Early Findings of the Pollution
Prevention Program - June 1995
Part II: Preliminary Results of Industrial
The Department of Environmental Protection estimates that
486 facilities were required by the Pollution Prevention Act
to prepare Pollution Prevention Plans and Plan Summaries by
July 1, 1994. Of these facilities, 408 facilities had submitted
Plan Summaries; and were entered into the Department's pollution
prevention database as of April, 1995. Of the 78 facilities
that had not submitted Plan Summaries, 36 had stated in writing
their intent to submit a Plan Summary in the near future.
The remaining 42 facilities were unresponsive. Counting those
who have submitted Plan Summaries or who have stated in writing
that they will do so in the future, the compliance rate for
submittal of Plan Summaries is approximately 90%.
The Department is currently undertaking a detailed analysis
of the data submitted on the Pollution Prevention Plan Summaries
and will issue a report in fall 1995 that will outline pollution
prevention trends. These preliminary data are intended to
give a brief overview of some of the general findings, to
date, from a cursory review of the Plan Summaries. The Department's
fall 1995 report will combine its analysis of Plan Summaries
with analysis of relevant data reported under the federal
Toxics Release Inventory and the Environmental Release and
Pollution Prevention Report of the Department's community
Right-to-Know Program (also known as the DEQ-114).
Outlined below are some basic findings from the Plan Summaries:
of the 408 facilities that submitted Plan Summaries made
a confidential information claim. Pursuant to the Department's
Pollution Prevention Rules, the confidential version of
the Summary is automatically treated as confidential and
a company-sanitized version of the form is entered into
- Approximately 75% of the facilities that submitted Plan
Summaries had reduction goals greater than zero for at least
one chemical. Approximately 48% of the facility-wide chemical-specific
reports, however, showed reduction goals of zero. Of the
408 facilities which reported, 111 had reduction goals of
zero for all chemicals. The charts below show distributions
of facility-wide use and nonproduct output (npo) goals for
individual chemicals and for all chemicals reported
by each facility.
- The mean number of covered chemicals per reporting facility
is 4. Of the 405 facilities in the database, 29 reported
more than 10 chemicals, and 114 reported only one chemical.
- The total goal for the reporting facilities for reducing
the use of hazardous substances over five years is approximately
120 million pounds. However, in its review of Summaries
of those facilities contributing the largest quantities
to this total, the Department determined that some facilities
erroneously included reduction quantities in their goals
which represent processes which have been, or are planned
to be, shut down. These quantities have been removed from
the totals outlined in this report. The Department intends
to conduct additional quality checks to determine any other
facilities which may have made the same reporting error.
The 5-year 120 million pound use reduction goal translates
to reductions of approximately 24 million pounds per year
(assuming uniform progress). Total statewide use of hazardous
substances by covered facilities is approximately 4 to 5
billion pounds per year.
- The projected 5-year NPO reduction goal is approximately
66 million pounds. This number also may be inflated by inclusion
of quantities from processes which have been, or will be,
shut down. The 5-year 66 million pound NPO reduction goal
translates to reductions of approximately 13 million pounds
per year. (assuming uniform progress). Total statewide generation
of hazardous substance NPO by covered facilities was 320
million pounds in 1993.
- Approximately 13.4 percent of the facilities took advantage
of the opportunity to fill in the optional section indicating
reductions between 1987 and the base year. The total use
reductions in the optional section were 32.2 million pounds.
The total NPO reductions were 30.0 million pounds, and the
total release reductions were 9.3 million pounds. Most facilities
calculated their reductions in this optional section from
1987; a few started with a later year.
- Nearly half of the total use goal is accounted for by
one facility, the DuPont Chambers Works, in Deepwater. Over
half of the NPO total is also accounted for by the same
DuPont facility. In the case of both use and NPO totals,
several other very large firms contribute most of the remaining
total; small contributions from many smaller facilities
make up the balance.
- The mean number of production processes at facilities
- According to the data reported on the Summaries, most
production processes in New Jersey are batch processes.
Of 1874 manufacturing processes, only 209 (11%) are continuous.
Of all manufacturing processes reported, approximately 60%
produce chemicals and approximately 30% produce articles.
Of the 60% that produce chemicals, almost all (93%) are
batch processes. Of the 30% that produce articles, 83% operate
in the batch mode.
- Overall, about 50% of the processes use more than one
chemical. The average goals per unit of product for all
chemicals for each type of process do not differ significantly
except for one type of fairly uncommon process. This type
is "separate storage and handling". In the database,
there are 62 processes described in this way. For these
processes, the average per unit of product npo reduction
goal is 44%, which is significantly higher than the use
and npo reduction goals for all other types of processes.
- The 6 chemicals with the largest total USE reduction
Chemical 5-year USE Reduction Goal (millions
Sulfuric acid 29.1
Nitric acid 12.2
Benzyl chloride 6.6
Copper compounds 5.2
- The 6 chemicals with the largest total NPO reduction goals
Chemical 5-year NPO Reduction Goal (millions
Sulfuric acid 22.9
Hydrochloric acid 14.6
Toluene . 4.1
Methyl Ethyl Ketone 2.3
- Process-specific data differs from facility-wide totals,
in that it does not aggregate across all processes at a
facility. Facilities reported that some production processes
had greater opportunities for pollution prevention. The
types of processes for which NPO reduction goals per unit
of product averaged more than 35% include:
AA6 (coating, adhesive application)
- Certain combinations of specific chemicals and production
processes are associated with large use reduction goals
per unit of product. The three combinations associated with
the largest average use reductions are:
- The three combinations associated with the largest average
NPO reductions are:
ethylbenzene/CP3 (formulation blending)
- In their Summaries, facilities report the pollution prevention
methods that they intend to apply to achieve their goals.
Facilities report some pollution prevention methods are
associated with higher average reduction goals. The pollution
prevention methods associated with the highest use reduction
* raw material substitution
* substituting different coating materials
* changing to aqueous cleaners.
- Pollution prevention methods associated with the highest
NPO reduction goals per unit of product are:
* modification of stripping and cleaning equipment
* reuse and recovery procedures
* substitution of different coating materials.
- The average use and NPO goals per unit of product for
each chemical among all targeted processes was calculated.
One chemical has much higher reduction goals than all the
others; 1,1,1-trichloroethane (methyl chlorofo).rm This
chemical is among those whose production will be phased
out by the end of 1995 pursuant to international agreement.
For chemicals reported by 25 or more facilities, those with
the 10 highest percentage reduction goals for both use and
npo per unit of product are shown in the graphs below.