United States National Risk Management

Environmental Protection Research Laboratory

Agency Cincinnati OH 45268

Research and Development EPA/600/SR-96/110 September 1996

Pollution Prevention Assessment

U.S. Postal Inspection Service

National Forensic Laboratory

Project Summary

As part of its Waste Reduction Evaluation at Federal Sites Program, the U.S.

Environmental Protection Agency (EPA)

National Risk Management Research

Laboratory worked cooperatively with

the U.S. Postal Service (USPS) to integrate waste prevention and recycling

activities into the waste management

programs at various postal facilities

through the conduct of pollution prevention opportunity assessments

(PPOA).

This PPOA documented and quantified waste generation at the National

Forensic Laboratory, a Postal Inspection Service crime laboratory that examines physical evidence and performs

chemical analyses relevant to crimes

involving USPS operations.

The report makes recommendations

concerning procurement of office supplies, maintenance supplies and hazardous materials; management of

hazardous materials and wastes; purchase of chemicals on EPA’s 33/50 list;

improvement of source separation and

recycling of paper and paper products,

metals, and plastics; management of

unwanted equipment; and other options

for reducing or eliminating pollution.

This Project Summary was developed

by EPA’s National Risk Management

Research Laboratory, Cincinnati, OH,

to announce key findings of the research

project that is fully documented in a

separate report of the same title (see

Project Report ordering information at

back).

Introduction

Since 1988, EPA’s National Risk Management Research Laboratory (NRMRL)

has managed a technical support effort

known as the Waste Reduction Evaluations at Federal Sites (WREAFS) Program.

WREAFS was established to provide pollution prevention solutions to environmental issues through research, development

and demonstration of pollution prevention

techniques and technologies, and transferring lessons learned within the federal

community and related private sector industries.

The U.S. Postal Service (USPS), in cooperation with NRMRL’s WREAFS program, is engaged in an effort to integrate

pollution prevention and recycling activities into the waste management programs

at postal facilities. The purpose of this

project was to perform pollution prevention opportunity assessments (PPOAs) at

Postal Service facilities, recommend implementation strategies, and develop facility

guidance that could be incorporated into a

revision of the USPS Waste Reduction

Guide. The project was funded by the

U.S. Postal Service through an interagency

agreement with EPA NRMRL.

This report describes the findings of the

PPOA conducted for the U.S. Postal Inspection Service, Forensic and Technical

Services Division’s National Forensic Laboratory in Dulles, VA. The PPOA was conducted during the week of November 14,

1994.

Carole O. Bell, Mary Hoel, John Nuckels, and John Conrick
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Facility Description

The National Forensic Laboratory is situated in a rural industrial park several miles

from Dulles International Airport. Three

other Postal Service facilities are located

at this site: a Stamp Distribution Network,

a Vehicle Maintenance Facility, and a mail

Processing and Distribution Center. The

Forensic Laboratory is a two-story building of approximately 44,000 square feet,

divided into six functional areas or sections. The Chemistry Section examines

controlled substances submitted by postal

inspectors; Forensic Photography provides

photographic support to all the sections;

Technical Services supports a national

communications network; the Physical Evidence Section examines explosive devices, firearms, and toolmarks; the Latent

Fingerprint Section processes evidence to

develop latent fingerprints; and the Questioned Document Section identifies handwriting and establishes document

authenticity.

Waste Description

The nature and volume of the workload

at the Forensic Laboratory depends on

Postal Inspection Service criminal cases.

Quantities of waste disposed or released

to air and water may vary considerably

from month to month and year to year;

however, on the average, the Forensics

Laboratory generates approximately 31

tons of solid waste per year. Annual cost

of solid waste management is approximately $6,000. Exhibit 1 presents the primary components of the Forensic

Laboratory’s solid waste stream. In addition to solid waste, the Forensic Laboratory generates small quantities of hazardous wastes. Most hazardous materials are

utilized in very small quantities. The Forensic Laboratory has had occasion to

dispose of hazardous waste only once in

the past three years.

Pollution Prevention

Opportunities

The PPOA identified several pollution

prevention opportunities at the site. Some

of these opportunities simply reduce the

quantity or toxicity of the waste stream,

while others offer the USPS economic as

well as environmental benefits. Exhibit 2

presents the pollution prevention opportunities that offer the USPS significant cost

reductions in addition to reducing pollution. The annual savings for the combined

facilities could be as high as $25,000. In

addition, by marketing dependable quantities of quality materials, the postal facilities increase the possibility of receiving

revenues from the sale of their recyclables.

All of the pollution prevention opportunities identified by the PPOA team are addressed below.

General Recommendations

• Reduce the amount of packaging,

including corrugated containers,

shrink/stretch wrap, and strapping,

entering the facility. Reuse incoming containers and utilize reusable

packaging whenever possible.

• Introduce and promote a variety of

techniques to reduce the quantity

of paper generated for disposal.

• Repair unwanted equipment and/or

donate to schools and other facilities for reuse.

• Provide training for professional and

custodial staffs on source separation.

• Establish a multi-facility recycling

program for the four Postal Service

operations located in Dulles, VA.

Affirmative Procurement

• Establish preference programs and

adopt EPA guideline recommendations for the purchase of products

made with recovered materials.

• Substitute products that do not contain ozone depleting chemicals; exhaust the current stock and then

modify procurement specifications

to prohibit purchase of products

containing 33/50 chemicals.

Procurement of Chemicals and

Laboratory Supplies

• Centralize ordering and stock/inventory control, including budgeting for

supplies, at the laboratory director

level. Utilize the existing on-line inventory program to track current

and future chemical inventory and

optimize ordering and stock rotation to avoid the need to dispose of

expired chemicals.

• Establish a single point of responsibility for receipt and labeling of

chemicals.

Carbon Filters

The Forensic Laboratory uses 22

Flanders Model T-2V-N63-F16, GG-16, VBed Carbon Adsorber Cells, located within

seven ventilation systems, the largest of

which includes nine cells. The filters contain nuclear grade carbon and have an

estimated life expectancy of three years,

according to the manufacturer. Actual use

of the filter systems is very light so the

replacement of the filters on a three-year

schedule may not be warranted. The

changeout of all of the filters will generate

2,200 pounds of spent nuclear grade carbon and will cost more than $30,000. As

shown in Exhibit 3, during the first

changeout of the filters, the cost per filter

will be slightly lower due to the purchase

of spare filters. During subsequent

changeouts, however, the per filter cost

should be significantly lower than the purchase of new filters and will prevent the

disposal of spent carbon. In addition, as

shown in Exhibit 4, the per pound replacement cost of nuclear grade carbon is

substantially higher than commercial grade

carbon. If the Forensic Laboratory converts from nuclear grade to commercial

grade carbon, cost savings of $5,455 can

be realized when the carbon in replaced.

Exhibit 1. Forensic Laboratory Solid Waste Stream

Waste Waste components

Paper Mixed office paper, computer printout, corrugated cardboard, paperboard packaging,

paper towels

Food Food scraps, food-contaminated paper products

Metal Food and beverage containers, aerosol cans, paint cans, electronic equipment, wire

Glass Containers from laboratory and photoprocessing chemicals, food and beverage containers, broken laboratory glass

Plastic Containers from photoprocessing chemicals, food and beverage containers, gloves,

shrink/stretch wrap, bubble wrap, packaging peanuts

Wood Pallets, cable spools

Other Toner cartridges, circuit boards, communication equipment, computer equipment,

carbon filters

Batteries Various sizes and types
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Conclusions and

Recommendations

The USPS has encouraged reduction

and recycling activities in its facilities. Emissions to air and water from the Forensics

Laboratory are minimal. The Laboratory

faces a significant expenditure in replacing the carbon filters and should seek a

Exhibit 2. Cost-Saving Pollution Prevention Opportunities

Pollution Prevention

Item(s) of Concern Current Practice Opportunity Estimated Potential Savings

Carbon filters Replace all carbon filters Measure filter Eliminate costs associated with

after 3 years breakthrough unnecessary filter replacement*

Carbon filters Replace all carbon filters Rejuvenate filters on $600-$1055 in filter

after 3 years rotating schedule replacement and disposal fees**

Carbon filters Filters contain nuclear Convert from nuclear $1,000 certification fee for

grade carbon grade to commercial disposal of nuclear grade

grade carbon filters carbon

$4,455 replacing 22 nuclear

grade carbon filters with

commercial grade carbon

filters

Recyclables Collect aluminum, Establish one multi-facility recycling $4,440 in fees for container

plastic and glass mixed program for 4 local rental and collection of

food and beverage Postal Service recyclables

containers, and paper operations

products $544 for smaller container and

less frequent pick up charges

Procurement of Decentralized process Centralize ordering Eliminate expenses associated

chemicals and and inventory control with overstocking and disposal

laboratory supplies of expired chemicals*

* Dollar figure associated with potential savings is unknown.

** The per filter cost to replace and dispose of the carbon filters is estimated to be approximately $1600. The estimated per filter cost to regenerate the carbon

filters is between $545 and $1005; however, for the first changeout, the per filter cost is estimated to be approximately $1600 due to the extra expense

of purchasing spare filters.

regeneration option. The full report provides detailed analyses regarding the cost

of various filter options.

Additionally, annual solid waste expenditures could be reduced 83%, from $6,000

to $1,016, by coordination of reduction

and recycling activities with the other

USPS facilities. The laboratory could also

establish a centralized system for chemical receipt and labelling to reduce waste

and minimize disposal of expired or unneeded chemicals.

The full report was submitted in partial

fulfillment of Contract No. 68-C2-0148,

Work Assignment No. 3-10 by Science

Applications International Corporation under the sponsorship of the U.S. Environmental Protection Agency.
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Exhibit 4. Replacement Cost of Carbon

Material Quantity Cost/lb Total

Nuclear grade carbon 90 lbs./filter; 22 filters $3.75 $7,425

Activated carbon 90 lbs./filter; 22 filters $1.50 $2,970

Exhibit 3. Options for Filter Management

Option 1: Option 1 Option 2: Option 2

Dispose of 22 spent filters Costs Regenerate carbon Costs

and replace in the filters

Testing costs: $230 Testing costs: $450-600 *

Prior to disposal, the Forensics Laboratory must Prior to regeneration

test the carbon to determine whether it is or disposal, the nuclear

a hazardous waste. grade carbon must be tested

for contaminants.

Disposal costs including collection and

transport: Regeneration costs: $525-978 each

22 spent Flanders Filters at an estimated $1,760 Regeneration of

weight of 2,200 lbs. as nonhazardous Flanders Filters V-bed

waste at $80 per filter (the steel may or Carbon adsorber cells

have recycling value)

Purchase costs: $11,595-14,400

22 spent Flanders Filters at an estimated $2,860 One time purchase of

weight of 2,200 lbs. as hazardous waste nine spare Flanders Filters

at $130 per filter. Model T-2V-C63-F16, GG-16,

V-Bed Carbon Adsorber

Cells. Each adsorber

Purchase costs: $32,150 complete with an initial

22 Flanders Filters Model T-2V- charge of commercial grade

C63-F16, GG-16, V-Bed carbon.

Carbon Adsorber Cells complete

with an initial charge of

commercial grade carbon.

Total $34,140 - $35,240 $23,537 - $36,516

First Changeout Cost Per Filter $1,552 - $1,602 $1,070 - $1,660

Second Changeout Cost Per Filter $1,552 - $1,602 Second changeout does not $545 - $1,005

require purchase of new

filters

* Price range reflects bids from different vendors.
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BULK RATE

POSTAGE & FEES PAID

EPA

PERMIT No. G-35

United States

Environmental Protection Agency

Center for Environmental

Research Information (G-72)

Cincinnati, OH 45268

Official Business

Penalty for Private Use

$300

EPA/600/SR-96/110

Carole O. Bell, Mary Hoel, John Nuckels, and John Conrick are with Science

Applications International Corporation, Newport, RI 02840.

James S. Bridges and N. Theresa Hoagland are the EPA Project Officers (see

below).

The complete report, entitled “Pollution Prevention Assessment, U.S. Postal Inspection Service National Forensic Laboratory,” (Order No. PB97-100010; Cost:

$21.50, subject to change) will be available only from

National Technical Information Service

5285 Port Royal Road

Springfield, VA 22161

Telephone: 703-487-4650

The EPA Project Officers can be contacted at

National Risk Management Research Laboratory

U.S. Environmental Protection Agency

Cincinnati OH 45268