Using E3 to Incorporate Sustainability and Green

Technologies in Tonawanda, NY

Patricia Donohue, MS, QEP

New York State Pollution Prevention Institute

Copyright © 2015 Rochester Institute of Technology (RIT)

Contains portions of some materials initially prepared with support of the New York State Department of Environmental Conservation for

New York State Pollution Prevention Institute at Rochester Institute of Technology.

New York State Pollution Prevention Institute(NYSP2I)

Vision:

The vision of the NYSP2I is to foster the transformation and development of sustainable businesses and organizations in New York State in a collaborative program committed to making the State a leader in environmental stewardship

Mission:The mission of the Institute is to provide a high-impact, comprehensive and

integrated program of technology research development and diffusion, outreach, training and education aimed at making New York State more sustainable for workers, the public, the environment and the economy through:

• reductions in toxic chemical use• reductions in emissions to the environment and waste generation• the efficient use of raw materials, energy and water

- Core funding from NYS Department of Environmental Conservation

- Statewide Coverage

- Committed Partnerships:

- 4 Universities

- 10 Manufacturing Extension Partnerships (NYS Regional Technology Development Centers)

New York State Pollution Prevention Institute(NYSP2I)

NYSP2I

Rochester Institute of Technology

• Founded in 1829

• One of America’s leading technological universities

• More than 17,000 students

• Among the nation’s 15 largest private universities

• Bachelor’s, Master’s, and Ph.D. programs

GOLISANO INSTITUTE FOR SUSTAINABILITY

• Academic Programs and Applied Research Labs

Enhancing the environmental and

economic performance of products and processes

Condition AssessmentMaterials Aging and

Restoration

Alternative Fuel Propulsion

Technologies

Center for Sustainable

Mobility

Center of Excellence in Sustainable Manufacturing

Center for Remanufacturing

and Resource Recovery (C3R®)

NanoPowerResearch

Laboratory

Development &Characterization of

NanomaterialsIndustrial Sustainability Assessments

Sustainable Supply Chain Green Technology Accelerator

NYS Pollution PreventionInstitute

Industrial OutreachManufacturing Tech

and training

Center for Integrated

Manufacturing Studies

Using E3 to Incorporate Sustainability and Green Technologies in Tonawanda, NY

• The Challenge – Conditions in Tonawanda

• The Concept – E3 Initiative

• The Companies – NYSP2I Assistance

• The Conclusion – Sustainable Results

7

• One of the highest densities

of industrial development in

New York State (59 facilities).

• 2008 TRI reported

approximately 1 million

pounds of toxics released

from the 10 biggest facilities.

Map of Tonawanda

Manufacturing FacilityResidential Neighborhood

The Challenge:Industrial and Residential - Conflicting Land Uses

9

NYSDEC Air Monitoring Study: Six HAPs Exceeded Guideline Concentrations

Benzene: fossil fuel combustion (FF), manufacturing

Formaldehyde: FF, manufacturing, atmospheric

1,3 Butadiene: FF, manufacturing

Acetaldehyde: FF, manufacturing, atmospheric

Acrolein: FF, manufacturing, atmospheric

Carbon Tetrachloride: atmospheric, historical artifact

Sources vary according to chemical, but approximately:

15%-95% from large stationary sources, including both fossil fuel combustion and manufacturing

5%-60% from mobile sources, fossil fuel combustion

10% from atmospheric oxidation (transport from other areas)

Lead Technical Resource

in Tonawanda

E3 Initiative

The Concept:

Introduction to E3

E3 — Economy, Energy, and Environment — is a coordinated

federal and local voluntary technical assistance initiative that helps

communities work in conjunction with their manufacturing base to

adapt and thrive in a new business era focused on sustainability while

using green technology. EPA, DOE, DOL, DOC, SBA, USDA

All projects pursued under E3 are focused on achieving the following five goals:

1. Increased energy efficiency and sustainability;

2. The provision of valuable technical training, jobs and skills training,

assessments and support;

3. Improved profitability of the local economy;

4. Enabling growth; and

5. Creating and retaining manufacturing jobs.

The Tonawanda E3 Sustainability Initiative

Goal: Improve overall air and environmental quality for the Tonawanda Community and Workforce

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NYSP2I & Tonawanda E3

NYSP2I is the lead technical resource for Tonawanda E3 in assisting to develop and invest in pollution prevention and green engineering technologies

NYSP2I, with the assistance of the E3 Stakeholder Committee, initially identified a number of prospective companies in the Tonawanda area for assistance using:

– NYSDEC “Tonawanda Community Air Quality Study”

– US EPA Toxics Inventory Reporting database

– Existing relationships with Insyte Consulting (local MEP) and the Town of Tonawanda

– NYSP2I “priority sector list”, based on our target study performed at NYSP2I to identify manufacturing sectors that:

1. Generate large quantities of toxic and hazardous wastes

2. Contribute significantly to the New York State economy

Submitted for an EPA SRA Grant –Lean, Energy, and Environment (LE2)

• Focuses on a manufacturing process

• Provides a comprehensive assessment balancing

the objectives of all three areas (Lean, Energy, &

Environment) to achieve optimum results

• Prioritizes environmental impacts or waste streams

• Processes are improved as a whole system to result

in an enhanced process without sub-optimization

(i.e. saving pennies on one aspect only to lose

dollars on another aspect)

LE2 Approach

To assist Tonawanda companies, NYSP2I partnered with:

• Insyte Consulting

• RIT’s Golisano Institute for Sustainability

The process steps for company engagement include:

(a) Scoping - initial contact and discussion with a company, and the identification of improvement opportunities;

(b) Assessment - assistance with the development of a baseline, and the development of product and process improvement recommendations, including cost and engineering feasibility analyses; and

(c) Implementation - technical assistance in support of the implementation of recommended solutions, including annual follow-up to track critical environmental and cost metrics.

The Companies:

Out of the 59 facilities, 12 were prioritized for outreach

Outreach began in fall of 2011 - took over one year for companies to sign up

NYSP2I, Town of Tonawanda, Insyte reached out to 12 companies

EPA Regional Administrator Judith Enck and ESD Regional President Sam Hoyt met with companies

Challenges included: Working through large company hierarchy, existing resources, finding right lead

Building constructive relationships

Identifying voluntary projects

Need for confidentiality while work is underway

Reporting out to community

Connecting projects to company and E3 goals

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Air Compressor Energy Savings in Automotive Assembly

General Motors Tonawanda Engine Facility, Tonawanda, NY Facility occupies 3.5 million square feet on 190 acres of property

Central compressed air supply system has a capacity of 40,000 scfm

Plant 4 uses about 20% of the total compressed air generated by the

air compressor supply plant

Work PerformedAudit assessed the potential for energy and cost reduction recommendations for two major aspects of the

compressed air system:

• Supply Side - compressors, dryers, storage, staging, and pressure control

• Demand Side - compressed air system leaks and misapplications

ResultsFour Energy Conservation Measures (ECMs) were recommended that if implemented, in combination,

provide a potential annual savings of $262,600 that may be realized with a payback of 3.1 years.

• ECM-1 Install Smaller Centrifugal Air Compressors

• ECM-2 Install Dewpoint Sensors and Controls on Desiccant Dryers

• ECM-3 Repair Plant 4 Air Leaks

• ECM-4 Install VSDs on Compressor Cooling System Loop Pumps

If all are implemented, there is a potential annual electricity savings of 3,671,680 kWh and greenhouse

gas emissions annual avoidance of 2,591 metric tons of Carbon Dioxide Equivalent (CO2e). This is

equivalent to annual greenhouse gas emissions from 540 passenger vehicles or CO2 emissions from 356

homes’ electricity use for one year.http://www.epa.gov/cleanenergy/energy-resources/calculator.html#results

NOCO Energy –potential 1,785 MMBTU/year reduction of natural gas

Air Emission Quantity Avoided

(with insulation

replaced on 124 ft)

(lbs / year)

Criteria

Pollutant

(Yes / No)

Hazardous Air

Pollutant

(Yes / No)

Greenhouse Gas

Contributor

(Yes / No)

Nitrogen Oxides (NOx) 175 Yes No Yes

Nitrous Oxide (N2O) 4 Yes No Yes

Carbon Monoxide (CO) 147 Yes No No

Lead 0.001 Yes Yes No

Total Particulate Matter (PM) 13 Yes No No

Sulfur Dioxide (SO2) 1 Yes No No

Carbon Dioxide (CO2) 209,969 No No Yes

Total Organic Compounds (TOC) 19 No No No

Volatile Organic Compounds (VOC) 10 Yes No No

Methane 4 No No Yes

**Benzene 0.004 No Yes No

**Formaldehyde 0.131 No Yes No

Source: U.S. EPA “AP-42, Compilation of Air Pollutant Emission Factors”, http://www.epa.gov/ttnchie1/ap42/,

2

0

Project Mission: Reduce the amount of Volatile Organic Compounds (VOC) exhausted

at the Goodyear Dunlop Tire North America (GDTNA) Plant located

in Tonawanda, New York. Reduce the amount Cement applied to

the end of treads on the 224 and 227 Extruding lines and reduce

the amount of dollars spent on Tread-End Cement.

Improvement Goals Current State

Future Goal

1. Reduce VOC at Buffalo Plant Not Optimal Better

2. Reduce Tread-End Cement6.8

grams/Tread3.5 grams/

Tread

3. Reduce Tread-End Cement Cost$54,000 /

Year$24,000 /

Year

Title: Tread-End Cement Reduction

Improvement Category:

X Safety Delivery

X Quality X Engagement

X Cost X Communications

Buffalo Plant Continuous Improvement Project

Line 224 Pilot results – 3.3 grams/tread

0

2

4

6

8

10

12

Jan-14 Feb-14 Mar-14 Apr-14 May-14 Jun-14 Jul-14 Aug-14 Sep-14

Gra

ms

/Tre

ad

Date

Goodyear Dunlop Tires North America, LTD. Tonawanda, New York

Monthly Average of Grams VOC per Tread End Cemented2014 Dept. 228

Dept. 224

Dept. 227Average monthly regulatory limit = 10 grams / tread.

No cementing in D228

• Improved gun height above the tread• Changed photo eyes from AC to DC• Shortened air lines between solenoid valves and

spray guns

Baseline = 6.8 grams / tread

New Average =

3.3 grams / tread

PeroxyChem LLC manufactures hydrogen peroxide, peracetic

acid, persulfates and adjacent technologies in Tonawanda, NY.

Work Performed

Evaluated new metal cathodes to find the root cause of

corrosion and shorter life-span using Scanning Electron

Microscope (SEM) analysis and SEM Energy Dispersive X-ray

(EDX).

Identified potential coatings and conducted accelerated

corrosion and delamination tests.

Results

Determined original coating had poor performance and the new

metal had a manufacturing defect.

Identified an alternative coating material that can potentially

withstand the process environment, prevent corrosion, and

provide improved longevity for the new cathode metal.

Should the new coating material be implemented, it would

enable the replacement of the previous cathode metal thereby

eliminating toxic materials and the generation of over 1,000

pounds of toxic hazardous waste.

Assessment of Alternative Coatings for Improved

Cathode Longevity and Toxic Metal Elimination

Laboratory setup for accelerated

corrosion/delamination testing of

coatings on cathode substrates

1500 magnification using SEM

showing a defect as the point of

initiation for the corrosion

The Conclusion:

Engage

Industry

Select

geographic

area

Work

collaboratively

with

stakeholders

Secure funding

streams for

improvements

Strengths of the E3 Model

NYSP2I ResultsFunding:U.S. EPA Source Reduction Assistance

grant 2 years, $130,000 Assess opportunities for local

manufacturers to reduce– energy– environmental impacts – associated costs

Requirements: Screen 8 manufacturing companies for

potential projects

Assess 4 of the screened companies for LE2 projects - Baseline metrics collected

Implement 2 recommendations from the assessment at the assessed companies

Outreach and dissemination of successes after implementation of solutions is completed

Status:

Screened 13 manufacturing companies for potential projects

4 company assessment projects completed with EPA grant

1 feasibility study completed with EPA grant

2 implementations completed with EPA Grant

Resulting in potential reductions:

102,151 lbs of hazardous materials

1,040 lbs of toxic hazardous waste

21,320 lbs of VOC emissions

over 3 million kwh of electricity

3,000 MMBTU of natural gas

5 additional projects in Tonawanda also assisted through NYSP2I funding

© 2014 Rochester Institute of Technology

Copyright © 2015 Rochester Institute of Technology

Contains portions of some materials initially prepared with support of the New York State

Department of Environmental Conservation for New York State Pollution Prevention Institute at

Rochester Institute of Technology.

© 2014 Rochester Institute of Technology

Trish Donohue, MS, QEPSenior Pollution Prevention Engineer

Sustainable Supply Chain Program Manager

New York State Pollution Prevention Institute, at Rochester Institute of Technology

Patricia.Donohue@RIT.edu

(585)425-4638

Thank You!

NYSP2I: http://www.rit.edu/affiliate/nysp2i/