Center for Industrial Services

In this issue ...

1. EASTMAN CHEMICAL COMPANY RECEIVES GOVERNOR’S AWARD FOR EXCELLENCE IN HAZARDOUS WASTE MANAGEMENT
2. DON’T WASTE YOUR CRTs: THEY’RE HAZARDOUS WASTE
3. SALES OF SOLAR CELLS TAKE OFF
4. OSHA ISSUES FINAL RULE ON RECORDING HEARING LOSS
5. THOUSANDS OF LOST-TIME INJURIES REPORTED IN 2000
6. WORKER COMP BENEFITS IN 2000 DROPPED BY 39 PERCENT FROM 1992 PEAK
7. GROW YOUR POLLUTION PREVENTION PROWESS AT PLANTING P2, THE TENNESSEE POLLUTION PREVENTION PARTNERSHIP'S CONFERENCE
8. QUALITY, MANAGEMENT, AND ENVIRONMENTAL, HEALTH AND SAFETY WORKSHOPS MAY: August - September

EASTMAN CHEMICAL COMPANY RECEIVES GOVERNOR’S AWARD FOR EXCELLENCE IN HAZARDOUS WASTE MANAGEMENT

Eastman Chemical Company of Kingsport, Tenn., was awarded the Governor’s Award for Excellence in Hazardous Waste Management during the 2002 Annual Solid and Hazardous Waste Conference. This award is made annually to Tennessee companies that show an outstanding commitment to reducing hazardous waste and preventing pollution. Following is an abstract of the nomination for Eastman’s recent award-winning environmental accomplishments:

On April 19, 1996, EPA proposed the hazardous waste combustor Maximum Achievable Control Technology (HWC MACT) rule. As proposed, the rule would establish new emission standards for Eastman’s existing hazardous waste combustors. Although Eastman’s existing equipment might be able to comply with the new rule, Eastman decided to upgrade its incinerators to ensure the units would reliably meet the proposed new standards. It is important to note that Eastman proceeded proactively to evaluate the new rule prior to EPA’s initial publication.

Eastman’s engineering and operation personnel, working with Franklin Engineering Group, conducted a study of the incineration complex to define opportunities for improved operation and to review technology advancements. Based on these studies, phase one of the plan was implemented in 1996 with the installation of a new distributed control system to provide an infrastructure adequate to support increasingly complex system control and recordkeeping requirements. The cost was $7,000,000.

Upon publication of the proposed HWC MACT rule, Eastman requested bids from 15 vendors for upgrades identified in the engineering studies. Eastman used the team approach to evaluate vendors’ proposals for the upgrades necessary to reliably meet the standards. In 1997, the vendor proposal chosen was not the least expensive option but rather the technology package that would provide the company with a “showcase” state-of-the-art facility that would reliably perform for many years. These upgrades involved replacing all existing air pollution control equipment with new technologically advanced air pollution equipment that would reduce emissions below the proposed HWC MACT standards. Although Eastman could have simply installed a new final “polishing” stage to its existing air pollution control equipment to meet the proposed stands, the company opted to design and build an integrated system.

All stakeholders in the process, including vendors and construction teams, understood Eastman’s goals. The combination of air pollution control equipment technology at this facility is not used anywhere else in the nation. This was and is an ongoing massive construction project. The cost of these upgrades will exceed $50,000,000. Eastman proceeded in a proactive manner and received the necessary permit modification in August 1999 to begin the upgrades to the smallest of three incinerators (Chemical Liquid Destruction) prior to publication of the final HWC MACT rule. This was one of the first, if not the first, facility in the nation to request and receive approval to conduct these MACT upgrades. The upgrades were completed in January 2000. Emission testing documented that the new unit comfortably met all existing permit emission limits and all new proposed emission limits under worst-case operating conditions.

In January 2000 Eastman received approval to proceed with upgrades to the other two large incinerators (rotary kilns). The upgrades to number one line were completed in August of 2001. Emissions testing was completed in November of 2001. Upgrades to kiln number two are scheduled for early 2003.

Because Eastman considered the public to be a stakeholder in this process, it provided information to its Citizen’s Advisory Panel consisting of members of the local community, including representatives from local schools, clergy, Eastman neighbors, elected officials, and physicians. Stories concerning the installation were presented on local television stations and in the local newspapers. Additionally, throughout this project several public notices were issued, and public meetings were held to inform the community of activities associated with the upgrades.

Congratulations to Eastman Chemical Company for this well-deserved honor.

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DON’T WASTE YOUR CRTs: THEY’RE HAZARDOUS WASTE

Just say yes to recycling. At least that’s what the EPA proposes. What happens when your computer becomes obsolete, or the television conks out or simply become too old? How you handle your electronic wastes could be affected by EPA’s newly proposed hazwaste rule.

Computer monitors, televisions and other electronic equipment have cathode ray tubes (CRTs) that contain lead and various other chemicals such as mercury, cadmium, and arsenic. CRTs are currently classified as hazardous wastes under the Resource Conservation and Recovery Act (RCRA) and are subject to stringent and costly disposal regulations.

The new rule proposes an exclusion from the definition of solid waste for CRTs and the glass removed from them if they are recycled. The proposed rule also would treat unused CRTs and used, intact CRTs the same with respect to recycling. Used CRTs would then be treated as an exempt commodity rather than as RCRA-regulated waste.

Advances in digital technology (e.g., flat panel displays) are likely to reduce the repair and resale value of older televisions, just as advances in computer speed and software have made it uneconomical to repair older computer hardware. Many facilities don’t know what to do with their old equipment. Therefore, approximately 20 to 24 million computers and televisions are added to storage each year. The new rule would help encourage a responsible way to manage your electronic waste.

Under the proposed rule, your options would include the following:

• Reuse. There are numerous nonprofit organizations, such as charities and schools, that take donations of used electronic equipment.
• Recycle. Many counties have drop-off centers or TV repair shops to take your old monitors. Some manufacturers and retailers even have recycling program incentives.
• Dispose. If neither of the above work for you, there are always municipal landfills and waste-to-energy (WTE) facilities. But remember, if you recycle, it’s not waste. If you don’t recycle, you’re subject to RCRA requirements for handling.

Outlook: As technology progresses, electronic waste issues are coming to the forefront of environmental concerns at a rapid pace. The message EPA is sending is that facility owners and original users of CRTs need not have specialized knowledge to decide the future of their accumulating e-waste. Sending used CRTs to resellers for potential reuse does not make you a RCRA generator. By lessening the regulatory burden, EPA hopes to encourage recycling of such equipment.

--From BLR “EHS e-Lert!”

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SALES OF SOLAR CELLS TAKE OFF

In Japan, the top five producers of solar cells in 2001 were Sharp, BP Solar, Kyocera, Siemens Solar, and AstroPower, accounting for 64 percent of global output. Japanese manufacturers, with 43 percent of the world total, benefited from government policies to encourage solar cell use. The 70,000 Roofs Program, which initially provided a 50 percent cash subsidy for grid-connected residential systems, has been the primary driver of Japan's photovoltaic (PV) market expansion. The subsidy declined to 35 percent in 2000 as production increased and solar cell prices dropped. In addition to residential subsidies, government spending of $271 million in fiscal year 2001 -- on research and development, demonstration programs, and market incentives -- was key to the growth.

In contrast to Japan, the U.S. government spent only $60 million on solar programs in 2000. The 24 percent U.S. share of the global market was surpassed in 2001 by the European Union (EU), which now accounts for 25 percent. Government commitments to renewable energy are more robust in the EU than in the United States. In Germany, the Renewable Energy Act of 2000 offers citizens preferable loan terms for purchasing solar systems and gives them a guaranteed price when feeding excess energy back into the power grid (known as net metering). As a result of such support, the German PV industry, the most advanced in Europe, is projected to grow from its current installed capacity of 113 MW (megawatts) in 2001 to 438 MW by 2004.

As a result of government policies in Japan, grid-connected residential installations totaling 100 MW dominated sales in 2001. Germany's grid-connected systems accounted for around 75 MW. The 32 MW installed in the United States were divided between grid-connected systems and those in remote areas not linked to a power grid. All of India's 18 MW were for off-grid installations. The 120 to 130 MW installed in some 50 to 60 developing nations were also for off-grid projects.

Both Japan and the United States were net exporters of solar cells in 2000. Almost two-thirds of U.S. output was exported, while Japan exported 42 percent of its total.

The cost of electricity from solar cells remains higher than from wind or coal-fired power plants for grid-connected customers, but it is falling fast due to economies of scale as rising demand drives industry expansion. Solar cells currently cost around $3.50 per watt for crystalline cells, and $2 per watt for thin-film wafers, which are less efficient but can be integrated into building materials. Industry analysts note that between1976 and 2000, each doubling of cumulative production resulted in a price drop of 20 percent. Some suggest that prices may fall even more dramatically in the future.

Recent research surrounding zero-energy homes, where solar panels are integrated into the design and construction of extremely energy-efficient new houses, presents a promising opportunity for increased use of solar cells. Julius Poston, a progressive builder in the southeastern United States, builds homes that use half the energy of typical ones. His company, Certified Living, has constructed two prototype zero-energy homes with integrated solar panels. If eventually adopted on a wide scale, this ground breaking concept could eliminate the pollution associated with fossil fuel-generated electricity for households.

Continued strong growth suggests that the solar cell market will play a prominent role in providing renewable, non-polluting sources of energy in both developing and industrial countries. A number of policy measures can help ensure the future growth of solar power. Removing distorting subsidies of fossil fuels would allow solar cells to compete in a more equitable marketplace. Expanding net metering laws to other countries and the parts of the United States that currently do not have them will make owning solar home systems more economical by requiring utilities to purchase excess electricity from residential solar systems. Finally, revolving loan funds and other providers of microcredit are essential to the rapid spread of solar cell technologies in developing nations.

Solar cell manufacturers are beginning to sense the enormous growth in the market that lies ahead. Japan-based Sharp Corporation, already the world's leading producer of solar cells, plans to double its capacity in 2002, going from 94 to 200 megawatts. For the industry as a whole, output is expected to increase at 40 to 50 percent annually over the next few years, bringing the solar age ever closer.

--From Sustainable Business, 2002

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OSHA ISSUES FINAL RULE ON RECORDING HEARING LOSS

On July 1, 2002, OSHA issued a final rule revising its employer requirements for recording job-related hearing loss. Beginning January 1, 2003, employers will have to record work-related hearing loss cases when an employee’s test shows a marked decrease in overall hearing. Employers can make adjustments for hearing loss caused by aging, seek the advice of a physician or licensed healthcare professional to determine if the loss is work related, and perform additional hearing tests to verify the persistence of the hearing loss.

Under the new criteria, it will be necessary to record 10-decibel shifts from the employee’s initial hearing test when they also result in an overall hearing level loss of 25 decibels. The old criteria required recording only 25-decibel shifts. Commenting on the change, OSHA administrator John Henshaw said, "Hearing loss can result in a serious disability and put employees at risk of being injured on the job." He believes the new approach will help employers better protect their workers.

OSHA also announced it is seeking public comments on a proposed one-year delay of the recordkeeping rule’s definition of musculoskeletal disorders (MSDs) and whether to include MSDs and hearing loss columns on the OSHA Form 300 Log of Occupational Injuries and Illnesses.

--From BLR “EHS e-Lert!”

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THOUSANDS OF LOST-TIME INJURIES REPORTED IN 2000

During 2000, 4,559 workers every day were hurt seriously enough on the job to require time off to recuperate, according to the Bureau of Labor Statistics. Truck drivers, laborers in non-construction jobs, and nursing aides and orderlies most frequently suffered these lost-time injuries.

Back injuries continue to put employees out of work. In 2000, 411,000 back injuries occurred -- that's more than 1,000 a day. It's no surprise that overexertion in lifting accounted for 256,000 lost-time injuries. A typical back injury results in six days away from work. The most non-productive injuries involve carpal tunnel syndrome; cases average 27 days away from work. Forty-five percent of carpal tunnel cases keep workers off the job for more than a month (31 days or more). There's no doubt lost-time injuries, as their name implies, hurt productivity. The average lost-time case keeps a worker off the job for more than a week.

The price paid for lost-time cases is a major reason that many injured workers are being brought back for restricted duty. Restricted duty cases jumped nearly 70 percent in the 1990s, leveling off at about one million for the last three years.

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WORKER COMP BENEFITS IN 2000 DROPPED BY 39 PERCENT FROM 1992 PEAK

Workers' compensation benefit payments and costs declined in 2000, marking the eighth straight year of declining benefits relative to covered wages and the seventh consecutive year that employer costs declined relative to wages, according to a new report released by the National Academy of Social Insurance.

Workers' comp benefits for every $100 in wages dropped by 39 percent from their peak of $1.68 in 1992 to $1.03 in 2000. Employer costs declined by 42 percent between 1993 and 2000, or from $2.16 to $1.25 per $100 of wages. The number of workplace accidents resulting in lost workdays plummeted from 3.0 per 100 workers in 1992 to 1.8 per 100 workers in 2000, according to the Labor Department. But there are also concerns that the drop in comp costs stems from more injured workers being denied benefits as states have tightened eligibility rules for workers' compensation, and more aggressive -- some say too hasty -- return-to-work programs. (Injury cases resulting in restricted work activity have climbed dramatically since the early 1990s.) These trends are examined in the NASI Brief, Workers' Compensation and Older Workers.

--From “Safety Currents”

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GROW YOUR POLLUTION PREVENTION PROWESS AT PLANTING P2, THE TENNESSEE POLLUTION PREVENTION PARTNERSHIP'S CONFERENCE

Regardless of where your company is in its pollution prevention activities, the Planting P2 conference can nourish your growth. This conference is presented by the Tennessee Pollution Prevention Partnership (TP3), organized by TDEC’s Division of Community Assistance. TP3 is a statewide network of schools, community organizations, government agencies, businesses, households, and manufacturers united to promote environmental excellence through pollution prevention.

This year’s conference is designed to encourage and assist Tennessee industries in developing a new appreciation and responsibility for our shared environment. You will hear environmental success stories straight from company representatives. You will network with other companies working on goals similar to yours. And, you will learn how to earn recognition for your environmental good deeds from your peers and from the state of Tennessee.

The conference will be held at Montgomery Bell State Resort Park September 5 - 6, 2002. Register for this unique experience today! Call (888) 615-7497 for more information or to receive a registration form by fax.

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QUALITY, MANAGEMENT, AND ENVIRONMENTAL, HEALTH AND SAFETY WORKSHOPS - August- September

For more information about the courses listed below, please visit our Web site. Or, call us: (615) 532-8657 or toll-free at (888) 763-7439. To register for any of these courses, please use this registration form.

QUALITY MANAGEMENT

ISO 9001:2000 Internal Auditor

• Knoxville -- September 17-18

ENVIRONMENTAL MANAGEMENT

Hazardous and Special Wastes

• Chattanooga -- September 25
• Jackson -- September 26

Tennessee Environmental Regulatory Overview

• Knoxville-- August 28
• Memphis -- August 14
• Nashville -- August 21

HAZARDOUS WASTE/CHEMICAL SITE WORKER

24-Hour HazMat Chemistry

• Gatlinburg -- August 27-29

40-Hour Site Worker

• Memphis -- September 16-20

8-Hour Site Worker Refresher

• Memphis -- August 13
• Nashville -- September 4

24-Hour Emergency Response Technician

• Murfreesboro -- September 23-25

8-Hour Emergency Response Refresher

• Memphis -- August 14
• Murfreesboro -- September 26

DOT COMPLIANCE

16-Hour DOT

• Knoxville -- August 7-8
• Nashville -- September 5-6

SAFETY

8-Hour Excavation Competent Person

• Murfreesboro -- September 27

In-plant courses on topics such as Lean Manufacturing, Quality Management, Human Performance Technology, eBusiness, Manufacturing Management and Operations, and Environment, Health and Safety also are available on your schedule. Please visit our Web site for course information, or call us at (615) 532-8657 or (888) 763-7439 to request a catalog.

SUBSCRIBE FREE: http://www.tmep.utk.edu/

Feedback by e-mail: gsmelcer@tennessee.edu
Feedback by phone: (615) 532-8657 or (888) 763-7439
WRAP Sheet archive: http://www.tmep.utk.edu/formspub.html
WRAP Sheet is published by the Tennessee Manufacturing Extension Program: http://www.tmep.utk.edu

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