Projects

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Technology Demonstration

Modular Syngas Plant

LMG prepared process information and air emission documentation to successfully obtain an agency exemption from new construction air permitting requirements for the technology demonstration of a modular syngas plant. The plant uses patented gassification and wet scrubber gas clean-up technology to produce syngas from petcoke or biomass. The syngas is then burned in existing boilers located at the adjacent physical plant for a major university.

As part of the project, LMG conducted extensive research and evaluated existing plant data to determine emission factors for various air pollutants. We then used this information to estimate syngas production and combustion emissions. These emission estimates were then evaluated with existing natural gas and coal-fired boiler air pollutant emissions to demonstrate net emission reductions in a number of criteria pollutants and HAPs. This information was then compiled to clearly demonstrate that firing syngas in the boilers did not require modification of the air permits for these emission units.

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Power Siting

Modular Syngas Plant. LMG prepared process information and air emission documentation to successfully obtain an agency exemption from new construction air permitting requirements for the technology demonstration of a modular syngas plant. The plant uses patented gassification and wet scrubber gas clean-up technology to produce syngas from petcoke or biomass. The syngas is then burned in existing boilers located at the adjacent physical plant for a major university.

As part of the project, LMG conducted extensive research and evaluated existing plant data to determine emission factors for various air pollutants. We then used this information to estimate syngas production and combustion emissions. These emission estimates were then evaluated with existing natural gas and coal-fired boiler air pollutant emissions to demonstrate net emission reductions in a number of criteria pollutants and HAPs. This information was then compiled to clearly demonstrate that firing syngas in the boilers did not require modification of the air permits for these emission units.

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Grid Interconnection

Co-Generation Facility. LMG has acted as the Project Manager and electrical grid interconnection application consultant for the FDS Co-Generation Facility. FDS is a 135 MegaWatt co-generation power plant that uses steam produced by waste heat from an adjacent non-recovery coke plant to generate electricity. The facility is located within the Midwest Interconnection Systems Organization (MISO) Planning Agency interconnection area. As Project Manager, we have overseen the identification and preliminary design specifications for the interconnection equipment. In addition, we have worked with local governmental entities in the designation of a interconnection plan including transmission line routing.

As the MISO Interconnection application consultant, LMG compiled the inital MISO application package. We have also acted as the MISO technical and project planning contact. As such, LMG has coordinated planning and execution with MISO of the Feasibility Study and System Impacts Study. We have also prepared responses to MISO initial application questions and requests for additional information and represented FDS in communications with MISO staff.

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Risk Assessment

Automotive Products Manufacturer. A manufacturing operation that produces ammonia based automotive products had been acquired by a large oil company which invested in a closed ammonia handling system to eliminate the need for a respirator program. LMG was retained by the manufacturing operation to assess the continued need for a respirator program, found the conflict between the manufacturer and it’s corporate office and developed the corporate documentation needed to obtain corporate support for the manufacturer’s respirator program.

Industrial Equipment Manufacturer. An industrial equipment manufacturer had grown rapidly over the last few years; in part causing dust and noise to carry between different departments in a crowded work spaces. To resolve this issue, LMG was retained to conduct an occupational health evaluation of the local exhaust ventilation systems and the noise contribution of different activities. Based on this evaluation, LMG provided workable recommendations that were successfully implemented by the manufacturer.

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Safety and Health Support

Grey Metal Foundry. LMG provided ongoing safety and health program development support on a monthly retainer basis for a new operations manager who is striving to turn around a grey iron foundry’s safety program after several years of dwindling resources and bankruptcy. We provided on call advice and biweekly onsite services. Previous plant records were very limited and a number of programs had to be reconstructed including silica exposure monitoring and control, respirator program, lockout tag-out, and emergency response.

Foundry Holding Company. LMG provided a number of worker safety services to a ferrous and nonferrous foundry holding company with eight operations located in the U.S. The projects have included comprehensive safety reviews and alternative control recommendations for controlling cutting torch emissions.

National Commercial Property Manager. After a year of employee complains, LMG was retained to evaluate the state of IAQ in the basement. The property management firm had moved 39 of its own people into renovated leased office space in the basement of it’s parent’s property. The owner did not believe there were any concerns about IAQ in the building. LMG was able to provide solutions that worked for all parties. All eleven recommendations were adopted.

Automotive Products Manufacturer. A manufacturing operation that produces ammonia based automotive products had been acquired by a large oil company which invested in a closed ammonia handling system to eliminate the need for a respirator program. LMG was retained by the manufacturing operation to assess the continued need for a respirator program, found the conflict between the manufacturer and it’s corporate office and developed the corporate documentation needed to obtain corporate support for the manufacturer’s respirator program.

Industrial Equipment Manufacturer. An industrial equipment manufacturer had grown rapidly over the last few years; in part causing dust and noise to carry between different departments in a crowded work spaces. To resolve this issue, LMG was retained to conduct an evaluation of the local exhaust ventilation systems and the noise contribution of different activities. Based on this evaluation, LMG provided workable recommendations that were successfully implemented by the manufacturer.

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Exposure Monitoring

Not-for-Profit Construction Research Center. LMG provided ongoing field testing for construction worker exposures to emerging issues such as hexavalent chromium and manganese in the welding trades and isocyanates in the roofing trade. The purpose of these studies is to characterize representative exposures and in some cases the effectiveness of engineering controls to reduce exposures, and then make recommendations for the implementation of engineering, personal protective equipment, and work practice controls.

National Commercial Property Manager. After a year of employee complaints, LMG was retained to evaluate the state of IAQ in the basement. The property management firm had moved 39 of its own people into renovated leased office space in the basement of it’s parent’s property. The owner did not believe there were any concerns about IAQ in the building. LMG was able to provide solutions that worked for all parties. All eleven recommendations were adopted.

PVC Pipe Manufacturing Operation. LMG evaluated indoor air quality parameters and chemical exposures at a PVC pipe manufacturing operation where there had been union complaints about respiratory problems and skin irritation. Based on the exposure monitoring and our onsite observations, we were able to address the union concerns and recommend improvements in better utilizing and upgrading the plant’s many ventilations systems.

Wire Reel Manufacturing Operation. LMG conducted a comprehensive employee exposure assessment at a captive wire reel manufacturing operation that was being considered for outsourcing. The assessment included an evaluation of worker exposures to metal welding fumes and the existing exposure controls and ventilation systems. Based on the assessment, LMG identified several worker welding fume exposure control alternatives that supported keeping the operation captive instead of outsourced.

Industrial Equipment Manufacturer. An industrial equipment manufacturer had grown rapidly over the last few years; in part causing dust and noise to carry between different departments in a crowded work spaces. To resolve this issue, LMG was retained to conduct an occupational health evaluation of the local exhaust ventilation systems and the noise contribution of different activities. Based on this evaluation, LMG provided workable recommendations that were successfully implemented by the manufacturer.

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Safety and Health Audits

Confidential Plastic Company. As part of an OSHA settlement agreement, LMG performed one year of monthly safety compliance inspections of a plastics company. The safety inspections were comprehensive but specifically focused on LOTO, and machine guarding requirements. Monthly safety inspection reports were submitted to the President of the Company to provide to OSHA. The reports document facility operations at the time of the inspections with respect to OSHA safety program requirements. In addition a more detailed inspection report was provided to the company under attorney client privilege.

Confidential Consumer Products Manufacturer. LMG conducted a comprehensive OSHA compliance assessment of a consumer products distribution operation in preparation for an acquisition due diligence. Based on the results of the assessment, LMG updated the distributor’s safety manual including providing an organizational framework for the company to build an employee safety team that management had formed during the acquisition discussions.

Confidential Consumer Pesticide Manufacture. LMG performed a comprehensive S&H audit of a pesticide manufacturing plant which had been improving their OSHA compliance implementation over several years and wanted an independent assessment. Performance of the audit included a multi-day field inspection of the plant with daily briefings of plant management and performance of an audit close-out meeting with plant management and corporate S&H staff. Every major OSHA program was evaluated including but not limited to Process System Safety, Fire Protection, Confined Space, Electrical Safety, Machine Guarding, Laboratory Safety, Radiation, Chemical Storage, Worker Exposure, and Recordkeeping

Federal Aviation Administration (FAA). LMG performed S&H inspections including monitoring for non-ionizing and ionizing radiation exposures at 18 radar and control tower sites. The overall purpose of inspection was to provide an independent, professional opinion regarding recognized deficient safety and health conditions.

Metro Regional Transit Authority (Akron, Ohio). LMG conducted a comprehensive Energy Source assessment including detailed field inspections for the Metro Regional Transit Authority (MRTA) operational buildings located in Akron, Ohio. Based on the assessment results, LMG wrote the Lockout/ Tagout (LO/TO) Program at MRTA’s bus maintenance facility. We also provided a detailed inventory of all energy sources and wrote specific additional safety procedures where needed.

Integrated Specialty Steel Plant. LMG conducted comprehensive EHS reviews of integrated specialty steel manufacturing operations in Ohio and Pennsylvania. These operations include the use of large natural gas furnaces, steel casting, pickling, and finishing. In addition, one site had a captive onsite railroad and wastewater treatment plant. The results of the S&H reviews were used by senior management to identify safety compliance and risk management issues.

Ceramics Manufacturer. LMG provided comprehensive S&H compliance assurance services to an Ohio-based manufacturer of ceramic components for electronic parts. This assistance included conducting an initial S&H compliance evaluation and management systems gap analysis. Based on the results of these activities, LMG developed an action plan for the facility and provided task-specific support for implementation of the plan. This support included updating safety programs and procedures for lock-out tag-out; provision of personal protective equipment; and conducting S&H training of personnel.

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Water/Wastewater Compliance

Metal Casting Operation. LMG provides ongoing regulatory compliance assistance for a metal casting operation in Ohio with both NPDES and POTW-permitted wastewater discharges. As part of these activities, we have negotiated to use laboratory results of split samples collected quarterly by the POTW authority resulting in an annual cost saving of $10,000. LMG also has prepared annual wastewater surveys and an NPDES permit renewal application for the casting operation.

Reinforced Plastic Composite Products Manufacturing. LMG provides ongoing NPDES permit storm water monitoring and reporting services for two reinforced plastic composite product manufacturing operations in Ohio. These services include monthly storm water sampling, completion of electronic DMRs, annual storm water inspections, and employee training.

Electro-Ceramic Manufacturing. LMG Developed a Total Toxic Organic (TTO) plan and SWPP plan for an Ohio electro-ceramic manufacturing operation with goal of obtaining No-Exposure Certification within 1 year

Metal Casting Operation. LMG Resolved NPDES oil & grease discharge issues at metal casting operation to eliminate non-compliance and obtain lower cost general NPDES permit coverage

Aluminum Extruding Company. LMG provided wastewater treatment consulting services for a major aluminum extruding company in Ohio. The project consisted of a technical, economic and regulatory evaluation of treatment methodologies for an existing caustic stripping line. The current configuration resulted in the generation of a hazardous waste stream (caustic). The final recommendation was a caustic recovery system that eliminated the hazardous waste stream, reduced caustic usage and scrubber water usage by >75%, and resulted in a non-hazardous filter cake.

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Waste Generator Assistance

Confidential Metal Parts Manufacturing Plant. LMG developed the technical design, acted as general contractor, and provided P.E. certification/oversight for the installation of a hazardous waste 90-day accumulation tank system for liquid acid wastes. The tank system was designed with multiple tanks to allow for potential segregation of acid waste streams for future recycling or resale. Installation of the AST system was completed in less than 2 weeks and the entire project was conducted in approximately 60 days.

Fiberglass Reinforced Plastics Operations. LMG is providing ongoing hazardous waste management assistance for two fiberglass reinforced plastics operations located in Ohio. The assistance includes managing all aspects of the facility solid, universal, and hazardous waste generation and onsite accumulation. These management activities include conducting required weekly inspections, tracking required follow-up actions, training personnel, and performing required internal recordkeeping.

Metal Casting, Medical Parts, and Plastics Manufacturing. For the past six years, LMG has prepared annual hazardous waste reports for metal casting, medical parts, and plastics manufacturing operations in Ohio. In 2004, these reporting activities were conducted electronically. In preparing the reports, LMG works directly with facility personnel to collect and validate data reported in the reports. This data is also typically reported to senior management in a summary format for cost tracking purposes.

Integrated Steel Plant. LMG prepared a Source Reduction Strategy (SRS) program required for submittal for an integrated steel manufacturer in Pennsylvania. As part of this project, we conducted a comprehensive review of more than 25 processes generating residual wastes to identify specific methods and procedures currently used or historically evaluated to reduce the generation or toxicity of the residual wastes. LMG then investigated potential additional source reduction opportunities that could be applied to the processes in the future. Finally, we assisted the client in the development of policies and procedures to encourage and reward source reduction and pollution prevention at the facility.

Metal-Related Manufacturing Plants. LMG has provided required annual hazardous waste generator training to employees at a specialty steel facility, piezoelectric ceramics manufacturer, aluminum extruder, and steel coating operation. The training sessions include plant-specific information and materials to ensure personnel are instructed on company procedures and policies not just regulatory requirements.

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Remedial Costing

Specialty Chemicals Manufacturing Plant. LMG was retained by the current owner of a specialty chemicals manufacturing plant to develop remedial cost estimates for soil and groundwater contamination issues undergoing agency oversight at the plant. In developing the remedial cost estimates, we reviewed historical information and investigation data to evaluate the probability that contamination at specific areas of concern (AOCs) were related to releases by the current owner’s operations. LMG then evaluated existing investigation and remediation cost information, identified alternative remedial options that could be more cost-effective, and developed independent costing information for comparison purposes.

This information was then modeled in reasonable and conservative future costing scenarios. The modeling of the costing scenarios incorporated the probability results and investigation/remediation costs in an excel-based remedial costing analysis that also used statistical processes and the net present value (NPV) of money. The results of the remedial costing efforts were used for public company SEC reporting and by attorneys to defend the company from legal actions for additional reimbursement for environmental cleanup actions taken at the plant by the historical owners/operators.

Vacant Metal Products Plant. LMG conducted a third-party evaluation of remedial costing for a former metal parts manufacturing plant with a historical anodizing line. The existing remedial costing was based on traditional demolition and excavation of the anodizing line and surrounding soil. LMG’s evaluation identified use of risk-based RCRA closure as a viable option for closure. The risk-based closure was estimated to provide expected savings of greater than $300,000 compared to prior engineering estimates. The client is currently working with Ohio EPA to complete the risk-based closure.

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RCRA Closure

Sign Manufacturing & Installation Company. LMG provided oversight, investigation, design, and project management for the successful completion of an Ohio EPA Consent Order associated with the closure of an unpermitted hazardous waste management unit at a sign manufacturing and installation company. Project activities included preparation of a Sampling and Analysis Plan (SAP), Remedial Action Plan (RAP), and management/oversight of the final closure remediation activities. LMG closure tasks included design of a cost-effective soil removal work plan that was approved by Ohio EPA, contractor oversight, final inspection and sampling of the area, and preparation of the final closure report.

Metal Products and Resin Manufacturing. LMG provided expert regulatory compliance assistance and project management for the successful completion of an Ohio EPA Consent Order associated with hazardous waste management at a metal products and resin manufacturing facilities in Ohio. Project activities included design and oversight of RCRA generator closures of 90-day accumulation areas at the facilities. LMG closure tasks included design of a cost-effective work plan approved by Ohio EPA, contractor oversight, final inspection and sampling of the area, and preparation of the final closure report.

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Environmental Auditing

Glass Manufacturing Company. LMG conducts annual comprehensive environmental, health, and safety (EHS) audits of the North American operations of a Fortune 500 glass manufacturing company. The EHS audits are conducted as part of corporate legal risk management procedures and involve coordination and follow-up with individual plants, corporate EHS staff, company general counsel, and outside counsel.

Metal Casting Foundry. LMG conducted a comprehensive environmental compliance review of one of North America’s largest metal casting foundries. The foundry’s operations included aluminum lost foam and grey iron/ductile sand casting with more than 150 air emission units, an onsite special waste landfill, and extensive wastewater treatment including settling ponds. The foundry is a Major Source of air emissions, significant NPDES discharger, and large quantity generator. We conducted this review under tight timelines and reported the results of the audits directly to in-house counsel.

Iron & Steel Plant. LMG conducted comprehensive E&S audits and Environmental Management System (EMS) reviews of an integrated steel manufacturing operations in Ohio and Pennsylvania. These operations include the use of large natural gas furnaces similar to Pilkington float plant. The results of the E&S audits were used by senior management to identify environmental or safety compliance and risk management issues. The EMS reviews served as a gap analysis for the facilities in anticipation of complying with the ISO 14001 standard.

Automotive Parts Supplier. LMG conducted a comprehensive environmental permit review of an automotive parts supplier in Ohio. As part of the review, LMG conducted an evaluation facility’s compliance with federal, state, and local environmental requirements. We then developed an overall action plan for the facility that was designed to implement corrective actions cost-effectively and consistent with the company’s internal policies and procedures. LMG also developed a simple Excel-based electronic environmental data management system to assist the facility with tracking and recordkeeping associated with various environmental aspects of its operations.

Fiberglass Reinforced Plastics Manufacturing. LMG conducted a baseline environmental compliance assessment of a fiberglass reinforced plastics facility prior to the acquisition of the facility by an investment group. The assessment included a detailed evaluation of documentation and facility operations associated with an air emission inventory calculations, NPDES and drinking water well permits, historical SARA reporting and waste management. Based on the results of the assessment, a number of pre-acquisition corrective actions were implemented. LMG is also providing ongoing compliance assurance services to the facility.

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