OMB No. 2010-0032
Expiration Date 01/31/2010
2004 Performance Track Annual Performance Report















John Zink Company LLC
A060050
 Year 2 Annual Performance Report

























SECTION A: GENERAL FACILITY INFORMATION

A.1Name of your facility:
John Zink Company LLC

A.2Name of your parent company:
Koch Chemical Technology Group LLC

A.3Facility contact person for the Performance Track program:
  Name:Mr. Steve A. Clark
  Title:Environmental/Facilities Manager
  Phone:(918) 234-2730
  Fax:(918) 234-2700
  Email:steve.clark@johnzink.com

A.4
Facility location:
  Street Address:11920 East Apache
  Address Cont:PO Box 21220
  City:Tulsa
  State:OK
  Zip Code:74116


Mailing address (if different from above):
  Mailing Address:
  Address Cont:
  City:
  State:
  Zip Code:

A.5
Facility's website address (if any):
http://www.johnzink.com

A.6
Number of employees (full-time equivalents) who currently work in the facility:
500-1,000

A.7
North American Industrial Classification System (NAICS) Code(s) that is(are) used to classify business at the facility:
332322  332313  332341    

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:

No Changes


A.9
Have the environmental requirements applicable to your facility changed during this reporting period? If yes, please describe these changes here.

No Changes


SECTION B: ENVIRONMENTAL MANAGEMENT SYSTEM

B.1.aWhen was an EMS assessment last conducted by an independent party at your facility?
2004

If an assessment was conducted during 2004, please provide the type (e.g., ISO 14001 certification), the scope, and the month(s) of each assessment.

Type
Scope
Dates
ISO 14001 Routine surveillance audit of EMS by Lloyds Register Quality Assurance (LRQA) to maintain ISO 14001 Certification   July  2004  
ISO 14001 Routine surveillance audit of EMS by Lloyds Register Quality Assurance (LRQA) to maintain ISO 14001 Certification   December  2004  



B.1.bWhen was an internal EMS assessment last conducted at your facility?
2004

If an assessment was conducted during 2004, please provide the scope and month(s) of each assessment.

Scope
Dates

Our ISO 14001 internal audit team audited compliance to ISO 14001 elements, and our own tier II operating procedures and tier III work plans and procedures - It takes about 8-months to conduct a full cycle audit of EMS by internal auditors, thus a segment of total EMS is audited each month. We have a continuous ongoing audit cycle of EMS each year at our facility.

October  2004



B.1.cWhen was an internal or corporate compliance audit last conducted at your facility?
2004

If an audit was conducted during 2004, 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

Compliance audit of applicability and compliance to Federal, State and Local regulations

September  2004Facility EH&S Staff

Corporate audit of facility Compliance Calendar, Facility Compliance Manual and all plans, permits and reports

May  2004Corporate Staff Koch Chemical Technology Group



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.

City of Tulsa conducted annual site inspection for compliance to stormwater permit and industrial sanitary sewer discharge permit.

B.1.eBriefly summarize corrective actions taken and other improvements made as a result of your EMS assessments and compliance audits.

1. Revised our air emissions data base which we use to calculate daily air emissions from each process area and source unit to correspond with new reporting requirements of ODEQ's revised (RedBud) Annual Air Emissions Reporting data base system.


B.1.fHas your facility corrected all instances of potential non-compliance and EMS non-conformance identified during your audits and other assessments?
Yes

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



B.1.gWhen was the last Senior Management review of your EMS completed?
December  2004
Who was the senior manager present at the review?
Name: Mr. Stephen Pirnat
Title: President CEO

B.2.aISO 14001 Certification. Is your facility currently certified to ISO 14001?
Yes

B.2.bIs your facility a Responsible Care-certified facility?
No

B.3Environmental Aspects Identification. When did your facility last conduct a systematic identification and/or review of your environmental aspects?
December  2004

B.4Progress Toward Achieving Objectives and Targets. 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 in Section C. 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? Yes



Environmental Aspect
Progress Made This Year (e.g., quantitative or qualitative improvements, activities conducted)
Contractor Performance Evaluation Extended our contractor environmental performance evaluation and approval process to international suppliers requiring participation in environmental compliance surveys and classification of risk impact of goods or services supplied.
Water Conservation Project at R&D Combustion Test Center Reduce water consumption by replacing old style steam spargers on test furnace stacks to reduce steam usage when pulling draft on furnace during test monitoring. Install new control equipment on process steam boilers to maintain less steam pressure and lower steam temperature during hours of idle operation, thus reducing the amount of water and fuel usage of steam boilers.


SECTION C: ENVIRONMENTAL PERFORMANCE COMMITMENTS

COMMITMENT 1

Category:Waste
Aspect:Hazardous Solid Waste
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2002
2003
2004
2005
2005
Actual Quantity (per year):
6,229
7,057
7,128

5,983
Measurement Units:
lbs
   Other:
Normalizing Factor:
1.0
1.23
1.25

1.12 *
Basis for your Normalizing Factor:
Pounds of product shipped (including low NOx process burners, vapor recovery systems, flare systems, and thermal oxidation systems).
Normalized Quantity per year:
6,229
5,737.4
5,702.4

5341.96
* Estimated

C.1.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
Continued to reduce hazardous waste paint stream by improving manufacturing processes, by using greater amounts of water borne and low VOC paints, by improving manufacturing work quality standards and material specifications.

C.1.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).



COMMITMENT 2

Category:Waste
Aspect:Total Solid Waste
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2002
2003
2004
2005
2005
Actual Quantity (per year):
1,878,240
1,762,856
1,612,220

1,253,991
Measurement Units:
lbs
   Other:
Normalizing Factor:
1.0
1.23
1.25

1.12 *
Basis for your Normalizing Factor:
Pounds of product shipped (including low NOx process burners, vapor recovery systems, flare systems, and thermal oxidation systems).
Normalized Quantity per year:
1,878,240
1,433,216.26
1,289,776

1,119,634.82
* Estimated

C.2.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
Continued manufacturing process improvements; expanded purchasing of pre-cut to size stainless steel sheet material as well as carbon steel pre-cut sheets which creates less drop of scrap steel, Continued robust recycling programs for paper, cardboard, wood pallets and metals.

C.2.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).



COMMITMENT 3

Category:Water Use
Aspect:Total Water Use
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2002
2003
2004
2005
2005
Actual Quantity (per year):
75,393,276
65,894,400
66,225,940

56,544,957
Measurement Units:
gallons
   Other:
Normalizing Factor:
1.0
1.23
1.25

1.12 *
Basis for your Normalizing Factor:
Pounds of product shipped (including low NOx process burners, vapor recovery systems, flare systems, and thermal oxidation systems).
Normalized Quantity per year:
75,393,276
53,572,682.93
52,980,752

50,486,568.75
* Estimated

C.3.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
Reduce water consumption by replacing old style steam spargers on test furnace stacks to reduce steam usage when pulling draft on furnace during test monitoring. Install new control equipment on process steam boilers to maintain less steam pressure and lower steam temperature during hours of idle operation, thus reducing the amount of water and fuel usage of steam boilers.

C.3.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).



COMMITMENT 4

Category:Air Emissions
Aspect:Emissions of VOCs
Baseline
Year 1
Year 2
Year 3
Performance
Commitment
Calendar Year:
2002
2003
2004
2005
2005
Actual Quantity (per year):
6.8
6.14
4.8

5.8
Measurement Units:
tons
   Other:
Normalizing Factor:
1.0
1.23
1.25

1.12 *
Basis for your Normalizing Factor:
Pounds of product shipped (including low NOx process boilers, vapor recovery systems, flare systems, and thermal oxidation systems).
Normalized Quantity per year:
6.8
4.99
3.84

5.18
* Estimated

C.4.bBriefly describe how you achieved improvements for this aspect or, if relevant, any circumstances that delayed progress.
Continued standardization to lower VOC paints

C.4.cPlease list any other EPA voluntary programs to which you are also reporting these data (e.g. Energy Star, Project XL).


SECTION D: PUBLIC OUTREACH AND PERFORMANCE REPORTING




D.1Please 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.

Our John Zink Institute continued offering of educational accredited combustion engineering courses, John Zink also continued to expand new partnerships with customer and their commuities to participate in air emission studies to help determine ways to improve air quality for our customers and their communities. John Zink held an open house celebration at our Tulsa Facility to honor our acheivements such as EPA Performance Track, OSHA VPP Star Site, ISO 14001, OHSAS 18001 and ISO 9001 certifications with community officials and neighbors.

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

Web Site
Open House
Meetings
Press Releases
URL: http://www.johnzink.com


Attachments (if applicable) :