Document YrEKdbzJG8evmgngn3338a7vk

hlooGLOBAL news and analysis for the industry June 17,1992 u.aaLv.AAAUAAA UAL LILLY LALYA. LlALAA LAC. LdlLLLJALY ClLALJlCLJ. L s: ! .'L.AiAYlA L..J LL'.C.. AaiiL.....AA.l J.UiulClS LAAJCA CAALACiA. LYAAVA LLAALAA LYAYLlLA Cl'JJL-LC'J- lYAAllL... j..A-CALaiL.C l:LAAILCYL.A L-UL^lCt- L'-ALLLAAI CAAy.LCALA L: ALLAl ALLY l'-ALYALA ,i - LYAYi.CALL AAYOAa.- AL i ' ':::iLLi jC-lx I A LLALi'J.AlLo.li'i L'A ALLA Cl ALL C. ARCAlA AlA C'LACiCLJ_A liUALlAL. O.LAL..L0.J_ LLALClLLLALY C`.LAL.J.CLA_A LLAllcY LLJaAAULlA, !::.YA-AaALAALC LLA LLL.. LAYA LLLA.A LIALLl. VAClL LlAAICALLA-LYARaA Ai.Ul.iAJ. CA ...LY.id AAA Al ClLAL.LLCL.LA AiAlIALJAL ACl AI'LiY ClLALuLCL.YA AcXlU-ALYLJilLA ALLALL CiLLCLCA. ALLAY LLALlA ClLAlICL.L AlLALAL cyLAUCLL CALJ-LLYY A'JAAA LLYL'AAULlA |_ClUALJ.C CLLAl.iCLJ_A aALY/.Y d.ClliCLY AYACulAL. 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LLaVLlaALLLl ALLLL RAHilLCl L-AULAAALALAAAi L'LCLctLL-La LuLCACLAAl L-AAlAULLuLLl L'-ALLCC : AAAIULALLA V AALAClAAA L'ALtLAA CALA-ALAlULA LCA-LlACALALlL L-ALLIuL-LLAA L-ALLaLAC L-ALLL-LLlC l-alujjalllac llaauaaa *Lf.LUiC L-lLAAliClAC AA L-AULACAA L-LLAAACIUC L:U2LA L'ALAAACIAC A.ALILACAC CAUL L-lLAAliClAA C'LC'LiAl L-LlaVA-AAUil L-YAA ULiACLlL:AIULALA/lL aALLCLCLL LAAALL aULLYlLcLl LLaACLLAV A A LilALACA aALLllLClI ALaAAiL AALLLAQl AALLlLAL AALLiYLC AALLLlLLAl AllALCAA LAAlCCLALYAA aALLiYLCIA LLAALLClA AA LLlC.LCA ALLLClIIAA Y AALlLYlAAAA ALlLCLRAUA AA LuALACA ALALAAL AA LLlALAQ AAAL-AcAACA ALLYVAALA ALlCAYLCllA AAAA YCuCaCa UAAaiAL CALAA.AAl ALlLALY vlALALAA AALLiACAA Y ALilAllCYiA ALYLYA CTL010151 chemscafweek \Pci&fc'iSrt&r S 888 Seventh Avenue. New York, NY 10106 (212) 621-4900; FAX: (212) 621-4949/4950 Editor-in-Chief...................................... David Hunter Managing Editor............ .... Albert H. Kislm Senior Editors Companies/People....... Special Reports.............. Technology...................... News/Markets................. Finance Editor............... Associate Editors Chior-Alkali Wire/News News/Issues................... Environment................... Copy Editor........................ Elizabeth Kiesche .............Rick Mulltn .......David Rotman .......Andrew Wood ... Emily S. Plishner . Maunce Martorella ..........Karen Heller Elisabeth Kirschner ............ John Dioso WASHINGTON Bureau Chief............................................. Ronald Begley Telephone: 202-628*3728, Fax: 202-628-3628 ear Reader, D This issue of Chemical Week is the second annual special re port on the progress that chemical compa nies in the U.S. and worldwide are mak ing in implementing the Responsible Care initiative. The measurable improvements in environmental performance by many companies over the past year are testa HOUSTON Gulf Coast Editor............................Gregory Dl Moms Telephone: 713-977-9271; Fax 713-953-7074 LONDON ment to the leadership of an industry that continues to demand a higher environ mental performance standard in its own 24-25 Scala Street, London W1P1LU manufacturing processes, as well as in Telephone: (44) 71 436 7676; Fax: (44) 71 436 3749 those of its vendors, partners, and all involved in the product life cycle. In Executive Editor........................Natasha Alperowicz i News/Finance Editor......................Debbie Jackson Environment/Technology Editor Emma Chynoweth Markets Editor............................................Ian Young Companies Editor............................. Michael Roberts Creative Director............................Mitchell F. Holmes j Assistant Art Director............... Ellen Costa Grodjesk | Production Manager........................Michael D. Kraus j Assistant Production Manager.........Wiliam D Fick ------------- CORRESPONDENTS-------------- USA: Nashville, Paul Kernels, New York City, Daniel J McConviBe a marketplace as fiercely competitive as the chemical industry, coopera tion in this initiative has been truly extraordinary. Yet for all it has already achieved, Responsible Care still has much to accomplish. The 3 million-plus employees, worldwide, of the chemical industry need to be continually informed of the program's objectives and codes, as well as to understand their companies' and their own individual role in helping it achieve success. As a reader and an employee of the industry, we hope you will accept Europe: Austria, George Hamilton. Italy, JohnGlover Finland, Gerard the vision of Responsible Care by integrating its codes into your area of OTK^ France. Ralph Back. Germany, Mary Neth, Netherlands, Jan Schoenmakers, Switzerland, Laura Piarski, Russia. Alexander Bykov; | responsibility. In turn, if you believe that your company is not doing Yugoslavia, Nada Stantc ! enough to embrace Responsible Care and it has yet to become "a way of Far EastfAsia.* China, Sandy Hendry; Hong Kor^Aice Cheng; India, ; Sheta Tefft, Japan, Stuart Dambrot Korea, Paul Shn Ho-Chul. New I life" in your organization, our hope is that you will use the case histories Zealand, PattnckSmelie, Pakistan, RaufSrddrqi, Philjppines.Bemardo Ronquflo, Singapore, Ian Love; Taiwan, John R Westbrook. and success stories chronicled here to illustrate internally the importance LatinAmerica: Argentina. Richard Kessler; Brazil, RikTumer Mexico. of committing the necessary resources to implement the codes. Your Leslie Layton, Venezuela, Jack Sweeney; Chile, Raul Ferro ------------------- BUSINESS-------------------Chairman & company's survival and your future may rest with it. ! In the final analysis, the virtues of Responsible Care will be determined Chief Executive Officer..................... Louis Perlman by the enthusiasm and support of those of you charged with the daily Vice Chairman.......................................Mason Slaine Executive Vice President responsibility of running the plants, controlling quality, shipping and Publisher.........................................Michael Weiskopf Associate Publisher..................... Alan M. Schlanger Associate Publisher/lntemadonal Business Development.........................LynTattum Vice President, Finance............... Peter Cipriano | ----------------- ADVERTISING------------------ Regional Managers.........Julie E. Falk, Elizabeth Katz, John G. Markovic, Norman H Plotkm Buyer's Guide Manager.............. Joseph J Mennella Classified Advertising...................... Elama Sherman handling products, and disposing of waste. Only when the entire chemi cal industry community is committed to the program and can offer collective results can Responsible Care achieve another important objec tive--that of greater public awareness and acceptance of the role the chemical industry has in everyone's lives. For our part, we are excited about doing our job as a communications vehicle, bringing both the success and the challenges of this ambitious European Sales Managers..........Adnanne Fishman Alan Seth initiative to our pages. International Sales Italy ..r..................Luigi Rancati Director of Circulation.................. Judith L Giordano International Circulation Manager ....ClareWalter (London) Telephone: (44) 71 436 7676 Conference Director.................. Judith C. Marcovrtch Marketing Director........................................... SusanHogan Conference Manager........................ StevenWilson Circulation Manager..................................... ElizabethHoch Circulation Assistant..................................... AracelioRoman Circulation Associate.......................... JulieCalcagni Director of Production...................................tawtonLatimer Buyers' Guide Production .............. Frank Gonzalez Controller.............................................. Kevin F. Higgins Executive Vice President, Publisher Accounting Manager.................. .............. Dipali Dhar Accounts Payable.................. . Katenna Tamopolsky Accounting Assistant........... ............... Pam Sukhram Advertising Assistant......................................DonnaSaguinsin Executive Assistant.................................. Julie Gold Receptionist......................................................... ManeJankowski CTL010153 i chemicalweek 5 PROGRESS IN IMPLEMENTATION 6 GETTING THE NETWORKS IN PLACE_____________ 8 STOKING THE CULTURAL REVOLUTION__________ 10 ADS, ADVOCACY, OUTREACH, AND ACTIVISTS 14 WANTED: A SYSTEM TO AUDIT CARE RESPONSIBLE CARE: A USER'S GUIDE 17 CAER: GROWTH IN AWARENESS AND RESPONSE Open doors, open minds, and fire drills. 20 PROCESS SAFETY Integration with the new OSHA rules. 23 POLLUTION PREVENTION Changes are tough and expensive. 25 DISTRIBUTION Supplier/distributor dialogue drives progress. 28 EMPLOYEE HEALTH AND SAFETY Launching worker input, but caution on labor issues. 30 PRODUCT STEWARDSHIP The challenges of the most sweeping code. TECHNOLOGY 34 THE NEXT STEP Searching for new chemistry CASE STUDIES 37 NIAGARA FALLS WEST VIRGINIA TEXAS CITY SARNIA Chemical Week, ISSN 0009-272X (including Chemical Specialities and Chemical Industries). Copyright 1992 by Chemical Week Associates. is published weekly, except for five combination issues' 1/1*8, 5/27*6/3, 7/1-8, 8/26*9/2 and 12/23-30. plus the annual Chemical Week Buyers' Guide published in October. Subscriptions: One year rates (48 issues) are S99 in the USA and possessions, and $129 in Canada, Europe-8258. Japan and Far East-8278. Brazil-Sl73, All Others-$157. Single copies; USA and possessions. $8. elsewhere $10 Postmaster please send all correspondence related to subscription matters, including address change to: Fulfillment Manager, Chemical Week, P.O. Box 1074, Southeastern, PA 19398 USA. To telephone, call collect 215-630-6360 from anywhere in the U.S. except Alaska and Hawaii. Second-class postage paid at New York. NY. and at additional mailing offices. Postage paid at Montreal. P.Q., registration No. 9443. Title registered in U.S. Patent Office. Registered with the British Post Office as a newspaper CTL010154 42 WHAT THE COMPANIES ARE DOING SYBRON CHEMICALS EXXON CHEMICAL FMC TEXACO CHEMICAL 3M CORP. LUBRIZOL NALCO BP CHEMICALS UNIROYAL AKZO CHEMICALS NATIONAL STARCH BFGOODRICH RHONE-POULENC CHEMDESIGN WITCO GENERAL CHEMICAL AMERICAN CYANAMID NOVACOR OTHER INDUSTRIES' VIEW From emulation to dismissal. 58 CANADA S COMPLIANCE DEADLINE APPROACHES The focus is on tough issues. 61 MEXICO: RESPONSABILIDAD INTEGRAL Guadalajara explosions ignite community interest. EUROPE 63 AIMING FOR A UNIVERSAL PROGRAM The message: Think globally, act locally. CTL010155 R&gponsitb Care'\ apid transfer of technology has country's program deserves to be called Ralways been a feature ofthe chem Responsible Care," says Louis Jourdan, ical industry. Now, a parallel ICCA's secretary and technical director transfer--of a package of industry oref the European Chemical Industry sponses to society's environmenCtaoluncil. But devotees recognize that expectations, Responsible Care--is tak countries' programs can reflect national ing place. cultures, while meeting certain stan "We are meeting the challenges of dards so that the essence of Responsible Responsible Care with many new and Care is not diluted. innovative ideas--ideas we share as ICCA has a proselytizing role, we strive to capture that elusive moral though. It aims to "globalize" the parts high ground on environment, health, of Responsible Care that will benefit and safety that we crave," Dow Chem from a worldwide approach, and ensure ical president Frank Popoff reminded the efficacy and constancy of programs Chemical Manufacturers Association worldwide. Aims also include provid members earlier this month. ing a platform for information exchange Two developments stand out in the in areas where it makes sense to adopt year since CWs first special issue on uniform measures internationally. Responsible Care--the strides made by Those could include management stan companies to implement the initiative, and the worldwide scope it is taking--from its origins in Canada, through the U.S., arid on to Europe and other points on the globe. Nineteen countries have now met the International Council of Chemical Associa tions' (ICCA) Responsible Care standards--Australia, Austria, Belgium, Brazil, Canada, Fin land, France, Germany, Ire land, Italy, Japan, Mexico, New Zealand, the Nether lands, Spain, Sweden, Swit zerland, the U.K., and the U.S. The next ones likely to join are Hungary, Poland, and Turkey, with South Korea, Taiwan-- and as this issue shows--India and dards and--most important--perfor South Africa showing interest. mance indicators. TRANSCENDENCE. "It seems to us that "We are trying to attract a number of Responsible Care is transcending what CEOs from countries not yet committed we are doing," says CMA president [to Responsible Care] in Central and Robert Roland. "As more and more Eastern Europe and developing coun countries join, people are saying, `Re tries such as India," says Jourdan. He sponsible Care must mean something. ' " hopes that company chiefs already com How will "the true way" be enforced? mitted to Responsible Care will also Roland's response: "I only know it's attend to share their experiences and become an ethic. The more you pre encourage "nonsubscribers" to partici scribe an ethic, the more people will pate. The first ICCA Responsible Care resist. The more they see it doing good, seminar, held in Rotterdam in spring the more they will embrace it.!' 1991, was a notable success; the next is Brussels-based ICCA has codified planned for Lisbon in October, to coin what can be called Responsible Care. cide with the Society of Chemical In ICCA's leadership group is highly inter dustry annual meeting. national, though--three from the U.S., Industry is already being pulled to two each from Canada arid Japan, one gether. Mexico consulted with Canada from Australia, and five from Europe. and CMA as it prepared its Responsa- It acts as "a jury to decide whether a bilidad Integral initiative; the U.K.'s Chemical Industries Association (CIA) is helping countries like India and South Africa; and U.S. firms have opened their doors to Japanese manag ers eager to see how the initiative is being put into action. Communication between national chemical industry associations is rife, as they try to devel op a united front on how the initiative should be enacted, says Tamar Posner of CIA. "Several federations around the world are preparing product steward ship documents, and we are all ex changing information like crazy." PRESSURE. Peer pressure is working at both company and countrywide level. Multinationals are playing a particular ly crucial role in the global movement-- as the hefty showing in the pre-Earth Summit business forum testi fied. In India, for example, multinational affiliates are far thest down the road in imple menting the program, and such companies are seen as role models by wholly Indianowned companies, sources say. Seven out of the world's top 10 chemical firms now have public pollution reduc tion goals (p. 32). "You'd like to think that down the road, at the turn of the century, just about every thing that involved chemi cals--bending molecules-- will be working along similar principles to Responsible Care," says John Johnstone, Olin chairman and CEO and outgoing CMA chairman. "I'd like to think that by the turn of the century, with that common set of objectives, the world would be a hell of a lot safer--in terms of emissions, safety, transportation in cidents. For a lot ofpeople, poverty may now be a lot higher priority, but as societies worldwide become more af fluent, people get to be more concerned with the things Responsible Care cares for. If by peer pressure we could ad vance the rates at which Responsible Care would advance worldwide--a chemical industry accident anywhere in the world is a chemical industry accident--we could hope to see an im pact from the Responsible Care pro gram." EMMA CHYNOWETH and DAVID HUNTER 4 CTL010156 Responsible, 6are\ -IMPLEMENTATION TIME Public outreach advances lead the way iven the scale of the undertaking, ensuring consistency across their oper Gthe Chemical Manufacturers As ations. They are also working on objec sociation is pacing its expecta tive evaluation mechanisms--to show tions, if not its efforts, on Responsibthleat the management practices are in Care. "Nobody has ever put anything place and to monitor the absolute im this big together before," says CMA provements in environmental perfor president Robert Roland. "Inculcating mance the codes are driving toward. safety awareness took years at the big Meanwhile, chemical industry tox companies. Now we're working with ic releases continue to trend down. something that transcends even that-- Signatories to the Environmental Pro Responsible Care." tection Agency's voluntary air toxics Progress has been substantial. The reduction initiative--the 33/50 pro six management practice codes are gram--are well on the way to their complete, with the last--the ambitious targets. Some, like Miles Inc., have product stewardship code, dubbed already completed it. "the mother of all codes" by many a There is significant momentum be Care specialist--approved in April. hind new clean process development CW visits to sites across the U.S., and (p. 77). Responsible Care programs are our update on the codes (p. 37), reveal tying up with other initiatives: parallel a widespread mobilization to imple implementation of the OSHA process ment the program. safety regulation with the Care code is Progress in public outreach--the under way across the industry. core of the initiative, along with Straightening out industry's envi- ronmental record to head off the risk of crippling regula tions remains the number one issue for chemical indus try leadership, ahead of concerns over the economic climate. Identified as a prerequisite for industry's survival, this preoccupation seems set to assure the continued mo mentum for Re sponsible Care--us ing the initiative's principles of im proved perfor Redrawing the industry/community interface mance coupled with dialogue as the improved environmental perfor basic technique. mance--is the most striking, with "Today we are judged primarily as 160-plus public advisory panels in practitioners of Responsible Care," place, compared with 89 at the end states Dow Chemical president and of 1990. An increasingly compre CEO Frank Popoff, newly appointed hensive web of networks--geo CMA chairman. But "we have a long graphical, sectoral--is being put in way on a hard road before Responsible place to bring smaller firms and Care is fully operational." service organizations into the fold, Industry and the program have had following the lead of the major com their share of challenges in the past panies. year. There have been no accidents on Companies are driving ahead with the scale that rocked the Gulf Coast in internal programs to fine-tune imple 1989-'90, but chemical-related prod mentation of the management codes, uct scares continue to make head lines--for example, silicone breast implants. And Responsible Care--now a year into a national magazine adver- , tising campaign--has had its own bap- j tism by fire, as environmental groups have taken up the "Don't trust us. track us" pledge. That has been at both the national level--the U.S. Public Interest Research Group survey released in March--and the local level. At several locations, industry's newly declared spirit of openness has encouraged environmen talists to ask for more data to be shared: in some cases it has (pp. 19, 88). "Activist groups have increased their efforts in the past year; grassroots activists see that we're affecting their power base," says Jon Holtzman, CMA's v.p./communications. "But criticism makes us stronger. Regard less of their intentions, they're helping us." As a result of the new commitment to dialogue, the transformation of plant managers into a media-aware, communications-savvy cadre is well under way. One casualty has been the numer ical evaluations of code implementa tion, at the urging of industry lawyers who fear liability entanglements, in favor of a vaguer, worded evaluation. Most firms continue to use the num bers internally, however. DISDAIN DWINDLING? Is there any mea surable impact yet on the public's dis dain for the industry as a result of efforts under the Responsible Care pro gram? "I think we have done signifi cant damage control and arrested the slide," says Popoff, "but I don't know if we have turned it up at all. Still, I think our abysmal position isn't getting more abysmal." It's a steep climb out. Take the latest Toxics Release Inventory numbers. While CMA members' 1990 releases were down 17% from 1989, the U.S. chemical industry's 1.59 billion lbs of releases, 44% of the national total and three times that of the metals indus try--the next biggest contributor--re mains a major liability. Safety data is another mixed picture: the industry's overall record is excellent--in the top three nationally along with oil and gas extraction and textiles--with incident rates for deaths and lost-time injuries at one-third of the national average, according to National Safety Council data. But there is no clear improve ment trend. "Our guts and hearts tell us we are improving. Each company has data to suggest that," says J. Roger Hirl, presi dent of OxyChem and chairman of CTL010157 5 i Responsible, Care CMA's executive com CMA members have lar value of lost equipment or lost pro mittee. "Are we a zero- roughly 1,500 sites in duction. already tracked for insurance risk industry? No. and the U.S.; while mem purposes. CMA is also studvino when accidents hap bers are under no obli schemes [pp. 44, 62.) pen, they tend to hap gation to set up panels, "I see the momentum of the Re pen with a magnitude there is no question that sponsible Care program primarilv sus that affects the whole there is a considerable taining itself by CMA putting in place industry." distance still to travel. a monitoring and measuring system," Adds Earnest Deav- Du Pont, for example, says Eastman's Deavenport. "We're enport, president and doubled its tally of pan still not to the point where we have CEO of Eastman Chem els in the past year to 35. good, objective data that validates ical and CMA vice But with 105 sites in the what a company is doing, tracked chairman, "In the U.S., the company has a against milestones. There will be a lot minds of the vast ma long way to go. of public pressure once we get that jority of people, envi Code implementa data out, and the program will be an ronmental conscious tion also has a learning ongoing part of every company. Proba ness is still on the up ward trend. [Attitudes Popoff: A long, hard road. curve--with evalua bly the majority of CMA members real tions tending to toughen izes we must have objective validation toward industry] are not going to swing as familiarity with the codes builds. of Responsible Care. "Where we differ all of a sudden at a few positive signs. " "Facilities that had studied the codes is, how do we get there? There's a Take Louisiana. Louisiana Chemi have marked themselves harder than certain amount of fear of the un cal Association membership has cut those that hadn't studied them very known," he says, as well as wariness emissions and pioneered outreach carefully," notes Richard Zielinski, by smaller firms--whose resources are techniques, including local television v.p./manufacturing and engineering already spread thin--on taking on ad advertising, and Dow's Plaquemine with Amoco Chemical. ditional burdens. "Helping across the plant won a CMA award for its com STRIDES. Hence the move under way industry will be the key to better per munity awareness and emergency re at companies to standardize their eval formance on Responsible Care." sponse (CAER) program last year. uation systems, linkinggradings to pre At this point, morale looks good. Tracking of public sentiment on the cise requirements. "This has been one "From regional meetings, I can see that industry has even registered some of the main strides forward over the a lot of people are struggling," states headway on industry's readiness to past year," says Donna Carville, Dow Jack H. Ferguson, director of manufac listen and its emissions reduction Louisiana Division Care coordinator. turing and Responsible Care coordina record. But the New Orleans Times Besides auditing CAER (p. 37), Dow is tor at Neville Chemical, one of CMA's Picayune won a journalistic award and one company looking hard at ways to smaller firms, with 425 employees. was a Pulitzer Prize finalist for an early quantify environmental perfor "But what I pick up is this: nobody sits 1991 investigative series on pollution mance--considering existing mea there and says, `This is ridiculous and I and the local chemical industry that sures like OSHA injury logs, internal don't think we should do it.'" did not even mention the Responsible safety compliance logging, and the dol DAVID HUNTER Care program. Possibly a pointer to sustained reader interest, a similar se NETWORKS BROADEN THE PUSH TO CAREries ran recently in the Baton Rouge Advocate, entitled "Environmental Racism?'' Mutual assistance, peer pressure come into play Still, "there is a significant increase in the frequency of dialogue," says Ben n an attempt to get the Responsible lem with a non-CMA plant associates Woodhouse, Dow's director/global is sues management, environmental health and safety. Panels are prolifer ICare initiative to encompass the us all with a black eye." entire $285-billion/year U.S. chem In Louisiana, for example, some ical industry and to bring in key servermajor non-CMA member chemical pro ating "because industry is finding industries like transportation, a huge ducers like Formosa Plastics, Union they're really working for us. Panel network is being put in place. Texas Petroleum, and a couple of large members take a hard look and give us Key components are the regionally fertilizer makers are exploring affilia advice." - based executive leadership groups tion with the program, says Dan Borne, CHALLENGE. Learning to really make (ELGs), ties with trade associations like president of the Louisiana Chemicals panels work is a challenge. "Panel mem SOCMA that are working with non- Association (LCA). Companies also can bers' interest is in what a plant is doing CMA member firms, and state chemical tie in directly as partners. Chemical to flare less, stink less, and about emer industry associations. The aim: con Waste Management, for example, be gency response," says Diane Sheridan tacts to facilitate cooperation and assis came an associate earlier this month. of the Keystone Center, facilitator of tance--particularly from large compa Links between suppliers and cus five panels and a member of CMA's nies to small companies, and spreading tomers are also being encouraged. national panel. Often they lack the the net of Care compliance as wide as While there is emphasis on personal knowledge to translate that into specif possible. There is also a clear intention networking, these efforts are being ic requests for action, which is where to mobilize peer pressure. backed up by a communications net activists can help. "There's a powerful "We're trying to bring everyone into work--electronic bulletin boards. message to a company when it hears the the family," says Jim Dixon, chemicals Having found their rhythm, the same concern from both activists and group Responsible Care manager with ELGs--now 13 across the U.S.--are nonactivists," Sheridan says. Air Products and Chemicals. "A prob proving a useful part of Responsible 6 CTL010158 Rexponsiile, Care. "There's been tre we do to help?'" rather than exclusive." savs Hal mendous feedback." Coordination among Bozarth, executive director of C1C/N) says CMA president Robert Roland. Each is the associations is re (Trenton). Pennsylvania CIC (PCIC: quired to avoid duplica Harrisburg) executive director David chaired by a board mem tion of efforts. "There's Patti notes. "Even if [members] imple ber. "We learned they no pride of ownership ment only one code, they're still a better needed to meet local here," comments Car company, by improving environmen ly--mutual assistance olyn Covey, manager of tal, health, and safety performance." requires cohesion." performance excellence A lot of Responsible Care has been In northern New Jer programs at the Synthet from the top down. Patti savs. noting sey, a 17-companv ic Organic Chemical CICs are taking the "bottom-up" ap group holds five-hour Manufacturers Associa proach. "We hope the two efforts are meetings twice yearly. tion (SOCMA; Washing- successful." He observes that "things Two forums meet, one ton) on the cooperative aren't filtering down quickly." A lot of for top company leader nature of Responsible companies "know they should be do ship, the other for Care Care. And there's a nat ing something, but they're not sure coordinators, "who spend their time going Bozarth: 'Let's be inclusive.' ural connection be what." tween state chemical SOCMA and the state associations over the nitty-gritty," industry councils (CICs) are trying to educate their member says Ernest Drew, chair and the CMA, since ships about Responsible Care and eval man of Hoechst Cel- CMA funded the star uate needs. By year-end, SOCMA staff anese and head of the tup of many CICs. will have visited almost all member ELG there. Resulting SOCMA, the Chlo companies, says Covey. "Now we're from the discussions: rine Institute, and sev focusing on how what they're alreadv combined community eral CICs have signed on doing is related to Responsible Care," advisory panels at sev as partner associations she savs. Companies may have mecha eral locations; mutual in Responsible Care. nisms in place that fulfill some require assistance initiatives; Partner associations ments, says Covey, but they may not be shared feedback on in pledge to encourage associating that effort with a code. "We ternal communication their members to imple try to show them how things fit togeth and outreach, and self- ment Responsible Care er," as well as where they are most evaluations; and resolu- and to sign on as partner vulnerable, and need to develop a sound tions to encourage companies. strategy. chemical engineering The coordination SOCMA has formed a work group schools to teach pollu among chemical indus for each code to collect and review tion prevention cours es. "We're getting issues Covey: How things fit together. try groups forms a threetiered structure. CMA's materials already available to aid in implementing Care. "The purpose is to out, getting some real discussion, " Drew members are mostly large chemical pro ensure sufficient resource materials says. ducers, and its activities usual- mmmmm In Connecticut, Crompton & lv involve top executives. On Knowles chairman Vincent Calarco is the second tier, SOCMA deals ELG chairman, with Olin chairman mostly with the issues facing John Johnstone, last year's CMA chair smaller, specialty chemicals man, as his deputy. "The meetings have companies. State associations brought up issues that we can then feed have a mix of large and small back to CMA, like how to approach the companies, but these groups codes--no one has all the answers. Peo generally take on the plant man ple can vent frustrations, talk about ager's perspective and deal with their successes," Johnstone says. the specific legislative and reg "When people vented frustration, oth ulatory environment of that par ers offered help." As for attendance, ticular state. "everyone comes injthe course of the CMA members are required year. If attendance drops, the chair to apply Responsible Care to man/vice chairman can make a few phone calls, so we can put on a little their operations, as a condition of membership. SOCMA mem nirtrMfil programs are fundamental to Care. peer pressure," he says. bers are required to implement the com available for small facilities to imple Improvements to come on ELGs? munity awareness and emergency re ment each code," says Covey. Eventu "Eighty percent are working pretty sponse code. Although SOCMA does ally, the groups will develop resource well," says Eastman Chemical presi not require members to practice the materials to fill in the gaps. dent Earnest Deavenport. "We need to other five codes, it provides informa Smaller companies are looking at develop a `shepherd program'--so that tion and assistance in meeting all of Responsible Care in terms of time, ex a certain number of firms feel a respon them. pertise, and money, says CIC/NJ's sibility for the total number of people in State associations urge members to Bozarth. "For a small guy, that becomes their group. Small companies may not take Responsible Care at their own pace. a large chunk of money. Just assembling want to ask for help. It-'s incumbent on The initiative "is such a new program. the expertise is difficult." New Jersey those with resources to ask, `What can Our philosophy is let's be inclusive, firms, subject to some of the strictest CTL010159 7 Responsible, environmental legislation in the nation, may see Responsible Care as "more bur STOKING THE CULTURAL REVOLUTIONden and more paperwork," he adds. And while Louisiana's chemical in dustry has made strides in emissions Setting buy-in to Care from the top down reductions, its members have expressed concerns about how to communicate progress to the public, says Richard Kleiner, LCA public affairs director. e have an industry that got reli `W gion fairly quickly in the last 10 years. We have CEO buy-in; it's will look on him as a policeman." says Richard Zielinski, v.p./manufacturing and engineering and Responsible Care For example, chemical producers in not so clear below the surface," states coordinator at Amoco Chemical. Louisiana have reduced total emissions Diane Sheridan of the Keystone Center, "The employees have to know the by 51% between 1987 and 1990, but facilitator at five community advisory program, and we rely on them to make it only 16% of Louisiana residents sur panels and a member of the Chemical happen," says Susan Engelman, v.p./ veyed say emissions are decreasing. Manufacturers Association's national environmental, health, and safety affairs And 84 % say they do not believe indus panel for Responsible Care. "My fear at Hoechst Celanese. "It's like safety: you try statements about its impact on the would be that the average worker at the can't just want it; they've got to make it environment. LCA is developing a pub plant will know there's Responsible Care happen. And they're the contact to the lic understanding campaign pro- but thinkit's just community. They're our ambassadors." posal, which would include another fad and Top managers are girding themselves some type of advertising, Klein say: `Just let me with an arsenal of techniques--many er says. do my job, and borrowed from TQM programs, which a Mutual assistance networks it'll go away.'" large number of companies have used are springing up in all three tiers. Top manage as the basis for Responsible Care imple CMA and SOCMA have such ment under mentation, since both share the under programs, which usually match lines this con lying principle of continuous improve up larger, more experienced cern. "The big ment. These include goal setting, team firms with smaller ones. These gest issue for the building, and quarterly reviews. networks vary from electronic chemical indus Improved internal communications bulletin boards to printed direc try is having are a given. Besides diffusion of videos, tories. CIC/Illinois (Rosemont) management letters to employees, and articles in has started a statewide mutual who are all real employee magazines as each code is assistance program using tele ly committed to launched, "there's a great increase in phone conferencing, in which the program, the number of meetings with employ larger companies "are going to and who can ees--managers are meeting plant staffs be the resources for smaller com panies," says John Hand, associ loretfc Committed management "itmern" down on a quarterly basis, whereas three years ago, an annual meeting would have ate director. Still, he reports, "every to the worker and the plant site," says J. been exemplary," says James Vines, body feels they need help--small com Robert Lovett, executive v.p./gases and v.p./environment, safety, industrial panies and large." SOCMA's mutual equipment at Air Products and Chemi hygiene, and security at Miles Inc. assistance program matches up compa cals (AP). Opening the plants to outside visitors nies looking for advice with companies At Du Pont, Gerry is also having an impact, that have experience in that area. Faigle is now full-time Vines says. "Visitors are SOCMA has a "Responsible Care Update" newsletter, published every other month, and a Responsible Care Idea of the Month bulletin. PCIC has Care director, reporting directly to the head of Du Pont Chemicals. "It's an important signal to impressed by the tidiness of our operations. And having the visits helps keep plant housekeeping also compiled a manual that brings people in Du Pont," he up." Keystone's Sheri together materials from PCIC, CMA, SOCMA, and the National Association of Chemical Distributors' Responsible Distribution program. CIC/NJ has not done anything "pro says. "I'm much closer to the line. " A lot of oth ercompanies have made similar, senior level ap pointments to underline dan sees this contact with communities as funda mental to pushing the program through. "One piece of making workers active, press-wise," says Bozarth. But it plans to spread the word of the chemi cal industry's progress once the state chemical industry is able to show mea the program's status. Another approach: At Hoechst Celanese, 25% of the evaluation for se aware is contact with the public, to focus employ ees at all levels to think: `what would the public surable improvement through Respon sible Care. "When the timing is right, we are going--with CMA and member companies--on editorial board'visits, and do an all-out legislative blitz," vis nior management remu- say?' If you're talking neration progress is based on with imple Robertson: Full reach. about that in the work place, it makes the whole menting the Care program. Responsible Care thing come true." Borrowing from industry's experi At Monsanto, the Responsible Care iting regulatory agencies and familiar izing their technical people with Re sponsible Care, says Bozarth. ence with Total Quality Management (TQM) programs, there is unanimity that full employee involvement is es program has been built into its own Monsanto Pledge program. "One of the keys to success is internalizing so that DAVID HUNTER sential. "If the Care coordinator is the employees feel ownership," says Ni and EUZABETH S. KIESCHE only one who makes it happen, people cholas Reding, executive v.p./environ- 8 CTL010160 i Regponsiiie, Care' ment, health, safety, and man- ufacturing. "There's tremen dous ownership bv employees in the Monsanto Guidelines pledge, but less individual own ership in Re sponsible Care." His strategy is to keep the strengths and add areas ..................... Hirl. Kicking tires. that are expanded on by Respon sible Care. "We've gotten buy-in by in volving all the operating units and staff groups in the selection of priorities. So they've already been part of it when we announce the target--operating people don't like corporate targets." Safety-related practices find a ready audience. At PPG Industries' Lake Charles, LA site, it does not surprise David Angell, works director/environ- mental assurance, that drug-testing has been readily accepted. "If I were step ping on an airplane, I'd want to know the pilot had been tested," he says. How far do firms think they have come with getting the program in place? At Eastman Chemical, surveys show that 80% of employees know what the program is, says CEO Earnest Deaven- port. "Responsible Care is translated for each person, rather than teaching them about the entire program, which may not affect their job." At Exxon Chemical Americas, work place attitude and site surveys show that "implementation has reached down to the lowest level of the organization," declares Ken Robertson, president. "On an ABC scale, we're a solid B, and we expect to be an A in two more years." "Not everyone can recite chapter and verse on Responsible Care yet--where as they can on safety," says AP's Lovett. "We've so successfully indoctrinated our work force on safety that to come back and say safety is just part of Re sponsible Care is a little difficult. We'll succeed, but it will take a few years." He assesses the firm "roughly halfway" to implementation. "I have the reputation for being a tire kicker," says J. Roger Hirl, president of OxyChem, who enforces compliance reviews of Oxy's sites to satisfy himself that implementation is going ahead-- and whose headquarters'- security staff wear Care badges. "Responsible Care is the modicum for operations in this in dustry." DH CIBA-GEIGY POWERS CARE WITH EMPOWERMENT Ciba-Geigy's St. Gabriel, LA site has a novel approach to ensuring employee buy- in to Responsible Care. Instead of top management, a 12-person committee drawn from middle management at the 1,000-employee site reviews " implementation of the program and makes recommendations. "It's a sign to management to get things done, because we'll check up on them," says committee member Kerry Foster, a data-processing supervisor. - ; .. Jhe committee spends three to four . ' ; hours per week in meetings, and `then members go back into the plant, and to the community," assuring feedback, notes - i j j committee member and senior staff engineer Martin Fontenot. "Employees want to work where they can go home and talk to their children arid know they're working in a plant that's operating in a ,, responsible manner." \-;v-- Improvements already in place at the site, the biggest atrazine herbicide plant in the world, include a program to test operator proficiency and the expedition of ' some pump replacements." - . y The concept of committees is well established at the site, with ones in place on safety, the environment--and even the annual festival. "We're trying to develop a ' culture where everyone takes ownership," says plant manager Ken DeVun: "lt's not ' ' easy management, it's more time- '-" consuming, everyone has an opinion, but - ; you get solutions that stick.; --^ThekeyTogetting employeesto fully i-- 'take up Carets that thefsee relevance to"1,- the long-term success of the business, 'says Ciba-GeigychairmariRichard Barth.-' \"It's a combination of competitive advantage and--maybe--business : - ' *- survival,"-he says -= Performance Chemicals CTL010161 9 i Rzspongiib Core, ADS, ADVOCACY, OUTREACH, ACTIVISTS "Responsible Care says we will im prove performance in managing our products and processes: that compa Sparks fly, but connections are being made nies will implement the six codes to improve performance: and improve he past year has been a water making plans for the future or explain performance by soliciting the opinion Tshed for the Responsible Care ing the past. We are dedicated and we program. On the positive side of are going to find a wav to do it," he the dividing line, it has gone publicaindds. "And we hope that we learn of the public," Holtzman says. "No where is there a list of what informa tion "we must provide." national magazine advertisements thfarot m this, and can pass on what we've Responsible Care does not say that have begun to gain public recognition learned to other sites." Topics Poje being responsive to people's concerns for the program. And there is anect- says the group hopes to discuss in means giving them a copy of anything dotal evidence that the program is im clude the accident, practices that may thev want. Holtzman says. "A lot of proving employee morale and employ have led to it, and steps that have been companies do a lot of different things. ee relations. But on the other side, taken to correct those practices. A full Our long-term goal is more openness. Responsible Care and the chemical in er agenda is still being established by Nor do we demand that companies be dustry have begun to run into increased the coalition, he adds. in lockstep with each other." challenges from local and national en Environmentalists like Fred Millar A 'TWO-FACED COIN.' In the long haul, vironmental groups. And in the course of Friends of the Earth (Washington) Holtzman continues, "it remains a ques of those encounters, groups have in and Gary Cohen and Sanford Lewis of tion of trust, and that includes our voked the spirit, the letter, and even the National Toxics Campaign Fund trust of them [environmentalists and the strategy of the Responsible Care (Boston) view the meeting as a test of skeptics], too. We won't earn their program in support of their demands. Responsible Care. The coalition re trust by saying give it to us; and that is For example, at Seadrift, TX, Union quested the meeting, along with sever a two-faced coin," he says. Carbide is in a dispute with a neighbor, al other demands, in a formal petition Two other challenges to Responsi Diane Wilson, and a coalition of envi of grievance sent to CMA in April, ble Care came from the Public Interest ronmentalists called Communities Con asking the trade group to kick out Car Research Group (PIRG) (CIF, April 3, cerned About Carbide. Wilson, presi bide for failing, among p. 6) and Mother Jones dent ofCalhoun County Resource Watch, other things, "to pro magazine. PIRG tried to has requested a meeting with managers vide citizen information call contacts at 192 and engineers at the plant. The request and access to the facili chemical plants to ask was triggered by an explosion at the ty." Adherence to Re questions about, among plant in March 1991--which killed one sponsible Care is a con otherthings, emissions, worker and injured 32 others--and an ! dition of membership what toxic chemicals go ensuing federal investigation. | in CMA. into products, and ac What is unique about Wilson's re Information request cidents. At 81 plants, quest is that she has asked to bring one ed in the grievance in no contact was reached. or more experts to the meeting to help cluded documents on But 35% of the compa her shape a dialogue that puts her on groundwater contami nies were not CMA equal footing with Carbide's engineers nation, hazardous waste members. PIRG did not and experts. disposal practices, tox use the CMA 800 num DEDICATED. A few weeks ago, Carbide ic waste reduction plans ber but called plants di set a precedent for the industry, by the for the next 5-10 years, rectly. Nor was PIRG company's own reckoning. It agreed J and internal safety au aware that companies to meet not only with a member of a dits for the past 20 years. have Responsible Care plant community--a central commit In response, CMA Hartmann: Accountability needed. coordinators. ment of the Responsible Care outreach called the plant and the corporation to Mother Jones, on the other hand, program--but also to meet experts. So make sure they were implementing called the 800 number, got the names far, that means Jerry Poje, a toxicolo Responsible Care and communicating of 10 member companies, and phoned gist with the National Institute for En i with the community. They were doing them. But, the magazine told CMA, it vironmental Health and SGiences. A both, says CMA v.p./communications did not get satisfactory responses. firm date has not been settled between 1 Jon M. Holtzman. Holtzman promptly called those 10 the parties. And Wilson hopes to have The Seadrift conflict highlights how companies and set up a test call of more than one expert on her team. But j easy it has been for the Responsible every member company. "We were the stage has been set, following a visit : Care program to be misinterpreted. In successful in reaching 70%," which to Poje in Washington by Carbide's the past, environmental groups and i he says "is not good performance." As Fred Moore, assistant director/corpo- others have requested information or j a result, CMA has created a new proce- jrate health, safety, and environmental action of chemical companies on envi dure of quarterly checks of its 800 to explore the issues to be discussed. ronmental, health, and safety issues i phone system, including some CMA "We are trying to establish a dia and have had high expectations, per calls to the callers to ensure that they logue with Miss Wilson and Poje, but ceiving their petitions to be consistent are satisfied with their answers. it is not easy to do smoothly. We are with the Responsible Care program. While the PIRG study may not have learning, too, " says Seadrift plant man- j But the responses have included a les been a true test of Responsible Care, or ager Ron Cottle. We're feeling-our way son on what CMA says Responsible the phone system or the openness of along with this situation, rather than Care is not. CMA member companies, study au- 10 CTL010162 Regpottgiiie' Care, thor and attorney Carolyn Hartmann ers (which range from the public to isiana Fortier plant have been im sticks bv her reasons for it. "There is a communities to customers to Wall pressed by Responsible Care (p 107) need for accountability. You can't build Street) there is a noticeable positive It has improved employer/emplovee trust or make a program work if infor shift in opinion because of Responsi relations, which has influenced the mation is only in the hands of one ble Care. Chemical industry employ plant's community relations, says panel side." ees are, observers say, gaining pride operator and union committee mem That gets to the heart of what chem and confidence in the environmental, ber A.J. Boudreau. Because workers ical companies and environmentalists health, and safety efforts at their com feel safer, he says, they encourage peo are now trying to address: how to go panies. ple to participate in plant outreach about accurately tracking the progress i "I think [Responsible Care] has made activities. Or at the very least. Boud of Responsible Care. | a huge difference internally," says Pe reau adds, they do not discourage them Another criticism of Responsible 1 ter Sandman, consultant in risk com from using the corporate park adja Care is that the lobbying practices of munication and professor at Rutgers cent to the manufacturing site for fear industry representatives do not match University. "Those who work at com that the plant will blow up. the spirit of the initiative. "The biggest panies constantly mention it. There is That kind of support will become Achilles' heel of the program is the enormous interest in the fact that the even more important when CMA steps lobbyists in Washington, and espe cially at the state level, who are shoot- ] ing Responsible Care in the foot at ! every turn," says Ross Vincent, an en vironmental consultant and member of CMA's national advisory panel. Vincent is particularly upset over what has been going on in Louisiana. A controversial program called the Scorecard, a centerpiece of the state 1 environmental movement, which bit into local chemical company tax ex emptions based on the volume of pol lutants generated by a facility, was eliminated by the new governor, Ed win Edwards. The chemical industry has fought Scorecard tooth and nail since its conception. In response to these and other like criticisms, CMA recently created a com mittee on advocacy. The committee has nothing to do with Responsible Care, notes Holtzman, who declines to name its 10 members. "We, inside CMA, Activists: Protesting as a way to establish dialogue. understand there is a potential for con industry is changing," he say's. "I also up its advertising program, scheduled flict. We want to make sure we manage hear complaints that `our company for this fall, from print to television. it correctly. We are looking at how we probably won't take it seriously,' or So far, CMA's advertising task force should manage it. And we intend to that management would never have has examined one set of ads that in test ourselves against the goals of Re the courage to `admit a screwup to clude the 800 number, says Dick Dal sponsible Care." local citizens.'" That is said sadly, ton, Dow Chemical's manager/corpo- STAYING FLEXIBLE. But Holtzman again Sandman notes. "But overall it's a rate advertising and chair of the task invokes a Responsible Care communi healthy response: they are pleased and ! force. The plan is to test the ads and cation gap. "Advocacy relates to com hopeful that change is taking root, and run through a "media weight" test to mand and control. And Responsible they remain skeptical." determine when and where to run Care is voluntary," he says. "By doing The reason the program has begun them, and how to reach the most peo things voluntarily we maintain flexi to influence employees is that "they ple--while staying within the 59-mil bility. The command and control pro are seeing their managers stay the course lion advertising budget for 1992-'93. cess gives dates, and names technolo on Responsible Care. It is not going The ads are challenging to create, gies that may not be best for everyone, away as have most flavor-of-the-month Dalton says, "because they don't ful- [technologies] that limit innovation," programs," says Dow Corning v. p./com full an immediate need from consum he adds. "We are going to continue to munications Barrie Carmichael, who ers; we're not selling a thing that they take positions on bills based on our is head of the CMA committee on out lust after. It's a low-interest category." experience of what works. And we reach to employees and the public. "If He predicts that the outcome from the intend to make our Responsible Care anything, they are seeing executive ads in terms of their impact on public activities and advocacy compatible. management even more supportive of opinion will engender "a lot of bitter But we don't intend to find ourselves it in the face of pressures on budgets. I ness" from member chemical compa in the position of supporting what we think it has stayed extremely strong in nies that have never invested in con consider bad policy." corporate budgets," she notes. sumer advertising and will expect great Despite these bones of contention, At least one group of employees at er results. But he notes that a typical among at least one group of stakehold a unit of the American Cyanamid Lou automobile advertising campaign costs CTL010163 ii Regpongiiie, Care, up to SI.5 billion/year. into an ad campaign ples. "It is very difficult CATCHING ON. Meanwhile, says Dal- ; don't expect changes. for the industry to ton, his sense of the response to the But we've had 12,000 mount an action pro print campaign is that "people are calls." gram around the idea beginning to catch on." As proof Dal- : At the end of this that everything is im ton and Holtzman cite the following: I month, CMA's public portant," says Shute. The most successful print ads have j opinion task group will "The questionnaire is been the first and last of the series, have the data from a designed to give CMA nicknamed "driving by," and "fish yearlong opinion track and its membership fur ing." The last one, which asks "how ing study. The results ther guidance on what safe is your local fishing hole," has ; will be significant be they really need to do received the most inquiries on the 800 cause after three years a to address public con number: 1,800 in the month of April. trend will begin to cerns about the indus A total of 12,000 calls to the 800 emerge, says Gary try: and somewhere in number, generating more than 14,000 Shute, head of the task the future to meaning requests. ! group and director of fully change public per The largest firms have received an planning and research ceptions about the in average of 100 calls each. Nine percent of the calls have been at Amoco. "We are looking at Cottle: `We're learning.' dustry." Responsible Care is sent to CMA's chemical referral cen how the industry's image stands over a process of listening and learning for ter for questions about household time, better or worse, and how it has people in and outside of the chemical chemicals: 4% have required CMA to changed in relation to other indus industry. "I think we are the ones who call back to answer questions about tries," Shute says. Those polled in are learning," says Dow Coming's Car the organization and its positions on clude employees and 4,000 randomly michael. "We are learning about pub issues. i selected members of the general pub- | lic expectations, and we are listening. "We are trying, through rolling re lie and 3,000 plant community resi It takes a while for the lessons to sink search, to demonstrate that people are dents. in. A person or group can understand beginning to understand what we are The questions include a query on something conceptually, but it takes a doing," says Holtzman. "Most people the relative importance of each of the while to act on that awareness." would say only six to eight months 10 Responsible Care guiding princi KAREN HELLER Polymers & Plastics Group -- Vinyls Division With a comprehensive line of products and technology, OxyChem is the largest merchant producer of PVC resins and flexible and calendered film in the U.S. We are in the forefront of developing innovative OxyChem* programs to deal with environmental concerns. Examples include a unique, nationwide buyback program established for PVC bottles, and a new plastics recycling center underway in Dallas, Texas. 0 The Chemical operation's of Occidental Chemical Corporation OxyChem is a registered trademark of Occidental ChemcaJ Corporation 12 CTL010164 Regponsiiie, Cart \ George Krug He agrees with most of i FINANCIAL IMPACT? WALL STREET YAWNS Wall Street in expecting Responsible 1 Care to be a "minor influence" on the j valuation of chemical stocks "It's a step Linking environment and P/Es foils analysts in the right direction." Krug says, "but you need a good, long walk--and with even' company, not just the chemical proactive environmental policy | price negotiations for chemical busi industry." A makes business sense. That's a nesses, often to the point where the basic premise underlying the Re issue is resolved by defining a proce sponsible Care initiative. But if envdiu re for dealing with potential prob Furthermore, whatever benefits ma\ accrue to the industry from Responsi ble Care are not yet fully in place. A ronmental responsibility pays, whleyms, rather than pricing it. program that takes time to show palpa does Wall Street show so little interest Still, analysts think environmental ble results is going to meet with skepti in Responsible Care? issues play some role in the industry's cism from the Street, which is notorious "Interest in Responsible Care is not valuation. Donald Pattison, chemical for preferring short-term over long-term real high in the financial community," analyst at C.J. Lawrence, Morgan Gren returns. says Charles A. Goding, director/corpo fell (New York), says, "The chemical LOW INTEREST. While the difficulty of rate communications at Nalco and head industry will never sell at the multiple quantifying the benefits from Responsi of CMA's Outreach Committee's stake a squeaky clean company like Disney ble Care mav have something to do with holder task group, which is looking into does." Pattison is the only Wall Street investor indifference, the costs of it are how to get the Responsible Care mes analyst who has mentioned Responsi just as hard for financial analysts to sage out to investors. ble Care in a written report. "Responsi isolate. If there were an immediate ef The stock market is the classic exam ble Care is just the minimum," he says. fect on next quarter's earnings. Wall ple of an "efficient market"--one that "If they don't even do that, there's a Street might be more interested. factors all available information into problem." The CMA task group is encouraging pricing. While most analysts agree that Pattison wrote about Responsible companies to include discussions of environmental risks should be one of Care after taking a group of analysts on the program in financial communica many factors affecting the valuation of a a series ofGulf Coast plant tours late last tions such as annual reports. Jayne chemical business, those risks are rare summer. "They were talking about it j Davis, manager/communication issues ly the driving force behind incremental everywhere we went," Pattison says. at CMA, is currently going through a change, except when there is an acci However, his comments about the pro stack of the most recent annual reports dent or a strong perception that envi- ; gram are acerbic: "Not one Asiatic-con mailed out by CMA members to see ronmental concerns can block the | trolled U.S. operation is listed as a mem how participating companies present growth of a specific product--like chlo- I ber--not too smart," his report reads. ed the program to their shareholders. rofluorocarbons (CFCs). "Environmen- j Morgan Stanley's tal risk is already embedded in the j Ravitz says that he multiple," explains Leslie Ravitz of i treats Responsible Morgan Stanley (New York). "It's no ! Care specifically, longer new news." and environmental 'RISK.' Observers disagree about good citizenship whether the chemical industry as a generally, as "a giv whole has a depressed price/eamings en." He suspects that multiple (P/E) because of perceived the management of environmental risk; stock analysts, con any "company that cerned about incremental change, are ! isn't expressing con less likely to think so than investment cern about the envi bankers. "Chemical companies don't | ronment shows a sell at a discount because of perceived general lack of vi environmental risk. The majors are j sion" and is not the priced on cyclical issues, and the mul kind of company tiples for the specialties have increased whose stock he significantly over thajast several years," would recommend says Jeffrey Zekauskas, specialty chem to investors. icals analyst at First Manhattan (New Compared with York). the public at large, Peter Young, investment banker at Wall Street may perceive the chemical Figures on environmental spending Wertheim Schroder (New York), says, industry as doing relatively well on contained in the footnotes of financial "It's very hard to see a correlation be environmental responsibility issues. statements do attract attention from tween environmental issues and P/Es "The industry has been doing a pretty analysts. However, companies are put unless there's a well-known major prob good job, says Anantha Raman of S.G. ting the most mention of the Responsi lem." Nonetheless, he says, "there's no Warburg (New York). "About 25%-30% ble Care initiative in the text of annual question in my mind that it's part of the of capital spending is already going to reports--the CEO's letter, the discus reason major chemical companies have environmental projects." sion of goals--not back with the num lost relative value." Young notes the "Environmental considerations are bers, where Wall Street concentrates its cost of potential environmental liabili not limited to chemical companies," attention. ties can be a major stumbling block in says Oppenheimer (New York) analyst EMILY S. PUSHNER CTL010165 13 Regponsiih Care, \ In the pre-Earth Summu easiness WANTED: A SYSTEM TO AUDIT CARE forum in Rio this month, union Car bide chairman and CEO Robert d' Environmentalists and industryforge ahead Kennedy said. "Responsible Care ha its critics. Among them are those who sav it relies too heavily on self-report on't trust us, track us" is a noble `D sentiment. But how do you shadow chemical operations and tion Resource Center (New York) to "look at Carbide." To evaluate a plant site. Ginsburg ing. That we are grading our own ex amination papers. They have a point Many critics don't like our progress judge whether Responsible Care is more says, a community would need a reports. But our voluntary reports are a than a public relations exercise? Obvi baseline of information to start with, random walk. Companies use different ously, getting a measuring system in like a unit's safety haz-op studies. "Then reporting formats, data bases, time place is implicit in the prospects for the after we have reviewed the informa frames, and definitions." success of Responsible Care. tion. our experts would do an inspec "Ultimately, we need to develop a Lack of progress in developing mea tion for the community. This would system of uniform reporting standards sures has triggered a race on both sides give the community the resources it around the world, much as financial of the Atlantic between industry and needs to track a company." he says. auditing does for our balance sheets environmentalists to get systems in More information is needed from com today. It won't be easy, especially when place. For the moment, while industry panies than is currently available, proprietary information is involved. But has promising programs under study, claims Ginsburg. the value of an independent, certifiable such as linkage to ISO 9000, environ Available data such as the Toxics reporting system will far exceed the cost mental groups have the initiative with a Release Inventory mmmmmmammmmmmm variety of schemes. (TRI) is either un A report assessing the environmen reliable or insuffi tal performance of the world's top 50 cient, Ginsburg chemical earners is being compiled by says. Communities the Environmental Protection Encour need "technical agement Agency (EPEA; Hamburg). people who speak Drawn up from the companies' answers the appropriate to 25 questions, which are designed to technical lan find out how environmentally sustain guages to evaluate able (and independently verified) their the plant," he adds. operations are, the report will be pub Once that system is lished in the next six months. in place, he feels TACITURN. Douglas Mulhall, managing that it will be more director of EPEA, remains tight-lipped effective than "get about how companies rate--other than ting an auditor to saying that some with traditionally clean audit the auditor images are big polluters and vice versa. and so on," because He stresses that benchmarking is impor it will create a di tant, as all companies need to be com rect dialogue be pared. "Responsible Care does not do tween the commu this," he contends. nity and the plant. In the U.S. a coalition of environ That kind ofdia- mental groups called Communities Con losue is one of the . cerned about Carbide is organizing to main objectives of Cvanamid checks trucks three times before they go on the road. get more and better information from the community awareness and emer and trouble of developing one." Union Carbide plants that communi gency response (CAER) code and of the CMA national advisory panel mem ties, with the help of outside experts, creation of the 160-plus community ber and environmental consultant Ross can use to track the environmental per panels that now exist in the U.S. But Vincent offers an explanation for why formance of the plants. At present the many environmentalists are deeply con environmental groups are not waiting group has focused its attention on the cerned that the advisory panels spon for that to happen. "I think the longer company's Seadrift, TX petrochemicals sored by companies, which select the the chemical industry puts off creating plant, but the model being developed members, fail in two areas. Environ an auditing system, the worse the skep there is intended to be widespread. mentalists suggest they do not enlist the ticism becomes," Vincent says. "They "We are trying to develop a group of skeptics in the community, nor are they have spent time and money and energy technical experts who would be work provided with the information they need building expectations that they can't yet ing for communities around the various in an understandable form. deliver on. It is late for them to be chemical facilities--who would provide "What is implicit in CMA's public thinking about this." those resources when they are needed relations machine is that residents are It is not only outsiders that want to by a community," says Robert E. ignorant and have to be spoon-fed di see evidence of improvement within Ginsburg, an environmental health con gested information," Ginsburg says. the industrv. Throughout the industry sultant who is a chemist and toxicolo "Technical information is just like an in the U.S., Canada, and Europe, com gist by training. He has been hired by other language. Communities need those panies are taking the lead on developing groups, including the National Toxics resources. Once that happens, then they audits. Dow Chemical, at its Plaquemine, Campaign (Boston) and the Bhopal Ac can start reaching common ground." LA site, has conducted what it believes 14 cTLOloi66 Rzgpongiib Clare. is the first outside audit of the imple mentation of a code. Dow's auditors included the head of the state police hazmat unit: the former state emergency response commission chairman who is the hazmat officer of the Baton Rouge fire department; and a parish civil de fense director, to study implementation of the CAER code. Specifically, the group looked at how the company would respond in the event of an emergency. It looked at the code and developed its own list ofwhat should be evaluated, including documented proof of the site's system to notify the public in the event of an emergency. The group wanted to know how the company communicates with local offi cials and first responders, and it inter viewed the sheriffs department and the local emergency planning committee. The pending results will be of great interest to both Dow and the CMA, notes Dow Louisiana Division Responsible Care coordinator Donna Carville. In Washington, CMA is adding a tracking system to its process safety code [p. 44) due to start up in 1993; a system compiling incident data in the transportation area is also targeted for 1993 (p. 62). OTHER LOOK. CMA has taken the step of examining what is being done in other industries. Among other systems it looked at the hospital accreditation board and the nuclear industry. The nuclear industry is represented by the Institute ofNuclear Power Opera tions (INPO; Atlanta), funded by the electric utilities that operate the plants. It has developed criteria for plant opera tions and since 1980 has studied every plant for two weeks on a roughly 18month cycle. The audits are conducted by both full-time INPO employees and employees on loan from companies. In Community panels: Watchdogs? formation on every as believes that Respon pect of operation and sible Care had to start management is shared off as a self-policing ex among plants because ercise. but now the time utilities are regulated is right to take the next and noncompetitive. step and get third-partv INPO audits every confirmation of health, nuclear plant in the U.S. safety, and environ Information from the mental management audits is shared with the procedures. nuclear regulatory'com Under the CIA mission and state regu guidelines on certifica lators. tion of Responsible The Joint Commis Care programs the sion on Accreditation of "product" is seen as Health Care Organiza health, safety, and the tions (Oakbrook Ter environment, and the race; IL) rates hospitals ,, . . . .. against a standard and Kennet*V: A System IS needed "customer" is the local communities, and au- not one another. Each hospital pays for thorities. Four CIA members have pi the study, so the commission has a cli loted the plan. ent/consultant relationship with the The audit will show companies have group. The information is not shared a management system in place to con with the public. Similarly, in Canada, tinually improve health, safety, and the Canadian Chemical Producers As environmental performance. In the fu sociation formed a committee to study ture, the audit may be expanded to pro credibility, and to study options to mea vide a rating of performance, along the sure compliance (p. 130). lines of the International Safety and In Europe, Louis Jourdan, technical Reliability System/Standard. director of the European Chemical In EUROPE COMPLIANCE. Posner notes that dustry Council, states that environmen the CIA Responsible Care auditingguide- talists say they will accept Responsible lines comply with the European Care only when companies can pro Community's voluntary eco-audit pro duce figures showing that it is working; posal, which is based on EN29000--the "and I agree." Some national chemical EC equivalent of ISO 9000. The pro associations--notably those that claim posal was approved by the European a history of better environmental per Environment Council of Ministers last formance--are particularly keen to de December. It should be adopted by the velop standard performance indicators council bv the end of this year and, as a that can be used internationally. The regulation, will be enforced throughout Japan Chemical Industry Association the EC 18 months after adoption. (Tokyo) is one (p. 152), and Germany's Participating companies will have Verband de Chemischen Industrie to produce site environmental state (Frankfurt) is another. ments, validated by accredited envi The U.K. Chemical Industries Asso ronmental auditors, for the public. The ciation (London), along with Canada, statements have to include: a descrip New Zealand, and tion of the site; an assessment of all France, has pio significant and relevant environmen neered the modi tal issues related to the activities; fig fication of the ISO ures for pollutant emissions, waste gen 9000 quality stan eration, raw material, and energy and dard to Respon water consumption; the company's sible Care pro environmental policy and objectives; grams so that they an evaluation of the environmental can be audited by performance of the site's protection independent in systems; and a deadline for the next spectors. "We re statement. ally need a third Activities with high environmental party to come in impact will be expected to carry out eco- and certify that we audits once a year; low-impact sites will have got Respon have to do an audit every three years. sible Care," says Companies that meet the requirements Tamar Posner, CIA will be able to use the eco-audit logo on executive direc stationery, for example, but not on prod tor/product regu ucts. Posner says companies with Re latory affairs. She sponsible Care certification will be "well CTL010167 15 Responsible Cart' placed" to meet the EC eco-audit re quirements. Companies will have to is sue a public statement for EC audit requirements, which, she adds, will be relatively easy to derive from the Re sponsible Care audit. In addition, the CIA's Responsible ; Care auditing guidelines correspond to the relevant section of British Standard j Institute's new BS 7750 environmental j management norm. The CIA developed its system on ISO 9000, as it is eager to j have one standard covering health, i safety, and the environment rather than | three. "From our point of view, we can not have three sets of audits when there j is a perfectly good standard out there, j One audit team will come in and do the lot," says Posner. She expects it will take at least two years for the first com pany to gain certification. Posner does not expect the U.S. to ' move down the same path. "Respon- j sible Care is managed differently in the ! States," Posner notes. Furthermore, she adds that U.S. firms are worried about auditing because of the ramifications of the country's legal requirements. Indicators of performance are key in the development of Responsible Care. The CIA has developed six measures j that all members' sites will have to re port annually: environmental spending \ in pounds sterling; lost-time accident statistics for a company's own employ- j ees and contractors; quantities of red list, or toxic, chemicals discharged in kg, amount ofspecial or hazardous waste disposed of in m.t., and an environmen tal index based on five key site pollut ants; distribution incidents per million m.t. ofproduct transported; total on-site energy consumption in giga-joules; and all complaints. The index was invented by RhonePoulenc in 1987 for water pollution tracking, and has now been adopted by the CIA and France's Union des Indus- ! tries Chimiques (Paris) as an environ mental performance indicator. The CIA has provided guidance for companies needing help on compiling site environmental indices. "They must adopt a system that enables them to make a comparison," Posner notes. Compilation of indices at CIA level will, Posner claims, provide a useful background against which the public can ask, `What's my (local) plant look ing like?."' It is unlikely groups like Friends of the Earth will be satisfied with the index, though. "They have a fixation with TRI, and are going to be hard to satisfy," Posner concludes. EMMA CHYNOWETH and KAREN HELLER MEANWHILE, COMPANIES WORK TOWARD SELF-SET TARGETS J GOALS PROGRESS Air Products Reduce SARA releases by 70% in 1995 and by 74% in 2000 (1987 baseline). Reduce hazardous waste emissions 70% by 1995 (1987 baseline) A 44% SARA reduction in 1992 A 20% hazardous waste reduction in 1992 Allied-Signal Reduce all waste against a 1988 baseline. A 22% reduction in 1991 Releases of SARA chemicals and off-site transfers were reduced by 75% Arco Chemical Reduce hydrocarbon air emissions 85%. Reduce generation of other waste by 40% (both 1986 baseline). Air emissions target expected by year-end 1993. Other waste target expected by year-end 1992 BP Chemicals For its 10 major plants, to cut 1990 hydro carbon air releases by 50% by 1997 and to cut total discharges to water by 66%. Chevron Chemical Reduce disposal of routinely generated hazardous waste 99% by 1992 (1986 baseline). Reduce SARA air emissions by 50% by 1995 (1987 baseline). Hazardous waste reduced by 98% from 1986 to 1992. SARA air releases reduced 16% in 1990, compared with 1987 Dow Chemical For U.S. operations, expanded EPA's 33/50 emissions reductions program to all SARA-listed compounds. Worldwide, meet EPA's 50% reduction goal by 1995. In the U S, a 30% SARA reduction reported between 1988 and 1990. Du Pont A 60% reduction in SARA air emissions Reported a 24% drop in air emissions in by 1993 (1987 baseline). A 90% reduction 1990. in airborne carcinogens by 2000 (1987 baseline). Reported a 54% drop in carcinogen A 35% reduction in hazardous waste by 2000 emissions in 1990. (1990 baseline). Exxon A five-year plan was implemented in 1990 to reduce global emissions of process and solid wastes by 50%. A 28% reduction in SARA emissions between 1987 and 1990. Hoechst 50% reduction of heavy metals organics into the Rhine river by 1995 (1985 baseline). Hoechst Celanese Reduce emissions of SARA compounds 70% by end of 1996 (1988 baseline). SARA emissions reduced by 20%. ICI Reduce waste production 50% by 1995 Hazardous air emissions (1990 baseline). were cut 4% between 1990 to 1991. Hazardous water emissions were cut 52% in period 1990-1991. Monsanto Obn A worldwide 90% cut in SARA air emissions by end of 1992 (1987 baseline). For chemical operations, a 70% reduction in hazardous waste generation by1995 (1987 baseline). By 1994, a 70% reduction in SARA air emissions, and 60% reduction in other SARA emissions and transfers (1987 baseline). A 58% reduction in 1990 SARA air releases. Expects to have equipment and processes in place so that 1993 emissions will meet 90% reduction goal. Reported a 42% reduction in air emissions in 1990. Overall, SARA emissions and transfers down by 40% in 1990. OxyChem A 10%/year reduction in air emissions. A 5%/year reduction in solid waste generation. A 5%/year reduction in water emissions Quantum Reduce SARA air emissions 50% by 1999 (1987 baseline). Reduce airborne carcinogens by 90% by 1999 (1987 baseline). Reduce hazardous waste generation 40% by 1999 (1990 baseline). Reports 1990 air releases reduced by 20%. Rhdne-Poulenc Halve 1990 emissions and waste production by 1994 and achieve a 65% cut by 2000. Rohm and Haas Reduce U.S. air emissions of SARA compounds Reports 1990 SARA emissions down by 75% by end of 1996 (1987 baseline). by 62%. Reduce process waste by 25% by end of 1995 (1990 baseline). Union Carbide Reduce total SARA releases and off-site transfers by 55% in 1995 (1987 baseline). Reduce SARA air emissions by 60% by 1995 (1987 baseline). Reduce wastewater discharges 59% by 1995 (1987 baseline). Source: Chemical Week survey. Ail but three U.S. locations in conformance; last three have targeted reductions as necessary. 16 CTL010168 Re^ponsiiie, Care, IK ffl I MIBffl! KKIKE AFR , An update on implementation GROWTH IN AWARENESS AND RESPONSE mitted Nixon to sit in on the meetings as an LEPC liaison. "They are making an effort." she says, although they have Open doors, open minds, and fire drills yet to include worst case assumptions and risk reduction plans in the LEPC ven though the third-year self- ; tion (OSHA) regulations and the Clean program. Eevaluations will not be available j Air Act amendments of 1990, extend until July, David Hastings, the I the emergency response requirements. Chemical Manufacturers Association's The chemical industry "has a lot The chemical industry has often been the "force behind the LEPCs," says Jim Dutcher, public affairs man associate director in charge of commum-o1re at stake than anybody else, in ager at American Cyanamid's VVest- nity awareness and emergency re- | cluding govern sponse (CAER), says that companies > ment" when it are on the right track. More than 160 ! comes to emer community awareness panels (CAPs) gency prepared are up and running, double the number ness, says David of two years ago. Open-house visits, Speights, the En community newsletters, and plant tours t vironmental Pro are becoming commonplace. tection Agency's Because emergency response pro- ' director of chemi grams were already in place through cal emergency out much of the chemical industry, the preparedness. community awareness aspect of CAER "The whole in has been emphasized during the past ! dustry is at stake." few years. CMA, the Synthetic Organic ; Industry's emer Chemicals Manufacturers Association ; gency response ef (SOCMA), and state chemical industry fort should center councils distributed newsletters, vid on supporting and eotapes, and guidebooks and held work tapping into or shops on communicating with neigh bors, employees, schools, medical per leading the nearly 4,000 local emer Hoechst Celanese employees practice fighting fires. sonnel, and activists. "In this past year, " gency planning committees (LEPCs) wego, LA plant and chairman of the says Hastings, "we feel that the two that have been established under SARA Jefferson Parish LEPC. Emergency re components have caught up with each Title III, says Speights. sponse operations work through the other." So now, he says, CMA plans to | 'MORE TO DO.' Many plants offer train LEPC, while a local mutual aid organi shore up emergency response training ing, emergency drill programs, equip zation addresses details that go beyond and encourage coordination with gov ment, and office services to the LEPCs, LEPC activities, such as equipment ernment-established response teams. but he charges that some will not work sharing. Dutcher agrees with Speights The two arms of the CAER code are with the LEPCs or only meet the mini that many LEPCs need a jump start. intertwined: The code requires dialogue mum requirements. And industry "Once you have an emergency system between the plant and the community, groups that established private emer in place, there's a laxity of attendance," including employees, neighbors, and gency response programs decades be he explains, "I don't think one can ever emergency responders, as well as a com fore SARA Title III should fold those say we're all set. It's a continuing pro prehensive plan for emergency re programs into the LEPC effort, he adds, cess. There's always room for improve sponse and public notification. The to assure community participation. ment." CAER code, initiated as a voluntary Chemical manufacturers have " done an Emergency response, especially measure just after the Union Carbide awful lot across the country to help the when it requires community notifica Bhopal tragedy, became mandatory for state and local emergency systems," tion, can be improved through commu all CMA members in 1988, when Re- I says Speights, "but I think there's a nity awareness. Residents near the sponsible Care was born. In 1990, great deal more that they can do." Hoechst Celanese Coventry, RI plant, SOCMA required its members to ad Pam Nixon, vice chairman of given a number of options, chose a here to the code. And, Title III of the Kanawah Valley's LEPC, says the local computerized neighborhood telephone Superfund Amendments and Reauth chemical industry has helped finance emergency notification system. When orization Act of 1986, also called the ` the group, contributing $15,000 of this activated, a computer dials the Emergency Planning and Community- j year's $18,000 budget when govern preprogrammed phone numbers ofresi Right-to-l6iow Act, made parts of the [ ment funding was cut. However, there dents within a half-mile of the plant, program legal requirements through are some difficulties. For example, the and a recorded message informs them out all industries. local industry's private emergency of the emergency and tells them what Other federal laws; including Occu planning committee, which has always actions to take. The residents can relay pational Safety and Health Administra- * held closed sessions, only recently per- ' touch-tone responses to say that the CTL010169 17 R&sponsihie, Care, \ message was understood and whether Community relations help is needed. The phone calls are efforts can produce tan more informative than blaring sirens gible returns. Last July, and alleviate instead of compound fear, the Louisiana Depart says plant manager Darell Nordeen. ment of Environmental SLICK. Community relations at the Quality (LDEQj granted Coventry plant hit a low point five ICI an air permit for a new years ago, when powder releases and hydrofluorocarbon plant odors went unexplained. "The neigh at its St. Gabriel site in bors felt they were asking questions half the usual processing and getting no answers," says Nordeen, time. The LDEQ attrib and formed a group called SLICK-- uted the quick turn Sick of Living in Chemicals that Kill. In around to ICI's commu 1987, realizing that it was facing a cri nity outreach efforts, sis, Hoechst met with SLICK and other which included open neighbors and addressed some of their meetings, door-to-door .concerns. Hoechst enclosed the sludge- flyers, and an 800 num nandling operation and installed ber that linked callers di biofilters to clean process air. The CAP, rectly to plant manager which includes two members of the Mike Maher. Maher cred Community outreach takes many forms. now-disbanded SLICK, meets regularly. ited the efforts, based on Responsible | ness and explaining risk reduction pro "We have evolved from meeting with a Care's CAER code, with keeping the grams they can clear up misconcep hostile group," savs Nordeen, "to a col project on schedule--the plant should tions that lead to much of the laborative program." Company re open in the first quarter of 1993. community's fear. After getting over sponse to incidents since the commu Accomplishments like these have the outreach barrier, companies fre nity outreach began, he adds, has been increased interest in community out quently find that small changes and judged acceptable by the public and reach. In the communications process, perceived openness can improve com press. companies often find that through open- munity attitudes. Questions and com ments span from the anticipated ones REAL-TIME TECHNOLOGY FOR DISASTER ALERTS about environmental impact to con cerns about hiring policies, local wild Few locations confront emergency plan plant operating control rooms to the station. life, and even the color of a fence. ners with worse worries than dense mixes of The command station then activates sirens, Although community advisory pan petrochemical installations and residential and broadcasts a selected message based on els are not mandatory under the CAER neighborhoods. One such area is the Beau 10 worst-case scenarios to emergency re code, many companies have found they mont/Port Arthur conurbation, home to sponders like police and fire departments, and could best tap into community atti 240,000 people and 24 petrochemical installa to the general public via local TV and to tudes through the groups. With only a tions--chemical plants and refineries, "with schools, nursing homes, and the like. The sys handful of the CAPs at more than a few people living just across the fence lines," says tem also provides communications between years old, "we're still in the early stages Dick Nugent, coordinator of emergency man the plants, police, and fire authorities and of implementation," says Diane agement for Jefferson County, which covers emergency medical services, and the emer Sheridan of the Keystone Center [Key the area. . gency management station. The equipment is stone, CO] and facilitator of five CAPs. To help cope in the event of a catastrophe, even able to activate radios in homes. Initial meetings often consist of educat a $3.2-million. high-tech public alerting system "We have real-time technology now," says ing the panel about chemicals and pro is due to become fully operational in Septem Ed Gearhart, plant manager of Elf Atochem's cesses, and--with time--the panel may ber in the county, the first of its kind in North sulfur chemicals plant in Beaumont, TX. "We take over the meetings. "Anyone who America. Local emergency services and a can literally notify every citizen in the county thinks that's happening overnight is group of 12 local companies, led by Elf Ato- in under 60-90 seconds." But with that power kidding himself," says BASF Respon chem and Olin, banded together to form a non ful technology comes some difficult questions sible Care coordinator Joe Nalio. profit company--the Community Alerting Net about how to use the system, he notes. Now, While CMA dismisses critics who work (CAN)--to execute the project The a coalition of county, industry, and community hold that CAPs should have an official scheme dates back to 1986, with the search representatives must develop a set of rules-- say in company policy, Sheridan claims for technology starting in 1988. 'a systematic method of using the system that they often have that effect. "They With experiences at accidents like the wisely," he says............... get small changes, not terribly dramatic Phillips disaster in Pasadena. TX in 1989 Jefferson County may prove to be the ones," she says, citing Vulcan's Wichita, showing that telephone systems rapidly over testing grounds for a nationwide system. KS community panel, which persuaded load under emergency conditions, CAN decid Gearhart says that the Federal Communica the company to change their telephone ed to adopt a radio-based system. The equip-. . tions Commission is considering a proposal manners--neighbors who called the ment being installed is a SAGE 1 warning and from SAGE Alerting Systems to update the plant with queries felt intimidated by notification system from Bosch/Blaupiinkt of outmoded National Emergency Broadcast the old method of requesting names Germany and Hormann GmbH, the world's System. Such high-tech systems as SAGE, and addresses of callers. The CAP also largest siren and alerting systems manufactur "could slowly become part of the national pressured the company to adopt an er. In the event of an accident--or a natural scene," says Gearhart. aggressive emission program that in disaster--the central control station in Beau cludes the elimination of deepwell acid mont is alerted, with direct radio-contact from DAVID HUNTER and ELIZABETH S. KIESCHE disposal. Vulcan's responsiveness paid off. This year, the Kansas chapter of the 18 CTL010170 Responsible, Cart' Sierra Club called off what would have Openness extends not only to the knowledge of the plant. Says Baker, been its third annual Earth Day protest community, but to other companies, `it's kind of impressive when you ask of the Wichita plant, citing the with mutual assistance programs and them about the plant [now]." company's openness at CAP meetings. the multicompany CAPs. "We had a One plant manager was alerted to "It's nice to see them stepping in the meeting just to talk about what was the need for worker awareness by a right direction," says chapter chairman going on at our [Painesville, OH] plant," letter in a local newspaper. After a 700- Bill Cather, although more changes are says Arco Chemical Responsible Care lb vinyl chloride leak, the writer asked needed. Members of the CAP at adviser Hy Gillman, "and at that meet his neighbor, a worker at the plant, Monsanto's Chocolate Bayou plant at ing [the neighbors] asked us about other about the incident. The employee knew Alvin, TX, although acknowledging plants. The community really views nothing about the overall plant opera that the company's injection wells are the industry as a whole." Those ques tions. Now, employees are informed handled within regulations, are still tions opened Arco's eyes to its other about what's going on at the plant trying to convince the company to halt neighbors, the nearby their use. chemical plants. "There Hoechst Celanese participates in was a lot of ignorance on seven CAPs and plans to establish 12 our part," says Gillman, more this year. Kevin Lombardozzi, and now, "the plants are manager of environmental regulatory communicating with affairs, says the success of the each other." company's outreach is varied. While Companies are finding some do quite well, he says, small plants employees to be a valu and small companies often have diffi able resource in their culty in taking a leadership position outreach efforts. Dow when they try to set up a panel. "[The Chemical's Plaquemine, community says] `You're very small, LA plant has trained more we're not that interested.' We have to than 2,400 employees seek new and different ways that are and contract employee not as formal," says Lombardozzi, such supervisors in its Envi as an open house. Betz Laboratories ronmental Ambassadors (Trevose, PA) went another route. In program in the past two stead of starting its own CAP, says Betz' external affairs manager Jack Pounds, years. The day-long pro gram includes training on Arco communicates with neighbors, as well as other plants. "we piggybacked onto an existing risk perception, environmental laws through meetings, are invited to ask group," a local civic organization. and regulations, plant environmental questions and voice concerns through a Ironically, facilities programs and a ques- Responsible Care suggestion box, and that do not have a history tion-and-answer ses are forming an internal employee advi of problems may have sion. "They're very sory panel. more of a challenge in credible sources, FINE-TUNING. "If the CAER code is not getting community mem much more credible going well, the rest [of Responsible bers to participate and than a [public rela Care] won't either," says CMA's CAER remain active in a CAP. tions] person would chairman and Rohm and Haas public "It is difficult--if you be," says Dow Chemi affairs manager Jack Coe. Overall, the have not had problems-- cal senior environ chemical industry has put a lot of effort to keep interest," says mental specialist into the code, he adds, and most CMA Brian Hanson, manager of Christine Baldridge, members are at "acceptable levels." environmental and safety who helped develop CMA will begin to fine-tune the pro affairs and community the program. Many gram, Coe says, based on the three years outreach at the Hoechst employees would not of self-evaluations. Preliminary results Celanese Clear Lake answer questions suggest that plant manager networks plant, "people have very posed to them by and cooperation between plants in con short attention spans. '' So friends and neighbors centrated industrial areas have sped right track. before the program, the success, while plants in isolated she says, because they areas continue to have difficulty, he tion--a plant, church basement, town did not know the answers. Now, she says. hall--every month. And some CAPs says, they feel comfortable answering "The Dows of the world--the ma have delved into highly technical dis questions and referring others to her jors--are fully implemented, " says A.D. cussions of risk assessment and toxicol office. "We're going to see more dia Little director ofcrisis management and ogy studies. logue out there in the community." risk communications Mary Woodell, Environmental activists on a CAP "Our employees are our best good while many small to midsize compa can bring a knowledge base, tough ques will ambassadors," says Thomas nies are still getting on board. This "sea tions, and issues to meetings. "They Baker, president of Du Pont change" in chemical industry execu know how to probe," says Sheridan, Agrichemicals Caribe. Since Septem tives' attitudes has paid off. "You have "they make a panel lively." However, | ber 1989, Du Pont has had an em open-minded skepticism instead of some CAP organizers say that other ployee empowerment program at the open hostility, " explains Woodell, "and members may tire of an activist's com site, with a huge increase in training skepticism is healthy." bativeness. and a boost in the level of worker ELISABETH KIRSCHNER CTL010171 19 i Responsible, Care, PROCESS SAFETY I (ORC), which drew on specialists to GOING BEYOND REGULATIONS compile a good process safety practice guide. ORC also sparked the 12-point safety approach of the American Insti Integrating Responsible Care with the new OSHA rules tute of Chemical Engineers' (AIChE) Center for Process Safety. However, the process safety code uccess of the process safety code of pieces," says Donald Helin, director of and the OSHA PSM rule differ consid SResponsible Care is perhaps one of safety and plant operations at the Chemi the trickiest things to measure. cal Manufacturers Association. "Imple Although there may be demonstratiomn entation ofthe process safety code will erably in approach, notes Vincent E. Boyen, director/corporate safety and property protection at Monsanto. "The of continuous improvement, it takecsertainly help companies to meet the spirit of the process safety code goes only one major explosion to overturn OSHA rules--most of the elements of beyond the OSHA regulations in re that and seriously damage the image of the code are also in the OSHA rule." quiring management leadership and the chemical industry. Helin says there is no plan to modify the ensuring continuous improvement. However, there will shortly be an Responsible Care code to make it closer to The OSHA requirements are very spe external arbiter of process safety issues. the OSHA requirements. "The key to pro cific--the Responsible Care code is not In addition to Responsible Care efforts, cess safety is to work toward a goal of there to help prevent companies from chemical plants must also deal with new regulations from the Occupational Safety and Health Administration (OSHA) covering process safety man agement (PSM), which subjects plants to regulatory inspections. Although the two initiatives overlap in several areas, they differ substan tially in spirit: The Responsible Care code covers the whole industry with a goal of continuous process safety im provement; the OSHA PSM rule covers specific hazardous chemicals, with a goal ofmeeting certain minimum safety requirements. "Put the two side by side, and look at the number of pages of the OSHA re quirements vs. Responsible Care, and they look pretty different," says Ray Olsen, chiefsafety engineer with Exxon Chemical and chairman of the Respon sible Care safe plant operations task force. "However, the two have a great deal in common in spirit. When you break them down, you will find there is Regular inspections are vital to the safety process. a great deal of similarity." continuousimprovement.TheResponsible | getting a citation from OSHA." OVERLAP. "There is a great amount of Care program provides an umbrella plan, "In general, the OSHA rule requires overlap," agrees Leon C. Schaller, rather than specifying certain minimum \ a lot ofdocumentation and record-keep former safety and occupational health standards. But companies have to be mind ing that might not be inherent in Re fellow at Du Pont and member of the ful and tailor the code to cover specific sponsible Care," says Olsen. "However, task force. "The majority of the OSHA federal or state laws." OSHA does not apply everywhere; the PSM requirements are addressed in the The PSM rule, which covers 130 j process safety code, on the other hand, process safety code. However, the code specific chemicals, centers on process j does: It requires you to identify all your doesn't mention proprietary informa hazard analysis, which includes a sys- j potential hazards, and makes manage tion, while the OSHA rule doesn't cover tematic review of what could go wrong I ment accountable for ensuring im management responsibility, which is and what safeguards must be imple- ; provement." an integral part of Responsible Care. mented to prevent release of hazardous i Experts agree that management re "In particular, OSHA acknowledges chemicals. At least one-quarter must be j sponsibility is crucial to process safety. proprietary information has to be pro completed two years after the effective ! "There's a lot of competing demand on tected in the course of enforcement," date,withanadditional25%completed ] management time, much of it concen Schaller notes. Although Responsible each succeeding year, so that, five years I trating on short-term issues," Schaller Care encourages companies to share on, employers will have evaluated ev- I says. "Process safety is long-term--you process safety information, he says, pro ery affected process and implemented ! may never get a return on it. But the prietary information is not addressed, appropriate safety recommendations. I most effective element of process safety since companies would already be In fact, both the Responsible Care j is strong management commitment." mindful of what not to disclose. code and the OSHA rule grew from a Observers note that purely technical "As you overlay the two, there's more document commissioned in 1986 by ] solutions to process safety have ad agreement than there are missing the Organization Resource Counselors ' vanced probably as far as possible. 20 CTL010172 i Ris/jonsiile, Care, "OSHA has got the muscle to enforce "We're 70%-90% in certain safetv requirements." Olsen compliance with OSHA's notes. However, he says that Respon requirements." says H. sible Care differs in that it goes beyond FosterGerrard. directorof these requirements, focusing on man safety and loss prevention agement systems to ensure a continu at Olin Corp. The main ous improvement in process safety. work still to be done is Parts of the OSHA rule have been "what if" training and f% delayed for 90 days, because of timing operator training. Olin difficulties, but the whole rule will be in has to extend work on its t operation by the end of August. At the detailed hazard analyses moment, companies are working flat out of small plant modifica implementing the OSHA rule--CMA is tions. "I think we have sponsoring a series of workshops this one of the best process - tSSkJae*'* ' * fall, with a view to working toward hazard identification sys OSHA compliance, Helin explains. tems, but it doesn't cover Monsanto's Boyen insists the efforts everything. We have to meet the PSM rule have not taken about 5% to go." away from Responsible Care efforts. SPECIFICS. "The Respon Increased training for plant employees is essential. "Actually, meeting the OSHA require sible Care code leaves up ments is helping push the Responsible to individual companies how they will grams, especially for contractors. "Most Care program along," he says. "Compa develop documentation, but the OSHA companies had systems, but they didn't nies have to address the safety issue, requirements are much more specific," always have a well-developed, stan and the overlap in the two programs explains Helin. Responsible Care calls dardized plan," says Boyen. "The prob means both are being tackled." for the use of the CAER program to lem, particularly for many smaller com OSHA PRIORITIES. Joe Nalio, Responsible communicate with communities. The panies, is the level of resources." Care coordinator at BASF Corp., says: OSHA PSM rule, on the other hand, The contractor issue in process safety' is "We're working feverishly at implement focuses on the workplace and includes possibly the most thorny one for the chemi ing the OSHA rule. That's where our a specific section on employee partici cal industry, with the suggested connec priorities are right now. OSHA wants pation. This is covered under the Re tion between the use of contractors as con something demonstrated and something sponsible Care employee health and tributing to recent explosions--"an issue tested. That's probably where the whole safety code. which deserves some sensitivity," says industry falls down." He says it may be One particular problem identified in Boyen. But both OSHA and Responsible necessary for BASF to bring in some implementing the process safety code Care address the need for adequate training extra people temporarily to draw up has been the initiation of training pro- process and instrumenta 1 tion diagrams for some of its 1------------------------------------------------------- older plants. I COMPARISON OF PSM SYSTEMS 1 1 of contractor workers. Responsible Care also goes further in covering the fitness ofemployees for work. "The OSHA rule does not address the The OSHA rule requires much more defined docu Responsible Care OSHA 29 CFR 1910.119 process safety code element that employee safety is critical and must not be compro mentation than the Respon Management Leadership Process safety information mised," he says. This includes drug testing. sible Care code--and that Commitment PPG Industries uses computer simu documentation has been identified generally as a problem. To ease this pro cess, the majority ofcompa nies is looking to integrate the OSHA programs with the Responsible Codes and existing Quality and ISO 9000 programs. "We are in the process of getting ISO 9000 certifica tion," says David Bock, plant manager at Fina CosMar. Fina has internal audi ' Accountability _ Performance measurement Incident investigation Information sharing CAER integration Technology Design documentation Process hazard information . Process hazard analysis Management of change Facilities` ' .. Siting Codes and standards Safety reviews - Maintenance and inspection Process hazard analysis Operating procedures Training Contractors Pre-startup safety review Mechanical integrity Hot work permits Management of change lators for training operators at its Lake Charles, LA site, explains David C. Angell, works director/environmental assurance. "This has paid dividends in terms of better operating strategies and less reliance on training from older op erators and on-the-job training." The biggest challenge of the Respon sible Care process safety code is opera tor training, agrees Jim Dixon, Respon sible Care coordinator at Air Products and Chemicals. "We need an operator skill certification program to meet the intent of the Responsible Care code." tors making sure it has proper documentation. Multiple safeguards Emergency management ' y. incident investigations A The company is looking at a couple of models, including an interactive train "This dovetails into Re Personnel 1 :'- .* . -- ing program, PC-based. "We're getting a sponsible Care," says Bock. "We have a person doing nothing but updating for ISO and OSHA--there are several overlaps, hut it doesn't matter as long as it gets done." ' Job skills " Safe work practices initial training Employee proficiency Fitness for duty Contractors Some: Chemical Manulacuen Assoaaaon. Emergency planning and response Compliance safety audit Employee participation couple of calls a week from training program vendors, probably driven by the OSHA legislation," he adds. "One of the key points of both pro grams is training," says Richard Zielinski, Amoco Chemical's v.p./ manufacturing and engineering and CTL010173 21 RvspOKsiib Cars' i C\$P, Or' pi .rtV TJ W A**' vv \\^ OSHA's Hivhpst OxyChem Wins Safety Award w? . S.j.f WftiCf * couple of,* nunm> aloott i Zxjo0^ r^ ... \ O^A St--*" Nf' o-n> .a0. We've got good news and good news. Chemical companies are used to being in the news. So we're glad to see the kind of reporting OxyChem has been generating recently. These stories reflect a very inten sive effort to improve our performance in the areas of safety, quality, community involve ment and environmental commitment. It's all part of the leadership role we're playing in the Chemical Manufacturers Association's Responsible Care initiative. But it's also part of a larger commitment to improving the quality of life for all of us. OxyChem oxt The Chemical operations of Occidental Chemical Corporation <8 OxyChem is a registered trademark of Occidental Chemical Corporation 22 Responsible Care coordinator. "We have had detailed training for years. Now we're looking at it again, and checking technical training in the engi neering department, so we can make sure that designers, operators, mechan ics. and contractors are all well trained." "The first set of process safety code evaluations showed companies most concerned about deveiopingagood pro gram for contractor training--that's where much effort has been directed." says Helin. "We are waiting for the second set of evaluations, which are due in a month or so." Most companies are still a ways from full compliance with the code, but have moved imple mentation a step forward. "My feeling is that the industry is making great progress," says Schaller. He reiterates there is no need to make I the code any more specific to marry up with the OSHA requirements. "It is not consistent with the aims of the code to get so specific--Responsible Care cov ers all chemical plant processes." CMA does compile safety perfor mance data, based on voluntary data i submissions. It is now in the process of i setting up a detailed mandatory proi gram--Process Safety Tracking System i (Prospect)-- which should test the suc| cess of the code. If all goes to plan, that system should be in place by 1993. FORCE FOR GOOD. Success of the code will be of interest to the new presidentially appointed Chemical Safety and Hazard Investigation Board, a new watchdog for the industry. If that body is not satisfied, there is the risk of more i complex legislation--otherwise, observers feel it may be possible to sim plify regulations covering chemical plants "If we show improvement, it would be a force for good." says Helin. ! And observers believe the imple! mentation of the code will demonstrate improvement. "1 don't feel that the U.S. chemical industry experience has been bad. There have been incidents, but overall it has turned in a reasonably good performance," Schaller says. What we are saying is there is room for im provement. It wouldn't be wise to say we have succeeded yet, but we will." "If we are doing things a little better, that's an improvement," says Boyen. "In view of the data, the baseline for the chemical industry was not exemplary, but solid. Every indication, so far, is that we are making progress. My own experience is that there is an ever-in creasing institutionalization ofRespon sible Care into the chemical industry, and a commitment to improve safety." ANDREW WOOD with David Hunter CTL010174 Re*?f)onsiiie Cart POLLUTION PREVENTION CUTTING WASTE GOES PUBLIC Changes are tough and expensive ourteen months after its approval processes and facilities. It also cov Fby the Chemical Manufacturers As ers--in four additional provisions ap sociation, the Pollution Preven proved last September--waste man tion code is beginning to mean tougahgement practices and programs to and expensive changes in how somreeview and clean up old manufactur companies do business. And with the ing sites. federal Toxics Release Inventory (TRI) "One ofthe key challenges" in imple and CMA's annual waste survey acting menting the code, says Gene Dworsky, as public scorecards, it is becoming director/operations staff at Texas clear that the stakes are particularly high. Eastman, the Longview-based division "The Pollution Prevention code is of Eastman Kodak, "is the develop the one with the public scorecard at ment of technology--and that means technology that is economi cal. How you make basic changes in processes." The industry's develop ment of such cleaner pro cesses is, says Robert Brunson, Quantum's (Cin cinnati) assistant director/ environmental and state affairs, a particularly tough feat because it means get ting together manufactur ing and research efforts. "Without a well-coordi nated effort, it's not going to happen, except at a piece meal level. It has been a particularly difficult hurdle to mesh research withmanu facturing underthe pollution prevention umbrella. But that is changing rapidly." Still, reducing emissions and cleaning up manufac turing processes is not cheap. And, say some CMA members, one of the major tricks in meeting the pollu tion prevention code is find ing necessary funds during economically tough times. "Everyone has limited re Monitoring emissions at Hoechst Celanese. sources and the business recession makes it particu the forefront," points out Jerry B. Mar larly challenging," says Eastman's tin, DowChemical's director/environ Dworsky. Indeed, suggests Brunson, "the mental affairs. And the challenge, he biggest challenge in pollution preven adds, is an industry one because "the tion is competing for capital resources. public remembers the worst members. " Given the economy, it's difficult to find The ambitious pollution preven the resources necessary to change pro tion code calls for CMA members to cesses and improve pollution control. take a series of actions to quantify No matter how creative we are, ultimately generated waste, emissions and re capital expenditures are required." leases, set priorities--in cooperation Tight budgets have made it particu with communities--for.reduction ef larly important that companies have forts, and beef up research and devel well-thought-out strategies for imple opment efforts in designing cleaner menting the pollution prevention code. "The overall challenge is in organiz ing under the code, and it has been difficult to organize various plants." says Brunson. To achieve that goal. Quantum recently made the Respon sible Care coordinator a full-time po sition and developed an environmen tal management committee that met for the first time in April. "Eventually each plant will develop its own goals and strategies for pollution preven tion." says Brunson, "but we are start ing from the divisional level and work ing down. We are trying to move quickly to lay the groundwork at the divi sional level. We're not very far on the local level." Like other sections of the Respon sible Care program, the pollution pre vention code calls for companies to work closely with the public, talking about risks, developing pollution re duction priorities with communities, and publicly reporting--and explain ing--performance. And, as in other Responsible Care codes, improving the communication links has been tough. HARD PART. "The hardest part is the outreach portion of the code," says Richard Dennis, American Cyanamid's environmental affairs manager who chaired the pollution prevention code drafting committee. "Members are do ing pretty well in quantifying releases, setting priorities and establishing in ventories, but the area they are strug gling with is community outreach. It is the area with the greatest need for improvement." The key word in the code, he suggests, is "dialogue. Send ing out newsletters in the mail is not having a dialogue with the communi ties." And, he adds, companies' selfevaluations show "overall scores are pretty low. A lot are just in the begin ning stages of dialogue." The pollution prevention code pre sents some particularly thorny com munication issues. Perhaps most no table, how do firms explain the mean ing of large TRI numbers? "Engineers like to deal with numbers and facts," says John Selmela, Chevron Chemical's (San Ramon, CA) Responsible Care coordinator. "The public wants to know what is the impact on me and my family. It is tough to develop the mes sage." But companies report making head way. "The TRI tends to focus on high numbers, not the high health risks," Dworsky points out. "But people are willing to listen and can even under stand probabilistic risk. We ought not to say the risk is zero, but when we avoid that, we can tell an excellent CTL010175 23 Chrome Chemicals 24 Reeponsitfe Cart' story." One way CMA members are handling the public out reach effort called for in the pollution prevention code is to coordinate it with other codes, using, for example, the community advisory panels (CAP) set up under the Com munity Awareness and Emer gency Response (CAER) code. Outreach under the pollution prevention code "fits closely with CAER. The CAP can be a vehicle and mechanism," sug gests Cyanamid's Dennis. While the main body of the pollution prevention code was set in April 1990, last Sep tember CMA approved the four additional provisions on waste management and cleanups. And the sections are provid ing their own list ofchallenges. There is, for example, one pro vision singling out ground- water protection. Most federal groundwater regulations BWttCI-lip R&D efforts are called for. relate only to materials governed by the larger chemical producers. the Resource Conservation and Re Another of the management prac covery Act (RCRA), and the pollution tices added last September calls for prevention code aims to extend ground- CMA members to address the need to water protection to a far broader range clean up old manufacturing sites. The of compounds. objective is to get companies to look at And, says Dennis, if firms do not inactive sites and be proactive in already have such programs, that could remediating areas that do not fall un be expensive. "The programs will have der the cleanup plans of the federal a great long-term payoff," he says, "but RCRA and Superfund laws. One clear setting them up will require substan reward is avoiding the legal entangle tial engineering efforts." Some compa ments and confusions of the federal nies might, for instance, have to dig up cleanup laws. "Once you're sucked and replace underground storage tanks. into the front end of the regulatory Another of the four new provisions schemes," says Dennis, "it is very dif calls for CMA members to evaluate ficult to get a piece of paper saying and review waste management prac you're done." tices of contractors and toll manufac But while CMA members continue turers. And that, say some, could be to struggle to implement fully the spe tricky and expensive. "There is al cifics of the pollution prevention code, ways a concern about auditing third the overall objective remains clear: to parties," says Quantum's Brunson. create a pollution prevention ethic Evaluating equipment and toll manu throughout the industry and commu facturers is costly and, he says, "I sus nicate the effort to the public. And even pect there will be some resistance" firms leading the effort acknowledge among the contractors. there is still much work to be done. 'IT'S DOABLE.' Others downplay the "We're making progress, but on the difficulty. "For those not already do other hand we need to create a waste ing it," says Dennis, "it will take some reduction mentality among all our em work and may seem difficult. But it is ployees," says Dow's Martin. "And quite doable." He maintains that since we're not there yet. You can have the the 1980s, Cyanamid has had a pro CEOs talk about it, but the challenge gram to inspect and evaluate the facili for the industry is to get everyone to ties and practices ofthird parties. And, have the philosophy." And, says Mar he adds, such firms "have been recep tin, "We still have a long way to go tive" because they want the business until people feel comfortable when and they tend to be smaller companies the phone rings." that can benefit from the expertise of DAVID ROTMAN CTL010176 r f\ wpOKsiile, Care DISTRIBUTION CONNECTING THE PIECES. . . . . . . . . . . . . . . . . . The code is doing `reasonably well' Caustic Potash y the end of this month, the sec Cichowicz, "That dialogue is improv Bond round of companies' self- ing, as is the communication between evaluations is due under the Re purchasers of transportation services sponsible Care distribution code oanf d carriers." management practice. The code was M1 ike Heimowitz, manager of dis published about a year ago, and the j tribution safety programs for CMA, first round of self-evaluations was says the association's distribution code due in May 1991. workshops are still well attended, es Chemical producers, distributors, pecially as companies begin to grapple carriers, and warehouses all agreed with risk assessment programs. "The that it would take some time to figure early seminars were more like over out how best to implement the provi views, but now that people under sions of the code. Now, the product stand the codes for the most part, we stewardship code has just come out, are getting into the nuts and bolts of with many provisions that affect how to make them work, the nitty- chemical distribution. "It's like we've gritty." just learned to hit the fastball, and One resource for CMA members is now we've got to learn to hit the the electronic bulletin board for the curve," says one distributor. distribution code. It includes lists of Few parties expect any serious com people at member companies, along plications, but the focus has been on with their telephone numbers, who understanding what is in the distri have had success at one aspect of bution code, and putting it into op- code implementation or another. It CALI OXYCHEM (716)286-3632 World's largest producer of caustic potash Supplier of all forms, liquid and dry eration. "The product stewardship code has a very big role in chemical distribution," says Judith Cichowicz, director of operations support for dis tribution major Van Waters & Rogers (VW&R; Kirkland, WA). "It brings the end-user into the Responsible Care loop." However, even under just the dis tribution code, "Clearly, what has worked is the dialogue between sup pliers and distributors," says represents a way for firms to pass along tested and proved techniques and knowledge. Another important trend Cichowicz notes is the improved involvement of the sales and marketing operations within chemical producers. "Market ing people never had to address the issues that are important under Re sponsible Care; now they are an im portant part of selling chemicals." However pleased distributors and Only supplier with multiple plants (3) and barge distribution capability 17 terminals for liquid KOH; 14 stock points for dry KOH/caustic soda Technical & handling information provided by staff with longest history in caustic potash OxvChem* ^ Basic Chemicals Group P.O.Box728 Niagara Falls, NY 14302 > j * * if ; CTL010177 25 -I Responsible' Care' producers may be with the improved us how you've changed your packag tributors in North America--have put communications, distributors report ing to comply with new regulations, together the Distributor Self-Audit that much of the dialogue is still one before that shipment hits our docks." Protocol, to help speed the distribu sided, flowing down from the manu While all that can usually be ironed tor certification process, facturer to a much greater degree than flowing back up. Distributors also say that there is a tendency on the part of out fairly quickly, the whole issue of distributor and carrier audits has been the topic of an immense effort on the "We cut and pasted from a lot of the audits out there, and came up with something we can hand to the producers, especially the large com part of distributors. "About 80% of customer when he comes through the panies that make up the CMA, to any audit is the same as all the oth door," says Mulliken. "We welcome throw bureaucracy at Responsible ers," says Bill Mulliken, v.p./general audits and spot checks, but to save Care. Distributors, most of whom are counsel for ChemCentral (Bedford everyone time and effort, don't ask us much smaller than the manufactur Park, 1L). Under the auspices of the about the things that are already on ers, cannot keep up. CMA Chemstar program for special the protocol." With that, and the evalu "Just sending us the Material Safety projects, Mulliken's firm, VW&R, and ations many companies had already Data Sheets [MSDS] isn't enough," Ashland Chemical (Columbus, OH)-- done, he says "the auditing hasn't says Cichowicz. "How about telling by far the three largest chemical dis- been the horrendous burden I was 9999999999999999999t afraid it was going to become." NACD DRAWS THE LINE FOR MEMBERS TO SIGN UP Other communal efforts include similar types of assessments for car Deadlines are what separate the Responsible Distribution coordinators, as riers. Heimowitz says a protocol for National Association of Chemical well as sales representatives and motor carriers is almost complete, Distributors' (NACD; Washington) Responsible Distribution Process from CMA's Responsible Care. executives. While NACD represents more than 200 distributors in the U.S., including Van Waters and procedures for rail and marine \ transporters is coming along. i Ron Jacobson, materials risk and NACD member companies had to sign on & Rogers (Kirkland, WA), one of the largest, systems manager for Rohm and Haas to the provisions of Responsible Distribution, there are thousands of chemical distributors j (Philadelphia), was chairman of the as CMA members did for the codes of in the country, and neither of the other two distribution code drafting commit management practice. But NACD members majors, Ashland Chemical (Columbus, OH) ; tee. "The code is doing reasonably had a deadline of March 1 to name a and ChemCentral (Bedford Park, It), are : well, and there are a couple of areas company code coordinator, who has until members. One estimate shows NACD of significant improvement, includ July 1 to attend a one-day training seminar membership to include only about 20% of ing a steady move toward more defi and to be sure the company has filed an the chemical distributors in the U.S., the nite and complete risk management," interim self-assessment report. Other such association says its members account for he says. "There hasn't really been reports are due every six months, and the about 80% of the $13 billion-$15 billion/year anything startling, but there have been company must be in full compliance with all in chemical distribution revenues. some sensitive issues that take time aspects of Responsible Distribution by Jan. Whatever the measure used, the to evolve." 1,1995. boldness of the NACD initiative has won COMFORT. He adds that although there Any member not complying with those praise all around. "Ves, it has thresholds and might not seem to be much progress "milestones" will "not be eligible for deadlines, and those are things that the after a year's time, that there is now continued membership in NACD, and that other similar initiatives will come to sooner "a feeling of comfort and confidence. company's name will not appear in the or later," says one distribution executive. But At first, there was a lot of hesitancy NACD directory. The association's bylaws other than that aspect, the Responsible because people didn't know how to are being revised to reflect the requirements Distribution Process is virtually identical to do this. Now they see it's doable. But of Responsible Distribution. According to NACD notices, "a company that consistently Responsible Care. "We looked at the Canadian codes that we still have to struggle with the issue of trust, big companies vs. small demonstrates a lack of good-faith effort and came first, and at the U.S. code," says ones, producers and distributors and progress in meeting requirements of the Mullins. "Obviously, a lot of what was in carriers." code can expect warnings that its progress is those programs pertained to chemical One of the aspects of trust is in the not satisfactory and that unless corrected manufacture, and not to chemical relationship between the distributor could result in membership being dropped." distribution. So for many of our members, and the end-user. Few businessmen Three warnings and ample time to comply pledging to all that really didn't make much want to alienate a customer by refus will be given. sense. Responsible Distribution blends ing to sell, even if it may be that the "We are not saying whom to do business certain features of what other programs buyer does not have the proper train with and whom not to." says Christopher have under various codes, and some of the ing or equipment to handle the mate Cathcart, v.p./general manager of NACD and language is identical.' . rial. Mulliken says ChemCentral has coordinator of the Responsible Distribution It has yet to be established whether the developed a simple questionnaire with program. "What we are saying when we various sectors of the chemical process items like "Do you have the MSDS?" publish our membership list is that here is a industry, the public, and the regulatory and "Do you need information on list of companies that have agreed to meet environment will be served best by a variety safe handling?" certain obligations. That should mean of Responsible Care-type codes, or whether Mulliken and other distributors something to someone." ultimately, the various initiatives will be say that once an element of trust The upcoming publishing of the NACD merged. Until then, however, NACD's efforts and cooperation is established, directory will be the first time it will be made serve as an affirmation of what is good smaller customers are usually available to nonmembers. It will include the about such programs and as a contrast in happy to have the help and guid names and telephone numbers of methods for realizing progress. ance of the distributor. Those points get back to product 26 CTL010178 i R&fponsittfe Care' stewardship, says Tom King, president and general manager of the industrial chemicals and solvents group at Ashland. "YVe are fairly far along with our own model that tries to en sure that the customer is using the product sold to him properly, that the customer's em ployees are properly informed on safe han dling and storage, and that the customer is dis posing of all by-prod ucts, coproducts, and residues properly. We have put together a com Transporters are adjusting to the code. pliance kit that has been very popu cause such facilities take possession lar." of, but not title to, the materials they KITS. Ashland is also working on a handle. Distributors usually do their contractor compliance kit and a con own storage, so it has fallen to the tainer management compliance kit that chemical producers, who often use will cover cleaning and disposal of warehouses for inventory control, to drums and bulk containers, and clean bring that portion of the distribution ing of tank trucks and railcars. Each network into the fold. kit contains training materials,. in "We have recommitted ourselves cluding workbooks, checklists, and to the chemical industry with the videos. Responsible Care initiative," says Rob One major gap in the distribution Stillwell, vice president for Houston code, and even in product steward of warehousing and transportation ship, is the role of the public ware company Houston/California Distri house. The complication comes be bution (HCD; Houston). "We saw the increasing liabilities in the mid-1980s, but in those days we couldn't even get an MSDS from the manufacturer, it was considered proprietary infor mation." YY'orking with some of its larger chemical customers. HCD worked though facility and safety evaluations with most of its major chemical cus tomers. Storing everything from sugar to hydrazine makes the warehouse responsible for myriad handling re quirements, and the operators say thev found chemical producers eager to cooperate. "If we get complacent, we get dis appeared," says Stillwell. But that does not seem to be the case. Chemi- ; cal storagOe now accounts for half of | HCD's square footage, up from less than one-third just a year ago. "The most important thing is to keep the dialogues going in both di rections," says Cichowicz. "and to incorporate all of Responsible Care, the distribution code, the product stewardship code, and everything into the total quality process. None of the initiatives should be viewed sepa rately. Unless you have them inte grated into the whole process of im proving vour operations, then vou are dooming them all to failure." GREGORY DL MORRIS in Houston TRANSPORT CODE BENEFITS ARE BECOMING EVIDENT .' Some firms are already starting to see f' " be fully trained by year-end. "~v has used the code as the basis to assess third party-owned warehouses and -??' benefits from Responsible Care-based ; ;? Changes that have already taken place in terminals. "Responsible Care is becoming a programs inthetransportation area.Take the : Eastman's practices include rerouting of trucks common vernacular," he says. ' ??* examples of Eastman Chemical and Shell; - away from population centers and along routes . Shell has cut by two-thirds, to 37. the with good emergency services. Since Eastman number of trucking carriers it uses over the t "IncidentsTnthedistribution system have \ -does not own its own trucks, this has required past five years. Do its remaining carriers ' ` decreased fromthree per month three years ? .much closer contacts with carriers, scrutinizing know about Responsible Care? "I can't ago to one per month," says Fielding Ralston,. "'their driver training, safety record, and guarantee that," says Medley, "but they do Eastmanvrpl/supply and distributionand procedures. Eastman has also halved the know about Quality, and we're getting a let member of the Chemical Manufacturers number of trucking firms it uses to just the' of mileage out of that." Association distribution code committee??"? three biggest U.S. operators. "We know from How can these performance ... Ralston sees a direct replationship between - .the CMA committee that this is a trend across improvements be demonstrated across ; that improvement, and Eastman's application - . the country," he says.: ' . of the Responsible Care cade, in aformat???? *??At Shell,fnonaccidental release incidents - ttaaiilloorreedd hbSyr EEaassttmmaann??*1* ;;from railcars dropped 40% between 1990 and - the industry? "One of the things we`re?fi ? looking for and desperately need isa??? 1 - measure that can be broadly accepted]:^? . Key elements of that are thewritingofa- "1991, to 17 out of 65,000 shipments. Buddy vision statement of what full fmplerfientation'^Medley. manager/land transportation for ? by the chemical industry and bythe gei> eral public," says Ralston, who adds.that4^ of the'code'wbijld be; a"descrrptiofi;bfthe^l ^Shell's chemicals arid oH products, puts that -there is currently no`data that firm's positionlnow; and a detailed action-^' ^ifownto a combination of the Responsible Care systematically collected that offers'true?-^? plan,"with target'dates and responsibilities^. program, and Shell'si own Quality Improvement v- ^comparability. CMA has a goal to establish.>- ,alloted, toclose the gap. Nowinto its third`s? : Process, which waFalready in place. --' t-/- a reporting system by July 1993. The likely? assessment of the program; "the process has .v'7::'They go hand in hand," says Medley.' r' model: tracking of incidents that involve - ' ' worked even better than we had- A-??*? ^-"Responsible Care provides an Improved focus, 'release of chemicals that have the potential anticipated," Ralston says! A further -with the measurement techniques and ."? ' for human or environmental injuiy, byjruxte... enhancement of the program vyill be adoption' structure. We've realized some good `_ of transportation,adjusted forvolurne/-^ . ' of a risk management model For ,' ' 7 ' improvements." Besides providing the basis.for . Ralston suggests. transportation activities, with employees to?A quarterly assessments of ad its carriers. Shell * --david Huma CTL010179 27 ( Regponsitb EMPLOYEE HEALTH AND SAFETY THE HOMESTRETCH: WORKER INPUT Caution advised on labor issues he CMA committee that drafted j raise a number of concerns on the Tthe employee health and safety ! labor front. An administrative law judge code (EHS) for Responsible Care-- ! in New Jersey, for example, recently adopted as the fifth code in January--ruled that Du Pont's establishment of was sent back to do additional homeem ployee groups to review health and work before finishing its assignment. safety procedures at its Deepwater, NJ After reviewing an in-house draft ver plant was in violation of the National sion of EHS, the national advisory Labor Relations Act, because the com panel asked the committee to compile pany had created an employer-domi employee input on the code from as nated workers organization, circum many member companies as possible. venting union negotiation on a work That last push made sense, says ing-conditions issue. Sandra Tirey, CMA's associate direc EHS also covers on-site contrac tor/health programs and staff coordi tors, raising concerns in the contract nator for the code, because, of all the engineering community over supervi codes, EHS may have the most direct sory authority and training on the job impact on workers. In fact, EHS is site. Still, most contractors are sup written in such a way that employee portive of Responsible Care, which input and involvement will be central provides a handy vehicle for them to to any company's compliance with it. prove they are competent and quality- Involving employees in policy de oriented--a fortuitous development cisions regarding health and safety in following the perceived anticontractor the workplace, however, is sure to slant to the Occupational Safety and Health Administration's (OSHA) John Gray report, an investigation of chemi cal industry accidents. Overall, Tirev says, implementing EHS calls for a high level of thought fulness and sensitivity to labor issues-- as well as a thorough knowledge of union contracts--but that any road blocks to employee involvement should be addressed proactively. IDENTITY CRISIS. The committee was concerned about the relationship of EHS to two existing codes in particu lar--process safety and community awareness and emergency response (CAER). EHS also addresses an area already covered by federal regulation under OSHA. Initially, CMA consid ered a unified safety code for Respon sible Care. EHS, therefore, has had to work through something of an iden tity crisis. Tirey explains that EHS was finally established as a separate code not only because employee health and safety is distinct from the issues addressed in safe process management and emer gency response, but because EHS, pro cess safety, and CAER will be man- Petrochemicals--Ethylene Oxide & Derivatives Division OxyChem's Ethylene Oxide & Derivatives Division is an industry leader in ethylene oxide, ethylene glycols and glycol ethers, ranking second in U.S. merchant sales in each. We're also the largest U.S. producer of DOT 3 brake fluid. OxyChem The Chemical operations of Occidental Chemical Corporation OxyChem is a registered trademark of Occidental Chemical Corporation 28 CTL010180 R&sponsiitfe, Care' \ D aged by different professionals--engi perfect entree for workers interested established the health and safety groups neers will oversee the process safetv in understanding and influencing the illegally. code, for example, while health and implementation of Responsible Care Tirey says the committee high safety and medical professionals will throughout the company. "They wanted lighted union negotiation as an area of oversee EHS. While CAER covers medi to become informed ambassadors." concern, noting that the code does not cal response to emergencies, EHS cov Feedback from Hoechst was typi prescribe an approach dealing with ers continual medical surveillance and cal--employees asked for clarification organized labor. She and others say ongoing health concerns, adds Tirev. on some points and for thatcompaniesshould Still, there is some overlap. For additional specific in strive to work around example, while medical fitness for duty formation on others. any roadblocks with falls under EHS, substance abuse re Overall, Johnson says, their unions as part of mains under process safety because of feedback was positive a good-faith effort to the impact of drug or alcohol impair and workers were glad include employees in ment on safe equipment operation. to see they were called decision-making. "EHS addresses issues such as whether upon to help build the Sources agree that the worker can wear a respirator or system. such efforts should be climb a ladder," says Tirev. Steve Kemp, man fruitful, given that most EHS is meant to go much further ager/facility safety and union contracts require than OSHA's process safety Manage health at OxyChem employees to become ment code, Tirey says, addressing is (Dallas) and chairman involved in health and sues like contractor oversight, em of the EHS code draft safety, albeit through ployee involvement, generalized health ing committee, says the union representation. and medical surveillance, and the es group had not intended Tirey says that prob tablishment of a system to track per to systematically solicit lems will most likely formance. "The philosophy is to go beyond regulations to incorporate the employee input before the advisory panel rec Kemp: Labor issues. arise only where unions have histori best business practices and ensure con ommendation. He notes, however, that cally been contentious. tinuous improvements," she says. "We many companies were doing this in She says other areas ofrisk on which used OSHA as a base, but it's a given formally, reporting through company the committee recommends a cautious that our members are representatives on the approach include perceptions of in compliance with the code committee. He coemployment for contractors and law." also notes employee/ medical surveillance. Lori Ramonas, FEEDBACK. On advice labor issues as central CMA's director of Responsible Care, of the advisory panel, to the formation and says that the code provides for train Tirey says, the commit implementation of the ing of contract workers by the con tee asked member com code. tracting firm or the chemical com panies to take the code "The whole issue of pany, with the mutual agreement of to their employees. employee participation both parties. Again, the recommenda Sixty-six companies is a hot one," says tion is for cautious, thoughtful imple filed responses in vari Kemp. "Youcan'tman- mentation toward the end of includ ous formats that re date participation in a ing all on-site workers in the company's flected the different lev union environment. It's health and safety program. els at which companies a negotiable issue. " The GULF COAST TRADITION. Despite the an were already involving code encourages mem ticipation of various roadblocks, com workers in health and bers to involve their panies with mature health and safety safety policy. The over employees fully, says programs may not have to change much all message was that the committee was on the Tirey: Proactive approach Kemp, and the nego to accommodate EHS. On the Texas tiation will be required Gulf Coast, for example, there is a right track. Ratification of the code, , at any union site. tradition of cooperation between Tirey adds, came off on schedule. Although Du Pont claims the chemical manufacturers and their con At Hoechst Celanese (Somerville, Deepwater ruling does not affect its tractors that extends to shared respon NJ), "We got rid of the formalities," implementation of Responsible Care, sibility for training and other pooled says David Johnson, director/occupa sources say the incident serves as an resources, all of which would trans tional safety and a member of the EHS illustration of a possible pitfall in the late smoothly to compliance with EHS. code drafting committee. Johnson or area ofemployee involvement on health According to Don Smith, executive ganized breakout sessions in the and safety issues. According to Michael v.p. of the Associated Builders and company's three business groups--fi Szep, human resources manager at Contractors of Texas Gulf Coast (Lake bers, chemicals, and specialty prod Deepwater, the seven employee health Jackson, TX), the chemical firms work ucts--to review and discuss the code. and safety groups named in the suit with the contractors on safety council Hourly, 25 employees reviewed EHS. predate the company's Responsible and apprenticeship boards and gener "The employees did their home Care initiative, which is handled in ally emphasize on-site response to work," Johnson says. "And they looked cooperation with the local Chemical safety hazards as a shared responsibil broadly at Responsible Care. They re Workers Association through another ity. "This may not be characteristic of ally wanted to know more about it." company committee. The union, how other regions," Smith says, "but it's Johnson stresses thgt involving the ever, prevailed in its claim that by nothing new for us." employees on health and safety was a excluding union participation, Du Pont RICKMULUN CTL010181 29 Responsible, \ PRODUCT STEWARDSHIP * 3 ? IMPLEMENTING A PHILOSOPHY Facing the challenges of the most sweeping code hen the Chemical Manufactur go; any number of people could take Wers Association sent the draft responsibility for it," says Claudette product stewardship code out M. Cofta. CMA's associate director/ to its members for comment behfoeraelth programs and staff executive approval, the overwhelming respoonnsethe product stewardship code com was concern over how difficult they mittee. "You have to think through thought it would be to implement. and be somewhat creative about what Now that the code has won CMA board in your company would represent a approval, companies are rolling up product stewardship action under the their sleeves and spreading the word i code," she adds. to their employees and business part In CMA's implementation materi ners about the most ambitious code in als, due to be completed by the end of the program. this month, Cofta will recommend writ Prioritizing resources, educating : ing a vision statement of what would salespeople in their key roles as cus- j tomer contacts, deciding how to ap- 1 proach self-evaluation forms with a STEWARDSHIP'S KEY CHALLENGES code that does not lend itself well to | quantitative measurement, and unify ing a company's disparate components together around a new philosophy are some of the challenges companies of all sizes are grappling with, whether ' Stretching resources to cover an all-encompassing code Training salespeople to understand product hazards and track customer use habits. or not they already have some kind of ; Requiring suppliers to practice product stewardship program in place. stewardship. HARD WORK. Even Dow Chemical (Mid land, MI), widely regarded as having Defining benchmarks and measuring the most advanced product steward- j progress in self-evaluation form. ship program in the industry, sees , hard work ahead for itself now that the j Extending PS to foreign customers code has been finalized, especially in : and suppliers. deciding how to complete the self- j evaluations. "The first thing we're \ constitute having each management working on now is writing a vision ; practice in place; firms will then have statement for what having a manage to come up with their own bench ment practice in place is," says Larry marks or milestones by which to mea Rampy, global product stewardship sure progress. Year-to-year consistency director/chemical and performance may be difficult: "Companies will sell products, hydrocarbons, and affiliated or acquire or discontinue product lines, companies. "Dowecallallorjust j so accounting may be imprecise, to some of the customers? Do we have a say the least," says Cofta. formal or informal hazard classifica Dow has had a fairly comprehen tion system? We try to answer these i sive product stewardship program in questions in the vision statement," : place for more than two decades, but Rampy says. _ the code still brings with it new de Each division will then evaluate i mands, including consistency among itself according to the vision state- j the different business groups. "Prod ments. "It sounds great," Rampy adds, j uct stewardship is a cultural reality at "but it will be complex to figure who i Dow," says Rampy, "but it's not seen is to be involved." Determining the I the same by everyone." As the evalua appropriate unit of measure for the j tions are performed, those inconsis evaluations--business units, depart- i tencies will start to show. What may ments, product lines, products--is i be required, he says, is more unifor another hurdle, which demonstrates a J mity in hazard assessments, product major question mark for product stew- J risk reviews, and degree of interaction ardship: how to organize the imple- I with customers. mentation of a philosophy. . Developing a close relationship with "There'snoobvioushomeforwhere [ customers is essential to product a product stewardship code should ` stewardship's feedback loop of bring ing complete customer use informa tion back to the company to better enable it to assess exposure and risks. The code's emphasis on knowledge of how a company's products are actu ally used is new for most companies, savs Cofta, and the element many people "think is probably the biggest challenge. This is a highly competi tive industry, and often suppliers and customers are competitors." Sensitivity is required in gathering data on use patterns, Cofta says, "so you don't intrude on a customer's pro prietary information and so they un derstand you're seeking health, safety, and environmental information, and what you're planning to use it for." She adds, "This sets up a mechanism for customers to have their needs ad dressed. We may find some momen tum, some driving force from our cus tomer community after we get over the initial reaction of, `Why are you ask ing me all these questions?' Your cus tomers will appreciate reducing their liability and feeling like they're doing a better job of protecting their employ ees and customers, and that they have a better handle on regulations regard ing the product." 'A COMPETITIVE THING.' Du Pont (Wilm ington, DE), another industry giant with a well-established product stew ardship program, will be training its sales and marketing staff in the fall in their key role in that risk assessment feedback loop. Bill Haaf, manager/environmental issues and chairman ofDu Pont'sglobal product stewardship committee, says the sales force will be trained to understand a product's hazards, how the customer is actually using it from handling to disposal and emissions to the environment, and, most important, that these efforts improve their offer ing to the customer. "We've got to think of this as a competitive thing-- our salespeople understand that," Haaf says. Dow's basic sales training includes product stewardship. "The fundamen tal need is to get them to embrace this as a selling tool," says Rampy. "We want to tell the customer, 'We'll help you understand your health, safety, and environmental requirements, which will help keep you out oftrouble. ' You've got to be cautious not to go in there and look like an OSHA inspector and to make them think you're there to punish them when they're bad." Elf Atochem's (Philadelphia) Craig Farr, manager/product safety and tox icity, says, "CMA struggled with the 30 CTL010182 Rejponsiitfe, Care, question of how much is it our busi is enough, he sa\s. "That line is con- adds. "As product stewardship be ness to go downstream into our cus stantlv being redrawn across the turf comes more perwisive. there will be a tomers' business. But it's a value-added as vou move along." natural competition in reassessment thing for our salesmen to use in their Charles Donohue. Akzo's director/ We will see an e\olving kind ot stan efforts. Corporate responsibility is never regulatory affairs and Responsible Care dard." a negative." Kev to the process, he coordinator, sees more company ex Along with many of her colleagues. adds, is taking safety, health, and en perts--staff from manufacturing, prod Janice Warnquist. director/environ vironmental information and translat uct safety, and toxicology, for in mental health and safety for Crompton ing it from technical jargon into more stance--getting involved in risk as & Knowles dyes and chemicals divi common terminology so company rep sessment, "and getting a consensus sion (Stamford. CT). emphasizes that resentatives can effectively communi across four or five disciplines. The risk assessment is a continuous pro cate it to each other and to customers. "business differentiation of the future cess. "We're constantly maintaining Amoco Chemicals' (Chicago) Mike will be in the regulatory arena," he hazard information. We have hands- Collins, supervisor/industrial hygiene in the environmental, health, and safety department, provides an example of PESTICIDE INDUSTRY'S STEWARDSHIP LESSONS stewarding a hazardous product. In Pesticide manufacturers have a jump on through a monthly pullout section in a major 1988 the company learned from test some other segments of the chemical farm magazine, and ACRE is developing results that exposure to its chemical industry when it comes to focusing on their materials for nonagricultural pesticide users, intermediate trimellitic anhydride products' effects on the environment, rather further down the road is a program to reach (TMA) was linked to respiratory sen than just on human health and safety Given home gardeners. sitization, causing reactions ranging from asthmalike to flulike symptoms. that their products are applied directly into i and onto the environment, Skip Ragland, manager/public relations with Ciba-Geigy's (Ardsley, The manufacturing, marketing, they have had to steward NY) agricultural group, says sales, and industrial hygiene depart their products more closely his firm started a dealer site ments worked together on stewarding The pesticide industry assessment and improve the product, and Amoco developed a formed the Alliance for a ment pilot project in Illinois safety-handling video, brochures, and Clean Rural Environment last year, with company other materials to provide customers (ACRE) three years ago to representatives visiting over with proper handling information. ! help serve that function 550 dealer sites to help Amoco says it will suspend sales to a Originally funded by 19 of ensure safe use and customer mishandling TMA, "until the largest companies in the handling of their products practices are improved." industry, the National He says his firm has been on Collins says the videotape, 1 Agricultural Chemicals the cutting edge of low- translated into eight languages, ex- : Association (NACA; Wash dose, low-exposure prod plicitly shows what safe work practices, ington) membership voted ucts, including dissolvable such as proper ventilation, "look like." 1 last year to fully fund it. packaging Amoco is just getting off the ground John H Thorne, director Monsanto (St. Louis) with its product stewardship program, using the TMA program as a model. of ACRE as well as director/ Thorne: One on one. water quality programs at agricultural group v.p/ environmental and public Fundamental to stewarding a prod NACA, explains that ACRE reaches farmers | affairs. Bob Harness, says his company uct is a comprehensive understanding by putting safe use, storage, and handling | offers an eight-volume set of environmental of its risks. Chevron's (San Ramon, information into practical and readable j information to dealers, on topics ranging CA) Glenn Weckerlin, manager/plan language and distributing it to national, from environmental site assessment and ning and analysis and CMA product state, and regional farm-related organiza groundwater to emergency response The stewardship committee chairman, says, tions in the U.S. "In effect, what we've Product Stewardship code is leading his "You can control and understand your created is a syndicated environmental company to do more stringent product product's personality traits--toxicity column," says Thorne, that is published in screening early in the development stage and so on--more than you can control those organizations' magazines and newspa "We use efficacy as the primary screen," he the way your customers use it." pers, which can choose from a number of says, "and now we're using preliminary FEEDBACK. How much testing is re specific topics such as water protection, health, safety, and environmental data as quired on a given product depends on worker safety, and container disposal. Also, another cut The product has to have what is already known about its haz nearly 2,000 farm radio stations broadcast superior qualities in that area too." ards and how it is used, which is ACRE'S 30-second announcements Thorne Motivation for the sales force to keep a where the importance of the sales- says a Gallup poll showed 78% of farmers watchful eye on customer use and handling focused feedback loop comes in. who had heard of ACRE changed one of their of their products comes from environmental "The bulk of this is getting out and j pesticide use practices as a result of needs being "high on the customers' list of talking to people," Weckerlin says, j reviewing the materials. concerns in selecting and using a product," "Once the feedback loop is established, "Member companies are really expert in Harness says, adding that greater involve a system to collect the data is peanuts. " the area of stewardship," says Thorne, "but Akzo's (Chicago) Doug Klapper, j they didn't have the wherewithal before ment by the sales force can lead to opportu nities in terms of product development and manager/product safety and product j ACRE to have a one-on-one dialogue with finding new applications. ''Companies that stewardship, says, "Companies can- their end-users," since manufacturers' j can address these important societal not rest on their laurels' with the infor customers are frequently distributors and j issues," he says, "can win a competitive mation they have. You definitely have dealers, not farmers. Dealers are reached i advantage." to do more." Asked how much testing CTL010183 31 Regponsiiie, Care' on safety people always Excellence program, keeping that current. VVe which adds employee don't feel we have to go wellness and an back to the beginning." electronic environmen Dow's Rampy sees tal, health, and safety more environmental information system to testing in the years the Responsible Care ahead. "The historical codes. development has been Sullivan is planning to emphasize human product stewardship health and safety first," forums to acquaint em he says, "but more ployees with the goals people are seeing the of the program. Point need to improve the way ing out that Hoechst we treat the environ Celanese has a "decen ment. Many customers tralized organization" are not used to that, so that includes pharma they welcome our help on things like air emis cofta: Need to be creative. ceuticals, fibers, and bulk chemicals, she sions and our product's persistence in says, "It's likely that different business the environment. It's a growing area of groups within the company will get to interest." the same end results in different ways. " Michele Sullivan, Hoechst Resources are a major issue with Celanese's (Somerville, NJ) director/ this code. Training can be a big dollar product stewardship, says, "In the fu expense up front, especially when one ture, there will be as much emphasis adds the cost of sales staff sitting in an on environmental testing as on toxic auditorium instead of visiting custom ity testing." ers. Chevron's Weckerlin says that for Her firm is combining product stew a company to jump into a product ardship with its corporate Vision of stewardship program without ap proaching resource priorities first "just raises the stress level and lowers effec tiveness." Chevron determined what was re quired to achieve Code in Place status on the evaluation form, "then they'll back into it and determine what the resource needs are." says Weckerlin. When this is added to the other codes and to other programs like Total Qual ity Management (TQM) and ISO 9000, as well as conducting the company's business, it can lead to an imbalance of resources, to say the least. "You can't do this by just adding 10% to someone's job--it wouldn't be worth anything. This is a completely differ ent way of doing things. You have to reshuffle the deck resources-wise and make sure this comes out on top," he says. Product stewardship's amorphous nature makes calculating resources an even tougher job than it might other wise be. Witco's (New York) Howard Cunningham, manager/product safety, says, "By far, product stewardship is the largest code in scope and the least narrowly defined. It covers a very broad area, and the level of applicability will Castle Hayne, North Carolina, is'the site of North America's largest and most technologically advanced chrome chemicals plant. Here, OxyChem produces chrome products for a range OxyChem* of industries. The company also has facilities to produce other special proprietary products, such as sodium silicates, sodium hypophosphite, and flame retardants. The Chemical operations of Occidental Chemical Corporation OxyChem is a registered trademark of Occidental Chemical Corporation 32 CTL010184 Re^ponsibUe, Care, varvgreatly from location to location." pains." Haaf acknowledges. "It'll take Smallercompanies have been particu time." larly concerned about resources. Monsanto's (St. Louis) Jim Barnett, the Synthetic Organic Chemicals manager/product safety with the chemi Manufacturers Association (SOCMA: cal group, says his firm "believes that Washington) became a partner group Responsible Care is a value added, under Responsible Care in May, and and we try to communicate that to our Carolyn Covey, manager/performance customers. But how do you ensure excellence programs, has been visit that added value is coming to you from ing member companies' sites to talk vour suppliers?" That brings home one about the program. "They of the basic challenges wanted to know how what of product steward they were already doing fit in. When they see ship: measurement. "There have been they're already doing it. some efforts at Mon they get excited and want santo to create indices to do more. A smaller of how these environ- facility that sees it's partly there has more motivation." She adds that SOCMA's members "are at the very early stages," and that her task is "not so much convinc ing them [to practice the code] but showing them how to do it." SOCMA's product stewardship work group is gathering existing Donolfue: Evolving standard. implementation materials from the mental ethics likes of CMA, Dow, and Du Pont, and will be mea will examine whether something sured. It's a further is needed specifically for little hard to" smaller companies. Covey points out judge suppliers that smaller companies frequently sup ply larger ones. "The trend," she says, without those, Barnett adds. Farr: `A lot of legwork.' "has been toward larger customers Most companies see practicing wanting more of a partnership product stewardship with foreign cus relationship with their supplier," pro tomers and, especially, suppliers, as a viding a pathway for aiding them with step to be taken later. "For now," says implementation. Barnett, "we are keying most of our NEW CHALLENGE. Extending prod activities in the U.S. and waiting for it uct stewardship backward toward to evolve in Europe. You have to walk suppliers is a new challenge of before you can run." product stewardship. Dow's Rampy The code also requires companies says the outreach to suppliers is to consider product stewardship at "new to most of us. Most companies the product design phase. "R&D is have TQM partnerships with their key," says Du Pont's Haaf. "If there is suppliers, but not so many are no mindset of this with new processes, making sure they get good you're nowhere. If you don't do this environmental, health, and safety in R&D, forget it, it'll never really information from their suppliers, work." or asking if they behave respon Product development people need sibly." to question things like whether they Haaf says Du Pont hopes to build are minimizing waste at the source or guidelines into its purchasing con whether there are highly toxic com tracts by year-end, requiring suppliers pounds present that can be dispensed to indicate whether they are a Respon with. "We have huge R&D all over the sible Care company, or afe willing to place," says Haaf, "and right now it's abide by those principles. "We're go a little inconsistent" in terms of asking ing to set a low hurdle for a couple of these questions. Training for R&D staff years; mostly, we want to send a mes begins in the fall, he adds. sage," Haaf says. Further extending "No longer can people developing this to foreign suppliers will be an products just ask what the customer other step: "There will be growth needs and what are the cost param eters. but how dangerous is the pro cess. what kind ot waste is generated how can we minimize it. what is the product's environmental fate as it's used or misused?" savs Akzo's Donohue. All these new considerations at the design phase require technical staff to communicate with personnel handling areas such as product salet\. environment, transportation, and in dustrial hygiene. Donohue says. For a dye producer like Crompton & Knowles, changing its product lineup as fashions change, the development stage becomes even more important. "Customers come to us with a product profile telling us what they want. That's going to be a lot more elaborate with product stewardship. We'll be consid ering raw materials, the waste produced; we'll be looking at a broader scope of things than in the past," savs Warnquist. She sees a big but rewarding challenge: "Bringingall the func tions of the company together. We all have our own jobs to do. but now we have to all work together toward the same goal. I think it has a positive, unifying effect, and makes the company more cohesive." Each business function-- R&D, purchasing, sales and marketing, manufacturing, and so on--has written a product stewardship action plan, all of which will be brought together, finalized, and prioritized by September for inspec tion by a senior management product stewardship committee. COAST TO COAST. Elf Atochem's Farr says one of the biggest challenges ahead is "the fact that we have to reach across the entire company with this. Just pushing it deep enough into the com pany to make it take. It will take a tremendous amount of planning and execution to penetrate all the different areas. It'll take a lot of legwork." But people in the industry report that they are seeing greater levels of cooperation, as companies help each other on Responsible Care in general and product stewardship in particular by sharing information, resources, and expert personnel. CMA has a sharing bulletin board that regionalizes oper ating sites to facilitate cooperation. "The powerhouses of CMA have been terrific about sharing information with other people," says Donohue. "That's one of the real pluses spiritually about the way this thing is working." RONALD BEGLEY CTL010185 33 TECHNOLOGY and some facilities are not as far along as Hirschhorn. CLEANING UP others," he savs, "the numbers are encouraging and a step in the right direction." But while experts argue over the extent of progress, they agree that sig nificant reductions ultimately mean PROCESSES Success stories abound (p. 79). And fundamental process changes. And that leading firms, including Monsanto, means going back upstream to find wa vs Taking the next step Dow, Du Pont, and Hoechst Celanese. to improve yields, avoid unwanted by j report progress in meeting corporate products, better separate waste reduction goals. products, and substitute more ublic disclosure of the releases of a Still, some industry observers are benevolent raw materials. Pwide range of compounds in the skeptical. "I don't believe that the TRI federal Toxics Release Inventory numbers indicate real source reduc (TRI)--published initially in 1989--hatsion," says Joel Hirschhorn, president of 'NOT ROCKET SCIENCE.' Such efforts will take rethinking of many existing pro cesses--and significant capital invest put a glaring spotlight on the industryH'sirschhorn and Associates, a Washing ments. But some experts sav that in pollution prevention efforts. The bad ton-based consulting firm. One prob many cases it is already a feasible news is that U.S. chemical producers lem, he says, is that the TRI numbers are technological feat. "It's not like rocket still release a staggering 880 million lbs/ not correlated to production levels or science--it's chemistry used in a novel year of TRI-listed chemicals, dwarfing product mixes. "There is no current way," says Gerald P. Ceasar, manager/ the contribution from any other national data base that measures waste emerging environmental technologies at manufacturing sector. The good news is reduction," maintains Hirschhorn. BP America (Cleveland). "It will not take that the industry's releases have dra Further, he says, available data indi a quantum leap in science," agrees James matically dropped by 35% since 1987. cates that "virtually every company's Cusumano, chairman of Catalvtica "There is a positive downward trend waste reduction efforts have leveled off (Mountain View, CA). "It is all there if due to a wide range of efforts, including in the last two to three years." Initially, companies are willing to spend the time upstream changes to eliminate waste at he suggests, firms made the easy "low- and money to develop the technology." its source," says Jerry B. Martin, Dow hanging" changes and producers are Long-term pollution prevention suc Chemical's (Midland, MI) director/ now running up against the need to cesses mean involving research and environmental affairs. Richard Dennis, make expensive modifications in manu development groups. And leading environmental affairs manager at facturing processes to achieve further firms, such as Du Pont, Monsanto, American Cyanamid (Wayne, NJ), reductions. "Industry is just beginning i Bayer, and Dow, are increasingly pur agrees. While "there is still a way to go : to confront that fact of life," says suing such process R&D. THE INDUSTRY'S 1990 TRI SCORECARD (in lbs) American Cyanamid (Westwego, LA) Monsanto (Alvin, TX) Vulcan Chemicals (Wichita, KA) Freeport McMoRan, Agrico Chemical (St. James, LA) Du Pont (New Johnsonville, TN) Courtaulds North America (Le Moyne, AL) Tennessee Eastman (Kingsport, TN) Du Pont (Pass Christian, MS) Du Pont (Beaumont, TX) Freeport McMoRan, Agrico Chemical (Uncle Sam, LA) Du Pont (Victoria, TX) BP Chemicals (Port Lavaca, TX) Sterling Chemicals (Texas City, TX) BASF (Lowland, TN) BP Chemicals (Lima, OH) Monsanto (Cantonment, FL) __ Arcadian (Geismar, LA) ICI Americas (Mount Pleasant, TN) Mississippi Chemical (Yazoo City, MS) Triad Chemical (Donaldsonville, LA) Hoechst Celanese (Narrows, VA) Cabot (Tuscola, IL) IMC Fertilizer (Mulberry, FL)' OxyChem (White Springs, FL) ' Du Pont (Orange, TX) . '' GE Plastics (Mount Vernon, IN) Dow Chemical (Freeport, TX) Coastal Chem (Cheyenne, WY) Royster Phosphates (Palmetto, FL) - OxyChem (Castle Hayne, NC) Source: Environmental Protection Agency! Air emissions 582,489 350,029 582,059 14,211,310 8,962,315 45,496,420 36,117,800 5,890,700 3,399,178 703,717 1,498,030 185,263 1,497,015 22,646,550 3,563,645 1,356,503 2,193,515 142,546 12,287,721 11,302,774 11,608,003 4,011,269 690,645 752,020 2,877,067 7,942,183 7,476,374 1,008,044 4,427,300 45,909 Surface water discharges 262,493 0 0 42,061,200 40,400 35,860 2,587,011 430 64,600 35,210,300 4,774 1,210 15,100 16,150 78,355 2,030 14,200,265 2,000 653,180 475,124 660 0 0 837 34,320 -44,754 461,816 0 0 64 Underground injection 161,186,000 64,404,300 56,606,820 0 41,000,000 0 0 33,000,000 33,740,360 0 33,360,681 32,430,887 30,832,355 0 20,640,015 17,129,872 0 13,068,261 0 0 0 7,358,760 0 0 5,655,679 0 0 6,818,227 0 0 1Land releases Total 0 69,400 0 266,305 1,250 400,750 445,759 2,000 2,360 241,950 233,728 14 0 2,394,000 0 0 238,000 0 0 0 5,563 0 9,213,250 9,000,000 0 0 4,017 82,390 3,346,000 7,404,801 162,030,982 64,823,729 59,188,879 56,538,815 50,003,965 45,933,030 39,150,570 38,893,130 37,206,498 36,155,967 35,097,213 32,617,374 32,344,470 25,056,700 24,282,015 18,488,405 16,631,780 13,212,807 12,940,901 11,777,898 11,614,226 11,370,029 9,903,895 9,752,857 8,567,066 7,986,937 7,942,207 7,908,661 7,773,300 7,450,774 34 CTL010186 suggests, can lead directly to modifica friendly, including new routes for prod tions of parameters, such as pressure ucts that once required phosgene or S and temperature. Increases in computa chlorine. The scientists have also de- I tional muscle are also allowing a better veloped biotechnology processes for | understanding of how to control and end-of-pipe treatments and optimize the mixing of reactants. And at bioremediation. "In one of our major the same time, sophisticated process dirty processes." says Brodsky, "we've controls are allowing researchers to bet actually had a breakthrough, and we are ter manipulate stoichiometry, says now building a pilot plant." Snvder. The attack on Monsanto processes THE DIRTY DOZEN. At Monsanto (St. starts with a life-cycle analysis, which Louis], a team of top scientists has been examines raw materials, energy needs, turned on the firms' most polluting process by-products, and product use. processes and products--"The Dirty While the study is limited, says Dozen." Director of corporate research Brodsky, "you'd be amazed at what you and environmental technology Philip can do with just thinking through these Brodsky says that over the past two issues." For example, a life-cycle years his group has reviewed every analysis suggested that Monsanto could major Monsanto process, looking for "mine" adipic acid from used nylon novel opportunities to clean them and carpeting. Brodsky: 'Create new chemistry.' "create new chemistry." The research is used to set up a most- In the past, he says, there was no wanted list. The team catalogues the There are several areas of opportunities incentive to search for more environ worst processes in Monsanto from an for R&D in fine-tuning manufacturing : mentally benign replacements for stan environmental perspective and a yield processes to produce less waste, says : dard chemical reactions, which had long perspective. Then, for each of the Irv Snyder, Dow's director/process ago been optimized for cost. Now, there "dirtiest" processes, Monsanto rounds technology development. Usingsophis- ' is not only the environmental payoff for up a brainstorming team that can grow ticated computational simulations, he > innovation, but a new cost consideration, to "dozens and dozens" of people, says, researchers are gaining increased ' as waste disposal fees skyrocket. Brodskv says. "We assemble a team of understanding of the chemistry, includ The group has already chalked up a oxidation chemists, biological scien ing intermediate reactions, by-prod number of successes in reinventing old tists who think fermentation rather than ucts, and kinetics. Such insights, he processes to be more environmentally traditional chemical processes, and FINDING THE ANSWER IN TECHNOLOGY Under the public gun to slash toxics re leases, U.S. chemical producers are reporting a growing list of successes and ambitious projects. After gaining notoriety for having the larg est releases reported under the TRI at its Fort ier plant in Westwego, LA, American Cyanamid has launched a $50-million program to slash releases by 80%. Projects will include a regeneration unit--scheduled to be complet ed m late 1993--to recover 120 million lbs/ year of sulfuric acid that is now disposed of by deepwell injection. Cyanamid has also in stalled a unit to recover 12 million Ibs/year of acetonitrile and expects startup within months. It will also add a unit to recover hy drogen cyanide and plans to replace a strip per column at the acrylonitrile plant, reducing process water and effluent discharge to the deepwells. Facing a federal ban of mercury waste at landfills, PPG Industries (Pittsburgh) is install ing a thermal treatment unit for mercury-con taining solid waste produced from its chloralkali manufacturing at Lake Charles, LA. "To day it's not possible to make high-purity caus tic soda without using the mercury process," says David Angell, works director/environ mental assurance. "We're trying to develop a membrane process to do that. Meanwhile, we're required to remove the mercury con taining wastes from landfills." PPG's new $5-million unit, due onstream by May 1993, will vaponze mercury, which will then be recycled to the electrolysis unit. The firm's process will use technology developed by Hazen (Boulder, CO), under a joint program organized by the Chlorine Institute (Washing ton). PPG will also take mercury wastes from its Natrium. WV site. When the new unit is in operation, "the net result will be a major pollu tion prevention step," says Angell. Air Products and Chemical's (Allentown, PA) new 70-million Ib/year polyvinyl alcohol unit in startup at Pasadena, TX will have vola tile organic compounds (VOC) emissions at one-tenth the level of its older plant at Cal vert City, KY, due to redesign of parts of the 12-step process. "Three to five years from now, that will probably be legislated," says Robert Gadomski, v.p./chemicals. "Retrofit ting is very expensive, so when we designed the facility, we based it on a view of where the laws will go" Building its first grassroots adipic acid plant in over a decade and facing mounting concern over nitrous oxide (N20) emissions, Du Pont (Wilmington, DE) has taken a series of design steps to cut both VOC and N20 emissions from its $225-million plant being built tn Singapore. The up-front integration of environmental considerations with process design, explains Edward Reiff, business man ager/nylon intermediates, led to dramatic im provements over existing plants, including a 35% drop in energy consumption, a 20% de crease in water use, and a 97%-99% reduc tion in air emissions. Du Pont was also able to design into the new plant an online pro cess for making saleable dibasic esters from by-products. The Singapore plant, says Reiff, has 25%-30% new technology. Computer simulation played a key role in the design process, he explains, allowing Du Pont scien tists to model and predict the effects of dif ferent modifications. Union Carbide (Danbury, CT) eliminated the use of methanol at its Seadrift, TX manufac turing site by redesigning the coolers. The change cut the need for methanol injection, and as a result, the effluent stream does not contain methanol and can be recycled for benzene recovery. The change cut 150,000 lbs of benzene and methanol emissions. BP Chemicals (Cleveland) will cut 1992 re leases of nitric and nitrous oxide by 95% at its Lima, OH site by replacing a 1955 unit for nitric acid production. About 80% of the re duction will result from improved design and operating parameters, while 15% will come from the use of selective catalytic reduction technology. CTL010187 35 Rigponsitie Care' ACID RECOVERY SOLVES MMA WASTE PROBLEM ! the acid recycle plant was commissioned about 15 months ago Dealing with process wastes is in transi ating carbon dioxide and water As a result, 10 As well as recycling acid from MMA pro tion from end-of-pipe solutions to the devel kg/hour of organics will not go into the atmo duction, Mole says, SAR know-how can be opment of clean technology. For example, sphere and 1 m.t./hour of organics in effluent applied to acids from refinery alklylation, and Matthew Rigby, ICI's (London) technical will be eliminated. Mole adds that safety was a number of other processes where acid planner/methacrylates, notes that the next a big concern in construction generation of methyl methacrylate (MMA) of the new MMA plant. The technology will likely move from acetone overall cost of the MMA cyanohydrin feeds, on which over 85% of all units and associated servic world production is based. When ICI's plants es is put at 120 million: were built, they were based on the best "probably 10million-15 technology, says Rigby, but they produce 3 million is extra in terms of m.t. of waste for every 1 m.t. of product. environmental improve Additionally, cyanohydrin is based on hydro ments," he says gen cyanide, which the authorities may The SAR technology is clamp down on. also employed at ICI's MMA Nevertheless, ICI hopes its sulfuric acid plant in Taiwan. Three years recovery (SAR) route will be specified for use ago the company decided to under the U.K.'s "best available technology double the capacity of the not entailing excessive costs" regulations. 35,000-m.t./year plant and SAR can use oxygen instead of air as the build an acid recycle plant to combustion medium and is being offered un treat the wastes, which der license by L'Air Liquide (Paris). were dumped by barge at As well as recycling 215,000 m.t/year of sulfuric acid from its two 100,000-m.t./year, sea under permit from the local authorities. At about ICI installs a sulfuric acid recovery (SAR) unit MMA plants at Billingham, U.K., Jim Mole, the same time, the company says, a typhoon waste is a concern. These include acryloni senior chemical engineer/sulfuric acid tech caused dumping of plant waste from a barge in trile. caprolactam, the sulfuric acid route to nology, says it reduces emissions and efflu-. the mouth of the harbor. As a result, local fish titanium oxide, and nitration processes used ents. Low emission levels of organics in the ermen blockaded the plant, the authorities re in dyestuffs production. aqueous stream and from vents are collected fused to renew the company's waste dumping and fed to the burner in the SAR unit, gener- - permit, and a year's production was lost, until EMMA CHYNOWETH we'll bring in catalysis experts." Some members are from within Monsanto's corporate research group, some are signed on from academia, and some are brought in from the operation unit un der examination. Then they brainstorm. At a two-day retreat, the group discusses new, cleaner ways to get to the product and eliminate or find uses for by-products. "Because you have this mix of people," explains Brodsky, "you come in with these wild mixes sometimes, such as step processes that may be something very unique, that any single-discipline person might not have thought up." Some of the ammunition is research from Monsanto's own labs. For example, although chlorine is the accepted pathway to organic-ring substitutions, Monsanto scientists have been able to substitute that process with a nonchlorine technique. In biotechnology, the firm has looked into fermentation for creating chemicals. "The economics is still not terrific" for commodity ethanol production, Brodsky says, but the group continues to study the process. Microbes that have the capability of selective reac tivity, such as catalyzing para-s'ubstitution on a benzene ring, have been found, but as yet are not connected with a specific product. hyde. But then--rather than using a One success has been a new chemis copper chloride cocatalyst--Catalytica try for polyurethane production. While uses a phosphomolybdovanadate Monsanto does not produce polyure polyoxoanions catalyst. And by fine- thane, Brodsky says, "it's such a dirty tuning the exact composition of the chemistry that it represents a tremen anions, Catalytica is able to optimize dous opportunity for a breakthrough." the oxidation potential of the catalyst, Monsanto's process uses carbon reducing the amount of chlorinated dioxide instead of phosgene and elim wastes by up to a thousandfold. inates isocyanates. It also generates half | Cusumano says the yield is compa- the amount of chlorides of the original 1 rable to existing processes, without the reaction. The scientists also developed environmental drawbacks. And, he a technology for producing isocyanate adds, the catalyst could have applica without any chlorides. tions in other olefins production, in Technology transfer, through pilot cluding the direct oxidation of butenes plants and even through the reassign j to methyl ethyl ketone, ment of researchers into production j But getting chemical firms' R&D units, completes the process. The end groups and engineers on the pollution results, Brodsky hopes, will be new prevention bandwagon is not always options for Monsanto's product lines easy. Observers point out that chemists and new business opportunities. and chemical engineers have to rethink CATALYSTS. Much of the R&D effort to priorities in developing products and develop cleaner processes is sure to focus designing processes. And success on catalysts. Catalytica, for one, has requires intimate ties between R&D and successfully pilot tested--and is ready manufacturing. to commercialize--a novel catalyst that Indeed, says Hirschhom, the effort aims to the avoid chlorinated organic by will require a fundamental retraining products during acetaldehyde pro and retooling ofthe industry's scientists. duction. He adds: "They'll have to change their The process--like conventional goals and relearn how to evaluate R&D." Wacker technology--uses a palladium DAVID ROTMAN catalyst to oxidize ethylene to acetalde with ELISABETH KIRSCHNER 36 CTL010188 i Responeiitfe, Care, Fundamental to the intentions ofResponsible Care are improved relations between the chemical industry and the communities in which companies operate. In the following pages, we include case studies offour ofthe most important regions in the industry--areas where the industry has had a history of difficult relations with the community. We examine how the Responsible Care approach is being applied and how it is beginning to solve problems in each location. And ive chart how it is starting to heal some of the wounds of the past. We continue with our company profiles, examining how the Responsible Care program is beingimplemented across company operations. CASE STUDIES NIAGARA FALLS: CASCADING CHANGE says Porter. "We already had a dia logue with the community, but this Rebuilding relationships after Love Canal increases it on a continuous basis." t OxyChem, for one, has also boosted its public outreach in other areas. Un he mystery began two summers information." der the community awareness and Tago. Trees in the working-class The defoliation problem illustrates emergency response (CAER) code, it neighborhood directly across the the critical role for Responsible Care in j has scheduled both an open house and street from Du Pont's and Olin's largNeiagara Falls. But in a community still I frequent informal plant tours. And sev- Niagara Falls manufacturing facilities haunted by the specter of Love Canal, it j eral times, OxyChem workers have gone began to lose their leaves. The damage also points to the particularly stiff Re i door-to-door explaining changes at the lessened but continued last summer. sponsible Care challenge facing the lo plant. And everyone is holding their breath cal chemical industry. And with the "Prior to the CAER program," says for this summer. area dominated--both economically Bernard J. Carreno, the plant's Respon In many ways, the unsolved prob and physically--by chemical majors sible Care coordinator, "there was com lem has presented an early test of Du such as Du Pont, OxyChem, and Olin, munity contact, but it was relatively Pont's Responsible Care effort in the few observers downplay the stakes. minimal. Community meetings were heavily industrialized area. Du Pont Much ofthe recent Responsible Care ad hoc and poorly attended, and there has gone door-to- were limited plant tours, he remem a :a e door to talk to resi dents about the problem and will set up an information bers. And, says Carreno, the plant tended to supply information through announcements, not dialogue. PRIOR 'CARE.' Improved relations .e :e t, d center in the com munity this summer to handle any com plaints. And it ex pects to work closely between the Niagara Falls commu nity and chemical industry can be traced to long before Responsible Care. "Because of the special past issues--i.e., Love Canal," says i.e e with its new com munity advisory panel (CAP) on the issue. i- "We're closing in l- on a solution," says Blasius, "there was a lot of`respon sible care' prior to Responsible Care." Blasius describes a dramatic turnabout by OxyChem in the mid- 1980s: "Ten to 15 years ago, we were very closed-door. We weren't Robert Porter, man open with anyone. Now we're going D n ;s ts k d ;s d ager of the Niagara plant. The source of the problem has been, tracked to a series of 15 stacks among Du OxyChem's Niagara plant is one of its largest. Pont's and Olin's adjacent operations, effort has focused on strengthening he says. And, he adds, "We'll do what community relations. Both OxyChem ever we need to stop it. We're just as and Du Pont have set up community frustrated as the community." advisory panels within the past six in the opposite direction." And the Responsible Care effort at Niagara goes far beyond commu nity outreach. OxyChem's Niagara plant--which is based on chlor-alkali production and is one of the firm's largest production sites--reports under the federal Toxics Release Inventory (TRI) a 39% reduction in total releases rt Despite Du Pont's efforts, some months, with OxyChem holding its first in 1990, compared with 1989. The num Niagara Falls residents remain skep CAP meeting in January, and Du Pont bers included a decrease of air, land, s. ir tical. "My response," says Margaret Guiliani, a community activist, "is anger." Du Pont, she maintains, has its first meeting at the end of April. "The CAP gave us guidance for the existing programs and an interface with and water releases from 97,724 lbs in 1989 to 81,629 lbs in 1990. And the plant has slashed TRI-listed air emis N R "dealt with the [federal and state] the community," says Gary Blasius, sions by 65% since 1987 and hazardous agencies, but with -the community manager at OxyChem's Niagara plant, j waste generation by 62% since 1984. there has not been a whole lot of "It is a big and very important step," OxyChem has corporate reduction CTL010189 37 Responsible, Care' goals--set up three years ago--to re duce hazardous air emissions by 10%/ WEST VIRGINIA NETWORKS ITS PANELSyear, solid waste generation by 5%/ vear, and water pollution bv 5%/vear, and the Niagara plant has several capi Self-evaluations shared with activist groups tal projects to keep pace. The unit just completed a S5 million-S6 million in est Virginia's Kanawha Valley, a meeting at which any citizen could vestment to recover hydrofluoric acid. Du Pont's Niagara plant is also re porting progress in waste reduction W40-mile stretch of dense chemi come and question company represen cal and heavy industry develop tatives about any issue. ment centered on Charleston, is considS ix years later this approach is still efforts, but the drop in numbers has ered the birthplace of the key Respounsseid successfully in parts of the vallev. been less dramatic. With higher pro ble Care concept of community adviso especially at Institute, where the former duction levels, its 1990 releases actu ry groups. Union Carbide complex is owned bv ally increased compared with 1987. But after six years of experimenta several groups, including Rhone-Pou- But, says Porter, expect to see pollu tion, the issue of how to carry out a lenc Inc. (RP: Princeton. NJ), FMC (Chi tion prevention efforts beginning to dialogue between industry and local cago), and Arco Chemical (Newtown pay off in lower 1991 TR1 numbers. citizens is still an open question in the Square, PA), together with Carbide. Du Pont's capital investments in region. Several different formats for in The CSA meetings in Institute nor clude an $8-million project to reduce teraction between the two sides are used mally draw at least 15 to 20 people and barium waste in its metallic sodium in various parts of the valley, operations. The effort includes a series and at times different commit of process improvements, including tees and contact groups exist better process controls and the local side by side. ized collection of particulates that al In early 1992 a new dimen lows the material to be reused. The sion was added to the debate plant expects the three-to-four year ef when a West Virginia antitox fort to lead to a 50%-70% reduction in ics group, working outside the barium waste when fully implemented normal community advisory in 1993. framework, successfully GOOD GRADES. The Niagara industry pushed local chemical plants gets good grades for its efforts from to divulge in-house evalua some observers. OxyChem, for one, tions of their Responsible Care "has done a very good job in its com programs. Building on that vic munications efforts," says Gerald tory, the group says it hopes to Goldhaber, a communications profes go after other types of informa sor at the State University of New tion, including individual York (Buffalo). And, suggests company plans to handle Goldhaber, the communications skills worst-case scenarios at its lo greatly helped the firm through the cal plants. Love Canal episode. "The public didn't The initiative to create a sys crucify OxyChem. That doesn't mean j tem of contacts between indus they accepted everything, but overall, > try and local citizens in the people have been receptive." Kanawha Valley began in 1984, But some in the community will when the Bhopal disaster in take much more convincing. Sitting in j India was followed by a small front of her house and monitoring the parade of children and grandchildren I . er methyl isocyanate (MIC) re lease at a local Union Carbide Du Pont formed a breakaway cap at Belle, wv. going in and out, longtime resident (Danbury, CT) plant in Institute, WV. several times that when a major issue Guiliani outlined her concerns. Active Residents living near plants began arises, says Bonnie Blashford, Respon in the community for the past two demanding more information about sible Care coordinator for RP in West decades, she remains unaware of any company activities, and a nonprofit re Virginia. The CSA has sponsored major "direct communications with the com search group, the National Institute for educational programs aimed at grade panies." And a continuing problem, I Chemical Studies (NICS), was created school children and also supplied rep she says, is that the chemical produc in Charleston to act as an intermediary resentatives for company-wide emer ers do not always provide accessible j between industry and the public. gency simulation training. technical information. CHANNEL OF COMMUNICATION. This group But in the Belle, WV area east of Yet Guiliani remains open to solu- \ soon proposed the creation of four com Charleston, major plant operator Du tions. CAPs could "be a good thing," j munity safety assessment (CSA) panels Pont has begun to bypass the open meet she says. And, she adds, "I would love 1 at key chemical industry locations in ing approach, saying it has not been to get inside the plants. Knowledge the valley to give concerned citizens a effective. While keeping the CSA active helps." But her bottom line is clear: j direct channel of communication with for emergencies, Du Pont has set up its "We're not trying to force industry out j plant managers. own community advisory panel (CAP) of Niagara Falls. But the trade-off can The original NICS model, according with neighboring OxyChem (Dallas), not be health problems." to group president Paul Hill, used a made up of selected community repre .DAVID ROTMAN "town meeting" concept in which one sentatives who meet with companv of in Niagara Falls, NY night a month was set aside for an open ficials privately. 38 CTL010190 Responsive, Care, i Under this concept the CAP is con sidered more a sounding board for the companies to use to find out how new programs and environment-related ini tiatives might be viewed by the public at large, savs Du Pont plant manager Richard Knowles. "The problem with the CSA is that if own CAP with a core of selected citi zens for the immediate area around the plant. Based on this small target group, Murrav savs the CAP has begun to take hold and produce results including an in-depth community opinion survey. The Olin CAP bypasses anotherCSA in South Charleston that covers Union we do a good job, no one shows up," Carbide and FMC plants in the area. savs Knowles. "If we want a boom in NICS's Hill says that the results from attendance, we have to screw up." different types of outreach groups show Knowles, who has already had expe that "each community in the valley has rience addressing prickly community special characteristics which determine relations problems in the Niagara Falls, what will and what will not work." NY area for Du Pont, has also pioneered RESPECT. In general, local people like a state level "chemical working group" the CSA approach "where they don't in which industry and community lead feel people are handpicked by the com ers meet to develop common approach panies," he says. But the one successful es to state legislative and regulatory CSA at Institute has worked in large part issues. because a small core of highly respected Knowles says this state level cooper citizens has stepped forward to provide ation to iron out differences before they leadership. These include CSA chair become burning political issues in the man Charles White, a retired business legislature appears to be a first in the man with a long involvement in com U.S. The group, which was set up last munity service, and Mildred Holt, who year, is currently tack- initiated questioning ling budget levels for about MIC production state regulatory agen in 1984. cies, where both envi At the same time, ronmentalist and in says Hill, industry dustry representatives groups lean toward the have a stake in healthy CAP concept since they funding levels. At the get better feedback and same time it is working the results fit better on changes in state laws with the formal Re to reduce toxics use. sponsible Care require Elsewhere in the ments. valley at Nitro, Mon In any case, says santo (St. Louis) is dis Hill, the ongoing dia satisfied with its origi logue has clearly had nal CSA program and is an impact on the atmo considering dropping it sphere in the valley. in favor of the Du Pont CAP approach, accord Knowles: A U.S. first. NICS itself had orig inally envisioned the ing to company safety and health super CSAs as working on their own, but it has visor Patrick Conlon. gradually assumed a role as a middle The CSA has produced some fruitful man and referee between the two sides. initiatives such as starting a campaign The group, which is funded mainly by to develop a state tumor data center. the Environmental Protection Agency But, complains Conlon, attendance at and major foundations, publishes the the monthly open CSA meetings dwin annual toxics release data from local dles to almost nothing unless there is an industry and also carries out specific accident or other immediate concerns studies on health, transport, and emer such as rumors about sabotage during gency planning issues. the 1991 Persian Gulf War. The group recently released a study Another company in the valley, Olin covering respiratory problems of chil (Stamford, CT), has taken yet another dren living near local chemical plants. approach. With a small chlorine pool Although NICS found correlations be products plant located in the South tween health and the environment, it Charleston area, close to several big did not specifically point to plant emis firms, it has decided not to participate sions as the key problem. in a joint CSA or CAP program with The actual usefulness of both the other companies. "We don't want to be CSA and CAP concepts is disputed, lost in the shuffle," says Olin plant however, by the West Virginia Citizen's manager Micheal Murray. Action Group, which through its toxics Instead, in early 1991, Olin set up its tracking committee has tried to end run the regular format and force the compa- ! nies to provide more information about their operations. j According to the group's toxics coor- ! dinator, Wendy Radcliff, CAPs like Du j Pont's can be easily influenced by other company programs such as donations of materials to local schools or selection of people with an indirect interest in the plant--for example, former company employees or relatives of employees. While the CSA approach is more democratic, it also can be influenced. Radcliff savs. by tactics such as holding meetings inside company compounds, where the public can be intimidated. Radcliff brought the information is sue to a head in early 1992 when the group asked each company in the val ley to supply their most recent Respon sible Care report card. Companies ini tially balked, saying the data could be misinterpreted and the standing com munity groups should be involved. Monsanto's Conlon says that his company feared the number codes un der the Chemical Manufacturers Asso ciation reporting system might be mis read so that the public would not un derstand the idea of continuing im provement. "If we gave ourselves a six for something, they might think we weren't going to do anything further about it." he says. PRESSURE. In the end, under pressure ofgetting bad press, all companies com plied, usually presenting the data to Radcliff after giving it to their commu nity groups or doing it at a joint meet ing. Radcliff says the data turned out to be too dense to be put into readable form for the public and that probably nothing will be done with it until the group has another year of data to com pare it with and to look for trends. In any case, she feels her group now has its foot in the door and can begin to seek more sensitive information. "This was a milestone for us, but it is still baby stuff," she says. The next objective will be detailed emergency planning data that will outline the worst-case impacts from spills and other events. "While the companies are afraid we would use this for scare tactics, we feel the people have a right to know what can happen here," she says. According to Radcliff, a major rea son for problems with the CSAs and CAPs is that people do not get satisfac tory information on key safety issues at the meetings. "They get worn out trying to get root answers to questions," she says. "It's not the most exciting thing you can do with your evening." PAULKEMEZIS CTL010191 39 Kespoifsihie Care vironmental affairs for Sterling and the There will also be a mobil monitoring TEXAS CITY BUCKS COMPLACENCY company's Responsible Care coordina tor, "we had communication programs in place, and we thought they were effective, but we found that they were not. The reaction to industry's efforts unit to be positioned at the request of the CAP. An agreement has also been reached with a local radio station for broadcasting emergency information. Whenever there is an incident, whether Plans emergency drills has been very positive, but you've got or not emergency sirens sound, people the few active and concerned people, can tune in, and the station has agreed I and a large percentage of people who to break in and broadcast updates. exas City, TX has the dubious dis are still sitting back there." While plants and their personnel Ttinction ofbeing the only U.S. city Jeff Eller, director of risk manage to have been destroyed by a chemi ment and safety for Texas City, says that cal-related catastrophe. That occurrethde community awareness and emer- train and drill constantly, there has never been a chemical emergency drill involving the community. One is being in 194 7. But today, industry represe]ntgaency response (CAER) group was very planned for the fall, with another set for tives there say public complacency is j active for a couple of years, but that it next summer. Two drills will then be their single greatest obstacle to imple had fallen dormant for about 18 months. held every year. menting much of the Responsible Care ! He began his duties in January, and GREEN BELT. A point of friction, Eller initiative. j soon after, a series of unrelated inci says, is that at one time process com "Waste reduction? No problem," dents piqued public awareness. plexes were remote from residential says David Glenn, manager of Amoco One problem is that the local emer I areas, but urban sprawl has eliminated Chemical's Texas City plant. "We've gency planning committee (LEPC) has a ! that buffer zone. Sterling has been es- reduced our solid waste 99.93% since mandate but no funding. Eller says the I tablishing a green belt around its plant 1983. Groundwater monitoring? We've CAER program has been revitalized as by buying up adjacent properties when been doing it for years on our own. the operational arm of the LEPC. "The ! they come on the market. Process improvements? We spent big community advisory panel (CAP) also "I have kids and grandkids in Texas bucks developing a new catalyst for one provides input," says Eller, "but CAER, City, and they have the same concerns of our processes because the one we with the support of industry, has to as everyone else. How do we get infor were using became a hazardous waste pony up to get things implemented." mation? What are we supposed to do in tainted with heavy metals when it was One of the major cooperative efforts ! an emergency? We're trying to address spent..But our number one problem is will be going into effect this summer-- that," says Glenn. communication, and public misper an air-monitoring system that will cover GREGOR Y DL MORRIS ceptions." the whole Texas City-La Marque area. in Texas City Glenn's plant produces a variety of aromatics and polymers, and its bul SARNIA: CANADA'S FRONT LINEbous, silvery styrene unit is something of a local landmark. Sterling Chemical (Houston) also makes styrene. In 1947, Cooperation and spills in the Chemical Valley when the plant was owned by Monsanto, the styrene train was the arnia, located on the St. Clair River, tively large explosion at Polymer Corp. first process unit to fall victim when a fire aboard a nearby freighter caused an explosion that blew the ship apart on Sacross from Port Huron, MI, is the in 1951, however, is memorable in center of Canada's chemical in that it had a galvanizing effect in the dustry. With four oil refineries and 2f0ormation of Canada's first local emer April 16. A chain reaction of explosions ; chemical companies on a 30-km rivegrency response cooperative, the Chemi and fires continued into the next day, side stretch, the aptly named Chemi cal Valley Emergency Coordination Or leveling the waterfront, destroying most cal Valley is noted for its long ofTexas City's downtown business dis history of industry cooperation and trict, and claiming almost 500 lives. community outreach. It has served 'MONOLITHIC.' The other two CMA as an important resource in the member companies at Texas City are development of Canada's Respon Union Carbide, with an olefins plant sible Care program. and International Specialty Products The region is also well known, (Wayne, NJ)--formerly GAF--making especially in the downstream com acetylene derivatives. After some ini munities and by environmental tial hesitation, the three oil companies ists in the U.S. and Canada, for its at Texas City--Amoco, Marathon, and history of frequent spills into the Phibro--joined in the meetings with river. While river separation and the Community Awareness Panel, zero-spills policies have emerged which was formed in mid-1991. "The at companies such as Dow Canada, oil companies are glad now that they Du Pont Canada, ICI, and Imperial joined in, but the leadership had to Oil, responding to spills and clean come from the chemical companies," ing the St. Clair has largely been a says a panel member. "Community coordinated industry effort facili people wouldn't accept it any other tated by two 40-year old industry co ganization (CVECO). Because Canada's way. They see industry as monolithic." operatives. first community awareness and emer Before instituting Responsible Care, Sarnia has never experienced a cata gency response (CAER) initiative was says Sam Chamberlain, director of en strophic industrial accident. One rela later started at CVECO in the early 40 CTL010192 Responsive, Cart 1980s. some date the earliest roots of puter svstem for its membership, which 1985. went a long wav in invigorating Canada's Responsible Care program to includes refineries and a local power LIS's outreach efforts The Blob--ac that blast at Polvmer (now called station, and publishes several news tually a perchloroethy lene spill at Dow Polvsar. a division of Baver AG). letters on environmental conditions. Canada that resulted in patches of vis According to Gordon Crooks, man It also reports data to the Ontario Min cose chemical deposits on the bottom ager of government relations and regu- istry of the Environment of the river--made the first of what latorv affairs at Polvsar. the explosion "LIS and CVECO help all of our would be many headlines on spills in at the rubber manufacturing plant was companies with the community aware the region and began a period of in loud, but not lethal. It did, however, ness and emergency response aspects creased community reporting at LIS turn into an emergency response night of Responsible Care," savs Bob and member companies. mare. as spectators from all over Grimshaw. Responsible Care special In essence. Responsible Care has Lambton County rushed to the site. ist with Novacor in Sarnia. "If these been an overlay on an existing CAER program in Sarnia. In its broadest form, it has also been absorbed into com pany policy at the plant level. Paul Ireland, director of environmental is sues and public affairs at Dow Canada, for example, says Dow adheres to the codes of Responsible Care largelv bv sticking to its own policies, which include long-standing corporate posi tions on product stewardship and employee health and safety. Dow Canada's policies have generally in ternalized the guiding principles and codes of Responsible Care, according to Ireland. As such, the firm is pub lishing data compiled from its river separation project. Base year in this analysis is 1985, according to Ireland, Dow having "pressed the reset but ton" after the Blob incident. BELLS AND WHISTLES. Like many other regions of Canada, Sarnia currently lacks a local community advisory panel. Dow and others are working Polysar: A1951 explosion here had a galvanizing effect on the community. on establishing such a group, but Newman, Grimshaw, Munro, and oth putting themselves at risk and cutting ! things hadn't been in place, we would ers lament a certain apathy that many off access for emergency vehicles. The j be putting them in place now as a see as pervasive in Canada. Kris Lee, need for community organization on ! result of Responsible Care.- But be- | a member of the Responsible Care emergency response was obvious. "Af cause of the way we run our busi national advisory panel who lives in ter the explosion, Polymer, Dow, and nesses, we had them in place before the downriver community of Imperial got together, called in the 1 the codes came along." Wallaceburg, ON, offers this perspec police, and had a good chin-wag," J Grimshaw, on the other hand, cred tive: "I'm not sure anyone in savs Crooks. "They introduced a traf- j its Responsible Care with accelerating Wallaceburg knows about Responsible fic control program. Then they called the community outreach program at Care or would care about it. People in the fire department and formed LIS. "It's fair to sav that over the past don't care about how much money cveco." ; couple of years we've tended to be you're spending or how many bells A year after the explosion the three ; more open with information than we and whistles you have. They just want companies met again. Interested in were in the past," says Grimshaw. David to know if the water is safe." tracking visual evidence of pollution , Newman, environmental and occupa Industry sources in Sarnia concede in the river and evident problems with , tional health coordinator at Du Pont that while interest in published air pollution, they formed the St. Clair , Canada agrees. "In the past we told progress reports is growing, each spill River Research Committee in 1952. , people that information was available that occurs is a serious setback in get The committee grew to 14 members by to them," says Newman. "Now we are ting the message of Responsible Care the time it was incorporated in Ontario shoving it down their throats." I across to the general public. While as the Lambton Industrial Society (LIS) THE BLOB. Because of the continued incidents have decreased markedly, in 1967, according to Scott Munro, spills, local communities seem quite "systematic elimination of spills ab general manager of LIS. The group's comfortable with this force-feeding, solutely means we'll have another function has expanded to monitoring and the media has keyed in on both spill," says Dow's Ireland. "We have and reporting river and air pollution individual company and LIS monitor to build a dialogue with a community as well as groundwater contamina ing programs--which for the most part that acts as if we can just shut the tion. With a network of eight air-moni illustrate great improvements [chart, valve." toring centers and a-river-monitoring ! p. 92). One spill in particular, the leg station, LIS has set up an online com endary "Chemical Blob" incident of RICK MULLIN in Sarnia CTL010193 41 Rig/jonsitle. Care COMPANIES SYBRON CHEMICALS Sybron Chemicals (Birmingham, ones who put the plan in place. SNJ) embraced the concepts of the Sybron's efforts to establish commu CAER code of Responsible Care nications with its neighbors include a before it knew such a code existed. Focromputerized system whereby resi years a low-profile firm operating in a dents can receive updated information rural residential setting, Sybron experi on the status of the plant and register enced a harsh awakening in 1988 after complaints or questions, a neighbor two high-profile incidents forced the hood involvement council (NIC) that company to grapple with community meets monthly, open-house events, and outreach issues. In October of that year, an odor identification team made up of an ethyl acrylate release at the plant area residents. resulted in noxious fumes in the neigh The project receiving the most pub boring community, and in response the licity is the computerized prompt in local fire department evacuated resi quiry and notification system (PINS). In notification mode, the sys tem calls PINS subscribers to notify them of plant inci dents that might be a haz ard to its neighbors. So far, the company has not had to activate the notification mode for anything other than test purposes. PINS changes not only the company's relationship with the community but also the way its employees think and work, says John H. Schroeder, v.p./manu facturing. Part of the shift supervisor's job is answer ing complaints that are left on the PINS, underscoring the importance the com pany now attaches to its relationship with the com munity. Also, shift supervi sors are the ones who record Odor identification team has its own weather gauge. and update the status re ports used on the system's dents from nearby houses. Then in No inquiry mode. "In the past, productiv- vember, a flash fire at the plant seri ity, quality, and safety inside the plant ously injured two workers. were important," says Schroeder. "Now Those incidents sparked outrage in odor outside the plant is important, the community, says Richard M. Klein, too." chairman, president, and CEO of Sybron has also set up an odor iden Sybron Chemicals, a maker of ion ex tification team made up of community change resins, textile chemicals, and members that are trained to identify biochemicals, with $131 million in odors and determine if they are coming sales last year. Then the company real from the Sybron plant. This team has ized "it made good business sense to be helped Sybron pinpoint and correct agood neighbor," comments Klein. "We odor problems at the plant. embarked on a program that anticipated The number of complaints from and embraced the CAER code." nearby residents about odors from the Using the results of a door-to-door plant is one measure of its progress in survey conducted after the incidents, improving environmental and commu the company, along with its public rela nity relations performance. At the worst tions consultant, devised several pro period, the New Jersey Dept, ofEnviron grams to improve its relationship with mental Protection (DEP; Trenton) was the surrounding community. The com getting a few calls a week about odors pany management .and staff, not the from Sybron's Birmingham, NJ plant. public relations consultants, were the Now the calls are down to less than one a month, says Schroeder. and the com plaints are generally made directly to the company rather than through a govern ment agency, another sign of increased communication between the company and the community. Sybron shares the results of its au dits at the NIC meetings. For example, Stone & Webster engineers, who con ducted an environmental acccident risk assessment of the Birmingham plant, gave a presentation at one NIC meeting. But Sybron management realized that a community relations program by itselfwouldnotaccomplishmuch with out a concurrent effort to improve its environmental and process safety per formance. The company's process safety study has led to much better plant documentation and the installa tions of several safety devices, says Schroeder. And through Sybron's odor abatement program, additional equip ment has been installed to deal with the three worst odor sources at the plant. Management is particularly pleased with the improved relationship with state authorities. Before the community relations efforts were in place, govern ment authorities may have heard of Sybron, but only in a negative light. "They have started viewing us as a credible organization," says Klein. The image turnaround was exemplified by the attendance of then-DEP commis sioner Christopher Daggett at the company's inauguration of the PINS system. SIGNIFICANT COST. The cost for these ef forts is not cheap. The community awareness portion has cost the com pany almost $100,000/year--with about half of that figure representing people's time and the other half reflect ing dollars spent. It is still a significant ongoing cost, says Schroeder. And the dollars spent on community awareness are the hardest to put a dollar return on, he adds. Klein remarks that the pro grams result in "a mutual comfort be tween the company and the commu nity, which allows more to get done. You don't get a lot accomplished if life is miserable and uncomfortable." While the company has made a good deal of progress in the CAER and pro cess safety aspects of Responsible Care, it sees areas where it could improve performance. Sybron did not have for mal programs in product stewardship and distribution, says Klein. And Schroeder adds that while Sybron is "largely compliant with the codes as it is," there are points within each code that the company still needs to address. 42 CTL010194 i Regponsiib Cart Sybron won the Public Relations So uct, and train the employees receiving ciety of America's Silver Anvil Award the material. In addition, the sodium in 1990 for best community relations cyanide trucks--which are tracked by program in the U.S. But perhaps even satellite--are equipped with computers more convincing evidence of Svbron's that monitor everything they do. turnaround comes from reference let Now, FMC is formalizing and carry ters supporting its application in the ing over that same attention to its other President's Environmental and Conser chemical products, which are trans vation Challenge Awards Council on ported by common carriers and may be Environmental Quality. They were stored in public warehouses. And that written by former DEP commissioner changes FMC's relationship with its Daggett; Bud Clark, chairman of the vendors. The objective is to transfer Pemberton Township (NJ) Environ FMC's standards to its contractors. mental Commission and member of the By demanding more of its vendors, NIC; and Caron Chess, associate direc FMC is whittling down the number of tor of the Environmental Communica carriers it will hire to a select few. The tion Research Program at Rutgers. number of core carriers for FMC's bulk ELIZABETH S. KIESCHE chemicals in 1991 was 42; that is now down to 12, says Yochum, adding that FMC FMC's goal is to reduce that number to eight by the end of the year. The reduc tion in carriers for its packaged goods vidence of Responsible Care at will be even more dramatic--from 400 EFMC Corp.'s Chemical Products last year to 50-70 this year. Group (CPG; Philadelphia) can be FMC uses audits--a vital tool in Re found in its sales contracts. "We hadstpoonsible Care--not only internally but change the terms of the sales contractatolso to evaluate carriers and other ven delivered pricing," says Paul R. dors. For example, the company has a Yochum, CPG's operations manager/ standard audit form that it uses when sales and distribution. "That allows considering public warehouses. And FMC to control carrier selection and audits have already "knocked out some carrier rout ing," he ex plains. FMC points to transporta tion and distri bution opera tions as one area where it excels in implement ing Responsible Care. But FMC's effort in trans portation does not apply only to the distri bution code; it encompasses a number of codes, includ ing community FMC developed rigorous procedures for transporting sodium cyanide. awareness and emergency response, employee health people from being considered," says and safety, and product stewardship. Yochum. FMC also audits plants that Before instituting the Responsible clean FMC's transportation equipment. Care initiative, FMC already had strong "We don't use a cleaning facility that similar programs in distribution of its hasn't been approved by our environ sodium cyanide and hydrogen perox mental group," says Joseph J. Jaskot, ide--products that the company uses CPG manager of distribution for safety/ its own equipment and drivers to trans hazardous materials. port. FMC's driver/technicians who FMC may require the warehouse or transport those two products are sala common carrier to make further invest ried employees who conduct a product ments before FMC will use them, says quality check, inspect the customers' Joyce A. Stratis, safety/hazardous mate equipment before transferring the prod rials management coordinator for dis tribution for CPG. Depending on the product line the vendor will be han dling, FMC may require the carrier to add rollover protection to tractor trail ers or valve covers. And in many cases FMC will specify that a core group of drivers, who will receive FMC safety training, be dedicated to FMC's product line. The objective is to make the carri ers' drivers "as close to our drivers as possible," says Stratis. NO SECRETS. The auditing process is not secretive, but an "open, mutual pro cess," says Yochum. Carriers are given a copy of the audit, and know exactly which areas they will need to improve if FMC is to continue to use them. FMC cannot audit all its carriers, though. The company is working on a program for contracting third-party au ditors, and expects it to be in place by the end of 1992. Standardized audit protocols may also ease the audit bur den, so that every customer would not have to audit that particular carrier or warehouse. FMC also offers to audit customers' use and handling of FMC products. That process is a fundamental building block in the relationship between cus tomer and supplier, says Yochum. FMC finds it helpful to have outsid ers, like the U.S. Bureau of Explosives, audit their own operations. Jaskot says this "fresh, outside look has been a very valuable asset." The company has also asked federal railroad inspectors to do the same. One area that still needs improve ment is distributor relationships, says Yochum. With 20% of the CPG's prod ucts sold through distributors, it is im portant that companies in the network have the same focus and safety philoso phy as FMC, he says. FMC has set up a special task force in conjunction with its sales staff to address that issue, he adds. The company is coordinating its efforts with the National Association of Chemical Distributors, which has its Responsible Distribution program. One of the more time-consuming parts of FMC's Responsible Care pro gram is community outreach, says Jaskot. When FMC began producing liquid sodium cyanide, the company talked to Local Emergency Planning Councils along transportation routes in Wyoming, Nevada, Idaho, and South Dakota. "It was very time-consuming, but well-received," says Jaskot. That kind of effort is being extended to other FMC product lines, such as elemental phosphorus. ELIZABETH S. KIESCHE CTL010195 43 Rbgponsihie- Cara i companies with good research and de The key problem he has tried to 3M CORP. velopment need to share it to bring all avoid is making it become too much companies up to speed." work. "It makes a big difference if The company has begun to get a good people view Responsible Care as a posi n the late 1980s, when the Chemical flow of ideas from materials vendors it tive. We don't want to let it become a IManufacturers Association began to deals with and has begun offering help discuss Responsible Care concepts, to other firms. 3M Corp. (St. Paul, MN) was far ahead The chemical division, which sup negative thing." PAUL KEMEZIS of the game. plies materials to 3M's consumer prod NALCOThe company, with its strong re ucts divisions--including tapes, abra search and innovation ethic, had al sives, printing and medical supplies-- ready acted in the late 1960s to create an is the only part of the company that is a he financial community pavs little environmental engineering and pollu tion control department that developed in-house solutions to pollution prob member of CMA and therefore the only one directly involved in Responsible Care, says Reihle. Tattention to Responsible Care, until it sees the program affecting the bottom line. But companies are lems. But given the strong corporate-wide confident there will be a long-term In 1975, 3M set up its a unique Pol emphasis on pollution prevention and payoff and are beginning to see the lution Prevention Pays, or "3P," pro control, this split appears to make little , importance of communicating infor gram to encourage employees through difference. There is even a strong tech mation about the program to analysts. out the company to invent ways to re nology transfer system among 3M's j Anthony J. 1 duce emissions and save energy. The manufacturing sites, about 100 world Sadowski, v.p./ f i 3P program is still going as strong as wide, that allows pollution control tech- i environmental ] ever and has saved the company an niques to be spread quickly. The 3P ; health and safety estimated S570 million in pollution plan itself is based on a set of tenets at Nalco Chemi- ! control and operating costs. starting with "3M will prevent pollu- ; cal (Naperville, I In 1987, CEO Al Jacobson started the tion at the source wherever and when IL), recently ; J35 plan, under which he asked the ever possible." Employees compete to briefed analysts j company employees to reduce pollu come up with the innovations that pre about Respon- , tion, energy use, and cycle times by vent pollution and save money and en sible Care as part | 35% each by September 1991, when he ergy. Winners receive awards, and the j of a corporate was scheduled to top five each year get special commen presentation, i retire. They did dations from the company's brass, in- I "We have [since] j and he did, mov eluding a lunch with the chairman. j had two requests | ing on to join WINNERS. Recent prize winners have I ronmenU^bj- SadOWSki:NotCOStly. President Bush's included a system developed at a ; Commission on Northridge, CA plant for replacing sol- ' havior profiles, says Sadowski. "It's Environmental vent coatings on medicine tablets with hard to say whether it was as a result of Quality. a water-based coating and an improved our presentation or just coincidental." With all these system for cleaning batch reactors, us- | Although it is hard to determine the activities going ing a sound wave device borrowed from payoff of Responsible Care, Sadowski on already, 3M the trucking industry, at the Cordova, IL believes it is important that the finan was immediately adhesives plant. cial community be informed. "We re interested when The chemical division developed 14 ceive questionnaires from our custom CMA began dis valid 3P projects in 1991, including ers about our commitment to Respon Reihle: Sharing need. cussing Respon sible Care issues, ways to recover fluorocarbon gas, sell used materials, reduce solvent washes, sible Care--that's important if they want sole-sourcing of product. If as a says Peter Reihle, safety and systems recycle heptane, back out use of silica company we don't progress in Respon manager for the 3M chemical division gel and increase use of inert chemicals. sible Care, we can lose business, and and the company's Responsible Care Corporate-wide, 97 separate 3P projects that would hurt profits." coordinator. ! were recognized in 1991. At the moment, the financial result The company participated in sev- i Reihle says 3M has also replaced the of Responsible Care is mostly a nega eral early CMA efforts and has begun to J35 program with a 33/50 program tive one, as companies spend to meet implement formal Responsible Care drawn from Responsible Care and also requirements. However, Sadowski does programs at its four chemical plants in has been active developing community not regard Responsible Care as a costly the U.S. and its unit in Belgium. advisory groups modeled in its program. The company has appointed "We found that the CMA effort en Chemolite plant in St. Paul, which has mostly existing directors to take on the hanced our own activities, especially had a community outreach program for i role of Responsible Care coordinators. since it allowed us to get new ideas from several years. | Only in the case of process safety code other companies which we couldn't I Overall, says Reihle, the company's i did the company elect to hire an out have gotten before," says Reihle. long-standing proactive approach to side specialist. At the same time, he says 3M has problems had made the Responsible Even before CMA came up with Re been willing to share its years of pollu Care program easy to implement. Cur sponsible Care, Nalco had targeted pol tion control expertise without worrying rently, he says, the main challenge is to lution prevention. "Admittedly it was about losing a competitive advantage. roll together several of safety manage- > air releases we targeted first," says "We realize now that the real question j ment and toxics reduction programs j Sadowski. "But we have done pretty is industry survival," says Reihle. "The I into a coherent whole. I well--there has been a 62% reduction 44 CTL010196 i Regponziiie Care in TRI releases from 1988 to 1991. nies would not choose to sell to an Chemical We have agreed to join the EPA's 33/50 program." Overall, last year TRI emis sions were down 40% from 1987 levels. Generally, code implementation has irresponsible firm. We can help them to improve." Those that don't, Sadowski asserts, will be driven out of business. Intermediates been easy for Nalco, but Sadowski ac ANDREW WOOD knowledges some difficulties with the distribution code. "The other codes are UNIROYALsite specific--this is the first that ad dresses what happens outside the site; and including other places where we niroval (Middlebury, CT) started are involved, like toll producers or warehouses, it increased the number of sites tenfold." Ua Responsible Care program even before CMA announced its effort in 1989. So impressed by what the Cana Implementation of the distribution dian Chemical Producers Association code took 18 months. The company (CCPA) had established, Uniroyal-- insists that employees of common car- ; which owns riers delivering Nalco product must un a specialty dergo training, and even wear a Nalco chemicals uniform. "This resulted in a halving of i plant in El the number of distributors the com- j mira, ON-- pany uses," Sadowski says. "They ; brought in charge more, but we're happy to pay for ! consultants the improved quality of sendee." j from CCPA Sadowski points to some obstacles I to develop in the self-assessment process, even i company though the company was already audit- ' codes, says ing its sites with its own plant opera director of tions review team, started in 1985. "The engineering first couple ofyears ofResponsible Care, and Respon we let each facility have a free rein on how they interpreted the goals. But we Harris: Stronger position. sible Care coordinator realized as more codes came in we Jack Harris, "more or less based on what needed a bit more structure and a more \ Canada was doing." stringent set of guidelines." j While Uniroyal, with just under SI NET IMPROVEMENT. With the more de- j billion/year in sales, has folded the manding work load, Sadowski admits ] codes it developed into the standard some sites might have dropped back CMA framework, Harris says that the one level of implementation for some innovative path it took to get to Respon codes, "but there is still a net improve- j sible Care compliance was beneficial. ment. Each site is different, and it wasn 't ; "We knew how [CMA's] codes were easy for each one to think the same way. j going to develop," says Harris, and "we But, generally, the tougher grading has 1 wanted to get a jump on it." Announced been welcomed." ! on July 10,1989, Uniroyal's codes gave One area where Sadowski differs the company, in some cases, a year's from many of his chemical industry head start. Harris says the extra time for colleagues is his calling for some exter- j implementation made the process nal certification of performance. "I j smoother--"we didn't have to play wouldn't like to see a specific agency catch-up." set up to do it--I think it could be done Uniroyal created four codes based on by the community advisory groups." the Canadian plan: process safety, dis Sadowski notes instances in Nalco, tribution and transportation, waste re where some plants that had previously duction, and research and development. been objected to by communities have "They're just about identical" to CMA made the necessary modifications and codes, says Harris, although the R&D are now receiving support--or at the code puts a different twist on product very least disinterest--from local stewardship by "building safety into the groups. "If we can make each facility i product." explain and justify itself to its own j "The fact that we started off with an advisory board, then [the communities] R&D code gave us a stronger position," can see how well we are improving." j says Harris, and while the code has He also hopes that peer pressure-- i been rolled into CMA codes, employ particularly through the Product Stew ees still follow it in developing new ardship code--can be brought to bear products and processes. The R&D code on companies that have riot embraced called for building Responsible Care Responsible Care. "That way, compa into R&D planning, particularly into CTL010197 45 RespOKeiitfe, Car&\ the "go/no go decision points of re which has not vet been commercial such as that in the 1989 scare that search and development maps," he ized, was altered in the process. The pulled Uniroval's Alar off the market says. "The scientists are considering toxicology of an intermediate in one of may be avoided in the future. "If there the Responsible Care implications dur the 10 process steps was considered to had been a program like this, where ing all steps of development," says be too high for Uniroyal to deal with the whole credibility of the chemical Harris. For example, developers try to safely. "We decided that it was in our industry was better." says Harris, use more environmentally benign sol- I best interest not to make it," says Har "maybe the willingness of the public vents and strive for chemical stability ris. Should the chemical become com to believe our side of the story would in storage and safety during the reac mercialized, Uniroyal plans to pur have been much easier. Hopefully, it tion process. "If employees are doing chase a ready-made intermediate one : will help in giving us a fairer hearing." their job," he explains, "when we get step beyond the highly toxic material. to the milestone reviews, there won't "The supplier is making a lot of the : ELISABETH KIRSCHNER be any surprises." compound," explains Harris, "and we 1 In the overall examination of a new trust them to do it safely." NATIONAL STARCHproduct, Uniroyal brings together pro POINTS. Auditing of R&D facilities cess chemists, manufacturing, market under the old code meshed with pro ing, the R&D director and the engi cess safety, and risk analysis of new ational Starch and Chemical is neering director and decides whether to proceed. "We've analyzed several new products and several new formu Nand existing products is now part of product stewardship. Uniroyal also ' developed a strict auditing process for ! selling its sales staff on Respon sible Care. Previous codes have involved the health, safety, and environ lations through the R&D code," Harris its 14 plants based on the program i ment group and manufacturing opera says, but Uniroyal has not yet com used for examining suppliers for qual- i tions. In following the new product stew mercialized any new products that ity. The plants get points for having ardship code, salespeople "will be ex have been evaluated. "Most of our safety procedures, systems, and faith posed to Responsible Care virtually for products take many years to develop ful execution. the first time," says v.p. ofextemal affairs and the failure rate is quite high," he Harris is hopeful about the implica and Responsible Care coordinator John adds, especially for pharmaceuticals. tions that Responsible Care could have Doherty. "We're now moving out and Although many products have gone for the chemical industry. With safer talking with our suppliers, customers, through evaluations with flying col processes and more community aware and distributors," he adds. ors, one new agricultural chemical, ness, Harris says that public outcry More than 500 employees from the Polymers & Plastics Group -- Alathon Polymers Division A recognized leader in the supply of HDPE resins for a broad spectrum of end products, the Alathon Polymers Division has also taken the initiative in addressing concerns of source reduc- tion and recycling. OxyChem is producing high quality HDPE resins that are recyclable, products made from post consumer packaging, and resins that can be mixed with PCR. OxyChem* __________________________________________________ The Chemical operations of Occidental Chemical Corporation OxyChem is a regislerecl trademai* of Occidental Chemical Corporation 46 CTL010198 RejpOH&'itfe, Care' i sales force, technical marketing, purchas that, but now it's important that we ing. and ancillary personnel will begin reallv. trulv prove to people that we training by the fall. A steering committee are doing it." that National began four months ago to With the added attention from the tackle the code acquisition of Union Carbide's Insti decided that the tute, WY plant, which had a methyl best wav to isocyanate release in 1990, RPI estab handle product lished an environmental, health, and stewardship was safety policy and then focused on pro by turning the cess safety. Ziemann says the initia sales force into tives at RPI fit in well with the Respon stewards. "The sible Care Process Safety code. time commit INSURANCE. A three-year program has ment--the sweat laid the foundation for safety through equity--will be out RPI. Corporate engineers and plant costly," says employees must update process flow Doherty, al diagrams and operating instructions, though he can- and audit processes. The company will _ . . , ... , Doherty. Selling Core. not put a price on install backup equipment, instrumen the training ses tation, and processes, says Ziemann, sions. By next summer, Doherty expects "to insure that a problem does not that all 500 will have "at least rudimen grow into a crisis." The program sets tary training in the requirements of the up a systematic approach to operating product stewardship code." a plant, where, says Ziemann, "every The sales force will be required to thing is looked at, is documented, and learn potential health and environmen is in true operation." tal hazards ofall the company's specialty The program started two years ago chemicals and how to communicate safe and is nearing the finish line. "Some methods of use with a "view toward plants were able to essentially finish assisting [their customers] in adopting implementation of the entire policy the best possible practices." The sales already," he says, while "others still and technical marketing staff may even have a lot of work ahead of them." help customers modify processes. They Process safety also figures into RPI's will also be trained in the basics of the "15" program, which encompasses six entire Responsible Care program. permanent, continuing goals, includ Doherty says that commitment from ing an annual 15% reduction in SARA top management was essential to recruit Title III hazardous air releases and a the sales force as stewards. 15% reduction in recordable injuries. ELISABETH KIRSCHNER Although SARA emissions dropped 45% between 1987 and 1990, the pro RHONEPOULENC cess safety goal has remained elusive until this year. During the first part of a program, there is significant improve fter an acquisition binge that ment, explains director of corporate Apulled in 18 units, Rhone- safety Patrick Ragan, "then you hit a Poulenc Inc. (RPI; Princeton, NJ) plateau." RPI pressed for a "culture needed to develop a common cultucrheange" to continue the declines and, and standards. With 8,800 --mmmm--m mmmmmmmm says Ragan, results are employees from Stauffer, "finally starting to show Union Carbide, GAF, and up." Year-to-date injury from small entrepreneur reports are down by more ial "garage" plants*- pro than 50% from last year. cess safety was inconsis RPI instituted a num tent. ber of systems to reach "The public wants to the process safety goals. be reassured that the A group of scientists and chemical industry is, in engineers at the corporate fact, trying to operate in research center at the very, very safest pos Cranbury, NJ examine ba sible manner and that we sic problems--such as cor- are not endangering the en rosion--and help in vironment," says RPI's se nior v.p./engineering and Ziemann: Actions count. implementing plant pro grams. operations services Ted Ziemann. In Every new project must be engi Responsible Care, "the chemical in neered through the Safety Guidelines dustry has made a commitment to do for Process Industrialization, a step- by-step framework imported from France in the mid-'80s. Engineers as sess the chemical reaction route, in dustrial feasibility, process engineer ing. construction, and the process op eration itself. "This defines all the detail that's necessary throughout the entire growth," says health, safety, and environmental affairs director Robert Briggs. It "defines the documentation that's necessary and defines the meth ods of hazard assessment." Recently, a Process Safety Hazard Assessment program was established to review existing processes. RPI trained over 100 engineers and plant manag ers in following the program. Processes, contaminants, fire protection, and the process description are examined, and where necessary, additional controls or procedures are implemented. RPI is also piloting an operator cer tification program at five plants in cluding the Institute site. Three levels of certification--technician, supervi sor/operator, and supervisor of total operation--require 15 to 18 months of training. Employees study pumps, vessels, math, and science, then are tested. Those who fail are either re trained or transferred to other jobs. The process safety efforts also yield pollution prevention gains, says Briggs. "When you take a process safety re view, you're going through the details, and ideas come out." And, with the success of the process safety guide lines, RPI is beginning a trial on envi ronmental guidelines for new programs. As for process safety, "I'm not satis fied, and I won't be satisfied until we're in the top five" of the CMA safety ranking, says Ziemann. (RPI is now ranked seventh of 54 in lost-time injuries for Group II plants, those with 2 million-20 million work-hours) "The support--particularly in the process safety area--goes all the way to the top. With that support, I think we'll get there." ELISABETH KIRSCHNER iimco........... itco's (New York) petroleum Wadditives and specialty lubri cants plant at Gretna, LA, with about 120 employees, is among the company's top sites in implementing Responsible Care. Unlike other Loui siana plants along the Mississippi, however, Gretna has not been in the public eye for environmental prob lems, nor has it had a hostile commu nity or activists to placate. But in its CTL010199 47 RispQHsiiie, Care, quiet way, the plant is making techni cal and capital improvements. "Responsible Care made us more aware of our responsibility to the com munity. So we have tried to do a lot of work to reduce SARA Title III and NOx emissions, as well as a lot of concreting to improve drainage and control spills," says plant engineer Neal Christoph. About 90% of the plant's emissions were vapors from methanol used as a catalyst in the production of sulfonate detergents for motor oil. So the plant has invested in a system that distills the methanol and condenses it with solvent and water; the solvent is sepa rated from the methanol, and the metha nol is routed to a methanol recovery tower, which captures 90% for reuse. "And we have just gotten project approval to get a new high-efficiency structured packing that will recover 98%-99%," says Christoph. In about two months, the money saved in buying less methanol will cover the costs of the new system. "And it will save us S100,000/year," Christoph adds. The drainage project will not show such immediate bottom-line results. "We are doing a complete study of the plant drainage system andare making recommendations to concrete large sections of the rest of the plant," says Christoph. This is especially impor tant in the areas where chemicals are loaded into railcars. "It has been hard to clean up spills on the rocks," notes Christoph. "The industry as a whole has had spill containment for some time, " notes Dean Sibert, Witco's director of safety, health, and environmental affairs. "But we are upgrading significantly on a corporate basis. We are looking at the best practices, and we are not waiting for a knock on our door hydrogen cyanide unit into an area with a request to do this." where special clothing was required. One challenge has been "People would go into the unit in their to spread Responsible Care own clothing and get HCN on their observance to Witco's units clothes. It reacts slowly and an hour or that make things besides two later they would feel faint or sick. chemicals, such as grease We pushed for years to make it a cover guns and battery packings. all area," says Boudreau. When the "I think a lot [of] elements company began to make community rela of the codes are applicable tions a priority--a key innovation of Re to engineered materials, sponsible Care--"they realized we cou 1 d such as the worker safety take this stuff home," says Boudreau, code, the CAER code, and and the coveralls were provided. to some extent the process Also, as Boudreau puts it, "now, safety code," says Sibert. when things break, they get fixed." For grease guns, for ex Specifically, he says, a practice of fix ample, the company, un- j ing jammed control valves in the methyl der the product steward methacrylate (MMA) unit by bypass ship code philosophy, has ing them has ended. This practice main increased the information * tained flow, but the valve was no longer it gives to consumers about product j in the control of the panel operator. use and handling. Boudreau used to worry that if an op Still, the plant is working to open eration had to be quickly shut down, lines of communication with the com- the bypassed valves would have been munity, says plant manager Robert left open. "Luckily, a lot of our prod Williams. The plant is now setting up ucts are not extremely volatile," he a citizens panel so its neighbors "be adds. come more comfortable with us," he Overall, Boudreau feels Responsible commented. Care has improved relations between The company has also created a employees and the company manage new corporate-level position with the ment. "The biggest thing that they re task of assisting Witco's 55 plant sites alized through Responsible Care is that to get up to speed on the codes, help j we can be an enemy or a friend. If we the plants implement them, and assist I feel like our lives are in jeopardy, we in community outreach programs. ] will tell people it is a bad place to Overall, notes Sibert, resources have work, or you must be crazy to picnic in been made available for Responsible the park near the plant. But as far as Care projects because it is a "top-down" worker safety goes, we are 100% be driven initiative. "I don't know of one hind Responsible Care." That attitude case where a request for a project at a has evolved. In the beginning, says plant site has been denied." Boudreau, workers feared that Respon sible Care, "would be used as a new KAREN HELLER tool to punish people and not correct a problem." AMERICflH CYflHfllWIP The pressure of a community look ing over its shoulders has also influ enced the practice of addressing leaks t some chemical plants it is not and spills. Now every leak, no matter Ayet easy to get a straight answer to the question: What has changed since the adoption ofResponsible Care? But at the American Cyanamid Fortier plant in Westwego, LA, employees are beginning to have answers. "Five years ago, managers would supply us with some safety equipment that was not necessary and would refuse to give us other things that we requested," says panel operator A.J. Boudreau, who is also a member of the safety committee ofthe Oil, Chemical and Atomic Work ers union at the plant. That has changed since the implementation of Respon sible Care, he says. Specifically, Boudreau refers to re peated employee requests to change a Applying 'wounds' for emergency drill. 48 CTL010200 i Core, was primarily because of the Fortier plant, and 80% of the problem comes from the plants' practice of using deepinjection wells to dispose of a by-prod uct of MMA and acrylonitrile produc tion. While employees at Fortier are adamant that deepwelling, if main tained, is a safe method of disposal, the company has embraced the belief that public perception is reality. So Fortier is planning to change over from deepwelling to a combina tion of recycling and incineration. The final plan has not yet been approved. 1 but the company hopes to reduce its j wastes by catalyzing waste sulfur di- j oxide into a useful form of sulfur tri- ! oxide. Cvanamid hopes to incinerate the remaining waste, sulfuric acid, with natural gas. "It is a good way to man age our wastes, but more important, over the long term it will allow us to stav in business," notes Hicks. KARE.X HELLER Evacuation practice with drill 'victims.' Jhow small, is investigated following | quality guidelines that include what is called a corrective action, which re- j quires recommendations for prevent- ( ing it in the future. "If one cup of sulfuric acid dripped from a pipe, we : used to catch it in a bucket. Now we I have to investigate that. We are trying j to prevent big accidents from happen ing by going after minute releases now," explains Joe Hicks, MMA production 1 manager. A leak into a bucket also does not look professional when people in the community come to visit the plant. Hicks has given tours to groups, in cluding "busloads of Boy Scouts," he says, and science teachers. About 2,000 people have toured the plant in the past three years, says plant manager Donald Romanik: "More than the first 35 years of operation." Changes in any operation require money. One of the benefits of adopting ; Responsible Care, says Richard Den nis, corporate vice president/environ- j ment, health, and safety, is that "when plants request resources to implement this program, it provides a vehicle 1 outside of the regular business of the j plant to bring attention to the resources j needed for EHS." At Fortier, Hicks was able to create a new position called a process safety coordinator. This new position includes responsibility for all of the elements in the process safety pxogram, including process change operations. "That has changed dramatically. Now if there is going to be a change in process, every one learns about it; part of that change now is training the operators. Now we discuss what could go wrong and an swer all of the what-if type questions," says Hicks. PUBLIC PRESSURE. The Fortier plant also faces pressures from the national pub lic. American Cyanamid was ranked j the nation's third-largest polluter, ac- j cording to EPA's Toxics Release In- j ventory data last year. That ranking 1 OxyChem: A Fully Integrated Manufacturer OxyChem's unique product integration gives us flexibility unmatched by other manufacturers. Because we're one of our own best customers, we can be one ofyour best suppliers. OxyChem. The chemical operations of 'W Occidental Chemical Corporation OxyChem is a registered trademark of Occidental Chemical Corporation CTL010201 49 R&sponsiMe, Core* is produced in the whole process. It's a CAPs in Port Arthur and Port Xeches in EXXON matter of how you run vour operation the last couple of years." says Garv and how others are involved." Graham, manager of community rela- , Another point is that the newest tions for Texaco's huge Port Neches ! s enthusiastically as CMA mem component of Responsible Care, the complex. "And we had a pretty typical | Aber companies have taken to the product stewardship code of manage Responsible Care initiative, and ment practice, makes the manufacturer as thoroughly as they have incorproesponsible for the ultimate disposition relationship with them. But when we i were planning a S450-million pro- j pylene oxide/methyl ferf-butvl ether | rated the codes of management practiocef the goods manufactured. It is not [PO/MTBE] train, we decided to solicit i into their everyday operations, there is such a far leap from a spill on a highway any concerns the CAPs might have very still a tendency to think of Responsible or a toxic material leaking into the water early." Care only in its own terms. But most . table to a municipal waste problem. Texaco loaded the combined Port firms have many programs and projects They all involve materials that are safe Arthur and Port Neches CAPs into vans, that should properly be considered part and useful if handled properly, ending and took them on a "field trip" of the of the overall Responsible Care effort, up where they are not supposed to. scale model of the planned expansion, even ifthey did not spring directly from Exxon acknowledges that develop which practically filled one office at the it. ing market demand for recycled resins headquarters of engineering firm M.W. One such undertaking is Exxon is a steep challenge for all recycling Kellogg (Houston). Ralph Cunningham, Chemical's (Houston) polypropylene programs, but in the case of the firm's | president of Texaco Chemical, and Ron (PP) recycling effort. Based at a process PP program, the reprocessed resins usu Brown, the company's general manager ing plant in Summerville, SC, the pro ally cycle back to die same end-use that of operations, were the hosts for the gram began in earnest in March. The they saw as virgin materials. Address expedition. The Kellogg engineering plant is designed to take in as much as ing one common concern for recycled team briefed the CAPs on how the plant 20 million lbs/year of PP bale wrap plastics, Prioleau notes, "We don't see was designed, and Texaco personnel recovered from textile mills, and other any appreciable loss in performance. explained how it would be run. bulk industrial film applications. The Theoretically, there is a limit to how QUESTIONS. Most of the briefings con resin is cleaned and reprocessed into i often you can recycle the materials, but cerned the environmental and safety pellets, most of which are used to make in practice we haven't found a limit." aspects of the planned units, but some similar PP fabrics. | Fulton says Exxon's Responsible technical specifications were also cov While most polyolefin resin manu- ! Care meetings have become full of ideas ered. The whole program took all day. facturers now have some type of recy and programs coming down from man For the most part, the senior citizens, cling program under way, or are at least j agement or up from the operations end. doctors, homemakers, environmental planning one, these programs tend to \ "People want to know if this or that can ists, school teachers, and others who exist in a vacuum, unconnected to the 1 be considered part of Responsible Care. make up the CAPs had questions con virgin resin production or other aspects If it meets the guiding principles, the cerning how the construction would of company operations. In some cases, answer is yes." affect traffic patterns, who the operators the recycling effort has been isolated Adds Prioleau, "There are tremen would be and how they would be under a separate subsidiary or joint dous efforts under way all over the trained, and what kind of control and venture company. j industry that are being accelerated be safety equipment would be used. COMMUNITY CONCERNS. "But look at the cause ofthe Responsible Care initiative. Based on previous citizen inputs, guiding principles to Responsible I For the most part, Responsible Care is and drawing on the experience of other Care," says Keith Fulton, strategic focused very tightly on plants and dis chemical communities, the PO/MTBE analysis manager for Exxon and the tribution, but there is no reason that it project as first designed included such firm's Responsible Care coordinator. shouldn't include everything you are modifications as a flare at ground level, "The very first guiding principle is `To making and how it is used." rather than on a several-hundred-foot recognize and respond to community GREGORYDL MORRIS in Houston tower. To keep them smoke-free, as is concerns.' Communities are clearly concerned with plastic litter and plastic TEXACO. . . . . . . . . . . . . .in landfills. The seventh principle is to required by federal law, the spires in ject high-pressure steam into the flare, occasionally causing sonic booms that support research on the environmental never fail to alarm nearby residents. effects of our products, and again, our uch of the trust-building and Despite not making any specific rec Mrecycling efforts speakhirectly to that. '' Robert Prioleau, manager ofthe poly- j mers group recycling venture, allows community relations that are in ommendations that were included in tegral to Responsible Care are the plant, members of the CAPs indi damage control efforts. The chemcicaatel d that they felt as if they were part of that the PP effort did not owe its genesis industry acknowledges that it has a bad the design process, rather than having a to Exxon's Responsible Care initiative, overall image, and it is trying to repair major new petrochemical project im but rather to a decision that there were that; trying to build bridges to a popu posed on them. already strong efforts under way in lace that is at worst hostile and at best "We are aware that the citizens are polyethylene and that PP recycling was indifferent. looking over our shoulder," says Gra ripe for development. Texaco Chemical's (Houston) efforts ham, "And that's okay, we are comfort He adds, however, that "there is a i in Port Arthur and Port Neches, TX, able with that." He has been with link at the broadest levels. Under codes | were no different until the company Texaco for 32 years, including a good like product stewardship and waste re- ! took the two communities' Citizens' amount of time as manager of engineer duction, you are weighing the pros and j Advisory Panels (CAPs) on a tour of a ing services, and feels that comfort level cons of one material vs`. another and, i plant that hadn't been built yet. is a pleasant change from times gone by. among other factors, how much waste ' "We took the lead in establishing the "There was never any effort in the past 50 CTL010202 Care, posters illustrating where he concludes there was a gap the ideas of Re The firm is working on a formal pro sponsible Care. cess to measure the results of Respon Embracing Re sible Care and to incorporate the new sponsible Care has employee health and safety and prod helped Lubrizol. uct stewardship codes. j traditionally a con Muskat does not regard Product j servative compam Stewardship as a separate initiative. "I not used to talking think this code touches on every single ' about itself, be one of the others. It says we can't come more open, accept products made using manufac explains David A. turing processes that generate waste, Muskat, the and we can't sell products if they cre company's senior ate a problem downstream." v.p./operations ENDLESS ROAD. Lubrizol has four sites and Responsible in the U.S. that participate in the Re Care coordinator. sponsible Care program. Muskat says "It's a new concept none has vet reached full implementa for us to share in tion, averaging about midway, "although formation." with the objective of continuous im With its busi provement, we are never going to com ness concentrated pletely reach the end of the road," he Graham displays the scale model of Texaco's planned expansion. in the lubricants market, Lubrizol adds. Muskat notes a difference in the to involve the public. We had a fence, has not had the same environmental various sites implementing codes--"one and what went on behind it was problems as many chemical compa may make progress in one category, nobody's business." nies, and Muskat says the company while another makes progress in a dif There has been a trust established on has a favorable image. However, he ferent area." And, like others in the all sides. Not only were residents wary adds, the Responsible Care codes, par industry, he regards self-assessment as of what went on inside the plant, but the ticularly the formation of advisory i one of the hardest parts of the Re company was uneasy with the compli committees for its sites, "have a very sponsible Care initiative to implement. cations that community involvement substantial merit. "That represents maybe just one might bring. "We have citizens who express con sentence of the code," he notes, but Despite the fears, Texaco has cerns, things like the level of truck there are different interpretations when warmed nicely to the whole Respon- , traffic, which we need to address," it is a subjective assessment. "One site sible Care program, says Jim Kmiecik, Muskat says. "The most important thing would sincerely regard itself as being manager of environmental, health, and is to work on improvement and make close to perfect in one area, whereas safety for the company and Responsible sure there is no reason why anyone another wouldn't, although both are at Care coordinator. "It is important that should be concerned." But that, he a comparable level," he says "There's all six codes have been published now, contends, will only come by if the a long wav to go to standardize." and the synergies and overlaps can be ' results can be successfully communi realized." cated. , ANDREW WOOD While the company's two largest However, Muskat acknowledges the j complexes have CAPs, its two other difficulty in promoting Responsible j BP CHEMICALSsites do not yet. "We are very close to Care within the company. "We have j having one in place, and the other is struggled with the need to highly pub- [ coming along," says Kmiecik. The firm licize Responsible Care and make sure s a major producer of acryloni holds regular Responsible Care reviews for the benefit of experienced employ ees, and as an introduction to new work it is not looked on as just another program," he says. "We want the guid ing principles to be incorporated into Atrile worldwide--and a major licenser of technology--BP Chemicals Inc. (Cleveland) faces chal ers. "Internally, things are going very , the way we do business." lenges in worker safety, pollution pre well. Externally we are very reliant on Muskat adds that Lubrizol is trying vention, and, particularly, in product the CAPs for communication and com to make Responsible Care part of stewardship. "It will be very complex-- munity involvement." everyone's job, not just the job of the there are going to be many pieces to GREGORY DL MORRIS ' coordinator. As a result, the Respon this code," admits Richard B. Stalzer, in Port Neches 1 sible Care codes have been incorpo manager/health, safety, and environ iUBRIZOL. . . . . . . . . . . rated into Lubrizol's existing initia tives, including waste minimization and emergency response, and its qual mental quality. "One aspect involves the safe han dling of acrylo, as well as safe produc ity program. "It's hard to separate the tion and disposal of waste." BP already isit Lubrizol's (Wickliffe, OH) cor various programs. We have used the ' offers a seminar on the safe handling of Vporate headquarters in suburban codes as a checklist to revise and im Cleveland and you won't find prove our existing practice." the lobbies filled with "annual reports, Muskat says Lubrizol is currently acrylo for customers and licensers. Stalzer says the company is eager to share information to contribute to safer company brochuresror product litera focusing attention on improving docu practice: " Responsible Care gives a con ture. What you will find are some big mentation, an important area, but one sistent set of rules to do that." CTL010203 51 Responsible, Core,\ The company has faced several The company has already built a dozen court cases brought by workers plant to recover one acrylonitrile co at customer sites affected by acryloni product--acetonitrile, which is used trile exposure. "We can't sell to just as a pharmaceutical intermediate. It is anybody, we have to ensure they are also building a new unit to produce reputable firms," Stalzer says. "Ifsome- nitric acid: "It not only makes good one is affected bv material we have business sense, but it eliminates ni sold, then we are responsible for that." trous oxide emissions 97%," says Implementing the stewardship code Valins. may be straightforward in the U.S., OPEN DIALOGUE. Despite its reduction, but there are problems once the mate the company still stands high in TRI rial has been handed to customers emissions, mainly because of overseas. "There is an antidote to acrylo deepwelling of hazardous waste from exposure; but where there is a danger, acrylonitrile, and ammonia produc we would suit up the workers to pre tion. As a result, the company was not vent exposure," Stalzer says. But in popular with Lima residents, Stalzer China, he says, workers are given the says, but there has been a "dramatic antidote beforehand. "Of course, that turnaround," through the implemen kind of practice would be unaccept tation of open dialogue. able in the West." In 1986, Lima residents objected Fred F. Valins, the company's se strongly to a BP permit to build a pilot nior environmental specialist and Re incinerator unit. But last year, when sponsible Care coordinator, says BP the company presented its plan to ex found Responsible Care was connected tend deepwelling at Lima, out of 50 to its existing initiatives speakers attending a meet and has been integrated ing of 300 residents, only using a quality team ap three were against it. proach. He estimates BP "That's a good indication was probably already do of how far we've come." ing "about 80% " of what Costs forimplementing was required as part of its the Responsible Care codes ongoing operations. "The have been lower than BP extra 20% is really the had estimated. For ex depth on involvement, ample, distribution code particularly documenta costs have been about one- tion." third below projections, The experience of its Valins says. "The cost pro U.S. operation has helped jection came from the idea its European parent. BP of the code being brand- recently joined the small Stalzer: A 'dramatic turn.' new. In fact, we were al number ofEuropean firms ready doing many of the revealing emissions data. "When they points." were looking around at a system, they Stalzer says BP is "far along" with ended up with a list modeled on the the implementation ofmost codes, and U.S. Toxics Release Inventory," says it has modified the Process Safety Stalzer. There has also been a cross code--one of the hardest to imple over of staff in the implementation of ment, so far, Stalzer says--to fit in Responsible Care. with the upcoming Occupational Safety "The U.K. is also showing a very and Health Administration (OSHA) keen interest in Responsible Care," regulations. He says the distribution Valins says. "In the case of the distri code is about 50% in place, and the bution code, a colleague from the U.K. company is in the process of risk as has been seconded to assist in devel sessment. opment. That knowledge can then be In process safety, Valins says the taken back. I think it's important--the OSHA program has become a driver message is spreading and it is becom for the code deadline. "The only prob ing an international requirement." lem has been to free up enough people-- To address emissions, BP is work but there has been good support from ing on technology that would produce management, and Responsible Care acrylo without any waste product. Fol has been written into some job de lowing studies focusing on cost-effec scriptions." In that area -too, Valins tive reductions, the company has re says, BP will share experience with duced air emissions by 60% at Lima, other companies--"After all, the whole OH from 1987 levels, and is targeting industry will suffer when there is a an additional 30% by the end of 1993, bad accident." Stalzer explains. ANDREW WOOD flKZO CHEMICALS imply put. Responsible Care "S is good manufacturing prac tice," says David R. Drummond, manufacturing manager/ polymer production chemicals at Akzo Chemicals (Chicago). It has improved community relations, he says, and has provided a focus for employee involve ment. "The hardest thing is not doing it but documenting it." Akzo has incorporated Responsible Care into its existing ISO 9000 and quality programs. Generally, Drummond says, the implementation of Responsible Care has been reason ably straightforward, although progress has been at different speeds at differ ent sites. "YVe are averaging a four for the codes, so far. It really depends on the particular site--at Deer Park, TX we are part of a major petrochemical area, and the CAER code is well in place. At smaller sites like Burt, NY--which is not part ofa chemical area--we are not as far advanced." PLANT PERFORMANCE. Drummond notes that many of the requirements of the codes--such as distribution--had al ready been handled by previous cor porate rules and regulations. "Most of the codes are centered on performance of the plant. In the case of product stewardship, it will bring in the marketing people. Now, we have to make sure the products themselves are acceptable." Like many U.S. subsidiaries of Eu ropean majors, Chicago-based Akzo has been a testing ground for its Dutch parent. "Responsible Care has been slow taking hold in Europe. The ini tial European attitude was, `It's no one's business but ours what we do,'" says Drummond. "That's now chang ing, and there is strong support com ing from Europe. They realize they are not far enough involved with the com munities." However, he concedes that the industry in Europe is being forced to change by legislation such as the German packaging law. "The chemical industry was once regarded as progress, but we seem to have reversed that view," Drummond adds. "As the industry comes of age in the U.S., we need the benefit of good community relations. As the environ mental groups get more power, it pays to have the community on your side. That's also going to be the case for Europe." 52 CTL010204 Responsible, Care, Cost has not been a major factor in He cites the case at Burt, NY. where implementing the Responsible Care Akzo produces organic peroxide, which initiative, Drummond says. "Initially, got some bad press. "The public dis when we looked at the Responsible trusted us--they thought we were mak- Care codes, people said ^ ing bombs," Drummond we didn't have the re says. "Part of the problem sources. But we have was an audible alarm at mostly made use of exist the site that the commu ing resources and combin nity was fearful of. After ing our programs." our open house got the There is an "inherent community in, we ended cost," Drummond notes, up getting a favorable re in Responsible Care, in view in the local newspa cluding longer training, per--and we changed the more emphasis on process siren." engineering and safety-- Although local commu this is the first year the nities may now be better company has included the informed about Respon program as a line item. sible Care, Drummond ac "It's just the cost involved Drummond: Good practice. in good manufacturing knowledges problems in internal communications. practice," he says. "The communities now know some Whatever the cost, Drummond says, thing about us--admittedly not as much it is bringing benefits. "I think we have as we'd like them to. We now have to a better image from a marketing point make sure all our employees are better of view by being part of Responsible informed--a lot of our corporate staff Care. I can't say it gives you more still don't have any idea what [Re dollars, but it does bring a lot of pluses, sponsible Care is] all about." particularly in better relations with the community. ANDREW WOOD BF600DRICH he principles of Responsible Care Tare already being adapted to other process industries, particularly the oil sector, and they are also spread ing to other parts of companies that have chemical operations. BFGoodrich (Akron, OH) has embraced Responsible Care so that it covers everything from its chemical interests to its aerospace op erations. "There's been a total commitment to Responsible Care across the whole or ganization by our chairman John Ong," explains Michael M. Marshall, v.p./en vironmental health and safety at BFGoodrich's Geon Vinyl division (Cleveland). "And it makes good sense--the aerospace division is han dling a lot of solvents and cleaners that bring hygiene and effluent concerns." Like many other firms, Marshall says, Goodrich has tried to "weave" Responsible Care into its other initia tives. It has generally appointed direc tors of existing groups to manage the various codes--"with enough clout to International Group OxyChem's International Group is responsible for chemicals and plastics operations worldwide, as well as for the development of overseas markets for the company's domestic businesses. Plants are located in Brazil, Mexico, Belgium, Chile, Singapore and Thailand. OxyChem 5^ The Chemical operations of Occidental Chemical Corporation OxyChem is a registered trademark ot Occidental Chemical Corporation CTL010205 53 RispOKStitfe, Care' \ ensure that things are carried out," he lower. "Getting sufficient interest to set says. up these kinds of groups will be a prob CHEMDESIGNThe company says its code imple lem for some of the other divisions of mentation has reached level four for Goodrich," Marshall says. process safety and distribution and five The company's experience in f exceeding regulatory compliance for CAER and pollution prevention. It expects those to move up bv one level in 1994, by which time it expects the new Canada is also giving it a head start on the product stewardship code. How ever, Marshall raises the question of Iexpresses the spirit of Responsible Care, then ChemDesign (Fitchburg. MA) is well on its wav to making the codes--health and safety and product potential cost. "If we take a hard line industry-wide initiative gospel in its stewardship to be at level four. Marshall with product stewardship, we may risk operations. The initiative fits in well says the company's U.S. operations a loss of sales. It's a difficult thing to say with the specialty chemical company's have built on the experience gained at to a customer, "Unless you meet the corporate philosophy, says Eckhard E. its facilities in Canada. "VVeTe now get minimum requirements, I won't ship to Muhlhauser, president of ChemDesign, ting to the point where we are auditing vou."' which was formed in 1983 and now has to actually see sales of about S40 million/year. And as how we are pro- a supplier to major chemical producers, gressing," the company "is used to a lot of what Marshall says. Responsible Care calls for," he adds. The com The company's wastewater treat- pany has bian I ment unit represents ChemDesign's nual audits, philosophy of going beyond what is some of which required by law. "We hardly use any of are in-house, our limit in allowable salt," says Robert and some of G. Brinkley, senior v.p./regulatory af which are car fairs. "We feel we shouldn't release salt ried out by in into the river." dependent con ChemDesign invested S7 million in sultants. "They two wastewater treatment plants--one are beginning to in Fitchburg and the other at its wrestle with ex Marinette, WI site--and achieved a 95% ternal audits in reduction in the chemical content of its Canada now effluent from 1989 to '91. The treatment he says. "It's j plants also allow ChemDesign to reuse important to | more of its water, significantly reducing have a reputable organization to Goodriclt expects its CAER code implementation to move up. releases of water to the publicly owned treatment works. do this." He suggests that independent He believes the Responsible Care While the technology employed in consultants, already used by Goodrich j program is reaping dividends. "Ourbig- the wastewater plants is not unique, the in site evaluations, could participate. i gest problem was at Calvert City, where combination of its operations builds in Marshall says he would welcome i the whole place was turning against redundancy to provide a rigorous sys such a move for Responsible Care-- ; industry," Marshall says. "But since we tem, says Brinkley. The plant is com "whatever it takes to give it credibility." ! started public outreach there, we prised of a double-effect evaporator, a He notes that external audits are begin j haven't had problems for several crystallizer, a stripper, and a carbon bed ning anyway--such as OSHA, with its j years--we won't really know how well may seem pricey for a company with new process safety regulations--and he j we've done until a major issue comes ChemDesign's annual sales, but would welcome an "outside arbiter" of . along." Muhlhauser considers it an investment Responsible Care. Goodrich's Calvert Marshall says it is hard to reckon the in the future, "a foundation that allows City, KY site recently underwent chemi I overall cost of Responsible fiare--the you to grow." cal safety audit by EPA under its Chemi \ company does not break those costs out Still, Muhlhauser realizes that the cal Accident Prevention program. EPA i separately in its environmental spend- firm has its work cut out in reshaping its was favorably impressed--"a credit to ; ing budget--but he describes them as own procedures to fit the Responsible the Responsible Care- approach," . "substantial." However, he cites ben- Care framework, says Muhlhauser. Marshall says. j efits with the pollution code. "That's "What we really need to do is formalize Echoing some other companies, ! just good economic sense. If you pol- the process to a greater degree than we Marshall acknowledges there are some ! lute, you're going to have to clean it up. have so that it [conforms with] Respon difficulties implementing CAER, espe ! "Cost associated with the employee sible Care exactly." As one of CMA's cially at remote sites, and particularly health and safety code you'd be doing newest members, ChemDesign is com where there is apathy among locals to anyway," says Marshall. He also cites mitted to implement the initiative. The get involved in the community advisory the costs associated with the CAER, company is also a member of the Syn panels. "Getting the community inter distribution, and process safety codes, thetic Organic Chemical Manufacturers ested is hard." and the upcoming cost of implementing Association and the Drug Chemical and At Goodrich's chlorine and deriva , product stewardship. Substantial, Allied Trade Association, and it re tives sites, Marshall says, interest of the maybe, he says, "but the benefit is sur- cently joined the Massachusetts Chemi communities is high. However, at other ; vival." cal Technology Alliance. units, particularly for polyvinyl chlo One area that illustrates what still ride compounding, concern is much 1 ANDREW WOOD needs to be done to implement Respon- 54 CTL010206 i Ces'^o^io^e Care sible Care is community re lations. While the company has been active in this area and has strong rela tionships with local and state officials, it is now in the de sign stages of forming its com munity advi Muhlhauser: Formalize. sory' panel. Community relations has been an integral part of ChemDesign since its inception in 1983. In fact, "the community was instru mental and involved in getting seed money" to start up the company, says Brinkley. ChemDesign was recruited by the city of Fitchburg as part of an initiative to create jobs in the area. Thus, Muhlhauser describes the relationship between ChemDesign and Fitchburg as a "symbiotic" one. "Elected officials have an ongoing need to be involved. If it has created jobs and is a well-man aged business, that's part of their achievement," as well, he remarks. ChemDesign invites officials to see the unit and maintains a regular dialogue with senators, congressmen, the gover nor. and state legislators. And the company's cooperation with state agencies has borne fruit, in the form of new technology. ChemDesign has designed a new sys tem to reduce air emissions, what Brinkley calls a case of "spearheading technology for ourselves and the state. " He adds the state environmental agency was supportive in developing liquid nitrogen-based technology for batchtvpe operations. ChemDesign plans to have the system installed bv the end of the year. And although Muhlhauser is aware of the progress that still needs to be made, he is proud ofwhere ChemDesign stands today and the recognition the company has received. After all, it is not everyday that a town names a day after a chemical company executive. But last year, the mayor of Fitchburg did just that, proclaiming Aug. 23, 1991 as Michael A. Ryan Day. Ryan, a senior v.p./engineering at ChemDesign, had decided to leave ChemDesign to be come a teacher, and the town honored him for his contributions to the com pany and the citv. ELIZABETH S. KIESCHE GENERAL CHEMICAL AND NOVACOR orGeneral Chemical (Parsipparn. FNj). implementing Responsible Care is largely a story of a smallto-medium-size chemical firm coordi nating separate efforts in the U.S. and Can ada. The same is true for Novacor Chemical (Calgary), which has manufactur ing and research and develop ment operations in five locations in the U.S. In the case of Novacor, an existing Ca nadian effort, Burns:Integration, managed at headquarters, is being exported to the U.S. For General, it is a game of catch-up for the home office, as it incorporates the initiative it had admired at its Canadian operation since OTHER INDUSTRIES EMBRACE CMA'S GOALS One mirror of the impact of the j would question whether they can enforce the Responsible Care program outside of the ! standards among their member companies, chemical industry is its acceptance among i and whether all the member companies other manufacturing industries. "Responsible i comply with them Cm skeptical about the Care has the potential to become an j level of compliance. I'd have similar industrial ethic--to have a profound impact j questions if all our members were espousing on society," says Dave Newman, site j it," says Roy Carwile, director/environmental environmental coordinator for Du Pont, in i affairs for the Aluminum Association, whose Sarnia, ON "But if other industry segments 79 members represent the majority of the either do not adopt Responsible Care or a i aluminum manufacturing industry comparable program, then it is in danger of j Carwile goes on to say that the members becoming an interesting sidelight and never : of his organization have run into potential developing into a grassroots movement. So ; liability problems in the past related to health we are hoping that other industries do adopt ! and safety issues when the Aluminum it," says Newman. j Association had "espoused a standard of If that is the case, then, so far, the operations for member companies. In some program's place in history is far from assured. cases, he adds, that standard has been While three trade groups, the Chlorine questioned by employees injured on the job, Institute, SOCMA, and the Florida Phosphate ; who then brought lawsuits about the level of Council, as well as 10 state industry councils, j safety the company was supposed to have have signed on as partners to the Responsible ; reached. "That sort of fear is one of the Care program. Others such as the American j reasons we don't have environmental Paper Institute have created their own j programs or standards," notes Carwile It is programs that clearly borrow heavily from the I not that each company does not have form and intent of Responsible Care. Still i environmental programs that Carwile says others have never heard of it, and some are ; "go beyond compliance" clearly skeptical. The aluminum industry's claim to "I believe that the CMA program is good : environmental fame is that 64% of beverage and provides them with a lot of excellent j cans are recycled, the result of industry effort public relations and advertising copy But I i since the "1950s and '60s," says Carwile. 1) S. sugar cane growers recently got bad press in a highly publicized environmental lawsuit. The growers' Florida group says it never heard of Responsible Care But when given a description of the program, a Louisiana : representative j responds- "You have attracted my attention. You have I to be a-hermit not to i be interested, with j all the environmental concerns going on today. Everyone is Newman: `An ethic.' sensitive to the word environment.' We use chemicals and try to be as careful as possible, but you have to be on your guard. I'm interested in finding what it's about." On the other side of the equation are two industry groups that have studied Responsible Care and crafted a similar response to their public and environmental challenges. Last j year the American Paper Institute's (API; New | York) 175 members adopted a program that is i a requirement of membership subject to j scrutiny. "If there is an area where someone j is not in compliance, it will be a matter of 1 serious concern," says Red Cavaney, president CTLOl0207 55 Responsible, Cart' \ the late 1980s. In both cases, these companies are expending a great deal of time and effort getting two separate sets of codes to meld into an overall corporate ap proach. While the Canadian Chemical Processors Association (CCPA; Ottawa) and the Chemical Manufacturers As sociation (CMA; Washington) have a shared goal in Responsible Care, com panies like General and Novacor are finding there are fundamental differ ences in the method of achieving it. According to Ed Shields, corporate director of environmental management at General, Responsible Care created a unique situation in which the Cana dian subsidiaries took a leadership role within the corporation. "In health and safety as well as pollution control, the U.S. is several years ahead of Canada," says Shields, referring primarily to SARA Title III and EPA-prescribed methods for dealing with hazardous waste. "But with Responsible Care it's the other way around. We watch what thev're doing up there." RECOGNIZING DIFFERENCES. Brian Herner, president of General Chemical Canada (Mississauga, ON), agrees, though he credits the U.S. forgiving the Canadian effort a strong foundation in environ mental management. Both recognize CMA also aims for a consistent ap differences in their programs that reflect proach. but that it is more adaptable differences in Canadian and U.S. This is important. Shields says, given business philosophies. that smaller companies will not be A key difference in implementation able to devote the resources available is the level of documentation required. to larger firms and that open-ended The CCPA relies much more heavily implementation affords the appropri on the development of specific proce ate flexibility. He says that CMA has dural documentation, Shields says. In shown its concern for smaller compa- fact, step six in nies by complying with assembling a the codes in resource base of Canada is retired techni essentially the cal people to compilation of help companies written proce attain compli dures. In the ance. U.S., Shields Shields and notes, the codes Herner say that of management since CCPA repre practice avoid sents 73 compa target proce nies--compared dures, leaving with CMA's 185 implementa members -- a tion up to each stricter ap company sees fit. as it Shields: Looking to Canada for Care guidance. proach to spe cific implemen "The CCPA wants everyone tation may be more manageable. They operating at the same degree of effort," say there is also the matter of Canadi says Herner. "CCPA is specific on what ans, coming from a European tradi they want documented, and we can't tion, tending to be more bureaucratic take shortcuts." Shields says that the in problem solving. "Canadians look of API "The company will detail the problem and a proposed resolution. If they continue to exhibit behavior that is not consistent with a code of conduct, and cannot resolve it, membership will be rescinded" by API's board of directors, who are in the position of overseeing the program. While CMA's codes of management practice have names and large books on compliance to each one--such as pollution prevention, community awareness, and emergency response--the API's principles are, so far, spelled out on a single page. Implementation guidelines will not be approved until next fall, says Cavaney. But their principles are clearly similar to the CMA program. For example, one Sides: A game plan. S^fcatewith employees, customers, suppliers, the community, public officials, and shareholders to build greater understanding on environmental, health, and safety matters." Says Cavaney, "We wanted to come up with a way to signal that the leadership of the representatives are meeting "somewhere in industry had acknowledged new and expanded Michigan where the phones won't ring," says public interest and environmental concern. We director of health, safety, and environmental watched as groups like CMA and the affairs Steven Sides, "to come up with a International Chambers of Commerce dealt with game plan." The Responsible Care program this. It is fair to say that in looking at as written "is not a good fit," says Sides, but Responsible Care in its later stages of elements of it make sense to his industry. In development and approval and implementation the future, Sides envisions the industry that there was a great deal of interest in it. Of getting involved in having a better all the programs we looked at, Responsible Care is the most comprehensive, and the one i understanding of the end use of its products, j and getting feedback to producers of the that has received the most public notice " j materials that go into paints and coatings. Recently, API established an 800 number to i Coming up with its own program in the enable the public to call member companies shadow of Responsible Care is challenging, and ask questions. API will not place says Sides. "The name alone strikes fear in advertisements for the number in national the hearts of those who don't understand it. magazines as does CMA, but it has developed a It's an irritating and tough program to deal press kit, and may do some advertising for a with. The environmental professional who is newly established paper information center. in touch with all of the complexities of his Unlike chemical companies, Cavaney says, "our corporation and his own program has trouble public profile among manufacturing industries meshing it with Responsible Care. is fairly good. Our concern is that our "It's tough because many companies have operations, and the regulatory climate in which firmly entrenched ways of doing things," they operate, is becoming increasingly Sides says "They ask why should we change complex." In response, API has a voluntary to a whole new way of relating to our industry goal to recycle 40% of all paper used customers when we are doing just fine-- in the U.S. And "there has been very little increasing sales for the last 16 quarters." He regulation to recycle," notes Cavaney. says it is hard to "convince people to do Another group that is considering creating something new when they think the old way an environmental program for its industry is the | is working." National Paints and Coatings Association I (NPCA). At press time, a group of industry I KAREN HELLER 56 CTL010208 i Retfponsiife, Care at a problem like vve do, but they address the problem with explicit docu mentation," says Shields. "We in the U.S. resist this." Herner agrees but says that bevond whatever European tocol forrailways underthe FreeTrade Agreement, which is setting up a single continental system." Looking at the codes as they stand now. however. Burns prefers the CCPA programs such as Responsible Care I with Total Quality management and j ISO 9000. This he sees as a man-hour ! priority as well as an important ap proach to keeping a high level of cm- j traditions rule business behavior. codes because they focus on functions plovee involvement in Responsible Canada's proximity to the U.S. has such as manufacturers and R&D, as Care. He finds the ISO program espe had a more direct influence on how opposed to issues such as product stew cially applicable to Responsible Care Canadian companies conduct business. ardship, a CMA code. Burns says given its documentation and third partv Ross Burns, Responsible Care coor CCPA's approach more clearly matches auditing structure, and he is closelv dinator for Novacor, says he has to product life cycles with less duplica studying efforts in the U.K. to work the deal with a total of 12 Responsible tion of efforts. five programs into each other. Care codes--six for Canada and six for According to Burns, if CMA had Novacor manufactures polypro the U.S. Eventual integration is a pri not adopted Responsible Care, Novacor pylene in Marysville, MI and polysty ority, says Burns. "Wheneverpossible, would have put its U.S. facilities rene in Leominster, MA: Springfield, we integrate. In Canada there are sepa through the process as part of a corpo MA; and Decatur, AL. It also has a rate codes for distribution and trans rate policy. "We are the reverse of catalyst research unit in Pasadena, TX. portation. In the U.S. there is one code most companies in Canada," says General Chemical produces soda ash for both. Cross-referencing them, I Burns. "We are a Canadian company and calcium chloride at Amherstburg, found they were the same, and we are with U.S. subsidiaries and we focus on ON. now implementing a single program , a Canadian program. Now that the The greatest pressure toward inte for distribution and transportation." ! U.S. has its program, we'll make every gration may be manpower. Burns, Overall, Burns says he does not effort to incorporate them." Shields, and Herner emphasize that recognize an irreconcilable difference Burns's focus on integration goes despite the importance of Responsible between the two codes. "There is a beyond a combined U.S. and Canada ; Care, the industry is often limited by its natural evolution toward convergence, approach, however, encompassing a resources in implementing the program, and I'm a proponent," says Burns. "We more integrated world effort as Re and smaller companies operating in are pursuing joint efforts with the CMA. sponsible Care spreads. He is also in ternationally are feeling an acute strain. A good example is the assessment pro terested in combining quality-based RICK MULL1N Petrochemicals -- Olefins & Aromatics Division OxyChem's Olefins & Aromatics Division can produce 3.6 billion pounds of ethylene annually, together with a full range of co-prod- ucts for sale on the merchant market. In addition, OxyChem is a major producer of propylene, benzene, MTBE and butadiene. OxyChem The Chemical operations of Occidental Chemical Corporation _ OxyChem is a registered trademark of Occidental Chemical Corporation CTL010209 57 RCare,\ CANADIAN DEADLINE APPROACHES "You didn't want to attract a lot of discriminatory legislation that would Contemplating continuous improvement make world-scale competition impos sible. There was a real humanitarian drive, but also a fear of government s the year-end deadline for com lems," says Belanger. Specifically, there involvement." According to Wells, it Apliance with the Canadian Chem were concerns about the interpretation ical Producers Association's Re of a commitment to meeting and ex sponsible Care program approaches, tcheeeding the letter of the law and provid took pressure from high-profile disas ters such as Bhopal for the association to finally adopt a mandatory Responsi Ottawa-based association and its meimng open access to information. "As a ble Care program. bers are taking stock of the progress that result, it turned into a major wordsmith- While opinions range broadlv on has been made along the way. More ing exercise," he says. CCPA's intentions, many member com- important, they are focusing on tough Neff and Akitt, panies recognize issues that are surfacing as members however, continued that CCPA is tack reach the final milestones in their Re to push the issue. ling certain issues sponsible Care programs. "Neff noted at that before hard, fast Attendees at a recent CCPA clinic for time that there were regulatory action, company code coordinators in Toronto beginning to be so basically provid say the group's biggest concerns right many alligators-- ing a useful re now include community apathy, prod regulatory issues source to legisla uct stewardship, and coordination of coming up all over tors. The group has international programs--especially for the place--that recently launched firms operating in the U.S. and Canada. somehow or another National Emis Interpreting the meaning of a deadline we had to start think sions Reduction for a program that mandates continu ing as an industry Masterplan ous improvement is another major con about how to drain (NERM)--current cern, as are the issues of performance the swamp," says ly a voluntary sys measurement and possible third-party Belanger. "I always tem of reporting all auditing. thought that was a releases of danger Canada's current reflections on Re succinct way of put ous chemicals, in sponsible Care are significant in that ting it. If we could cluding C02, NOx, the CCPA has had the longest experi figure out a way of and SOx--is held ence with the program--the associa tion developed the guiding principle becoming proactive, then we could less Belanger: An evolution. up as the associa tion's latest model and the first codification of manage en the demands for that degree of regu to the federal government, which is ment practices in the early 1980s. lation." studying the development of a national EVOLUTION. "When you look back, you When the proposal was refloated in Green Plan. In general, Canadians see a see that this has been very much an the early 1980s, Belanger says, the tim regulatory landscape such as the one evolution," says CCPA president Jean ing was right. CEOs were looking be that exists in the U.S. as a thing to avoid. Belanger. Its history, as told by Be yond possible legal headaches, viewing 'REGULATION-HAPPY.' "EPA seems regu langer, shows CCPA taking the initia commitment to responsible practices as lation-happy," says David Bandy, man tive in codifying responsible practices, crucial to survival in Canada. Belanger ager of environmental affairs at the drawing on the experience of interna saw a wide range of influences--not the chemicals division of Imperial Oil tional players operating in the Canadi least of which a disastrous train derail (Toronto). "With the manpower neces an chemical industry'. An important ment in Mississauga, ON in 1979--fos sary to draft regulations and the time element of what has evolved in Canada tering a higher level of consciousness required in the consultation process through this proactive approach is a among management. In 1983 the associ and enforcement, it's way ahead of it mix of government regulation and in ation had a set of voluntary operating self." He adds that while the provinces dustry self-policing that many see as principles that by 1985 evolved into the have also introduced regulation, "ask preferable to the broad blanket of gov six-code Responsible Care program. ing for more documentation than they ernment oversight elsewhere, especial Compliance was established as a condi could process," Canada has taken ad ly in the U.S. tion of membership. vantage of an opportunity to learn to Belanger says the first roots of Some observers of CCPA's proactive track itself and establish a focal point CCPA's program date back to an effort endeavor believe the Canadian chemi for self-improvement in Responsible in the late 1970s when Bill Neff, then v.p. cal industry is consciously heading off Care. of technical affairs at CCPA, and associ legislation comparable to the U.S. Tox Robert Scott, manager of corporate ation board member John Akitt began ics Release Inventory (TRI) in an effort programs for Hercules Canada (Missis drafting guidelines for the safe handling to establish a self-regulatory industry. sauga) is among those who see Respon ofchemicals. The board of directors was "There is an element of altruism [to sible Care fostering a better mechanism asked to approve the statement they de Responsible Care], but a major motive than regulatory involvement. "I hope veloped. was to keep people out," says Allen Responsible Care acts to fill in for gov "At the time, board members took Wells, community awareness and emer ernment regulation," says Scott. He rea counsel from their legal .departments gency response (CAER) administrator sons that while provincial law tends to and were really given cause for concern at the Chemical Valley Emergency Co set only a minimum standard, Respon that this could create some major prob ordinating Organization (Sarnia, ON). sible Care mandates continuous im- 58 CTL010210 aare provement. However. Scott \fn- --. general man ager of the Lambton Inc_<trial Society, a cooperative of industries--mostly chemical manufacturer;--m Lambton County, ON. says it's best to back off the notion that Responsible Care is funda mentally a race with ;o\ernment to regulate the industry. "1 don't think Responsible Care is a preemptive strike," says Munro, "The government responds to its perception of what the public expects, and so does industry. 1 think Responsible Care is a recognition by industry that the public wants to and expects to know [how it operates]." David Newman, environmental and occupational health coordinator at Du Pont Canada (Sarnia) agrees. "The ef fect is not so much to preempt the legislation as it is to modify legislation that is put in place." savs Newman. "This way, government won't be start ing from a zero base." The notion of a preemptive strategy is flatly denied by CCPA. "I take strong exception to the term 'self-regulation,'" savs Brian Wastle, Responsible Care Dow hosts a dry run in Sarnia. director for CCPA. "It implies CCPA is taking over the rolemf government, and hence it needs to set up the auditing, enforcement, and disciplinary struc tures that government usually sets up. If the public credibility of Responsible Care is based on that vision, we'll never make it. We are not going to do those things." He describes the program as one of ethical commitment and cultural change driven by peer pressure, pride, and employee motivation. DEADLINE. A major motivator so far has been the 1992 deadline for compli ance--an arrangement agreed upon by members early in the' process. While most companies say they are well on the way to full lem company by show ing how, through assis compliance, the deadline tance from other member has raised the question of companies, things can what comes next. Be improve significant!v. langer says that because "So far." says Wastle. of the evolutionary na "we have seen a re ture of Responsible Care, sponse from companies as well as its relationship to public attention that to quality management, is different from what we companies are anxious to would have seen five or go further, which tends to 10 years ago. There is a work against the notion new force afoot." Wastle of a simple deadline. adds, however, that if at There are, however, some point it's obvious six codes, each with its that a company has own milestone to mea sure compliance. Imperi Wastle: End of the beginning "signed on in lip service only." the association is al's Bandy describes a typical situation: prepared to challenge its status. "Kris "We're 50 %-100% on our codes. The may get her example of one that didn't manufacturing code is near 100%; any work, but I think we'd all look upon thing requiring us to assess third-party that as a failure." contractors, distributors, or customers The association is also looking at is nearer 50%." ways to expedite the efforts of compa Ross Burns, Responsible Care coor nies that are operating in both the U.S. dinator for Novacor Chemicals (Cal and Canada--companies that are es gary), agrees with Belanger that the no sentially managing two sets of codes. tion of a deadline to Responsible Care is Sources agree that the CCPA codes are i somewhat artificial. However, far more function-oriented than the he says setting it has served a CMA codes, addressing research and purpose. "Deadlines are really development, manufacturing, transpor the only mechanism to move the tation, and waste management as sepa program ahead and give it ur rate items. The CMA's codes focus more gency. We're concentrating on on issues, such as product stewardship 1992 in Canada, after which our and safety, that cross functional bound emphasis will shift to the U.S." aries. Depending on the size ofthe com Burns feels that the Chemical pany, managing both the CMA and Manufacturers Association CCPA programs can become a manage (CMA; Washington) will follow ment and man-hour drain (p. 122). Canada's lead and eventually set BORDERLINE ISSUE. Sources note a ten a deadline for its program. "We dency in both the U.S. and Canada to have been working on the U.S. draw from existing programs and prac for about two years, but the sense tices, integrating Responsible Care into of urgency is lacking." He adds, the general functions of the companies however, that Novacor sets its and associations--Wastle, for example, own internal schedule for com notes CCPA's code committees have pliance. now been absorbed into long-standing An unavoidable issue is that committees within the association. In of consequences for companies explaining the differences that have that come up short. "What if emerged in this process, John Vincett, they don't comply?" asks Kris Lee, a v.p. of Pat Delbridge Associates (Toron member of the National Public Adviso to)--coordinators of the Responsible ry Committee (Toronto). "Are you going Care national advisory panels in Cana to kick them out? It's like with a drug da and the U.S.--notes that far more addict--do you kick this person out so major chemical companies are based in he can get into even more trouble, or do the U.S., and that many Canadian firms you try to work with him?" Lee, who are U.S. subsidiaries. "There is a sense teaches high school science in Wallace- of greater freedom in the U.S. in that burg, ON, says it may still be a good idea more of the CEOs are right there," says to make an example of a bad player. "If Vincett. "They may have seen codes you don't, they're just going to call your addressing broad issues as a better ap bluff." proach." CCPA's Wastle says the association Vincett also sees differences between will first opt to assist companies in the Canadian and U.S. trade association, trouble. He notes that it has already both political and in order ofmagnitude. made an example of at least one prob "The number of standing committees at CTL010211 59 i Responsive, Care' CMA is remarkable," says Vincett. "I bution. Compa wouldn't want to be a timetable person nies are striving for the meeting rooms at CMA because to achieve a de there are so many committees working gree of read- on so many issues all of the time." across on the The differences between the North ' two sets of American neighbors go beyond just the codes, while codes, however, revealing a divergence still orienting in business and community mentali operations to ties. At the root, some say, are the right- the appropriate to-know laws that exist in the U.S. and I association's not in Canada. One major difference is j program. This that the U.S. is ahead of Canada on the has been a much issue of community outreach, with far easier exercise more community advisory panels. for large-compa NEW FRONTIER. By most accounts, the nies. community liaison represents the new "The differ frontier in Responsible Care. When the ences between associations introduced their CAER Canada and the codes, it was obvious that emergency U.S. should not response would be a lot easier for the chemical industry than community i take up a lot of discussion Emergency response training: A binary thing. awareness. "Emergency response has time," says Paul Ireland, director ofenvi grams into Responsible Care, the ISO been around a lot longer," says Imperi ronmental issues for Dow Canada (Sar 9000 program, which is well advanced al's Bandy. "It's a legal requirement for nia) "We are implementing the same among Canadian chemical manufac handling high-risk chemicals." thing in both places." Ireland notes that turers, may prove an efficient model for It is also more in line with the basic Dow has a global council on employee instituting third-party review. He notes thinking of engineers. "With emergen health and safety as well as a well-estab that the Chemical Industries Associa cy response you can almost create a lished commitment to product steward tion in the U.K. has already established list," says Vincett. "Have you talked to ship--both specific codes at CMA. Still, a pilot program for Responsible Care the fire chief? Have you done this? Have the company's input was integral in the under ISO 9000 (p. 28). you done that? It's a binary thing. Once formation of CCPA's program. Dow re DOVETAILING. "It's a matter ofrealigning you get to the communi mains among the leaders resources for Responsible Care, ISO ty, it's like the difference in Canada, sponsoring a 9000, and quality management," says between asking a closed recent emergency re Hercules' Scott. "There is a lot of docu question and an open sponse drill in Sarnia as mentation involved in putting them all question. Many of the well as CAERtraining pro in place, so we are trying to dovetail sociological issues, if grams in other parts of the them on the level ofbasic philosophy." they are going to be taken country. According to Ire Novacor's Burns also sees ISO 9000 seriously, are going to get land, Dow feels it is taking as a close fit with Responsible Care: into three-page answers. " a consistent approach to "We've gone to great lengths to assess Wastle says he is un Responsible Care interna third parties with which we do busi sure why there are fewer tionally by sticking to ness. On this level, Responsible Care community advisory company programs. Com can be an onerous thing to apply. ISO panels in Canada than in pliance, he says, will lead will help companies qualify others, the U.S. However, he to conformity in Canadi eliminating the need for ongoing as feels that the CAER orga an and U.S. operations. sessment of other companies' facilities. nizations in many re Perspectives vary, It's part of the internationalization of gions are seen as efficient vehicles for dialogue be Vincett: Three-page answers. however, and some see a growing shadow of U.S. Responsible Care, and we as a company want to look closely at the ISO system. " tween the industry and the community. influence in Canada. "As U.S. programs Wastle says CCPA is keeping its op Member companies, in fact, place great come to maturity," says Novacor's tions open in measuring compliance. store in CAER, which in most cases is Burns, "it looks like the Canadian sub "At this `end of the beginning' period, handled as a regional industry effort, sidiaries of large U.S. companies are we see members asking for clarification and express commitment to bringing being told to get on the U.S. program, on whether they are doing what their community awareness up to par with while meeting the minimum require peers and the public expect them to do, their emergency response efforts. Most ments of the Canadian codes." and asking for help in that regard. That's agree that general community apathy is Belanger stresses that with Canadian the main engine for coming up with the as much an obstacle in this as the need firms nearing full compliance with the next phase, which may involve assess to change direction in business philos CCPA, significant change cannot really ment by people other than the member ophy. be considered. Rather, the focus must company." According to Wastle, the While nobody expects either CCPA shift to evaluation, which brings in the association recently formed a commit or CMA to drop its program in favor of question of whether to establish third- tee specifically to study concepts of the other, much thought is being given party auditing. credibility and study options for mea to consolidating approaches at certain Vincett notes that since the tendency suring compliance. levels such as transportation and distri has been to incorporate existing pro RICK MULLIN in Ottawa 60 CTL010212 i Ce-zponziofc Clcu^-e guiding principles make a stronger MEXICO: RESP0NSAB1LIDAD INTEGRAL statement on energ} and raw materials than the CMA program does. ANIQ hopes to have all members sign Guadalajara explosions ignite community interest the guiding principles by the end of September, with participation in the pro gram mandatory for membership. The he series of deadly explosions in have been on an individual plant basis, first three implementation codes, com Guadalajara's sewers on April 22-- although a corporate group maintains munity protection, pollution prevention, attributed to Pemex gasoline guidelines. The company has a long and process safety, should be ready this leaks--have made the Mexican public standing policy of keeping manufactur year; four more, transportation and dis much more concerned about the chemi ing locations away from populated ar tribution, employee health and safety, cal plants in their communities. "We eas. That may explain why no commu research and development, and product were visited by a committee of neigh nity group has expressed concern or stewardship, should be ready in 1993. bors, asking whether they should be con asked for information. Also next year, ANIQ members will cerned," says Raul Dick, general manag Efrain Salazar, director/health and be subject to performance evaluations er of Dow Corning de Mexico (Mexico environment for Du Pont in Mexico, says on their obligations under the Respon City). "That wouldn't have happened that his company is beginning training sabilidad Integral program. While the before the accident in Guadalajara. It's a on community outreach this week. Some details on the monitoring process are tremendous change in the society, and a plants, including those at Santa Clara, not yet firm, there are three possibilities good thing, I think." Altamira, and Matamoros, already have that may be applied according to social, The Dow Corning plant at S. Martin active community participation. political, and technological circum Texmelucan is within sight of a govern Salazar, like executives at most other stance. One of these is an annual self- ment-subsidized apartment complex. multinationals, says his company evaluation by members. Evaluation bv The operation already had informal "started to promote Responsible Care in an external committee, including rep safety and mutual emergency assistance Mexico when we did in the United resentatives of international organiza arrangements with other companies in States," putting Du Pont ahead of Re- tions is a second alternative. A third the same industrial complex, including sponsabilidad Integral's schedule. He would be a formal Responsabilidad In one Pemex plant, but those plans "will notes that the Chemical Manufacturer's tegral audit. be more formalized because of the mo Association gave a community aware Also beginning next year, compa mentum after Guadalajara," Dick says. ness and emergency response award to nies will meet with each other under Hector Gutierrez ofGutierrez Consul- four of Du Pont's Mexican plants (the ANIQ-sponsored executive leadership tores (Monterrey) says there are no na three mentioned above, plus one in Tlal- groups to share their experiences re tional environmental organizations nepantla)--the only plants outside the garding the implementation process, spurring the dialogue in Mexico, as there U.S. to get awards from the U.S.-based although many such meetings are al are in the U.S. and Europe, even though association. ready taking place on specific issues as there are local organizations in Mexico Salazar is confident that Responsabi- the codes are developed. ANIQ will City and Monterrey that have a general lidad Integral is the right way to go, and also put together a public advisory pan environmental focus. Instead, chemical i that the accident at Guadalajara has made el, which will begin meeting in 1993. companies seem to be hearing mostly a proactive plan for the industry more ANIQ committed to all these actions in from genuinely grassroots organizations urgent. "The community is scared about an appendix to a paper for the secretary in their own localities. Guadalajara," says Salazar. "Fear comes general of the United Nations Confer AGREEMENT. Grupo Cydsa's (Mexico from ignorance. If we are more open, ence on Environment and Development City) Luis Angel Gonzalez, general di they will be more comfortable about the in Rio De Janeiro, Brazil. rector/environmental improvement, plants in their neighborhoods." PINPOINTING. ANIQ is also conducting a says his company has signed an environ The Guadalajara accident came at a public opinion survey to pinpoint atti mental protection agreement with resi- ( time when Mexico's Asociacion Nacio- tudes toward the industry. Most observ dential neighbors of its Monterrey/Nue nal de la Industria Quimica (ANIQ; Mex ers believe the Mexican public has a vo Leon complex. About 100 of the fam ico City) has begun implementing its more positive attitude toward its domes ilies living closest to the complex are Responsabilidad Integral initiative (CW, j tic chemical industry than many other working with the company, and a time- j April 15, p. 12). As of the end of May, 72 countries' people do. table has been set for taking further steps i out of ANIQ's 280 members had signed j Also under way are ANIQ-sponsored toward environmental protection and the protocol affirming the guiding prin- j "road shows" presenting Responsabili accident prevention. ciples, which are similar to the analo- \ dad Integral to Chambers of Commerce, The neighbors, according to Gonza gous programs administered by industry j government groups, and other associa lez, "want emergency response train associations in the U.S., Canada, and j tions. "It's very important to have the ing," plant visits, and verification ofcom- ! Europe. support of public opinion, especially mitments in the contract under Respon- ! A Celmex official explains that "in | after Guadalajara," says ANIQ's Juan sabilidad Integral's community protec- I Mexico, we may not be as advanced as Carlos Vargas, director of health, envi tion code. Cydsa is now monitoring pro the United States, but as a principle, we i ronment, and safety. cesses much more closely, and planning have the same objective." In fact, Ron J ANIQ's membership consists of 35 to install a new technology involving Pingel, Dow Chemical's global director large companies, 145 medium-sized microorganisms, Bioqydsa, to reduce for Responsible Care at Midland head companies, and 100 small companies. sulfur emissions in the air. quarters, says that while the implemen ANIQ members have about 4,000 facil At Celanese Mexicana (Celmex; tation codes have not yet been fully j ities. The association claims the mem Mexico City), comrtiunity relations developed, the Mexican program's berships of all multinationals and all CTL010213 61 the large local companies doing chem pollution control laws were passed." hesion to the program. A Celmex official ical business in Mexico. However, state- He also says that "some plants have is not alone in noting that "in Mexico, controlled Pemex is not a member. been shut," including a chlorine plant many local regulations are not very pre The government has initiated steps and a leaking hydrochloric acid unit in cise." That can sometimes lead to confu to improve Pemex's standards, recently Mexicali, on the Baja Califomia/U.S. sion on enforcement. contracting with Fluor (Irvine, CA) for a border. In addition, the government is in the 90-dav review of Pemex's safety and While most multinationals operating process of enacting new regulations. emergency response plans at all its in Mexico claim that they apply their New rules on transportation are immi chemical sites, beginning with Pemex's environmental standards on a global ba nent, while requirements for safety and four largest petrochemical plants, along sis, and hence already meet or exceed risk assessment and on hazardous waste the Coatzcoalcos River, including a vi Responsabilidad Integral's require are expected later this summer. nyl chloride plant that had a major ments, many concede that in Mexico, SLOW GOING. The problems of coping accident in February 1991. , many producers, especially the smaller with new regulations may account for After the Guadalajara accident, a local ones, have been slow to come the limited progress in getting the spirit number of officials ofboth enforcement ; around to the view that a proactive envi- of Responsabilidad Integral into action. agencies and Pemex lost their jobs, and | ronmental stance makes business sense. One multinational's press office in the some were even arrested. That specta ! Several multinationals expressed hope U.S. contacted various Mexican plant cle has helped motivate much more that stepped-up enforcement post- managers and found none familiar with stringent enforcement of regulations. ! Guadalajara may motivate those with lax , the program. Not surprisingly, that com One manager at a multinational grum ; standards to take advantage of the infor- ' pany had not yet affixed a signature to bled that enforcement has become over- | mation and technology-sharing oppor- | the guiding principles. zealous on bureaucratic technicalities. | tunities Responsabilidad Integral is mak- With North American free trade ne "Every time we send out a truck, some | ing available. "The wolf [ofenforcement] gotiations under way, ANIQ hopes Re one stops it to check the papers," he is here. They're not going to be able to sponsabilidad Integral will demonstrate says. fight regulations with facilitating pay- ; that Mexico's industry meets interna While some ofthe enforcement mea ments anymore." tional standards on health, safety, and sures since Guadalajara may be petty, Cydsa's Gonzalez notes that increas environment issues. enforcement had gotten more teeth even ingly strict regulations in the federal dis- I EMILY PUSHNER before the tragedy. Consultant Gutier trict (around Mexico City) have been an with LESLIE LAYTON rez says, "About two years ago, some "important element" in encouraging ad in Mexico City Basic Chemicals Group -- Electrochemicals Division With multiple facilities strategically located throughout the U.S., force, a strong manufacturing team, and an innovative distribution OxyChem is among the country's leading producers of chlor-alkali system work to create business partnerships and ensure customer chemicals. A responsive, highly trained sales and customer service satisfaction. OxyChem* /-x. The Chemical operations of Occidental Chemical Corporation OxyChem is a registered trademark of Occidental Chemical Corporation 62 CTL010214 4 Responsible' Care' 1 1 I I take letters of commitment as a starting point, we have the basis for a program all over the European chemical indus try." declares Jourdan. Promoting Responsible Care is also being left to national associations, but Aiming to demonstrate a universal program CEFIC has been involved with lobbving the echelons of European government. Jourdan notes communicating the pro hink globally, act locally is the Responsible Care, it is effectively a con gram to the European Parliament is dif TEuropean Chemical Industry : dition of joining. Four chemical associ Council's (CEFIC) message to its ! ations, from Hungary, Czechoslovakia, member associations and companiePso. la; nd, and Turkey, have applied for ficult because it is strongly green and politically to the left. "They think Re sponsible Care is a track to avoid," he CEFIC technical director Louis Jourdan j membership in the council. adds. explains: "There is still a divergence of j The Dutch program, which was orig SHORTFALLS. Although it is still early, cultures across Europe, and Responsi inally restricted to the environment, Responsible Care has yet to make an ble Care needs to fit in with local tradi has been expanded to include health | impact on environmental pressure tion." and safety. Now CEFIC believes the groups. The Environmental Protection He illustrates that point with refer ence to a multinational like Dow Chem ical, which has a core program that reflects its corporate culture, but its actions are geared to local circumstanc es. In North America, for example, con tact with local communities is a "must," and dealt with through the formalized community panels. But in Spain, where Dow has a complex at Tarragona, there is also neighborhood liaison, but it is likely to be held in the local bar rather program is good, and Jourdan comments Encouragement Agency (EPEA; Ham that the Dutch are particularly fond of j burg) sees three key shortfalls in Re "voluntary approaches." sponsible Care. First, the program's fail Sweden, which operates under ure to provide a comprehensive stan tough environmental standards, started dard record of chemical stewardship. the program early last year but aimed it Douglas Mulhall, EPEA managing di at middle management. "This solves a i rector, believes that "there is a serious problem that occurs in many compa- ; need for a level playing ground within nies where bosses are very committed j the industry so all companies can be but middle managers drag their feet," he compared. Responsible Care does not contends. "But to be in harmony with [ provide that, so we are trying to do it." the definition of Responsible Care, we The agency has established 25 criteria than via committees. j asked them to get CEOs to sign up." CEFIC still oversees programs to Nevertheless, the German chemical make sure they meet certain standards. association (VCI; Frankfurt) made a for sustainability and is currently benchmarking the 50 largest chemical groups to assess performance (p. 28). So far, 12 country associations have set j block signing of members to the CEFIC up Responsible Care programs. Den program and does not intend to collect mark, Norway, and Portugal are "out of | CEO signatures. The VCI argues strong Second, Mulhall states: "We think there is one thing missing from Respon sible Care that flaws the entire program-- the picture, but showing signs of crack- i ly that such a move would slow it does not require companies to take ing," Jourdan says. The Norwegian progress. CEFIC appears resigned that it product back [after use). " He claims such chemical association has an observer will not convert VCI, but Jourdan says I a move would switch industry away on CEFIC's Responsible Care commit- i the council is constantly pushing for from a system of global waste manage tee and its largest member, Norsk Hydro individual companies to sign. j ment to clean technology. "Only compa (Oslo), favors the program. "If we insisted on it, we could crys nies that produce clean products will PRESSURE. "We are putting pressure on tallize discussions in Germany. Even if survive beyond the 1990s," he cautions. Portugal," Jourdan reports. The deci- [ Germany is distant from Responsible | Third, Mulhall thinks the program sion to hold the International Council j Care, it is a member of the Responsible ; fails to deal with unlimited liability of Chemical Associations' second Re Care family." insurance claims for environmental sponsible Care workshop in Lisbon National associations are charged damage--which could cripple the after the Society of Chemical Industry with guaranteeing that companies are chemical industry in much the same meeting in October "puts them on the | doing enough in Responsible Care. But way as it is currently ravaging the insur spot." CEFIC hopes that Portugal will j Jourdan notes there may be insufficient ance sector. Mulhall points out that four set the wheels in motion by that meet- j scrutiny and says the CEFIC committee of Lloyds of London's top 10 insurance ing--although Jourdan notes the indus could be a court of appeal. As yet, no claims last year were for environmental try association faces a difficult task, as it such cases have materialized. ly related damage. "Insurance compa comprises many small, domestic in Jourdan notes there are no real initi nies say they will not cover environmen dustries. However, Denmark is still not atives other than definition and promo tal accidents. This is the big change that interested in Responsible Care. Novo- tion: "Now is a period of implementa will affect the development ofnew prod Nordisk is the only CEFIC member not tion. " He notes that Finland and Austria ucts and processes," he claims. to have signed up to the council's Re have yet to submit their letters of com The EPEA has developed what it sponsible Care program. "Certainly mitment, but that both have decided to calls "intelligent product systems," there will be an action before the end of have a program. And Switzerland--one which categorizes products by use and the year," Jourdan asserts. "We want to of the last to agree to develop a pro sets up guidelines for production and demonstrate it really is a universal pro gram--has now started. the types of materials that are accept gram." ! "We are definitely satisfied with the able. Mulhall says this approach avoids Although CEFIC's statutes do not progress of Responsible Care. We are global waste management mentality. require new members to subscribe to not at the end of the journey, but if you EMMA CHYNOWETH CTL010215 ''9 'v. ;r'A Respo:n !-, / This is a fragile planet As individuals, we all have to act responsibly to safeguard the balance of nature and protect our environment for future generations. That means conserving resources, reducing waste, and recycling used products. It means, in effect changing our way of life. As manufacturers of essential chemical products, we ! have an inherent responsibility to preserve the i, ___ environment to encourage / 'sj safety, and to enhance the y'- 1 health and welfare of our . ^ employees and communities. /.-v J-`-\' c' -Sr / Recognition of this led the / Chemical Manufacturers / Association to develop the -'^j:. < " ' 0 , ' Responsible Care* initiative -- a neww way f Kfe fr fee chemical industry. t\. > V. Already, we're seeing a difference. As \ fe- . ` \ an industry, we're well aware of the extent to |-i / which our involvement can help - from ^ ' '. P protecting wildlife to cleaning up the air and ,; [ ' / water to safeguarding the health and welfare of | :y people. Through the ongoing, comprehensive . :, I,efforts of Responsible Care, we're becoming >.j, j more responsive, efficient and effective -- and we're inviting the public to become involved with us and learn more about our industry. While the first steps have been taken, much \ remains to be done. Developing and implementing \ the Codes of Management Practices -- the basic process by which Responsible Care will actually work -- is the most significant task ahead. I \ I j OxyChem is one of the companies playing a \-, | key role in drafting these codes. We're also setting up appropriate programs and accelerating existing ones within OxyChem to implement the codes. As a hB\ starting point we've conducted a series of employee orientations to foster better understanding of Respon- j? V \V vN~ \\ ; '< M-j \ . Wl \/ % f )f ^ stole Care. And we are developing a library of ' materials to inform and educate people both inside ^ and outside our company, To us, its all a logical extension'3*!^'. J j> j3 of the longstanding commitment to safety and the environment that OxyChem has practiced for years. Community Awareness and Emergency Response For years, OxyChem has been an industry leader in safety, j Part of that leadership includes a carefully planned program of emergency response. j j developed in close association with our dati# j plant communities. Since our concern Mymfo ? tradi |oper gplan blarr fScfe for safety extends beyond the boundaries of our plants __ into surrounding y.^- - /V communities, we / /?/ developed a / \*/ / . *i, / ' \ '- 4 Chemical Emergency ' " *- __ 'pjPIF'. `` = i ^ . - (CERP) as a mecha- 4 emergencies involving our ' ' products away from our facilities. -- The focus is on being prepared by providing Jtoroci j dent j WOxyC training to handle a wide range of possibilities. - `and ii The Responsible Care program is both comprehensive and ment empl detailed, leaving nothing to chance. Sometimes the only way to ultimi be sure you measure up to such specific guidelines is to test yourself. OxyChem conducted a simultaneous emergency stand no en disaster drill at two of our petrochemicals plants, testing all recor aspects of handling an emergency situation on multiple __ hasu ,K levels. The idea was to find out just how we would cope if two major accidents should occur at the same time at : we've r|- y different facilities, miles apart One of the objectives was to % An 0 %/ determine how well we could conform with a key area of fflr i Responsible Care -- proper handling of emergencies in j Krotei y / our plant communities, including correcting the problem,! pcontir pj taking care of injuries, and notifying the proper external * *the ai f ' agencies, emergency response organizations, community i leaders and OxyChem personnel. The drill tested communi cation procedures and capabilities at various company levels -- plant division, group and corporate. While the results identified some areas that could be improved, for the most part the various levels came m through with flying colors -- and the ^ril1 reinforce^the appropriate- . / ness of procedures already OxyChem is a registered trademark of Occidental Chemical Corporation CTL010216 m ronment As for community awareness, we have a long-standing tradition of active involvement in the areas in which we operate. Outreach programs are underway at many of our A few examples: for each pound of product we made from 1984 to 1989, we reduced the amount of hazardous solid waste generated by 31%. And we're utilizing new ilant locations. These range from informal get-togethers and technologies like . >. tafety. nt tours to participating on community advisory biotreatment immittees, to being represented in force in and energy lanizations like United Way, Adopt-a- from waste, School and Junior Achievement helping us make Isive and [y way to test ncy ; all IItiple j cope if leat Process and Employee Safety ^ A keynote of Respon- sible Care is an emphasis ,; on continuous improve- / ment Developing a ; comprehensive, i company-wide program for such ^ improvement in the area of [ocess safety has been fentified as one of Chem's major priorities nd is now being imple mented. When it comes to employee safety, our ultimate goal is to become the standard bearer for the industry with no employee injuries. And our track V * record of leadership in safety performance ' has us well on the way. By concentrating on fundamentals, we've reduced on-the-job injuries by 48% since 1987. Ongoing Commitment pxyChem is currently spending $ 100 million per year to valuable contribu tions to the environ ment especially in our i plant communities. /' ^Our performance in r / f implementing the already approved ^ Responsible Care codes has been and will continue to be timely, committed and enthusiastic. vv-,< A-- v ' v What lies ahead? OxyChem has set some pretty tough goals for the next five years. Goals like a 10% annual reduction in hazardous air \ emissions. A 5% annual reduction in solid waste. And a 20% reduction in water pollutants by 1994. These are goals that we have every intention of meeting. For it is only through a serious commitment to both the spirit and the letter of Responsible Care1* that we're going to survive--as a company, as an industry, as a society. And its only by turning in a consci entious environmental record that we'll all become winners -- making our world a healthier, cleaner, safer place. itect the environment While acutely aware of the need for Today, tomorrow and over the long haul. es was to itinuous improvement well also admit to some pride in ' area ofi -%e accomplishments we've already - X achieved. icies in iroblem, v^ jctemal For more information, call our Responsible Care Hotline: (800)729-2002 mmunity pmmunifny levels OxyChem the results )ved, for The chemical operations of Occidental Petroleum Corporation CTL010217 OxyChem. Locations______________________ BASIC CHEMICALS Headquarters: Dallas, TX 214/404-3800 Electrochemicals & Proprietary Products Division Headquarters: Dallas, TX 214/404-3300 Sales Offices: Edison, NJ 908/906-2200 Houston, TX 713/931-0485 Lisle, IL 708/505-3242 Marietta, GA 404/952-3700 Moreland Hills, OH 216/247-3655 San Ramon, CA 510/275-8100 Wayne, PA 215/640-1616 Electrochemicals Plants: Belle, WV Convent, LA Corpus Christi, TX Deer Park, TX Delaware City, DE LaPorte, TX Fertilizer Products Mobile, AL Plant: Muscle Shoals, AL White Springs, FL Niagara Falls, NY Tacoma, WA Feed Products Taft, LA Plants: Buffalo, IA Proprietary White Springs, FL Products Plants: POLYMERS & Ashtabula, OH PLASTICS Castle Hayne, NC Headquarters: Chicago, IL Dallas, TX Cincinnati, OH 214/404-3800 Dallas, TX * Jersey City. NJ Vinyls Division Lockport, NY Headquarters: Mobile, AL Dallas, TX Niagara Falls, NY 214/404-3800 Oxnard, CA Sales Offices: Taft, LA Des Plaines, IL 708/297-0125 Agricultural Marietta, GA Products Division 404/952-1816 Headquarters: Wayne, PA Dallas, TX 215/993-9980 214/404-3800 Westlake, OH Sales Office: 216/835-9560 Dallas, TX Plants: 214/404-3800(*) Addis, LA Burlington, NJ Pasadena, TX OxyChem Pottstown, PA Alathon' Polymers Division Headquarters: Dallas, TX 214/404-3800 Sales Offices: Houston, TX 713/623-2246 Wayne, PA 215/296-4946 Plants: Matagorda, TX Orange, TX Victoria, TX Durez Division Headquarters: ^Dallas, TX 214/404-3800 Sales Office: Dallas, TX 214/404-3800 Plants: Kenton, OH Niagara Falls, NY North Tonawanda, NY PETROCHEMICALS Headquarters: Dallas, TX 214/404-3800 Sales Office: Dallas, TX 214/404-3800 Olefins & Aromatics Division Plants: Chocolate Bayou, TX Corpus Christi, TX Lake Charles, LA Ethylene Oxide & Derivatives Division Plants: Bayport, TX Beaumont, TX Pipeline Operations Pearland, TX INTERNATIONAL Headquarters: Dallas, TX 214/404-3800 International Sales Division: Dallas, TX 214/404-3800 Operations: Carbocloro S.A. Industrias Quimicas, Brazil Industrias Oxy, S.A. de C.V., Mexico Occidental Chemical Chile S.A.I., Chile Occidental Chemical Europe S.A., Belgium Occidental Chemical Far East Ltd., Thailand Oxypar Industrias Quimicas S.A., Brazil Siam Occidental Electrochemical Corp., Thailand SumiDurez Pte. Ltd., Singapore Thai Occidental Chemical Ltd., Thailand Vulcan Material Plastico S.A., Brazil 4. n i (*) OxyChem is a registered trademark of Occidental Chemical Corporation