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General Pollution
Prevention Options for Industry
Below are general options to reduce
process waste and pollution. As a starting point, review
this list to consider what types of pollution prevention
options might be appropriate for your facility. Because
all facilities are different only some of these options
will be appropriate for your facility.
Extend chemical
life
Reduce or remove contamination
- Filter or separate contaminants
from useful chemicals
- Use de-ionized water to make up
hot baths
- Use squeegees to recover residual
fluid on product prior to rinsing
- Use mechanical wipers on mixing
tanks
- Use smooth equipment surfaces
- Line equipment to reduce fluid
hold-up
- Remove sludge from tanks frequently
- Aerate and remove solids from baths
susceptible to bacterial growth
- Circulate baths susceptible to
sedimentation
- Rack parts for maximum line density
to reduce overspray
- Select and operate spray
equipment for minimum overspray
Extend change intervals
- Use countercurrent rinsing and
chemical processing
- Test to see if the set changeout
frequencies are correct
- Make the changeout procedure quicker
so changes can be made when needed, not when convenient
- Pre-clean parts with waste or used
chemistries to protect critical baths
- Reduce volume of the bath
- Use tank sizes matched to the load
- Use dead rinses to make up lost
bath volume and chemistry
Measure and control key bath
parameters
- Even out fluctuations that can
cause defects
- Prevent or decrease worker
exposure to hazardous chemicals through automated
chemical makeup
Optimize Processes
Production scheduling
- Produce only the amount requested
or needed
- Reduce cleaning frequency at job
changes. Group similar jobs, transition from light
to darker colors, etc.
- Schedule difficult jobs for when
crews are fresh
- Maximize dedication of process
equipment
Improve procedures
- Identify and correct causes of
defects to improve efficiency and first pass quality
(avoids wasting raw materials for defective products)
- Choose the best procedures among
operators and shifts and make them the standard
- Provide feedback mechanisms to
operators on work quality and efficiency
- Clean only when needed
- Clean equipment and parts immediately
after use (many soils are more difficult as they age)
- Use less cleaner by using high
pressure sprays, pressurized air, steam and heated
cleaning bath, etc.
- Clean process equipment with process
fluids if possible
- Perform regular machine cleaning
and maintenance
- Relocate process equipment and
change piping configuration to avoid contamination
from other sources
- Prepare to handle predictable but
unavoidable problems and upsets
- Shift from batch manufacturing
to continuous manufacturing
Modify product/check product specifications
- Reformulate products (e.g. prepare
chemicals in pellet form instead of powder to reduce
dust emissions)
- Verify all specifications are appropriate
- Simplify products with fewer parts
and less required processing
- Design parts for the intended
processes, with appropriate drain holes for plating
and cleaning operations
Use a cleaner process, such as:
- Closed-mold fiberglass fabrication
in place of open mold
- Powder coating for liquid paint
- Mechanical or thermal processing
rather than chemical effects
Eliminate or combine process steps
- Look for ways to streamline the
process
- Interim storage often causes parts
to have to be cleaned before continued processing
Use better equipment
- Improve online control (e.g., with
computer control system)
- Automate start-ups, shutdowns
and product changeover
Identify and Prevent Losses
Spills
- Recover excess product prior to
cleanup
- Use dry or damp cleanup methods
for spills or leaks (e.g., use broom instead of hose)
- Use high-pressure, low-volume cleaning
systems
- Use drip catchers, spouts and funnels
when transferring liquids
- Use a gravity spigot or pump to
reduce spills when dispensing liquids. Avoid pouring
from a bung opening
- Tightly seal all bungs and lids
(even for empty containers)
- Install overflow alarms for all
tank and vessels
- Properly designated tanks and vessels
and use only for intended purposes
- Increase freeboard on tanks
- Install secondary containment areas
- Write procedures for all loading/unloading
and transfer operations
- Instruct operators to not bypass
interlocks or alarms, or to alter set points without
authorization
- Document all spills so you
can take precautionary measures in the future
Leaks
- Store containers in a way that
allows for visual inspection for corrosion and leaks
- Stack containers in a way to minimize
the chance of tipping, puncturing or breaking
- Prevent concrete "sweating"
and corrosion by raising the drum off the storage
pad (e.g., on pallets)
- Store materials to prevent damage
or contamination. Protect items stored outdoors from
temperature extremes, rain, snow, wind, etc.
- Establish Spill Prevention, Control
and Countermeasure (SPCC) plans
- Use seal-less pumps
- Use bellows-seal valves
- Install leak detection systems
in storage tanks
- Isolate equipment or process lines
that leak or are not in service
Evaporation
- Use vapor recovery (vapor balance)
systems for bulk chemical systems
- Use closed storage and transfer
systems
- Cover tanks and containers when
access is not required
- Reduce the temperature of hot tanks
when not needed
- Use floating ball or foam blankets
on process tanks in use
Procurement
Use the right chemical
- Use high-performance, longer lasting
raw materials
- Review material procurement specifications,
is the material best for the job?
- Switch to a less-hazardous raw
materials
- Reduce the number of different
brands and grades of chemicals
- Use one multi-purpose solvent or
cleaning chemical rather than several different solvents
- Don't accept off-spec materials.
Inspect/test materials before accepting a shipment
- Use suppliers who take back their
used materials for recycling
- Properly label all containers to
avoid mistakes and avoid having containers become
unknown product, with content that cannot be trusted
- Store products in locations/under
conditions that will preserve their useful shelf life
- Reformulate raw materials (e.g.
prepare chemicals in pellet form instead of powder
to reduce dust emissions)
- Use chemicals according to
the manufacturer's instructions
Get the right amount, in the right
container
- Purchase supplies in bulk and keep
in bulk dispensers to reduce dregs and container handling
- Purchase materials in smaller containers
when shelf life or handling of large containers are
issues
- Use reusable or returnable shipping
containers
- Use drums that can be rinsed or
recycled or used with plastic liners
- Use containers with height-to-diameter
ratio equal to one to minimize wetted area
Get materials at the right time
- Use "Just in Time" ordering
system (order materials on an as-needed basis)
- Implement first-in, first-out material
use policy
- Validate shelf-life expiration
dates. Eliminate shelf-life requirements for stable
compounds
Establish a
centralized purchasing program and policy
- Put one person in charge of ordering,
checking, labeling (purchase date, contents) and issuing
hazardous materials
- Designate one person to accept
chemical samples and return unused samples to suppliers
- Establish an inventory control
program to trace chemicals from cradle to grave
- Develop a running inventory of
unused chemicals that can be used by other departments
- Find less critical uses for off-spec
materials, that would otherwise be disposed
- Encourage chemical suppliers to
become responsible partners (e.g., accept outdated
supplies)
- Return unused materials to suppliers
Recycle/Reuse
- Reprocess or recycle cleaning and
process fluids by filtration, distillation, pasteurization,
separation or centrifuging
- Reuse high performance or high-purity
fluids that no longer meet spec for less stringent
applications
- Recycle samples back into
the original or similar product
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