Georgia-Pacific Resins, Inc. - Russellville, SC 2005 APR View/Print

OMB No. 2010-0032
Expiration Date 08/30/06

2005 Performance Track Annual Performance Report

Georgia-Pacific Resins, Inc. - Russellville, SC
A040103
Year 2 Annual Performance Report
Member Since 2004 (1st Member Term)

SECTION A: GENERAL FACILITY INFORMATION

A.1

Name of your facility:

Georgia-Pacific Resins, Inc. - Russellville, SC

A.2

Name of your parent company:

Georgia-Pacific Corporation

A.3

Facility contact person for the Performance Track program:

Name:	Mr. Ronald E. Rowland
Title:	Plant Manager
Phone:	(843) 567-3232
Fax:	(843) 567-2001
Email:	rerowlan@gapac.com

A.4

Facility location:

Street Address:	1028 Georgia-Pacific Drive
Address Cont:
City:	Russellville
State:	SC
Zip Code:	29476
Mailing address (if different from above):
Mailing Address:	P.O. Box 147
Address Cont:
City:	Russellville
State:	SC
Zip Code:	29476
If your facility has multiple street addresses, please list any other addresses for its sites or buildings.

A.5

Facility's website address (if any):

http://www.gp.com

A.6

Number of employees (full-time equivalents) who currently work in the facility:

50-99

A.7

North American Industrial Classification System (NAICS) Code(s) that is(are) used to classify business at the facility:

325199 325211

A.8

In your application and, perhaps, in previous annual performance reports, you described what your facility does or makes. Have there been any (additional) changes to your facility's list of products and/or activities?

If yes, please list them here:

A.9

Have the environmental requirements applicable to your facility changed during this reporting period?

If yes, please describe these changes here:

Section B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.a

When was an EMS assessment last conducted by an independent party at your facility?

2003

B.1.b

When was an internal EMS assessment last conducted at your facility?

2005

If an assessment was conducted during 2005, please provide the scope and month(s) of each assessment.

Scope	Dates
Management Review. Internal assement of Performance Track Objectives/Goals	March 2005

B.1.c

When was an internal or corporate compliance audit last conducted at your facility?

2005

If an audit was conducted during 2005, please provide the scope and the month(s) of each audit, and indicate who conducted the audit(s) (e.g., facility staff, corporate groups, third party). (Don't include audits, inspections, or site visits by regulatory or external organizations).

Scope Dates Who conducted the audit

An assessment of the facility’s Environmental Compliance with Federal and State regulations using official GP protocols. The audit protocols are comprehensve and address all federal environmental requirements (40 CFR) and state environmental requirements, as well as conducting facility permit reviews.
April 2005 Jim Eckenrode, Steve Wilson, Jennifer Welch, Charles King

B.1.d

(Optional) If you would like to describe any other audits or inspections that were conducted at your facility, please do so here.

SC DHEC Air Compliance Inspection

B.1.e

Briefly summarize corrective actions taken and other improvements made as a result of your EMS assessments and compliance audits.

Non Identified

B.1.f

Has your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?

No such instances identified

If no, please explain your plans to correct these instances.

B.1.g

When was the last Senior Management review of your EMS completed?

March 06

Who was the senior manager present at the review?

Name: Mr. Rick Turner

Title: Manager- Regional Manufacturing

B.2.a

ISO 14001 Certification. Is your facility currently certified to ISO 14001?

B.2.b

Is your facility a Responsible Care-certified facility?

B.3 Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?

March 06

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

C.1 COMMITMENT 1

Georgia-Pacific Resins, Inc. - Russellville, SC's first commitment is to reduce the facility's toxic air emissions, specifically ammonia.

C.1.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

Actions taken to achieve this goal: 1) Installed a chiller to maintain a lower storage temperature on the tank, 2) insulated the tank to assist in maintaining the lower temperature and 3) improved the closed loop system on the tank to reduce the buildup of pressure in the charging system. We currently are meeting our goal for 2005. The modifications made have greatly reduced our emissions that will exceed the goal of 100 pounds of Ammonia emissions released to the atmosphere.

Activities Conducted During 2004:
1. Installed and operated a chiller system to maintain a lower storage tank temperature of the Aqueous Ammonia and there by reduce vapor losses from the tank.
2. Additionally, we consulted with Aqueous Ammonia transporter to develop and operate a closed-loop unloading system.

C.1.b Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Perform.

Calendar Year 2003 2004 2005 2006 Goal Units

Actual Quantity (per year) 6,400 4,773 793.3 n/a Pounds

Specify other:

C.1.c Normalized progress toward goal.

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1 1

Normalized Quantity 6,400 4,773.00 793.30 100 Pounds

Specify other:

Basis for your Normalizing Factor: Total tons of resin produced.

C.1.d Please list any other EPA voluntary programs to which you are reporting these data.

C.2 COMMITMENT 2

Georgia-Pacific Resins, Inc. - Russellville, SC's second commitment is to reduce the facility's generation of hazardous waste, specifically routine generation of hazardous waste (excludes spill clean-up and soil from excavation in methanol plume).

C.2.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

Actions taken to achieve this goal: We have implemented Best Management Practices for the returning of unused raw materials (hazardous and non-hazardous). We are currently within our goal for this year. We generated 465 lbs Hazardous Waste in 2005.

Activities Conducted During 2004:
The enhanced management of raw material purchasing and utilization, process operations and finish product inventory control has reduced the generation of hazardous waste.

C.2.b Please report your facility's actual performance.

Performance Data

Waste Management Method Baseline Year 1 Year 2 Year 3 Units

2003 2004 2005 2006

Incineration

Specify other: Off-site treated
5,200.5 97 465 Pounds

Specify other:

Other management

Specify other: Treated & landfilled
200 Pounds

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

C.2.c Summarized progress toward goal.

Actual Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Hazardous Waste 2.60 0.15 0.23 n/a Tons

Specify other:

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1.0 1

Total Hazardous Waste 2.60 0.15 0.23 1.00 Tons

Specify other:

Basis for your Normalizing Factor:
Total tons of resin produced.

C.2.d Please list any other EPA voluntary programs to which you are reporting these data.

C.3 COMMITMENT 3

Georgia-Pacific Resins, Inc. - Russellville, SC's third commitment is to reduce the facility's generation of non-hazardous waste, specifically process wash water shipped offsite.

C.3.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

Actions taken to achieve this goal: We did not meet this goal for 2005. The main focus to meet this goal was placed on developing an on-site treatment process for our wash water. However, efforts to date have not yielded a satisfactory treatment process. Therefore, we have turned our focus toward preventing excess wash water from being generated. To this end we have written a Best Management Practices for our Product Storage Containments. This Best Management Practices includes product sampling and operation and maintenance procedures. Once the Best Management Practices is initiated (by the end of March), a contractor will steam clean the Product Storage Containment (PF, UF & RM) including sumps. The end goal of this effort is to enable us to directly discharge the storm water from these areas rather than having to ship off-site for treatment.

Activities Conducted During 2004:
Activities
1.Contracted and Performed a trial for processing the Process Wash Water to be used in other areas of the plant.
2.Established new BMP’s for containment areas to reduce the amount of Process Wash Water generated by contamination.
Circumstances
1.The trial was not performed and completed until the end of 2004. The results weren’t favorable.
2.The facility stopped making two of the four products that used the process wash water.
3. We will continue to work toward acheiving this goal .

C.3.b Please report your facility's actual performance.

Performance Data

Waste Management Method Baseline Year 1 Year 2 Year 3 Units

2003 2004 2005 2006

Other management

Specify other: Waste water treatment
16,400,000 17,080,000 14,327,130 Pounds

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

Specify other:

C.3.c Summarized progress toward goal.

Actual Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Total Non Hazardous Waste 8,200.00 8,540.00 7,163.57 4,500.00 Tons

Specify other:

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1. 1.0

Total Non Hazardous Waste 8,200.00 8,540.00 7,163.57 n/a Tons

Specify other:

Basis for your Normalizing Factor:
Total tons of resin produced.

C.3.d Please list any other EPA voluntary programs to which you are reporting these data.

C.4 COMMITMENT 4

Georgia-Pacific Resins, Inc. - Russellville, SC's fourth commitment is to reduce the size of an existing methanol plume and continue voluntary operation of a Soil Vapor Extraction (SVE) system.

C.4.a Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.

The plume area as of 12/2005 is 53,222 ft². This is a reduction in plume area of 44,500 ft². From approximately August 2005 until the middle of December the Methanol extraction rate reached a Plateau. However, from the Middle of December until the end of December the Methanol extraction rate appears to be on the increase. We will continue to monitor the extraction rate on a quarterly basis to ensure a continued reduction.

Activities Conducted During 2004:
Continued the voluntary operation of a soil vapor extraction system.

C.4.b Please report your facility's actual performance.

Performance Data

Baseline Year 1 Year 2 Year 3 Perform.

Calendar Year 2003 2004 2005 2006 Goal Units

Actual Quantity (per year) 97,722 65,552 53,222 38,000 Square feet

Specify other:

C.4.c Normalized progress toward goal.

Normalized Total Baseline Year 1 Year 2 Year 3 Perform.
Goal Units

Normalizing Factor 1.0 1 1 1

Normalized Quantity 97,722 65,552.00 53,222.00 n/a Square feet

Specify other:

Basis for your Normalizing Factor:
N/A

C.4.d Please list any other EPA voluntary programs to which you are reporting these data.

Progress Towards Other Significant Aspects of your EMS

In the table below, please provide a narrative summary of progress made toward EMS objectives and targets other than those reported as Environmental Performance Commitments. You may limit the summary to environmental aspects that are significant and towards which progress has been made during the reporting year.

Do you have additional environmental aspects to report? No

Attachments (if applicable) :

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

D.1 Please briefly describe the activities that your facility conducted during the year to interact with the community on environmental issues and to report publicly on environmental performance.

GP Resins, Inc.has a procedure in place for dealing with in-coming community issues. GP-Resins Russellville facility is featured prominently on the GP corporate web-site, which includes a streaming video related to the facility’s involvement in PT and what it means to the environment. The area surrounding the facility is quite rural. The facility is very involved in local community activities, including the LEPC, and local educational facilities. Facility has EPIC – employee participation involvement committee for which it makes funding available annually for various community-oriented activities. Performance report is available through the corporate website.

D.2 Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.

Web Site, Press Releases
URL: http://http://www.gp.com/csrr/environment/purpose.html

Attachments (if applicable):

OMB No. 2010-0032
SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT
The U.S. Environmental Protection Agency is not yet in a position to accept electronic signatures and therefore requests a faxed, signed copy of the Section E page. Please complete Section E online, then print Section E using the link on the Overview page. Section E should be signed by the senior manager of your facility and faxed it to the Performance Track Information Center at (617) 354-0463.
On behalf of Georgia-Pacific Resins, Inc. - Russellville, SC, I certify that: I have read and agree to the terms and conditions as specified in the National Enviromental Performance Track Program Guide. This facility, to the best of my knowledge, continues to meet all program criteria; I have personally examined and am familiar with the information contained in this Annual Performance Report. The information contained in this report is, to the best of my knowledge and based on reasonable inquiry, true, accurate, and complete; My facility has an environmental management system (EMS), as defined in the Performance Track EMS criteria, including systems to maintain compliance with all applicable federal, state, tribal, and local environmental requirements, in place at the facility, and the EMS will be maintained for the duration of the facility's participation in the program; My facility has conducted an objective assessment of its compliance with all applicable federal, state, tribal, and local environmental requirements; and the facility has corrected all identified instances of potential or actual noncompliance; and Based on the foregoing compliance assessments and subsequent corrective actions (if any were necessary), my facility is, to the best of my knowledge and based on reasonable inquiry, currently in compliance with applicable federal, state, tribal, and local environmental requirements. I agree that EPA's decision whether to accept participants into or remove them from the National Environment Performance Track is wholly discretionary, and I waive any right that may exist under any law to challenge EPA's acceptance or removal decision. I am the senior manager with responsibility for the facility and am fully authorized to execute this statement on behalf of the corporation or other legal entity whose facility is part of the National Environmental Performance Track program.
Signature/Date:	______________________________________________________
Name:	Mr. Ronald E. Rowland
Title:	Plant Manager
Phone Number:	(843) 567-3232
E-Mail Address:	rerowlan@gapac.com
Facility Name:	Georgia-Pacific Resins, Inc. - Russellville, SC
Facility Street Address:	1028 Georgia-Pacific Drive Russellville, SC 29476
Mailing Address:	,
Performance Track ID#:	A040103

B.3	Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?
	March 06

Georgia-Pacific Resins, Inc. - Russellville, SC's first commitment is to reduce the facility's toxic air emissions, specifically ammonia.
C.1.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	Actions taken to achieve this goal: 1) Installed a chiller to maintain a lower storage temperature on the tank, 2) insulated the tank to assist in maintaining the lower temperature and 3) improved the closed loop system on the tank to reduce the buildup of pressure in the charging system. We currently are meeting our goal for 2005. The modifications made have greatly reduced our emissions that will exceed the goal of 100 pounds of Ammonia emissions released to the atmosphere.
	Activities Conducted During 2004:	1. Installed and operated a chiller system to maintain a lower storage tank temperature of the Aqueous Ammonia and there by reduce vapor losses from the tank. 2. Additionally, we consulted with Aqueous Ammonia transporter to develop and operate a closed-loop unloading system.
C.1.b	Please report your facility's actual performance.

Performance Data
	Baseline	Year 1	Year 2	Year 3	Perform.
Calendar Year	2003	2004	2005	2006	Goal	Units
Actual Quantity (per year)	6,400	4,773	793.3		n/a	Pounds Specify other:

Normalized Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Normalizing Factor	1.0	1	1
Normalized Quantity	6,400	4,773.00	793.30		100	Pounds Specify other:
Basis for your Normalizing Factor:	Total tons of resin produced.

C.1.d	Please list any other EPA voluntary programs to which you are reporting these data.

Georgia-Pacific Resins, Inc. - Russellville, SC's second commitment is to reduce the facility's generation of hazardous waste, specifically routine generation of hazardous waste (excludes spill clean-up and soil from excavation in methanol plume).
C.2.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	Actions taken to achieve this goal: We have implemented Best Management Practices for the returning of unused raw materials (hazardous and non-hazardous). We are currently within our goal for this year. We generated 465 lbs Hazardous Waste in 2005.
	Activities Conducted During 2004:	The enhanced management of raw material purchasing and utilization, process operations and finish product inventory control has reduced the generation of hazardous waste.
C.2.b	Please report your facility's actual performance.

Performance Data
Waste Management Method	Baseline	Year 1	Year 2	Year 3	Units
Waste Management Method	2003	2004	2005	2006	Units
Incineration Specify other: Off-site treated	5,200.5	97	465		Pounds Specify other:
Other management Specify other: Treated & landfilled		200			Pounds Specify other:
Specify other:					Specify other:
Specify other:					Specify other:
Specify other:					Specify other:

Actual Total	Baseline	Year 1	Year 2	Year 3	Perform. Goal	Units
Total Hazardous Waste	2.60	0.15	0.23		n/a	Tons Specify other:

C.2.d	Please list any other EPA voluntary programs to which you are reporting these data.

Georgia-Pacific Resins, Inc. - Russellville, SC's third commitment is to reduce the facility's generation of non-hazardous waste, specifically process wash water shipped offsite.
C.3.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	Actions taken to achieve this goal: We did not meet this goal for 2005. The main focus to meet this goal was placed on developing an on-site treatment process for our wash water. However, efforts to date have not yielded a satisfactory treatment process. Therefore, we have turned our focus toward preventing excess wash water from being generated. To this end we have written a Best Management Practices for our Product Storage Containments. This Best Management Practices includes product sampling and operation and maintenance procedures. Once the Best Management Practices is initiated (by the end of March), a contractor will steam clean the Product Storage Containment (PF, UF & RM) including sumps. The end goal of this effort is to enable us to directly discharge the storm water from these areas rather than having to ship off-site for treatment.
	Activities Conducted During 2004:	Activities 1.Contracted and Performed a trial for processing the Process Wash Water to be used in other areas of the plant. 2.Established new BMP’s for containment areas to reduce the amount of Process Wash Water generated by contamination. Circumstances 1.The trial was not performed and completed until the end of 2004. The results weren’t favorable. 2.The facility stopped making two of the four products that used the process wash water. 3. We will continue to work toward acheiving this goal .
C.3.b	Please report your facility's actual performance.

C.3.d	Please list any other EPA voluntary programs to which you are reporting these data.

Georgia-Pacific Resins, Inc. - Russellville, SC's fourth commitment is to reduce the size of an existing methanol plume and continue voluntary operation of a Soil Vapor Extraction (SVE) system.
C.4.a	Briefly describe your activities and achievements related to this commitment or, if relevant, any circumstances that delayed progress this year.
	The plume area as of 12/2005 is 53,222 ft². This is a reduction in plume area of 44,500 ft². From approximately August 2005 until the middle of December the Methanol extraction rate reached a Plateau. However, from the Middle of December until the end of December the Methanol extraction rate appears to be on the increase. We will continue to monitor the extraction rate on a quarterly basis to ensure a continued reduction.
	Activities Conducted During 2004:	Continued the voluntary operation of a soil vapor extraction system.
C.4.b	Please report your facility's actual performance.

C.4.d	Please list any other EPA voluntary programs to which you are reporting these data.

D.1	Please briefly describe the activities that your facility conducted during the year to interact with the community on environmental issues and to report publicly on environmental performance.
	GP Resins, Inc.has a procedure in place for dealing with in-coming community issues. GP-Resins Russellville facility is featured prominently on the GP corporate web-site, which includes a streaming video related to the facility’s involvement in PT and what it means to the environment. The area surrounding the facility is quite rural. The facility is very involved in local community activities, including the LEPC, and local educational facilities. Facility has EPIC – employee participation involvement committee for which it makes funding available annually for various community-oriented activities. Performance report is available through the corporate website.
D.2	Please indicate which of the following methods your facility plans to use to make its Performance Track Annual Performance Report available to the public. Please check all that apply.
	Web Site, Press Releases
	URL: http://http://www.gp.com/csrr/environment/purpose.html
	Attachments (if applicable):

SECTION A: GENERAL FACILITY INFORMATION

Section B: ENVIRONMENTAL MANAGEMENT SYSTEM

SECTION C: ENVIRONMENTAL PERFORMANCE RESULTS

C.1 COMMITMENT 1

C.2 COMMITMENT 2

C.3 COMMITMENT 3

C.4 COMMITMENT 4

SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING

SECTION E: SELF-CERTIFICATION OF CONTINUED PROGRAM PARTICIPATION FOR ANNUAL PERFORMANCE REPORT