Reviewed P2 Options
Other Options Process
Following are a set of P2 options you may wish to implement. No option is perfect for everyone, but sometimes options that have worked at one facility can work at yours. They might also serve as inspiration.
Reviewed Other Options Options
Following are a list of options that have been reviewed by pollution prevention specialists.
These options have worked at other facilities and may work at yours.
Returnable tote containers and drums
|Use returnable containers for paints, solvents, chemicals, cleaning agents, and lubricating fluids.
You can sell cleaned reusable containers to scrap dealers or drum recycling firms or return to the vendor for refilling.|
Scrap metal recycling
|Consult Recycle Texas by calling 512-239-3100 to order or visit the Web site at www.recycletexasonline.org for a list of scrap metal dealers that work with Texas companies. The recycler may also take clean empty paint cans and punctured aerosol cans as scrap metal. If the volume of scrap is too small to interest scrap dealers, look to other small manufacturers in the area to see if you can pool your scrap. A recycler may do a pick up for all local companies once a month when the collected volume might be enough to make a pick up profitable.|
Minimize container waste
|Options for minimizing other container waste include: container recycling, cardboard recovery, returning containers for reuse, and solid waste segregation.|
|Consider replacing aerosol cans with simple pump spray bottles. Purchase the liquid material in bulk. If pressurized systems are required, consider reusable cans that can be pressurized with shop air. If you cant eliminate aerosol cans, empty and depressurize them before recycling them. Once depressurized and emptied, the aerosol cans can be recycled as conventional scrap metal.|
Large volume gas compressor speed control
|Save up to 25% electrical usage by trimming speed and amperage use of compressor in proportion to gas flow rates. |
|Rotating Screw Compressors & Variable Frequency Drives
Rotary air compressors are positive displacement compressors which use less energy than other air compressors. Additionally, since cooling takes place inside the compressor, the working parts never experience extreme operating temperatures. Therefore rotary screw air compressors are easy to maintain and operate.
The Compressed Air and Gas Institute (CAGI) Performance Verification Program provides a list of rotating screw compressors that have passed performance verification. A list of these compressors can be found at: www.cagi.org/pdfs/cagirotaryscrewdirectory.pdf.
In addition, installing Variable Frequency Drives (VFD) on a rotating screw compressor can further reduce energy cost. VFDs reduce electrical energy consumption by adjusting a motor's speed to match the required load. A major benefit of VFDs is their "soft-start" capability that gradually ramps up a motors operating speed at startup and greatly reduces the stress on components. Information on VFDs can be found at www.focusonenergy.com/files/Document_Management_System/Business_Programs/controlingcostsvfd_factsheet.pdf.|
Reusable super sacks
|Flush batches packaged in super sack versus 25 kg bags since the super sack can be reused.|
Compressor Washing Schedule
|Instead of doing a cmpressor wash of long term storage turbine engines every 6 months; attempt to change timeline to annually.|
Lighting - Energy Efficiency
|LEDs - Upgrading outdoor and indoor lighting to LEDs (light-emitting diodes) can reduce electricity usage by 50-70%. LEDs also last longer than conventional lighting. Energy-saving results from LED lighting demonstration projects from the U.S. DDepartment of Energy can be found at www1.eere.energy.gov/buildings/ssl/gatewaydemos_results.html and www1.eere.energy.gov/buildings/ssl/using_leds.html/. Energy Star Qualified LED Lighting is recommended www.energystar.gov/index.cfm?c=ssl.pr_why_es_com.
Skylights - Reduce electric lighting needs during daylight hours by installing skylights, solar tunnels, and/or solar tubes.
Light Sensors - Light sensors on light switches will allow the most effective use of electric lighting outdoors and in areas with skylights. The sensors will reduce energy consumption and extend the operating life of lighting equipment.
Motion Sensors - Lighting for all offices, breakrooms and production areas may not be necessary all the time. Motion sensors to control lights could be installed in many of these areas to reduce the cost of electricity for lighting.|
|When motors fail, the two options are usually repair or replacement. To evaluate repair check Vaughen's Price Publishing, Inc. for pricing information and guides for electric motor repair in the U.S. and Canada: www.vaughens.com/index.cfm. Two resources for evaluating motor replacement include a Department of Energy (DOE) tip sheet and a free, DOE-funded software package. The DOE tip sheet to help determine when to purchase more energy-efficient motors is available at www1.eere.energy.gov/industry/bestpractices/pdfs/whentopurchase_nema_motor_systemts1.pdf. The free software application called Motor Master +(MM) calculates the savings and payback period with replacing standard efficiency motors with high-efficiency motors. Using this tool, a company in Indiana decided to replace 125 motors with high efficiency motors saving the company approximately $80,000 per year. The most recent version of the software application tool can be downloaded at www1.eere.energy.gov/industry/bestpractices/software.html.|
|Installing pressurized pumps on drums reduces the potential for drips and leaks, and increases the amount of product extracted. This saves money on product purchased in drums and housekeeping as floors remain drier and cleaner. Gravity-draining drums pose a much greater risk of drips, leaks and other failures. For more information, you can visit a number of companies' websites including:
*Goat Throat www.goatthroat.com/,
*Morse Manufacturing www.morsemfgco.com/products/drum-pumps.htm,
*Lyn Distributing www.lyndist.com/drum_pumps/drum_pumps.htm,
*Global Industrial www.globalindustrial.com/c/material-handling/drum-barrel/drum-pumps and EBK Containers www.ebkcontainers.com/products/Drum-Pumps.asp. |
Compressed Air Systems
|Compressed Air Assessment - See Texas A&M University's Industrial Assessment Center website: www1.mengr.tamu.edu/IAC/. A few tips to keep in mind when it comes to compressed air include: Pressures of 110 psig and above usually indicate unnecessary usage. For every 2 psig increase, energy use increases by 1%. Raising pressure to accommodate leaks usually makes the problems worse. To remove water content/moisture, use automatic drains to waste less air. Use cooler air for intake; every 10 °F rise in air temp increases energy use by 1.9%.
Identify Leaks - Pressurize the system during plant downtime when the compressor should not be running because no pressure is lost due to usage. To quantify the rate of air pressure loss, measure the time required for the system to lose 10 psig. Also UE systems developed an Ultrasonic Leak Detection guide. www.uesystems.com/pdf/Compressed_Air_Guide.pdf
Piping Connectors - Pipe connections should be evaluated regularly for air leaks. One option to reduce the leaks at pipe connectors is Smart Pipes, a modular aluminum piping system with "leak-free" connectors: us.kaeser.com/Products_and_Solutions/piping/pipe.asp. Another option is the Transair Aluminum Piping System, which use the pressure in the lines to seal connections: www.centrair.ca/piping.html.|
|Cool roof technologies reduce energy and maintenance costs significantly when compared to asphalt-based roofs. A typical cool roof with an elastomeric reflective coating material allows the roof surface to stay cooler and transfer less heat to the inside of the building. Demonstration projects have shown that the coatings can save 20-70% on a building's cooling energy costs. Cool roof coatings commonly consist of a white poly vinyl chloride polymer that reflects solar energy Many of these products incorporate a ceramic material in the formula to increase their functional properties. These coatings have about the same life span (about 10 years) as asphalt-based roofs, but the cost to re-furbish the cool roof coating is typically about one-third the cost. Over 10 years, the cool roof can save $4 per square foot or more in maintenance costs, mostly on roof replacement expenses. More information on the subject can be found at eetd.lbl.gov/coolroof/ and coolroofs.org/.|