Industrial Waste Management Plans - Case Study Example

Running Headers: Review of Industrial Waste Management Plans Your Name Course: Instructor’s Name: Institution: Date: Introduction 2 The Australian car industry 3 Toyota Motor Corporation Australia, Limited 4 Waste generation 4 Cleaner production Activities 4 Pollution control devices 5 Waste treatment 6 Waste performance indicators 7 GM Holden Limited 7 Waste generation 7 Cleaner production activities 8 Pollution control devices 8 Waste treatment 8 Waste performance indicators 9 Ford Motor Company Limited 9 Waste generation 9 Cleaner production activities 9 Pollution control devices 10 Waste treatment 10 Waste performance indicators 10 Conclusion 11 Reference: 12 Introduction Waste is defined as any item or substance that people no longer have value or use for and thus, intend to get rid off or has been already disposed. They are items or substances such as toxic fumes, which people have to get rid off because of their toxic properties. These may include sewage sludge, domestic rubbish, industrial wastes generated from the manufacturing processes, discarded cars, garden waste noxious fumes and packaging items among others. Therefore, our daily routine activities can generate a range of wastes produced from diverse sources, which then should be managed and disposed off appropriately (Lewis, 2002). In Australia alone, it is estimated that more than ninety three million tones of wastes is generated annually. This is made up of wastes generated from commercial activities, agriculture, domestic wastes, industrial processes, quarrying and mining activities, energy generation and construction and destruction of projects. However, it is recommended that management plans are put in place to prevent the adverse effects of such wastes, at all levels of production. In addition, most countries, including Australia, have put in place stringent rules and policies to ensure effective management of wastes. This essay seeks to review some of the management plans put in place to guide waste management by various car manufacturing industries in Australia. The study will focus on three major car manufacturing companies, Toyota, Ford and GM Holden of Australia. The Australian car industry All businesses and manufacturing companies stand accountable for the wastes they produce during the production process, through handling and storage until the product is finally disposed off. Today, Australia is rated as one among the only fifteen nations of the world, whose auto sector incorporate all stages of the value-adding procedures from the design of their products through assembly and the final testing. The auto manufacturing industry drives innovation both directly and indirectly across the economy. The industry consists of not only the major car manufacturers, Toyota, Ford and Holden, but also numerous retail dealerships and auto-component companies. In this essay however, we shall consider the major car manufacturing companies, Toyota, Ford and Holden and review their industrial waste management plans (Lewis, 2002). Toyota Motor Corporation Australia, Limited Toyota Australia, located in Altona North, is one of the leading producers, distributors and exporters of all types of vehicles in the world. The main manufacturing processes done in Toyota include foundry, engine casting and assembly, vehicle assembly, vehicle painting, pressing of panel and units parts, bumper bars painting and resin moulding and welding of body and unit parts. These processes generate wastes such as toxic gases, contaminated waste water, dust, scrap materials, plastics such as PVC, packaging materials and oil spills among other wastes. We will first consider waste generation in the company (Lewis, 2002). Waste generation Wastes are mainly generated from the motor vehicle and motor vehicle parts manufacturing processes. According to the National Pollutant Inventory data, the wastes generated include substances such as sulphuric acid, lead and its compounds, oxides of nitrogen, hydrochloric acid, particulate matter, nickel and its compounds and toluene among other compounds. Each of these substances is treated separately (Lewis, 2002). Cleaner production Activities The company has put in place measures that aim at ensuring cleaner production. For instance, the company has improved its maintenance scheduling and the record keeping procedures to ensure waste minimization. It also uses aqueous based raw materials which generate fewer wastes compared to the solvent based materials. The manufacturing processes have also been modified to minimize waste production while loading, unloading and transfer procedures have also been improved. The company has also installed monitoring and inspection programs for possible leak or spill sources to ensure potentially hazardous or poisonous substances do not leak or spill to cause environmental risks. Mechanical shut off valves or overflow alarms have also been installed to regulate the amount of raw materials used and vapour recovery system, which is a control device for air pollution. It recovers the contaminants and puts them back to their re-usable states. The product specifications have also been modified to ensure they are eco-friendly while cleaner raw materials are preferred for the manufacturing process. The company has also implemented a high pressure cleaning equipment to achieve cleaner production. Pollution control devices The National Pollutant Inventory requires every company to install pollution control devices to ensure the industry’s manufacturing processes do not affect the quality of air as well as that of the water. As a result, Toyota Motor Corporation has several installed devices to achieve this objective (Lewis, 2002). In 1998, the company installed a fabric filter, also known as baghouse for dust collection. In the same year, a dry scrubber was installed to prevent the emission of poisonous gases into the atmosphere. The scrubber is a pollution control device that injects a dry reagent into the exhaust stream to eliminate acid gases such as Sulphuric acid and hydrochloric acid. An activated carbon filter was also installed to curb carbon emission into the atmosphere. The company has also established a waste water treatment device to ensure water discharged from the manufacturing processes is of the required quality. In 2007, a thermal oxidizer was installed to control air pollution. The thermal oxidizer decomposes hazardous gases at a very high temperature and then emits them into the atmosphere. Toyota Motor continues to implement environmentally friendly methodologies that ensure the company’s manufacturing processes impact the environment positively and is sustainable. Waste treatment The main reason for waste treatment is to ensure that the waste generated from the industrial process is less harmful to human life as well as, to the quality of the environment. This covers the processes and mechanisms applied to treat all substances generated from the industrial activities. For instances, if the company generates waste water that has been contaminated with other toxic compounds, the National Pollutant Inventory requires that before this water is discharged to the final sewer, it should be treated through a treatment plant to ensure that it is safe (Walter, 2005). Substances toxic substances such as ethyl benzene, ethylene glycol and toluene, it is a mandatory requirement that they should be transferred to offsite treatment. Other substances like ethyl acetate, methyl ethyl ketone and xylenes, they are transferred to off site recycling while others such as total phosphorus and total nitrogen are often transferred to offsite sewerage while their compounds are deposited in a landfill. Waste performance indicators Some of the waste performance indicators in this vehicle industry include reduction of waste per production process, recovery of waste materials for either re-use or recycling or both, the total amount of waste transported to a landfill and the waste generated per production process. These can are often used to determine the industry’s waste performance. GM Holden Limited GM Holden is located in Elizabeth South Australia as a motor vehicle components manufacturing and vehicle assembly company. It also deals with body assembly and painting, metal fabrication and stamping and body hardware (Lewis, 2002). Waste generation Wastes generated by GM Holden include carbon monoxide, Beryllium and its compounds, ethyl acetate, copper and its compounds, ethyl benzene, mercury and its compounds, the oxides of nitrogen, particulate matter, hydrochloric acid, lead and its compounds, sulphuric acid, sulphur dioxide, nickel and its compounds, toluene, methyl isobutyl ketone, polyclic aromatic hydrocarbons, chromium three and four compounds and arsenic compounds. The company also generates total volatile organic compounds and xylenes. These wastes are generated from the motor vehicle and motor vehicle part manufacturing activities. It is estimated that the company generates an approximate of twenty four substances. Cleaner production activities The company uses cleaner raw materials, which have been modified from the solvent based to the aqueous based materials. The company has also adjusted into film technology for coating of the vehicle’s body surfaces. Pollution control devices Waste water treatment facilities were installed in 2006, which are associated with stamping operations and surface coating. In addition, the company also has a thermal oxidizer to control air pollution. Thermal oxidizers are linked with surface coating processes. Waste treatment These substances are often treated separately, whereby others are recycled, some are re used while others are taken to onsite and offsite regional treatment plants. Substances such as ethyl acetate and its compounds are often taken to offsite recycling plants, while its non recyclable compounds are transferred to offsite sewerage. Ethyl benzene is also managed at offsite treatment plants. Manganese and its compounds are transferred to off-site sewerage facilities for mandatory treatment. Total nitrogen as well as phosphorus is transferred to offsite sewerage for treatment, after which it is then sent to an offsite landfill (Walter, 2005). Waste performance indicators The waste performance indicators in this company include the amount of wastes the company generates. Out of the total amount of wastes generated, certain factors have to be determined, for instance, the amount of wastes sent to a land fill, the total amount of wastes recycled, and the amount of wastes recycled. This helps provide a general view of the company’s performance with regard to waste production. Ford Motor Company Limited Ford Motor Company is located in Geelong, Victroria and was founded in 1925 and specializes in the manufacture and assembly of vehicles. Waste generation In Ford Motor Company, the wastes generated include substances such as waste water, beryllium, sulphuric acid, the oxides of nitrogen, ethyl benzene, xylenes, hydrochloric acid, particulate matter, manganese and its compounds and carbon monoxide among other substances. Cleaner production activities In order to ensure cleaner production, the company has put in place new measures while the old practices have been modified. For instance, the company’s coolant system has been modified from the mineral based to the contemporary synthetic coolants. Waste reduction programs have also been implemented such as the lighting upgrade to promote energy saving. The company has also modified its packaging and makes use of cleaner raw materials, which have been modified from the solvent based to the aqueous based materials. The product specifications have also been modified as well as the layout, equipment and piping processes (Walter, 2005). Pollution control devices The company installed an electrostatic precipitator in 2000, which is a particulate collection device designed to eliminate particles from the air produced using the force of a stimulated electrostatic charge. The precipitators act as filtration devices that remove fine particulate matter from the air stream. The company also has installed fabric filters to collect dust and a waste water treatment plant to treat trade waste before being discharged to the central sewer. The mist eliminator was installed in 2001, to eliminate mist from the gas streams. Waste treatment These wastes are often treated in the company while others are sent to offsite sewers and landfills. Some are transferred to offsite recycling. For instance, substances such as toluene and xylenes are often transferred to offsite recycling while total phosphorus is sent to offsite sewerage. Total nitrogen is transferred to offsite treatment, after which, is then deposited into a landfill. Waste performance indicators Waste performance indicators in this company include the amount of waste generated annually, considering what quantities are recycled; send to landfills, or sewerage, and what amounts are re-used by the company. These often gauge the company’s waste performance. Conclusion It takes a lot of valuable material and energy to design and manufacture products while the resulting industrial waste can prove difficult to manage. Most cities and countries of the world have implemented new regulations to manage waste disposal such as tax impositions for the heavy polluters. The tax collected is often meant to offset the environmental damage. However, people and companies should be educated about the importance of the environment and the need to conserve it. The companies have to be accountable for their own wastes and ensure it is disposed in an appropriate manner (Walter, 2005). The three vehicle manufacturing companies above give a detailed information of how cleaner production can be achieved. The companies are aware of the wastes they produce and the potential consequences they have to the total environment. That is why they have set up mechanisms to attain cleaner production as well as disposing their wastes in a proper manner. Therefore, if we have to continue benefiting from the environment, we should employ appropriate measures to protect it. Reference: Government of South Australia Zero Waste SA South Australia’s Waste Strategy 2005- 2010 Lewis, A. (2002) ‘Disposal disorder: automakers lead in recycling while the European Commission lags behind in writing end-of-life rules. But the whole industry wants to know who will pay for it. ‘Automotive Industries Vol 182 issue 8 p28 Walter, P. 2005 ‘Overcoming the plastics mountain: plastics recycling: waste not, want not (plastic products recycling)’ Chemistry and Industry issue 9 p 26 Read More

Waste generation Wastes are mainly generated from the motor vehicle and motor vehicle parts manufacturing processes. According to the National Pollutant Inventory data, the wastes generated include substances such as sulphuric acid, lead and its compounds, oxides of nitrogen, hydrochloric acid, particulate matter, nickel and its compounds and toluene among other compounds. Each of these substances is treated separately (Lewis, 2002). Cleaner production Activities The company has put in place measures that aim at ensuring cleaner production.

For instance, the company has improved its maintenance scheduling and the record keeping procedures to ensure waste minimization. It also uses aqueous based raw materials which generate fewer wastes compared to the solvent based materials. The manufacturing processes have also been modified to minimize waste production while loading, unloading and transfer procedures have also been improved. The company has also installed monitoring and inspection programs for possible leak or spill sources to ensure potentially hazardous or poisonous substances do not leak or spill to cause environmental risks.

Mechanical shut off valves or overflow alarms have also been installed to regulate the amount of raw materials used and vapour recovery system, which is a control device for air pollution. It recovers the contaminants and puts them back to their re-usable states. The product specifications have also been modified to ensure they are eco-friendly while cleaner raw materials are preferred for the manufacturing process. The company has also implemented a high pressure cleaning equipment to achieve cleaner production.

Pollution control devices The National Pollutant Inventory requires every company to install pollution control devices to ensure the industry’s manufacturing processes do not affect the quality of air as well as that of the water. As a result, Toyota Motor Corporation has several installed devices to achieve this objective (Lewis, 2002). In 1998, the company installed a fabric filter, also known as baghouse for dust collection. In the same year, a dry scrubber was installed to prevent the emission of poisonous gases into the atmosphere.

The scrubber is a pollution control device that injects a dry reagent into the exhaust stream to eliminate acid gases such as Sulphuric acid and hydrochloric acid. An activated carbon filter was also installed to curb carbon emission into the atmosphere. The company has also established a waste water treatment device to ensure water discharged from the manufacturing processes is of the required quality. In 2007, a thermal oxidizer was installed to control air pollution. The thermal oxidizer decomposes hazardous gases at a very high temperature and then emits them into the atmosphere.

Toyota Motor continues to implement environmentally friendly methodologies that ensure the company’s manufacturing processes impact the environment positively and is sustainable. Waste treatment The main reason for waste treatment is to ensure that the waste generated from the industrial process is less harmful to human life as well as, to the quality of the environment. This covers the processes and mechanisms applied to treat all substances generated from the industrial activities. For instances, if the company generates waste water that has been contaminated with other toxic compounds, the National Pollutant Inventory requires that before this water is discharged to the final sewer, it should be treated through a treatment plant to ensure that it is safe (Walter, 2005).

Substances toxic substances such as ethyl benzene, ethylene glycol and toluene, it is a mandatory requirement that they should be transferred to offsite treatment. Other substances like ethyl acetate, methyl ethyl ketone and xylenes, they are transferred to off site recycling while others such as total phosphorus and total nitrogen are often transferred to offsite sewerage while their compounds are deposited in a landfill.

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