APPENDIX B, U.S. EPA Facility Pollution Prevention Guide, EPA/600/R-92/088 INDUSTRY-SPECIFIC CHECKLISTS This appendix tabulates information that may be helpful to you if you decide to customize the worksheets in Appendix A for your own company's needs. Some ideas for achieving pollution prevention through good operating practices are shown in Table 1. Approaches to pollution prevention in material receiving, raw material and product storage, laboratories, and maintenance areas are shown in Table 2. Information in these two tables can apply to a wide range of industries. Industry-specific checklists for five example industries are presented in Tables 3 through 7. See Appendix G for a list of publications that provide industry-specific information related to pollution prevention. The tables contained within this appendix are as follows: Table 1. Pollution Prevention Through Good Operating Practices Table 2. Checklist for All Industries Table 3. Checklist for the Printing Industry Table 4. Checklist for the Fabricated Metal Industry Table 5. Checklist for the Metal Casting Industry Table 6. Checklist for the Printed Circuit Board Industry Table 7. Checklist for the Coating Industry Table 1. Pollution Prevention Through Good Operating Practices Good Operating Practice, Program Ingredients: Waste Segregation - Prevent mixing of hazardous wastes with nonhazardous wastes - Store materials in compatible groups - Segregate different solvents - Isolate liquid wastes from solid wastes Preventive Maintenance Programs - Maintain equipment history cards on equipment location, characteristics, and maintenance - Maintain a master preventive maintenance (PM) schedule - Keep vendor maintenance manuals handy - Maintain a manual or computerized repair history file Training/Awareness- Building Programs - Provide training for: - Operation of the equipment to minimize energy use and material waste - Proper materials handling to reduce waste and spills - Emphasize importance of pollution prevention by explaining the economic and environmental ramifications of hazardous waste generation and disposal - Detecting and minimizing material loss to air, land, or water - Emergency procedures to minimize lost materials during accidents Effective Supervision - Closer supervision may improve production efficiency and reduce inadvertent waste generation - Centralize waste management. Appoint a safety/waste management officer for each department. Educate staff on the benefits of pollution prevention. Establish pollution prevention goals. Perform pollution prevention assessments. Employee Participation - Quality circles (free forums between employees and supervisors) can identify ways to reduce waste - Solicit and reward employee suggestions for waste reduction ideas Production Scheduling/Planning - Maximize batch size to reduce clean out waste - Dedicate equipment to a single product - Alter batch sequencing to minimize cleaning frequency (light-to-dark batch sequence, for example) Cost accounting/ Allocation - Charge direct and indirect costs of all air, land, and water discharges to specific processes or products - Allocate waste treatment and disposal costs to the operations that generate the waste - Allocate utility costs to specific processes or products Table 2. Checklist for All Industries Waste Origin/Type, Pollution Prevention and Recycling Methods: Material Receiving/ Packaging materials, off-spec materials, damaged container, inadvertent spills, transfer hose emptying - Use "Just-in-Time" ordering system. - Establish a centralized purchasing program. - Select quantity and package type to minimize packing waste. - Order reagent chemicals in exact amounts. - Encourage chemical suppliers to become responsible partners (e.g., accept outdated supplies). - Establish an inventory control program to trace chemical from cradle to grave. - Rotate chemical stock. - Develop a running inventory of unused chemicals for other departments' use. - Inspect material before accepting a shipment. - Review material procurement specifications. - Validate shelf-life expiration dates. - Test effectiveness of outdated material. - Eliminate shelf-life requirements for stable compounds. - Conduct frequent inventory checks. - Use computer-assisted plant inventory system. - Conduct periodic materials tracking. - Properly label all containers. - Set up staffed control points to dispense chemicals and collect wastes. - Buy pure feeds. - Find less critical uses for off-spec material (that would otherwise be disposed). - Change to reusable shipping containers. - Switch to less hazardous raw material. - Use rinsable/recyclable drums. Raw Material and Product Storage/ Tank bottoms; off-spec and excess materials; spill residues; leaking pumps, valves, tanks, and pipes; damaged containers; empty containers - Establish Spill Prevention, Control, and Countermeasures (SPCC) plans. - Use properly designed tanks and vessels only for their intended purposes. - Install overflow alarms for all tanks and vessels. - Maintain physical integrity of all tanks and vessels. - Set up written procedures for all loading/unloading and transfer operations. - Install secondary containment areas. - Instruct operators to not bypass interlocks, alarms, or significantly alter setpoints without authorization. - Isolate equipment or process lines that leak or are not in service. - Use sealless pumps. - Use bellows-seal valves. - Document all spillage. - Perform overall materials balances and estimate the quantity and dollar value of all losses. - Use floating-roof tanks for VOC control. - Use conservation vents on fixed roof tanks. - Use vapor recovery systems. - Store containers in such a way as to allow for visual inspection for corrosion and leaks. - Stack containers in a way to minimize the chance of tipping, puncturing, or breaking. - Prevent concrete sweating by raising the drum off storage pads. - Maintain Material Safety Data Sheets to ensure correct handling of spills. - Provide adequate lighting in the storage area. - Maintain a clean, even surface in transportation areas. - Keep aisles clear of obstruction. - Maintain distance between incompatible chemicals. - Maintain distance between different types of chemicals to prevent cross-contamination. - Avoid stacking containers against process equipment. - Follow manufacturers' suggestions on the storage and handling of all raw materials. - Use proper insulation of electric circuitry and inspect regularly for corrosion and potential sparking. - Use large containers for bulk storage whenever possible. - Use containers with height-to-diameter ratio equal to one to minimize wetted area. - Empty drums and containers thoroughly before cleaning or disposal. - Reuse scrap paper for note pads; recycle paper. Laboratories/Reagents, off-spec chemicals, samples, empty sample and chemical containers - Use micro or semi-micro analytical techniques. - Increase use of instrumentation. - Reduce or eliminate the use of highly toxic - chemicals in laboratory experiments. - Reuse/recycle spent solvents. - Recover metal from catalyst. - Treat or destroy hazardous waste products as the last step in experiments. - Keep individual hazardous waste streams segregated, segregate hazardous waste from nonhazardous waste, segregate recyclable waste from non-recyclable waste. - Assure that the identity of all chemicals and wastes is clearly marked on all containers. - Investigate mercury recovery and recycling. Operation and Process Changes Solvents, cleaning agents, degreasing sludges, sandblasting waste, caustic, scrap metal, oils, greases from equipment cleaning - Maximize dedication of process equipment. - Use squeegees to recover residual fluid on product prior to rinsing. - Use closed storage and transfer systems. - Provide sufficient drain time for liquids. - Line equipment to reduce fluid holdup. - Use cleaning system that avoid or minimize solvents and clean only when needed. - Use countercurrent rinsing. - Use clean-in-place systems. - Clean equipment immediately after use. - Reuse cleanup solvent. - Reprocess cleanup solvent into useful products. - Segregate wastes by solvent type. - Standardize solvent usage. - Reclaim solvent by distillation. - Schedule production to lower cleaning frequency. - Use mechanical wipers on mixing tanks. Operation and Process Changes Sludge and spent acid from heat exchanger cleaning - Use bypass control or pumped recycle to maintain turbulence during turndown. - Use smooth heat exchange surfaces. - Use on-stream cleaning techniques. - Use high pressure water cleaning to replace chemical cleaning where possible. - Use lower pressure steam. Table 3. Checklist for the Printing Industry Waste Origin/Type, Pollution Prevention and Recycling Method Image Processing/Empty containers, used film packages, outdated material - Recycle empty containers. - Recycle spoiled photographic film. Image Processing/ Photographic chemicals, silver - Use silver-free films, such as vesicular, diazo, or electrostatic types.. - Use water-developed litho plates. - Extend bath life. - Use squeegees to reduce carryover. - Employ countercurrent washing. - Recover silver and recycle chemicals. Plate Making/Damaged plates, developed film, outdated materials - Use electronic imaging, laser plate making. Plate Making/ Acids, alkali, solvents, plate coatings (may contain dyes, photopolymers, binders, resins, pigment, organic acids), developers (may contain isopropanol, gum arabic, lacquers, caustics), and rinse water - Electronic imaging/laser print making. - Recover silver and recycle chemicals. - Use floating lids on bleach and developer tanks. - Use countercurrent washing sequence. - Use squeegees to reduce carryover. - Substitute iron-EDTA for ferrocyanide. - Use washless processing systems. - Use better operating practices. - Remove heavy metals from wastewater. Finishing/Damaged products, scrap - Reduce paper use and recycle waste paper. Printing/ Lubricating oils, waste ink, cleanup solvent (halogenated and nonhalogenated), rags - Prepare only the quantity of ink needed for a press run. - Recycle waste ink and solvent. - Schedule runs to reduce color change over. - Use automatic cleaning equipment. - Use automatic ink leveler. - Use alternative solvents. - Use water-based ink. - Use UV-curable ink. - Install web break detectors. - Use automatic web splicers. - Store ink properly. - Standardize ink sequence. - Recycle waste ink. Printing/ Test production, bad printings, empty ink containers, used blankets. - Install web break detectors. - Monitor press performance. - Use better operating practices. Printing/ (Continued) - Use alternative fountain solutions. - Use alternative cleaning solvents. - Use automatic blanket cleaners. - Improve cleaning efficiency. - Collect and reuse solvent. - Recycle lube oils. Finishing/ Paper waste from damaged product - Reduce paper use. - Recycle waste paper. Table 4. Checklist for the Fabricated Metal Industry Waste Origin/Type Pollution Prevention and Recycling Methods Machining Wastes/ Metalworking Fluid - Use of high-quality metalworking fluid. - Use demineralized water makeup. - Perform regularly scheduled sump and machine cleaning. - Perform regularly scheduled gasket, wiper, and seal maintenance. - Filter, pasteurize, and treat metalworking fluid for reuse. - Assigning fluid control responsibility to one person. - Standardize oil types used on machining equipment. - Improve equipment scheduling/establish dedicated lines. - Reuse or recycle cutting, cooling, and lubricating oils. - Substitute insoluble borates for soluble borate lubricants. Machining Wastes/ Metal wastes, dust, and sludge - Segregate and reuse scrap metal. Parts Cleaning/ Solvents - Install lids/silhouettes on tanks. - Increase freeboard space on tanks. - Install freeboard chillers on tanks. - Remove sludge from solvent tanks frequently. - Extend solvent life by precleaning parts by wiping, using air blowers, or predipping in cold mineral spirits dip. - Reclaim/recover solvent on- or off-site. - Substitute less hazardous solvent degreasers (e.g., petroleum solvents instead of chlorinated solvents) or alkali washes where possible. - Distribute parts on rack to allow good cleaning and minimize solvent holup. - Slow speed of parts removal from vapor zone. - Rotate parts to allow condensed solvent drop-off. Parts Cleaning/ Aqueous Cleaners - Remove sludge frequently. - Use dry cleaning and stripping methods. - Use oil separation and filtration to recycle solution. Parts Cleaning/ Abrasives - Use of greaseless or water-based binders. - Use an automatic liquid spray system for application of abrasive onto wheel. - Ensure sufficient water use during cleaning by using water level control. - Use synthetic abrasives. Parts Cleaning/ Rinsewater - Improve rack and barrel system design. - Use spray, fog, or chemical rinses. - Use deionized water makeup to increase solution life. Surface Treatment and Plating/ Process Solutions - Use material or process substitution e.g., trivalent chromium. - Use low solvent paint for coating. - Use mechanical cladding and coating. - Use cleaning baths as pH adjusters. - Recover metals from process solutions. Surface Treatment and Plating/ Rinsewater - Reduction in drag-out of process chemicals: Reduce speed of withdrawal Lower plating bath concentrations Reuse rinsewater Use surfactants to improve drainage Increase solution temperature to reduce viscosity Position workpiece to minimize solution holdup - System design considerations: Rinsetank design Multiple rinsing tanks Conductivity measurement to control rinse water flow Fog nozzles and sprays Automatic flow controls Rinse bath agitation Counter current rinse. Table 5. Checklist for the Metal Casting Industry Waste Origin/Type, Pollution Prevention and Recycling Methods Baghouse Dust and Scrubber Waste/ Dust contaminated with lead, zinc, and cadmium - Identify the source of contaminants, e.g., coatings on scrap, and work with suppliers to find raw materials that reduce the contaminant input. - Install induction furnaces to reduce dust production. - Recycle dust to original process or to another process. - Recover contaminants with pyrometallurgical treatment, rotary kiln, hydrogen reduction, or other processes. - Recycle to cement manufacturer. Production of Ductile Iron/ Hazardous slag - Reduce the amount of sulfur in the feedstock. - Use calcium oxide or calcium fluoride to replace calcium carbide as the desulfurization agent. - Improve process control. - Recycle calcium carbide slag. Casting/ Spent casting sand - Material substitution, e.g., olivine sand is more difficult to detoxify than silica sand. - Separate sand and shot blast dust. - Improve metal recovery from sand. - Recover sand and mix old and new sand for mold making. - Recover sand by washing, air scrubbing, or thermal treatment. - Reuse sand for construction if possible. Table 6. Checklist for the Printed Circuit Board Industry Waste Origin/Type Pollution Prevention and Recycling Methods PC Board Manufacture/ General - Product substitution: Surface mount technology Injection molded substrate and additive plating Cleaning and Surface Preparation/ Solvents - Materials substitution: Use abrasives Use nonchelated cleaners - Increase efficiency of process: Extend bath life, improve rinse efficiency, countercurrent cleaning - Recycle/reuse: Recycle/reuse cleaners and rinses Pattern Printing and Masking/ Acid fumes/organic vapors; vinyl polymers spent resist removal solution; spent acid solution; waste rinse water - Reduce hazardous nature of process: Aqueous processable resist Screen printing versus photolithography Dry photoresist removal - Recycle/reuse: Recycle/reuse photoresist stripper Electroplating and Electroless Plating/ Plating solutions and rinse wastes - Eliminate process: Mechanical board production - Materials substitution: Noncyanide baths Noncyanide stress relievers - Extend bath life; reduce drag-in: Proper rack design/maintenance, better precleaning/rinsing, use of demineralized water as makeup, proper storage methods - Extend bath life; reduce drag-out: Minimize bath chemical concentration, increase bath temperature, use wetting agents, proper positioning on rack, slow withdrawal and sample drainage, comput- erized/automated systems, recover drag- out, use airstreams or fog to rinse plating solution into the tank, collect drips with drain boards. - Extend bath life; maintain bath solution quality: Monitor solution activity Control temperature Mechanical agitation Continuous filtration/carbon treatment Impurity removal - Improve rinse efficiency: Closed-circuit rinses Spray rinses Fog nozzles Increased agitation Countercurrent rinsing Proper equipment design/operation Deionized water use. - Turn off rinsewater when not in use. - Recovery/reuse: Segregate streams Recover metal values. Etching/ Etching solutions and rinse wastes - Eliminate process: Differential plating Use dry plasma etching. - Materials substitution: Nonchelated etchants Nonchrome etchants. - Increased efficiency: Use thinner copper cladding Pattern vs. panel plating Additive vs. subtractive method. - Reuse/recycle: Reuse/recycle etchants. Table 7. Checklist for the Coating Industry Waste Origin/Type Pollution Prevention and Recycling Methods Coating Overspray/ Coating material that fails to reach the object being coated - Maintain 50% overlap between spray pattern. - Maintain 6- to 8-inch distance between spray gun and the workpiece. - Maintain a gun speed of about 250 feet/minute. - Hold gun perpendicular to the surface. - Trigger gun at the beginning and end of each pass. - Properly train operators. - Use robots for spraying. - Avoid excessive air pressure for coating atomization. - Recycle overspray. - Use electrostatic spray systems. - Use turbine disk or bell or air-assisted airless spray guns in place of air-spray guns. - Install on-site paint mixers to control material usage. - Inspect parts before coating. Stripping Wastes/ Coating removal from parts before applying a new coat - Avoid adding excess stripper. - Use spent stripper as rough prestrip on next item. - Use abrasive media paint stripping. - Use plastic media bead-blasting paint stripping. - Use cryogenic paint stripping. - Use thermal paint stripping. - Use wheat starch media blasting paint stripping. - Use laser or flashlamp paint stripping. Solvent Emissions/ Evaporative losses from process equipment and coated parts - Keep solvent soak tanks away from heat sources. - Use high-solids coating formulations. - Use powder coatings. - Use water-based coating formulations. - Use UV cured coating formulations. Equipment Cleanup Wastes/ Process equipment cleaning with solvents - Use light-to-dark batch sequencing. - Produce large batches of similarly coated objects instead of small batches of differently coated items. - Isolate solvent-based paint spray booths from water-based paint spray booths. - Reuse cleaning solution/solvent. - Standardize solvent usage. - Clean coating equipment after each use. Source Reduction - Reexamine the need for coating, as well as available alternatives. - Use longer lasting plastic coatings instead of paint.