treatment Systems Runoff Management 4Rs & Water Taking it Home 2012 Purdue Research Foundation 8
4R WASTE Hierarchy -- WATER Refuse (don t use) Most desirable Least desirable Refuse Reduce Reuse 4Rs Recycle Energy Recovery Disposal Reduce (conservation) Reuse/Recover/Recirculate (divert, don t discharge) Recycle (reuse after processing or treatment) 2012 Purdue Research Foundation 9
Conservation/Efficiency - Refuse Equipment, devices, and appliances that do not use water Alternative processes that do not require water Dry clean-up methods rather than wet cleaning 2012 Purdue Research Foundation 10
Dry Clean-up Examples Sweeping floors Vacuuming Squeegees Scrapers Pigs (to purge residuals from pipes) 2012 Purdue Research Foundation 11
Conservation/Efficiency - Reduce Efficient spray nozzles with automatic shutoffs on hoses Timers to shut off process water when process is down Flow restrictors in water lines that supply hoses and pressure washers Water-efficient equipment, devices and appliances 2012 Purdue Research Foundation 12
Air Module Topics Types / Categories of Pollutants Greenhouse Gases Climate Change Air Emission Reduction Technologies Carbon Footprint 4Rs & Air Taking it Home 2012 Purdue Research Foundation 13
4R WASTE Hierarchy -- AIR Refuse (don t use) Most desirable Least desirable Refuse Reduce Reuse Recycle Energy Recovery Disposal Reduce (quantity and toxicity) Reuse/Recover (divert, don t discharge) Recycle (reuse after processing or treatment) 4Rs 2012 Purdue Research Foundation 14
Solids Module Topics Zero Landfill Solid Waste Streams Solid Waste Management Dumpster D.I.V.E. Process for Zero Landfill Root Cause Analysis 4Rs & Solids Taking it Home 2012 Purdue Research Foundation 15
4R WASTE Hierarchy -- SOLIDS Refuse (don t use) Most desirable Least desirable Refuse Reduce Reuse Recycle Energy Recovery Disposal Reduce (lightweighting, errorproofing) Reuse (packaging reuse, waste exchange) Recycle (waste collection, separation) 4Rs 2012 Purdue Research Foundation 16
Dumpster Dive Process Divide Investigate Verify Eliminate Mixed? Materials X Product Specifications Sort Categorize Sample Weights Volumes Costs Oddities Sources Root Causes Interactions Apply 4R s Quantify Input Materials Technology Operating Practices Material Use/Waste Corrugated Cardboard Packaging 2012 Purdue Research Foundation 17
Dumpster D.I.V.E. Divide Investigate Verify Eliminate Mixed? Materials X Product Specifications Technology Input Materials Operating Practices Material Use/Waste Corrugated Cardboard Packaging 2012 Purdue Research Foundation 18
4Rs Applied Water Air Solids Toxicity Energy Waste collection/ separation at the source Buy product / materials with recycled content Design for Environment Product Lifecycle Analysis Alternative Materials Packaging reuse Waste exchange By-product upgrades Take-back programs Alternative Materials Dematerialization / Lightweighting Errorproofing 2012 Purdue Research Foundation 19
Reuse Where to Look Reusable packaging (!!!) Scrap or defective products Take-back programs for customers Take-back programs with suppliers Product returns reuse / repair 2012 Purdue Research Foundation 20
Eliminate WASTE using 4Rs Refuse Reduce Materials Divide Mixed? Materials Reuse Must consider costs and feasibility to justify the change X Product Investigate Verify Input Materials Operating Practices Recycle Corrugated Cardboard Packaging Eliminate Dispose Product Specifications Technology Material Use/Waste 2012 Purdue Research Foundation 21
Green Fast Facts The US population discards each year 16,000,000,000 diapers, 1,600,000,000 pens, 2,000,000,000 razor blades, 220,000,000 car tires, and enough aluminum to rebuild the US commercial air fleet four times over. Source: www.recycling-revolution.com 2012 Purdue Research Foundation 22
Toxicity Module Topics Green Chemistry Philosophy Regulatory Factors Hazard & Risk Assessment Chemical Substitutions Bioplastics 4Rs & Toxicity Taking it Home 2012 Purdue Research Foundation 23
4R WASTE Hierarchy -- TOXICITY Refuse (don t use) Reduce (quantity and toxicity) Refuse Reduce Reuse 4Rs Reclaim Energy Recovery Disposal Reuse/Recover (recirculation, energy recovery) Reclaim/Recycle (Solvent/chemical reclamation) 2012 Purdue Research Foundation 24
Energy Module Topics World & U.S. Energy Consumption & Production Non-Renewable Energy Sources Coal, Petroleum, Natural Gas, Nuclear Industrial Utility Bills Energy Intensive Systems e.g., Compressed Air, HVAC, Lighting, Boilers 4Rs & Energy Taking it Home 2012 Purdue Research Foundation 25
ENERGY Opportunities Nutshell Leaks Compressed Air, Steam, Doors, Windows Insulation Building, HVAC, Steam Pipes, H2O Heater/Pipes Maintenance Motors, Compressed Air, Steam, HVAC, Lighting Turning things off/down Equipment, Lights, HVAC, etc. Most desirable Least desirable Lighting Over-illumination, Technology, Layout Refuse Reduce Reuse Recycle Energy Recovery Disposal 4Rs 2012 Purdue Research Foundation 26
Conservation is the Best Alternative Energy! Conservation programs are easier to implement than any other alternative energy technology Much more cost effective Conservation should always be first on a list of solutions! 2012 Purdue Research Foundation 27
IN Manufacturer Replaced 285 400W Metal Halide fixtures with 6 bulb T5HO fluorescent fixtures. - decreased energy usage by 27% - increased floor level foot candles by 51% - reduced load on AC system - EPACT tax rebate, Utility Company rebate - Direct Payback (Energy Costs only) < 2.0 years Implemented recycling program for scrap wood, cardboard, & shrink-wrap - decreased solid waste generation by 89% within 1 year 2012 Purdue Research Foundation 28
IN Manufacturer Installed T5 fluorescent lighting replacing 400 watt HID lighting Installed VFD s on cooling tower fans, circulating pumps, and other applicable support equipment Replaced older air compressors with more efficient models including VFD controls Replaced air cooled chillers with much more efficient indoor water cooled chillers Installed motion controls on grinders to reduce idle running Savings averaged $100,000 annually with an 8-11% decrease in energy intensity each year since 2008 2012 Purdue Research Foundation 29
Questions? Thank You! Jon Guenin, PE, CEM Lead Project Specialist - Sustainability Purdue TAP EES West Lafayette, IN 765-337-7951 guenin@purdue.edu www.greenmanufacturing.purdue.edu 2012 Purdue Research Foundation 30