Niagara CAER Group Chemical Companies

National Emissions Reduction Masterplan
(NERM)

2006 Report for 2005 Emissions

Member Companies:

Chemtrade Logistics Inc.
CYTEC Canada Inc.
Durez Canada
Kemira Chemicals Canada Inc..
Lubrizol Canada Limited
Mancuso Chemicals Limited
Oxy Vinyls Canada Inc.
PolyOne Canada Inc.




Index

Page Description
- Index
2 Company Contact List
3 Introduction
4 Summary
5 Explanations
6 Chart No. 1 - Chemical Emissions
7 Chart No. 2 - Production Volumes
8 Chart No. 3 - Chemical Emissions per 1000 Kg. Production
9 Chart No. 4 - Chemical Wastes
10 Chart No. 5 - Chemical Wastes per 1000 Kg. Production
11 Chart No. 6 - Combustion Emissions
12 Chart No. 7 - Combustion Emissions per 1000 Kg. Production
13 Table 1 - Chemical Emissions Greater than 1000 Kg. per year
14 Table 2 - Chemical Emissions less than 1000 Kg. per year
15 Table 3 - Chemical Emissions Per 1000 Kg. of Production, 1993 to 2004
16 Table 4 - Chemical Wastes
17 Table 5 - Chemical Wastes Per 1000 Kg. Of Production, 1993 to 2004
18 Table 6 - Combustion Emissions
19 Table 7 - Combustion Emissions per 1000 Kg. Production




Niagara CAER Group Chemical Companies

2006 Company Contact List

Company Name and Business Phone Number
Chemtrade Logistics Inc. Tim Haniford 905.356.8763
CYTEC Canada Inc. Martin Lehman
Ken Milo 		905.374.5844
905.374.5812
Durez Canada, Fort Erie Kevin Rady
Robert Hunt		 905.871.3206
905.871.3206
Kemira Chemicals Canada Inc..
St.Catharines		 Bruno Montpetit
Clifton Brown 		905.688.6470
905.688.6470
Lubrizol Canada Limited Blair Schiebel
Bill Goodfellow 		905.358.5778
905.358.5778
Mancuso Chemicals Limited Robert Patel 905.357.3626
Oxy Vinyls Canada Inc. Don Davidson
Mike Waher 		905.374.5601
905.374.5646
PolyOne Canada Inc. Mario Tremblay 905.353.4229




Introduction

This report is issued by the Niagara CAER Group Chemical Companies as part of their commitment to being open to the public and to operating their businesses according to the principles of Responsible Care®, an initiative of The Canadian Chemical Producers’ Association. This is the fourteenth year of its publication. The results are presented as graphs with accompanying explanations for reported changes. Data is presented at the end of the report in the form of tables. Persons wishing to obtain more information are asked to e-mail their questions to pcollee@cogeco.ca, or they can contact the chemical company directly at the numbers listed in this report.

Operating the chemical plants with the absolute minimum impact on the health, safety and environmental well being of the communities in which we operate and live, continues to be our top priority. As may be seen from the graphs, we are making progress on our commitment.




Summary

Chemical Emissions were reduced by 8.2% while Production Volumes rose 1.7%. Chemical Emissions per thousand kilograms of Production has been reduced to the lowest level in five years, a full 50.6% lower than our Base Year of 1993. Chemical Wastes rose by 18.1% mainly due to disposition of outdated products and non-routine non-hazardous materials as well as materials from product improvement trials. Waste water equipment  modifications will significantly reduce wastes at one plant starting in 2007.

Combustion Emissions were reduced by 3.1% as the result of a new boiler installation matching our lowest level of emissions ever achieved. Combustion Emissions per thousand kilograms of Production has been reduced to the lowest level we have ever achieved, a reduction of  41.6% compared with our Base year of 1993, truly a significant achievement in the area of reducing Green House Gases.

 
 
Explanations

In 2005, Chemical Emissions were reduced by 8.2% while Production levels rose by 1.7%. This reduction was achieved as the result of improved process control and favourable product mixes at one facility. The result of the reduced emissions and increased production is that Chemical Emissions per Thousand Kilograms of Production has been reduced to the lowest level in five years, a full 50.6% reduction from our Base Year of 1993. For 2006 we are projecting further improvements bringing this number to a new seven year low.

Chemical Wastes increased by 18.1% as the result of several contributing factors. Two companies report disposal of obsolete products from non Niagara CAER Group sister plants and also from a company that was acquired. Also some wastes were non-routine, non-hazardous outdated products. One company reported the disposal of some contaminated soil as part of their plant site cleanup. Another plant reported increased non-hazardous PVC waste to landfill as the result of trials to improve product quality. This same company is installing waste water treatment equipment that will significantly reduce PVC waste presently sent to landfill. While we are expecting that the current level of Wastes will continue for 2006, we are estimating that some of the current projects will produce favourable results in the next several years.

In 2005 Combustion Emissions were reduced by 3.1% matching the levels in 2002 and 2003 which were the lowest achieved since we started keeping records in 1993. The replacement of an old boiler with a new one including a steam economizer and the removal of a thermal oxidizer at one plant contributed to this reduction. When the Production Volume increase of 1.7% is factored in to produce record volumes of 374.3 million kilograms, we achieved the lowest level of Combustion Emissions per Thousand kilograms of Production since we started keeping records, a full 41.6% lower than our Base Year of 1993. This represents a significant achievement as we strive to reduce green house gases in Canada. Projections for 2006 show continued improvement in this area.

 



































Chemical Emissions Greater than 1000 Kilograms (kg.) Per Year
2005 Emissions and Comparisons with 2004

Table 1

Chem.
No.

Plant
No.

Chemical Name

Amount Released in 2005
Kilograms

Total
2005
kg.

Total
2004
kg.

% Change
From
2004

Estimate
2006
kg.

Waterway

Air

A4

4

Nitrogenous Material

1,230

 

1,230

2,952

-58.3

1,200

A5

1,4,5

Ammonia

5,682

30,296

35,978

39,730

-9.4

33,300

A6

4,5,9

Methanol

 

3,924

3,924

3,895

+0.7

3,962

A10

4

Iso Octane

 

3,409

3,409

4,495

-24.2

3,500

A13

4

Vinyl Chloride

1

1,995

1,996

1,334

+49.6

1,200

A17

9

Toluene

 

2,797

2,797

2,894

-3.4

2,800

A19

2,5,7,9

Kerosene Type Solvents

 

6,158

6,158

7,011

-12.2

6,900

A20

5

Ethyl Alcohol

 

52,705

52,705

59,514

-11.4

50,000

A21

1

Nitrate Ion

41,039

 

41,039

40,094

+2.3

40,000

 

Emissions less than 1000 kg. per year – See Table 2

1,568

2,288

3,856

4,808

-19.8

3,999

Total Emissions

49,520

103,572

153,092
(-8.2% vs. 2004)

166,727

-8.2%

146,861
(-4.1% vs. 2005)

Identification of Companies: (1) Cytec (2) Lubrizol (4) Oxy Vinyls (5) Durez (6) Chemtrade Logistics (7) Kemira Chemicals (8) PolyOne (9) Mancuso Chemicals Number (3) was CYRO, now shut down.
The numbering system has been maintained to allow comparison with previous years.





Chemical Emissions Less than 1000 Kilograms (kg.) Per Year
2005 Emissions and Comparisons with 2004 results

Table 2

Chem.
No.

Plant
No.

Chemical Name

Amount Released in 2005
Kilograms

Total
2005
kg.

Total
2004
kg.

% Change
From
2004

Estimate
2006
kg.

Waterway or
Sewer

Air

B4

7

Isopropanol

 

117

117

132

-11.4

300

B5

4,5,9

Phenol

130

584

714

737

-3.1

713

B7

5,9

Formaldehyde

 

163

163

192

-15.1

170

B9

1

Hydrochloric Acid

 

243

243

242

+0.4

275

B13

9

Xylene

 

720

720

761

-5.4

750

B33

9

Ethyl benzene

 

126

126

133

-5.3

130

B39

9

1,2,4-Trimethyl Benzene

 

111

111

139

-20.1

130

B42

9

Naphthalene

 

49

49

139

-64.7

50

B62

4

Oil and Grease **

737

 

737

584

+26.2

500

B67

4

Phosphorus Salts

387

 

387

467

-17.1

450

B77

4

Aluminium Ion

139

 

139

171

-18.7

150

B78

4

HCFC

 

2

2

748

-99.7

10

B80

9

Furfuryl Alcohol

160

 

160

141

-13.5

180

10 Chemicals with emissions of 100 kg. or less.***

15

173

188

222

-15.3

191

Total Emissions in this category

1,568

2,288

3,856

4,808

-19.8

3,999

Identification of Companies: (1) Cytec (2) Lubrizol (4) Oxy Vinyls (5) Durez (6) Chemtrade Logistics (7) Kemira Chemicals (8) PolyOne (9) Mancuso Chemicals
** Tests show Oil and grease to be below Minimum Detection Levels, and probably they are zero. The amount reported is for the Minimum Detection Level.
*** Includes: Sulphur Dioxide, Sulphuric Acid, Zinc, Mercury, Phosphorous, 2,2 Di-t-butyl-4-methyl phenol, Calcium Hydroxide, Ferric Oxide, Cyanide Ion, Gasoline.



Chemical Emissions Per 1000 Kg. of Production, 1993 to 2005
Kg. of Emissions per 1000 Kg. of Production

Table 3

 

1993
Base Year*

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006
(Estimate)

Production Volume MM Kg

232

264

300.5

308.6

331.3

342

347

335

298.4

346.3

334.9

368

374.3

380
% Change from Base Year*   + 13.8 + 29.5 + 33 +42.8 +47.4 + 49.6 + 44.4 + 28.6 +49.3 +44.4 +58.6 +61.3 +63.8
 

Chemical Emissions M Kg.

194

160

150

161

149

125

136

134

140

149

143

167

153

147
% Change from Base
Year*		   - 18 - 22 - 17 - 23 - 36 - 30 - 31 - 28 -24 -26 -13.8 -21.1 -24.2
 
Chemical Emissions per 1000 Units of Production
Kg. per 1000 Kg. of Production		 0.83 0.61 0.50 0.52 0.45 0.36 0.39 0.40 0.47 0.43 0.42 0.45 0.41 0.39

% Change from Base Year*

  

- 27

- 40

-37

- 46

- 57

- 53

- 52

- 43

-48

-49.4

-45.8

-50.6

-53

*Base Year – 1993 is the year against which plant performance is being compared.





Chemical Waste Transfers – 2005 and Comparisons with 2004

Table 4

Plant
No.

Chemical Name

Amount Transferred in 2005
Kilograms

Total
2005
kg.

Total
2004
kg.

% Change
From
2004

Estimate
2006
kg.

Landfill

Recycled/
Treated

1

Tributyl-Phosphine Sulfide

5,933

0

5,933

8,632

-31.3

9,000

5,9

Phenol

4,320

0

4,320

52,442

-92

50,250

1,2,4,7,8,9

Solvents; Waste & Lube Oils

 

266,069

266,069

228,085

+16.7

245,000

2

Zinc

 

224

224

319

-30

500

7

Surfactants

 

46,550

46,550

8,500

+447

60,000

4

Vinyl Resins & Compounds

200,916

0

200,916

160,380

+25.3

200,000

1,2

Phosphorus Salts

 

2,734

2,734

2,159

+26.6

2,000

6

Sodium Chloride

 

2,225

2,225

580

+284

636

7

Waste Corrosives – Obsolete Prod.

 

8,400

8,400

24,700

-66

10,000

1,9

Hazardous Organic Wastes

4,360

79,032

83,392

60,113

+38.7

61,000

5

Formaldehyde

155

7,380

7,535

8,321

-9.4

7,200

2

Sodium Hydroxide

 

0

0

200

-100

0

2

2,6-Di-t-butyl-4-methylphenol

 

170

170

0

New

200

2

Contaminated Soil (oil)

26,030

 

26,030

1,224

2026

30,000
2 Chemicals with wastes of 100 Kg. or less per year * 81   81 74 +9.4 71

Total Chemical Wastes

 241,795 412,784 654,579 555,729 +18.1

675,857(+3.3%)

Identification of Companies: (1) Cytec (2) Lubrizol (4) Oxy Vinyls (5) Durez (6) Chemtrade Logistics (7) Kemira Chemicals (8) PolyOne (9) Mancuso Chemical

* Includes: Antimony and Lead



Chemical Wastes per 1000 Units of Production, 1993 to 2005
Kg. of Wastes per 1000 Kg. of Production

Table 5

1993
Base Year

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006
(est’d)

Production Volume
MM Kg.

232

264

301

309

331

342

347

335

298

346

344

368

374.3

380
% Change from Base
Year		   +13.8 +29.5 +33 +42.8 +47.4 +49.6 +44.4 +28.6 +49.3 +48.4 +58.6 +61.3 +63.8
 

Chemical Wastes
M Kg.

630

853

1,136

966

754

954

746

725

560

570

537

554

655

676
% Change from Base
Year		   +35.4 +80.4 +53.5 +19.8 +51.4 +18.4 +15.1 -11.1 -9.4 -14.7 -12 +4 +7.3
 
Chemical Wastes per
Production Unit Volume
Kg. per 1000 Kg. of Production		 2.71 3.23 3.78 3.13 2.28 2.76 2.15 2.16 1.88 1.65 1.56 1.51 1.75 1.78

% Change from Base
Year

 

+19.3

+39.5

+15.5

-15.9

+1.8

-21.0

-20.3

-30.6

-39.2

-42.2

-44.3

-35.4

-34.4




Combustion Emissions - Burning Fuel For Steam Generation
2005 Emissions and a comparison with 2004

Table 6

Combustion Product Component

Amount Released

 

2005

2004

2006 Estimate

Carbon Dioxide MM kg

52.94

54.62

53.2

Nitrogen Dioxide M kg

82.7

99.5

97.31

Carbon Monoxide M kg

33.2

38.9

38.4

Sulfur Oxides M kg

1.3

3.66

2.1

Methane M kg

1.7

1.78

1.7

Volatile Organic Carbon M kg

8.74

9.4

6.2

Totals Millions of kg

53.07
-3.1% vs. 2004

54.77

53.33
+0.005





Combustion Emissions Per 1000 Kilograms of Production, 1993 to 2005

Table 7

 

1993
Base Year

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006
(Estimate)

Production Volumes
Millions of Kg.

232

264

300.5

308.7

331.2

342

347

335

298.4

346.3

344.3

368

374.3

380
% Change from Base
Year		   + 13.8 + 29.5 + 33 + 42.8 + 47.4 + 49.6 + 44.4 +28.6 +49.3 +48.4 +56.6 +61.3 +63.8
 

Combustion Emissions
Millions of Kg.

56.3

57.4

60.4

60.4

59

58.5

60.9

62.3

55.8

53.1

53.1

54.8

53.1

53.3
% Change from Base
Year		   + 1.9 + 7.3 + 7.3 + 4.8 + 3.9 + 8.2 + 10.7 - 1.0 -5.7 -5.7 -2.7 -5.7 -5.3
 
Combustion Emissions
Kg. Per 1000 Kg. Of
Production		 242.6 217.3 201 195.7 178.1 172.2 175.5 186 186.4 153.3 154.1 148.8 141.9 140

% Change from Base
Year

 

- 10.4

- 17.1

- 19.3

- 26.6

- 29

- 27.7

- 23.3

- 23.0

- 36.8

- 36.5

- 38.7

- 41.5

- 42.3