Cleaner and Greener Manufacturing Seminar The business value of toxics reduction and pollution prevention planning Breakfast Seminars Fall 2010 Mississauga, September 21 Guelph, September 28 Kingston, September 30 Chatham, October 5 Welcome! 1
Agenda Welcome 5 minutes Fred Granek, VP Sustainability, OCETA Benefits of Focusing on Sustainability 20 minutes Blake Smith, Director, Environment, Energy and Vehicle Safety, Ford Motor Company of Canada Toxics Reduction Act Summary 10 minutes Nancy Coulas, Director Environmental Policy, CME Lean and Green 15 minutes Peter Corbyn, Project Manager Pollution Prevention & Toxics Reduction The Business Case 15 minutes Fred Granek Panel Q&A 10 minutes Fred, Peter, Nancy, Blake Next Steps 5 minutes Sustainability Blake Smith Director, Environment, Energy and Vehicle Safety Ford Motor Company of Canada 2
Toxics Reduction Act Requirements 1. Track and quantify the listed substances used or created at the facility (Toxic Substance Accounting) 2. Prepare a plan to reduce the use and creation of each of these substances (Toxic Substance Reduction Planning) 3. Plan is certified by highest ranking employee at the facility 4. Provide summaries of their plans to the public and notify employees the same day as summaries are made public 5. Report to the Ministry and the public on their progress in reducing listed substances 6. Review plans on a regular basis Plans 3
Are you subject to the Act? Yes Use or create one of the 47 priority toxic substances in Table A - 2010; remainder of NPRI and acetone 2012 Yes Yes Report under Reg. 127/01 or NPRI NAICS code starts with 31, 32, 33 (manufacturing), 212 (mining except oil and gas) Yes Stick around this affects you 4
Key Dates Phase I Jan 1, 2010: Start tracking and quantifying priority substances Jun 1, 2011: First report to MOE for 2010 Dec 31, 2011: Complete plan for each substance and summary to public and Ministry by this date Phase II Jan 1, 2012: June 1, 2013: Dec 31, 2013: Same as above + current NPRI list + acetone Same as Jun 1, 2011 for all substances Same as Dec 31, 2011 for all substances Steps to comply I 1. Toxic substance accounting Account for the listed substances used, created, transformed, destroyed, released, disposed of, transferred and contained in the product at your facility by tracking and quantifying them. Requires process flow diagrams and methodology. 2. Develop a plan to reduce toxics Establish a team (recommended) / identify costs / identify reduction methods / assess options and feasibility / choose best options / map out implementation timeline Option types include: 1. Material or feedstock substitution 2. Product design or reformation 3. Equipment or process modifications 4. Spill and leak prevention 5. On-site reuse or recycling 6. Improved inventory management or purchasing techniques 7. Training or improved operating practices 5
Steps to comply II 3. Provide summary Tell the public why your facility uses or creates a substance and whether you intend to reduce use and creation and how to achieve reductions, or not. 4. Report on your progress Report to Ontario government and public each year. Details on specific information to be shared are on their way. 5. Review your plans to reduce toxics Review processes, methods, options and trends. First review is required by Dec 31, 2018, then 2023, 2028, etc. Additional Notes Additional information coming soon from Ministry that provides more details on the overall process Individual fines up to $25k/day for first offence, $50k/day for second offence, corporate fines $50k/day and $100k/day Further information at http://www.ene.gov.on.ca/en/toxics/index.php Toxics Reduction Act is at http://www.elaws.gov.on.ca/html/statutes/english/elaws_statutes_09t19_e.htm Reg. 455/09 is at http://www.elaws.gov.on.ca/html/regs/english/elaws_regs_090455_e.htm 6
Lean and Green 7
PFD/EnVSM 8
9
Software 12/8/2010 10
11
12
Toronto Region Sustainability A one-stop pollution prevention (P2) & energy efficiency technical assistance program with funding incentive for smallto-medium sized (SME) manufacturers in the Greater Toronto Region 13
Reducing the Environmental Footprint Through Integrated Process Improvements Toronto Region Sustainability: Case Study Printer Bowne of Canada 203-person document management & lithographic printing company Bowne s Press Room OCETA and EcoSafe have been instrumental in helping us re-align our goals. We now have a solid action plan in place which will pay dividends and assist us on the road to true environmental sustainability. Brian Arrol, Environmental Health & Safety Manager 14
Toronto Region Sustainability: Case Study Printer Processes PRE-PRESS Computer-to-Plate Processor PRESSROOM Targeted Pollutants/ Waste Water Consumption Waste Fountain Solution (Process Waste and VOCs) Press Wash & Rags and Wipers (VOC-generating Solvents) P2 Options Installation of wash water recirculating unit Installation of ultra membrane filtration Centralized fount dosing system Vacuum distillation (re-use solvents) Improved Operating practices Results 29.3 Tonnes/yr of VOCs 51.6 Tonnes/yr of Process Wastes, 25.4 Tonnes/yr of Hazardous Waste 2.7 Kilotonnes/yr of Water & 8,265 m 3 /yr of Natural Gas 22.9 Tonnes/yr of Greenhouse Gases (GHGs) Total Savings upon full Implementation: $ 136 K Overall Payback = 0.6 Yr Toronto Region Sustainability: Case Study Chemical Specialty Anonymous 95-person chemical specialty manufacturer of glycerine, oleic and stearic acids Main Processes: Raw materials split into fatty acid and glycerine intermediate products Glycerine is concentrated, purified and sold in liquid bulk drums Fatty acids are separated into oleic and stearic acid fractions, hydrogenated, distilled, and sold in liquid bulk, drums and powdered products Participation Drivers: Toronto sewer use by-law Hazardous waste management and product loss costs 15
Toronto Region Sustainability: Case Study Chemical Specialty Processes FATTY ACID & GLYCERINE PRODUCTION MATERIAL TRANSFER BUILDING SERVICES Targeted Pollutants/ Waste Zinc, Nickel & Hazardous Waste Oleic Acid, Stearic Acid & Glycerine Wastes Nonyl Phenol Ethoxylates, Water Consumption P2 Options Precipitation of Nickel waste from modifier condensate Improved process efficiency Retrofit transfer lines Install line pigging system Reuse air compressor cooling water Reduce Ammonia compressor water consumption Material Substitution Aggregated Results 6.7 kg/yr of Metals 17 kg/yr of Toxics 120 tonnes/yr of Hazardous Wastes (Annual savings $ 140K, Payback <1 month) 68.2 tonnes/yr of Process Wastes & 39.2 kilotonnes/yr of water Total savings upon full implementation: $270 K with Overall Payback of 5 months Toronto Region Sustainability: Case Study Paint Manufacturer Anonymous 100-person paint and resin manufacturer Two Main Processes: Manufacture of liquid paints Manufacture of epoxy phenolic resins Participation Drivers: Municipal sewer use by-law & MOE Regulation 127 Process optimization Minimizing impact on environment 16
Toronto Region Sustainability: Case Study Paint Manufacturer Processes Paint Mixing Tanks Resin Plant Loading and Scrubber Cleaning Targeted Pollutants/ Waste Solvents (VOCs) Bis-phenol (Toxic) GHGs, Water Chromium, Zinc, Lead Toluene, Xylene P2 Options Chill mixing tanks Use pelletized form of bisphenol Eliminate fugitive releases Recycle & re-use srubber water Cleaning process change Efficient use Equipment modification Aggregated Results 30.5 tonnes/yr of VOCs 13 tonnes/yr of Particulate Matter/Toxics 4.7 kg/yr of Metals 38,324 tonnes/yr of Water consumption 70.5 tonnes/yr of GHGs Total savings upon full implementation: $97 K with Overall Payback of 2.1 Years Financials Pollution Prevention & Toxics Reduction The Business Case Cost Avoidance & Profitability Cost savings Payback period Operational Efficiencies Non-financials / Reputation Company Value Business Risks Reduction Hidden costs of non-compliance Workers Health & Safety Spills, fines, high remediation costs Changing regulations Competitive Advantage Green marketing Access to Global markets 17
Toronto Region Sustainability: Financial Results Totals Savings (Annualized) Capital Investment Return on Investment $5.1 million $4.4 million 10 Months 90% of program clients are implementing all or most of the P2 projects recommended in the assessment reports. Toronto Region Sustainability: Key Program Outcomes Implementation rate: 90% Payback < 1 year Clients with public P2 case studies: 50% 18
Panel Q&A Next Steps Presentations will be available on the Cleaner and Greener Manufacturing Program web portal www.cme-mec.ca/clean Cleaner & Greener Manufacturing two day workshops: Mississauga October 19/20 Kitchener-Waterloo November 2/3 Chatham November 16/17 Kingston November 30/December 1 Toxics reduction/pollution prevention technical assistance 16 confidential toxics reduction/p2 assessments through the Toronto Region Sustainability Program with $7K cost share. First come, first serve! Register early! Please fill out the evaluation forms THANK YOU! 19