“GREEN” CONSTRUCTION AND ENVIRONMENTAL MANAGEMENT SYSTEM IMPLEMENTATION AT A

SMALL PARTS MANUFACTURING FACILITY USING THE CONCEPTS OF INDUSTRIAL ECOLOGY

Jamie RussellLaboratory for Sustainable Solutions

Ferol Vernon (coauthor)President and CEO, SDST, LLC

Dr. Wally Peters (coauthor)Director Laboratory for Sustainable SolutionsLaboratory for Sustainable Solutions

The Building of SDST’s Columbia Facility as a Green and Sustainable Industry

� Developing SDST as a good neighbor to the community: people, critters, and economy – Green Building Practices– ISO 14001 Implementation (using IE concepts)

Green Building Practices

� Site Initiatives--flexible siting to work with the wetlands, advanced jobsite siltation control, low mow/low water landscaping

� Energy Efficiency Measures--high efficiency chiller system, insulated prepoured tilt up slabs, low E glazing, minimal solar gain orientation

� Construction waste recycling-- 73% construction waste recycled or 294 tons diverted from the landfill, at a cost savings vs. landfilling!

C&D Debris Recycling

SDST Columbia Site

Construction Waste Recycling

Summary

Material

Amount Recycled

(yd 3̂)

Amount Recycled

(tons)Recycling

CostsRecycling

Transportation

Amount Landfilled

(yd 3̂)

Amount Landfilled

(tons) Landfill CostsLandfill

TransportationRoofing/Gen 0 0.00 $0.00 $0.00 140 24.53 $343.38 $400.00Gen. Waste 0 0.00 $0.00 $0.00 210 71.90 $1,006.56 $630.00Cardboard 230 7.67 $0.00 $480.00 64 2.14 $29.97 $80.00

Wood 159.6 23.82 $670.99 $1,800.00 0 0.00 $0.00 $0.00Masonry 240 256.80 $600.00 $960.00 8 8.54 $119.61 $80.00Metals 0 0.00 $0.00 $0.00 0 0.00 $0.00 $0.00Plastic 0 0.00 $0.00 $0.00 0 0.00 $0.00 $0.00

Gypsum 30 6.00 $84.83 $150.00 0 0.00 $0.00 $0.00Totals 659.6 294.29 $1,355.82 $3,390.00 422 107.11 $1,499.52 $1,190.00

Trans. costs if landfilled: $1,860.01Current Costs $7,435.34 Cost to Landfill all Materials ($14/ton) $8,669.56

SDST Columbia Site

EPA RTP Project

61.0% NA73.3% 90%

Volume percentage of material recycled to total:Weight percentage of materal recycled to total:

� Must be flexible:– Work with the land not against it– Be able to change design

� Time constraints critical, it’s a one time shot� Must have financial flexibility to incorporate

efficiency that pays off in operation costs� More information:

– www.engr.sc.edu/research/lss

What is an EMS?What Does ISO 14001 Require?

� Use the Deming Cycle (continuous improvement) to establish and maintain an EMS including:

�Management Rev.�Audits�Record Keeping�Training�Corrective Action�Objectives Targets�Emergency Prep.�Aspects Impacts�Operation Control�Legal Req.’s�Doc. Control�Policy Statement

� Appropriate to nature, scale, and environmental impacts of activities, products, or services

� Include commitment to continual improvement and prevention of pollution

� Commitment to comply with environmental regulations (i.e. regulatory compliance)

� Framework for setting and reviewing environmental objectives andtargets

It is the goal of SDST to be a leader in the protection of our world, meeting and exceeding regulatory requirements while creating a model for our community.

Specifically, we will aggressively pursue sustainable solutions for our interactions with the larger environment for the life cycle of our product including:

– Pollution prevention– Manufacturing processes– Product use– Remanufacturing at usable life cycle

These solutions will be created using the principles of industrial ecology.

This includes the concept of continuous improvement, which is a foundation for SDST’s operating philosophy.

It is the responsibility of all SDST associates to work in a safe and environmentally responsible manner.

� Regulatory Requirements (EPA)– Focus on outputs: end of pipe/command and control

� Aspects (Inputs, Outputs, Processes)– ISO focused on but not limited to local operation– IE broadens the focus to life cycle effects

� Impacts (Interaction with Environment)– ISO focus “controlling impacts on the environment”– IE coherence with earth systems

Getting The Big PictureThe Earth is a closed system”

Energy From Sun

Spent Energy(Heat)

The Earth SystemFor over 4 billion years, the Earth System Could be represented by four spheres

Ayres & Simonis (1994)

Modern Earth SystemRecently, we need a fifth sphere to complete the description

Anthrosphere

Ecosystem (subsystem of the Biosphere)Ecosystems are technically considered open systems, but mass is recycled through the system

Industrial System(subsystem of the anthrosphere)Industrial systems are open systems and normally do not recycle mass

Extractors Producers Consumers Disposers

Industrial System: Closing the LoopNeed demanufacturing to close the loop

Extract Produce Consume Demanufacture/Decompose

Sunlight Precipitation

Air Emissions

Noise, Light,Heat

Product, Spent Materials

Sewage, Spent Water, Storm Water

Vehicles, People,Information

Utilities, Materials

Customer

Machining Washing Assemble& Test

Air Emissionsheat, noise

Air Emissionsheat, noise

Air Emissionsheat, noise

CuttingFluid

GrindWheels Steel Cleaning

Fluid Water CalibFluid

Swarf:Steel

AbrasiveFluid

Maint:Oil, Rags,

Filters, Oily Water

SpentCutting Fluid Spent

Wash WaterRejects

Maint:Oil, Rags,

Filters, Oily Water

SpentCalib Fluid

Input Energyto all processes

� ISO 14001– Scale of impact– Severity of impact– Probability of occurrence– Duration of impact– Regulatory/Legal exposure– Difficulty to change impact– Cost to change impact– Effect of change on other

products or processes– Concerns of interested

parties– Effect on public image

� Industrial Ecology– Balancing loops or

(waste=food)– Mass flow rates– Purity (configurational

entropy)– Imparted structure or form– Chemical energy– Earth Systems Interactions– Transportation energy

(distance to consumer or decomposer)

– Life cycle impacts of product

� ISO 14001 & Industrial Ecology are compatible� Explain Industrial Ecology principles before beginning

ISO 14001 implementation� Start with the “big picture” and zoom in� Don’t get stuck in the process:

– Focus on big items first– Will get to the smaller using Deming cycle

� The key interface between IE and ISO occurs when examining Aspects and Impacts

� Full Presentation Available on the Web www.engr.sc.edu/research/lss