DSHW-1998-002336 - 0901a0688013dad7

PROPULSION GROUP
"—f
P.O. BOX 707
BRIGHAM CITY, UT 84302-0707
801.863-3511
THMOKSn.
AEROSPACE & INDUSTRIAL lECHNOLOGlES
3 March 199g
W8700:FY98-ST068
Dennis R. Downs, Director
Division of Solid and Hazardous Waste
288 North 1460 West
P.O.Box 144880
Salt Lake City Utah 84114-4880
O/V/s/o/i ^^0
Attention; Jeff Vandell
Dear Mr. Downs
Subject: Waste Minimization Certification for Calendar Year 1997
According to Paragraph II.M.4 ofthe Hazardous Waste Storage Permit, Thiokol is required to
certify it has a waste minimization program.
Thiokol Corporation has a program in place to reduce the volume or quantity and toxicity of
hazardous waste to the degree detennined by Thiokol Corporation to be economically
practicable.
The current methods of treatment, storage, or disposal are the most practicable methods available
to Thiokol Corporation to minimize the generation and future threat to human health and the
environment ofhazardous wastes.
An annual waste minimization report detailing specific efforts and activities is on file at our work
location.
Sincerely
JTT). Thompson, Director
Environmental, Fire, and Security
ANNUAL WASTE MINIMIZATION
CERTIFICATION REPORT
Date: 2 April 1998
This Document supports the infonnation required to certify waste minimization activity per RCRA
Section 3002(b).
• Thiokol Corporation's Environmental Policy 3.301 states that "each Business Unit will comply with all
applicable Federal, State, and local environmental protection rules, regulations, and requirements. When
introducing new operations, processes, or products, the Business Unit will consider and minimize, to the
extent technically and economically feasible, potential adverse environmental impacts of new operations
and processes."
• Enviroimiental Services personnel have the responsibility to address the impact of major environmental
laws and other environmental project requirements. These laws and their associated regulations are used
as criteria to determine the scope and purpose of company environmental projects. Pennitting, licensing,
and reporting information is submitted as required for all environmental regulations.
• Environmental Services developed a Waste Minimization Plan. The fiinction ofthe plan was to
provide generic steps to reduce waste. The plan was divided into two phases:
Phase 1. Provide training in waste reduction concepts and identification
and characterization of waste streams.
Phase 2. Evaluate information from Phase One, perform feasibility studies, and
implement waste reduction technology.
• Each Business unit is responsible to develop its own Waste Minimization Plan. Environmental Services
personnel train persormel and support individual work centers with specific needs or infomiation
requirements. They also communicate with Waste Minimization Committees to explain the need for
documentation of waste minimization activity. Activity reports are to be generated and sent to
Environmental Services from all business units.
The activity report is to include a description of all waste minimization activities on a semi-annual basis.
Environmental Services compiles this waste minimization information into a semi-annual report. .The reports
from all business units located at Thiokol Corporation Utah-Based Operations are reviewed by Thiokol
Management for compliance and certification.
WASTE MINIMIZATION CERTIFICATION
This is to certify that all Thiokol facilities in Northem Utah (EPA I.D. # UTD009081357) have a
waste minimization program as follows:
1. Thiokol Corporation has a program in place to reduce the volume or quantity and toxicity
ofhazardous waste to the degree determined by Thiokol Corporation to be economically
practicable.
2. The proposed method of treatment, storage, or disposal is the most practicable method
currently available to Thiokol Corporation to minimize the presence and fiature threat to
human health and the environment.
W. N. Brtmdige
Vice President and General Manager
Defense and Launch Vehicles
Date W. T. DoUing
Vice President, Science and
Engineering and Technical Director
Date
M. A. Kahn, Vice President
Operations
Date J. A. Lombardo
Vice President and General Manager
Space Operations
Date
R. L. Crippen, President
Thiokol Aerospace Group
Date
PROPULSION GROUP
WASTE MINIMIZATION
SEMI-ANNUAL REPORT
JULY - DECEMBER 1997
JANUARY 1998
Prepared By: ^Afy^Y.fg.
J. Evans
Approved By:
1, Vice President
Operations
Table of Contents
Section! INTRGDUCTIQN 1
Secdon n OBJECTIVES AND TEAMS FOR JULY - DECEMBER 1997 2
A. Propulsion Group Waste Minimization Team Goals 2
B. Production Center Objectives 3
C. Waste Minimization Teams 5
Section m ACCOMPLISHMENTS FOR JULY - DECEMBER 1997 7
A. Propulsion Group Waste Minimization Team 7
Improve Material Utilization 7
Improve Recognition and Understanding of Waste 7
TCA Reductions 8
B. Specific Production Center Accomplishments 9
Component Refurbishment 9
Insulation and Component 9
Nozzle 9
Mix/Cast 9
Final Assembly 10
Test 10
Section rv PLANS AND GOALS FOR NEXT SIX MONTHS 12
A. Propulsion Group Production Goals 12
Essential Use Waiver Solvent 12
Improve Material Utilization 12
Improve Recognition and Understanding of Waste 12
Continue TCA Reductions 12
B. Work Center Goals 12
Component Refurbishment 12
Insulation and Component 12
Nozzle 12
Mix/Cast 13
Final Assembly 13
Test 13
Section V ODC USAGE GRAPH 14
Attachment I DLV Waste Minimization Report 15
Attachment II Science and Engineering's Year End Waste Minimization Activities Report 17
Section I
INTRODUCTION
Thiokol production reports waste minimization activities through Thiokol Propulsion Group to the Environmental
Protection Agency (EPA) and other state and local agencies. This report summarizes the plans and accomplishments
of the five production work centers and Test Operations;
Refiirbishment
Insulation and Component
Mix/Cast
Nozzle
Final Assembly
Test
DLV
Science & Engineering
This document incorporated the combined effort of the above organizations and reports the individual
successes of each. In some cases, similar efforts are combined for reporting. Where practical, the identity
of specific organizational goals and successes has been maintained. This report covers the second six
months in calendar year 1997.
Minimizing waste is a paradigm of good management accepted by the Corporate Production teams. For every waste
identified, there is an opportunity for reduction with a corresponding savings to the environment and the corporation.
Part of the focus has been to maintain an awareness of the requirements for waste control and the value of
eliminating waste through process improvements.
From 1993 to July 1997 this report was published under the Space Production Waste Minimization Team. Starting
witii January 1998, the charter of tiiis report will include summaries of all waste minimization initiatives in the
RSRM centers. Science & Engineering and DLV Operations; thus the titie Propulsion Group Waste Minimization
Semi Annual Report.
The Propulsion Group Waste Minimization Team developed the following mission statement in 1993:
The Propulsion Group Waste Minimization and Disposal Team will strive to reduce both hazardous and
non-hazardous waste. As the focal point for waste reduction and environmental issues in Production, the
team will:
1) Review and disseminate •waste issues for the •work centers;
2) Coordinate the development of training, planning, procedures, etc.; and
3) Develop consensus among the work centers and communicate recommendations to support
organizations and management.
Wute Minimization Rcpon; Jul-Dec 1997
Section II
OBJECTIVES AND TEAMS FOR JULY - DECEMBER 1997
A. PROPULSION GROUP WASTE MINIMIZATION TEAM GOALS
The semi-annual Waste Minimization Report defined the following goals and objectives for the second six
months of 1997. Most of these goals will be carried over into the first six months of 1998. The goals are as
follows:
1. Improve Material Utilization
• Reduce waste through improved work-in-process inventory techniques, material use, recycling, and
disposal.
2. Improve Recognition and Understanding of Waste
• Improve recognition and understanding of waste through increased operator awareness, recycling,
and improved disposal.
3. Reevaluate Recycling of Paper Products
• Reevaluate recycling of paper goods by investigating new vendors, new guidelines, conducting a
cost benefit analysis, and obtaining management approvals as the paper market dictates.
4. Continue TCA Reductions
• Even though the degreasers have been shut down, continued efforts to reduce the use of TCA by
better control and finding acceptable substitutes in cognizant with the ODC Elimination Team.
• Study our processes for better understanding.
• Reduce to a minimum the amount of material used by:
a. Reducing the amount of material called out in planning minimizing scrap.
b. Emphasizing the importance of waste minimization through training.
c. Changing processes and procedures where possible after management review and
approvals are obtained.
d. Improving the distribution of materials and sharing of coinmon resources.
Waste Minimization Rcpon: Ju) - Dec 1997
Section II
B. PRODUCTION CENTER OBJECTIVES
1. Component Refurbishment Work Center
• Qualify and implement the small StA machine in H-6.
• Complete the timely qualification of the large Proceco SIA machine to support the FSM-7
hardware and start production hardware by December 1, 1997.
• Install and qualify the ultra sonic units.
2. Insulation and Component Work Center
• Support the evaluation of altemative cleaners.
• Evaluate the feasibility of using environmentally safe fluorescent light bulbs.
• Continue TCA reduction and monitor essential use TCA to assure proper applications.
3. Mix/Cast Work Center
• Continue reduction of TCA contaminated propellant.
• Continue progress on follower plates, (modification) and reducing propellant waste.
• Continue implementation of PF-Degreaser & lonox-BC as ODC replacement solvents.
• Continue flame coating, nickel plating, and polyurethane paint coatings on tooling to reduce
maintenance manhours, costs, and contamination.
4. Final Assembly Work Center
• Reduce TCA and implement ODC replacement cleaners in cognizant with the ODC phase
program.
• Emphasize waste minimizations through training and OJT.
• Continue looking at bill of material quantities and reduce materials where possible.
• Evaluate waste streams, re-evaluate disposal methods with Environmental Engineering (UDLV).
• Coordinate with other work centers to implement changes that could affect Final Assembly
processes.
Waste Minimization Repon: Jul-Dec 1997
5. Test
• Evaluate the usage of Tyvek suits in areas where they may not be needed and eliminate their use if
feasible.
• Educate team members on waste minimization principles.
• Coordinate with other work centers to implement changes that could affect test processes.
6. Nozzle
• Phenolic tape reduction.
7. DLV
• See Attachment I.
8. Science & Engineering
• Waste minimization initiatives are summarized in Attachment II.
Waste Minimization Repon: Jul - Dec 1997
C. WASTE MINIMIZATION TEAMS
1. Production-Level Waste Minimization Team
In April 1993, Space Production established the Waste Minimization and Disposal Team under the direction of Vice
President Mike Kahn. The objectives of the team were to increase the interaction of personnel working directly with
hazardous waste issues, and to increase the visibility of significant waste concerns to senior management.
Membership on the team included representatives from each work center's manufacturing engineering group, the
work center hazardous waste specialists and dock coordinators, and representatives from other key organizations.
Current membership of the team includes:
Production Engineering: Larry Evans
Refurbishment: Charlie Burt, Tim Baumann
Insulation & Component: Cyndi Jorgensen, Ralph Rhodes
Mix/Cast: Dayna Serna, Ricky Hansen
Nozzle: Vickie Fair
Final Assembly: Nik Ther, Doug Hansen
Test Operations: Merrill Johnson
Haz Waste Disposal (DLV): Gene Curtis
Ind Safety-Hygiene: Doug Cannon
2. Science & Engineering team includes:
B. A. Lloyd
L. W. Poulter
N. A. Mumford
D. J. Fife
J. C. Hinshaw
Waste Minimization Repon: Jul-Dec 1997
2. Work Center Teams
The Refurbishment Work Center Waste Minimization Team has been in effect since 1990. Current membership of
the team includes:
C. Burt T. Baumann K. Argyle
The Insulation and Component Work Center Waste Minimization Team has been in effect since 1991. Cunent
membership of the team includes:
M. Cope K. Leishman C. Jorgensen
R. Plowman R. Rhodes G. Larsen
C. Olsen
The Nozzle Work Center Waste Minimization Team has been in effect since January 1994. Current membership of
the team includes:
V. Fair E. Stewart F. Huggins
L. Jerome B. Mather D. Godfrey
F. Jones J. London J. O'Grady
The Mix/Cast Work Center Waste Minimization Team has been in effect since 1991. Current membership of the
team includes:
D. Sema B. Hatting B. Davis R. Hansen
R.Clark B.Davis D. Merrell E.Johnson
N.Miller J.Cooper C. Ricks
The Final Assembly Work Center Waste Minimization Team has been in effect since 1993. Current membership of
the team includes:
M. Johnson M. Smitii N. Ther
Test organized a Waste Minimization Team in the first part of May 1994. We have met periodically to coordinate
waste minimization activities and to implement the Space Production Waste Minimization Plan TWR-64935. The
team consists of the following:
M. Johnson K. Erekson E. Robinson D. Spackman
The DLV Waste Minimization Team membership includes:
G. Tooley G.Curtis
The Science & Engineering Waste Minimization Team membership includes:
L. Carlson
J. Hinshaw
J. Thompson
D. Fife
B. Lloyd
N. Mumford
L. Poulter
Waste Minimization Repon: Jul - [)cc 1997
Section III
ACCOMPLISHMENTS FOR JULY - DECEMBER 1997
A. PROPULSION GROUP WASTE MINIMIZATION TEAM
ACCOMPLISHMENTS
1. Improve Material Utilization
The team continues to address improving material utilization. Improvements continue in kitting and
utilization of the work-in-process inventorying techniques combined with better utilization of the MRP II
system has reduced waste. Several systemic problems such as minimum-order quantities, dual number
compounds, maintenance type projects and other potential inefficiencies which generate unnecessary waste
and add cost to the program are being worked. The team will continue to examine current operations from
a waste-conscious perspective, and the on-going challenges with materials and procedures, and underlying
paradigms which unintentionally increase waste.
2. Improve Recognition and Understanding of Waste
Increasing awareness and disseminating information across work centers and the plant continue to be a
challenge. This will be an area that is continually focused on through the years. Some of the items the team
will be focusing on for next year are: 1) Increase awareness and provide sources for new information and
projects. 2) Purchase of environmental magazines. 3) Increase technical conference participation. 4)
Increase fraining by plant experts on environmental issues. 5) Continue participation in the dock
coordinators meeting. 6) Continue participation in the core waste minimization team. 7) Utilize plant
communication lines such as Segments.
Training
Hazardous waste management/disposal fraining materials have been developed for all Work Centers and
Test. All of these groups are now training personnel yearly on area specific waste disposal and common
guidelines. The feedback from personnel in these classes has been positive and training has helped to
reduce inconsistencies and improve waste management.
The Dock Coordinator meetings sponsored by Waste Management and Environmental Services were
supported by all Dock Coordinators, Hazardous Waste Specialists and other key members of the core Waste
Minimization Team. The meeting has helped to identify areas of concem in waste dock management and
update personnel on new regulations. The meeting has provided an invaluable source of information and
has helped to identily areas for improvement. This information has then been disseminated by the dock
coordinators and hazardous waste specialists in their respective work centers and has helped to increase
operator awareness which in tum has resulted in less waste generated, i.e., kraft paper, thickness panels and
paint filters used in the application processes are now disposed of as normal garbage through controlled
testing in laboratory.
Waste Water Treatment Plant Support
The M-52 Proceco aqueous spray-in-air machine has been qualified with the Brulin 1990 solution. No rinse
or Brulin wash water will be dimiped into the plant sewer system. Rinse water will be cycled to the wash
tank and wash solution that does not meet the engineering specification (TS 10282) requirements will either
be shipped to and disposed at the DLV industiial waste facility (E-541 or M-422) or will be evaporated in
the M-10 Landa evaporator. Similarly, Clearfield wash water will be evaporated in the H-7 Landa
evaporator or shipped to the E-541 facility.
Waste Minimization Repon: Jul-Dcc 1997
Air Emissions Tracking Support
The Hazardous Waste Specialists and other key members of the waste minimization team supported efforts
to maintain the system for complying with air emissions fracking requirements 'Title V of the Clean Air Act
Amendments". These team members are instrumental in identifying point sources for emissions within each
Work Center and Test. A system was designed utilizing COPICS for recovery of information monthly by
work center. This information is compiled in the Hazardous Material Tracking report published and
submitted to the state by the UDLV division monthly.
3. TCA Reductions
Phase I and Phase U ODC Elimination Effort
Phase I ODC Program
For all intents and purposes, the Phase I ODC Program is complete and on December 1, 1997 with the
implementation of the M-52 SIA (Spray-In-Air) process and the shutdown of the M-52 degreaser. Flight #
73 segments were partially processed with the SIA system and Flight #74 segments were totally processed
using the Proceco SIA system. This completes the 90% TCA reduction milestone.
Any initiatives associated with minimizing waste materials, i.e., Brulin wash/rinse solutions, to this baseline
process will be identified in fiiture waste minimization initiatives.
Phase n ODC Program
• ETP-1600 is complete. This test plan tested the 26 selected cleaners with subsfrates for
compatibility, dry times, solubility and ability to clean in a hand wipe application. From this ETP
down selection the most promising nine cleaners have been determined. Each Space Operations
center ODC design engineer has the metal, composite and rubber cleanability results and will
evaluate these cleaners, plus other candidate cleaners that engineering wants to evaluate on the
various substrate bondlines.
Waste Minimization Repon: Jul - Dec 1997
B. SPECIFIC WORK CENTER ACCOMPLISHMENTS
1. Component Refurbishment
• The H-6 small degreaser was shutdown on December 1, 1997.
• The center has reduced TCA use from 150 gallons per month to about 75 gallons per month.
• The large Proceco SIA machine is on line and in use. FSM-7 hardware has been processed
through this machine, plus production RSRM hardware started December 1, 1997.
• The Brulin 815GD Ultra Sonic Unit was placed on line about tiie 17"" of November 1997. The X-
Caliber Ulfra Sonic Unit is waiting delivery and installation.
• Installed and placed in operations the "Water Blaze" Evaporation Unit. This allows us to
evaporate most of the Brulin wash water from spray-in-air units. This reduces 2,000 gallons into
about 80 gallons of bmlin and oil sludge. This sludge is then sent off plant for disposal.
2. Insulation and Component
• Essential use TCA was infroduced to operations line on October 20, 1997. Training to team
members was completed on the use and requirements of this material to insure compliance to the
Montreal Waiver.
• In-depth training on environmental awareness was conducted. This included topics of the Toxic
Substance Control Act, The Clean Air Act, Clean Water Act, Emergency Planning and Community
Right To Know Act, and Thiokol Environmental Responsibilities.
• The M-52 vapor degreaser was successfiilly shutdown on December 1, 1997. All remaining TCA
was pumped from the system, and the equipment locked and tagged out. We anticipate
approximately 15,000 gallons per year in reduction of TCA.
Nozzle
Phenolic tape reduction - End item material reduction team is continuing work on reducing
phenolic tape widths to reduce the amount of material overstock required to be machined off. An
estimated cost savings of $800,000 per year is projected. This project is pending completion of
the pocket erosion UUEC investigation.
Mix/Cast
TCA propellant contaminated waste going to the burn pits for disposal has been reduced from 50
pounds a week to 50 pounds a month.
UPDATE:
On December 18, the CCB approved a Type II change to incorporate a 4,500 pound propellant
mix size on center segments. Previously, 4,500 pound mixes were only approved for use on aft
segments. This was done to reduce propellant waste which reduces open pit burn quantities. In
addition, raw material purchase quantities will be reduced. Therefore, this change will save over
$175,000 annually in raw material and in propellant disposal costs. The change will be effective
on the FSM-07 center/forward segment tiien on Flight 77 (block change). The added 4,500 pound
mix replaces one 6,900 pound mix and results in a propellant waste reduction of 9,600 pounds per
flight.
Waste Minimization Report: Jul-Dec 1997
lonox-BC solvent used in the tooling parts washer at M-27 has been approved to clean six sets of
casting tooling before scrapping. Reducing the gallons of lonox-BC solvent that is scrapped.
Three follower plates have been modified to date. Two follower plates are being used in
production. The two modified plates are used on the average of 14 times per cast. We are
currently generating 800 pounds of residual propellant per segment. This could mean a possible
mix size reduction.
Plastic Flame Coating of tooling and equipment is still on going with great success. All items that
have been flame coated are being used and are holding up to everyday use exceptionally well.
More than three dozen tools and facility items have been coated to date. Many other facility items
and tools are in work for coating. Also many items are being evaluated for flame coat.
Nickel Plating of tooling is also on going with the core centering ring center segment, core
centering ring forward core, tote bin lifting beam, fin puller forward segment, and the forward
spider.
Flame and nickel coating of tooling and facility items have greatiy reduced paint contamination as
well as up keep, paint, paint supplies, and man hours on preservation of tooling.
The use of new water based polyurethane paints (Stock Number 35-583296) has greatiy improved
tool preservation quality. The paint has great adherence and chip resistance. Implementation of
this paint is a real savings to the work center.
Final Assembly
6. Test
Reduced TCA usage on NJAD through OJT and continued emphasis on TCA reduction with line
personnel.
Continued hazardous waste training and emphasis on minimum usage in process where possible.
Through evaluation of usage of K5NA, implemented using all of particular lots of K5NA before
shelf life expired.
Continued to dispose cured waste paints into IWT french which has reduced our waste paint
accumulation.
The evaluation of Tyvek suite usage is ongoing. KSC does not use Tyvek suits in their assembly
of the motor. They shipped us a pair of coveralls they wear in this operation. It was poor from a
contamination standpoint. It was felt that a different material should be sought to be cooler for the
workers as well as provide contamination control for joint assembly. This is still being evaluated.
Test used 55 gallons of methyl chloroform for the reporting period. We continue to look for
further reduction.
We continue to educate and train team members on the proper use of essential use TCA.
We have made Test workers aware of the seriousness of improper discharge into the waste water
system.
1 f\ Waste Minimization Repon: Jul - Dec 1997
• Test received permission from the EPA to dump water used at T-l8 for Castor 120 case
hydroproof testing. Before this permission was obtained, this perfectly good water had to be
caught and trucked for disposal in the waste water freatment facility. This change saves us about
$1000 in labor for each motor tested.
• Flame coating equipment has been purchased and recently arrived for coating tooling. This will
reduce the painting and the waste associated with it for many tools.
7. DLV initiatives are summarized in Attachment I.
8. Science & Engineering initiatives are summarized in Attachment II.
1 1 Waste Minimization Rcpon: Jul-Dec 1997
Section IV
PLANS AND GOALS FOR NEXT SIX MONTHS
A. PROPULSION GROUP PRODUCTION GOALS
1. Essential Use Waiver Solvent
• To comply with approved Essential Use Waiver listed cleaning applications of TCA solvent
procured under the ODC policies and guidelines, the Waste Minimization Team will support the
u-aining, implementation, monitoring, record keeping, and support audits associated with this
material.
2. Improve Material Utilization
• Reduce waste through improved work-in-process inventory techniques, material use, recycling, and
disposal.
3. Improve Recognition and Understanding of Waste
• Improve recognition and understanding of waste tiirough increased operator awareness, recycling,
and improved disposal.
4. Continue TCA Reductions
• Continue efforts to reduce the use of TCA by better control and support finding altemate cleaning
materials through scientific research conducted by the ODC Phase n Program.
B. WORK CENTER GOALS
1. Component Refurbishment Work Center
• Implement a pH auto-neutralization unit for the industrial waste water generated in the H-7
equipment room. Current process is to manually neufralize the waste water, which creates a
personal hazard. This unit would continuously monitor the pH of the waste flow and if the pH
goes above the Sewer Districts limits it would automatically add an acid and lower the pH.
• Install and implement tiie X-Caliber Ulfra Sonic Unit.
2. Insulation and Component Work Center
• Evaluate altemative cleaners.
• Continue TCA reductions and implement replacement cleaners in cognizant with the ODC Phase II
Program.
3. Nozzle Work Center
• Pending the pocket erosion UUEC investigation completion, the phenolic tape reduction
evaluation will continue. An estimated cost savings per year is estimated to be $800,000.
1 o Waste Minimization Repon: Jul - Dec 1997
• Part of the nozzle fabrication process involves touching up paint that is inadvertently removed
during assembly and handling of the hardware. The paint includes steel and aluminum paint and
primer (four different stock numbers). Because a small amount of paint is used for touch up, and
the paint has a short shelf life, a good majority of the large gallon containers must be disposed of
as hazardous waste. We recentiy set up small pint containers for steel primer and paint. The paint
in these small containers is used up prior to expiration, thus leaving none to be disposed as
hazardous waste. We currentiy are working to set up the aluminum paint and top coat in smaller
containers to further decrease our hazardous waste disposal.
Mix/Cast Work Center
Continue efforts on eliminating TCA contaminated propellant that is sent to the burn pits.
Continue to use altemative coatings (Flame Coating & Nickel Plating) to minimize waste and
contamination.
Continue follower plate modification on remaining plates.
Look at lengthening solvent (lonox-BC) life in M-27 parts washer.
Final Assembly Work Center
Continue TCA reductions to fulfill ODC program requirements.
Continue NJAD testing (TCA usage). NOTE: Because of this program, continued use of TCA is
required.
Continue fraining of proper usage of TCA and look for ways to reduce usage and replace TCA
when possible.
Implement smaller container for waste paint.
Reduce consumption of K5NA when possible in mix sizes by using small K5NA kits.
Test
Support TCA solvent replacement on FSM-7, plus evaluate other processes using TCA and reduce
if possible.
Implement flame coating to reduce paint on tooling.
Continue assessing the use of Tyvek suits and evaluating new materials as a replacement.
Educate team members on waste minimizing principles and procedures.
13 Waste Minimization Repon: Jul-Dec 1997
Section V
ODC USAGE GRAPH
Actual and Projected Reduction In TCA Usage
111 rri \ 11
iil
CD
Projected
-Actual 3
Year
ATTACHMENT I
DLV WASTE MINIMIZATION REPORT
• M-508 Degreaser Shutdown
On December 1, 1997 the M-508 TCA vapor degreaser was deactivated. This facility was replaced with a
Brulin 815 wash/rinse unit. The degreaser shutdown represents a significant reduction in TCA usage. The
average usage of TCA (methyl chloroform) was 400 gallons per month.
• Waste Paper Recycling Program
Recycle paper prices are still down, and appears to have leveled off at these lower prices. Based on this
information, it still is not economically feasible to recycle paper at the Promontory Facility.
• Drum Crushing Program
The drum rinsing and crushing program is in place and working well. Dmms are rinsed then crushed prior
to placement into our landfill for disposal. The purpose of this effort is not to minimize waste, but is for
minimizing fiiture liability associated with sending our dmms to a reconditioner for reuse. We are cunentiy
waiting for a more permanent processing facility to perform this operation.
1 c Waste Minimization Repon: Jul-Dec 1997
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ATTACHMENT D
SCIENCE & ENGINEERING'S YEAR END WASTE MINIMIZATION ACTIVITIES REPORT
The EPA requires semi-annual waste minimization reports from permitted facilities to demonstrate an active program
(awareness) addressing the issue of waste minimization.
Thiokol's Science & Engineering (S&E) Division approaches tiiis mandate from two directions. First, they attempt
to find methods for decreasing waste from their many research and development activities and, secondly, they are
continuously involved in new technology development that may ultimately lead to reduced and/or less toxic waste
streams from production processes. Other successful technologies cunentiy being pursued include reclamation of
rocket motor propellant washout products, alternate fuel source/supplement from de-energized propellant
components and contracted technology programs to develop green (environmentally friendly) energetic materials
(GEM).
The following items fall into the waste minimization activity categories discussed above.
• The 600 gallon verification mixes in the Minuteman program are now qualified as part of the Change
Verification Motor (CVM) phase of the MM PRP Program. The verification mixes are made to qualify sub
contractor materials (ammonium perchlorate and aluminum powder) and were previously throw away mixes
generating 5,000 to 6,000 pounds of waste propellant per verification mix.
• The M&P Propellant and Liner (MPPL) group is presentiy working with the demilitarization office to
reclaim ammonium perchlorate (AP) from aged and obsolete Minuteman, Titan and Space Shuttle (RSM)
solid fiiel rocket motors after wash out operations. They have also recentiy demonsfrated the feasibility of
using the AP depleted binder residue as an altemate fiiel source/supplement. Approximately 8,000 pounds
of shredded binder residue was successfully bumed in the Utah State University (Logan) stoker fumace on
January 13, 1998, under the auspices of an Army HazMin contract.
• A new spray lining process was developed by the MPPL group for qualification and production of the NDI
2.75 inch rocket motor. This process generates less waste liner than the previously used "fill and drain"
process used in the development and demonstration programs.
• S&E's M&P Composites (MPC) group has developed a unidirectional, pre-impregnated tape tiiat, unlike
other competitive products on the market, is manufactured without the use of a process solvent. It is also
storable at ambient temperatures with a long shelf life that reduces scrap material significantly.
• The MPC group has also developed a braided tubular Kevlar pre-impregnated product. It replaces a fabric
lay-up process that had a 50% material scrap rate whereas the pre-impregnated braided material's scrap rate
is less tiian 20%.
• The S&E Analytical Laboratories has reduced its use of 1,1,1-Trichloroethane to absolutely essential items.
It is no longer used as a common reagent or cleaning solvent. Small quantities are purchased for analytical
standards in trace element analysis and in environmental analyses problem solving. This solvent has been
targeted by the Monfreal Protocol as being a significant ozone depleting chemical (ODC).
• Hexane has replaced Freon in the environmental laboratory's oil and grease analyses. Freons have also
been implicated by the EPA for their role in ozone depletion. Additionally, the environmental lab is
researching a solid phase extraction method that would greatly decrease the amount of solvent(s) used.
1 n Wasle Minimization Repon: Jul-Dec 1997
ATTACHMENT H (Continued)
MPPL has developed a new ambient cure phenolic sliver material (UF-3346) for the Minuteman program
which uses Versamid 140 (a polyamide resin) as the curing agent. This replaces the much more toxic (and
potentially carcinogenic) aromatic amine curatives EPON Z and EPON W that were present in the old
formulation.
The Energetic Materials group is currentiy engaged in three separate contracts from the U.S. Navy Naval
Surface Warfare Center/Indianhead, MD, to develop and characterize a rocket propellant, a gun propellant
and an explosive formulation which does not use environmentally unfavorable materials either in the
formulations or manufacturing processes (Green Energetic Materials (GEM) program). The formulations
will also be easy and environmentally friendly to demilitarize if, and when, it becomes necessary.
Bids have been send out by the Insulation Elastomers group for the purchase of two new aqueous cleaning
machines to replace the methyl chloroform degreasers. These machines should be operational by mid 1998.
1 Q Waste Minimization Repon: Jul - Dec 1997