Number of Activities Reported, 2013

To see examples of source reduction activities reported by TRI facilities, click on the color-coded legend next to the pie chart.

• Good Operating Practices (3,941)

  Good Operating Practices

  Examples:

  • An industrial gas manufacturer increased the frequency of its planned maintenance, with a focus on packing and gasket materials. This resulted in decreased emissions and a decreased use of raw materials.
  • The production scheduler and production supervisor at an organic chemicals manufacturer continuously adjust the batch schedule to minimize product changes, which reduces waste from cleanouts.
  • A transformer manufacturing facility reduced overall operator-controlled scrap through a technical hands-on training, funded by a grant from North Carolina. This yielded a 50% overall reduction in operator-controlled scrap.
• Process Modifications (2,287)

  Process Modifications

  Examples:

  • To reduce the amount of solvent used, a plastics product manufacturer modified the facility’s process to allow for an additional cycle of trichloroethylene distillation and use prior to disposal. The change was made in 2011, and from 2010 to 2012, the facility’s trichloroethylene releases declined by 71%.
  • A commercial printer added a more efficient and automated solvent still to improve its recovery of solvents and also installed a more efficient printing press. From 2011 to 2012, the facility reduced its methyl isobutyl ketone waste by 20% while production increased by 15%.
  • One electric generating facility reduced the amount of ammonia used in its selective catalytic reactor to control nitrogen oxides (NOx) emissions by optimizing reaction conditions and replacing ammonia injection control valves.
• Spill and Leak Prevention (1,297)

  Spill and Leak Prevention

  Examples:

  • An organic chemical manufacturer implemented a new policy to reduce spills due to hose failure. This policy requires the electronic identification and annual testing of all hoses that are used to transfer chemicals.
  • A coke plant rebuilt 23 coke ovens and implemented numerous end-flu repairs to reduce the amount of leaks in the ovens. This reduced the facility’s total stack emissions in 2012.
• Raw Material Modifications (1,034)

  Raw Material Modifications

  Examples:

  • A distillery reduced its use of coal for generating steam and relied more on its natural gas boiler instead. This change corresponded with a 30% decrease in the generation of hydrochloric acid aerosols from 2011 to 2012 and reduced greenhouse gas emissions even though production increased.
  • A motor vehicle seating and trim facility is largely eliminating the use of a high xylene content material, except for minor use in service parts manufacturing. Two key technology changes that enabled this change are the use of flame and plasma surface treatments and better formulations of water-based painting technologies. Total disposal or other releases of xylene at this facility fell by 30% between 2011 and 2012, and reductions are expected to continue in 2013.
  • A paper mill installed a new power boiler to generate steam from natural gas rather than coal. Total disposal or other releases of barium compounds from this facility fell by over 40% between 2011 and 2012, even though production associated with barium compounds rose slightly in the same time frame.
• Product Modifications (532)

  Product Modifications

  Examples:

  • A brass and aluminum casting facility is working with customers to replace its current alloy, which has a maximum 6% lead, with a new alloy that has a maximum of 0.09% lead. The facility reports that customers are looking for low-lead or lead free alternative alloys, including national water works associations which require less lead in materials that contact drinking water.
  • A disinfectant products manufacturer is phasing out a cleaning product that uses 2-phenylphenol (OPP) as a reactant and has developed new products that do not use OPP. This has resulted in a large reduction in offsite disposal of this chemical.
  • A fiberglass building insulation manufacturer tested a new resin with lower formaldehyde content for one of its production lines in 2012 and 2013. The facility is working on formally implementing the change.
• Inventory Control (862)

  Inventory Control

  Examples:

  • A communications equipment manufacturer improved inventory scheduling and reduced the quantity of expired products of which it must dispose. This facility also reclaims lead off-site from solder dross and uses on-site administrative controls to maximize the usage of lead solder.
  • Through participative team management, a meat processing facility identified a change in inventory control where the sodium nitrite inventory is carefully controlled using premeasured amounts in small quantity bags.
• Cleaning and Degreasing (396)

  Cleaning and Degreasing

  Examples:

  • Based on an employee recommendation, a fabricated metals facility decommissioned its dichloromethane degreaser in 2012 after purchasing a new parts washer that uses hydrocarbons. This change will entirely eliminate the facility’s use of dichloromethane.
  • An aircraft manufacturer substituted an alkaline cleaning process for some of its tetrachloroethylene degreasing in 2011. Its tetrachloroethylene releases and production-related waste managed declined by about 30% from 2010 (prior to the change) to 2012, even though production increased by more than 30% during this time period.
• Surface Preparation and Finishing (274)

  Surface Preparation and Finishing

  Examples:

  • The engineering team at a coated and laminated paper manufacturing facility has identified a new adhesive coating technique that drastically reduces the need for their main diluent solvent.
  • A farm machinery and equipment manufacturer is in the process of replacing their current paint system with a powder booth, which will begin production in 2014. They expect that releases of 1,2,4-trimethylbenzene will drop below reporting threshold.