SGP Worksheets WorkshopWinston-Salem, NCDecember 12, 2000

George Cushnie

NMFRC

Overview of Today’s Workshop

• Calculations of Seven Core Goals

• 2000 Worksheet

• 1999 Progress Reports

• 1999 Cost Analysis

• Benchmarking

SGP Core Environmental Goals

• 50% reduction in water use • 25% reduction in energy use• 50% reduction in land disposal of hazardous sludge

and a reduction in sludge generation • 50% reduction in metals emissions to air and water• 98% metals utilization • 90% reduction in organic emissions to air and water • Reduction in human exposure to toxic chemicals

50% Water Use Reduction

• Current year is 50% less than baseline, adjusted for changes in production.

• Can be based on total water purchased, water used for metal finishing, or process wastewater discharged.

• Zero discharge for current year automatically achieves goal.

• Be consistent from year-to-year.• Keep records/calculations.

25% Energy Reduction

• Current Year is 25% less than baseline, adjusted for changes in production.

• Based on all sources of energy purchased (electricity, natural gas, fuel oil).

• Energy sources converted to BTUs for calculation.

• Captive shops may limit goal to metal finishing.

50% Reduction in Land Disposal & Overall Reduction in Generation

• Two Parts:– Current year haz. to landfill is 50% less than

baseline, adjusted for changes in production.– Current year overall < baseline, adjusted for changes

in production.• Can achieve Part 1 by:

– Decreasing hazardous sludge quantity shipped to landfill.

– Switch from landfill to off-site recycle.– Delisting sludge.

50% Reduction in Land Disposal & Overall Reduction in Generation

• Can achieve Part 2 only by overall reduction in sludge generation.

• Zero sludge generation for current year automatically achieves goal.

50% Reduction in Metals to Water and Air

• Current year is 50% less than baseline, adjusted for changes in production.

• Includes TRI metals plus cyanide.

• Based on sum of all parameters, do not have to achieve 50% reduction individually.

• Based on available data, additional monitoring not required.

98% Utilization

Two methods for determining achievement/ progress:– Facility is recycling 100% of sludge.– Current year sludge reduction is 50% less

than baseline, adjusted for changes in production.

98% Metals Utilization: 100% Recycle Method

• This is a new method of calculating progress.

• 100% of waste treatment sludge is recycled.

• Zero sludge generated for current year automatically achieves goal.

98% Metals Utilization: 50% Reduction Method

• Sludge quantity is determined on a dry weight basis.

• Companies with zero sludge generation for the current year automatically achieve this goal.

90% Reduction in Organic TRI Emissions

• Current year is 90% less than baseline, adjusted for changes in production.

• Painting-related emissions are not counted.

• Companies with zero emissions for current year automatically achieve this goal.

Reduction in Human Exposure

• This has been revised for 2000.

• Based on responses to four human exposure questions.

• Only considers current year information—not compared to baseline.

Significance of SGP Worksheets

• Maintain active status in SGP for participating companies.

• Provide data for measuring progress toward seven “core goals” and other SGP objectives.

• Aggregated data measure program impacts at national, state, and local levels.

Strategic Goals Program/Worksheets

General Suggestions:• Use most current Worksheet• Refer to “Worksheet Instructions”• Print clearly (or type)• Fill out as completely as possible• Attach explanations, (when necessary)• Call or email George Cushnie with questions

– 703-264-0039– geoc@nmfrc.org

Data CollectionPrimary Data Sources

• Water/sewer bills• Energy bills• Laboratory records• Purchasing/inventory

records• Production logs• Process solution logs• Financial records• MSDS/Suppliers

• Mandated reporting and recordkeeping– CWA– RCRA– CAA– EPCRA

• P2 and other plans• Observations• Interviews

Worksheet Due Dates

• Existing SGP Companies:– Mailed to existing SGP companies in early January– Due by March 1 for the proceeding year

• 1999 data were due on Feb 15, 2000• 2000 data are due March 1, 2001

• New SGP Companies:– Current year due 60 days from sign-up

I. Background Information

II. Accounting for Changes in Production

II. Accounting for Changes in ProductionSelecting a Baseline Year

• Use any year from 1992-2000.

• If missing any baseline data (e.g., electricity), use data from the next closest year for which data are available.

II. Accounting for Changes in Production

• Provide as many as are relevant.• To use a current year factor, there must be a

corresponding baseline factor.• Sales and labor hours--only use metal

finishing related values.• Most companies don’t know surface square

feet---however, if they do, this is an excellent normalizing factor.

II. Accounting for Changes in Production

Other Normalizing Factors

• Rectifier amp hours (Cr plating)

• Layer surface square feet (PWB)

• Weight of parts processed (mass finishing, barrel plating)

• Pounds of anodes or chemicals used

• Energy use

Usable Not Usable

III. Water and Wastewater

III. Water and Wastewater

• Check “Yes” if company discharges process wastewater from metal finishing to either a POTW or receiving stream.

• If there is a discharge, enter the volume of fresh water used in metal finishing and the volume discharged.

III. Water and Wastewater

• Use laboratory reports, discharge summary records, and/or compliance reports.

• Calculate and enter average concentration of each metal for reporting year.

• If any parameter is not measured at end-of-pipe, attach explanation.

III. Reasonable Values for Water Use

Gals/$

High 10.0

Low 0.1

Avg. 2.91

Median 2.19

Std. Dev. 2.45

IV. Wastewater Treatment Sludge

IV. Wastewater Treatment Sludge• Refers to wastewater treatment sludge only.• Do not include other hazardous wastes, such as tank bottoms or

ion exchange canisters.• Row 1: Amount of all WWT sludge generated during reporting

year.• Row 2: Amount from row 1 that is sent off-site for land

disposal as hazardous waste.• Row 3: Amount from row 1 that is sent off-site for

recovery/recycle.• Row 4: Average water content of WWT sludge.• Row 5: Indicate dewatering method(s).

IV. Reasonable Sludge Values

Lbs. Sludge/$1000

High 71.4

Low 0.31

Avg. 17.9

Median 13.5

Std. Dev. 17.6

V. Inorganic Emissions to Air

V. Inorganic Emissions to Air

• Most companies do not have air emissions data, unless they are chromium platers or chromic acid anodizers.

• Some companies have estimates that were reported under EPCRA.

• If no data or estimates are available, leave Part V blank.

VI. Organic Chemical Emissions

VI. Organic Chemical Emissions

• Most organic chemicals used by metal finishers are used for cleaning.

• Examples are on worksheet.

• Check the company’s TRI From R for applicable organic chemicals.

• Most releases are to the air rather than water.

VII. Energy Use

VII. Energy Use

• All companies use electricity and most use natural gas.

• About 25% of companies use fuel oil (usually #2).

• A small percentage use other energy sources (e.g., propane).

VII. Reasonable Data for Energy Use

kWh/$ Therms/$

High 0.83 0.11

Low 0.1 0.01

Avg. 0.39 0.03

Median 0.36 0.02

Std. Dev. 0.17 0.02

VIII. Compliance with Envirn. Stds.

IX. Reduction in Human Exposure

X. Resource Utilization and Compliance Costs

Data Availability

In order to preserve your confidentiality, each

worksheet sent to the NMFRC is stripped of its contact

and company information. Your facility is given a unique

ID number before data are publicly displayed. IF YOU

STILL HAVE PROPRIETARY CONCERNS ABOUT

THE ANONYMOUS DISPLAY OF YOUR FACILITY’S

PROGRESS, MARK YOUR WORKSHEET

“CONFIDENTIAL.” If marked "confidential," your data

will only be use to compile aggregate industry results.

Additional Resources

SGP Web Site– SGP info.– Worksheets– Progress Reports– Cost Reports– Worksheet Database– Benchmarking