905R97021
   I .N. EPA Region 5
Waste Minimization
      Conference
         1997

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                                             Sponsored by
   UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
                                             REGION  5
                         Valdas V. Adamkus, Regional Administrator
         Norman R. Niedergang, Director,  Waste,  Pesticides and Toxics Division
                                           Presenters Include:
3M Company
A.T. Kearney, Inc.

Abbott Laboratories
Amerdec, Inc.
Amoco Corporation
Bowling Green State University
Cartwright Consulting Co.
Chicago  Mayor's Office
Chrysler Corporation

City of Cincinnati Office of Environmental
Management
ComAd Management Group, Inc.
Commonwealth Edison

Eastman Kodak Co.
Enviro Filtration, Inc.
Environmental Resources Management

Fluor Daniel Fernald
General Electric
General Services Administration
Harza Environmental Services, Inc.
Illinois EPA
Industrial Towel and Uniform
Iowa Waste Reduction Center,
University of Northern Iowa
Modern Technologies Corporation

Motorola, Inc.
PRC Environmental

PROCOR Technologies
RUST Environmental & Infrastructure
Sinclair Mineral and Chemical -
Better Engineering Manufacturing Rep.
Tennessee Valley Authority
U.S. EPA Region 5
U.S. EPA Headquarters
U.S. EPA, Waste Minimization Branch
University of Louisville
University of Wisconsin
University of Wisconsin Extension School

Viatec Recovery Systems, Inc.

Waste Management and Research Center
Wisconsin Department of Natural Resources

WRATT Foundation
                                           Exhibitors Include:
AlliedSignal Aerospace
Better Engineering Mfg., Inc.
Chemco Manufacturing Co., Inc.
Chemical Management Services, LLC
EnviroPure Solutions

EPI Electrochemical Products, Inc.
ERM - North Central, Inc.
Full Circle, Inc.
Graymills Corporation
Indiana Department of Environmental
Management
Industrial Towel & Uniform, Inc
Kinetico, Inc.

Modern Technologies Corporation
National Environmental Testing, Inc.
RUST Environment & Infrastructure
U.S. EPA
Versar, Inc.
Viatec, Inc.
State of Wisconsin's Environmental Assistance
Programs
                                             Coordinated by:
                           Janet L. Haff, Waste Minimization Coordinator
                                                  of the
                           U.S. EPA Region 5, Waste  Management Branch

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             U.S. EPA Region 5 Waste Minimization/P2 Conference
                                       for
                          Hazardous Waste Generators
                          PROCEEDINGS MANUAL


                                February 25-27, 1997



TABLE OF CONTENTS

Section

A.    List of Speakers  	 A-l

B.    List of Exhibitors	 B-l

C.    Short Biographical Sketches of Speakers and Corresponding Materials
      Submitted for Speaker Presentations
               Regretfully, this manual is not available on disk. Due to cost
               prohibitive production of such a manual and the difficulty in
               coordinating formatting issues with the volunteer speakers, we
               apologize that the manual can not be obtained electronically.

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                                                        SHWECi
         Extension  • University of Wisconsin—Extension
Pollution Prevention
Case Study
      Modine Manufacturing Company
       Racine, Wisconsin

      Zero Discharge Aqueous Cleaning Line
Industry; SIC Code




Process



Type of Waste


Strategies
Background
Motivation
Changes Implemented
Manufacturer of Heat Transfer Products for Vehicles, Heavy Equipment
Commercial Heating and Ventilating Products for Buildings; SIC 3714,
3583, 3442

Cleaning or degreasing of metal parts prior to assembly or painting.
Hazardous wastes and emissions from 1,1,1 TrichloroethanefTCA).

Eliminate the use  of TCA through implementation  of an aqueous
cleaning system. The  original strategy considered  a conventional
alkaline cleaning system with all gallon per minute(GPM) flow to
wastewater treatment. However after careful study it was determined
that a zero discharge cleaning system was feasible.

The Modine facility in Racine Wisconsin is the corporate headquarters
and manufacturing research and development cent.er for the corporation.
Extensive prototype work and testing is accomplished at the plant.
These processes require cleaning of sub-components before they are
assembled and or in some instances prior to painting.
The Modine Company used TCA as the cleaning agent to remove grease
and oils from parts in an open top vapor degreaser.

The Modine Company has a strong corporate commitment to reduce
waste and emissions wherever possible. In recognition of the costs and
issues associated with TCA it was decided to eliminate the chemical by
implementing an aqueous cleaning process.
The attached schematic demonstrates the general layout of the cleaning
system designed and built by company process chemists and engineers.
Evaporation is incorporated as part of the cleaning system and operates
on demand versus continuous operation. Incoming water is also on a
demand basis which is driven by the total amount of water consumed
during operation. Permeate from the filtration system is returned to the
cleaning tank. There is zero discharge from this cleaning system.

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Problems Encountered
Material/Energy Balance

Original Approach

Feedstocks
9,800 Ibs/yr TCA
Cooling Water

Wastes/Disposal
TCA 9,800 Ib/yr Emissions
Hazardous waste 55 gal/yr
Cooling Water Discharge

Economics

Operating Costs
TCA            $8,900
Cooling Water     $2,200
Chemical Disposal $ 550

Totals           $11,560

Capital  Investment
                $-0-

** Microftltration System Cost: $15,000

Energy Costs, in BTU/Hour
        Selecting the best filtration media for the process and the actual
        engineering and design of the filtration system was the most
        challenging task.  Other consideration were selection of the cleaning
        chemical and achieving the supply/consumption balance for water
        needed to operate the system.
Considered Approach
        Zero Discharge System
        Feedstocks
        275 gal/yr Alkaline Cleaner
        Process water

        Wastes/Disposal
        990 gal/yr Cleaner/Water
        15,840gal/day Wastewater Treatment
        Sludge Unknown Ib/yr
               Feedstocks
               55 gal/yr Alkaline Cleaner
               Process Water

               Wastes/Disposal
               0 gal/yr Cleaner/Water
               0 gal/yr Wastewater Treatment
               0 Ib/yr Sludge
        Operating Costs
        Alkaline Cleaner
        Process Water/Disposal
        Chemical Disposal
                Unknown
$ 750
$8,700
$5,400

$14.850
                               $18,510
                               577,980
Operating Costs
Alkaline Cleaner
Process Water/Disposal
Chemical Consumption
$150
$115
>$150

$415
                                       $59,950**
                                       110,480
Approximate Payback
Based upon a minimum annual savings of $14,435 experienced in operating costs only, the payback period
on $59,950 capital investment is 4 years. However this payback period does not include cost savings for
labor, avoided costs for handling wastes, reduced time for reporting emissions and hazardous waste and
the liability that was eliminated because there is no accountable waste from the zero discharge system.

Other Minimization Activities Modine Manufacturing has had an aggressive and very effective waste reduction
program for several years. The "ShrinkingDrum" is awarded to each facility that achieves the waste
reduction goals which are established by that facility. The Corporate Headquarters in Racine leads this
program by testing new pollution prevention/waste reduction measures such as the zero discharge system,
before they are implemented  in the field.
Company Address
Contact Person
        Modine Manufacturing Company
        1500 Dekoven Avenue
        Racine, Wisconsin 53403
        Mr David Peterson, Process Chemist, 414-636-1253
        Mr Edward Besaw Environmental Engineer, 414-636-1396
                               FAX 414-636-1424

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Additional Publications           SHWEC Publications
Available                     Pollution Prevention: A Guide to Program Implementation.
                            Industrial Cleaning Source Book.
                            Waste Reduction Assessment for the Fabricated Metal Prod. Ind.
                            Closed Loop Metal Finishing, factsheet.

                            Department of Natural Resources Publications

                            Contact the Wisconsin Department of Natural Resources,  Pollution
                            Prevention Clearinghouse, P.O. Box 7921, SW/3, Madison WI 53707,
                            for a Publications Order Form, # PUBL-SW-199, or call 608/267-9700.
                            Suggested publications include:
                            Aqueous Industrial Cleaning Chemicals, # PUBL-SW-147.
                            Aqueous Parts Washing Equipment, # PUBL-SW-148.
                            Guides to Pollution  Prevention,  The Metal Finishing  Industry,
                            EPA/625/R-92/011
                            Guides to Pollution  Prevention, The  Fabricated Metal  Products
                            Industry, EPA/625/7-90/006.
                            Facility Pollution Prevention Guide, EPA/600/R-92/088.

Other Pollution Prevention         Free, Nonregulatory, On-site Technical Assistance
Resources Available              University of Wisconsin-Extension
                            Solid and Hazardous Waste Education Center
                            Pollution Prevention Specialists
                            Area Code 414 call the Milwaukee Office at 414/475-3371
                            Area Code 608 call the Madison Office at 608/262-0385
                            Area Code 715 call either Madison or Milwaukee for assistance.
                            To learn more about on-site assistance programs call SHWEC at either
                            office listed above  and ask for "Understanding Pollution Prevention
                            Assessments", a factsheet which explains SHWEC! on-site assessments.


             For More Information, Contact Your County Extension Agent

Call the University of Wisconsin-Cooperative Extension Office in your County. Ask for the Community
Natural Resource and Development (CNRED)  Agent.  The CNRED agent can provide  information
concerning local community resources as well as  information  available from SHWEC pertaining  to
recycling, solid waste management, yard waste, composting, household hazardous waste and industrial
pollution prevention.

Other SHWEC Offices

UW-Green Bay                    UW-Stevens Point
University of Wisconsin              College of Natural Resources
Environmental Science 317           University of Wisconsin
2420 Nicolet Drive                  Stevens Point,  Wisconsin 54481
Green Bay, WI 54311                715/346-2793, FAX 715/346-3624
414/465-2707, FAX 414/465-2143

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    Zero Discharge Cleaning System

    Modine Manufacturing Company
                 Provided by

               David S. Peterson
                    and
               Edward L. Besaw
          Current System
Microfiitration System
  ollection,
   aporatiou
   Tank
                  No wastewater discharge
                       to WWTS
      Minimum  System Required
                    11 gpm to
                      drain
           Alkaline
           Cleaner
 Rinse
(Heated)
Total 15,840GPDto
    WWTS)

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   ^/dilution
   retention
    Case Study
                 APV  Crepaco
                                     Machining Fluid Waste Reduction Program
Industry/SIC Code


Company Background
Original Process
Pollution Prevention
Process
Equipment for food processing, pharmaceutical, cosmetics
and chemical Industries/3556

APV CREPACO is a 650-employee company manufacturing
equipment for the food processing, pharmaceutical,
cosmetics and chemical industries. It operates a large metal
fabrication shop in Lake Mills employing 300 machinists
using over 130 machine tools to fabricate equipment from
ferrous and nonferrous stock.

APV CREPACO uses metal working fluids as coolants and
lubricants for machining ferrous and  non-ferrous metals.  In
1993 the company  began experiencing serious problems with
its machining fluid management system. Although the
existing mediod of fluid management was; well within
regulatory guidelines,  the system was generating problems
with product quality due to excessive fluid usage and
disposal.  There were  also employee  health problems
resulting from contact dermatitis caused by spoiled fluids.

During 1993 APV  CREPACO employees founded the
"Missing Link" machining fluid management team and began
an organized effort to  develop a machining fluid
management program  to reduce waste and eliminate health
problems.  The team was made up of seven members
representing die employee groups that used or managed the
fluids (i.e.,  machinists and maintenance personnel).  The
team began by defining the nature of the machining fluid
problem, first as a small group,  and then by applying
statistical analysis of the input of other  employees  in the
facility. The team men identified the following problems
related  to the machining fluid system: the use of obsolete
fluid formulations; poor mixing  water quality;  lack of quality
control over fluid concentrations; cross  contamination
between fluid types; bacterial and fungal contamination of
fluids;  and machining  fluid recycling equipment diat was
inoperative.
    Wisconsin Department of Natural Resources  •  Office of Pollution Prevention

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The team members then made use of a number of
educational opportunities, including vendor videos and
UW-Extension teleconferences, to learn more about coolant
management and waste reduction.  They put together a list
of possible solutions to the machining fluid problems and
surveyed other employees for both additional suggestions and
to encourage project ownership by non-team members.
Based on their research and findings, the team implemented
a number of waste reduction options and used outside
vendors and the UW-Extension Solid and Hazardous Waste
Education Center to review progress and make additional
recommendations. These options include:

•     Using best available fluid formulations to extend fluid
      life
•     Reducing the numbers of fluid types to two,
      simplifying recycling
•     Improving mixing water quality to avoid fluid
      degradation
•     Adding external sumps  and reservoirs with skimmers
      to maintain fluid quality
•     The creation of machine clean-out and a fluid
      recycling schedule to eliminate equipment
      contamination and unnecessary fluid disposal
•     Improvement of ease of fluid level monitoring to
      simplify fluid maintenance  and minimize unnecessary
      fluid change-out
•     Training machinists to measure fluid quality to insure
      ongoing fluid quality
•     Tracking of fluid waste generation to identify problems
•     Labeling materials to avoid cross contamination
•     Brought the fluid recycling equipment up to operating
      specifications
•     Development of standard operating procedures for
      fluid use, recycling, and disposal.
                                             &
The team conducted employee training sessions to,insure that
the new fluid management program would be accepted by
the machinists and be integrated  into normal duties.  The
team insured the long term  viability of the fluid management
program by:  calculating the financial gains and reduced
waste resulting from their efforts; making a presentation to
             -2-

-------
Material/Energy
Balance
Economics
Benefits
Obstacles
company employees and management to explain the program
and underscore the importance of their accomplishments; and
making recommendations for ongoing management and
machinist support of the new fluid management program.

Original Process
     Feedstock
     Soluble oil type grinding and cutting fluids*,

     Waste
     Spoiled coolant and waste machine cleaner.
     50,000 gallons/year of machining fluid was being
     disposed of as waste.

     Disposal
     Hazardous waste was removed by  a waste management
     company.

Pollution Prevention Process
     Feedstock
     Synthetic grinding and cutting fluids*,

     Waste
     24,000 gals/year of used coolant.  New fluid purchases
     have been reduced by 60%.

     Disposal
     Hazardous waste is removed by a waste management
     company.   Waste machining fluid  disposal has been
     reduced by 50%.

The company was originally spending over $75,000/year on
new fluids and fluid disposal.  Ongoing annual cost savings
of $54,000 (a 70% reduction).

As a result of the changes implemented,  cases of dermatitis
attributed to spoiled fluids have been eliminated.  The
improved fluid quality has also reduced tooling wear and has
improved product quality.

Organization and education of machine operators.
                                         -3 -

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Technology Transfer
Pollution Prevention
Resources
The team has transferred the lessons learned from their
experience to others by providing tours of their facility to
other companies with similar problems and their experiences
have served as a machining fluid management model for
other metal fabricators in Wisconsin.

Company Address
APV CREPACO
100 South CP Avenue
Lake Mills, Wisconsin 53511

Company Contact
Kevin Q. Johnson
414/648-8311

Free, On-site Technical Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385

Pollution Prevention Information  Clearinghouse
Wisconsin Department of Natural Resources
Hazardous Waste Minimization Program
608/264-8981, 608/264-8852, 608/267-9523 or
608/267-3763
                                            Prepared by the Office of Pollution Prevention
                                            Wisconsin Department of Natural Resources
                                                          P.O. Box 7921
                                                        Madison, Wl 53707
                                                          608/267-9700
                                       Printed on Recycled Paper
                                           PUBL-TS-036 95
                                        -4-

-------
               Office of Technical Assistance
               Executive Office of Environmental Affairs
               Commonwealth of Massachusetts
   Toxics Use Reduction  Case  Study
                          • t
          COOLANT MANAGEMENT AT BELOIT
                           CORPORATION

    SUMMARY

    Beloit-Jones Fiber Finishing Systems Division of Beloit Corporation in Dalton, MA,
replaced the water-based coolant used in its metalworking operation with a mineral oil-based
coolant. This change has nearly eliminated the dumping of spent coolant due to rancidity caused
by tramp oil accumulation.  Beloit expects that the change will save it more than $88,000 in
associated machine tooling costs. This amounts to cutting costs by 28% in the first year and 32%
in succeeding years.

    BACKGROUND

    Beloit Corporation employs nearly 400 people at its Fiber Finishing Systems Division,
which manufactures heavy machinery for paper mills, designs paper mills and factories, and
rebuilds old machinery. In the manufacturing process, metal stock and large castings are placed
in CNC machines, lathes and milling machines to be cut into the required shape. The cutting tools
on the machines are flood-cooled to reduce heat and increase lubricity. Every two weeks the
coolant becomes rancid due to bacteriological growth. Tramp oil floating on the top of the sump
prevents aeration, resulting in the flourishing of anaerobic bacteria. This requires that the sump
be emptied, the coolant filtered in  a central area, and the sump recharged. Additionally, the
machine operators experienced dermatitis due to contact with the coolant

    TUR PLANNING

    The coolant at Beloit had many drawbacks: short life, high disposal costs, poor lubricity
and skin irritation problems. Plant  Engineering Manager Paul Norcross, togeiJier with the  tool
room and maintenance supervisors, began looking for alternatives which would remedy these
problems.
    The first step was to invite representatives from five coolant manufacturers to run tests on
machines within the plant. Beloit chose three milling machines which are used to manufacture
identical stainless  steel pans. The substitute coolant used in" the first machine produced
immediate results. The operator's skin irritation ceased and the cutting tool ran two to three times
longer between changes. After three weeks, the coolant remained unaffected by tramp oil.  The
other two machines were changed over to different coolants, but dermatitis and poor cutting  tool

-------
 life problems persisted.
      By the 75th day of the trial, other operators were clamoring for the coolant used on the first
 machine and all other testing was terminated.  The other 37  cutting machines were then
 systematically switched over to the new coolant with similar positive results, (it was found that
 the new coolant produced poor results in the grinding area.)

     TUR MODIFICATIONS
                    {
     The change required no operator retraining in order to implement Maintenance operators
 are required to check coolant concentration and make-up levels. An oil skimmer for the tramp
 oil was added to the sump of each machine which did not already have such a skimmer, in order
 to achieve the maximum benefit from the coolant The new coolant has eliminated dermatitis
 problems and increased tool life with no apparent need for disposal, thus reducing maintenance.
 Operators have been able to increase machine feed rates, yet even with the increased tool use,
 the savings potential in tool costs is around 24%, and finished surface quality has improved
 dramatically.

     RESULTS

     Reductions Achieved:  Beloit no longer has to dispose of spent coolant, and this has
 reduced the amount of hazardous material which is disposed of off-site.

     Economics: Equipment costs for the wheel skimmers, which were manufactured in-house,
 amounted to $9,000. The new coolant costs $1134 per gallon, an increase of 47% over the old
 coolant However, reduced disposal costs and make-up for spent coolant saves Beloit $ 18,000
 annually.  While difficult to quantify due to a wide variety of operations and materials,
 maintenance time and costs for the coolant has been reduced. Tool life  has been extended by
 two to two-and-a-half times that achieved with the old coolant  Machine  feed rates have
 increased at a similar rate (from 7 in7min. to 18 in7min.), more than doubling productivity.
 These factors combine to yield a savings of $61,200 (24%) annually in cutting tool purchases.
 Overall, this project generated savings of more than S88.000 of 1991.
     Ifsis caststutfy is one. ofa.sc.nes ofsucfi documents prepared By tfie Office, of 'lunnitaL'Assistance. (OTR.),
a. kronen oftne Massncfuisttts "Executive. Office. cf&ivironmcntatAffauy whose mission, is to assist industry
in reducing the use aftcn&c. c&cmrfif* and/or the generation afttrxjc manufacturing Syprocfucts. C?I%. 'snon-
regulatory services an ava&iSU. atno charge to Massachusetts businesses andinstitutians that use. topics.
for further information a£out this or other cast, studies, or aSout CfEA. s technical services, contact: Office
of Technical Assistance, Executive Office of Environmental Affairs, 100 Cambridge Stree.
Boston, Massachusetts 02202, orpfume Ctt. at(6J7) 727-3260.

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                                         EPA/600/R-95/070
                                         May 1995
  POLLUTION PREVENTION POSSIBILITIES
FOR SMALL AND MEDIUM-SIZED INDUSTRIES

        Results of the WRITE Projects
                   by
               Ivars J. Licis
     Pollution Prevention Research Branch
     Risk Reduction Engineering Laboratory
            Cincinnati, OH 45268
RISK REDUCTION ENGINEERING LABORATORY
 OFFICE OF RESEARCH AND DEVELOPMENT
 U.S. ENVIRONMENTAL PROTECTION AGENCY
          CINCINNATI, OH 45224
                                      Printed on Recycled Paoer

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NEW JERSEY

        Seven technologies were evaluated under the New Jersey contingent of the WRITE program.
The projects were performed with the help of the New Jersey Department of Environmental Protection and
Energy (NJDEPE, Project Officer, Norine Binder) and the New Jersey Institute of Technology (NJIT,
Project Officer, Daniel Watts). The EPA Project Officer was Johnny Springer Jr.


#23 MOBILE ONSITE RECYCLING OF METALWORKING FLUIDS


Participants

        The hosts for the evaluation were three, small-to-medium sized machine shops in the
Philadelphia, PA, area (known to EPA only as E1, E2, and S1). The Safety-kleen Corporation of Elgin,
Illinois  was the vendor, providing the metalworking fluids and operating the mobile, on-site recycling units.
Battelle, Columbus Laboratories helped design the test program, supplied test personnel and equipment,
and wrote the draft report.


Technology/Testing

        Safety-Kleen provides metalworking fluid recovery services to a variety of businesses, primarily
those that generate relatively small quantities of fluid waste.  The mobile service performs the recycling on
the generator's property, thus eliminating the need to transport potentially hazardous waste.  Each mobile
truck-mounted unit, operating on its own power, is capable of processing fluid at a maximum rate of 300
gal/hr.

        The recycling process (Figure 1) consists of filtering, pasteurizing, and centrifuging the spent fluid.
The fluid is first sent through a 100-b filter to remove any large particulates.  It is then pumped through a
preheater and then a heat exchanger to kill bacteria and fungi, as well as to reduce fluid viscosity.
Centrifuging to separate tramp oil and other debris from the usable fluid, is next. Additives are then
incorporated into the fluid to restore performance.  In the final step, the fluid flows through a 1-(3 filter to
remove any remaining particulates.

        The technology was evaluated at three small-to-medium sized machine shops (sites) in the
Philadelphia, PA, vicinity. The three sites were chosen from among Safety-Kleen's customer base.  Two
of the sites (called E1 and E2) used emulsion-type metalworking fluids.  The third site (called S1) used a
synthetic fluid.

        At each site, one sample each of the spent, recycled, and virgin fluids (at their normal use
concentrations) was collected and subjected to a series of tests.  The comparison were then made
between the virgin, spent and recycled fluids.

        The accumulation of very small particulates over time and use could limit the number of times a
given batch of fluid could be recycled. Conductivity of the samples was measured as an indicator of the
dissolved solids levels in the fluids.

        Users of metalworking fluid often monitor the pH as an easily measured indicator of fluid quality.
A change  in pH may indicate chemical degradation or degradation due to microbial growth. The  recycling
process seeks to restore pH to a range of 8.5 to 9.5. This alkaline pH improves emulsion stability and
corrosion resistance characteristics of the fluid.
                                              106

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    Vacuum
     Hou
1 SO Mem
                                                                                         Racircutato:
Fluid
Holding
Tank
1

                                                                                      Injections
Fluid Test
Pass
fc»/
                 CWiBOW
                   Mtett
                   Vm

To
Centrifuge
Bypass
Centrifuge
                       Figure 1. Metalworking fluids recycling system flowchart
        The main purpose of metalworking fluids in machining operations is to provide lubricity and
cooling without causing corrosion or other problems.

Results:

        Degree of removal of non-dissolved and dissolved particulates during recycling is shown in
Table 1.  High concentrations of these particulates affect tool life, surface finish, and chemical
breakdown. Particulates also provide substrates for microbial growth. At all three sites, the results
showed considerably lower concentrations of nondissolved particulates in the recycled fluids (E1-R, E2-
R, and S1-R) as compared with concentrations in  the spent fluids (E1-S, E2-S, S1-SO).

        Dissolved solids levels remained approximately the same after recycling, which indicated the
effect of contaminant precipitation and fresh additive introduction. At the three sites tested, the pH of
the recycled fluids was returned  to a range between 8.5 and 9.5.
                                               107

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        Corrosion characteristics are important parameters for water-based metalworking fluids because
of their effect on workpiece quality and tool life. The results of the iron chip corrosion test (ASTM D4627)
on the virgin samples (E1-V, E2-V, and S1-V) showed that E1-V and S1-V generated no rust at the use
concentration (approximately 5% solution of the concentrate in tap water).

        Tramp oil is the nonemulsified floating oil that builds up in metalworking fluid sumps from sources
such as leaking equipment seals (hydraulic oils, gear oils) or from the workpiece itself. No phase
separation was noticed in any of the recycled samples, indicating the tramp oil had been removed.


                        TABLE 1. ANALYSIS OF NON-DISSOLVED SOLIDS

                                Non-Dissolved Solids Concentration
                          	(mg/100mL)a	
            Sample No.            Total               Inorganic          Dissolved Solids
                                                                        (Conductivity)
                                                                         umhos/cm2
E1-S"
E1-R
E1-V
E2-SB
E2-R
S1-S
S1-R
S1-V
79.10
22.55
3.55
12.55
5.60
33.80
17.00
5.18
27.25
1.45
2.50
0.50C
3.00
14.50
1.95
0.78
2,400
1,810
700
1,820
1,750
1,450
1,460
1,930
        * By ASTM D 2276. Particulates smaller than 8 microns
        b Analyzed skimming off and discarding the floating tramp oil  E1 -S=spent emulsion, site 1,
        E1-R=recycled emulsion, site 1; E1-V=virgin emulsion, site 1; etc
        c Possible inhomogeneity giving a low value.


        The results of emulsion stability testing at elevated temperature showed small amounts of phase
separation in spent samples E1-S and E2-S.  The recycled samples remained as a single phase even
after 96 hrs, indicating that emulsion stability had been restored during recycling.

        Foaming can reduce effective film strength, reduce heat transfer, and interfere with the settling of
metal fines.  Tendency of the fluids to foam was tested by ASTM D 892-89. Foam volume in the recycled
samples (E1-R, E2-R, and S1-R) was significantly higher than that in the spent or virgin samples. This
can be attributed to introducing fresh emulsifier (surfactant) during recycling. A correction can be made
for this effect by adding an antifoam  agent during reycling.  Safety-Kleen, however, does not add an
antifoam agent unless the user specifically reports a foaming problem.

        At all three sites, the recycled and virgin fluid viscosities were very close. This indicated  that the
recycling process had restored this parameter. The viscosity measurements also indicated that the
recycling process succeeded in returning the fluids to the required use concentration (oil/water ratio).
                                               108

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       Lubricity and wear preventive characteristics of a metalworking fluid affect workpiece quality and
tool life. Lubricity and wear characteristic were measured by the standard "four-ball test" (ASTM D 445).
For Site E1, the recycled sample caused a much lower average scar diameter than did the spent sample,
but not as low as the virgin sample. This indicated that the recycled and virgin samples performed about
the same. The presence of some emulsified tramp oil could have improved the lubricity results of the
spent sample E2-S.

       A major factor in metalworking fluid spoilage (rancidity) is microbial growth. In the recycling
process, existing microbes are killed during the pasteurization step, the dead biomass is removed during
the centrifugation step, and a measured quality of biocide is added to control future microbial growth.
ASTM E 686-85 evaluates the effectiveness of biocides at use concentrations.  No microbial growth was
observed in the samples up to 6 weeks after recycling.

       Currently, there are no published standards for recycled  fluids. Each user establishes
requirements based on the same factors used in selecting a virgin fluid.  At the three test sites evaluated
in this study, recycled fluids appeared to satisfy the functional requirements of the  users.

       On an average, Safety-Kleen  visits each user once every 10 weeks and recycles 250 gallons of
spent fluid per visit, thereby yielding a potential annual reduction  of 1250 gallons for a typical small user.
Approximately 4 gallons of tramp oil per visit are generated during recycling. The tramp oil1 is hauled away
at a competitive fee by Safety-Kleen for use as supplemental fuel.  Residue generated on the filters
(mostly metal chips) is transferred to the user's waste metal bin and later reclaimed for its metal value.

       According to a 1991 study by  the Independent Lubricant Manufacturer's Association, the volume
of metalworking fluids (concentrate) manufactured in the United States, has increased from 67 million
gallons in  1985 to 92 million gallons in 1990. By extending the life of metalworking fluids through onsite
recovery, considerable amounts of fluid can be prevented from going to waste. The total volume of fluids
going to waste, may be significantly higher than the manufacturer volumes (as much as 20 times higher.in
some cases) since many types of fluids are diluted into 3% to 5% solutions with wate?r.

       The economic evaluation compared costs for recycling versus costs for disposal. Recycling costs
included the onsite service charge  for the customer and tramp oil disposal cost.  Disposal costs included
spent fluid disposal cost and hazard analysis costs.  The annual  savings for a typical small user, who
recycles 1,250 gallons/yr of metalworking fluid was approximately $1,600 if the spenl fluid was
nonhazardous, and $7,800, if the spent fluid was hazardous (by the Toxicity Characteristic Leaching
Procedure).

       This evaluation found that  recycling of metalworking fluids is a good option for small-to medium-
sized plants with machining operations.  In the absence of published standards for recycled fluids quality
and performance, the user has to evaluate the recycled product by the same criteria used to select a virgin
brand. Direct, extended time testing of tool life and work piece quality vs. recycled fluid characteristics
may be desirable to establish recycled fluid standards.
       The full report, titled "Mobile Onsite Recycling of Metal Working Fluids" by Arun Gavaskar, et al.,
is available as report no. EPA/600/SR-93/114.
                                               109

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#24 A FLUID SORBENT RECYCLING DEVICE FOR INDUSTRIAL FLUID USERS


Participants

       The  host for the evaluation was Cook's Industrial Lubricants Incorporated of Linden, NJ who is a
custom blender of industrial lubricants. Battelle, Columbus, Laboratories supplied test personnel and
equipment, and wrote the draft report.


Technology/Testing

       In the process of mixing, handling, and packaging of fluids, spills occasionally occur.  At the end-
users's sites, the fluids may be spilled or cutting oils splattered during their use in the machining process.
Currently, the spilled or splattered fluid is removed by hand with sorbent pads made of melt-blown
polypropylene. Workers simply lay the pads over the spilled fluid and mop the spilled areas.  Once the
pads are saturated with fluid, they are drummed for disposal.

       During the evaluation the Extractor™, manufactured by Environmental Management Products,
was used to  recover the spilled fluid from the saturated sorbent pads.  The Extractor™, recovers the fluid
by compressing the pads between two gear-driven counter-rotating rollers. The desaturated sorbent pads
are then reused several times until the quality of the pads degrades.

       The  two types of waste considered in this study were the spent sorbent pads themselves and  the
waste fluid adsorbed. The current practice of once through use was compared to desorption and
recycling. The roller compression method extracts the sorbed fluid and permits reuse of the pads.
Although the extracted fluid is contaminated with the dirt and debris picked up during the spill, it may be
processed for reuse. Therefore, this technology reduces the number of sorbent pads used and the
volume of sorbent pads and fluids sent to disposal.  Additionally, there is potential for reprocessing and
recycling the desorbed fluid.

       The  extraction efficiency test  (ASTM Standard Method F726-81) was used to determine the
number of extraction cycles a sorbent pad could endure before becoming unusable due to tearing,
deforming, and other general deterioration. The test was also used to examine the rate of decrease in the
pads' sorbing capacity (or adsorbency ratio)  and the percentage of fluid to be removed by roller
compression. Because fluid removal  is dependent on the fluid viscosity, tests were conducted with three
different fluids covering a range of viscosities.

       The  correlation of performance of the sorbent pads vs. the number of cycles through the
extraction process was investigated.  To determine product performance, both quantitative and qualitative
aspects of pad degradation were examined. Pad degradation was quantified using the rate-of-release test
(ASTM Standard  Method F716-82).

       The  Maximum Practical Pickup (MPP) and  Maximum Effective Pickup (MEP) of  new pads were
compared with those of pads that had passed through the Extractor™ four and eight times, respectively. If
the used  pads had a different rate of release, the test indicated degraded pad performance.

       The  ability of sorbent pads to leave a clean floor after use was measured by the  fluid pickup test.
The percentage of pickup by a new pad was compared with that of recycled pads.
                                              110

-------
        The average adsorbency ratio and extraction efficiency for low viscosity fluids Is plotted against
the number of extraction cycles In Figures 1 and 2.  The average adsorbency ratio 13.99 g to to 14.79 g
of fluid per g of dry weight of pad.

        The results of the rate-of-release tests are given in Table 1.  The MPP and MEP of the fresh pads
for the low-viscosity fluid were 6.19 and 5.21 g/g, respectively. The decrease in MPP was 23.6% and
28.9% for pads reused for four and eight times, respectively, and the decrease in MEP was 24.8% and
31.1%, respectively.

        Although the pad performance was degraded by approximately 25% after four uses, the
degradtion in performance was relatively insignificant for 4 additional uses.  For the medium and high-
viscosity fluids, the MPP and MEP were measured only for the fresh sorbent pads.

        The results of the fluid pickup tests are presented in Table 2.  Regardless  of fluid types, the
sorbent pads effectively removed fluids from the floor.  Only 2.4% to 5.2% of the spilled fluids were left
on the floor.  Moreover, the sorbent pads effectively removed low and medium-viscosity fluids even after
they were reused four or eight times.

        The objective of comparing  costs of pad disposal versus reuse was met by using fluid capacities
and process time measured during the study and supplemented by  literature and  company hitorical
data.  Fow low-viscosity fluid, substantial savings occurred as a result of pad recycling. Savings of up to
51.4% and 75.3% were possible with as few as two and as many as eight reuse cycles, respectively.
Additional savings  were also possible, but much less significant, as reuse cycles increased to more than
eight times. Similarly, the cost per use was greatly reduced, from $4.80 for single use to $1.19 for eight
uses (see Figure 3).  For medium viscosity fluid, the annual pad recycling savings were 50.5% and the
per use cost was $2.38 for two uses.  Additional uses and savings are very unlikely because the sorbent
pads became severely separated and  deformed  as a result of the extraction process.
               16
               IS  —
               14  —
               11  —


               10


               9  -


               8  _
Four extract-on cycles

Eight extraction cycles
    Hi	-_«_
                                               i       I       I
                                               456

                                              Extraction CYC!*
                          Figure 1. Absorbency ratio for low-viscosity fluid

                                               111

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              80  —'
               78
               76
               74
                                                            • Four extraction cycles

                                                            • Eight extraction cyciai
                                                   4        5


                                                 Extraction cycle
                           Figure 2.  Extraction efficiency for low-viscosity fluid
              TABLE 1. MAXIMUM PRACTICAL PICKUP AND MAXIMUM EFFECTIVE PICKUP
Pad
condition
Fresh



Extracted
four
times

Extracted
eight
times

Fresh



Fresh



Fresh



Fluid
viscosity
Low



Low



Low



Medium



Medium



High



Pad
texture
Unpleated



Unpleated



Unpleated



Unpleated



Pleated



Unpleated



Pad no.
1
2
3
Average
4
5
6
Average
7
8
9
Average
10
11
12
Average
108
11B
12B
Average
19
20
21
Average
Fluid
sorted at
saturation
(fl)
346.54
360.28
350.83
325.55
255.95
203.96
195.71
218.54
194.06
195.57
197.65
195.76
445.65
447.36
452.59
448.53
306.25
292.09
303.41
300.58
444.54
417.91
392.16
418.20
Time to
"stop"
dripping8
(min)
120
120
120
120
120
120
120
120
>120
>120
>120
>120
>120
>120
>120
• >120
>120
>120
>120
>120
120
120
120
120
Maximum
effective
*&
5.55
6.57
6.45
6.19
4.51
4.62
5.07
4.73
4.42
4.34
4.45
4.40
11.82
11.18
11.75
11.58
7.78
7.80
7.81
7.80
13.67
13.54
13.68
13.63
Time to
"stop"
dripping0 with
fan on (min)
61.0
61.5
62.0
61.5
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.0
60.9
60.9
60.9
60.9
Maximum
effective
pickup
to/8)
4.69
5.57
5.37
5.21
3.90
3.75
4.13
3.92
3.58
3.47
3.58
3.54
9.19
8.58
9.36
9.04
6.86
6.96
6.95
6.92
12.14
12.19
12.38
12.24
* At the end of the time recorded, dripping continued at a rate of more than 5 to 15 drops/min.
° Maximum Practical Pickup « Fluid sorbed at the end of 2 hr/sorbent pad dry weight.
  Maximum Effective Pickup » Ruid sorbed at the end of 1 hr with fan on/sorbent pad dry weight.
                                                   112

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                          TABLE 2. FLUID PICKUP BY SORBENT PADS
                                                               Fluid pickup (%)
                                                    Replicate No.  /pad No.
Fluid
viscosity
Low



Medium0



High


r, P3-d.
Condition
Fresh
4Xa
8Xb

Fresh
4X
8X

Fresh
4X
8X
1/28
96.4
93.2
94.2
1/31
97.1
97.5
95.8
1/34
100
N/A
N/A
2/29
98.2
97.2
95.8
3/32
96.2
94.1
93.8
2/35
94.2
N/A
N/A
3/30
98.2
96.2
95.8
3/33
97.5
94.2
99.5
3/36
100
N/A
N/A
Average
97.6
95.5
95.3

96.9
95.3
94.8d

98.1
N/A
N/A
'        Pad extracted four times.
b        Pad extracted eight times.
c        For all medium-viscosity fluid tesfs, pads were soaked at 50% pad sorbing capacity before extractions.
d        Based on the performance of Pads No. 31 and 32 only.
        N/A = Data not available because pad could not pass through Extractor™

        Because the capital cost for the Extractor™ was relatively insignificant ($699) and the annual
savings would  be substantial, the payback period of the investment would be only 2.8 to 5 weeks.

        The sorbent pad recycling  evaluation demonstrated that roller compression technology can be
effectively used to extract low and  medium-visocsity fluids from meltblown polypropylene sorbet pads.
The Extractor™ is particularly useful for low-viscosity fluid applications; the sorbent pads can be reused at
least eight times.  For medium-viscosity fluids, no more than two to three reuse cycles are possible.  The
potential to reduce waste by recycling sorbent pads can be substantial.  For example, for a  1,858-m2
(20,000-ft2) plant, annual sorbent pad consumption can be reduced from 3,600 pads to 1,800 or 450 if the
pads can be reused for two or eight times, respectively.  Correspondingly, the number of drums for
disposal of pads would be reduced from 24 drums (assuming 150 oil-saturated pads per drum) to 6.5 or
1.6 drums (assuming 275 desaturated pads per drum). The 14 to  16 drums of waste fluids extracted from
the sorbent pads would be processed for reuse or hauled away for disposal at a waste-to-energy facility.

        The economic benefits of the roller compression technology were substantial. The use of the
Extractor™ by  shops and plants  that handle and/or use various oils and fluids would result in annual
savings of 51 % to 75%.  The savings  come primarily from the lower disposal costs for spent pads.
Further savings may be possible if exracted fluids can be recycled. The per use cost of sorbent pads can
be significantly reduced from $4.80 for a single use to $1.19 or less for eight or more reuse cycles.


Report
        The full report, titled  "A Fluid Sorbent RecyclingDevice for  Industrial Fluid Users" by Abraham S.C.
Chen, et al., is available as EPA/600/SR-93/154.
                                               113

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          Todd Balzer
          Jack Smith

Modern Technologies Corporation

-------
                           BIOGRAPHIES
Todd Balzer
Todd is Business Development Manager for the Environmental Technologies Division of
Modern Technologies Corporation in Dayton, Ohio. Todd is responsible for sales and
marketing activities of MTC's software and consulting services. Todd holds a Bachelor
of Science degree in Industrial Management from University of Cincinnati and is a
Certified Hazardous Materials Manager.  He has been in the environmental services
industry for nearly ten years and has worked for Rust Remedial Services, Chemical
Waste Management, Maecorp, and CECOS International.
Jack Smith
Jack is a Lead Environmental Analyst with Modern Technologies Corporation in Dayton,
Ohio where he is involved with EH&S software implementations and consulting to
industry and government. Jack received a Bachelor of Science in Hazardous Materials
Management from the University of Findlay and is currently working toward a Master of
Science in Environmental Management also from Findlay.

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   Peter S. Cartwright





Cartwright Consulting Co.

-------
         BIOGRAPHICAL INFORMATION FOR PETER CARTWRIGHT
       Born December 2, 193 7

•      Education:    University of Minnesota, Minneapolis, MN
                    B.S. Chemical Engineering -1961

•      Registered Professional Engineer in: Minnesota, Pennsylvania, Vermont

•      Entered the water/wastewater treatment industry in 1974

•      Self-employed consulting engineer since 1980

Peter Cartwright  specializes  in  technical  consulting  for environmentally  conscious
manufacturing processes for water purification, wastewater treatment and  food/chemical
processing applications. His expertise includes such high technology separation processes as
reverse osmosis,  ultrafiltration, microflltration,  electrodialysis,  deionization , carbon
adsorption and ozonation & other disinfection processes.

Peter provides complete training and education programs in all areas of his expertise.

He has authored more than 100 papers, written several book chapters and presented many
lectures in conferences around the world.

He is also active in most of the societies and professional organizations associated with the
water and wastewater treatment industry.

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      Consulting Engineering
        Water Purification
        Waste Treatment
        Food and Chemical Processing
Cartwright Consulting Company
                                                                            United States Office:
                                                                            8324-16th Avenue South
                                                                            Minneapolis, MN 55425
                                                                            Phone:  (612)854-4911
                                                                            Fax:    (612)854-6964

                                                                            European Office:
                                                                            President Kennedylaan 94
                                                                            2343 GT Oegstgeest
                                                                            The Netherlands
                                                                            Phone:   31-71-154417
                                                                            Fax:     31-71-156636
  MEMBRANE SEPARATION TECHNOLOGIES FOR ENVIRONMENTAL COMPLIANCE
                             By: Peter S. Cartwright, P.E.
INTRODUCTION

What's in a name? The mindset which has infiltrated America's industry with regard to
environmental stewardship has been called "pollution prevention", "effluent treatment", "reuse",
"resource recovery", etc.  The paridigm shift behind this plethora of names signals a perceptible
movement from a regulatory driven to an economy driven industrial climate.

This attitudinal change can only become a reality if there are treatment processes to
support and facilitate it. Membrane separation technologies do just that. The
characteristics which contribute to their usefulness in pollution environmental compliance include.

 - Continuous process, resulting in automatic and uninterrupted operation

 - Low energy utilization involving neither phase nor temperature changes

 - Modular design - no significant size limitations

 - Minimum of moving parts with low maintenance requirements

 - No effect on form or chemistry of the contaminant

 - Discrete membrane barrier to ensure physical separation of contaminants

 - No chemical addition requirements

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There are many examples of membrane separation technologies applied to water purification,
ranging from seawater desalination to the production of ultrapure water for semiconductor device
rinsing or pharmaceutical production. The same engineers who readily accept these technologies
to purify water for an industrial application cringe in fear when approached with the idea of using
them to dewater a waste stream or recover a valuable component from a process effluent.

If asked to explain their fear, they likely try to disguise their ignorance by citing one or more of
the following reasons:

         - Waste streams are too concentrated.

In reality, there are few waste streams with a higher concentration of ionic contaminants than sea
water.

         - The quality of the waste stream varies over time.

While to an extent this is true, many water purification feed streams come from multiple sources.

The quantity from each source can vary from time to time, thereby significantly altering the feed
water analysis.  In addition, if the wastewater source is a manufacturing operation, its rigid quality
control requirements guarantee an extremely consistant wastewater stream analysis, certainly
more uniform than many raw water feed streams.

         - Waste stream chemicals will harm the membrane.

Although there are certainly chemistries and extreme concentrations that will degrade many
membranes, the newer polymers are much more stable than the earlier materials. Chemistries
which still cause problems with polymeric membranes (particularly RO) include pH extremes
(below 1 and above 13), high concentrations of very strong oxidizing agents and certain oils,
greases and surfactants,  The point is that the vast majority of waste stream chemistries can be
readily accommodated by most of the currently available membranes.

         - The waste stream is likely to foul the membrane.

Because  waste streams are usually the result of carefully  controlled processes, their compositions
are well known and usually quite consistent.  Since testing is absolutely mandatory in all waste
treatment applications, a well designed testing program will evaluate the effect of increasing
concentrations of the waste stream on the fouling propensity of a given membrane or element
configuration.  This will allow the total system design to  minimize fouling.  In water purification
applications, colloidal materials and slightly soluble ionic species such as iron, barium, calcium,
silica, etc. create their own fouling problems in membrane applications.

         -The life of a membrane element is much shorter in a waste application.
                                            2

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The primary cause of membrane failure is fouling. If a system is designed with proper
pretreatment and sufficient turbulent flows within the membrane element, the membrane life
should not be dependent upon the source of the feed stream.
TECHNICAL

Having said all of this, it is important to point out that there is one significant difference between
the average water purification application and a waste treatment application But first, some
definitions are in order. Figure 1 illustrates a typical reverse osmosis system (or single membrane
element). Note that the stream that passes through the membrane and is purified is called the
"permeate" stream, while that stream which exits the system containing the rejected contaminants
is known as the "concentrate" stream.
                Membrane Element/System
                                            Permeate Stream
   Feed Stream
             -*
    QF  CF
Qp     CP
                                                              -*
                                                       Valve
                                       Concentrate Stream
Recovery  =
                                         Qc         Cc
              Qr
(Expressed as Percent)            QF - Feed Flow Rate
                                 CF - Solute Concentration in Feed
                                 QP - Permeate Flow Rate
                                 CP - Solute Concentration in Permeate
                                 Qc - Concentrate Flow Rate
                                 Cc - Solute Concentration in Concentrate

FIGURE 1, Membrane System Schematic
Recovery is defined as the permeate flow rate divided by the feed flow rate; in other words, that
percentage of the feed flow which is pumped through the membrane. Typically, for wastewater
treatment applications, recovery is at least 90%, whereas for water purification applications, it
rarely exceeds 80%.  As recovery is increased (to decrease the concentrate volume), the
concentration of solute and suspended solids in the concentrate stream increases rapidly.

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In an ideal system, all of the contaminants to be removed are separated by the membrane and exit
in the concentrate stream. As recovery is increased, the concentration of contaminants in the
concentrate stream increases dramatically. Table 1 summarizes this increasing concentration
factor as a function of system recovery, and Figure 2 illustrates this graphically.
TABLE 1, Effect of Recovery on Solute Concentration
                                1 - Re cov ery
                                                     -  vr
                                                     -  ./Y V_- F
                               X = Concentration Factor
Recovery X
33%
50%
67%
75%
80%
90%
95%
97V2%
98%
99%
1.5
2
3
4
5
10
20
40
- 50
100

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              100-
              90-
              80-
              70-
              60-
              50-
              40-
              30-
              20-
              10-
                                 20
 I
40
 I     I      I
60   80  100
                                               f££
                           Concentration Factor v
FIGURE 2, Concentration Effects of Increasing Recovery
For the processes of nanofiltration and reverse osmosis (and to a lesser extent, ultrafiltration)
which deal with dissolved materials, a property of the solution known as "osmotic pressure"
usually becomes the limiting factor. Osmotic pressure is a characteristic of all solutions, and is
loosely defined as the resistance of the solvent portion of the solution to passage through the
membrane. Osmotic pressure is a function of both the particular solute as well as its
concentration. A specific test is almost always required to determine osmotic pressure.

As recovery is increased (typically through the use of a flow restrictor or concentrate valve), with
the resulting decrease in concentrate flow, the concentration of solute in the concentrate stream
increases resulting in increased osmotic pressure.

No membrane is perfect in that it rejects 100% of the solute on the feed side; this solute leakage is
known as "passage". Expressed as "percent passage", the actual quantity of solute which passes
through the membrane is a function of the concentration of solute on the feed side. Under high
recovery conditions, the concentration of solute on the feed side is increased, and, therefore, the
actual quantity of solute passing through the membrane also increases. Because most effluent
applications demand that, in addition to a minimum concentrate volume, the permeate quality be
high enough to allow reuse or to meet discharge regulations. The "catch-22" predicament of
permeate quality decreasing as recovery is increased can impose design limitations  Additionally,
the increased osmotic pressure resulting as recovery is increased also imposes a design limit.
Generally, pumping pressures in excess of 68 bar (1000 psi) are impractical for most applications.
                                            5

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Membrane polymers must be packaged into practical "device" or "element" configurations which
allow the most efficient use of the polymer.  The typical element configurations available today
include tubular, capillary fiber, hollow fine fiber, plate and frame and spiral-wound.

Packing density is an indication of the membrane area contained within a given volume of an
element. In general, as packing density increases, element cost decreases, but, as a result of the
closer spacing and restricted flow patterns, the propensity for fouling increases.

Typical membrane element configurations are illustrated in figure 3.
           PLATE AND FRAME                   SPIRAL WOUND
                TUBULAR        _     HOLLOW FIBER
                                      ""v.
                               " ceJaxnutt
FIGURE 3. Membrane Element Configurations

Tubular
Manufactured from ceramic, carbon, or a number of porous plastics, these tubes have inside
diameters ranging from about 3/8 inch up to approximately one inch (9 to 25 mm). The
membrane is typically coated on the inside of the tube and the feed solution flows through the
interior from one end to the other, with the permeate passing through the wall to be collected on
the outside of the tube. Packing density is low, but resistance to fouling is very high.

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Capillary Fiber
These elements are similar to the tubular element in design, but smaller in diameter and usually
require rigid support such as is obtained from the "potting" of a fiber bundle inside a cylinder.
Feed flow is either down the interior of the fiber or around the outside of fiber. Packing density
is medium and fouling resistance is high.

Hollow Fine Fiber
Also similar to the tubular element in design, the hollow fine fibers are very much smaller in
diameter (about the  diameter of a human hair).  Feed flow is from outside to inside. Packing
density is very high, but fouling resistance is very low. As a result, this configuration is generally
not applicable to pollution control applications.   '

Plate and Frame
This device, similar to a plate and frame filter press, incorporates sheet membrane stretched over a
frame to  separate the layers and facilitate collection of the permeate. Packing density is low and
resistance to fouling quite high.

Spiral-Wound
This device is constructed from an envelope of sheet membrane wound around a permeate tube
that is perforated to allow collection of the permeate. Packing density is medium and resistance
to fouling is moderate.

Following is a list of important physical characteristics of the various membrane element
configurations available today:
Element
Configuration
Tubular
Capillary Fiber
Hollow Fine Fiber
Spiral-Wound
Plate and Frame
Packing
Density *
low
medium
high
medium-low
low
Fouling
Resistance**
high
high
very low
moderate
high
               * Membrane area per unit volume of space required.
               ** Tolerance to suspended solids

As stated earlier, the primary difference between a water purification application and a wastewater
treatment application is the much higher recoveries utilized in the latter to make the concentration
stream as small as possible. As indicated, these high recoveries exact a price in that the increased
osmotic pressures require higher pressure pumps; the higher concentrate concentrations can result
in precipitation of slightly soluble materials; and with reverse osmosis and nanofiltration
technologies, the lower permeate quality.

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TESTING

So how does one determine the efficacy of membrane technology in a wastewater application?
The answers are: testing, testing and more testing.

In general, every stream must be tested to determine the following design factors.
             Optimum membrane element design
             Total membrane area
             Specific membrane polymer
             Applied pressure
             Maximum system recovery
             Flow conditions
             Membrane element array
             Pretreatment requirements

Specific properties of streams which influence the design factors include.

       Stream chemistry
             Total solids content
                    Suspended (TSS)
                    Dissolved organic  (TOC, MBAS, COD, BOD)
                    Dissolved inorganic (TDS)
             Specific chemical constituents
                    Oxidizing chemicals
                    Organic solvents
                    Saturated solutes
             Operating temperature
       Osmotic pressure as a function of recovery
       Variation in chemistry as a function of time
One or more of the following test procedures should be utilized when evaluating membrane
technology with a particular effluent stream.
Cell Test

Utilizes small (approximately 40 sq. cm.) cut pieces of sheet membrane mounted in a "cell" that
exposes the membrane to the test solution using the crossflow mechanism.  This test is effective
for quick evaluation of a number of different membrane polymers to determine degree of
separation.  The cell test device is illustrated in Figure 4.
                                           8

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FIGURE 4. Cell Test Apparatus
Advantages:
Disadvantages:
Fast
Inexpensive equipment involved
Only small quantities of test solution required

Cannot indicate long-term effects of solution on polymer
Does not provide engineering scale-up data
Gives no indication of optimum membrane element configuration
Does not provide data on fouling effects of test solution
Applications Test

This typically involves the evaluation of a 100-200 liter sample of solution with a production-sized
membrane element.  The element is mounted in a test machine with the engineering features of
production systems. For a given element, the test can be completed within 1-2 hours.  Figure 5
illustrates the applications test system design.
Advantages:
Disadvantages:
Fast
Provides scale-up data (flow, element efficiency, osmotic pressure as a
   function of recovery, pressure requirements, etc.)
Can provide an indication of membrane stability

Does not indicate long-term chemical effects
Does not provide data on fouling effects of the test solution

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                            PERMEATE RECYCLE
           TEST
        SOLUTION
                                            MEMBRANE ELEMENT
                                  PUMP
                           SYSTEM RECYCLES
                            CONCENTRATE RECYCLE
                                                     PERMEATE
                                                              1EH
                                                       CONCENTRATE
FIGURE 5, Applications Testing Schematic
Pilot Test

Usually this involves placing a test machine (such as that used for the applications test) in the
process, operating on a "side-stream" for a minimum of 30 days.
Advantages:
Accomplishes all of the functions of the applications test plus provides
   long-term membrane fouling and stability data
Disadvantages:      Expensive in terms of monitoring and time requirements

SPECIFIC APPLICATIONS

Although there are many applications of membrane technologies applied to wastewater streams,
the actual number is tiny when considering the total market potential.
Existing applications include reverse osmosis used to recover and recycle electroplating salts in
rinse water baths. Chemistries include nickel, copper and zinc, among others.

Ultrafiltration and some microfiltration membranes have proved very effective at separating
emulsified oils from machine coolants and aqueous cleaning baths. In some cases, valuable
surfactants and emulsifiers pass through the membrane into the permeate stream and can be
reused. There are even some cases where the concentrated oily waste can be used as fuel.

Ultrafiltration membranes have been used for years to dewater electrodepostion paint baths. The
latex based emulsions are returned to the bath, and the permeate is recycled to the rinse stream; a
true "zero discharge" application.
                                         10

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There are a number of "once-off' applications, primarily concentrating waste components for
further processing or transportation to landfills. One such application follows.

CASE HISTORY

A large transportation maintenance facility generates a concentrated wastewater stream from their
metal cleaning operation.

Cadmium, a regulated heavy metal, has been found in this stream in concentrations as high as 3
ppm.  The wastewater analysis, although highly variable, is represented as follows:
       Parameter                        Maximum Concentration, ppm
       TDS                                    6000
       TSS                                    1000
       TOC                                    4500
       Oil & grease                               100

Cartwright  Consulting Co. was retained to evaluate membrane technologies to be used to
preconcentrate the contaminants prior to studge generation to facilitate removal to a hazardous
waste disposal operation. The water obtained during this ""dewatering" activity had to be suitable
for discharge to the local POTW or reused within the facility.

An applications test was performed to identify the best membrane candidates, followed by a four
month pilot test on a side stream to identify the optimum pretreatment technologies and
accumulate long term operating data. The pilot testing revealed that this particular wastewater
stream contains "film formers" which tend to coat the surface of normal depth cartridge filters and
render them largely ineffective for pretreatment.

The optimum pretreatment, in this application, was determined to be crossflow microfiltration,
which effectively reduced the potential foulants (suspended solids, oil & grease) ahead of the
spiral wound membranes.

In one location, the permeate is to be discharged to surface water. This requires an extremely low
concentration of cadmium. Testing with a reverse osmosis membrane consistently produced
permeate streams with cadmium concentration below the analytical detection  level of 0.02 mg/L.

The other location uses a municipal wastewater treatment plant to accept the  permeate. This
POTW discharge limit for cadmium is 0.26 mg/L. A nanofilter membrane produce a permeate
stream which consistently met this requirement.

The outcome of this program was the design of one 10,000 gpd reverse osmosis system and 2 -
20,000 gpd (each) nanofiltration systems for the one client. 2 of the 3 systems have been
constructed and are satisfactorily treating the effluent from the 2 locations.
                                           11

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CONCLUSIONS

The time is right for the serious integration of membrane technologies into wastewater treatment
and processing applications. The potential user needs to understand and appreciate the flexibility
and diversity of currently available membrane polymers and element configurations.

As the user recognizes the attributes of membrane technology and the provider displays
proficiency in process evaluation, waste stream testing and system design, membrane technologies
will become standard unit operations in the lexicon of waste treatment.
                                           12

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   Jennifer Cawein





Commonwealth Edison

-------
        ComEd's Pollution
        Prevention Strategy:
      Life Cycle Management
       PRODUCTION OF ELECTRICITY
                             GENERATOR
EMISSION
CONTROL
EQUIPMENT

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       Life Cycle Management Definition
    Life Cycle Managment is the process of strategic asset
 management. It is the systematic consideration of the total life
   cycle of an asset, from effective design and aquisition to
           prudent consumption and disposition.
             Life Cycle Management
 Design

Design or choose
products that last
longer, are more
efficient or create
less waste.
  Acquire

 Acquire products
 that actually cost
 less than others
 overtime.
 Dispose
Dispose of what's left
more economically or
find other uses for it.
 Consume
  Consume
  products more
  efficiently.

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        LCM Guiding Principles

     Reduce life cycle costs
     Extract the greatest value from each asset
     Share responsibility through teamwork
     Promote environmental stewardship
ComEd's Strategy for Implementing Rapid
   Pollution Prevention Improvements

 • Create LCM staff separate (but closely
    aligned with) environmental group
 • Explore grassroot employee ideas
 • Encourage the team concept
 • Incorporate environmental concerns into
    business decisions

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            Com Ed LCM Projects


• Chemical Commodity Replacement Program
• Waukegan Retired Equipment Removal

• Dehumidification - Biofouling Control without Biocides
• Wood Pole Re-Use Project

• Expansion of Coal Ash Reclamation Program
 Chemical Commodity Replacement Program



   • Accounting
   • Cross-functional team

   • Goa!: Reduce inventory, create safe working
     environment, minimize waste, lower costs
Result:   Replacement of over 100 different
          solvent commodities with non-
          hazardous alternatives AND annual
          cost savings of $61,000.

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    Applying Life Cycle Management
                  Solvents
            ACQUISITION
CONSUMPTION
                                  DISPOSITION
                      CONSUMPTION
 Chemical Commodity Replacement Program
  300000
         Hazardous Solvent Minimization
                 (kilograms)
          1992
1993
1994
1995

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   Waukegan Retired Equipment Removal


     • Vendor & supplier partnerships
     ^ Innovative contracts
Result:    Every scrap of recoverable material
          is recovered and not discarded.
          Biocide Use Reduction
        Thermal Controls & Dehumidification


        Cross-functional team

        Innovative technologies
Result:    Elimination of chemical biocides
          (bromine and chlorine) AND
          estimated capital cost savings of
          $700,000 and annual operational
          cost savings of $67,000.

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 Condenser Tube Biofouling - Biocide Reduction
       Use of Chlorine and Bromine (Gallons^
         1992
                 1993
                         1994
                                1995
                                        1996
   Data from two ComEd generating stations, able to fully utilize
  dehumidification to control condenser tube biofouling, show how
       they have eliminated the use of chemical biocides.
         Wood Pole Re-Use Program


      Search for Opportunity (SFO)

      Cross-functional team
      Goal: Investigate cost-effective,
      environmentally responsible opportunities
      in the management of used poles
Result:    Save trees, avoid landfilling, with
           anticipated cost savings of $100,000
           per year.

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                Wood Pole Re-Use Program
 Remove pole in one
      piece

 (see Work Practice)
     Return to
     Stores
  Stores puts back
     into stock
                     Job issued to
                      replace pole
                     (relocated, etc.)
Remove pole  I
 per Work   I
 Practice    I
  Crew
checks pole
 for reuse
  criteria
                                    Recycle lumber. Use for:
                                     fencing, pallets, etc.
                                      Donate to public*
             Coal Ash Reclamation
       Vendor partnership

       Innovative technologies
Result:    Nearly 90% of ComEd's coal ash
            was kept from commercial landfills
            through  recycling and beneficial
            stabilization.

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     Expansion of Coal Ash Reclamation Program
800,000
700,000
     Coal Ash Recycled (Tons)
                            Re-Use/Recycling
         1994
1995
                                 Landfill
Beneficial
Stabilization
                 Key to Our Effective Strategy
        Organized approach
        Dedicated LCM staff (drawn from business)
        Grassroot employee ideas
        Cross-functional teams
        Partnering with vendors & suppliers

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   Phebe Davol





A.T. Kearney, Inc.

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                                   PHEBE DA VOL
                                     A.T. Kearney

Ms. Phebe Davol is a Project Director and certified professional soil scientist with A.T. Kearney,
Inc.  She has over 15 years of experience in various projects involving investigations/remediation
projects, environmental regulations and engineering processes for management and treatment of
hazardous wastes. She as a B.S. and M.S. from Texas A&M University.

Recent projects include assisting EPA and states in working with the regulated facilities to
develop strategies for investigating and remediating sources of contamination under the RCRA
Corrective Action Program. She is also currently involved in developing training courses for
EPA and state regulators as well as the regulated community.  The courses encompass many
areas of the RCRA program including Corrective Action, Sampling Procedures, the conduct of
inspections for storage treatment and disposal facilities, as well as compliance with groundwater
monitoring requirements. Her interest in the Texas Clean Industries 2000 program began in
1995 when she returned to her home state of Texas and began working with the Texas Natural
Resource Conservation Commission (TNRCC) on various projects in several programs.

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    TEXAS CLEAN INDUSTRIES 2000 PROGRAM-1996 UPDATE
                                 Phebe Davol
                              A. T. Kearney, Inc.
                                 Dallas, Texas

                                     and

                               Robert Borowski
               Texas Natural Resource Conservation Commission
                                 Austin, Texas

Texas generated approximately one-third of the nation's hazardous waste total in 1991
and is ranked fifth in the nation in the number of large quantity hazardous waste
generators. Beginning in 1991 with the passage of the Waste Reduction Policy Act and
the Omnibus Recycling Act, the Texas Legislature directed the Texas Natural Resource
and Conservation Commission (TNRCC) to create programs that would help facilitate
voluntary pollution reductions, including technical assistance programs, pollution
reduction incentives and a statewide public  education and awareness campaign. To
manage these initiatives,  the Legislature required TNRCC to establish an office of
recycling and waste minimization and an office of pollution prevention and
conservation. In response to these mandates, the TNRCC created CLEAN TEXAS
2000 to bring these mandated programs under one unifying theme.

Clean Industries 2000, a  program developed from the Clean Texas 2000 initiative, is a
national model for government/industry/public cooperation in the environmental arena.
It is currently the nation's largest statewide environmental public-private partnership to
address industrial pollution.  Texas' Clean Industries 2000, asks industrial facilities to
achieve a 50 percent reduction in volumes of hazardous waste generated and/or releases
of pollutants and contaminants into the environment  by the year 2000 from 1987
baseline levels.  Membership in this program is based on four commitrnents by
industry.  These are a commitment to reduce hazardous waste, toxic release inventory
(TRI) releases, or both; a commitment to develop an internal environmental
management program; a commitment to implement a citizen's communication program;
and a commitment to perform a community outreach project.

Since it's advent, Clean Industries 2000 members have pledged to reduce hazardous
waste generation by 68 percent and toxic chemical releases by 62 percent.  Since  1992,
actual reductions of hazardous waste have been 15.3 million tons. In the past three
years, the program has grown to  147 Clean Industries 2000 member facilities.  In
1994, Clean Industries 2000 members continued to make progress by reducing their

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hazardous waste generation by 5.9 million tons, a 6.6 percent reduction in one year.
Clean Industries 2000 members now participate in or sponsor 515 community
environmental projects across Texas, including 154 educational programs, 66 cleanups,
57 recycling programs, 47 household hazardous waste collection programs, 42
scholarships, and 32 nature preserve and habitat restoration programs. In addition, the
facilities have established or participate in 152 citizen communication programs which
provide regular forums for the discussion of environmental issues between facility
managers and members of the community.  Programs include 90 citizens advisory
panels, 30 facility open houses and 32 environmental ombudsmen.

Advantages to participating in the program include improving public relations and
outreachability. As an added benefit, the participant receives pollution prevention
technical resource and service assistance from the TNRCC.  Companies who join Clean
Industries 2000 receive public recognition for their commitments to pollution
prevention.  Members are recognized with a letter from the Governor of Texas and
local press releases. Members are highlighted in the CLEAN TEXAS 2000 newsletter
and are able to use the CLEAN INDUSTRIES 2000 logo. Each year the  annual
Governor's Awards Banquet  for Environmental Excellence is held to recognize
CLEAN TEXAS 2000 participants with outstanding environmental projects and
accomplishments.  Finally, all CLEAN INDUSTRIES 2000 members are  special
honorees each year for their commitment to pollution prevention and receive special
recognition from the governor.

This paper conveys the program's goals, discusses mechanisms to achieve the
program's four commitments, and provides an overview of the program's success.
The presentation consists of a 15 minute video highlighting case studies from actual
Clean Industries 2000 facilities.

Texas' Clean Industries 2000 Program Goals

Clean Industries 2000 participation is offered on a facility basis.  Participants must
meet four criteria:

1.      Commit to carry out a pollution prevention plan  that will  reduce TRI chemical
       releases and/or reduction of hazardous waste that is disposed of or released to
       the environment, fifty percent or more from 1987 levels by the year 2000.

2.      Implement an internal environmental management program to assure high levels
       of environmental compliance with state and federal standards.

3.      Participate in a citizen communication program.

4.      Participate in one or more community environmental .projects each year.

                                       2

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Mechanisms for Achieving Goals

The TNRCC's Permanent Pollution Prevention Program (P4), an eight step workshop
prepared by the TNRCC, is one mechanism used to assist Clean Industries 2000
members in achieving the four criteria.  The following eight steps apply total quality
management (TQM) principles to develop a program to implement pollution prevention
ideas.  The goals of a permanent pollution prevention program are to eliminate end of
pipe thinking, establish permanent pollution prevention programs at facilities, have
facilities form partnerships, reduce environmental impacts and maintain economic
competitiveness. The video highlights each of the steps.

1.      Management Proclaims Support

Management support  may involve an evaluation of the total costs of a waste stream, a
determination of the true savings of a pollution prevention project, and assessment of
the benefits of achieving "beyond compliance". In order to formally initiate the
program, a new mission statement and company policy should be developed or
renewed.  Management should involve the whole team in the final version of the
mission statement and policy. The policy should reflect teamwork and a sense of
ownership.

2.      Select Pollution Prevention Team

Employees are the first to recognize the problems because they are on ithe firing line
therefore are the most appropriate team  members. The team may be developed from
existing teams such as those from the Safety or Quality Assurance/Quality Control.
The team should consist of a mix of management arid line workers.  The team should
have representatives from each department.  Representatives  serve as volunteers and
alternates.  Benefits of the team  approach include workers who are more receptive to
change, managements confidence is increased and there are fewer departmental "turf
battles".

3.      Select Team Leader

The Team Leader should be selected from and by the team.  The leader does not
necessarily need to be the environmental manager but should exhibit enthusiasm for the
program and be respected by both management and workers. Team leader skills
include strong communication and organization capabilities, effectiveness as a project
manager, possess team-building  skills and have the ability to handle multiple tasks.
Examples of the team leader's duties will be to chair meetings and publish the agenda,
list and track task assignments, link to outside organizations and keep upper
management informed.

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4.     Educate the Organization

Educating the organization requires three phases.  The phases are to educate the team,
educate management and then educate line employees. Team education consists of
reviewing the facility and waste streams, determining any environmental impact off-
site, determining the economic costs and reviewing environmental health and safety
issues.

As the first phase, the team tours the facility in order to understand the process and to
look for good pollution prevention examples.  The team is further educated by
reviewing the results of the reviews and tour. Through the findings, the team identifies
main waste issues, outlines action items, and formulates program goals. These are
presented to upper management.  Through management's  guidance the team develops a
presentation which concentrates on important issues, and proposes goals, through the
inclusion of success stories.  The goal of the management presentation is that it
educates on the costs and liabilities, and shows that pollution prevention can save
money. At this point the mission statement can be formalized/presented and obtaining
support for the program goals can be achieved.

Finally, in order to educate line employees the team takes the information back to the
respective department.  The team representative reviews the mission statement and
goals with the employees, uses photographs/slides to illustrate points, and describes the
environmental and economic costs. Emphasis on the importance of their ideas are
essential.

Once employees understand the economic and environmental impact of their actions
they will want to do their part in reducing waste.  It is management's responsibility to
provide the supporting structure to help employees implement a permanent pollution
prevention program.

5.     Brainstorm Ideas

The best place to look for ideas is your employee resource.  The employees are the
most knowledgeable about where to reduce and prevent waste.  Brainstorming meetings
facilitate the generation of ideas. During the meetings, write down all presented ideas
and let everyone have a say and withhold judgement.  Alternative means to gather ideas
are through circulation memos and suggestion boxes. Where there is a financial
incentive to respond are the most successful.

6.     Evaluate Ideas

In order to evaluate ideas, selection and screening criteria should be developed.
Considerations include the amount of effort and time required, health and safety as well

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as regulatory compliance, the cost of the project/availability of funding, impact on
personnel/training, high visibility for promotional efforts and impact on the
community. The team should develop a proposal for management.  This proposal will
determine a baseline of costs/wastes, project benefits to the company, show buy in by
workers and address uncertainties.

7.     Implement Ideas

In a study conducted of 350 executives in 1994, management  identified barriers for
change were due primarily to a lack of organizational buy in.  Other barriers include no
senior management champion, lack of skills or experience, turf battles, and lack of
appropriate rewards.

In order to implement ideas, the most obvious is to address the "low hanging fruit"
first.  This will build program momentum, win support for complex projects and builds
confidence in the program.  As part of the implementation, barriers  and uncertainties
should be addressed.  Quantification of the results should be made and then be
remeasured.  Examples of quantification would be to take before and after
photographs/slides and documenting all savings.

8.     Continue the Process

In order to continue the process, upper management support is imperative.  Pollution
prevention should also be on the agenda and added to merit reviews. Good ideas
should be rewarded and  there should be support for promotional activities.
Promotional activities keep the program going.  These promotions can be announced,
placed in newsletters or on bulletin boards, or publicized through awards.

Successes should be documented through the local press, having  open houses for the
community, ideas should be transferred throughout the corporation.  Communication of
the success to the regulatory agency will enable information sharing with other
industries. By forming partnerships with suppliers, customers, contractors, local
companies, governmental agencies, and community groups, the process will continue.

Overview of Program's Success

Texas leads the major industrial states in reducing the amount of pollution produced by
industrial facilities in  1993, according to a report released in March 1995 by EPA.
Data compiled for the national TRI show Texas, with 60 percent of  the nation's
petrochemical production capabilities and 25 percent of its oil refining capacity, in the
forefront of industrial reduction efforts.

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Members involved in the Clean Industries 2000 are achieving substantial results in
reducing the amount of toxic emissions or hazardous waste generated.  The following
examples are all based on normalized data. From 1992 to 1993, for example, Phillips
Petroleum's Sweeny Complex reduced toxic releases by 488,000 pounds by enclosing a
wastewater treatment system and recovering vapors, recycling catalysts, and
establishing more reliable operations to prevent upsets. During the same period,
DuPont's Victoria facility reduced toxic releases by  734,000 pounds by recycling nitric
acid and installing a thermal incinerator to reduce emissions.

Other Texas industrial facilities are implementing similar measures. Mobil Oil
Corporation's Beaumont Refinery reduced TRI on-site releases by over 500,000 pounds
from 1992 to 1993, even with an increase in production.  The facility  implemented a
fugitive leaks program that reduced methyl ethyl ketone and toluene emissions,
installed carbon canisters on tanks to reduce hydrocarbon emissions, changed cooling
tower technology  to eliminate chromium and zinc compounds from release, and
installed a scrubber to reduce hydrogen chloride and chlorine emissions. Amoco
Chemical, located in Alvin, reduced hazardous waste generation by 99 percent, almost
two million tons - by installing a system to recover hydrocarbons now used in the
production process.

ARCO Chemical's Bayport production facility reduced on-site releases of TRI
chemicals by 22 percent from 1992 to 1993, largely from improvements in chemical
processing that  prevent chemical losses into the plant wastewater collection system.
These improvements reduced on-site releases by 560,000 pounds and off-site transfers
for treatment by 1.6 million pounds.  Shell Oil Company's petrochemical facility and
refinery in Deer Park reduced the amount of hazardous wastewater generated by  9.4
million tons each  year.  Plant operators reuse benzene and keep it out of the waste
stream.

The Phillips 66 Borger Complex, a petroleum  refinery, is one of the first participants
in TNRCC's new flexible Permit Program.  The flexible permit is a joint effort
between Phillips 66 and the TNRCC to reduce air emissions by replacing multiple
permits  with a single permit which sets maximum allowable emissions  but allows
facility managers  to decide how to meet the requirements.  Under the terms of the
permit,  emissions are decreased during the next 10 years. By the final year of the
permit,  in 2005, total emissions will be reduced by 13,000 tons per year, a 40 percent
reduction.

The Huntsman Corporation Organic Chemical Research and Development Center in
Austin installed the first commercial-scale Supercritical Water Oxidation Unit
developed jointly  by Eco Waste Technologies and the University of Texas at Austin.
By using this unit, Huntsman will be able to reduce  its releases and transfers of waste
methanol reported under the Toxic Release Inventory (TRI) program by 93 percent.

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The Amoco Chemical Company in Texas City involves 560 employees in an ongoing
Responsible Care Program that has encouraged source reduction and waste
minimization projects since 1991. Several projects have cut Toxic Chemical Inventory
emissions by 65 percent from 1988 levels and hazardous waste generation by 99.9
percent from 1983 levels.  Successful projects  include elimination of 500,000 pounds
of hazardous waste and reductions in the use of chlorinated solvents.  Amoco also has
established a comprehensive community outreach program that includes other Amoco
sites, fellow industries, schools, civic groups and environmental organizations.

Future plans for the Clean Industries 2000 staff and Team members includes working
to develop the next phase (Clean Industries Plus) beyond compliance, which is a
voluntary program to further encourage pollution prevention and community programs.
The Clean Industries members currently are working with representatives of the Clean
Cities 2000 program to provide mentorship in pollution prevention projects and
leverage resources.

In conclusion, the Clean Industries 2000 program has created productive and viable
partnerships between government, environmental groups and industry.  Specific
questions regarding the program may be directed to Mr. Borowski at 512-239-3187.

Resources utilized to prepare this paper include the following documents.

1.     Clean Industries 2000 Directory, TNRCC, Office of Pollution Prevention  &
       Recycling (GI-135), March 1995.

2.     Community Environmental Programs, Resource Guide, TNRCC, Office of
       Pollution Prevention & Recycling (GI-133), March 1995.

3.     Texas Natural Resource Conservation Commission,  Pollution Prevention
       Training Workshops Office of Pollution Prevention & Recycling/Clean Texas
       2000, 1995.

4.     Pollution Prevention and Waste Reduction in Texas, A Report to the 74th  Texas
       Legislature, TNRCC, Office of Pollution Prevention & Recycling (SFR-16),
       March 1995.

5.     Permanent Pollution Prevention Program; Eight Step Program Workshop
       Manual, Version 2.5, August 30,  1995.

6.     Texas Natural Resource Conservation Commission News Release, March  25,
       1996.

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  Marvin Fleischman





University of Louisville

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                                 Marvin Fleischman
                                University of Louisville

Dr. Marvin Fleischman is a Professor of Chemical Engineering at the University of Louisville,
where he has beeen a faculty member since 1970. He is also Co-Director of the University of
Louisville Industrial Assessment Center (IAC), funded by the USDOE. He holds a B.Ch.E. from
the City College of New York and M.S. and Ph.D. from the University of Cincinnati. His
research interests are in pollution prevention and waste minimization and waste management.
He has been a AAAS-EPA Environmental Science and Engineering Fellow and a 3M McKnight
Distinguished Professor at the University of Minnesota-Duluth. Industrial and government
positions include Amoco Chemicals, Exxon Engineering, Monsanto Research, and the U.S.
Public Health Service.

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   POLLUTION PREVENTION AND ENERGY ASSESSMENTS AT A SMOKELESS
     TOBACCO PRODUCTS MANUFACTURER &  AN INDUSTRIAL LAUNDRY
                                          by
      Marvin Fleischman*, Eric Lewis, James C. Waiters, and W. Geoffrey Cobourn
                             Industrial Assessment Center

                                     Introduction
       Using engineering-student faculty teams, the U.S. Department of Energy sponsored
Industrial Assessment Center at the University of Louisville does free pollution prevention,
energy, and productivity assessments at small to medium size plants in Kentucky and Indiana
(Fleischman, 1996). Assessments at an industrial laundry and a manufacturer of smokeless
tobacco products are briefly described, with an emphasis on waste minimization/pollution
prevention.
                             Smokeless Tobacco Products
       The plant produces loose leaf, plug, moist snuff (a fermented product), and smoking
(pipe) tobacco. They also do silk-screen printing on and packaging of about 75 million butane
lighters per year. There are about 350 employees, and annual sales of the 30 million pounds of
tobacco products (at 21% moisture) are between $80 million to about $100 million, including the
lighter operation. The entire facility is housed in one building of about 10 acres (400,000 ft2).
       Leaf yields vary with type of leaf, for example cigar (large leaf) and Sumatra (small leaf).
Production efficiency is generally about 75-80% leaf yield and as low as 50% on some grades.
80% yield means that 20% of the incoming tobacco leaf (including stems) is not converted into
product, i.e., about 7.5 million Ib./yr. is wasted, most of it being landfilled or composted.
Figure 1 is a process flow diagram for the loose leaf process line. There are three other similar
manufacturing lines at the facility which are similar to the loose leaf line. Table 1 summarizes
waste generation and disposal costs for the entire plant.

Process Description:
Receiving
       Cured tobacco received in bales, burlap bags, or boxes, is unloaded by hand onto a
conveyor, from where it is unloaded by hand onto racks. Considerable tobacco is lost during
unloading because it is  dry and brittle, and falls apart and shrinks. There is no guard on the
conveyor to prevent falloff.  Any tobacco that hits the floor is swept up, along with string, paper,
etc. and placed in a general trash dumpster.  Mechanical methods of unloading have been tried to
reduce this waste, but the leaf got cut up and damaged. Another major limitation to automated
unloading is the variety of sizes and shapes in which the tobacco is delivered.
       Any product returned from retailers e.g., expired, is shredded (both foil and product)
because of scavengers who may have taken expired product from landfills or dumpsters. An
excise tax (Bureau of Alcohol, Tobacco, and Firearms) refund is given for the destroyed product,
with destruction being required by law. If this product were resold, this tax would have to be
paid again.
*Dept. of Chemical Engineering, University of Louisville, Louisville, KY 40292,502/852-
6357, FAX: 502/852-6355, email:mOflei01 a ulkyvm.louisville.edu

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Leaf Processing
      Stems and wigglers (byproducts) are separated from the leaf in the stemmary. Leaf bundles
are broken up in the delaminator, and tobacco is segregated into different sizes and weights in a
thresher with air separators, ideally removing stems and wigglers from the leaf. Stems are
wetted in an ordering cylinder, flattened in the stem mill, and sent to bulkers for blending with
the leaf from which they were removed. A vibrating screen passes the very fine leaf pieces into
an open box. It was observed that the box was not centered, creating the potential of tobacco
missing the box or the box overflowing onto the floor. These fines go into the manufacture  of
pipe tobacco elsewhere in the plant. The leaves then pass through velcro rollers and a magnetic
sensor to remove hair, string, feathers, metal shavings, etc., which are commonplace in the  barns
where tobacco ages. Metal detectors for pins, baling wire, ferrous & non-ferrous machine pieces
are found in several places in most if not all of the product lines. Following metal removal,  the
tobacco goes to bulking.
     Dust from the stemmery is captured in the dust room in bag collectors through an airlock
screw conveyor, and the collected dust is composted. The dust cannot be reused in the tobacco
products because of sand, dirt, and wheat seed. If the machines in the stemmary are set wrong,
leaves will carry over into the dust collectors. A great deal of dust was observed on the walls and
floor. On average, 75%-80% of the incoming tobacco makes it through the stemmary.
Some yields are as low as 50%, and others are as high  as 80-85%. It appears that the
largest generation of waste tobacco occurs in the stemmary, including the byproduct stems
and wigglers.
     The tobacco is layered in bulkers  (long horizontal  silos) and then run through spiral  doffers
(mixers) that turn and shear the different layers to blend them into a uniform product. Mixed
tobacco is conveyed to casing and drying where weighed and dried tobacco is mixed in
wringers with flavoring (liquid casing) such as molasses or dark syrup metered in from the
kitchen. Excess liquid is caught in the tub and reused. The plant tries to use the exact amount of
materials needed for a batch, but the 15 gal.  residual in the 40 gal. reservoir is required to keep
the tobacco submerged in the wringer.  When the flavoring formulation is to be changed for  the
next day, the residual flavoring is drained from the reservoir. There was some confusion as to
whether this liquid went to the sewer or was saved for the next run of that formulation. If it
goes to the sewer, the residual would probably be the largest or one of the largest BOD
contributors.
     The tub and wringer are then sprayed down with hot water from hose, causing splattering
and dripping of casings and solids onto the floor. This is the only equipment cleaned at this  point
because of the stickiness of the flavoring. Without almost immediate cleaning, the flavoring
would "glue-up" and intense cleaning would then be required. All of the wash water runs through
a dike (which restricts the water to a limited area) and subsequently to a floor drain with a wire
mesh basket. The floor is washed at the end of the day by  a contractor.  Solids are not removed
from the casing equipment by dry (mechanical) cleaning prior to wet cleaning. Solids from
the floor sweeping and the mesh basket go to the dumpster.
    In the kitchen, water, liquid ingredients from dedicated tank farm pipelines, and powdered
flavorings for the casing, are added to steam jacketed kettles for cooking. Glycerin and glycol are
used for parts lubrication and to keep product from sticking, as many of the parts come into
direct contact with the product. Currently all powdered materials are added from paper bags to
the kettles by hand. Empty bags are landfilled, and the company is considering pneumatic

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loading. To minimize washing frequency, the exact amount of flavoring needed for a batch is
used. Thus most kettles are usually empty by the end of the shift and are rinsed daily. Some
kettles however, are only emptied and cleaned as necessary, e.g., these will be used again shortly
for the same formulation. Lines are rinsed and flushed three times weekly and at the onset of a
brand switch. Between brand changes, the flavoring in the line is recaptured, i.e., the initial plug
pushed out by the rinse water is stored until the next run of that formulation.
    After casing and drying, the tobacco is again fed to a large bulker where the flavor sets into
the leaf during several hours storage. Then the leaf is conveyed through a wall of doffers to
thoroughly mix the layers, followed by drying. Due to the large amount of flavoring now in the
leaf, mostly molasses or dark syrup, a significant amount of casing (high BOD) drains from
the bulker to the floor.  This liquid is washed through the floor drains to the POTW at the end of
each shift. The tobacco is again run through a large bulker for final mixing prior to packaging.
   After a series of inspections, 85 grams of tobacco are added to a foil pouch, which is then
sealed, boxed, and cased for shipping. Waste foil results from loading new rolls onto the feeder
spools, i.e., start up waste, and foil comprises about 90% of the 2 yd3 dumpster in this area.
Waste pouches containing tobacco are generated in automated packaging due to
under/over-filling, improper pouch sealing, empty pouches, torn pouches, etc. These
pouches are blown from the conveyor into adjacent plastic trash bins. It is not clear whether all
incorrectly filled pouches are reworked. The assessment team was told that overfilled pouches
are emptied back into the front end of the line and the pouch is trashed, and underfilled pouches
are trashed with the tobacco.

Waste Generation and Management
      Table 1 summarizes waste generation. The company is a limited-quantity hazardous waste
generator, and is concerned with possible generator status change to a higher level. Hazardous
waste includes solvent and paint wastes from painting (maintenance) cleanup, and spent silk-screen
printing cleaner. These are disposed in a fuels program or incinerated. Solvents from the quality
control lab to extract nicotine are also hazardous and are burned in an incinerator. Naptha from a
leased parts washer service and non-hazardous waste oils, including water based machining
coolants, are reclaimed off-site.
      The company landfills about 22 million pounds of waste per year at a cost of about
$40,000. Landfilled waste includes tobacco, burlap bags, paper bags, aerosol cans, aluminum
foil, and incoming lighter trays from butane lighter screen printing About 3.5 million pounds of
waste (nearly 100% tobacco) is composted yearly, at a cost of about $28,000. An average of
about 40,000,000 gallons of water costing about $56,000 are consumed annually in tobacco
processing, and approximately 60% is discharged to the POTW (Publicly Owned Treatment
Works) without any pretreatment. Annual sewer bills average about $57,000/yr., plus quality
surcharges of about $36,000 per year for biochemical oxygen demand (BODs) and total
suspended solids (TSS) above 400 ppm, respectively
      The assessment team's observations include:
   • Tobacco falling to the  floor from equipment such as conveyor belts and during unloading in
     receiving
   • Tobacco leakage through or from equipment, e.g., dust collectors, between the head roller
     and a cutting knife  on one unit, and under a drier

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   • Tobacco clingage to equipment, e.g., sides of conveyor belts, because it is wet and sticky,
     requiring equipment washdown
Equipment washdowns carry tobacco solids and associated sorbed flavorings onto the floor and
into the sewer. Also, some of the tobacco solids that hit the floor (from conveyors, etc.) enters
the sewer when the floors are washed down.
      Conveyors are not covered (to accommodate periodic visual tobacco inspection and
sampling ) leading to product falloff to the floor and dusting, particularly when transporting dry
leaf. Airborne particles collect on equipment, walls, and floor. In addition, most conveyor
systems are not optimally placed at points where tobacco transfers between 2 belts. Thus, at
direction changes, i.e., turns or drop-offs, tobacco sticks to the conveyor's rnetal sides and/or
spills to the floor. Throughout the plant, any tobacco that hits the floor is landfilled.
       Waste tobacco, which ends up in the landfill, compost, or wastewater effluent, is
generated in almost every operation observed during the plant tour. An estimated 1.7
million Ib/yr. of waste thus results in large solid waste hauling and disposal fees, POTW
quality surcharges, and labor for on-site waste handling. In addition, the lost product value
and associated production costs to the point of waste generation is estimated at $6.9
million/yr.

Assessment Recommendations (ARs)
Energy
       Recommendations for energy conservation are summarized in Table 2. Additional energy
conservation measures considered but not costed, out include:
. Light timing systems in areas occupied only during certain periods
. Set back thermostats in temperature controlled areas such as offices
. Preheating  inlet boiler air using the exiting stack gas

Waste
       Potential pollution prevention/waste minimization recommendations are summarized in
Table 3.  Estimated waste reduction from implementing the suggested ARs could be as high as
6.1 million pounds of solid waste. In addition, the current amount of hazardous waste generated
could be reduced by as much as 790 pounds per year. Implementing the hazardous waste
reduction suggestions could avoid the possibility of a higher waste generator status. The total
potential net annual savings that could be realized by implementation of all 3 ARs is estimated at
about $32,000/yr. Other potential pollution prevention/waste minimization opportunities that
were identified but not costed,  out include:
       . Standardization of paints to reduce the number of different types of paints used in
       plant maintenance
       . Reuse plastic trays from incoming lighter shipments
       . Put  empty canvas bags from tobacco delivery on a waste exchange
       . Extend machine shop  coolant life by: using deionized water, adding biocides, aerating
       sumps, recirculating coolant during down time, and keeping trash out of the sump.
       . Get powdered kitchen ingredients in bulk containers rather than paper bags
       . Recycle  steel banding from incoming materials shipments as scrap metal
       . In Packaging, place the weight sensors before the pouch sealer to avoid over or
       underfilling,  and otherwise make reject pouches with tobacco available for rework.

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       . Use catch pans in the Cutting and Bulking area to prevent excess flavoring from draining
        to the floor and reuse the captured material
       Several additional potentially important waste reduction ideas listed below, could not be
addressed adequately. These areas should be explored as the potential for savings and waste
reduction is significantly greater than for the above mentioned ARs:
1)  Reducing the amount of water used in processing and therefore wastewater volume
2)  Reducing the surcharges levied by the POTW
3)  Preventing tobacco wasting (or recovery of waste tobacco) for greater finished product yield.

       Each pound of finished tobacco requires about 1.3 gallons of water. This ratio could be
reduced by dry-cleaning or mechanical methods prior to water washing of equipment. Also, more
use of high pressure water spraying would reduce water consumption. Mechanical (dry) cleaning
of equipment prior to aqueous washdown would also accomplish:
       • Recovery of tobacco for possible reuse or alternative uses
       • Keeping solids from the floor and drain during washdown, thereby reducing labor for
        sweeping, and cleaning drains, which in turn would decrease POTW quality surcharges.
Removal of solids prior to washdown can also reduce soluble BOD by eliminating solubilization of
flavorants sorbed on the tobacco solids. Potential dry cleaning methods include:
       • Continuous or periodic compressed air blowing
       • Sweeping or scraping residual tobacco from equipment

       A preliminary economic analysis indicated that even a 3 year payback would be difficult to
meet for treating the final effluent for TSS and BOD surcharge removal. Depending upon the
number and nature of individual wastewater sources,  it might be more feasible to treat strong waste
streams at their source. For example, belt casing wash water showed TSS as  much as 300 times
that of total effluent and total and soluble COD up to 5 times greater. Total effluent flow rate is
almost 5 times as great. Thus smaller units, lower space requirements, and more flexibility in
treatment methods are possible. Because of the much higher wastewater COD (and by inference,
high BOD), a relatively high percent BOD reduction should be achievable at the source by ozone or
hydrogen peroxide oxidation.
       Available data indicate that the smaller sized particles contribute more significantly to the
COD. This suggests that microfiltration could be effective in removing TSS and associated BOD
surcharges. However, because of the stickiness of the tobacco, filtration could be difficult, and
flocculation/coagulation (or electrocoagulation) followed by settling might be more appropriate.
Since most of the solids readily settled in beaker and centrifuge tests, a hydroclone might also be
effective.

       Additional benefits from reducing tobacco wastage are further illustrated by using night
cleaning (major source of waste tobacco to composting and effluent to the POTW) as an example.
If all the solids could be recovered and used in processing, the savings could be as high as
$6,800,000/yr. Conservatively estimating that only 10% of the lost value can be recovered, a one
year payback would require an investment of no more than $680,000, not accounting for reduced
POTW surcharges and cleaning labor. It would seem that a lot of tobacco could be recovered by an
investment of this magnitude, and some potential measures described below  should involve little or
no operating costs.

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       . Cover conveyors in receiving and throughout the processing lines. Hinged clear plastic
        covers would allow tobacco removal at selected points for unloading, sampling, and
        visual inspection. Perhaps only the sections where falloff or dusting is greatest would have
        to be covered.
       . Strategically placed containers to catch and prevent tobacco from hitting the floor and
        becoming "worthless", e.g., catch pans below conveyors. For example, a vibrating screen
        is used to collect the very fine leaf pieces into an open box. Centering the box would
        reduce the potential of tobacco missing the box or overflowing.
       . Reduce product losses from transfer between belts with strategically placed
        sterile catch pans or boxes below the intersections. Covers at these points would deflect
        falling tobacco onto the lower belt. Another approach is to redesign the conveyor systems
        to avoid or minimize changes in direction, i.e., drop-offs, turns
       . Switch to enclosed air blowing (conveying systems). This would require a partial or
        complete redesign and new equipment. Compressed air costs would be a primary
        consideration, and additional air compressors might be necessary
       . Reduce dust room leakage by tightening up the system and initiating a preventative
        maintenance program
       . Increase or extend height of conveyor side walls
       . Wider conveyors
       . Belts with better release characteristics to reduce tobacco sticking, e.g., nylon surfaces
        rather than metal at conveyor turns, coating or spraying belts with non-stick material, e.g.,
        Silicone, Teflon. This can this lead to product recovery and reduce the amount of solids
        washed off of equipment, some of which gets into floor drains and the sewer..

       Of the above measures, replacing current conveyors with a closed air blowing system
should be the most effective, but could also be the most expensive. Priority could be given to
covering conveyors and reducing product losses at transfer points between conveyor belts.

                                   Industrial Laundry
       The facility rents and launders uniforms, shop towels, shop aprons, coveralls,  and other
items for a variety of manufacturers. There are about 120 employees, and annual sales are about
$8,000,000. Washing is done in seven washers, and subsequent drying in 5 gas fired  dryers.
Approximately 7,000,000 Ibs. of laundry is processed annually. Figure 2 is a process flow
diagram and Figure 3 shows the water flow.  Table 4 summarizes the waste generation.
       An estimated 13 millon gallons of process water are consumed annually. Sewer bills are
based on the amount of water purchased rather than what is  actually discharged to the POTW.
Lint, dirt, sand, and metals pieces (nuts, bolts, etc.) are removed from the washer discharge
(waste)water by a series of stationary screens and one vibrating screen. POTW surcharges are
incurred for BOD above 250 mg/1. and for TSS above 275 mg/1. Heat from the wastewater is
reclaimed in a shell and tube heat exchanger to preheat incoming city water. Modification of the
pretreatment system is a priority, since the facility was in significant non-compliance  for oil and
grease, with a potential penalty of $ 10,000/day. The facility does not have a preventive
maintenance program, but one is being developed.
       The plant is not a hazardous waste generator nor a SARA 313 TRI reporter. Air permits
are not required for the dryers which have baghouses to remove particulates.  A wastewater

-------
discharge permit is required by the POTW.  A small amount of waste hydraulic oil generated
from washer, dryer, and compressor changeouts is reclaimed off-site. Pit sludge (containing dirt,
oil, grease, and other solids) are landfilled as special waste. All other wastewater solids are
landfilled as general trash.

Assessment Recommendations
       Table 5 summarizes energy conservation recommendations  Additional energy
suggestions not costed out include:
       . Light timing devices
       . Set back thermostat
       . Boiler air preheat
       . Switch to lower Industrial Power rate from General Service rate
       . Insulate dock doors
       . Reduce leaks in compressed air lines

       Table 6 summarizes potential waste minimization recommendations. Reuse of the
relatively clean rinse waters in the early stages of subsequent wash cycles would save water and
associated sewer charges. Additional piping and trenching and washer reprogramming would be
necessary. A skimmer in the settling basin might consistently reduce oil and grease below
regulatory levels, thereby avoiding potential fines and reducing BOD surcharges. However,
because free and emulsified oil are present, testing would be required. If O&G removal were
insufficient, more expensive removal methods would be required, e.g., coalescers, dissolved air
flotation, or membrane separators.  In this case it may be sufficient to process only the
washwaters from the most oily loads.
       Additional waste minimization possibilities not costed out include:
       . Segregation of high oil content wastewater
       . Redesign pretreatment system following equalization, to provide solids removal prior to
        heat recovery. This should reduce heat exchanger fouling and float more of the oil for
        greater removal by skimming
       . Additional pretreatment for reduction of TSS and BOD and water reuse
       . Optimize and revise chemical usage program
       . Re-evaluate criteria for accepting customer items, e.g., require customers to remove
        excess oil and nuts and bolts
       . Increase mixing in solids pit to minimize solids settling and subsequent required pit
        cleanouts
       . Use a shaker or magnetic device to remove metal pieces from laundry prior to washing
       . Install a sewer meter and pay sewer volume charges on actual discharge

                                      References
Fleischman, M.; Walters, J.C.; & Cobourn, W.G., "Examples from P2 & Energy Assessments at
  Small to Medium Size Manufacturers", Proc. EPA Region III Waste Minimization/Pollution
  Prevention Technical Conference for Hazardous Waste Generators, June 3-5,1996, Phila, Pa.

-------
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Table 2 - Energy Recommendations
               (Tobacco)
  Summary of Savings and Costs
AR
No.
1
2
3

Description
Reduce
Compressor
Operating
Pressure
Install High
Efficiency
Motors
Adjust Boiler
Air-Fuel Ratio
Total Savings
Potential
Conservation
(MMBtu/yr)
78
462
6,331
6,871
Potential
Savings (S/yr)
$880
$4,620
$16,145
$21,645
Resource
Conserved
Electricity
Electricity
Natural Gas

Impl., Cost ($)
$100
$12,140
$2000
$14,240
Payback Time
1 month
3 1.5 months
(2.6 years)
2 months
* 8 months
          Table 3 - Tobacco
Summary of Waste Assessment Recommendations
Current Practice
Waste tobacco is either
landfilled or composted
The company is concerned
about their hazardous waste
generator status increasing
from limited to small quantity
generator
Waste foil (and some
tobacco) generated in the
packaging area is
landfilled or composted
Proposed Action
Give the waste to potential
users through a waste
exchange or go through
a broker
Reduce hazardous waste
generation by using an
aqueous-based parts
washer and substitute
the silk screen cleaner
Give the foil to an Indiana
manufacturer for use as
a raw material
Estimated Net
Annual Savings
Waste Reduction: 4.2 million Ib.
Investment: Minimal
Savings: $24,250/yr.
Staple Payback: Tim e: Immediate
Waste Reduction:
790 IbJyr. hazardous waste reduction
Investment:1 $572
Savings:2 $4,677/yr.
Simple Payback Time: 5.3 months'
1.5 months3
Waste Reduction : 1.9 million Ib.
Investment: Minimal
Savings: $3,500/yr.
Simple Payback Time: Immediate
            For the substitute parts washer only
            Includes administrative & analytical savings
           3 Based on total savings and pants washer investment

-------
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-------
                  Table 4
            (Industrial Laundry)

Waste
Effluent to POTW
Surcharges (BOD, TSS)
Solids from trench,
from sleds,
from equalization/screens,
from vibrating screen,
from dryer exhaust bags.
Total
Oils from machines
Pit sludge
Cardboard Boxes
General Trash, includes:
White Paper
Fluorescent Bulbs
Pallets (damaged)
Drums (some)

Operation
Washing
Water Treatment
H
H
H
Drying
Maintenance
PitCleanouts
Receiving
Overall
Total Waste to Landfill:
Total Landfill Cost:
Waste Generation
Annual
Quantity
13,000,000* gal
lyd3
6yd3
2yd3
7yd3
100yd3
116yd3
250 gal
4yd3
150yd3
520yd3
640 ydV
$l,800/yr
Management
Method
POTW
Landfilled
H
II
H
II

Off-site Reclamation
Landfilled (?)
Recycled
Landfilled
H
H
(Reused, Reconditioned or Trashed)
(Returned, Reused, or Trashed)
Annual
Disposal Cost t
$29,000
$10,000

$360
$200
N/A
$600
$1,440
t - Includes 6% tax
* estimated - see Appendix I
N/A = not available
                  Table 5
         Energy Recommendations
            (Industrial Laundry)
AR
No.
1
2
3
4

Description
Adjust Boiler Air-
Fuel Ratio
Reduce Compressor
Operating Pressure
Install High
Efficiency Motors
Install High
Efficiency Lighting
Total Savings
Potential
Conservation
(MMBtu/yr)
725
11
109
78
923
Potential
Savings ($/yr)
2783
219
2143
1537
6682
Resource
Conserved
natural gas
electricity
electricity
electricity

Impl. Cost ($)
2000
20
2720
2468
7208
Payback
Time
9 months
1 month
13 month
19 months
1 1 months

-------
                                     Table 6
                              (Industrial Laundry)
Summary of Proposed Waste Assessment Recommendations
Current Practice
/
No water is recycled; all water used .
for all stages is fresh city water
NTo system is in place to remove
oil and grease from the
wastewater effluent
Removal of solids using
a series of fixed screens and
a vibrating screen
Proposed Action
Reuse the last few rinse stages of
each wash cycle in subsequent
washes
Purchase and install an oil
skimmer to facilitate oil and
grease removal
Install a hydrocyclone in series
with the screens to increase
solids removal
Potential Estimated
Annual Benefits
Waste Reduction: 4,800,000 gal
Investment: $10,500
Savings: $14,800
Simple Payback Time: 37 weeks
Waste Reduction:
Investment:
Savings: *
Simple Payback Time:
Waste Reduction:
Investment:
Savings:
Simple Payback Time:
3100 Ib.
$8,000
$60,500
7 weeks
54,000 Ib
$5,400
$4,000
1.4 years
* Savings include avoided potential fines for non-compliance with oil and grease in discharge to POTW.

-------
   Glenn Gabriel





Abbott Laboratories

-------
                                   Glenn Gabriel, P.E.
                                  Abbott Laboratories
                                 Dept. 539; Bldg. AP52
                                 200 Abbott Park Road
                               Abbott Park, IL 60064-3537

                                     (847) 935-2845

Glenn Gabriel joined Abbott in 1995 as its corporate pollution prevention programs coordinator.
Glenn's prior experience includes environmental management and manufacturing support posiitons
with G.D. Searle, Baxter, and AT&T.  Glenn has a B.S. degree in Chemistry from the University
of Illinois at Chicago and an M.S. in Chemical Engineering from the Illinois Institute of
Technology. Glenn is also a registered professional engineer in Illinois.

-------
November 26, 1996

Title: Lessons Learned from Abbott's Pollution Prevention Program

Abstract:

My presentation will include a discussion of several recent pollution prevention successes as
reported by various Abbott manufacturing, research and development facilities located in
Northern Illinois (Lake County). These case studies will focus on the lessons learned from each
scenario and will present a "how to" picture from which the audience can learn.

These cases will be organized by the familiar P2 hierarchy: source reduction, recycle, reuse, etc.
Furthermore, cases will be discussed from various stages of the production life cycle, i.e., design,
production, use, and ultimate product disposal.  There will be a general discussion of the various
categories of P2 cases with a more detailed treatment of three  of four of them.

Abbott Laboratories is a global, diversified company dedicated to the discovery, development,
manufacture, and marketing of health care products and services.  Abbott has several diverse
operating divisions with facilities in Lake  County, Illinois. Each division is a unique entity unto
itself with pollution prevention cases which reflect this diversity.  Therefore,  the cases presented
will be relevant to people employed outside the health care products industry.

-------
        Dave Heinlen





Bowling Green State University

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           BIOGRAPHICAL INFORMATION FOR DAVE HEINLEN
•     Safety and Health Coordinator for the Department of Environmental Health and
      Safety - Bowling Green State University since 1984

•     Bachelor of Science degree in Zoology - Ohio State University

•     Masters of Science and Education in Public Health degree - University of Toledo

•     Worked for the City of Bucyrus and City of Galion, Ohio health departments prior
      to joining BGSU

•     Registered Sanitarian

•     Affiliate faculty with BGSU's College of Health and Human Services


Orphan Chemical Recycling Program Recognitions

•     Award of Distinction for Innovative Programming from the National Safety
      Council/Campus Safety Association

•     Governor's Award for Outstanding Achievement in Pollution Prevention

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             BGSU'S ORPHAN CHEMICAL RECYCLING PROGRAM:
                               A COMMUNITY EFFORT


                                         Introduction

In most academic laboratory settings, it is common for chemicals that are still useful to remain on shelves,
under hoods, and in other areas of storage, unwanted or unneeded by those who maintain them. Eventually,
a majority of these "orphans" make their way into a particular waste stream, necessitating some form of
appropriate management. In addition to  staff time and disposal costs associated with this management,
environmental and liability issues attend the handling and disposal of chemical waste. While these chemical
"orphans" remain in storage, departments within the University may be purchasing virgin chemicals identical
to the orphans in other University locations.

Because of these circumstances, the Department of Environmental Health and Safety at Bowling Green State
University (BGSU) began an in-house orphan chemical recycling program in the fall of 1991.  This project
was implemented primarily to identify and transfer unwanted chemicals between University departments as
a means of minimizing hazardous waste generation.  Even though this initial project was not extensively
promoted, it is estimated that 700 pounds of solid materials and 50 gallons of liquids were transferred
between University departments.

In the fall of 1992, BGSU began to develop a plan that would expand the existing orphan chemical program
to include nonUniversity academic institutions. Reasoning for the participation of nonUniversity institutions
centered  on  several factors.  First of all, involvement of nonUniversity institutions would  increase the
potential for the distribution of the University's orphans. It was felt that similar departments (chemistry,
biology, art, etc.) from different institutions would have the same types of chemicals available, thus providing
a better opportunity for distribution.  Secondly, the program would provide a financial incentive to these
institutions as well as BGSU because of the added potential for orphan distribution. A dual cost-savings to
the participating institutions and the University could be realized by keeping usable materials out of wastes
streams as well as eliminating the need to purchase new materials. The expanded recycling program would
have an  additional  benefit of enhancing  the  cooperative  relationships between  the University  and
nonUniversity institutions by making assistance with other hazardous materials/waste management issues
available if requested.  Institutions  viewed as potential participants were high schools, Jr. high schools,
technical colleges, and similar facilities, primarily within Wood County, Ohio. Since the program was
designed to be of service to the participating institutions, a decision was made that no fee would be charged
for taking part in the program. Also, an institution would not have to submit an orphan chemical inventory
(explained later) to participate.

To assure that the program would not conflict with current regulations, a draft of the program proposal was
developed and submitted to the Ohio EPA and the Public Utilities Commission of Ohio for review.
Representatives from both agencies accepted the concept and the procedures outlined in the proposal.
Department  of Transportation officials were also informed of our intentions to confirm that our planned
method of chemical transfer was consistent with their requirements. Once the regulatory concerns had been
addressed, the plan was presented to the University administration where it was again favorably received.
Final acceptance of the program came following discussions with representatives of the Wood County Board
of Education.  After gaining the support of the proposal from these necessary constituency groups, a
description of program parameters and recommended handling procedures for the orphans was sent to the
institutions desiring to participate in the program.

-------
Thirteen nonUniversity academic institutions (eight high schools, two Jr. high schools, a medical college, a
technical college, and a joint vocational school) were initially considered formal participants in the recycling
program. In 1994, a local hazardous waste management company (RES) began participating in the program.
Due to the involvement of RES, other academic and nonacademic facilities in Ohio and Michigan (forty-two
to this point) have been a part of the program on either a one-time or an occasional basis.

                                            Methods

Under the provisions of the program, each participating institution/facility selects an individual to serve as
the contact for the facility. Generally, this person functions within the institution's department of chemistry,
facilities  research and development division, or similar science-related  area.  BGSU departments  are
represented by individuals who are the primary departmental contacts within the University's hazardous waste
management program.

Institution and facility representatives  subsequently conduct an inventory of their chemical stocks, listing the
available orphans on a standardized orphan inventory form.  The program's hazardous waste management
company is able to identify  potential orphans from the materials inventoried during routine disposal activities
for their clients. Requested information on the inventory include, for each chemical, the number of containers,
the total quantity of the material, the manufacturer and chemical grade (if known), and whether the chemical
containers are unopened or the chemical has been repacked.

As indicated earlier, the quality of the chemical is a major factor during the selection of orphans. It is the
responsibility of the facility contact to assure the usability of the chemical. The quality of the orphan should
not have diminished to the  point where it can no longer be used. If requested, the University or hazardous
waste management company may be able to assist the institution or facility in determining the chemical quality
of the orphan(s).

Institutional and management company representatives submit lists of their available orphans to BGSU's
Hazardous Waste Coordinator as frequently as the orphans are identified. The Hazardous Waste Coordinator
then compiles the chemical data onto an alphabetized master list using spreadsheet computer software.

Hard copies of the master list are then sent to each facility representative who oversees its distribution within
the institution, department, or facility.   Updates to the list are normally sent on a
quarterly basis.  Hard-copy updates may be sent more frequently if a significant number of "new" orphans
have been identified or numerous chemical transactions have taken place.

The orphan list is also a component of BGSU's GOPHER CWIS (Campus-Wide Information Server). This
computer resource is available to any institution/facility having access to the INTERNET system. The listings
can be viewed and/or printed from this source but cannot be modified.  The listings on the server are updated
regularly and are therefore  more current than the quarterly hard copy listings. The listings can be accessed
using the URL identification as follows:

                          gopher://gopher.bgsu.edU/l/Departments/ehs

Those alreadt into the GOPHER system can access the listings under the BGSU (Ohio) Gopher Server ~»
Departments -»  Environmental Health and Safety.

All orphan chemicals remain at the originating institution/facility until they are claimed or otherwise managed.
This limits problems in multiple material handling and prevents questions of responsibility for disposal should
the orphan(s) continue to be unclaimed.  An exception to this policy involves potential orphans identified

-------
by RES  during normal waste management activities.  Since these wastes/orphans generally necessitate
expeditious movement off site, there would be insufficient time to  disseminate information on orphan
availability prior to their removal.  To address this potential loss of orphans, utilization of the University's
hazardous waste facility for the temporary storage of "high visibility" orphans is being planned. Use of the
facility  would allow the time necessary to properly advertise orphan availability while providing a safe
storage site.  A formal agreement would be used to affirm RES's responsibility for the final disposition of any
unclaimed orphans.

An institution/facility desiring to obtain an orphan (or orphans) is responsible for initiating the transfer. To
facilitate the movement of orphans from one location to another, the facility representative contacts the
University's Hazardous Waste Coordinator or RES representative. Specific arrangements for orphan transfer
are then made through their combined efforts. This procedure permits the most feasible control of orphan
transport while assuring that all transfers are properly documented.

Handling procedures during the transfer of BGSU orphans primarily  follow DOT shipping requirements.
Containers of orphans covered by DOT regulations are packaged individually (or "labpacked" if compatible)
in DOT acceptable boxes and labeled according to DOT specifications. For orphans not covered under DOT
shipping requirements, no formal packaging is performed other than securing the containers during shipment.
Orphans transported by the  University are moved using a capped University pickup truck.  The containers
of orphans are placed in a 3" X 5' wooden box located in the rear of the vehicle.  The shipping box has a
bottom layer of absorbent material and is equipped with removable partitions for separating containers of
various sizes and compatibilities. A spill kit and shipping paper are also taken during BGSU's movement of
regulated orphans.

In conjunction with each shipment, a Material Safety Data Sheet (MSDS) for each orphan is offered to the
institution/facility receiving the orphan(s).  A formal document on MSDS distribution has recently been
developed. This form will be used to indicate whether the orphan recipient needs particular data sheets or
currently has them available.  The form will accompany all orphan transfers and will tie signed by the recipient
of the orphans.

Once a transaction has taken place, the Hazardous Waste Coordinator removes the chemical(s), in whole
or in part, from the master list. Changes in the orphan inventory are reflected on the hard copies of the
updated master list resubmitted quarterly to those institutions/facilities not using the Gopher CWIS system.
Changes on the CWIS are made following each transaction.
                                          Conclusion

Since April of 1993, the orphan chemical recycling program has transferred approximately 3,000 pounds of
solids and 900 gallons of liquids to "needy" institutions and facilities.  The dual cost savings associated with
these transfers (for purchase and disposal) have been approximated at between $265,000 and $350,000.

In addition to the chemicals being transferred, there are also "nonchemical" items that are given away or
reused as a part of the orphan chemical program.  Empty five-gallon containers that have been cleaned and
sealed are taken from  one University department and delivered to others to use for storage.  DOT shipping
boxes used in the transportation of chemicals to the University are kept for transporting regulated orphans.
Bags of vermiculite are saved for packing orphans or given to the hazardous waste: management company.
Cleaned 55-gallon drums can be reused as refuse containers or kept for the storage of other liquid wastes
Cost savings for these storage/packaging materials are not included in the overall savings of the program.

-------
In addressing the issue of potential liability for the distribution of these chemicals, the University, together
with RES, has developed an indemnification document.  The document is an attempt to protect the University
and the waste management company from liability for the misuse of the orphan chemicals following their
transfer.  The document is to be signed by a formally designated representative of the institution/facility
(principal, superintendent, facility manager, etc.).

Yet to be determined is the length of time that an orphan spends on the list before implementing some other
form of management. Realized and planned expansions of the program have warranted that those on the list
remain, at least until newly added participants have an opportunity to obtain them.  Once program participant
levels have stabilized, a specific time frame for orphan availability will be set. The University and RES will
subsequently assist participants with disposal/management options for unclaimed orphans.

The cooperative efforts between the University and the local hazardous waste management company have
added a new dimension to the recycling program. As stated earlier, RES is able to identify potential orphans
during routine waste management activities at both academic and nonacademic facilities.  Working in
conjunction with facility representatives, the company's identification of orphans not only increases the
quantities of available materials within the program, but it also demonstrates appropriate waste management
techniques to these facilities while reducing their waste disposal costs.

Through this  established relationship with RES,  a further expansion of the program is  currently being
implemented.   The expansion is directed mainly toward academic institutions  within the seven counties
surrounding Wood County.  An explanation of the  program has been sent to representatives of these
institutions, requesting their consideration of participating in the recycling effort. Contact with  potential
participants will proceed on a regular basis to include as many institutions/facilities as possible within the
program.   Nonacademic facilities  will be encouraged to participate either as  a  one-time effort or on a
continual basis, depending upon their particular orphan inventories.

In conjunction with this expansion, periodic discussions with the contacts of participating institution and other
facility representatives are ongoing. These  informal meetings assist in resolving any  misunderstandings
encountered in program implementation and serve to further  strengthen cooperative relationships.  Also,
through formal presentations to environmental colleagues  and discussions with other interested parties,
information about the program will be disseminated whenever possible to encourage the development of
similar programs.

It is hoped that through the  success of this  program, more facilities will become participants, additional
monies  will  be saved,  cooperative relationships between  the University  and other nonUniversity
institutions/facilities will be strengthened, and further protection of the environment will be achieved. It is
also hoped that other institutions  and waste management companies  will investigate the possibilities of
implementing these or similar chemical recycling efforts.  Others may then experience success in minimizing
waste and preserving the environment while demonstrating financial responsibility by providing  cost savings
to both the "giver" and the "receiver."
Oiphprog

-------
              ORPHAN CHEMICAL RECYCLING PROGRAM
       FOR NONUNIVERSITY INSTITUTIONS AND FACILITIES
                                    (A PROPOSAL)

The  Department of Environmental Health and Safety (EH&JS) of Bowling Green State University in
conjunction with Rader Environmental Services of Findlay, Ohio, are proposing an expansion of an existing
chemical recycling program for academic and nonacademic institutions primarily within an eight county
region centering on Wood County.

The  recycling program involves the identification of useable chemicals that are unwanted (orphans) and
makes them available for other institutions/facilities to obtain and use.

Purpose

The  purpose of the orphan chemical recycling program is:

       1)  to  reduce  the amount of hazardous wastes being generated by participating
           institutions and the University thereby decreasing the costs of proper hazardous
           waste management,

       2)  to reduce the costs to these institutions in purchasing new chemicals,

       3)  to reduce the inventories of unwanted chemicals, and

       4)  to   strengthen   the   cooperative  relationships  between  the   University  and  area
           academic/nonacademic institutions by providing a means to minimize hazardous wastes and, if
           requested, to assist these institutions with other waste management issues.

Procedures

The information included with this proposal  provides an overview of the recycling program and the
procedures implemented by BGSU and other current program participants.  A brief explanation of the basic
program parameters is given below.

       1.  Identification of Participants

           Institutions/facilities interested in participating need to contact Dave Heinlen at (419) 372-2173
           or Joe Rader or Bruce Deppen of Rader Environmental Services at 1-800-858-7374.  Each
           participating institution will be asked to select a representative who wifl serve as the contact for
           their facility. Participants  will be placed on a roster which will serve as the primary "transfer
           network."

       2.  Submission of Orphan Chemical Information

           Using the enclosed form, the contact for each participating institution submits an inventory of
           any orphan chemicals available for  transfer. Only useable materials are considered acceptable.
           An institution is not required to submit an inventory in order to participate in the recycling
           program. Inventories should be sent to the following address:

-------

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     FREE
   CHEMICALS
Bowling Green State University's Orphan Chemical Recycling Program
       January 1997

-------
; No. of Tola
i Clismical Name Cont. Quant
Fuchsia Carbol I 5 g
i Unopen./ Chemical
ity Repacked. Manufacturer
Allied Chem.
Original
Grade

Fuchsin-Cajbol (Kinyoria modified staia) 1 16 oz.
Onbroth Hajna 1 1 ft>.
he^adecanol I 1 kg
Histidine Assay Medium I 100
Hydroquinone 1 400
g Unopened Difco
g


H/diOxy-L-Proline 1 I g Unopened Sigma
Lut'.jie 1 1 oz. Fisher
ijvisuol Aisay Medium I 100
g Unopened Difco
Certified

Ic.iiat; Gerinkitte 1 150 ml Lilly
'riiilV" Solution ffbif AlSKWfea rtiffT**"^3**"0) ' Tflfl ml Hnrlrn
Iron Sulfice I 2200 g
Iioci.~ci.rk Casein 1 60 g Difco
jcniser's Stain 1 25 g Matheson
Certified
Koser Citrate Medium 1 1 lb. Unopened Difco-
L(+) Arabinose ,1 4 g Unopened Sigma
I -Ckfulline 1 100
!. 'AM;>?.-K: 1 25
1 ^aii Carlonate (basic) 1 200
(.;...•: Clue mace I 250
'. ead Nitrate I 100
g
g
g
g
g
'.^uNiti-iie 1 4 oz. Fisher
L~ad Gxieie (Litharge) 8 40 Ibs. Repacked Coleman
Lead Peroxide 1 60
Lipid Crimson. Stsm 1 10
g
g ESBE Lab.





Reagent
Technical


L) sine Assay Medina 1 100 g Unopened Difco
Magnesium Chloride I 98 Ibs. Malin
Technical
Magnesium Hydrogen Oihophospnate 1 375 g Difco
Maleic Acid Hydrazide 1 100 g Eastman O.
Practical
Malt Extract 2 2 Ibs. Unopened Difco
May Greenwaid Stain 1 25
g Harleco

Mercuric Chloride 1 100 g
Meicaric Iodide 1 200 g
Methonine Assay Medium 1 100 g Unopened Difco
Methyl Red (granular) 1 9
g Difco

Methyl Salicylate 1 lib. Central
Methyl Sulfoxide 20 500
ml
MethylereBSueThiocyanate 1 100 tablets Unopened Pharmaceutical
Moly&dic; Acid 23 23 Ibs. Repacked FisherJBaker

Certified
Reagent
Molybdic Acid (85%) 1 400 g
Moncchlorobenzene i 1 pt Fisher
Monotnioglycerol 1 25 g Sigma
Certified
Grade II
Location
Code
BU(W)
BU(W)
BU(W)
BH(W)
BU(W)
BH(W)
BU(W)
BU(W)
BU(W)
BU(W)
BU(W)
E(W)
BU(W)
BU(W)
BU(W)
BU(W)
MC(L)
MC(L)
E(W)
E(W)
MC(L)
BU(W)
BU(W)
E(W)
BU(W)
BU(W)
BU(W)
BU(W)
BU(W)
BU(W)
BU(W)
MC(L)
BH(W)
BU(W)
BU(W)
BU(W)
MC(L)
BU(W]
BU(W]
E(W)
BU(W^
BU(W;
Mycobiological Broth 1 1 lb. Unopened Difco BU(W^
Mycobiotic Agar 1 1/4
^-1- Ethyl Maieimide 1 5
Naphthalene Acetic Acid 2 2
lb.
g
g Unopened Gen. Biol.



Naphthalene Monefcromide I 100 g Fisher
Neutral Red (graoohr) 1 10 g Baker
Reagent
Niacin 1 100 g
Niacinamide 1 100 g Unopened Sigma
l-fjcke! AmmoniuEn StdfMe 2 100 g
Nitrobenzene I 470 ml
0-DianisitiiaeDiHCI I 1
Ocladecsnol 1 1
g
kg


Octyi pherioxy polyethyoxyethanol 1 100 ml
Oil Red 0 I 25 g Matheson
Orange G 1 10 g Pharmaceutical
Gxythiamine HCL 1 0.
1 g Unopened Nutritional Bio.
BU(\v;
MCCL;
BU(W
BU(W
BU(W
MC(L
BU(W
E(W)
E(W)
MC(L
BH(W
BH(\V
BU(\V
BU(\V
BU(\V
"jpain. NFVa 1 100 g BU(W

-------
                   ORPHAN  CHEMICAL SHIPPING FORM
                          Bowling Green State University
Receiving Department/Institution
Date of Shipment
Receiving Department/Institution Contact

CHEMICAL/PRODUCT NAME






















NO. OF
CONT.






















TOTAL
QUANTITY






















HAZ.
CLASS























DOT ID#
(IF APPLICABLE)






















DOT
ERG #






















                                    HAZ. CLASS
                         I - Ignitable C - Corrosive  T - Toxic R - Reactive
                  CHEMTREC Emergency Number:  1-800-424-9300

-------
                 BOWLING GREEN STATE UNIVERSITY'S
              ORPHAN CHEMICAL RECYCLING PROGRAM
            MATERIAL SAFETY DATA SHEET  DISTRIBUTION
Please check one of the following:
      I have current Material Safety Data Sheets for the chemicals obtained as part of BGSU's Orphan
      Chemical Recycling Program
      I wish to obtain Material Safety Data Sheets for the chemical(s) identified below:
               Chemical Name
               (Name/Title - Printed)
                  (Signature)
                (Institution/Facility)
     (Date of Transfer)

-------
                    BOWLING GREEN  STATE  UNIVERSITIES
                 ORPHAN  CHEMICAL  RECYCLING PROGRAM
Dear, Program Participant:

Since April of 1993, BGSLTs Orphan Chemical Recycling Program has transferred free chemicals
between academic institutions and other facilities. These transactions have resulted in a dual cost savings
for disposal as well as purchase. It is the desire of Bowling Green State University and Rader
Environmental Services, Inc. to continue this program as long as possible.

Even though this program is a service to participating institutions and facilities, BGSU and Rader
Environmental Services, Inc. do not wish to incur liability for the mishandling of these chemicals once
they are received by the program participants. In addressing this issue, we have developed the agreement
below.  We ask that it be signed by the authorized representative of the institution/facility receiving the
materials. Thank you for you understanding and for your participation in this most valuable program.

Sincerely,

Dave Heinlen
BGSU

Joe Rader
Rader Environmental Services, Inc.
      LIABILITY RELEASE. WAIVER DISCHARGE AND COVENANT NOT TO SUE
	, ("Participant") in consideration for
participation in the Orphan Chemical Recycling Program sponsored by Bowling (3reen State University
("BGSU") and Rader Environmental Services, Inc. ("Rader"), agrees to release and hold harmless BGSU,
RADER, their officers, employees, agents, and students, from any and all liability, claims, demands, and
actions or causes of action, whether caused by negligence of BGSU or RADER or otherwise arising out
of its participation in this program. In no event shall BGSU or RADER be liable  for attorneys fees,
punitive damages, damages for pain and suffering, loss of companionship, consortium, and the like.
Participant recognizes that this release means it is giving up, among other things, rights to sue BGSU and
RADER, their officers, employees, agents, and students for injuries, damages, or losses that Participant
and its representatives, employees, and agents may incur.  Participant also understands that this Release
binds its heirs, executors, administrators, and assigns.

Participant has read this entire Release, and fully understands it and agrees to be legally bound by it.

   THIS IS A RELEASE OF YOUR RIGHTS. PLEASE READ CAFEFULLY BEFORE SIGNING
            (Authorized Agent for Participant)                                         (Date)

-------
  Stephen J. Hillenbrand





Tennessee Valley Authority

-------
             Overview of Fourteen
             Applied Technologies
                   Stephen J. Hillenbrand, PE
             Industrial Waste Reduction Engineer
                  Tennessee Valley Authority
                      Knoxville, Tennessee
                           Presented at the
      U.S. EPA Region 5 Waste Minimization/Pollution Prevention Conference
                         February 25 - 27, 1997
                           Chicago, Illinois
                   Waste Reduction Through
                   Applied Technologies (AT)

The following overview briefly describes fourteen technologies that have traditionally
not been considered for their Waste Reduction benefits, but primarily as process
technologies for enhanced product quality or for their economic benefits. These ATs
also do have potential Waste Reduction capabilities.

These technologies are not "one size fits all."  They are practical only under certain
conditions, but they can greatly reduce waste and save money where they can be used.
However, these technologies do lend themselves to innovative applications and should
be considered as an option even outside their traditional industrial sectors.

This overview will familiarize you with the basic information about ATs.  If a potential
application is suspected, contact an equipment vendor or an engineering consultant
that specializes in the technology. This should be the first step in determining whether
the potential use is practical. Your electric utility or the Electric Power Research
Institute (800-432-0267) are also valuable resources.

-------
                                                               L970110bdoc
This presentation is not intended as a recommendation of any particular
technology, process, or method. Mention of trade names, vendors, or
commercial products do not constitute endorsement or recommendation for use.
It is offered for educational and informational purposes and is advisory only.

-------
Waste Reduction through
  Applied Technologies
TECHNOLOGY
Direct
Resistance
EDM
Electrical Discharge
Machining
Heat Pump
Indirect
Resistance
Infrared
Induction
Laser
Membrane
Microwave
Plasma Arc
Plasma
Nitriding
RF
Radio Frequency
UV
Ultraviolet
Waterjet
Saves
$$$
X
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X
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Increases
Quality
X
X
X
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X
X
X
X
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Reduces
Air
Emissions
X
X
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X
X
X
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Hazardous
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X



X
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X
X
X
X

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X
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Water
X




X
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Use
X
X
X
X
X
X
X

X

X
X
X


-------
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-------
  Applied Technology: Direct
  Resistance

  Concept
                                                             Part to be heated

                                                                  Contacts
                                                    Source: EPRI TechCommentary V2, N8, 1S
Direct Resistance heating involves passing an
alternating current directly through the workpiece
to be heated. Since the part must be electrically
conductive, it is often also referred to as conduction heating. With this type of
heating, clamp or roll types of electrodes must be used to physically make
contact with the workpiece. For food products, the sauce or gravy is the
workpiece. The resistance (R) of the workpiece to the current (I) passing through
generates the I2R heating.  Low frequency current (60 Hz) heats the part
throughout.  High frequency current (400 kHz) tends to heat only the surface of
the part.
  Applications
  •  Hot Metal Working; forging,
     stamping, extrusion, rolling, and
     upsetting
  •  Heat Treating
                                           Metal Joining; spot, seam, and
                                           flash welding
                                           Preheated Glass and
                                           Semiconductor
                                           Food Sterilization (Ohmic Heating)
  Technologies Replaced
  •  Salt/Lead Bath Heat Treating
  •  Fossil/Electric (indirect
     resistance)  Furnace
  •  Retort Canning of Food

  Wastes Reduced
  •  Combustion Pollutants; ROG,
     SOX, NOx,COx, Particulate
  •  Material Oxidation; slag, scale
Potential in Manufacturing
                                           Flame Hardening
                                           Torch Welding
                                           Salt/Lead Bath; hazardous
                                           salts/metals
                                           Process and Waste Water (Ohmic
                                           Heating)
Indust SIC Pot
Food 20 MED
Tobac 21 LOW
Textile 22 LOW
Apparel 23 LOW
Indust S/C Pot
Lumber 24 LOW
Fum 25 MED
Paper 26 LOW
Printing 27 LOW
Indust S/C Pot
Cham 28 LOW
Petrol 29 LOW
Rubber 30 LOW
Leather 31 LOW
Indust SCfef
Stone 32 MED
Pmetat 33 HI
MetFab 34 HI
Mach 35 MED
Indust SIC Pot
Elect 36 MED
Transp 37 MED
Instr 38 MED
Misc 39 MED
Credits: George Bobart, Bobart Associates; Unhnar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                       AT01

-------
Direct Resistance continued
Technology Advantages
•  Fast Heating                         •  Moderate Cost
•  Selective and Uniform Heating         •  High Efficiency
•  Small Space Requirements


Technology Disadvantages
•  Heating; uniform part cross-           •  Welding; part configuration must
   section required                        provide high resistance to flow of
•  Heating; part must be long and            current
   slender                              •  Contact Surfaces; must be clean
•  Heating; low to moderate                 for good electrical connection
   production rates

Typical Costs

Capital Costs                0 & M Costs                Potential Payback

moderate: $25k -            low maintenance,           1-2 years
$100K                     costs
                           highly dependent on
                           electric rates

Installations
Case A - An open flame oxy-fuel type of heat treat equipment was originally
utilized by a midwestem machine tool manufacturer to selectively harden the
teeth on a long gear rack.  Using the flame process, there were basic problems
with part distortion and uniformity of the hardening pattern. Due to the extremely
low heating efficiency, the flame process also had high energy costs and air
pollutants (combustion by-products). All of the process problems were corrected
by installing a direct resistance heating system with direct contacts on each end
of the hardened area. This greatly improved the quality of the part, reduced the
energy cost by 70%, and eliminated all of the air pollutants.

Case 6 - Most of the tube and pipe around the world was produced by a process
that utilized a fossil furnace to heat flat strip, form it into pipe and weld it along
the length with an oxy-fuel torch. A newer type of high frequency direct
resistance heating only heats a narrow area of the edge of the pipe that is to be
welded. It therefore significantly reduces the energy required and the air
pollutants associated with the older fossil fuel based welding processes. It is
also much faster than certain conventional rotating electrode or the arc welding
technologies, such as TIG or MIG processes.  In addition, it provides far greater
control of the seam temperature for the welding process, thus reducing product
scrap due to rejects. While induction heating is often used for small diameter
pipe and tube, direct resistance RF contact welding is extremely cost effective on
larger diameter pipe, and generally provides a payback of less than 1 year.

-------
Major Vendors

Direct Resistance

APV Crepaco
395 Fillmore Avenue
Tonawanda, NY 141 SO
 (716) 744-2336
* For Ohmic Heating (Food)
IHS-lnductoheat
5009 Rondo Drive
Fort Worth, TX 76106
 (800) 486-5577
Newcor Bay
1846 Trumbell Drive
Bay City, Ml 48707
 (517) 893-9509
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.
Seco/Warwick
180 Mercer St
Meadville, PA 16335
 (814) 724-1400
Taylor-Winfield
P.O. Box 500
Brookfield, OH 44403-0500
 (216) 448-4464
Thermatool
31 Commerce St
East Haven, CT 06512
(203)468-4100

-------
Index to EPRI DOCUMENTS

Direct Resistance Heating

Direct & Encased Resistance Heating^ EPRI CMF TechCommentary, Vol 3, No 8,
1986

Direct Resistance Heating Blanks ForForging^ EPRI CMF TechApplication, Vol 1,
No 19,1987

High-Frequency Resistance Welding of 7i/6e4 EPRI CMF TechApplication, Vol 1,
No 15,1987

Electric Arc Furnace Steelmaking... The Energy Efficient Way to Melt Steelt EPRI
CMF TechCommentary, Vol 1, No 3,1985

Understanding Electric Arc Furnace Operations for Steel Production^ EPRI CMP
TechCommentary, Vol 3, No 2,1987

Direct Current Electric Arc Furnaces^ EPRI CMP TechCommentary, CMP-063,1991

Static Var Control for Electric Arc Furnaces, EPRI CMP TechApplication, CMP-
100,1995


Special Publications

Parrott, Dr. David L.; Use ofOhmic Heating for Aseptic Processing of Food
Particulates; Food Technology, December 1992, pp 68-72
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
  Applied Technology:
  Electrical Discharge Machining (EDM)

  Concept
  Electrical Discharge Machining (EDM) is a technique used
  to cut complex shapes, particularly in very hard materials such as tool steels.
  Conventional EDM immerses the workpiece in a dielectric fluid, such as oil, and
  brings it close to a specially shaped tool.  The tool is connected to DC, high
  voltage/frequency power. Millions of tiny electric arcs erode away microscopic
  bits of the workpiece, producing a hole which exactly matches the shape of the
  tool.

  Wire EDM passes a very fine wire through a starter hole in the workpiece and cuts
  complex shapes as the workpiece is moved.  The wire is continuously spooled,
  much like a bandsaw blade, to prevent it from breaking.
                             Electrode

                                Workpiece
  Applications
  •  Cutting; dies, punches and molds
   Drilling; small micro-holes
  Technologies Replaced
  •  Mechanical Milling, Cutting, and
     Drilling
     Broken Cutting and Drilling Tools
•  Laser Cutting and Drilling

Wastes Reduced

•  Scrap, Filings, and Swarf
Potential in Manufacturing
Indust SIC Pot
Food 20 LOW
Tobac 21 LOW
Textile 22 LOW
Apparel 23 LOW
Indust SIC Pot
Lumber 24 LOW
Fum 25 LOW
Paper 26 LOW
Printing 27 LOW
Indust 8£ Pot
Chem 28 LOW
Petrol 29 LOW
Rubber 30 LOW
Leather 31 LOW
Indust SJ£Pot
Stone 32 LOW
Pmetal 33 LOW
MetFab 34 MED
Mach 35 HI
Indust SIC Pot
Elect 36 HI
Transp 37 HI
Instr 38 MED
Misc 39 MED
Credits: Or. Philip Schmidt and Dr. F.T. Sparrow;
     Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                            AT02

-------
Electrical Discharge Machining (EDM) continued


Technology Advantages
•  Non-Contact; handles delicate         •  Produces Complex, Deep, or 3-D
   tasks                                  Shapes
•  Cuts or Drills Very Hard Material        •  No Burrs
•  Highly Accurate; very small kerf
   (wire EDM)

Technology Disadvantages
•  Slow Cutting Rate                   •  Thin Brittle Heait-Affected Zone
•  Electrode Wear

Typical Costs

Capital Costs              0 & M Costs               Potential Payback

$100k - $200k             Low energy costs;          < 1 year or more
depends on size,          maintenance are
cutting rate, and           application and
controls                  automation dependent
Installations
Case A - The auto industry used conventional drills for precise holes in fuel
injector nozzles. Tolerance and accuracy were a problem. Annual replacement
costs for drills was $180,000.

A switch was made to EDM. Typical drilling time is now 3-15 seconds per hole,
and tolerances of better than 0.0025 mm (0.0001 ") are maintained on a hole
diameter of 0.175 mm (0.0069 "). In addition to the high degree of repeatability,
annual tool replacement costs were reduced to $2,000.

Case B - An aerospace fastener firm replaced their conventional manual process
for producing special dies for custom orders with a wire EDM machine driven by
CNC software. Time required to produce dies for prototype fasteners reduced
from 40 hours to 4. Production die sets are now produced in 125 hours
compared with 300 - 400 hours previously. This substantially reduces inventory
requirements for special die sets.

Die quality and durability also improved since EDM parts are of more consistent
dimensional tolerances and a harder steel can be used than was feasible with
conventional production techniques.

Scrap rates reduced from 10 - 20% to less than 1%.

The company estimates its Payback period on the EDM system to be about 6
months.

-------
Major Vendors

Electrical Discharge Machining
(EDM)
Agie and Elox Corporation
565 Griffith Street
Davidson, NC 28036
(800) 438-5021
Easco-Sparcatron
10799 Plaza Drive
Whitmore Lake, Ml 48189-9737
(800) 523-4443
Hansvedt industries Inc.
803 Kettering Park
Urbana, IL 61801
(217) 384-5900
MC Machinery Systems, Inc.
Mitsubishi EDM Division
1500 Micheal Drive
Wood Dale, IL 60191
(708) 860-4210
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.

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Index to EPRI DOCUMENTS

Electrical Discharge Machining (EDM)


Electrical Discharge Machining, EPRI CMF TechCommentary, Vol 3, No 1,1986

Electrical Discharge Machining, EPRI CMF TechApplication, Vol 1, No 9,1987
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

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                                                                     neai

1






4 — '
Applied Technology: Industrial Heat
Pump

Concept
Industrial heat pumps are used to recover waste heat
from one part of a process and boost its temperature    credit: U s DOE
so that it can be used in another part. The basic means to avmcvc UH* 10
mechanical compression. In a closed cycle heat pump, the working fluid
circulates through heat exchangers, picks up waste heat in a low temperature
evaporator, is compressed and elevated to a higher temperature in a mechanical
compressor, and discharges heat to the process through a higher temperature
condenser before being returned to the evaporator. In an open cycle heat pump,
also called a Mechanical Vapor Recompression (MVR) heat pump, the process
stream itself (e.g., low pressure discharge steam) is compressed to provide a
higher temperature heat source to the process, eliminating the need for one or
both heat exchangers.
                                                                     Heat
Applications
•  Heat recovery from wastewater,
   process, or refrigeration streams
•  Facility heating, cooling, and
   dehumidification

Technologies Replaced
•  Direct fuel fired lumber kilns
•  Steam heated evaporators
•  Fossil fuel  heating

•  Combustion products: COx, SOx,
                                         Multistage evaporation systems
                                         Distillation separation systems
                                         Lumber kiln drying
                                      •  Steam heated reboilers for
                                         distillation
                                      •  Chemical dehumidification
                                      Wastes Reduced
                                      •  Hot wastewater stream thermal

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Industrial Heat Pump continued

Technology Advantages
•  Reduces overall energy                •  Reduces combustion related
   consumption                            emissions
•  Reduces distillation system            •  Boilers may be shut down for
   pressures giving higher efficiency         lower maintenance costs
•  Faster, more uniform lumber
   drying

Technology Disadvantages
•  More sophisticated controls and        •  High capital costs
   technical support required

Typical Costs

Capital Costs               0 & M Costs                Potential Payback

$20k - $50k/MBTU          Energy cost reductions of        1.3 years
depending on size and      60-90% are not unusual         depending on
application                                          application
Installations
Case A - A conventional distillation column for separation of propane and
   propylene in a petrochemical plant was retrofitted with an MVR heat pump to
   recover the latent heat of the overhead vapor and recycle it into the reboiler.
   The heat pump AT or lift in this case was about 11 C°. The suction side of the
   1,300 kW compressor reduced the pressure in the column, enabling
   distillation at low temperature. Once started, only the electrical energy of
   compression was required to operate the system, completely eliminating
   steam heating. Operating costs were reduced by over 70%, yielding a return
   on investment of 39% or payback less than 3 years for the installation.


Case B - Closed cycle dehumidification heat pumps are used in about 20% of
   existing lumber plants (approximately 1,000 units in place). These units are
   typically rated at 1-2 MBTU/hr of output and costs are $100k <• $300k. Energy
   savings compared with conventional direct gas-fired kilns are on the order of
   90%, yielding simple paybacks of 3-5 years on energy savings alone. Because
   the closed-cycle kilns operate at lower temperature and more uniform
   humidity conditions, product quality is higher and losses lower than in
   conventional kilns. It is claimed that many firms now prefer to buy lumber that
   has been dehumidification-kiln dried.

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Major Vendors

Industrial Heat Pump
APV Crepaco (heat exchangers)
395 Fillmore Ave.
P.O. Box 366
Tonawanda, NY 14150
(716) 692-3000

Atlas Copco Comptec
(compressors)
Applications Department
46 School Road
Voorheesville, New York 12186
(518)765-3344

Brown Fintube
(heat exchangers)
12602 FM 529
Houston, TX 77041
(713) 466-3535

Crispaire Corporation
(industrial water heaters)
E-Tech Division
3285 Saturn Court NW
Norcross, GA 30092
(770) 734-9696

E Back Systems, Inc
(dehumidiers)
106 John Jefferson Road, Suite 102
Williamsburg, VA 23185
(800) 454-6012

Hitachi Zosen USA, Ltd.
150 East 52nd Street, 20th Floor
New York, NY 10022
(212)355-5650
McQuay, Inc. (HVAC)
P.O.Box 1551
Minneapolis, MN 55440
(612) 553-5330

Nyle Corporation
(wood drying)
P.O. Box1107
Bangor, ME 04402
(800) 777-6953

Tecogen (chillers)
P.O.Box 9046
Waltham, MA  02254
(617) 622-1400
             —Afofe—
 Most process heat pump applications
 are custom engineered. Check with a
  process engineering consultant for
          your application.
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.

-------
Index to EPRI DOCUMENTS
Industrial Heat Pump

Industrial Heat Pumps, EPRI TechCommentary, Vol 1, No 4,1988
Drying with Electric Heat Pumps, EPRI TechApplication, Vol 1, No 1,1988
Pinch Technology, EPRI TechCommentary, Vol 1, No 3,1988
       Parts of this manual are copyrighted as Indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

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                                                            Refractory
Applied Technology: Indirect
Resistance

Concept
                                                                     Insulation
Indirect resistance heating involves passing line             l
frequency current through high resistance heating  Source: EPR, TechCommentary va, N7R, 1994
elements. The resistance to the current flow gener«»»> i •«;<».  • ,,* „•*»,. ,*
transferred to the workpiece via conduction, convection, and/or radiation. The
workpiece temperatures can range from ambient to 1700 C° (3100 F°) or more
(with an inert atmosphere), depending on the application and type of heating
elements. This type of heating is typically performed in a well insulated
enclosure, like an electric oven. This minimizes thermal losses and provides a
high heating efficiency, typically in the 80% range.
Applications
•  Heat Treating
•  Forming
•  Melting
•  Drying
Cooking
Joining
Curing
Sintering
Technologies Replaced
•  Fuel-Fired Furnace or Flame
   Hardening

Wastes Reduced
•  Combustion Pollutants; ROG,
   SOX,
   NOX, COX, Participate
Salt/Lead Bath Heat Treating
Salt/Lead Bath; hazardous
salts/metals
Potential in Manufacturing
Indust S/C Pot
Food 20 HI
Tobac 21 MED
Textile 22 MED
Apparel 23 MED
Indust S/C Pot
Lumber 24 MED
Fum 25 MED
Paper 26 MED
Printing 2? MED
Indust SIC Pot
Chem 28 MED
Petrol 29 MED
Rubber 30 MED
Leather 31 MED
Indust KSfiSl
Stone 32 MED
Pmetal 33 MED
MetFab 34 HI
Mach 35 MED
Indust SIC Pot
Elect 36 MED
Transp 37 MED
Instr 38 MED
Misc 39 MED
Credits: George Bobart, Bobart Associates; Unbnar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                     AT04

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Indirect Resistance continued
Technology Advantages
•  Application Flexibility
•  Precise Temperature Control
•  Melting; can decrease dross or
   material loss
Technology Disadvantages
             •  Accommodates Special
                Atmosphere or Vacuum
                                         Operating Cost may be high
                                         (depends on cost of electricity)
Typical Costs

Capital Costs

depends on size and
type; usually about
same as comparable
fossil: $10k - $200k
and more
0 & M Costs

low maintenance;
costs highly
dependent on electric
rates
Potential Payback

about 2 years
Installations
Case A - Foundry operations have generally used gas fired poll furnaces to melt
aluminum for permanent mold and die casting processes. However, the
aluminum reacts with the moisture created by combustion, causing up to 12%
dross or metal loss.  Gas fired furnaces have very low heating efficiency of 15% -
20% (Indirect Resistance is typically 70%) and melt quality is difficult to control.

Permanent Casting in Hot Springs, Arkansas replaced five of their gas fired
melting furnaces with electric indirect resistance melting units.  This conversion
provided a 28% savings in both energy and maintenance cost, 10% productivity
improvement, and reduced metal losses to nearly 0%.

Case 6 - Kopp Glass of Pittsburgh, Pennsylvania is a jobshop producer of
glassware for aircraft, medical, and theatrical applications. Their gas fired oven
used for annealing the finished glass was causing problems with startup time,
energy cost, temperature control, and downtime for maintenance. Replacing
their old unit with a conveyorized indirect resistance electric oven resulted in
instant startup/shutdown time and a significant improvement in process control.
It also reduced overall energy and maintenance costs.

-------
Major Vendors

Indirect Resistance


Abar-lpsen Industries
3260 Tillman Drive
Bensalem, PA 19020
(215) 244-4900 (in PA)
(800) 374-7736 (outside PA)
Industrial Heating and
 Finishing Co., Inc.
P.O. Box129
Pelham Industrial Park
Pelham, AL35124
 (205) 663-9595
Lindberg
304 Hart St
Watertown, Wl 53094
 (414) 261-7000
Bamstead/Thermolyne Corp.
2555 Kerper Boulevard
Dubuque, (A 52001
 (800) 553-0039
C. I. Hayes, Inc.
800 Wellington Ave
Cranston, Rl 02910
(401)467-5200
Cooperheat, Inc.
1021 Centennial Avenue
Piscataway, NJ 08854
 (800) 526-4233
Despatch Industries, Inc.
P.O. Box 1320
Minneapolis, MN 55440-1320
 (612)469-5424
Dynarad Corp.
575 Whitney St.
San Leandro, CA 94577
 (510)638-2000
The Grieve Corporation
500 Hart Road
Round Lake, IL 60073-9989
 (708) 546-8225
Seco/Warwick
180 Mercer St
Meadville, PA 16335
 (814) 724-1400
Rapid Engineering, Inc.
P.O. Box 700
Comstock Park, Ml 49321-0700
 (616)784-0435
Surface Combustion, Inc.
1700 Indian Wood Circle
Maumee, OH 43537
 (800) 537-8980
Thermotron
291 Kollen Park Drive
Holland, Ml 49423
 (616) 3934580
Thermtronix Corp.
17129 Muskrat Ave.
Adelanto, CA 92301
 (619)2464500
This list of vendors of the indicated
technology is not meant to be a
complete or comprehensive listing.
Mention of any product, process,
service, or vendor in Ms publication
is solely for educational purposes
and should not be regarded as an
endorsement by the authors or
publishers.

-------
Index to EPRI DOCUMENTS

Indirect Resistance

Indirect Resistance Heating, EPRI CMF TechCommentary, Vol 3, No 7R, 1994

Electric Resistance Melting, EPRI CMP TechCommentary, CMP-1188-036,1988

Resistance Melting for Low Capital Investment, EPRI CMP Tech Application, CMP-
045,1989

Electric Ladle Preheaters, EPRI CMP TechCommentary, CMP-0589-024,1988

All-Electric Annealing Furnace, EPRI CMP TechApplication, CMP-075,1991

Electric Resistance Ladle Preheating Improves Foundry Operations, EPRI CMP
TechApplication, CMP-079,1992

Resistance Melting - A Bellringerat Temple Aluminum, EPRI CMP
TechApplication,
CMP-086, 1993

Electric Resistance, Indirect Radiant-Heated Sand Reclaimer Economic Answer
to Sand Reclamation, EPRI CMP TechApplication, CMP-087,1993
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

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  Applied Technology: Infrared
  Concept
                                                                          IR emitter
                                   Coating
                                   ,or Ink
                                   Layer
                                 Substrate
  Infrared heating is produced by electromagnetic
  radiation generated from a heat source that     source: EPRI TechCommentary vs, N6R, 1994
  typically operates in the range of 425 C° (800 F°) to
  2200 C° (4000 F°).  It is similar to the heat on an
  object directly exposed to the sun.  Infrared is
  actually an extension of electric resistance heating
  since the electric IR emitters are heated by passing
  a current through a heating element. The elements
  may be in glass bulbs, quartz or metallic tubes, or
  in ceramic panels. IR is classified by its
  wavelength:
             Type
           long wave
            medium
            wave
           shortwave
  Emitter
Temperature
 450-750
 (800 - 1400)
 750 - 1100
(1400 - 2000)

 1100-2200
(2000-4000)
 Wavelength
range, microns
   10-4
   4-2
    <2
  Applications
  •  Surface Heating
  •  Preheating
  •  Space Heating
  •  Curing

  Technologies Replaced
  •  Convection Ovens
  •  Air Drying
  •  Salt/Lead Bath Heat Treating

  •  Combustion Pollutants; ROG, SOX,
     NOX, COX, Particulate
Potential in Manufacturing
•  Foundry Sand Reclamation
•  Food Cooking and Browning
•  Drying and Evaporation
*  Heat Treating
•  Gas IR
•  Steam Drying

Wastes Reduced
 •  Salt/Lead Bath; hazardous
    salts/metals
 •  VOC's from solvents (with powder
    coatings)
Indwt $g M
Food 20 MED
Tobac 21 MED
Textile 22 Ht
Apparel 23 NED
Indust SIC Pot
Lumber 24 MED
Fum 25 MED
Paper 26 HI
PrWng 27 HI
Indust SIC Pot
Chem 28 MED
Petrol 29 MED
Rubber 30 HI
Leather 31 MED
Indust SIC Pot
Stone 32 HI
Pmetal 33 MED
MetFab 34 HI
Mach 35 HI
Indust SIC Pot
Elect 36 HI
Transp 3? HI
Instr 38 HI
Mlsc 39 HI
Credits: George Bobart, Bobart Associates; Unhnar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                         AT05

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Infrared continued
Technology Advantages
•  Fast                               •  Easily Automated
•  Rapid Startup                       •  High Efficiency
•  Precise Temperature Control            •  Low Floor Space Required
•  Enclosure not Required               •  Low Capital and Operating Costs
Technology Disadvantages
•  Requires Line of Sight               •  Maintenance of IR Emitters Higher
*  Reflective Coatings are Difficult         in a Dirty Environment


Typical Costs

Capital Costs               O & M Costs                Potential Payback

low to moderate: $10k      low maintenance           1-2 years
- $500K depending on       primarily emitter
application and size        cleaning and
                          replacement,
                          operating costs low
                          due to high efficiency
Installations
Case A • A company cured the coating on an architectural column with a gas
fired oven in 1.5 hours using 8,000 ft2 of floor space. They also experience
environmental compliance problems with their emissions. The gas fired oven
solvent based coating process was replaced with a short wave powder coating
process.  The new process only required 210 ft2, cured in 34 seconds, increased
production capability from 300 to 10,000 parts/shift, and met full environmental
compliance.
Case B - A steel building components manufacturer bought strip precoated with
a plastic protective finish. The strips were formed into specific panel sizes at
their facility. They experienced high levels of inventory, scrap, and could not
meet many of the color requirements of their customers. The installation of a 32
foot medium wavelength IR unit and powder coat system reduced their inventory
and labor requirements by 50%, reduced their scrap generation from 30% to less
than 10%, increased available product colors for their customers from 12 to 300,
and kept them in full environmental compliance.

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Major Vendors
Infrared

BGK Finishing Systems
4131 Pheasant Ridge Drive North
Blaine, MN 55449-7102
(612) 784-0466
Research, Inc.
P.O. Box 24064
Minneapolis, MN 55424
 (612) 941-3300
Casso-Solar Corp
230 US Route 202
Pomona, NY 01970
 (914) 354-2500
Thermal Designs & Mfg. Inc.
16043 23 Mile
Macomb TWP, Ml 48045
(810) 786-0164
Fostoria Industries Inc
Process Heat Division
P.O. Box E
Fostoria, OH 44830
(419) 435-9201
Industrial Heating and
 Finishing Co., Inc.
P.O. Box 129
Pelham Industrial Park
Pelham, AL 35124
 (205) 663-9595
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.
Lindberg
304 Hart Street
Watertown, Wl 53094
 (414)261-7000
Rapid Engineering, Inc.
P.O. Box 700
Comstock Park, Ml 49321-0700
 (616) 784-0435

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Index to EPRI DOCUMENTS
Infrared
Infrared Processing of Coatings, EPRI CMF TechCommentary, \'o\ 3, No 6R, 1994
Infrared Drying in Papermaking, EPRI PIO TechCommentary, Vol 2, No 1,1989
Medium & Short Wave Infrared Curing, EPRI CMF Tech Application, Vol 1, No 3,1987
Short Wave Infrared Curing, EPRI CMF TechApplication, Vol 1, Mo 1,1991
Infrared Drying of Paint, EPRI CMF TechApplication, Vol 3, No 1, 1991
Infrared Drying of Anodized Aluminum, EPRI CMF TechApplication, Vol 7, No 4,
1994
Infrared Curing for Spot Repair of Auto Paint Surfaces, EPRI CMF TechApplication,
Vol 8, No  3, 1994
Infrared Heating, Drying, and Curing, EPRI CMF TechCommentairy, Vol 8, No 1,1992
Infrared Curing of Powdered Coatings, EPRI CMF TechApplication, Vol 4, No 1,1990
Infrared Drying of Inks, EPRI CMF TechApplication, Vol 6, No 3,1992
Infrared Curing of Silk Screen Apparel, EPRI CMF TechApplication, Vol 7, No 3,1993
Using Electric IR to Finish Oil Filters, EPRI CMF TechApplication, Vol 7, No 2,1987
Infrared Drying of Automotive Seat Risers, EPRI CMF TechApplication, Vol 8, No 1,
1994
Powder Coated Castings Achieve Cure With Electric IR, EPRI CMF TechApplication,
Vol 8, No  4, 1994
Infrared-Assisted Drying of Foundry Mold Wash Coatings, EPRI CMP
TechApplication,
CMP-091, 1994
IR Moisture Profiling of Linerboard, EPRI PIO TechApplication, Vol 4, No 7,1992
Electric Infrared Boarding of Hosiery, EPRI PIO TechApplication, Vol 5, No 1,1993
Electric IR Curing of Textile Resin Finishes, EPRI PIO TechApplication, Vol 6, No 3,
1994
         Parts of this manual are copyrighted as indicated on the bottom of each sheet
         and therefore may not be copied without the approval of the copyright owner.

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                                                                 Part
  Applied Technology: Induction
  Concept
                                                                         A C Power
  Induction heating uses an electromagnetic field that is         Source: Bobart Associates
  generated via an inductor coil.  The magnetic field is
  produced by applying an AC current with a frequency of 60 Hz to 800 kHz into the
  inductor coil. The magnetic field intersects the workpiece generating a
  circulating current. The resistance of the workpiece to this current generates
  heat.  Shallow heating for surface applications such as case hardening can be
  obtained with medium to high frequencies. Deeper or through heating
  applications such as hot metal  working is achieved at lower frequencies.
  Various types of inductor coils can be designed to heat any conductive material
  placed within, outside, or along side the inductor coil.
  Applications
  •  Melting
  •  Heating
  •  Heat Treating
  •  Welding, Brazing, Soldering, and
     Bonding
  •  Curing of coatings
•  Conductive Susceptor or Metal
   Interface: heat non-conductive
   materials
•  Electromagnetic Stirring and
   Casting
»  Levitation Melting
  Technologies Replaced
  •  Fossil/Electric Furnace Heating
  •  Salt/Lead Bath Heat Treating
     Combustion Pollutants; ROG, SOX,
     NOx.COx, Particulate
     VOCs (in curing powder coating)
•  Flame Heat Treating

Wastes Reduced

•  Material Oxidation; slag, scale
•  Salt/Lead Bath; hazardous
   salts/metals
Potential in Manufacturing
tndust SIC Pot
Food 20 LOW
Tobac 21 LOW
Textile 22 MED
Apparel 23 LOW
Indust SIC got
Lumber 24 LOW
Fum 25 MED
Paper 26 LOW
Printing 27 LOW
Indust SIC_ Pot
Ghent 28 MED
Petrol 29 LOW
Rubber 30 MED
Leather 31 LOW
Indust SIC Pot
Stone 32 MED
PmetaJ 33 HI
MetFab 34 HI
Mach 35 HI
Indust SIC Pot
Elect 36 HI
Transp 37 HI
Instr 38 MED
Misc 39 MED
Credits: George Bobart, Bobart Associates; Unbnar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                       AT06

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Induction continued


Technology Advantages
•  Fast, efficient, highly controllable     •  Reduced wastes
   heating                            •  Overall reduced operating costs
•  High level of productivity
•  High quality


Technology Disadvantages
•  High capital cost for low volume      •  Inflexible for production of wide
   applications                          range of sizes and shapes
•  Part must be conductive
Typical Costs

Capital Costs              0 & M Costs               Potential Payback

$25,000 - $1,000,000       low maintenance, costs     about a year
depending on size and     usually lower than
application               alternative fuels due to
                         greater efficiency
Installations
Case A - A major hand tool manufacturer in the Midwest installed an induction
heating system to replace a process that hardened hammers in a salt bath then
tempered them in a gas fired furnace. The induction system used a rotary table
to automatically harden and temper both the head and claw areas of the hammer.
This system provided a 50% reduction in energy costs and a 40% increase in
productivity. It also reduced rejects by 20%, improved safety, and eliminated all
of the hazardous wastes.
Case B - An aftermarket automotive supplier was hardening valves with an
aluminizing process. But higher compression engines required improved
hardening properties and environmental regulations were increasing the cost of
properly handling the aluminum waste stream. The company replaced the
aluminizing process with an in-line induction hardening system. The induction
system met all process performance requirements for use in high compression
engines, eliminated the aluminum sludge waste stream, reduced energy costs by
20%, and improved productivity by 25%.

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Major Vendors

Induction

Abar-lpsen Industries
3260 Tillman Drive
Bensalem, PA 19020
 (215) 244-4900 (in PA)
 (800) 374-7736 (outside PA)

ABB Metallurgy, Inc.
Induction Furnace Division
North Brunswick, NJ 08902
 (908)932-6134

Ajax Magnethermic Corp.
1745 Overland Ave
Warren, OH 44482
 (216)372-8511

American Induction Heating Corporation
33842 James J. Pompo Drive
Fraser, Ml 48026
 (810)294-1700

Cooperheat, Inc.
1021 Centennial Avenue
Piscataway, NJ 08854
 (800) 526-4233

IHS-lnductoheat
5009 Rondo Drive
Fort Worth, TX 76106
 (800) 486-5577

Inductoheat
32251 N. Avis Dr
Madison Heights, Ml 48071
 (810) 585-9393
Inductotherm Corporation
10 Indel Avenue
Rancocas, NJ 08073
(800) 257-9527
Pillar Industries
N92W15800MegalDr
Menomonee Falls, Wl 53501
(800) 558-7733

Taylor-Winfield
P.O. Box 500
Brookfield, OH 44403-0500
(216)448-4464

Thermatool Corporation
31 Commerce Street
East Haven, CT 06512
(203)468-4100

TOCCO, Inc.
30100 Stephenson Highway
Madison Heights, Ml 48071
(810) 399-6601
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.

-------
Index to EPRI DOCUMENTS

Induction Melting

Induction Melting, EPRI CMP TechCommentary, CMP-072,1991

Induction Melting fora Competitive Advantage, EPRI CMP TechApplication, CMP-
048,1990

Induction Melting for Pollution Elimination, EPRI CMP TechApplication, CMP-
1289-010, 1989

Induction Melting for Profit-Improving, EPRI CMP TechApplication, CMP-0689-
016,1989

Induction Melting for Business Building, EPRI CMP TechApplication, CMP-1289-
020, 1989

Induction Melting for Operating Flexibility, EPRI CMP TechApplication, CMP-
1289-021, 1989

Induction Heating Billets for Forging, EPRI CMF TechApplication, Vol 1, No 20,
1987

Induction Through Heating for Forging, EPRI CMF TechApplication, Vol 1, No 7,
1991

Vacuum Induction Melting Technology, EPRI CMP TechCommentary, Vol 3, No 3,
1987

Induction Heating, EPRI CMP TechApplication, CMP-0689-015,1988

Induction Melting for Higher Productivity, EPRI CMP TechApplication, CMP-1188-
018,1988

Electromagnetic Stirring for Aluminum Melting, EPRI CMP TechApplication, CMP-
101,1995

Transverse Flux Induction Heating of Continuous Caster Belts for Producing
Aluminum Strip, EPRI CMP TechApplication, CMP-102,1995

Induction Heating for Textile Printing and Embossing, EPRI Textile Office
TechApplication, No 1,1995

-------
Induction Heat Treatment

Induction Heat Treatment, EPRICMF TechCommentary, Vol 2, No 2,1990


Induction Hardening with a Flux Field Concentrator, EPRI CMF TechApplication,
Vol 1, No 11,1991

Post-Grinding Induction Hardening, EPRI CMF TechApplication, Vol 1, No 2,1987

Induction Heating Technology, EPRI CMF TechCommentary, Vol 2, No 1R, 1993

Selective Induction Heat Treatment, EPRI CMF TechCommentary, Vol 2, No 3,
1991

Induction Tempering, EPRI CMF TechCommentary, Vol 2, No 4,1991

Induction Hardening for Durable Camshafts, EPRI CMF TechApplication, Vol 8,
No 2,1994

Induction Susceptor Furnaces, EPRI CMF TechApplication, Vol 2, No  2,1988


Induction Bonding

Induction Bonding Metal to Plastic, EPRI CMF TechApplication, Vol 2, No 3,1988

Induction Heating of Thermoset Adhesives, EPRI CMF TechApplication, Vol 1, No
12,1987
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

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                                                       Workpiece

                                                        Support
Applied Technology: Laser


Concept

Lasers are beams of monochromatic (all one
wavelength) light focused precisely to produce a very
intense energy beam. The power density in the beam
can be high enough to vaporize, melt, or red-heat
virtually any material. Lasers commonly cut, weld, and      Credit: EPRl CMP V3,N9,1986
heat treat materials ranging from wood and plastics to the most heat resistant
metals and ceramics. Because laser light beams have no inertia, they can be
easily and rapidly controlled in intensity and direction with computer control
systems. Thus, laser material processing systems lend themselves especially
well to modern digital automation and flexible manufacturing operations.
  Applications
  •  Cutting and Drilling
  •  Welding
  •  Heat Treating

  Technologies Replaced
  •  Mechanical Metal Removal
  •  Arc and Gas Welding

  •  Metal Cutting Fluids and
     Wastewater (machining)
  •  Scale and Slag (welding)

Potential in Manufacturing
                                       •  Engraving
                                       •  Biomedical
                                       •  Sealing (packaging)
                                       •  Induction, Flame, and Plasma
                                          Hardening
                                       Wastes Reduced
                                       •  Wastewater and [Emissions (heat
                                          treating)
                                       •  Material Removal
Indust SIC Pot
Food 20 LOW
Tobac 21 LOW
Textile 22 LOW
Apparel 23 LOW
Indust SJC Pot
Lumber 24 LOW
Fum 25 MED
Paper 26 MED
Printing 27 LOW
Indust SJC Pot
Chem 28 LOW
Petrol 29 LOW
Rubber 30 LOW
Leather 31 LOW
Indust SIC Pjot
Stone 32 LOW
Pmetal 33 LOW
MetFab 34 HI
Mach 35 HI
Indust SJ£ Pot
Elect 36 HI
Transp 37 HI
Inslj 38 HI
Misc 39 MED
 Credits: Dr. Philip Schmidt and Dr. F.T. Sparrow;
      Unhnar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                    AT07

-------
Laser continued


Technology Advantages
•  Fast Cutting and Welding             •  Flexibility and Controllability
•  High Surface Quality                  •  Repeatability (non-contact
•  Ability to Machine Difficult                processing)
   Materials (e.g. superalloys,            •  Minimal or No Thermal Effects
   ceramics)
•  Reduced Material Loss

Technology Disadvantages
•  High Capital Cost                    •  Line-of-Sight Limitation

Typical Costs

Capital Costs               0 & M Costs                Potential Payback

high. 10 times some        application dependent.      very application
other cutting and           slightly higher energy       dependent.  Generally
welding systems; 5         for cutting and drilling;      good for high product
times induction heat        15-30% lower for            lots, high-valued
treatment units. These     welding and heat           products (requiring
costs due in part to         treating. Labor cost        high quality), or for
extensive digital            usually lower.              operations requiring
control equipment          Maintenance cost           high flexibility and
needed                   comparable                quick changeover
Installations
Case A - Carbon dioxide laser systems are used by a large auto manufacturer
for heat treating the inside of malleable cast iron housings for power steering
gears.  Because the laser beam can be accurately controlled and directed, only
specific areas of the housing wall that are contacted by metal components (so-
called "wear tracks") need be heat treated. The process saves over 10% of the
energy associated with induction heat treating on the entire housing inner wall
and eliminates the spray quenching required with induction hardening.  More
importantly, it is faster and requires less labor. Estimated savings of about $0.11
per part are realized.


Case B - Laser welding systems are used by an appliance manufacturer to weld
the corners of hot-rolled steel refrigerator doors. The laser system requires
about 16% less electricity than the competing arc welding process, and requires
less setup time.  Net savings of $150,000 have been reported on production of
970,000 doors per year.

                                                                     jX"».

-------
Major Vendors

Laser

Amada
2025 Firestone Blvd
Buena Park, CA 90621
(714)739-2111
Cincinnati, Inc.
Box 11111
Cincinnati, OH 45211
 (513) 367-7100
Coherent, Inc.
5100 Patrick Henry Drive
Santa Clara, CA 95054
(800)227-1955
Coherent General, Inc.
1 Picker Road
Sturbridge, Massachusetts 01566
 (508) 347-2681
Convergent Energy, Inc
1 Picker Road
Sturbridge, MA 01566
(508) 347-2681
Excel\Control Laser, Inc.
7503 Chancellor Drive
Orlando, FL 32809
(407) 438-2500

Hobart Laser Products
238 Executive Drive
Detroit, Ml 48083
(810) 588-8812
Laser Applications, Inc.
6371 North Orange Blossom Trail
Orlando, FL 32810
(407) 290-0336
Lumonics Corporation
6690 Shady Oak Road
Eden Prairie, MN 55344
(612)941-9530
MC Machinery Systems, Inc.
Laser Division
1500 Michael Drive
Wood Dale, IL 60191
(708) 860-2572

Mazak Nissho-lwai
140 E. State Parkway
Schaumburg, IL 60173
 (708) 882-8777

U.S. Laser Corporation
825 Windham Court North
Wyckoff, NJ 07481
(201)848-9200
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing.  Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.

-------
Index to EPRI DOCUMENTS

Laser

Laser Hardening, EPRI CMF TechApplication, Vol 1, No 18,1987

Laser Cutting, EPRI CMF TechCommentary, Vol 3, No 9,1986

Laser Cutting of Metal, EPRI CMF TechApplication, Vol 1, No 6,1987

Laser Cutting & Scribing of Ceramics, EPRI CMF TechApplication, Vol 1, No 5,
1987
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
                                           Membrane
                                              Credit: Ontario Hydro Research Division
Applied Technology: Membrane


Concept

Membranes selectively filter gases or
liquids in solutions or mixtures into their
different components. Membranes generally
use thin plastic tubes or sheets, bundled into a metal vessel similar to a heat
exchanger. Other membrane types, including porous metals and ceramics, are
also being developed. The membrane micropores are sized to allow some
molecules and particles through while blocking others. Thus membranes are very
application-specific, with their molecular structure tailored to the particular
species to be separated. The "pressure" used to drive the selected species
through the membrane can be mechanical (reverse osmosis, ultrafiltration,
microfiltration, and gas permeation) for molecules or electrical (electrodialysis)
for ions.
  Applications
  •  Wastewater purification for reuse
  •  Concentration of food liquids and
     proteins
  •  Desalting and deacidification of
     food
  •  Separation of organic chemicals,
     gas molecules (O2, N2), CI2 and
     caustic (chlor-alkali)

  Technologies Replaced
  •  Fuel fired distilling and
     evaporating
  •  Chemical wastewater treatment

  •  Combustion products: COx, SOx,
     ROG, particulates
  •  Wastewater pollutants and
     treatment chemicals

Potential in Manufacturing
                                           Recovery of sizing, dye, and
                                           others in textile/leather and
                                           electrophoretic paint in metal fab
                                           Removal of trace gases in oil
                                           refinery, bacteria'viruses from
                                           biofluids, and alcohol from beer
                                        •  Chemical separation
                                        Wastes Reduced
                                        •  Hazardous Air Pollutants (HAPs)
                                           from thermal treatment of process
                                           emissions
Indust SIC Pot
Food 20 HI
Tobac 21 MED
Textile 22 HI
Apparel 23 LOW
Indust SIC Pot
Lumber 24 LOW
Furn 25 MED
Paper 26 HI
Printing 27 MED
Indust SIC Pot
Chem 28 HI
Petrol 29 MED
Rubber 30 LOW
Leather 31 MED
Indust SIC Pot
Stone 32 LOW
Pmetal 33 MED
MetFab 34 MED
Mach 35 MED
Indust SIC Pot
Elect 36 MED
Transp 37 MED
Instr 38 MED
Misc 39 MED
Credits: Dr. Philip Schmidt and Dr. F.T. Sparrow;
     Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                     AT08

-------
Membrane continued
Technology Advantages
•  Provides major reduction in
   overall energy use and associated
   emissions
•  Suitable for temperature sensitive
   products
•  High separation % (product purity)
                No boiling/freezing point
                limitations
                Mechanically simple, reliable, and
                easy to maintain.
                Compact size
                Low capital cost for low
                capacities
Technology Disadvantages
•  Suitable membranes hard to find
   for some applications
•  Some stream contaminants may
   damage membrane
                May not be suitable for pressure
                sensitive products
                Little economy of scale; may be
                uneconomic for large flows
Typical Costs

Capital Costs

Very application, size,
and flow dependent.
Typical Ultrafiltration
costs: $600-$1200/m2
or $1-$3/literflow.
0 & M Costs

Energy savings
typically >90% over
evaporative systems.
Membrane
replacement 1-6 years
depending on type,
application, and
operating conditions.
Potential Payback

1-3 years depending
on application.
Installations
Case A - Conventional chemical treatment of oily wastewaters in a metal fab plant
produces an oily sludge. The sludge must be stabilized before disposal and the water
effluent must treated before discharge. Ultrafiltration systems directly produce water
pure enough to be discharged with no post-treatment. The oil is concentrated (3-5% of
the original stream volume) and can either be incinerated or reprocessed. Installed
capital cost for a 40,000 liter/day system is around $100,000. Total operating cost is
about $2.50/liter or a penny a gallon. And this assumes no credit for oil reuse or
combustion as fuel.  Energy requirements are about 400-600 kwh/day or 10-15 kwh per
cubic meter flow, and operating labor requires about 7-10 hrs/week.

Case B - Reverse osmosis systems are now commonly used to reprocess rinse waters
from metal galvanizing plants. The purification is effective enough to permit reuse in the
process, eliminating treatment and disposal costs. More importantly, nickel and other
valuable metals can be recovered, turning a liability (disposal of heavy-metal-
contaminated wastewater) into an asset. Membranes typically last over 2 years.
Paybacks of 2 months to 2 years have been reported based on the value of recovered
metals alone.
 inn

-------
Major Vendors

Membrane
A/G Technology Corp.
(Ultra and microfiltration)
101 Hampton Avenue
Needham, MA 02194
(800) 248-2535
Aqualytics
(electrodialysis)
7 Powder Horn Drive
Warren, NJ 07059
 (908) 563-2800
Dedert Corporation
20000 Governors Dr.
Olympia Fields, IL 60461
 (708) 747-7000
Koch Membrane Systems, Inc.
850 Main St
Wilmington, MA 01887
(800) 343-0499
Niro Hudson, Inc
1600 O'Keefe
Hudson, Wl 54016
 (715) 386-9371
Osmonics, Inc.
5951 Clearwater Dr.
Minnetonka, MN 55343
(612)933-2277
Graver Separations, Inc
(Micro, ultra, and nanofiltration)
200 Lake Drive
Glasgow, DE 19702
 (302)731-1700
Ionics, Inc.
5455 Garden Grove Blvd.
Westminster, CA 92683
(714) 893-1545
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.

-------
Index to EPRI DOCUMENTS

Membrane

Special Publications

Osmonics Relative Membrane and Filtrate Size Chart



EPRI Publications

Membrane Separation in Food Processing, EPRI PIO TechApplication, Vol 3, No
1,1991

Ultrafiltration in Food Processing, EPRI PIO TechApplication, Vol 4, No 6,1992
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
                                                                     Energy Input
  Applied Technology: Microwave


  Concept

  Microwaves are electromagnetic waves in the frequency
  range of 300 to 3,000 megahertz (MHz, million cycles per
  second) generated by a magnetron-type vacuum tube.
  Electromagnetic energy at 915 and 2,450 MHz can be
  absorbed by materials containing water or other "lossy"
  substances, such as carbon and some organics, and
  converted to heat. Because the waves can penetrate to the
  interior of the material, heating is volumetric ("from the inside out"). The degree
  of penetration and rate of heat generation depend on  the selected frequency and
  the dielectric characteristics of the material, as well as the power rating of the
  generator. Microwaves can heat certain products selectively. In drying, more
  uniform moisture profiling in the product is possible.
  Applications
  •  Drying, Tempering, Proofing,
     Precooking, Pasteurization of foods
  •  Preheating and curing of rubber
  •  Recycling spent asphalt paving

  Technologies Replaced
  •  Gas fired drying and curing ovens
  •  Salt-bath curing of rubber
  •  Wet-chemical etching
     semiconductors

  •  Combustion Pollutants; ROG, SOx,
     NOx, COx, Paniculate
  •  Equipment corrosion from salt
     vapors
  •  Startup product quality losses

Potential in Manufacturing
   Drying of foundry molds
   Drying and sintering ceramics
   Plasma etching semiconductors
  •  Cool room tempering frozen foods
  •  Disposing (landfill) waste asphalt
    paving

  Wastes Reduced
•  Wastewater in food processing
•  Wet-chemical etch haz chemicals
•  Used asphalt and viirgin asphalt
   emissions
Indust SIC Pot
Food 20 HI
Tobac 21 MED
Textile 22 LOW
Apparel 23 LOW
Indust SIC Pot
Lumber 24 LOW
Fum 25 LOW
Paper 26 LOW
Printing 27 LOW
Indust SIC Pot
Chem 28 MED
Petrol 29 LOW
Rubber 30 MED
Leather 31 LOW
Indust SIC Pot
Stone 32 MED
Pmetal 33 MED
MetFab 34 LOW
Mach 35 LOW
Indust SIC Pot
Beet 36 HI
Transp 37 LOW
Insu 38 LOW
Misc 39 LOW
Credits: Dr. Philip Schmidt and Dr. F.T. Sparrow;
      Unfmar Group, Ltd; The Electrification Council; Electric Power Research Institute
                           AT09

-------
Microwave continued
Technology Advantages
•  Fast heating, startup and shutdown   •  Compact, easy to clean equipment
•  Can dry to consistent levels          •  Low emissions
•  High energy efficiency               •  Can heat in vacuum or low
•  High quality and controllability          temperature


Technology Disadvantages
•  Product can overheat               •  Will not work on all products
•  Not as tolerant of product variability  •  Higher capital cost
   or geometry as convection           •  Requires specialized technical
                                        support
Typical Costs

Capital Costs               0 & M Costs                Potential Payback

High: $2k - $4k             low to moderate            1-2 years
      per kW              operating, high
                          maintenance

Installations
Case A - A number of U.S. pasta producers have installed microwave-enhanced
drying ovens for drying of short-goods products. The microwave ovens require
less than one-fifth the floor area of conventional drying ovens for the same
throughput and have often been selected to expand production capacity within a
constrained space environment. The microwave process decreases both fuel and
electricity requirements and their associated emissions; overall fuel costs are
reduced by about 30%. Because of their ability to come on-line and off-line in a
matter of minutes, the microwave units provide an increase in output of about 6%
in a typical 2-shift production day, compared with conventional gas-fired dryers
which take longer to heat up and cool down.

Case B - A new process has been developed using microwaves to reclaim
asphalt pavement that has been stripped from the surface of roadways. The
asphalt in paving mix is virtually transparent to microwaves, while the crushed
stone aggregate, which constitutes 95% of the  mix, is readily heated. A plant
which has been running for several years in Los Angeles, processing 1000
tons/day of reclaimed paving mix, has produced recycled asphalt at $15/ton,
compared with $22-28/ton for virgin mix. Recycling the paving mix eliminates the
land-fill costs associated with disposal of spent paving and the plant operates
with none of the liquid and gaseous effluents associated with conventional
asphalt production plants.
                                                                   f"'"<,
STffl

-------
Major Vendors

Microwave
AGL, Inc.
(semiconductor plasma processing)
1132 Doker Drive
Modesto, CA 95351
 (209)521-6549
Amana Refrigeration, Inc
Industrial Microwave Division
2800 220th Trail
Amana, IA 52204
(319) 622-5850
Sanitec (medical waste)
26 Fairfield Place
West Caldwell, NJ 07006
 (800)551-9897
Thermex-Thermetron, Inc.
60 Spence Street
Bayshore, NY11706
 (516)231-7800
Berstorff Corporation
8200 Arrowridge Blvd.
Charlotte, NC 28273
 (704) 523-2614
Cober Electronics, Inc
102 Hamilton Avenue
Stamford. CT 06902
 (203) 327-0003
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.
Microdry
7450 Highway 329
Crestwood, KY40014
 (502)241-8933
Nemeth Engineering Associates
5901 W. Highway 22
Crestwood, KY 40014
 (502)241-1502

-------
Index to EPRI DOCUMENTS

Microwave

Dielectric Heating: RF and Microwave, EPRI CMF TechCommentary, Vol 4, No 1,
1990

Industrial Microwave Heating Applications, EPRI CMF TechCommentary, Vol 4,
No 3R, 1993

Microwave Curing of Rubber, EPRI CMF TechApplication, Vol 2, No 1,1988

Microwave Process for Asphalt Pavement Recycling, EPRI CEC TechApplication,
No 2,1992

Food Processing Using Microwaves, EPRI PIO TechApplication, Vol 2, No 1,1990

Microwave Curing of Lumber Adhesives, EPRI PIO TechApplication, Vol 6, No 1,
1994
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
  Applied Technology: Plasma Arc

  Concept

  A plasma is an ionized gas which has become an electrical
  conductor. Gas is passed through an electric arc, thus
  reaching approximately 5500 °C. This is known as a
  "thermal" or "hot" plasma. See "Plasma (Ion) Nitriding" for
  "cold plasma" applications such as semiconductor etching. Containing
  tremendous energy, thermal plasmas produce very fast and precise melting and
  cutting of metals.
                 Credit. Philip Schmidt, University of Texas, Austin
  Applications
  •  Melting; metals, ceramics, and
     glasses
  •  Reduction; ores
  •  Ladle Refining; steel

  Technologies Replaced
  •  Cutting Metals by Mechanical or
     Laser
  •  Welding by Conventional Arc,
     Laser, or Gas

  •  Metal Cutting Fluids and
     Wastewater (machining)
  •  Scale and Slag (welding)
   Surface Treating; wear and
   corrosion resistance
   Welding; metals
   Cutting; metals
•  Melting Metals, Ceramics, and
   Glasses by Conventional Arc or
   Fossil Fuels
•  Heat Treating Metal Surfaces
Wastes Reduced
•  Wastewater and Emissions (heat
   treating)
•  Material Removal
Potential in Manufacturing
Indust SIC Pot
Food 20 LOW
Tobac 21 LOW
Textile 22 LOW
Apparel 23 LOW
Indust SIC Pot
Lumber 24 LOW
Fum 25 LOW
Paper 26 LOW
Printing 27 LOW
Indust SIC Pot
Chem 28 LOW
Petrol 29 LOW
Rubber 30 LOW
Leather 31 LOW
Indust SIC Pot
Stone 32 MED
Pmetal 33 HI
MetFab 34 HI
Mach 35 HI
Indust SIC Pot
Elect 36 HI
Transp 37 HI
Inslr 38 LOW
Mis: 39 MED
 Credits: Dr. Philip Schmidt and Or. F.T. Sparrow;
      Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                      AT10

-------
Plasma Arc continued
Technology Advantages
•  High Productivity; due to high
   speed of energy deposition
•  Small Equipment Size
•  Enhanced Flexibility; automation

Technology Disadvantages
•  High energy-Density Processes;
   leave small margin of error,
   require careful control
Cuts and Melts Difficult Materials
Eliminates or Reduces Oxidation
(due to controlled atmosphere)
Process Control Simplification
Typical Costs

Capital Costs

$1k - $50k for cutting
and spray;
similar to conventional
arc and oxyfuel-based
systems; about 1/10
cost of laser

>$1 million; for large
melting systems
          Potential Payback

          < 1 year; small plasma
          cutting systems
          require little capital
          investment

          < 1 year - 2 years or
          more; large melting
          systems are very
          capital intensive
                          O & M Costs

                          application
                          dependent; typical
                          operating cost,
                          including power, labor,
                          and inert gases of
                          plasma cutting for 6
                          mm (VV) steel plate is
                          about $0.23/m
                          ($0.07/ft); electrode
                          replacement every 2-8
                          hours ($15-$40/set)
                          takes only a few
                          minutes

Installations
Case A - Four shop workers using a mechanical cutting system in a plant
producing custom fabricated AC ductwork supplied 30 field installers. The plant
needed higher productivity and the metal cutting operation was the bottle neck.
Laser cutting was investigated but the capital cost was too high and the laser
precision was not necessary.

A plasma cutting system was installed. Now 2 shop workers supply 50 field
installers. The installed capital cost was $130,000 and payback was about 1 year.

Case B - Plasma heaters are now used in over a dozen steel mills around the
world for maintaining precise control of steel temperature as it passes down a
tundish to a continuous caster. These units range in power rating from 350 kW to
about 2.5 MW.  Steel temperature entering the caster is controlled to a precision
of 1 °C. The systems produce higher yields, better refractory life, and improved
steel quality.

-------
Major Vendors

Plasma Arc
Century Manufacturing Company
(cutting, welding equipment)
9231 Penn Avenue
Bloomington, MN 55431
(800) 328-2921
Hard Face Alloy
(spray coating equipment)
8351 Securia Way
Santa Fe Springs, CA 90670
(310) 945-5477
Hypertherm Inc.
P.O. Box 5010
Hanover, NH 03755
(800) 643-0030
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.
Thermal Dynamics
Industrial Park #2
West Lebanon, NH 03784
 (603)298-5711
Weldcraft Products, Inc.
119E. Graham Plaza
Burbank, CA 91502
 (818) 846-8181

-------
Index to EPRI DOCUMENTS

Plasma Arc

Plasma Arc Cutting, EPRI CMF TechCommentary, Vol 4, No 5,1987

Plasma Cutting, EPRI CMF TechApplication, Vol 1, No 14,1991

Plasma Arc Technology, EPRI CMP TechCommentary, No 76,1992
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
                                                                   Nz

                                                                   N2
                                                                .._
                                                                 N*
 N+ rr  2<>
>r NT  iKf
Applied Technology: Plasma (Ion) Nitriding
                                                        /

Concept

Plasma (sometimes called ion) Nitriding is a process for
surface treatment of metal parts to make them resistant to
wear and fatigue. Parts to be treated are placed in a vacuum chamber and a high
DC voltage (typically around 100 volts) is established between the parts and the
chamber wall. As nitrogen gas is introduced into the chamber, a glow discharge
plasma (ionized gas) builds up around the parts. This plasma is highly energetic.
The reactive nitrogen atoms thus bombard the surface, forming a thin layer of
hard metal nitrides.
  Applications
  •  Surface Hardening; dies, cutting
     tools, parts, and molds
  Technologies Replaced
  •  Salt Bath Nitriding (reactive
     ammonia and cyanide)

  Wastes Reduced
  •  Explosive Gases and Toxic Salts
  •  Chromium Plating wastes (from
     hard chrome resurfacing)
                                          Thermal Heat Treatment and
                                          Carburizing
                                          Combustion Pollutants: ROG,
                                          COx, SOx, NOx, and Particulate
Potential in Manufacturing
Indust SIC Pot
Food 20 LOW
Tobac 21 LOW
Textile 22 LOW
Apparel 23 LOW
Indust SIC Pot
Lumber 24 LOW
Furn 25 LOW
Paper 26 LOW
Printing 27 LOW
Indust SJC Pot
Chem 28 LOW
Petrol 29 LOW
Rubber 30 LOW
Leather 31 LOW
tnttust StC Pot
Stone 32 LOW
Pmetal 33 LOW
MetFab 34 MED
Mach 35 HI
Indust SIC Pot
Elect 36 Hi
Transp 37 HI
Instr 38 MED
Misc 39 MED
Credits: Dr. Philip Schmidt and Or. F.T. Sparrow;
     Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                                                                    AT11

-------
 Plasma (Ion) Nitriding continued
Technology Advantages
•  Better Product Quality
•  Faster Cycle Time
•  No or Little Thermal Effects
•  Simpler Automation and Control
                Easy to Mask Unnitrided Areas
                Less Floor Space (1/2 other
                technologies)
Technology Disadvantages
•  Parts Must Be Separated
Typical Costs (compared to other technologies)
Capital Costs

higher baseline; but
does not require
dissociaters and
cooling pits
0 & M Costs

energy costs: 1/3
labor: < other nitriding
overall: 1/2 (salt bath)
to       1
(ammonia)
Potential Payback

< 1 year or more; very
application dependent
installations
Case A - A company producing large injection molded fiberglass components,
such as outboard motors, basketball backboards, and automotive body
components, replaced its chromium-plated molds with ion nitrided molds. The
new molds last 5 times as many molding cycles as the chromium-plated molds
before they have to be refinished. This has reduced the number of spare molds
required (at $200k - $300k each) and reduced the number of mold-refmishing
operations (at $25k - $40k each) by 80%. The surface quality of the molded parts
is improved substantially, reducing part finishing costs.

-------
Major Vendors

Plasma (Ion) Nitriding
Abar-lpsen Industries
905 Pennsylvania Blvd
Feasterville, PA 19047
(215) 355-4900
Seco/Warwick Corp                      ™s 7/f ' °' ™*»* ofthe ,
180 Mercer Street                       indicated technology is not meant
M»9,iwiii*  DA -HS77R                     to be B complete or
(81 4 J 724-1 400                         comprehensive listing.  Mention of
'   '   "                             any product, process, service, or
                                      vendor in this publication is solely
_  ,    ^   .   ..   .                    for educational purposes and
?™ ?6.   ^  T,*   >                  should "<* ** regarded as an
 700 Indian Wood C.rcle                 endorsement by the authors or
Maumee, OH 43537                     publishers.
(419)891-7150                         p

-------
Index to EPRI DOCUMENTS

Plasma (Ion) Nitriding

Ion Nitriding, EPRI CMF TechCommentary, Vol 2, No 5R, 1994

Ion Nitriding Injection Molds, EPRI CMF TechApplication, Vol 1, No 13,1987
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
  Applied Technology: Radio Frequency (RF)
  Concept
                                                         Electrode
                                                      Alternaling
                                                     Etectnc Fields
  Radio frequency (RF) electromagnetic waves cover the frequency spectrum from
  30 to 300 MHz and, like microwaves, can be absorbed and converted to heat in
  nonmetallic materials known as "lossy dielectrics". For this reason, both RF and
  microwave heating are known as "dielectric heating". The two technologies can
  affect materials differently and require different equipment. RF energy mainly
  acts through the electrical conductivity of the material, so the presence of ionic
  species (e.g., dissolved salts) tends to make materials good heating candidates.
  RF generally heats more uniformly than microwave. RF energy is less expensive
  per kilowatt than microwaves; RF generator capacities range from a kilowatt to
  hundreds of kilowatts.  RF heating has been used for commercial applications
  since World War II.
  Applications
  •  Curing wood adhesives and glass
     fiber coatings
  •  Drying wood, textiles and paper
     adhesives
  •  Moisture leveling
•  Welding plastics
•  Preheating plastiics
•  Post-baking food
•  Plasma etching and vapor
   deposition for semiconductors
  Technologies Replaced
  •  Gas fired drying, curing, and
     preheating ovens
  •  Wet-chemical etching

  •  Combustion Products: COx, SOx,
     NOx, ROG, and particulates
  •  Off-spec moisture profile product
     waste
•  Use of organic solvent-based
   adhesives

Wastes Reduced
•  Wet-chemical etch hazardous
   chemicals
•  Solvent-based adhesive VOCs
Potential in Manufacturing
Indust SIC Pot
Food 20 MED
Tobac 21 MED
Textile 22 HI
Apparel 23 LOW
Indust SIC Pot
Lumber 24 MED
Fum 25 MED
Paper 26 MED
Printing 27 LOW
Indust SIC Pot
Chem 28 LOW
Petrol 29 LOW
Rubber 30 HI
Leather 31 LOW
Indust SIC Pot
Stone 32 LOW
Pmetal 33 LOW
MetFab 34 LOW
Mach 35 LOW
Indust SIC Pot
Beet 36 HI
Transp 37 LOW
Instr 38 LOW
Misc 39 LOW
 Credits: Dr. Philip Schmidt and Dr. F.T. Sparrow;
      Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                             AT12

-------
Radio  Frequency (RF) continued


Technology Advantages
•  Fast uniform heating
•  Some tolerance of complex
   shapes
•  Levels moisture while drying
•  Enhances use of water based
   coatings and adhesives
•  Fast startup/shutdown

Technology Disadvantages
•  Not inherently self-regulating;
   product can overheat
•  Can arc in high humidity or low
   pressure
•  Convection systems more tolerant
   of complex shapes
                                           Precise control (can be
                                           computerized)
                                           Compact equipment
                                           High throughput rate
                                           Low emissions
                                           High energy efficiency
                                           Effectiveness dependent on
                                           product dielectric characteristics
                                           High capital cost
                                           Requires specialized technical
                                           support
                                           Must be shielded (FCC regs)
Typical Costs

Capital Costs

$1.5k-$3k/kw
depending on size and
application
                                                      Potential Payback

                                                      About 1 year or
                                                      more
                                                      depending on
                                                      application
                           O & M Costs

                           Energy costs low due
                           to high efficiency and
                           elimination of large fan
                           loads associated with
                           combustion-fired
                           ovens. Higher
                           maintenance cost for
                           specialized technical
                           support.

Installations
Case A - Over 300 RF textile yarn drying units have been installed in plants in Europe,
Taiwan and the U.S. Typical reduction in energy consumption per unit of product is 50-
65%. Since this is all electric energy, on-site combustion emissions are eliminated.
Because of the high efficiency of RF-based drying, net emissions, including the
powerplant, are actually lower than those associated with conventional drying. The RF
units achieve 70-120% increase in product throughput in the same space, and require
about half the operating labor of conventional dryers..

Case B - A major wood products corporation installed a 300 kW RF redryer in one of its
plywood plants for production of softwood veneer. Due to wide variations in the moisture
content of wood, about 15% of the veneer exiting from the main steam-heated dryer is
typically above the target moisture level and has to be redried. Conventional redrying, by
recycling the veneer through the main dryer, results in scrap losses of 10 to 25% (1.5-5%
of total production) due to uneven moisture profiling, with associated splitting, warping
and cracking. With the RF redryer, scrap losses have been substantially reduced and
productivity of the primary dryer has been increased by 15-20%. Payback period on the
RF installation was estimated at 1.5 years.
R1TI

-------
Major Vendors

Radio Frequency (RF)
Microdry
7450 Highway 329
Crestwood, KY 40014
(502)241-8933
Nemeth Engineering Associates
5901 W. Highway 22
Crestwood, KY 40014
(502)241-1502
Strayfield
Green Hills Corporate Center
2675 Morgantown Road, Suite 1405
Reading, PA 19607
 (610) 856-5760
PSC, Inc.
21761 Tungsten Road
Cleveland, OH  44117
(216)531-3375
Radio Frequency Company
150 Dover Road
Millis, MA 02054
(617) 762-4900
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.
Thermex/Thermatron, Inc
60 Spence Street
Bayshore, NY11706
(516)231-7800

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Index to EPRI DOCUMENTS

Radio Frequency (RF)

E/ectroforming, EPRI CMF TechCommentary, Vol 3, No 5,1986

Radio Frequency Heating of Plastics, EPRI CMF TechCommentary, Vol 4, No 2,
1987

RF Curing of Furniture Adhesives, EPRI CMF TechApplication, Vol 5, No 1,1991

RF Drying of Textiles, EPRI PIO TechApplication, Vol 2, No 2,1990

[SEE ALSO MICROWAVE]
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

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  Applied Technology: Ultraviolet (UV)


  Concept

  Ultraviolet radiant curing is an alternative to conventional
  thermal curing of coatings, inks, and adhesives.
  Conventional solvent or water based formulations must be
  first dried (to evaporate the solvent or water), then cured with
  heat or long exposure to air to convert the soft organic base
  to a tough polymer. UV-curable formulations contain little or
  no solvent.  The organic base contains a photo-sensitive component
  ("photoinitiator") that triggers a nearly instantaneous curing reaction upon
  exposure to ultraviolet light. Thus UV curing produces a completely dry and
  finished surface in a second or two, compared with minutes or hours for
  conventional curing. This yields coatings and inks of the highest quality with
  very high production rates in minimal equipment space.

  UV can also disinfect clear or translucent fluids (water, air, etc.) for reuse or
  recycle.
  Applications
  •  Curing Coatings, Inks, and
     Adhesives; metal, wood, plastic,
     fabrics, mag tape, electronics
  •  Curing Textile Fiber Sizing
•  Compact Disc Production
•  Disinfection of Water, Wastewater,
  Technologies Replaced
  •  Conventional Thermal Curing;
     solvent based
   Air, and Other Fluids
   Chemical or Heat Disinfection of
   Some Fluids
  Wastes Reduced
  •  Combustion Pollutants: ROG, COx,
     SOx, NOx, Particulate
  •  VOC Emissions; from solvents
  •  Coating Overspray (can be recycled)

Potential in Manufacturing
   Waste Heat (curing ovens)
   Sludge, Chemicals, and Emissions
   from Chemically Treated Waters and
   Wastewaters
Indust SIC Pot
Food 20 LOW
Tobac 21 LOW
Textile 22 MED
Apparel 23 LOW
Indust §£ Pot
Lumber 24 MED
Furn 25 HI
Paper 26 MED
Printing 27 HI
Indust S£ Pot
Chem 28 LOW
Petrol 29 LOW
Rubber 30 MED
Leather 31 LOW
Indust #CPgf
Stone 32 MED
Pmetal 33 LOW
MetFab 34 HI
Mach 35 HI
Indpst SK PoJ
Elect 36 HI
Transp 37 HI
Instr 38 Hi
Misc 39 MED
Credits: Dr. Philip Schmidt and Or. F.T. Sparrow;
     Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                              AT13

-------
 Ultraviolet (UV) continued
Technology Advantages
•  Cures Fast
•  Reduces or Eliminates Solvents
•  No Curing Ovens
•  Can Coat Heat Sensitive
   Substrates (plastic and wood)

Technology Disadvantages
•  Higher Cost of UV Materials
•  Some UV Materials Require
   Special Care (toxic)
                Less Coating Materials Required
                Small Equipment and Staging
                Area Required
                Improves Coating Quality
                Aids VOC Regulatory Compliance
                More Worker Protection Required
                (high energy UV)
                Line of Sight Limitation
Typical Costs

Capital Costs

low; curing units < V*
thermal curing ovens;
control required little
or no emission control
required
0 & M Costs

energy cost: 1/3 - Yz of
thermal oven
labor cost: 1/3
floor space:  1/10
material: same
  cost/unit area
covered
Potential Payback

< 1 year or more;
application dependent
Installations
Case A -A major brewing company implemented a UV curing process for
coating 15 million cans per day. Wet UV curable inks are applied to the cans
followed by a clear overvarnish to give the can a high gloss and abrasion-
resistant surface. The entire ink/overcoat system is cured in about % second.
The system uses less than 10% of the energy required by a conventional thermal
curing oven (not even counting emission controls not needed) and occupies 1/5
of the space. Further energy, space and cost savings accrue from increased
production rates and elimination of the solvent vapor incinerator required to meet
tough new emission standards.

Case B - A printing company is using UV curing on a print line to produce
labels, coupons, and tags. UV-curable inks and overprint varnish maintain high
quality and consistency in the colors and give the product
an attractive and durable finish. Print quality variations due to evaporation of
solvent in ink trays .have been eliminated. Line speed is about 67% higher for the
UV-cured lines.  Startup and shutdown/cleanup times have been reduced
dramatically with the UV inks.  Rejects and product loss at startup have also been
sharply reduced.                                                     _

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Major Vendors

UV
Crown Metro
(coatings)
P.O. Box 5857
Greenville, SC 29606
(803) 299-1331

Eye Ultraviolet
(equipment)
42 Industrial Way
Wilmington, MA 01887
(508) 694-9060

Fusion UV Systems
7600 Standish PI
Rockville, MD 28055
(301)251-0300

Industrial Heating and Finishing Co., Inc.
(equipment)
P.O. Box 129
Pelham Industrial Park
Pelham, AL 35142
(205) 663-9595

Hanovia, Inc.
(equipment)
100 Chestnut Street
Newark, NJ 07105
(800) 229-3666

RPC Industries
(electron beam equipment)
21325 Cabot Blvd.
Hayward, CA 94545
(510) 785-8040
Specialty Coating Systems
5707 West Minnesota Street
Indianapolis, IN 46241
(800) 356-8260
Sun Chemicals
(coatings, inks)
135 West Lake Street
Northlake, IL 60164
(800) 933-7863
UCB Chemical Corporation
(coatings)
Radcure Business Unit
2000 Lake Park Drive
Smyrna, GA 30080
(770)434-6188
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.

-------
Index to EPRI DOCUMENTS

Ultraviolet Curing

Ultraviolet Curing Technology, EPRI CMF TechCommentary, Vol 4, No 4R, 1994

UV Curing of Coatings on Metals, EPRI CMF TechApplication, Vol 1, No 16,1991

UV Curing in the Label Industry, EPRI CMF TechApplication, Vol 1, No 17,1987
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without Hie approval of the copyright owner.

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                                                                      Nozzle
  Applied Technology: Waterjet

  Concept
         Pump
  Waterjet cutting applies the force of a very concentrated
  high velocity stream of water to cut through materials
  ranging from the hardest metals to food products.
  Special pumps and pressure intensifiers boost the
  water to pressures in excess of 3400 atmospheres.  The
  water is then concentrated through a metal or sapphire nozzle to a stream
  diameter of a few micrometers, reaching velocities several times the speed of
  sound. For cleaning, lower pressures (1/2 - 700 atmospheres) and larger nozzles
  are used. For very hard materials, abrasives may be added to the water to
  enhance cutting action.
  Applications
  •  Cutting; plastic, fiberglass, glass,
     metal, leather, food, composites,
     paper, cardboard, rock, concrete

  Technologies Replaced
  •  Cutting; by mechanical saw, laser,
     plasma, or oxyfuel

  Wastes Reduced
  •  Metal Cutting Fluids and
     Contaminated Wastewater
  •  Slag and Scale; from oxyfuel
•  Cleaning; scale, deposits,
   coatings, contaminated layers of
   concrete
   Cleaning; by solvents, chemicals,
   or abrasives
•  Dissolved Scale, Abrasives, and
   Solvents; from cleaning
•  Material Removal
Potential in Manufacturing
Indust SIC Pot
Food 20 MED
Tobac 21 LOW
Textile 22 LOW
Apparel 23 LOW
Indust SIC Pot
Lumber 24 LOW
Furn 25 MED
Paper 26 MED
Printing 27 LOW
Indust SIC Pot
Chem 28 MED
Petrol 29 MED
Rubber 30 MED
Leather 31 MED
Indust SIC Pot
Stone 32 MED
Pmetal 33 LOW
MetFab 34 HI
Mach 35 H!
Indust SIC Pot
Elect 36 HI
Transp 37 HI
Insitr 38 MED
Misc 39 MED
Credits: Dr. Philip Schmidt and Or. F.T. Sparrow;
     Unimar Group, Ltd; The Electrification Council; Electric Power Research Institute
                             AT14

-------
 Waterjet continued
Technology Advantages
•  Fast Cutting
•  Clean Cutting
•  Cuts Difficult Materials
•  Better Tolerances (than
   mechanical or torch cutting)
                No Thermal Effects
                Flexible and Controllable
                Reduces Material Loss
                Fast Cleaning of Difficult Scale;
                without solvents or abrasives
Technology Disadvantages
•  Higher Capital Cost
             •  Larger Tolerances than Laser
Typical Costs

Capital Costs

$165k-$600k;
baseline: $65k - $100k
controls: $100k -
$500k
abrasive: $10k
O & M Costs

overall operating
 nonabrasive: $3/hour
 abrasive: $11/hr
labor: often lower than
 alternatives
Potential Payback

< 1 year or more;
very application
dependent
Installations
Case A - An automaker installed six waterjet cutting systems on a conveyor line
to cut asbestos brakelining strips.  Waterjet was chosen because it produces a
minimum kerf, < % mm (<0.01 "), eliminates airborne asbestos dust, and is simple
to automate for safety and production control. Cutting efficiency increased an
estimated 30 - 50% with an annual savings of about $25k.

Case 8 - An Aerospace firm purchased a waterjet cutting system equipped with
hydroabrasive nozzles to cut titanium and other hard materials for aircraft
components.  The system feeds two cutting stations, one manual for complex
contoured components, and the other a CNC X-Y positioning table for sheet
metal.  The system cuts 1.5 mm (1/16") titanium plate at a rate of 5 mm/second (1
foot/minute).  The company estimates overall production cost savings is 50%.
 run

-------
Major Vendors

Waterjet
Aqua-Dyne Inc
3620 W. 11th Street
Houston, TX 77008-6004
(800)324-5151
Ingersoll-Rand
Waterjet Cutting Systems
634 West 12th Street
Baxter Springs, KS 66713
 (316) 856-2151
Jet Edge
825 Rhode Island Ave, South
Minneapolis, MN 55426
(800) 538-3343
This list of vendors of the
indicated technology is not meant
to be a complete or
comprehensive listing. Mention of
any product, process, service, or
vendor in this publication is solely
for educational purposes and
should not be regarded as an
endorsement by the authors or
publishers.
Pratt & Whitney Waterjet Systems
(cleaning and stripping)
P.O. Box 070019
Huntsville, AL 35807
(800) 239-2773
Robotics Inc.
2421 Route 9
Ballston Spa, NY 12020
(518)899-4211
Trumpf, Inc.
Large Machinery Sales
Farmington Industrial Park
Farmington, CT 06032
 (860) 677-9741

-------
Index to EPRI DOCUMENTS

Waterjet

Waterjet Cutting, EPRI CMF TechCommentary, Vol 5, No 1,1988
       Parts of this manual are copyrighted as indicated on the bottom of each sheet
       and therefore may not be copied without the approval of the copyright owner.

-------
James B. Hogenson





Eastman Kodak Co.

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                         EXECUTIVE  SUMMARY
The Silver Coalition and the Association of Metropolitan Sewerage Agencies (AMSA)
have prepared and issued recommendations on technology, equipment and management
practices for controlling silver discharges from facilities that process photographic
materials. These recommendations are known as the Code of Management Practice
(CMP), and will be used to develop a consensus among the regulated and regulatory
communities for controlling silver discharges in a cost-effective and environmentally
sound manner.  Implementation of the CMP recommendations will result in many
benefits, including  improved selection, operation, maintenance and monitoring of silver
recovery and management systems among all types and sizes of photographic
processing facilities; an increase in the amount of silver recycled and reused; and a
reduction in the amount of silver discharged to sewage treatment plants and the
environment.

The large numbers  of facilities that process small volumes of photographic products in
most communities make the control of their discharges to sewage treatment plants
through typical pretreatment programs difficult, costly and resource intensive.
However, there is a strong desire from both the regulated and the regulatory
communities to reduce the amount of silver discharged to POTWs, to achieve more
silver recovery and recycling,  and to encourage water conservation, particularly from
these numerous small volume  facilities.  Consequently, resources from the Silver
Coalition and AMSA developed the CMP.

The CMP describes the technologies and capabilities of the different types of silver
recovery and management systems and equipment. The CMP recommends specific
silver recovery and management systems and equipment, along with management
practices that will ensure optimum recovery in a cost-effective manner for all sizes and
types of facilities that process  photographic materials. Recommendations are provided
for both on-site and off-site silver  recovery and management.  Implementation of the
CMP recommendations will result in reduced  silver loading to POTWs, reduced
regulatory burdens and costs for municipalities, health care facilities, and small
businesses, and increased amounts of silver recycled and reused. These benefits have
been demonstrated  in three municipalities that have already implemented the
recommendations of the CMP ~ Hampton Roads, VA, Albuquerque, NM and
Colorado Springs, CO.  Other municipalities which plan to implement the
recommendations of the CMP in 1995 include New York City, NY, Atlanta, GA,
Salisbury, MD, and Tacoma,  WA.

Other groups which have expressed support for the CMP process include the
Environmental Protection Agency, the Water  Environment Federation, and the Ontario
Ministry of Environment in Canada.  For more information on the CMP, please contact
Tom Dufficy at the National Association of Photographic Manufacturers (NAPM) at
(914) 698-7603 or Sam Hadeed at AMSA at (202) 833-2672.

-------
Code of Management  Practices
          Introducing a...


                       Code of
                Management Practice

                          for
                 Controlling Silver Discharges
                         from
           Facilities Processing Photographic Materials
             Pollution
            Prevention
  is
critical
  to
Environmental
  Programs
             A Code of
           Management
             Practice
  is
         Pollution
         Prevention
                A Win-Win for Everyone!
           The Code of Management Practice
           Is Supported by:
                 •!• Silver Coalition
                 <* Association of Metropolitan
                   Sewerage Agencies (AMSA)

-------
Code of Management Practices
          The Code of Management Practice
          for Silver


              <• Conserves a natural resource
          The Code of Management Practice
          for Silver
              *J»  Conserves a natural resource
              •J*  Provides for the recovery and
                management of silver at the source
          The Code of Management Practice
          for Silver


              <* Conserves a natural resource
              •> Provides for the recovery and
                management of silver at the source
              <* Reduces silver loading to POTWs

-------
Code of Management Practices
           Facilities That Process
           Photographic Material:
               Banks
               Chiropractors
               Dentists
               Government
               Agencies
               Hospitals
               Industrial
               X-ray Labs
               Medical Clinics
Minilabs
Microfilm Labs
Motion Picture Labs
Printers
Photofinishers
Professional Studios
Schools
Universities
Veterinarians
           The Code of Management
           Practice Provides...
                1. Understanding of silver recovery
                  and management technologies
           The Code of Management
           Practice Provides...
                1. Understanding of silver recovery
                  and management technologies
                2. Equipment recommendations

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Code of  Management Practices
       10
           The Code of Management
           Practice Provides...

                1. Understanding of silver recovery
                  and management technologies
                2. Equipment recommendations
                3. Standards for operation
                  and maintenance
           The Code of Management
           Practice Provides...

                1. Understanding of silver recovery
                  and management technologies
                2. Equipment recommendations
                3. Standards for operation
                  and maintenance
                4. Analytical recommendations
           The Code of Management
           Practice Provides...

                1. Understanding of silver recovery
                  and management technologies
                2. Equipment recommendations
                3. Standards for operation
                  and maintenance
                4. Analytical recommendations
                5. Training  information

-------
Code of Management Practices
       13
           The Code of Management
           Practice Provides...

                1. Understanding of silver recovery
                  and management technologies
                2. Equipment recommendations
                3. Standards for operation
                  and maintenance
                4. Analytical recommendations
                5. Training information
                6. Improved record keeping
       14
           The Code of Management
           Practice Provides...

                1. Understanding of silver recovery
                  and management technologies
                2. Equipment recommendations
                3. Standards for operation
                  and maintenance
                4. Analytical recommendations
                5. Training information
                6. Improved record keeping
                7. Spill control plans
           The Code of Management
           Practice Also Provides...
                   A process of silver management
                   attractive to POTWs

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Code of Management Practices
     16
             There are more than
            360,000 facilities in the
           United States that process
            photographic materials
                   such as
               films and prints.
     17
           Over 99% of those 360,000
           facilities discharge to POTWs.
          However, many POTWs do not
           have the resources to regulate
           and monitor large numbers of
                small generators.
      18
          Management and recovery by
            the generator should be
         encouraged by both POTWs and
            the photographic Industry

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Code of Management Practices
        19
        20
            Sources of Silver
              Silver-based Photographic Materials Have a
              Light-sensitive Emulsion Coated on a Support
                            Emulsion:

                              Crystals of silver halides
                              in gelatin

                            Support:

                              Plastic film or paper
            Sources of Silver
              Processing of Photographic Materials
              Consists of Three Steps:
                  Development
                  Removal of some or all the silver
                  (fix, bleach-fix)
                  Stabilization of the image via rinsing
                  (stabilizers, washes)
             Sources of Silver
              Types of Photographic Materials:
                            Black-and-White
                            (X-rays, graphic arts films &
                            papers, microfilms, motion picture
                            films, professional films, & papers)

                            Color
                            (amateur and professional films
                            & papers, motion picture films)

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Code of Management Practices
       22
       23
           Sources of Silver
            After Processing


            •J*  Black & white films and papers contain
               an image of metallic silver
            *  Color films and papers contain an image
               formed by dyes (no silver remains)
           Sources of Silver
            During Processing,
            Two Types of Solutions are Generated:
                          Silver-Rich
                          Low-Silver
           Sources of Silver
             Silver-Rich Solutions:
             (a solution with enough silver to justify recovery)


                    * Fix, bleach-fix
                    * Low-flow washes
                    * Stabilizers from
                       washless minilabs

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Code of Management Practices
       25
           Sources of Silver
            Low-Silver Solutions:
                    Developers
                    Bleaches
                    Stop baths
                    Pre-bleaches
                    Stabilizers following washes
                    Wash waters
           Technologies for Silver Recovery
           and Management
               Recovery
            Technologies

            Management
            Technologies
Cost effective
silver recovery

Volume reduction for
off-site recovery

Primary focus on
discharge requirements

Costs are a
secondary concern
           Technologies for Silver Recovery
                    1. Electrolysis
                    2. Metallic Replacement
                    3. Precipitation

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Code  of Management Practices
       28
       29
           Technologies for Silver Management
                   1. Evaporation — Distillation
                   2. Ion Exchange
                   3. Reverse Osmosis
           Metal Finishing
              Technologies such as electrowinning
              cannot be used to treat photographic
              processing solutions
              Intense heat produces noxious odors and
              hazardous gases (due to presence of
              sulfur, ammonia)
       30
           Metal Finishing vs.
           Photographic Processing
             Never appropriate to apply Best
               Available Technology limits
             (0.24 / 0.43 ppm silver) used for
                   metal finishers to
                photographic processors

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Code of Management Practices
       3)
       32
           Discharger
           Small
           Medium
           Large
           Significant
           Industrial User
            Silver-Rich
Wash Water     Solution
Usage (GPD)  Generated (GPD)
  <1,000
  10,000
  10,000
 <2
<20
>20
 >25,000  (Process Waste Water)
          The Code of Management
          Practice Recommends
            Small Facilities...>90% removal
            Medium Facilities...>95% removal
            Large Facilities and SIUs...>99% removal
           The Code of Management
           Practice Recommends
                  <» Equipment specifications
                  * Operating procedures

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Code  of  Management Practices
        34
        35
             The Code of Management Practice
             Recommends for Small Facilities
               At Least (or >) 90% Removal of Silver Using:
                     A) 1 or 2 metallic replacement
                        cartridges with flow control
                   or B) 1 electrolytic unit
                   or C) 1 precipitation unit
                   or D) 1 evaporative or distillation unit

              (plus standard operating procedures and verification)
             Operating Procedures — Small Facilities
              <•  Spill prevention systems
              *t*  Spill plan
              <«  Analytical / record-keeping requirements*
                  I Weekly, if continuous
                  I By batch,  if batch processing
                  > Information recorded in silver recovery log
              Verification
                 Semiannual analytical test to
                 verify 90% recovery
             •with test papers, analytical test kit or lab analysis
        36
             The Code of Management Practice
             Recommends for Medium Facilities
               At Least (or >) 95% Removal of Silver Using:
                   A) 2 or more metallic replacement
                      cartridges with flow control
                or B) 1 electrolytic unit & 1 metallic
                        replacement unit and flow control
                or C) 1 precipitation unit
                or D) 1 evaporative or distillation unit

               (plus standard operating procedures and verification)

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Code  of Management  Practices
        37
        38
             Operating Procedures — Medium Facilities


               «> Spill prevention systems
               *> Spill plan
               * Analytical / record-keeping requirements*
                  I For batch operations:
                    • Primary unit checked before
                     & after each batch
                    • Effluent checked after secondary unit


             'with test papers, analytical test kit or lab analysis
             Operating Procedures — Medium Facilities

              *  Analytical / record-keeping requirements*
                  I For Continuous Operations:
                    • Weekly testing of primary unit
                    • Weekly testing of effluent from
                     the secondary unit
                  I Information recorded in silver recovery log

              Verification
                Quarterly analytical test to verify 95% recovery

             •with test papers, analytical test kit or lab analysis
         39
             The Code of Management Practice
             Recommends for Large Facilities
               At Least (or >) 99% Removal of Silver Using:

                  A) 1 electrolytic unit and 2 metallic
                     replacement units with flow control
               or B) 1 electrolytic unit arid
                     1 precipitation unit
               or C) 1 evaporative or distillation unit


              (plus standard operating procedures and verification)

-------
Code of Management Practices
        40
        41
             Operating Procedures — Large Facilities

                   Same procedures as medium facilities
                   In-line electrolytic units in use
                   Squeegees, air knives and low-flow washes used
                   Wash water conservation program
                   Analytical / record-keeping requirements*
                    I Access to analytical testing capability for rapid
                     process control evaluations
                    > Silver recovery system tested at least weekly
                    > Record information in silver recovery log

               Verification
                 Quarterly analytical test to verify 99% removal

             'with test papers, analytical test kit or lab analysis
             The Code of Management Practice
             Recommends for Significant Industrial User
                 All of the large facility requirements
                 as a minimum

                 POTWs could consider mass-based
                 loading to encourage water conservation
         42
             The Code of Management Practice
             Recommends the Following for
             Off-Site Silver Recovery

                A)  Notification to the POTW of the
                   off-site services used
                B)  Storage of silver-rich liquids in
                   DOT approved containers
                C)  Compliance with all hazardous waste
                   and transportation regulations
                D) Maintenance of records for three years

-------
Code of Management Practices
       43
      44
           Additional Recommendations of the
           Code of Management Practice:
                 A) A silver-rich solution inventory

                 B) Floor plan for spill containment

                 C) Response plan for spill handling
                    and proper disposal
           Considerations for Compliance
           with Silver Pretreatment Limits
            Provide...

              * Compliance sampling location

              <• Silver concentrations before recovery

              <» Silver concentrations after recovery
      45
          Silver Concentrations BEFORE Recovery
              Combined silver-rich solutions will
               range between 2,000 and 8,000
              mg/l or ppm, BEFORE treatment or
                         recovery.

-------
Code of Management Practices
      47






46
Silver
Concentrations AFTER Recovery
Silver in Silver
Rich Solutions
% Recovery After Recovery

90
95
99
99.9

(mg/L)
200-800
100-400
20-80
2-8

When Combined
with Low Silver
Solutions
(mg/L)
100-400
50-200
10-40
1-4

When
Combined with
Wash Waters
(mg/L)
10-40
5-20
1-4
0.1-4

          Compliance Sampling Location
              End of process

              I No categorical requirements
              End of pipe — facility outfall

              I Correct for uniform concentration limits
       48
           Silver Pretreatment Limits
             Range

           2.5-5.0 mg/L



           1.0-2.5 mg/L
  Technology Required

  99% removal Efficiency
  from recovery systems
•J* 99% removal efficiency
* Wash water
  control / treatment

-------
Code of Management Practices
        49
            Silver Pretreatment Limits
               Range

             0.1-1.0mg/L
                   Technology Required

                   On site silver recovery
                    I 99% removal efficiency
                    I Wash water
                      control / treatment
                    I Extensive equipment
                      modifcations ($$)
                   Haul away required for
                   many facilities ($$$)
             Less than 0.1 mg/L * Haul away ($$$)
        50
            Silver Pretreatment Limits

             Range
             Cost of
           Compliance
 Equipment
Requirement
2.5-5.0 mg/L   $200-8,000



1.0-2.5 mg/L  $400-16,000


0.1-1.0 mg/L  $600-29,000
                                  <5GPD: MRC's
                                  >5GPD: Electrolytic
                                  & MRC's
                                  Electrolytic and MRC:;
                                  Processor Modifications
                                  Electrolytic and MRC's
                                  Processor Modifications
                                  Wash water treatment
            Less than
            0.1 mg/L
         $1,100-105,000   Hauling

'Operating cost and capital equipment costs amortized over S years

-------








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        Evan Jones





Viatec Recovery Systems, Inc.

-------
        RECOVERING SPENT ACIDS USING THE WADR™ TECHNOLOGY

                                       Evan Jones
                               Viatec Recovery Systems,  Inc.
                              3200 George Washington Way
                                  Richland, WA 99352
                         Ph: (509) 375-0370   Fax: (509) 375-3017
Introduction
More than 15,000 companies, large and small, generate nearly 1 billion pounds per year of
spent acids and are affected by the problem of disposing of this waste. Typical industrial
activities that  generate these spent acids  include: electroplating and  surface finishing
operations  in  electronics, aerospace, automotive, metal working,  steel, and defense
industries.

The Waste Acid Detoxification  and Reclamation (WADR) system was designed to help
companies meet regulatory restrictions and public demand for pollution prevention by
transforming the waste into a  reusable acid and reclaimable metal byproduct.  Through a
combination  of simple  and proven distillation  technology  together  with  advanced
corrosion-resistant materials and specialty manufacturing, the WADR process concurrently
concentrates the metals  and recovers clean acid.  Over 90%  of the spent acid  can be
recovered as a reusable product, and the volume of waste to be disposed of is minimized
or possibly eliminated.   The concentrated metal byproduct  is frequently  suitable  for
recovery by metal reclamation companies.  Acid recoveries and waste reductions will vary
with the spent acid compositions and client requirements. Using the WADR™ system will
reduce  raw material  and waste disposal costs while improving  process quality through
cleaner process acids. Typical simple payback periods  range  from  12  to  24 months in
many cases, making WADR™ systems both economic and environmental friendly.

Viatec  Recovery Systems and the Viatec group  provide custom turnkey  acid recovery
systems, and can conduct sampling,  analysis,  and testing through process design  and
manufacturing to delivery, start-up, and technical service.


Description of the Technology


The WADR™ design can be tailored to accommodate  a wide variety of potential users,
types of wastes, and financial resources. The WADR™ system uses vacuum distillation and
crystallization technology to produce clean reusable water and concentrated acids and a
potentially reclaimable metal  by-product. The process produces concentrated acid (up to
18% HCI or 75% H2SO4) with ppm levels of metals and clean water with <200 ppm Cl-
or SO4'2. The diagram below describes the  WADR™ process. Operation of the WADR™
system varies, depending on the composition of the spent acid. The spent acid is heated
and partially vaporized under vacuum  in the reboiler. The acid and water vapors are then
separated and condensed.  The metals are concentrated in the  reboiler tank and  may
crystallize as rnetal salts (e.g., iron chloride or copper sulfate).

-------
  WADR™ Process Flow Schematic
   Feed Tank
            HCI or H2SO4 or
            HNO3 with dissolved
            metals
                                                      Condenser
                                         Vacuum
                                         Column
                                                                        Water
    Volatile
    Acid
     18% HCI or
     up to 60% HNO3
     (No H2SO4)
                                                        Reboiler
                                                          OPTIONAL
                                      Metal
                                      Concentrate
                                      Slurry
  Viatec Recovery Systems, Inc
  3200 George Washington Way
  Richland, WA 99352
  Tel: (509) 375-0370
  Fax: (509) 375-3017
Metal
Crystal
Concentrated
Acid
70% H?SO4
The key equipment in the system is constructed of advanced laminated materials using
corrosion resistant liners (e.g., polyvinyldiene fluoride (PVDF) fluoropolymer, chlorinated
polyvinyl chloride (CPVC), etc.) laminated with Fiberglass Reinforced Plastics (FRP). These
laminates combine the corrosion  resistance of fluoropolymers or other thermoplastics with
the strength  and  economy  of  FRP.   This  combination  provides corrosion-resistant,
lightweight equipment capable of processing nearly any type of mineral acid.  Due to the
fluoropolymer and other thermoplastic materials of construction, WADR™ acid recovery
systems can process nearly any type of concentrated mineral acid such as  hydrochloric,
nitric, hydrofluoric, and sulfuric acids contaminated with metals such as iron, zinc, nickel,
chrome, copper and others.

The key attributes of the system are highlighted below:

•  Vacuum Operation - Operating under a vacuum lowers fluid temperatures and reduces
   side-reactions,  lengthens  the  life  of the  equipment,  reduces equipment costs, and
   allows the use of lower-temperature heat transfer media (e.g., low-temperature steam).
   In addition, vacuum operation is an inherently safe operation with respect to personnel
   exposure and environmental releases.
•  Advanced   Materials  of  Construction   -  Dual-laminate  equipment  combining
   fluoropolymer  liners  with reinforced  thermosetting  plastic  (RTP)  is  lightweight,
   corrosion  resistant, and custom configured.

-------
   No dilution -  The WADR process does not use chemicals or water to perform the
   separation.  The  entire volume of spent  acid  is converted to a reusable acid  and
   potentially reclaimable metal byproduct; there  is no net increase in the  volume of
   chemicals used or discharged.
   Variety of Acids Rejuvenated - The WADR system is capable of processing a variety of
   spent acids using the same system.
   Uses Waste Energy for Waste Recovery - The WADR process can use low-temperature
   waste energy such as low-pressure steam to recover spent acids.
   Flexible and simple operation - The WADR process can be  designed  to  operate as
   batch, semi-batch, or  continuous operation for multiple or single acid streams, and it
   can be built as a  mobile or fixed system. It can be constructed as a large continuous
   system for aerospace and steel manufacturers generating thousands of gallons of spent
   acids every week.  It also can be constructed  as a portable  batch system for small
   plating shops generating only hundreds of gallons of spent acids per month.  Distillation
   is  a  proven technology that is  easily and safely operated  and maintained with little
   impact from misoperation or variation in feed compositions.
Industrial applications of the WADR   technology


M U.S. Air Force/Oklahoma City Air Logistic Center (OC-ALC) application

The electroplating shop at the U.S. Air Force/Oklahoma City Air Logistics Center (OC-ALC)
has several acid baths that were dumped after metal contaminant concentrations  interfere
with the bath efficiency. A 200-gallon batch WADR™ system was installed to process HCI,
HNO3 and  H2SO4 baths contaminated with Fe, and Ni at OC-ALC's electroplating shop in
late 1994. The OC-ALC acid baths that were treated with the WADR process include 14%
HCI, 10% HNO3, 12% H2SO4, and 40% H2SO4/1% HF. A significant volume reduction of
waste  ("80% to 90%) is achieved as the acid is  recovered.  For HCI and HNO3/  the
overhead distillate product  is clean and reusable representing 80% to 85% of the initial
batch volume.  The still bottoms with concentrated metal contaminants are cooled and
disposed of as waste. The H2SO4 acid is concentrated to 70 wt% while water evaporates
and gets  condensed as a relatively clean stream containing <  50 ppm SO4" to be used as
process makeup water or  discharged. Crystallized metal salts are separated from  the
concentrated bottoms after cooling and filtration.

21 U.S. Filter application

A 250 gallons/hr  WADR™  system was installed at US Filter waste treatment facility in
Minneapolis to process spent hydrochloric acids generated from the galvanizing  industry.
Spent acids concentrations  range from 5% to 15% HCI while metal  concentrations vary
from 5g/L to 50 g/L of Fe,  Cu, Ni. This is a large, continuous operation using fractional
distillation  to provide  a sharper separation  and produce clean, reusable  or disposable
process water with <  200 ppm Cl" and concentrated acid at 18 wt%  HCI to be reused in
the process.  The  recovered acid contains  less than 1  ppm total metals and has a high
purity. The concentrated metal byproducts are disposed  accordingly. The WADR process
achieves an 80% acid recovery and therefore substantially reduces the amount of waste to
be disposed.

-------
31 Watervliet Arsenal application

A 300 gallons batch WADR™ system was designed to regenerate sulfuric and phosphoric
acids for  reuse  in  the  electropolishing  baths  at  Watervliet  Arsenal.  The  spent
electropolishing  baths were rejected when the sulfuric and phosphoric acids get diluted in
the process or when the iron concentration exceeds the specified  tolerance level.  The
WADR ™ process  successfully maintains the acid mixture at desirable concentration by
vaporizing water off the solution. Clean water is then condensed and collected for reuse or
discharge.

A demonstration unit is currently under construction and will be available for companies
interested in on-site testing with their spent acid solutions. The demo unit will enhance the
acceptance of the WADR   process in the related industry in the US and worldwide.


Summary


The  WADR™ process  reduces disposal  costs, produces cleaner process chemicals, and
could eliminate  the liability from the  disposal of hazardous wastes - all this while using a
"waste" energy source such as low-pressure steam.  Several commercial  applications have
demonstrated  that  the  volume of spent acid can be reduced up to 90%. The WADR™
system frequently  has  payback periods of 12 to 24 months, proving the economics and
effectiveness of the WADR™ technology in recovering spent acids.

-------
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-------
   James Kiriazes





Commonwealth Edison

-------
           BIOGRAPHICAL INFORMATION FOR JAMES KIRIAZES
James Kiriazes is the Industrial Programs Manager for the Marketing Technical Services
Department at ComEd. James has been with ComEd for the past five years where he has held
positions as an Energy Engineer, Modification Design Engineer and Technical Staff Engineer
at the Zion Nuclear Generating Station. He has a strong background in manufacturing which
includes engineering positions in such companies as Miller Fluid Power and Camcar Division
of Textron.  James holds a BSME from Illinois Institute of Technology, an MBA with a career
organization in leadership and organizational development from DePaul University and is
currently a registered BIT in the State of Illinois.

-------
     Peter Ko





PRC Environmental

-------
                     Using Innovative
             Conductivity Control Systems to
                 Reduce Rinse Water Use
              in Metal Finishing Operations
                  Overview
                  Industry overview

                  Conductivity basics

                  System components

                  System installation

                  System operation and maintenance

                  Case study
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Ooerations

-------
                    Metal Finishing in the U.S.
                 In 1993, 98% of facilities had end-of-
                 pipe wastewater treatment systems
                 Average discharge is about 35,000 gpd
                 and average F006 sludge generation is
                 about 80 tons per year
                 The estimated number of industrial
                 facilities that use metal finishing
                 processes range between 20,000 to
                 80,000  (OTA 1993)
                    Conductivity Control Systems
                 Basic concept: Add water to rinse tanks
                 only when necessary instead of
                 continuous addition at a constant rate
                 How? Use rinse water conductivity to
                 determine when clean water should be
                 added to rinse tanks
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations

-------
                      Conductivity Control Systems
                   Perception: Conductivity control
                   systems are difficult to maintain and do
                   not significantly impact water use
                   Reality: With a small amount of regular
                   maintenance, conductivity control
                   systems can work effectively to control
                   rinse water flow
                      Conductivity Basics
                   Conductivity = a material's ability to conduct
                   electrical current
                   All aqueous solutions conduct electrical
                   current
                   Conductivity is an indicator of total ion
                   concentration in a solution
                   Increase ions = increase conductivity
                   Measuring conductivity
                    > Conventional sensor
                    >• Electrodeless sensor                   -.*,,.
Using Innovative Conductivity Control Systems to
Rorlnro Rinco Wafw TIcp in Mpfal Finishinff Onerations

-------
                               Conductivity Basics
                         Zinc Concentration and Conductivity vs. Cumulative Number of Rack!!
                     3,500
                     3,000	
                     2,500
                                                                   —r 6.00
                                        Concentration Slope =

                                        0.268 ppm/rack
- 500
                                                                    if 4.00
                                                                     3.00
                                                                        I
                                                                        N
                                       4       6

                                      Cumulative Number of Racks
                                                             10
                                                                     2.00
                                                                     1.00
                                                                    -- 0.00

                                                                    12
                   Conductivity Control System Components
                             Analyzer
                             Solenoid
                               Valve
                                 Sensor
                                              Rinse Tank
Using Innovative Conductivity Control Systems to

Reduce Rinse Water Use in Metal Finishing Operations

-------
                    Conventional Sensor
                     Conventional Sensor
                  Two electrodes are placed in solution
                  Electrical potential applied between
                  electrodes
                  Current and voltage values measured
                  Size and spacing of electrodes
                  determines cell constant
                  Cell constant values: 0.05, 0.5, or 10.0
                  Prone to fouling
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations

-------
                    Electrodeless Sensor
                     Electrodeless Sensor
                 Uses two parallel torroids
                 First torroid induces alternating current in
                 water passing through torroid
                 Second torroid senses the magnitude of the
                 induced current
                 Non-conductive casing (polypropylene or
                 PVDF)
                 No electrodes; no fouling
                 Can measure full range of conductivity
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations

-------
                         Electrodeless  Sensor
                                              INDUCED ELECTRIC
                                              CURKENTINTHE
                                              SOLUTION
                         Analyzer
Using Innovative Conductivity Control Systems to

Reduce Rinse Water Use in Metal Finishing Operations

-------
                        Analyzer
                      4 The system "brain"
                      + Receives input from sensor
                      + Displays conductivity reading
                         > Digital, analog, or none
                      + Sends output signal to solenoid valve
                      + Key features:
                         > Programmable set point
                         >• Programmable deadband
                      + Enclosure: NEMA 4X or regular
                      * Number of channels:  singe or dual

Conductivity Measurements
o rvv-j 	 	
1,800
W 1-600
3* 1,400
.•e" 1,200
£ 1,000
3 800
c 600
0 400
200
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-------
                    Component Purchase
              /A   Considerations
                 Conductivity range of rinse water
                 Mounting of analyzer and sensor
                  > Analyzer: panel, surface, or pipe mount
                  > Sensor: submersion or union mount
                 Environment where components will be
                 located
                 Distance from sensor to analyzer
                 Number of channels on analyzer
                    Sensor Installation
                  Sensor placement
                  > Halfway down from top of water level
                  x Away from stagnant areas
                  > Away from clean water inlet
                  >In final stage of multistage counterflow
                    rinse
                  Good circulation of rinse water
                  > Mechanical mixing
                  > Double dipping parts              j
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations

-------
                     Determining the Initial Set Point
                   Set point is the upper limit of acceptable
                   metal concentration for quality rinsing

                   Determines amount of water used

                   Before installation, monitor conductivity in
                   rinse tank to determine conductivity range

                   Program set point initially at high end of the
                   rinse water conductivity range

                   Deadband determines cycle frequency
                      NAMF Survey Says . . .
                 "... choosing the range [of conductivity]
                   is the hardest part of the design ... this
                   problem is mainly caused by lack of
                   information and data available."
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
10

-------
               Determining the Initial Set Point
                                     Date
                     Fine Tuning the Set Point
                  Maintain log of set points and reject
                  parts related to rinse quality

                  Increase set point until quality is
                  "threatened"

                  Reduce set point if parts are not rinsing
                  adequately
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
11

-------
                   Sensor Maintenance
                Conventional
                 > Regular cleaning required
                 > Cleaning schedule varies according to
                  process solution type and concentration in
                  rinse water
                 > Monthly calibration checks recommended
                Electrodeless
                 > No fouling
                 > Monthly calibration checks recommended
                       Conductivity
                     Control System
                         Case Study
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
12

-------
                        Facility Description
                      Sports, plumbing, automotive hardware
                      Specializes in electroplating zinc die-cast
                      parts
                       >• Also electroplates steel and brass parts
                      Hand Operated Rack Line
                       > Brass, copper, nickel, chrome
                      Manually-Operated Barrel Hoist Line
                       > Copper
                      60 employees
                        Facility Operating Costs
                   Rinse Water Use
                   Wastewater Discharge
                   WWTS Operation
                   Sludge Generation
                   Total =
                                      Monthly Rate   Monthly Cost
520,000 gal
520,000 gal
520,000 gal
  2.6 tons
 $640
 $260
$5,800
$1.400
$8,100
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
                                          13

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                    Conductivity Control Systems
                    Implementation
                 Nine conductivity control systems
                 Three systems from three different
                 manufacturers
                  > Cole-Fanner (conventional system)
                  >Foxboro (electrodeless system)
                  > Great Lakes Instruments (electrodeless
                   system)
                 Two on barrel line, seven on rack line
                    Conventional
                    Conductivity Control Systems

                     + Analyzer
                       >No conductivity display
                       > Single channel
                       > Regular enclosure
                     + Sensor
                       > Conventional
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
U

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                     Electrodeless Conductivity
                     Control Systems
                        Analyzer
                        >NEMA 4X enclosure
                        > Digital display
                        > Single channel
                        Sensor
                        > Electrodeless
                        > Small bore
                     Rinse Tank Types with
                     Conductivity Control Systems
                    Acid activation
                    (new parts)
                    Acid activation
                    (nickel-plated)
                    Acid activation
                    (barrel line)
                    Chrome
+ Copper cyanide
  and brass
* Copper (barrel line)
+ Nickel (satin)
4 Nickel (die-cast)
4 Nickel (steel)
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
                       (>
                                   15

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                     Conductivity Analyzers
                      Electrodeless Sensor
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
16

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                      Conventional Sensor
                     Installation and Operation
                     Issues
                     •••••••••
                   >  Contractor bids
                   >  Installation location of sensors
                     Final rinse of a 2-stage counterflow
                     Malfunctioning systems
                    Workers bypassing solenoid valves
                    Parts plating quality
                    Adjusting set points and deadbands
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
                                                                      17

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                      Conductivity Control System
                      Costs
                  Capital
                  Additional
                  Hardware
                  Installation
                  Total
                  (per system)
Conventional21
   $290

   $100
   $400
   $790
Electrodelessb
 $1,140

   $250
   $600
 $1,990
               a Conventional sensor, analyzer with no display, and analog set point and deadband
               b Electrodeless sensor, analyzer with digital display, and programmable set point and deadband
                      Impact of
                      Conductivity Control Systems

                      Rinse water use

                      Wastewater discharge

                      Sludge generation

                      Wastewater treatment system
                      operation
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
                                               18

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                       Conductivity Control  System
                r\   Results
                                          Per Month
                                     Before        After
                Rinse Water Use       516,000 gal    296,000 gal
                Wastewater Discharge  516,000 gal    296,000 gal
                WWTS Chemical Use    $4,000        $3,200
                WWTS Sludge                  Not Quantified

                        Total Cost for Nine Systems = $14,500
                          Total Cost Savings = $14,300/yr
                             Payback Period = 1.0 year
Monthly
Savings
  $280
  $110
  $800
                       Conclusion
                    Electrodeless sensors eliminate fouling
                    problems associated with conventional sensors
                    Analyzers with digital displays are more user
                    friendly and accurate
                    Conductivity control systems can reduce rinse
                    water use without sacrificing rinse quality
                    Conductivity control systems can reduce the
                    following operating costs
                     v Water use
                     >• Wastewater surcharges
                     > Treatment chemicals
                     > Sludge disposal
Using Innovative Conductivity Control Systems to
Reduce Rinse Water Use in Metal Finishing Operations
                     19

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     George A. Makrauer





ComAd Management Group, Inc.

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                              Author and Presenter:
                       George A. Makrauer. CPCM. President
                         ComAd Management Group. Inc.
                           119 - 108th Avenue, Suite 185
                          Treasure Island, Florida 33706
                              Phone 813-363-7373
                               Fax 813-367-0222
                          Email 
                          Web 
Engagements:
Certified Professional Consultant to  Management  and invited speaker  on management,
communications, environmental  affairs,  new  technologies and  government relations  in
manufacturing and service industries.  Spokesman  before the U.S. Senate Committee on
governmental Affairs Hearing on Degradable Plastics (Washington, DC, September 1988);
before a Joint Congressional  Sub-Committee Hearing on Foreign Imports (Washington,
DC, October 1980); and before the Ohio Senate Finance Committee (Columbus, Ohio, May
1995).  Invited lecturer, panelist and program moderator for universities and organizations
throughout the U.S.  and in Canada,  Japan, Sweden, Finland and The  Netherlands.   In
addition to corporate clients, has consulted for the PRISMA Project (NOTA and Erasmus
University, The Netherlands) and the TEM Organization (University of Lund, Sweden).
Personal recipient of a  1994 Ohio Governor's Award for  Outstanding  Achievement  in
Pollution Prevention, a U.S. Department of Commerce NOAA Public Service Award and
other recognitions.  Professional memberships include the  Air and Waste Management
Association, American  Society for Testing and Materials (ASTM),  Society of Plastics
Engineers (Senior Member), the Flexographic  Technical Association, and is credited with
an active role in founding the American Plastics Council.  Holds patents in package design
and trade secrecy agreements on manufacturing processes.  Board and leadership positions
have included many industry associations, private companies and civic groups.

Professional Service:
• The Society of the Plastics Industry (SPI), Board of Directors, Exec. Cmte, 1994-1995
• American Plastics Council (APC), Advertising Committee 1995-present
• Plastic Bag Association, President 1989-1992; Board and Exec. Cmte 1989-1996
• Degradable Plastics Council, Special Purpose  Group of SPI, Chairman 1989-1993
• Ohio  Technology Network (OTNET)  Ohio Department  of  Development, Board  of
  Directors 1994-1995
• Flexographic Technical Association, Board of Trustees 1985-1986
                                     Page 9

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                                    TM
Plastic Packaging and Pollution Prevention Working Together
                   A Case Study in Successful
        Product and Process Design for the Environment.
                         Presented at
                      U.S. EPA Region V
       Waste Minimization/Pollution Prevention Conference
                    February 25 -  27, 1997
                       Chicago, Illinois
                              by
             George A. Makrauer,  CPCM, President
                ComAd Management Group, Inc.
                    119 - 108th Avenue, Suite 185
                   Treasure Island, Florida 33706
                      Phone 813.363.7373
                        Fax 813.367.0222
                   Email 
                   Web 

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                              Abstract
Plastic Packaging and Pollution Prevention Working Together:  A Case
Study in Successful  Product  and Process  Design for the  Environment:
George A. Makrauer, CPCM,  President; ComAd Management Group,  Inc.;
119 - 108th Avenue, Suite 185; Treasure Island, Florida 33706; Phone
813.363.7373; Fax  813.367.0222; Email ;  Web
.  "Plastics" and "packaging" have been popular
targets  for  individuals  and  groups   concerned  about   environmental
degradation and the impact of pollution.  Amko Plastics Inc.  of Cincinnati,
Ohio  is an example of successful  product  and process design for the
environment while at the  same time satisfying customers  and business
objectives.  By involving its employees, suppliers and customers in the
process,  Arnko has shown  that a  plastic  packaging manufacturer  can
contribute positively to an enhanced environment - both inside and outside
its facility - in the manufacture, use, reuse,  recycling and disposal of its
products.

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Fear and profit are the two strongest motivators of business behavior, not necessarily in
that order. How motivated might a manager be after receiving the following communique?

       Dear (company):

       I represent Atlantic States Legal Foundation, Inc. ("ASLF'), 658 West Onondaga
       Street, Syracuse, New York 13204, telephone (315) 475-1170.

       NOTICE IS GIVEN by ASLF, pursuant to section 326 (d) of the Emergency
       Planning and Community Right to Know Act ("EPCRA"), 42U.S.C. 11001, et
       seq., and its regulations, of ASLF's intent to file suit against (your company) for
       violations of EPCRA.  ASLF, a not-for-profit environmental organization with
       members residing in your state and throughout the United States, is informed and
       believes  that (you), as the owner or operator of the manufacturing facility located at
       (address), has failed to comply with the reporting obligations imposed by section
       313 of EPCRA, 42 U.S.C. section 11023.

       ASLF is informed and believes that the (street address) plant of (your company) has
       manufactured, processed, or used toxic chemicals, including, but not limited to,
       various liquids in  excess of statutory thresholds and subject to the reporting
       requirements of section 313 EPCRA.

       As the owner or operator of the (street address) plant, (your company) is
       responsible, with respect to such toxic  chemicals, for the failure to accurately
       complete and submit toxic chemical release forms (EPA Form Rs) as required by
       section 313 (a) of EPCRA:

             (1) by July 1, 1988, for releases during the calendar year 1987;
             (2) by July 1, 1989, for releases during the calendar year 1988;
             (3) by July 1, 1990, for releases during the calendar year 1989; and
             (4) by July 1, 1991, for releases during the calendar year 1990.

       (Your company) may also be responsible for violations not yet known  to ASLF of
       other EPCRA reporting requirements.
                                     Page 1

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       YOU ARE FURTHER NOTIFIED that, after the expiration of sixty (60) days from
       the date of this NOTICE OF INTENT TO SUE, ASLF intends, on behalf of itself
       and its members, to file suit against (your company) in the appropriate federal
       district court pursuant to section 326 (a) of EPCRA. ASLF will request that the
       court enforce the requirements of section 313 of EPCRA, impose civil penalties of
       $25,000 per day of violation from the required dates of submittal, and award costs
       of litigation (including reasonable attorney and expert witness fees) to ASLF.

       During the sixty (60) day notice period, we will be available to discuss resolution of
       this matter. If you wish to avail yourself of this opportunity, please contact me.

                                                      Respectfully,

                                                      Counsel for Notifier

       cc:     Hon. William K. Reilly, Administrator; U.S. EPA
              Valdas V. Adamkus, Regional Administrator; U.S. EPA, Region V
              xxxxxxxxxxxxxxxxx, Director; (State) EPA

Welcome to the calm, peaceful world of environmental bounty hunting.

Consider this.  For several years, a midwestern metropolitan sewer district office failed to
adequately bring about improvements in the quality of industrial water discharges into its
municipal water sewer system.  The district was chastised and fined by its state EPA. After
several years of renewed effort, a district representative speaking at a Waste Prevention
Conference geared to educating business managers about pollution prevention proudly
offered the following as evidence of the district office's achievements in improving the
quality of discharges: "In 1989 we issued 25 citations with fines for violations; in  1990 we
issued 72."

In 1987,1 spoke at a state regional air pollution control association conference about my
work with a client in converting from alcohol based liquids to water-based liquids. In the
question/answer session, an attendee told me she had heard that three companies with
similar operations had "come into compliance" in  the Tampa, Florida area. Thinking I'd

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learn something about new P3l technologies, techniques or materials, I ceilled the Air
Quality Enforcement official for Hillsborough Count and repeated the comment, "I
understand three companies have come into compliance with the emissions regs. Is that
true?"  "Yes," he said, with enough satisfaction in his tone to suggest it was an exciting
accomplishment. Thinking I was getting closer to some enlightening new body of
knowledge, I asked, "Great. How'd they do it?" "Easy," he replied, "two of them shut
down, and one of them moved out of the county."

All the above stories are true; the names have been changed to protect the innocent - and the
guilty.

Second to fear, the incentive to increase profits has become the popular method of P2
pollution prevention.  When customers demand "cleaner" products and the processes that
manufacture them, and when implementing waste prevention includes source reduction and
sound-science/sound-economics recycling (along with other methods of integrated waste
management), then business people are even happier to practice P3 - Pollution Prevention
Pays.

Amko Plastics Inc. of Cincinnati, Ohio was founded in 1966 as a "converter" of plastic
films into plain and printed Low Density Polyethylene bags for food and industrial
packaging. As its markets changed through the 1970s and early 1980s, its product and
technology innovations allowed it to expand into the manufacture of specialty plastic bags
for non-food retail store carry-out. Products included drawstring, rigid handle, die-cut,
garment and other bags for up-scale retailers of clothing, accessories, jewelry, shoes and
similar consumer products.

By the mid-1970s, Amko's major manufacturing processes included:
       1. Blown film extrusion -  a process of heating and melting polyethylene plastic
          pellets into a highly viscous liquid and "blowing" a vertically moving, never-
          ending continuous  tube of plastic film which is cooled into a stable shape and
          wound into rolls of sheeting material for subsequent processing.
       2. Injection molding - a process of heating and melting High Density  Polyethylene
          pellets and injecting the molten material into a mold with cavities of rigid
  P3 = "Pollution Prevention Pays"
                                      Page 3

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          handles to be affixed in a subsequent manufacturing step onto the top opening
          of bags.
       3.  Flexographic printing - a method of rotary letterpress printing using flexible
          rubber or photopolymer plates and liquid inks which are air dried after
          deposition on a substrate using an inking system of either four rollers or a
          doctor blade assembly and three rollers.
       4.  Machine fabrication and repair - a machine shop with turning, cutting, grinding,
          drilling, welding and other metal fabrication techniques.

All of these processes were originally designed around the use of hazardous materials, high
energy consumption and inefficient materials usage. These materials and practices were the
"industry standard" of the time. One particular element of plastic film processing,
however, was inherently beneficial - plastic industry technology was continuously driving
to develop stronger resins with better, stronger physical properties in the finished film
structure. As stronger resins were introduced, industry practice became a cutback of film
thickness in the finished product. This "source reduction" was cost and profit motivated.
Not only would thinner plastic bags cost less than and replace thicker plastic bags made of
older type resins, but, more importantly, the new, thinner, lower cost plastic bags would
also replace the traditional paper bags that had always previously been less expensive than
plastic.  As the packaging materials war heated up at the check-out counter, a planned war
based on fear and paranoia was implemented using conspiracy, obfuscation and a bit of
fraud here and there. But, that's another story for another time.

Through it all, Amko Plastics evaluated its  position and made its decisions based on a
simple premise - it was going to obey the law; it was going to use available technologies
that seemed affordable; it would develop new techniques and introduce new  materials to
meet and then beat the regulations.  That was not the philosophical environment Amko
competed in.  It's three major competitors did the following.
       1.  A midwestern producer was its  town's major employer. That company's
          general manager proudly boasted that its local EPA was afraid to impose
          regulations that might result in lay-offs. It continued to run 6-color presses
          unregulated and uncontrolled with alcohol emissions directly vented to the
          atmosphere.
       2.  A Long Island competitor continued to run alcohol presses unregulated and
          uncontrolled, venting  directly outside in violation of the local regulations. It's

                                      Page 4

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          approach was to willingly run in violation and pay EPA fines, which amounted
          to $13,000 per quarter, $52,000 per year.  It viewed penalties for violation as
          nothing more than an indirect permit cost.
       3.  Another Long Island competitor continued to run alcohol presses unregulated
          and uncontrolled, venting directly outside in violation of the local regulations.
          It chose to do so, because the Suffolk County air quality inspector at the time
          believed that "if an emitter of alcohol fumes from printing does not directly vent
          its emissions outside its plant, it does not require a permit to install or to
          operate."  So, it continued to vent its printing presses inside its building. The
          concept of "fugitive emissions" was a mystery to the regulator... until she was
          smartened up, (True story.)  The company had to make a choice. It didn't
          want to invest in incinerators; it didn't want to spend money on modifications
          for water-based inks. It did the next best thing - converted to an ink system that
          poured through an EPA loophole, one based on the use of 1,1,1-trichloroethane
          as the solvent. After many years of use, this company became Suffolk
          County's second largest polluter. After EPA finally banned methyl
          chloroform's use, the company installed alcohol incinerators and converted
          back to alcohol-based inks.

All three of those competitors enjoyed significant economic cost benefit over Amko for
many years of competitive activity.

Nonetheless, following its commitments, Amko innovated processes and products which
not only improved the performance and  value of its products for its customers, but also
reduced the environmental impact  of its manufacturing activities and its products. Here is a
list of Amko's more significant work in  these areas.

    1. Solid Waste Reduction - In  1979, Amko Plastics was the first U.S. film and bag
      producer to introduce new thin gauge low density polyethylene materials (Linear
      Low Density Polyethylene,  LLDPE; Unipol technology from Union Carbide
      Corporation) which made the first substantive source reduction benefit in shrinking
      solid waste generated by the plastic bag industry.  Because of their superior strength
      and performance, these films allowed for a 25% to 40% reduction of raw materials  -
      in both manufacturing and later waste disposal - because of dramatically improved
      resin technology. The replacement of conventional thick plastic film  and thicker
      paper materials by these thin plastics resulted in benefits for customers, consumers,

                                       Page 5

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   and the environment.  Amko continues to work with its resin suppliers in
   commercializing new high strength materials which offer similar benefits in both
   monolayer films, 3-layer films, 7-Iayer films and more using coextrusion and
   solventless laminating technology.

2. Air Pollution Reduction - In 1984, Amko became the first plastic film printer to
   commit to and implement a company-wide elimination of alcohol based inks to
   reduce air pollutants in the printing process. Over the next three and a half years
   (through September 1987) Amko, in conjunction with its key suppliers, developed
   the systems, materials and process to convert entirely to water based inks for
   printing plastic film. As a result, Amko was able to make more than an 85%
   reduction in the emission rate of alcohol to the atmosphere in its printing operations.
   In addition, the health benefit to employees who no longer worked in an alcohol air
   plant environment was an added benefit.

3. Heavy Metal Reduction and Elimination - In 1987, Amko commenced the
   replacement of ink pigments based on potentially toxic heavy metal bases and
   replaced them with non-heavy metal  counterparts that comply with regulations of the
   Council of Northeastern Governors (CONEG).

4. Plastic Pellet Litter Elimination - In 1987, Amko introduced a railroad siding vacuum
   maintenance program to capture polyethylene resin pellets which were lost during the
   railroad hopper car unloading process. This keeps plastic pellets from contaminating
   the immediate vicinity and from potential contamination of waterways if flushed into
   sewer systems. It was not until  1992 that USEPA issued new stormwater permit
   requirements that this  practice was required of plastics processors. Amko
   commenced this practice early because it was the right thing to do, not because it was
   required.

5. Plastics Recycling - Beginning in mid-1989, Amko has  been incorporating
   post-industrial and post-consumer recycled plastic materials in select products of its
   own or its customers'  choosing. In April, 1991, Amko began operation of a plastic
   waste recycling and repelletizing system for recycling both its own industrial waste,
   purchased post-industrial waste, and some processable  post-consumer plastic bags
   returned via special customer programs.
                                   Pa2e6

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 6. Heat/Energy Conservation and Recapture - In 1985, 1987 and 1990, Amko installed
    heat recapture systems in air compressor, printing press, and film extrusion
    operations to reduce energy consumption in the operation of its equipment and
    processing of its materials.

 7. Recycled Newspapers - On an experimental basis, Amko used corrugated cartons
    which incorporated a liner board manufactured from 25% recycled newspapers. If
    that had become successful throughout its operations, based on average corrugated
    usage, the facility would have consumed approximately 8,000 Ibs. of old newsprint
    per month.  To date, however, the cartons have not performed satisfactorily and their
    cost has been prohibitive. The company hopes that improvements by its suppliers
    will allow Amko to re-evaluate that opportunity at some time in the future.

 8. Hazardous Waste Water Treatment and Elimination - In 1990, Amko installed a
    waste water treatment system to eliminate hazardous waste elimination and recycle
    printing system water. The system allows for disposal of remnant solids as
    non-hazardous waste in a sanitary landfill and provides recycling of the reclaimed
    water which was previously a part of our water based  inks.  When overflow
    conditions are met, the water is clean enough to meet standards for disposal into the
    sanitary sewer. This system has eliminated the generation of waste water from
    Amko's manufacturing and cleaning processes.

9. Toxic wastes have been eliminated throughout all of Amko's operations to the point
   where Amko is classified in the lowest category of hazardous waste generation as a
   Conditionally Exempt Small Quantity Generator.  To qualify for this designation, a
   facility must generate less than 220 pounds (100 Kg) of hazardous waste per month.
   Amko's operations comprise a 7-day per week, 24-hour per day production schedule,
   365 days a year in a 224,000 sq ft (20,810 square meters) facility.

10. Elimination of Perchloroethylene Use - In 1992, Amko eliminated the use of
   perchloroethylene as a solvent in the production of its photopolymer printing plates
   and replaced it with a petroleum blend as a solvent. This material completely
   eliminated the health issues uniquely related to perchloroethylene.  The new material
   is also recycled in-house by Amko for use in future batch processing.
                                    Page 7

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   11. Office and Plant Paper Collection and Recycling - Office paper waste (fax, copier,
      letters and others) and factory corrugated containers are collected for recycling.

   12. Shared Information - Since 1985, Amko has willingly shared its successes in
      environmental technological development with other organizations both in the U.S.
      and internationally. A list of selected papers and speaking engagements on those
      issues can be provided on request. In addition, private sector and public sector
      organizations from around the US and from other countries visit Amko to learn
      about Amko's efforts, successes and challenges in developing sustainable
      manufacturing practices ("clean production" practices in Europe.)

   13. Solventless Lamination - In 1996, Amko installed a solventless laminator which
      bonds two different web materials together using a 2-part chemically curing
      adhesive. This technology is relatively new in the U.S., where the traditional and
      majority of equipment uses either solvent-based or water-based adhesives.

Amko's work covers a wide range of efforts in product and process design for the
environment. In recognition of its work and successes, the Greater Cincinnati Chamber of
Commerce presented the company its 1994 Corporate Environmental Achievement Award.
In addition, Ohio Governor Voinovich presented Amko  Plastics as a company and its
president individually with 1994 Governor's Awards for Outstanding Achievement in
Pollution Prevention.
                                      Page 8

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        Joe Mattson





Industrial Towel and Uniform

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      NETWORKING TO MINIMIZE WASTE AND
                   PREVENT POLLUTION

A presentation outline by  Joe Mattson,  Sorblts® Product Manager,
Industrial Towel and Uniform, Inc.

I.  Biographical Information

     A.  Who is Joe Mattson?
     B.  Why would Joe Mattson have information valuable to me?

II.  Reduce - Suggestions for methods of reducing the volume of waste you
               generate.

     A.  Bulk Containers vs Convenience Packaging
         Examples:  chemicals, soap ...
     B.  Suppliers Involvement
         reusable containers & packaging, process changes, line employee
          involvement
     C.  Dumpster Diving

III, Reuse - Evaluate waste streams for alternatives to disposable products.

     A.  Sorblts -  launderable & reusable oil absorbents.
     B.  Wipers
     C.  Filters, gloves, leathers

FV. Recycle

     A.  Solvents, Cutting and Cooling fluids, foundry sand ...
     B.  Examples:  hangers,  uniforms, roll towels ...

V.  Resources - Where to look for assistance.

     A.  US EPA  - Wastewi$e and Assessment Programs
     B.  State Regulatory Agency
     C.  Trade Associations

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   Charles L. McEntyre





Tennessee Valley Authority

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          Waste Reduction - Metal Fabrication Fluids and Wastewaters

           U.S. EPA Region 5 Waste Minimization/Pollution Prevention
                  Conference for Hazardous Waste Generators
                     February 25-27,1997, Chicago, Illinois

                                      by
                        Charles L. McEntyre, P.E., CHMM
INTRODUCTION
Waste reduction is the most efficient and cost effective way to solve the environmental
problems of industry.  There are many reasons to do waste reduction. The best is it
saves money! Waste reduction is not usually high-tech or real complicated. The best
waste reduction program is a team effort with all employees doing their part.  It can be
adapted to your company's needs and culture. There are many resources available to
help you get started and succeed.

The metal fabrication industry needs technical assistance in this area. EPA CERI in
Cincinnati, Ohio, awarded an Interagency Agreement to TVA to develop training
manuals and workshops to help this industry apply current waste reduction techniques.

TVA is partnering with the Waste Reduction And Technology Transfer Foundation
(WRATT) and the Institute of Advanced  Manufacturing Sciences (IAMS) to deliver this
training. IAMS wrote the manuals with input from many companies and other
organizations. WRATT is coordinating scheduling and delivery of the workshops.
Partners and cosponsors for workshops are being used to ensure industries are
reached. Five workshops were completed in 1996 in locations ranging from Miami,
Florida, to Detroit, Michigan, and the remainder are being scheduled for 1997.

The training focuses on effective application of proven waste reduction processes for
metal fabrication companies.  The two waste types are metal fabrication fluids (coolants
and lubricants) and wastewaters. Plating and coating wastes have been well covered
elsewhere and coverage will be limited,  possibly tables listing options and references.
The primary audience selected are small to medium-sized companies with less than
200 employees. The metal fabrication processes covered include: broaching, turning,
milling, threading, and tapping.

WASTEWATER AND WASTE REDUCTION
Wastewater P2 can be very cost-effective. Based on 15 cases studied in California,
which covered several industries (electronics manufacturing, metal finishing, paper
reprocessing, and food processing), the water savings were 20 to 40 percent (2 to 470
million gallons per year).  The average cost savings were $150,000 per year with capital
pay-back periods ranging from 2  months to 3 years with most less than 1 year.

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Common sources of wastewater include the following:
•  Aqueous cleaning of parts or equipment
•  Water-based coolants
•  Cooling water
•  De-burring and mass finishing
•  Boiler blow-down
•  Wastewater from cutting and blasting
•  Wastewater from air pollution control such as scrubbers

As with all waste reduction you must be open to new ideas and evaluate various
options. There are no "magic bullets" which will solve every situation cost-effectively.
The first step is to determine which processes are generating wastewater and the
quantity and quality of each stream. You can not evaluate options if you do not know
what you are generating.  Track water use and wastewater generation over time,
including nights and weekends and outage periods. PROPER SAMPLING &
ANALYSIS ARE ESSENTIAL.  Most people don't understand importance and difficulty
of representative sampling. Bad data about wastewater streams results in bad P2
decisions.

Waste segregation is very important for pollution prevention. It is more difficult to find
beneficial uses for mixtures. Also, small concentrated streams are easier to manage
than large dilute streams and streams with  few contaminants are easier to treat than
complex mixtures.

There are several basic P2 measures for wastewater which  do not involve any
significant equipment or process redesign.  First ask if you can eliminate the process
(do the parts really need cleaned?). Then ask if you can eliminate the use of water in
the process. Can you reduce the use of water in the process? Finally can you reuse
the water in another process, with or without treatment? Examples include:
•  Turn valves down or off (automatic controllers instead of manual)
•  Preventative maintenance, i.e. stop leaks (pumps, seals, piping)
•  Change to dry clean up methods (use a broom not a hose)
•  Reuse water as is without treatment for a less stringent process
•  Ensure proper mixing of chemicals

The next level  is to evaluate P2 measures that are more complex. Examples  are:
substitution of  less toxic raw materials, training operators to  ensure proper and
consistent methods are used; optimizing your processes; installing closed-loop
systems; treating a wastewater to allow reuse; and exchanging wastes with other
industries.

Other P2 measures which are usually cost-effective include:
•  using de-mineralized water for makeup  for: metal working fluids, plating baths &
   rinses, or parts
•  using cleaning rinses

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•  reuse of cooling tower blowdown
•  recovery of metals from plating baths & rinses
•  reducing oily waste from aqueous cleaners

Cleaning
Cleaning is a process which often generates wastewater in the metal fabrication
industries.  Selection of the best cleaning process addresses the surface being
cleaned, the soil to be removed from the surface, and the required level of cleanliness.
The amounts of wastewater generated may be minimized by:  (1) avoiding the need for
cleaning, (2) maximizing the efficiency of the existing cleaning systems, and (3) using
the least hazardous media.  Some alternatives which will avoid or reduce the need for
cleaning include:  indoor storage, just-in-time delivery, using shrink wrap to protect
parts, and improving coating efficiency.  The latter will reduce rejects and the related
need to strip and clean parts.

Some source reduction options for cleaning wastewater include:
•  changing to non-detergent cleaning solutions, i.e. using hot water and/or high
   pressure,
•  extending solution life by on-line filtration or other means,
•  minimizing losses,
•  reducing drag-out or carryover from one process tank to the next,
•  making pre-cleaning inspections so you don't clean unnecessarily,
•  proper makeup and  mixing to ensure proper concentrations, and
•  periodically monitor concentrations and bring them back to recommended  levels.

Drag-out or carryover can be reduced by many methods which keep more of each
solution in its respective tank or container. Some options include the following:
•  using less concentrated solutions which reduces the contaminant load in each drop
   and may also reduce viscosity,
•  increasing drip times over the originating tank ( a total  of 10 to 30 seconds is usually
   adequate),
•  using drip boards to direct drainage back into the originating tank,
•  positioning the work-piece on rack to maximize drainage and minimize the volume of
   solution cupped within the piece,
•  increasing solution temperatures or adding wetting agents to reduce viscosity and
   speed drainage,
•  using air knives to blow drainage back into the originating tank, or
•  using drag-out tanks (dead or static rinse tanks).

Proper work-piece positioning depends on the shape of the part and the rack  or
conveying mechanism.  The best position will: tilt each piece so drainage is
consolidated; avoid, if possible, positioning parts directly over one another; tip parts to
avoid large flat surfaces or pockets; and position parts so only a small surface area
comes in contact with the solution surface as it is removed from the solution.

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Common pollution prevention measures for rinse-waters often involve relatively minor
piping or equipment changes. Examples are: counter-flow rinsing, still rinses, flow
and/or conductivity controls, spray or fog rinses, and agitating rinses to improve
cleaning.

Wastewater Treatment
Treatment should be evaluated if the wastewater can not be eliminated at the source.
Treatment processes should be optimized to ensure the most cost-effective treatment
of any remaining wastewater. Concentrated brines or sludges should be evaluated to
determine if their metal content can be recovered cost-effectively. The water content of
all sludge should be reduced to the maximum extent practicable using filter presses or
dryers.  This will reduce paying for shipping and disposal of water.

METALWORKING FLUIDS
Metalworking fluids are used to facilitate the cutting operation by one or more of the
following:  lubrication, cooling, cleaning out chips, and inhibiting corrosion. The
common waste fluids and lubricants in the metal fabrication industry include:
•  Non-dilutable straight oils
•  Water soluble oils
•  Semi-synthetic fluids
•  Synthetic Fluids
These range from 100 percent petroleum oil in the concentrate to zero.

Fluid management can have tremendous impact on metalworking costs and
productivity. The primary aim should be to extend the useful life of fluids through
source reduction,  reuse, and recycling. This will improve product quality, reduce
purchases of new fluids, decrease disposal of spent fluids, reduce downtime for
machine clean-outs, and improve working conditions for the operator.

Price should never be the primary criteria for choosing metalworking fluids. Many other
factors such as: part & machine requirements, fluid life, treatability, disposal costs,
microbial resistance, and corrosion protection.  If possible standardize on as few fluids
as practicable based on the issues above. This will simplify operations, minimize
contamination, enhance recycling, and allow volume price reductions.

Waste Reduction for Metalworking Fluids
The fluids must be routinely checked for such things as:  water level, tramp oil, fluid
concentration, biological growth, dirt, rust, foam, filterability, and surface tension.
Where practical checks should be made with a test method not some type of operator
observation so the results will be  more consistent and reproducible from operator to
operator.

Control  concentrations for optimum performance and life. Many people seem to
assume that a more concentrated solution delivers better performance, but in fact,
performance often decreases.

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The most common cause of fluid degradation is bacterial contamination.  It is essential
that sumps and machines be cleaned according to manufacturers recommendations on
a regular basis. If practical, the sumps should be disinfected.

Use demineralized water to blend synthetic coolants and lubricants. High mineral
content often causes stability problems with soluble oils and semi-synthetic fluids.
These minerals will also build up over time and result in changes in fluid alkalinity.
Therefore, demineralized water will increase performance and extend fluid life.
Maintain gaskets, wipers, and seals. These are essential in keeping contaminants,
such as tramp oil, out of the metalworking fluid.

Standardize fluids to enhance treatment and reuse options. This will usually also allow
for some economy of scale in purchasing new fluids. Keep metalworking fluids clean!
Install screens or covers to keep trash out of the fluid in the sump.  Also evaluate use of
ultrafiltration or skimming equipment to remove contaminants before they can further
degrade the metalworking fluid.
Address:         Charles L. McEntyre
                  Tennessee Valley Authority
                  1101 Market Street, WR 4P
                  Chattanooga, TN  37402
Telephone:       423-751-7310           fax: 423-751-8404
email:            clmcentyre@tva.gov

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          William M. Nelson





Waste Management and Research Center

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 William M. Nelson
Alternative Process Chemist
Waste Management and Research Center
One E. Hazel wood Dr.
Champaign, IL  61820
(217)244-5521
wmnelson(S}uiuc. edu
Abstract:
                           Solvent Substitution Testing Program
 Objectives of the Alternative Cleaning Technology Laboratory:

   -Assist industries with cleaning technologies appropriate to current
   environmental regulations
   -Provide an unbiased evaluation of cleaning technologies alternatives -explore new options in
   areas of alternative cleaning

 The increasing amount of regulations regarding the waste effluents from manufacturing
facilities has likewise increased the need for a systematic approach for industries to meet this
challenge.  The industries in USEPA Region 5 facing decisions regarding switching cleaning
technologies lack the information and/or resources to accomplish this task. The alternative
cleaning technology laboratory (ACTL) at WMRC is attempting to do this, providing direct
means of expressing practical pollution prevention. The approach of WMRCs ACTL is both
systematic and scientifically rigorous. The center, through funding by the USEPA, other
agencies, and industry investigates techniques and technologies designed to reduce or eliminate
the use of organic solvents.

 a. WMRC-Industry Dialog: Through channels ranging from public presentations to phone
inquiries to references from the state/federal regulatory agencies, potential clients learn of
WMRC's expertise in this area.  The discussions initially focus on the nature of the problem, then
gradually move to attempting to define a systematic plan, which will result in potential financial
savings, improved positive public image, safer and healthier workplace, and continued industrial
improvement. The subsequent work may range from a simple solvent substitution to
reevaluation of a cleaning operation.  WMRC is equipped  to do bench-scale testing of potential
cleaners and pilot-scale tests, as the work progresses.  It is at this point that we can assist
industries in directly implementing the new technologies.

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 b. Commercially available Alternative Cleaners:  The work involves a direct and scientific
search for a technology solution. Possible solutions to any industrial problem are dictated by the
currently available resources, and this is a primary consideration.  Ongoing work at WMRC
involves the evaluation of potential cleaners, regarding their effectiveness under numerous
possible conditions. The results are being systematically documented. Further, the cleaners are
being classified according to their physical properties, health and safety rmzards, the surfaces on
which they work, and their chemical activity.  The latter work does involve both analysis of the
available literature and doing actual laboratory experiments. From this work, potential
replacements for the existing cleaning methods of the client are identified. As the work
progresses, the experience will simultaneously expand WMRCs repertoire of cleaning
alternatives and will improve prediction of cleaning technology replacements.

 c. Alternative Cleaners Wastestream: The replacement of an undesirable cleaning technology
with a more desirable one is valuable, but it is only a partial solution. An important component
of the service which WMRC will supply to its clients will be the detailed understanding of the
resultant waste stream produced by the new cleaning technology.  WMRC also retains expertise
in close-looping cleaning systems and in prolonging the lifetime of cleaning systems.

 d. Database Development: The amount of data generated from this laboratory will be organized
in a readily accessible form. As part of this effort, a database is being constructed which will
systematize the detailed results of the ACTL work done at WMRC, incorporating both the
experimental results and existent literature and references to regulatory requirements.

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         Shawn R. Niaki





Harza Environmental Services, Inc.

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           WASTE MINIMIZATION/POLLUTION PREVENTION AUDITS
                                        FOR
                              10 MAJOR INDUSTRIES

                             Shawn R. Niaki, Ph.D., P.E.
                             Krishna V. Mayenkar, P.E.
                               Robert Nerenberg, P.E.
                             Jeffrey K. Cline, Ph.D., P.E.
                          Harza Environmental Services, Inc.
                                   Chicago, Illinois
                                1.0 INTRODUCTION

This paper presents detailed activities for the Pollution Prevention and Waste Minimization
(PP/WM) Program which were performed during a two-year period in one of the middle eastern
countries.  During this period, comprehensive PP/WM feasibility studies were performed at ten
major industries.  These industries included refinery, thermal power plant, steel, potash
manufacturing, phosphate manufacturing, brewery, sulfur-chemicals, vegetable oil, yeast, and
slaughterhouse.

                                 2.0  OBJECTIVES

Objectives of the Program are as follows:

       •     To assist the water-using and waste-discharging manufacturing industry to adopt
             and practice PP/WM; and
       •     To develop, stimulate, and strengthen the private sector environmental services
             and equipment supply sectors.

                                  3.0 APPROACH

The entire tasks for the PP/WM Program during the 4-year life of the project are as follows:

       •     Task 1- Prepare Work Plan and Establish Pollution Prevention Office
       •     Task 2- Conduct Audit, Feasibility Studies, Demonstrations, and Training
       •     Task 3 - Design and Assist in the Implementation of Financial Mechanisms
       •     Task 4- Short-Term Training

This paper covers Tasks 1 and 2 of the project.

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3.1 Prepare Work Plan and Establish Pollution Prevention Office

This task consists of the following steps:

       •     Establish PP Office;
       •     Establish PP/WM Committee;
       •     Prepare Work Plan for the Life of the Project; and
       •     Prepare Annual Work Plan.

       3.1.1 Establish PP Office

       In February 1994, with assistance of the Chamber of Industry (Chamber), a PP Office was
       established. With assistance from the Chamber, the industries are encouraged to conserve
       and monitor water use and to use PP/WM as part of the every day operational practice.

       The PP Office operates as the PP Section under the Chamber's Environmental
       Department. During the first two years of the Program.  The PP Office was directed by a
       Program Director, a pollution prevention specialists from Harza Engineering Company in
       Chicago, Illinois.

       3.1.2 Establish PP/WM Committee

       With assistance of the Chamber and the government a PP/WM Committee was organized.
       For this purpose, members from the following organizations were identified.

             Chamber of Industry (Chamber);
             Ministry of Water;
             Ministry of Planning (MOP);
             Private Scientific Society;
             Ministry of Industry and Trade (MIT);
             Central Bank;
             Two (2) Major Industries; and
             Ministry of Municipal and Rural Affairs/Department of the Environment.

       The committee was the driving force to provide guidance, advice, and suggestion on
       priorities for preparation of work plans for development of the PP/WM Program
       appropriate for majority of existing and new industries.

       3.1.3 Prepare Work Plan for the Life of the Project

       This step  consists of preparation of a WP for the 4-year life of the project.. This WP
       provided the background information and a summary of the tasks to accomplish the
       PP/WM objectives during the life of the project.  In design of each task, existing data from

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       other PP/WM projects were considered.

       3.1.4 Prepare Annual Work Plan

       An Annual WP were prepared for each year of the project.

3.2 Conduct Audit, Feasibility Studies, Demonstrations, and Training

This task consists of the following steps:

       •      Conduct Audits;
       •      Perform Feasibility Studies;
       •      Perform Demonstrations; and
       •      Provide Training.

This report covers the first two items. Training task was completed by Harza in the first two years
of the project. Currently, Harza is involved in implementation of demonstration task at a refinery
plant and a yeast manufacturing facility.

       3.2.1 Conduct Audits

       This step consists of the following activities:

                    Collect and Summarize Data;
                    Rank Polluting Industrial Facilities;
                    Select facilities for Auditing;
                    Select Audit Teams;
                    Define Scope of Work for Each Audit;
                    Hire Local Consultants;
                    Inform Short-Term and Local Consultants;
                    Conduct Audit;
                    Perform Reconnaissance Facility Visits;
                    Prepare Draft Audit Evaluation Report;
                    Prepare Pre-Final Audit Evaluation Report; and
                    Prepare Final Audit Evaluation Report;

       3.2.1.1 - Collect and Summarize Data In this step, the following information for both
       connected (discharging to the sewer system) and non-connected (discharging to a river or
       land) industrial facilities (facilities) were collected:

              •     Name;
              •      Type (i.e., facilities with similar processes);
              •     Effluent discharge characteristics (average, maximum, and standard

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              deviation); and
       •      Flow rates.

The above information were obtained from the MW's Industrial Department, and the
Chamber. The information was summarized in tabulated forms for subsequent ranking in
Section 3.2.1.2.

3.2.1.2 - Rank Polluting Facilities Data collected were used to estimate the average
total daily loading (TDL) of pollutants for each facility. Based on the average TDLs,
facilities were ranked for auditing purposes.

3.2.1.3 - Select Facilities for Auditing For each industrial type, at least one facility with
highest average TDL and/or hazardous nature effluent was selected, as the candidate for
the PP/MW auditing.  Exceptions to this criterion were made if the future planning
identified any other industrial types or facilities for selection and auditing purposes.

A list of the candidate facilities, including 10 with highest potential, was submitted to the
PP/WM Committee for review, comments, and approval.  Total of 10 facilities were
selected for the PP/MW auditing.

3.2.1.4 -Select Audit Teams  In this activity, qualifications of all short-term and local
Non-Government Organization (NGO) consultants proposed for PP component were
collected and reviewed.  For each industrial type selected for auditing, based on the
qualifications of these consultants, an Audit Team was selected. Each team consisted of a
combination of the following members.

              PP Program Director;
              The Chamber's Environmental Director;
              MW Counterpart;
              A Short-Term Consultant; and/or
              A Local NGO Consultant, if required;
              A Facility Manager; and
              A Production line Employee.

3.2.1.5 - Define Scope of Work for Audit For each audit, a Scope of Work (SOP) was
prepared for distribution to the members of the Audit Team.  This SOP provided
procedures, responsibilities of each member, and schedule for activities for each audit.

3.2.1.6 - Hire Local NGO Consultants Following the completion of activities described
in Sections 3.2.1.4 and 3.2.1.5, the local NGOs selected for auditing were hired. The
contract for each NGO included SOP, responsibilities, deliverables, budget, schedule, and
the required level of effort

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3.2.1.7 - Inform Short-Term Consultants  The SOPs described in Section 2.2.5 were
sent to the short-term consultants selected for auditing. Each consultants were informed
about his responsibilities, deliverables, schedules, budget, and the required level of effort.

3.2.1.8 - Conduct Audit The goal of the audit was to evaluate and identify the possible
PP/MW and water conservation techniques which were appropriate.

This activity consisted of the following activities:

       a.      Audit Coordination;
       b.      PP/WM Background Materials Preparation;
       c.      Pre-Investigation Meeting;
       d.      Audit;
       e.      Post-Inspection Meeting; and
       f.      Audit Evaluation Report.

a. Audit Coordination

At least four weeks prior to an audit at each facility, the Chamber sent a letter to the
management of the facility for scheduling a date for the audit. This letter also included the
types  of information needed to be provided by the facility during the: audit.  This
information included process flow sheets, mass balance, material inventory, costs, etc.

Additionally, with assistance of the Chamber, two weeks prior to the auditing date at each
facility, the date for the audit was confirmed with the facility managements by telephone.

Furthermore, upon confirming the audit date, all Audit Team were informed to attend for
auditing on this date. Also, as part of the coordination, arrangement, for transportation of
the Audit Team to and from the facility were made, as appropriate.

b. PP/WM Background Materials Preparation

For each audit, a comprehensive literature review was performed to identify the most
effective techniques  and clean technologies being practiced for PP/MW for the related
industrial type.  The literature review included, but not be limited to, the following
sources: published literature, vendors, and the United States (U.S.) Environmental
Protection Agency (EPA) personnel contact, and U.S.EPA's Pollution Prevention and
SITE Programs.

The literature consisted of PP/WM related articles, journals, proceedings, U.S.EPA
documents/communication, vendor communication and publications, and books on
pollution and controls.

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Based on the literature review, the PP/WM background materials were prepared for each
industrial type selected for audit.

This information was very useful for the facility, and as a consulting aid and/or
background information for the Chamber, MW, or other interested governmental
organizations and NGOs.

c.  Pre-Investigation Meeting

Prior to an inspection for each audit, a pre-investigation meeting was held at the facility.
All members of the Audit Team attended at this meeting.  The intent of this meeting was
to inform the team and the facility managements about the conduct and goals of the audit.
This meeting provided the Audit Team with specific background information about the
facility to be audited.

d. Audit

A PP audit was performed at each selected facility. The PP audit was based on a
comprehensive inspection of the facility, characterization of waste generated, compliance
with waste discharge limitations, reviewing the facility's compliance history, and
identifying issues involving potential non-compliance.

The intent of each audit was to collect the following information for each facility for
PP/MW evaluation purposes:

       •      Input materials summary (components, annual consumption rates, cost,
              etc.);
              Type of products;
              Facility/Equipment age;
              Production processes;
              Material balance;
              Manufacturing areas;
              Chemical storage and handling areas;
              Individual wastewater  streams' quantities and qualities for each process;
              Description of generation of each wastewater streams;
              Management method practiced for each wastewater stream;
              Wastewater treatment  facilities;
              Waste management practice;
              Ancillary facilities;
              Annual cost for management of the wastewater discharge;
              Data on water and energy use; and
              Photographic records.

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The above information was used to familiarize the Audit Team with the industrial
production processes, particularly those unique to each industry, and water use and
conservation techniques.

The Audit Team visually examined the facility for waste and wastewater issues.  The
objective was to examine the current conditions of the facility, obtain first hand
information regarding the size and layout of the facility, and characterize the waste
discharge characteristics and compliance status.

As part of the site inspection, the Audit Team reviewed the available records related to the
facility. The purpose was to compile available data regarding waste and wastewater
discharge characteristics, and other pertinent data sufficient for determining the status of
regulatory compliance.  Other available records, such as flow sheets, plans, operating
procedures, spill reports, spill prevention and control plans, releases and fires, and other
data were obtained and reviewed.

Facility personnel familiar with and responsible for the facility were interviewed to compile
information on the history, operation and current status of the facility.  Facility personnel
were interviewed during the course of either the visual inspections or the records review.
Follow-up interviews, if necessary, were conducted by telephone.

e. Post-Inspection Meeting

After each audit, a post-inspection meeting was held, prior to the leaving the facility.
Appropriate facility's management staff and members of the Audit Team attended at this
meeting. The goals of this meeting were as follows:

       •      To discuss preliminary findings with the facility's management staff;
       •      To provide technical training to all involved parties; and
       •      To encourage industry action and participation in PP/WM practices.

The Audit Team discussed findings and presented background information materials which
was prepared for worldwide existing techniques for PP/MW being used by the related
industrial type facilities.

f.  Audit Evaluation Report

An Audit Evaluation Report was prepared for each audited facility. Data compiled during
the facility audit, observations made during the reconnaissance site visit (s) at similar
industrial type facilities (Section 3.2.1.9) and during the visual inspection, and results of
personnel interviews were organized and  evaluated to identify significant waste and
wastewater discharge of concerns and to  identify potential existing PP/WM and water and
energy conservation techniques. These alternatives included instruments such as remote

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sensors for early monitoring of pollutants before discharge to the sewage system.  In
conjunction with the data evaluation, applicable standards and regulations that could
impact facility's waste and wastewater discharges or future operation of the facility were
reviewed and summarized.  This included assessment of pending legislation related to the
site activities.

The report provided a summary descriptions of significant concerns.  In essence, the
available information was used to determine the "what, how much, how, why, when, and
where"  of potential waste and wastewater discharges, issues necessary to identify and
describe significant potential constraints.  It also helped to identify data gaps and
determine the needs for further work to fill such gaps.

3.2.1.9  Perform Reconnaissance Facility Visits Several other facilities were visited by
PP/WM Program Director and members of the PP/MW Committee.  Attempts were made
to visit one or two facilities, other than the facility selected for an audit, among each
industrial type selected for audit. This visit was just for reconnaissance purposes.  The
PP/MW practices in these facilities were considered as some of the feasible  alternatives for
related industrial types.

3.2.2 Perform Feasibility Studies

The goal of the Feasibility Studies (FS) was to evaluate the technical, financial, and
logistical feasibility of the water conservation and PP/MW techniques provided in the
Audit Evaluation Reports for each facility.

The FS  consisted of the following steps:

              Select FS Team;
              Meeting for Initial Screening of Alternatives;
              Screening of Alternatives;
              Detailed Analysis and Selection of Alternatives; and
              FS Report.

3.2.2.1 Select FS Team Based on the background and experience of the short-term or
NGO consultants, for each FS, a FS Team was selected.  The members of the FS Team
were as follows:

       •      PP Program Director;
       •      Members of PP/WM Committee;
       •      Management staff from the selected facility; and
       •      Production staff from the selected facility.

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The FS Teams evaluated the potential water conservation and PP techniques and energy
reduction ideas identified in the audit reports, and develop FS Reports. The team
coordinated with representatives from the Chamber, and Non-Governmental Organization
(NGO).

3.2.2.2 Meeting for Initial Screening of Alternatives The FS Team for each FS met
with related facility representatives and local NGO environmental contractor to review and
discuss the alternatives presented in the Audit Evaluation Report for the facility.  During
this meeting, facility officials and local NGOs were encouraged to discuss the alternatives
with respect to  operation of the facility, and availability of the resources to implement the
possible alternatives. Those techniques determined to be technically infeasible were
deleted for further considerations.

3.2.2.3 Screening of Alternatives The screening of alternatives consisted of the
identification of a reduced list of alternatives for PP/WM which were analyzed in detail.
Alternative screening aided in streamlining the FS process while ensuring that the most
promising alternatives were being  considered for detail analysis.  The screening of
alternatives was accomplished by the completion of the following activities:

       •      Refinement of alternative definition;
       •      Preliminary evaluation of alternatives based on:

                     Effectiveness
                     Implementability
                     Cost

The cost evaluation involved the development of capital and operating cost estimates
based on preliminary process design, using facility-specific parameters such as:

              Wastewater characteristics;
              Quantities;
              Discharge criteria;
              Availability and cost for utilities;
              Assumed value for key design parameters; and
              Fate of by-products.

A treatment cost was assembled from:

       •      Operating cost;
       •      Labor;
       •      Capital cost; and
       •      Cleanup time.

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The completion of this initial task established the framework for completing the FS.

3.2.2.4  Detailed Analysis and Selection of Alternatives  Specific detailed evaluations of
the remaining alternatives from Section 3.2.2.3 were performed. This included the
detailed analysis of alternatives to be accomplished by refinement of alternatives definition.
Information included the following:

              Preliminary design calculations;
              Process flow diagrams;
              Sizing of the key process components;
              Preliminary site layouts;
              All assumptions; and
              Limitations and uncertainties.

Specific detailed evaluations of each of the remaining alternatives was performed. The
alternatives were evaluated based on the following criteria:

              Short-term effectiveness and performance;
              Long-term effectiveness and performance;
              Reduction of toxicity/mobility/volume;
              Implementability;
              Protection of human health and the environment;
              Compliance with regulations;
              Community acceptance; and
              Cost.

As part of this step, comparative analysis of alternatives was provided and preferred
alternatives were highlighted.

3.2.2.5  FS Report For each FS, a FS Report was prepared. This report  included results
of Sections 3.2.2.1 through 3.2.2.4.  Each report consisted of descriptions of
technologies/processes and alternatives and preliminary cost estimates for the most
feasible alternatives identified in the Audit Evaluation Report for the related facility.  .
                                     10

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    Joseph W. Phillips





Tennessee Valley Authority

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  Documented Results of
    35 Waste Reduction
      Assessments in
           Alabama
    Joseph W. Phillips, MPH, CHMM
     Tennessee Valley Authority
     Post Office Box 1010, CSC 1D
      Muscle Shoals, AL 35662
        phone: 205-386-3035
         fax: 205-386-3108

     Earl Evans, Executive Director
         WRATT Foundation
     Post Office Box 1010, CTR 2L
      Muscle Shoals, AL 35662
        phone: 205-386-3633
         fax: 205-386-2674
              for the
           U.S. EPA Region 5
Waste Minimization/Pollution Prevention Conference
          February 25-27, 1997
           Chicago, Illinois

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Introduction:

With the passage of the Pollution Prevention Act of 1990, congress established a
national policy that pollution should be prevented  or reduced at the source
whenever feasible.  Responsibility for  implementing this policy fell primarily to
state and federal environmental regulatory agencies.

These agencies recognize that many business lack sufficient technical resources
for the in-house identification of waste reduction opportunities. While  many of
these agencies are willing to allocate resources to waste reduction technical
assistance,  business  have demonstrated  a  reluctance to requires  such
assistance from regulators.  This reluctance has created a gap  between the
agencies  who have the  mandate  and resources to  provide  the  technical
assistance and the companies who most need the help.

An Alabama Waste Reduction and Technology Transfer Program (WRATT) was
begun in  1990 as a  Tennessee Valley Authority concept,  assisted by the
Alabama Department of Environmental Management to fill that gap by offering
technical assistance  in a non-threatening way to Alabama businesses.  This
program was so successful, that it was incorporated  in  1993 as the WRATT
Foundation a non-profit 501[c][3] Alabama  corporation  to enhance economic
development and  the quality of life in Alabama by providing resources to help
business and industry  reduce  costs and waste through technical assistance,
education, and research.  Services provided by the  Foundation are available to
both the public and private sector. All technical assistance activities offered by
the Foundation are conducted by teams of retired engineers and scientists.

The public/private nature of WRATT's support has been a model of cooperation
and efficiency in this era of reinventing government. From 1990 through 1994,
$695,794 was spent on this project. Of this only $100,000 was provided by TVA.
The balance was  provided by private companies, other foundations, and  EPA.
The TVA support for this project was leveraged nearly 7 times.

In 1995, the Foundation began asking past clients to  report on cost-effectiveness
of implementing recommendations of the WRATT assessment teams. Of the
first set of 50 companies,  responses were received from 35.   For a variety or
reasons   including  lack  of  capital,   and  simple inertia,  riot  all  of the
recommendations were implemented, but the total  savings reported  by these
companies was still almost  3.5  million dollars per  year.    In  addition, the
companies that did report acknowledged that other  savings have been realized
but cannot be quantified at this time.

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Summary
The  success of the  program is  measured  by the  number  of  companies
requesting  the  service,  but  more  importantly  by  the  actual  number of
assessments  conducted.   Since  its  inception  in  1990,  the  number of
assessments per year has increased dramatically through 1996. This annual
increase is shown in Figure 1.

Figure 1: WRATT Assessments by Fiscal Year	
                           Assessments Completed
           180
           160
        05  140
        5  120
        E  100
        jo   80
        »   60
        <   40
                                   161
54
                  11
                  90
91      92     93     94     95     96

           Fiscal Year
Another measure of the effectiveness of the WRATT Foundation program is the
dollar amount of savings achieved by the reporting companies as the result of
implementing WRATT suggestions.  The data presented in Table 1 represents
total amounts of dollars saved and waste quantities eliminated from only 35
reporting companies not all of which  reported savings and quantities. Most of
these data represent annually recurring savings or reductions.

Table 1: Summary of Savings and Reductions

Solid Waste
Hazardous Waste
Utility Savings
Water Usage
Volatile Organic Compounds
TOTAL
Savings
$2,648,432
$174,260
$444,400
$186,201
$27,000
3,480,293
Reductions
36,419.90 tons/yr
78.90 tons/yr

103,400 gallons/day
11.00 tons/yr

Still another fact to be considered  is the ratio  of company dollar savings to
dollars spent by WRATT on the assessments.   This is covered in detail in
sections "Study Results" and "Benefits to Cost Ratios" of this report.  However, to
summarize, saving the companies $3.48 million with an expenditure of $126,884
                                                                     4

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yields a benefit to cost ratio of about 27 to 1.  That is, the program saves the
companies about $27 for every dollar WRATT spends in providing this service.
Study Results:

The data received from 35 responding companies referred to in the introduction
are discussed in detail in the following Tables 2-6 in this section and Table 7 in
the section "Benefits to Cost Ratios" for WRATT assessments. Because of the
diverse nature of companies and the individual nature of the information that was
documented  the  data  are  not  comparable in all  cases.    However, the
overwhelmingly  positive  results  from  WRATT  waste  reduction opportunity
assessments is clear.

Tables 2 through 6 document annual  savings  and  waste reductions by the
individual companies as supplied by the companies themselves, Because of the
nature of the data, the amounts may not be related. Companies not included in
these tables reported that WRATT suggestions  have saved them money and
reduced waste, but the dollar amounts and tonnage have not been quantified.

Table 2:  Reported Reductions in Solid Waste
WRATT #
8/103
12
30
45-51
67-68, #1
#2
69
70
75
76
79-86
88
91
100
105
106
107
108
109
112
121
143
Total
Savings
$510,500
$49,500
$300
NA
$29,820
$28,000
$28,500
$1,540,000
$40,000
$68,000
$9,000
$8,100
$16,525
$4,500
$25,070
$42,000
$2,000
$6,289
$9,020
$250,000
$10,000
$5,508
$2,648,432
Reduction
850.0
5.5

28,000.0
7.2


5,200.0
75.0
79.0

108.0

4.2
846.0
1,200.0
25.0

20.0



36,419.9
Units
tons/yr scrap iron


tons @ 30 Ib/drurn (368 Scrap drums)
Reduced solid waste
tons/yr Solid waste
tons/yr solid waste
Reduced raw material (solid waste)
Reduced solid waste
tons/yr solid waste
tons/yr solid waste
tons @ 7 Ib/gal (22,500 gal/yr waste
Reduced Solid Waste
tons/yr solid waste
Reduced solid waste
tons/yr solid waste







oil)




tons @ 25 Ib/ft3 (2507 yd3/yr solid waste)
tons/yr solid waste
tons/yr scrap iron
Reduced solid waste
tons/yr solid waste
Reduced solid waste
Reduced solid waste
Reduced solid waste










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Table 3: Reported Reductions in Hazardous Waste
WRATT#
20
41-42
45-51
67
69
75
91
121
Total
Savings
$93,400
$420.00

$1,200
$1,190
$50,000
$4,050
$24,000
$174,260
Reductions
12.00
2.40
18.70
1.20

37.50

7.10
78.90
Units
tons/yr hazardous waste
tons/yr hazardous waste
tons/yr hazardous waste
tons/yr hazardous waste
reduced hazardous waste
tons/yr hazardous waste
reduced hazardous waste
tons/yr hazardous waste

Table 2: Reported Utility Savings
WRATT#
8/103
32
67
79-86
110
133
Total
Savings
$40,000
$80,000
$6,000
$134,400
$84,000
$100,000
$444,400
Reductions Units
Electrical usage
4,602.00 MCF Natural Gas & Utility
Utility cost
Reduced utility cost
Electrical usage
Electrical usage


Table 5: Reported Reductions in Water Useage
WRATT*
41-42
69
79-86
108

143
Total
Savings
$43,250
$4,042
$63,400
$50,789
$16,320
$8,400
$186,201
Reductions
86,400.00


17,000.00



Units
gallons/day water
reduced water consumption
reduced water consumption
gallons/day waste water
reduced water useage
reduced waste water


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Table 6: Reported Reductions in Volatile Organic Emissions
WRATT #
67
68
Total
Savings
$15,000
$12,000
$27,000
Reductions
6.00
5.00
11.00

tons/yr
tons/yr
tons/yr
Units



Benefit to Cost Ratios

The benefits of waste reduction opportunity assessments go far beyond savings.
In fact, the purpose of the WRATT program is to help companies to see waste as
a business competitiveness issue  as well as an  environmental issue.   Data
indicate that in many industry segments, the total cost of waste is more than the
cost  of labor; in some  cases the differential is  great.   Helping companies to
recognize this important fact and learn to identify and eliminate waste at every
opportunity is an important economic factor in strengthening the competitiveness
of our existing Alabama  industries.

Also, an important evaluation tool is the ratio of company savings to the cost of
assessments;  i.e.  the  benefit  to  cost  ratio.    To   evaluate the  savings
demonstrated by this study, it is necessary to determine the total and average
costs of  assessments  during  the  time  they  were conducted.   During  1990
through 1994,  the WRATT Foundation spent  $695,794 to conduct 195 waste
reduction  opportunity  assessments for  an  average  of  $3,570  for  each
assessment. The actual cost of each individual assessment varied based on the
size and  complexity of the company.  The Tennessee Valley Authority provided
$100,000 of the $695,794 to support these assessments, which represents a
leveraging rate of almost 7 to 1.

Therefore, the 50 assessments conducted at 35 ( 5 companies that could not
quantify costs were excluded) companies cost WRATT a total of $126,844 and
resulted in  reported savings at assessed  industries of $3,480,293. The overall
benefit to cost ratio for this work was 27  and the average savings per company
assessed was  about $102,000.  This is an amazing rate of return to have been
based on so few of the total number of assessments that have been conducted.

This evaluation has been so successful  that the Foundation has undertaken a
full study of all companies receiving assistance to determine results. This study
is being supported by the Alabama Department of Environmental Management.

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Table 7: Benefit to Cost ratios for WRATT Assessments
WRATT
No.
8/103
12
20
26
30
32
41-42
67-68
69
70
75
76
79-86
88
89
91
95
100
105
106
107
108
109
110
112
121
133
143
Total
Assessment
Cost
$8,079
$4,194
$2,347
$1,508
$1,769
$1,754
$3,889
$1,009
$3,557
$7,721
$10,761
$2,518
$7,151
$7,606
$7,785
$2,615
$3,062
$2,481
$11,938
$4,008
$6,894
$2,604
$1,181
$1,955
$7,449
$3,062
$5,103
$2,846
$126,844
Reported
Savings
$550,500
$49,500
$93,400
$0
$300
$80,000
$43,670
$57,820
$33,732
$1,540,000
$90,000
$68,000
$206,800
$8,100
$0
$20,575
$0
$4,500
$25,070
$42,000
$2,000
$73,398
$9,020
$84,000
$250,000
$34,000
$100,000
$13,908
$3,480,293
Benefit/Cost
Ratios
68
12
40
0
0
46
11
57
9
199
8
27
29
1
0
8
0
2
2
10
0
28
8
43
34
11
20
5
27
                                                                8

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           Mark Ralston





U.S. EPA, Waste Minimization Branch

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                                 MARK RALSTON

Mark Ralston is a senior analyst in the Waste Minimization Branch at the U.S. EPA in
Washington, DC. Most recently, he has supported the development and implementation of the
Waste Minimization National Plan. His work has focused on identification of risk-based
priorities for source reduction and recycling of hazardous wastes. He recently lead an EPA/state
team that recommended a cross-program cooperative effort to modify an existing EPA risk
screening tool for the purpose of identifying national priorities under the Waste Minimization
National Plan.  He is also  involved in EPA's work to develop measurement methodologies to
track national progress under the Plan.

Prior to his work in waste minimization, Mr. Ralston analyzed the costs and benefits of
hazardous waste regulations at EPA. He has a bachelors degree in biology from the State
University of New York at Albany and a masters degree in natural resource economics from the
University of Washington in Seattle.

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Developing Measures of Progress for the Waste Minimization National Plan

       The Waste Minimization National Plan established a goal to reduce the most persistent.
bioaccumulative, and toxic (PBT) chemicals in the nation's hazardous wastes by 50 percent by
the year 2005.  This goal has also been integrated in the Agency's Goals 2000 report, and
reductions in PBT chemicals will therefore serve as an important indicator of environmental
progress under the Government Performance and Results Act (GPRA).

       EPA is now working to develop methods to track progress toward this goal. As part of
this effort. EPA is working to develop appropriate measures to be tracked, which will include the
quantities of PBT chemicals themselves as well as the quantities of wastestreams that may
contain these chemicals. A measure based on the quantities of PBT chemicals is the preferred
way to assess progress, but implementation of this measure currently presents some challenges
due to the limitations in available reporting mechanisms (such as the Biennial Reporting System
(BRS) and Toxics Release Inventory (TRI)) for this purpose. A measure of progress based on
quantities of wastestreams containing PBT chemicals may be advantageous for tracking highly-
PBT chemicals that are generated in small quantities (and are therefore not reported in the TRI or
other sources) or as an interim measure en-route to tracking the PBT chemicals themselves.
However, this measure also presents implementation challenges related to identifying the
wastestreams and tracking them across reporting periods.

       For a measure of progress based on either PBT chemical quantities or wastestream
quantities, the starting point is a relative ranking of chemicals based on the PBT criteria.  EPA
has developed a risk screening tool to provide this relative ranking for hundreds of chemicals that
are regulated under RCRA and other statutes. This long list of chemicals ranked based on the
PBT criteria can be narrowed down and focused in a number of ways.  One  way is to "weight"
the PBT scores by national estimates of the quantities of the chemicals in hazardous wastes,
where these estimates are  available from the TRI or the National Hazardous; Waste Constituent
Survey. Another way is to focus on chemicals that are regulated not only under RCRA, but
under other media statutes, since there will be obvious cross-media concerns regarding these
chemicals.  A third approach is to focus on chemicals for which there are good analytical
methods. The end result of this process is a measure of progress based on PBT chemical
quantities.

       Once an appropriate subset of PBT chemicals is identified for measurement, the measure
of progress based on wastestream quantities can be developed by cross walking the PBT
chemicals first with RCRA waste codes and then with RCRA wastestreams reported in the BRS.
Alternatively, it may be possible to make a direct linkage between some chemicals and the
hazardous wastestreams containing them using the National Hazardous Waste Constituent
Survey.

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Peter A. Reinhardt and
   K. Leigh Leonard

University of Wisconsin

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      Peter A. Reinhardt is the Assistant Director for Chemical &
Environmental Safety at the University of Wisconsin-Madison's Safety
Department. Since 1979 he has held positions in radiation safety and as the
Hazardous Waste Officer and the Chemical Safety Supervisor mere. He
directs a staff of ten who perform hazardous waste management, industrial
hygiene, environmental engineering, chemical analysis, site remediation, and
environmental audits to manage the University's chemical and
environmental risks. His program oversees the University's compliance with
environmental and safety laws pertaining to hazardous waste, Superfund,
chemical emergency planning and response, toxic substances, water, air and
other chemical uses. He inspired and edited the University's Chemical Safety
and Disposal Guide (1984,1994) and assists other Wisconsin state agencies as a
member of the Environmental Management Committee.
      He is an active member of the American Chemical Society and its
division of Chemical Heath and Safety. He was appointed to the ACS's task
force on Laboratory Waste Management in 1989 and was selected as Chair in
1994.
      Since 1992 he has been elected to Chair the Dane County Local
Emergency Planning Committee. He had been elected Vice Chair since the
Committee's inception in 1987.
      He is an appointed member of the National Committee on Clinical
Laboratory Standard's subcommittee on waste management that prepared
the 1993 NCCLS guideline on Clinical Laboratory Waste Management.
      He coauthored Hazardous Waste Management at Educational Institutions
(1987), Infectious and Medical Waste Management (1991) and Laboratory Waste
Management (1994), coedited Pollution Prevention and Waste Minimization in
Laboratories (1996) and has written several other technical publications,
contributed chapters and articles. He is also a frequent speaker, instructor
and presenter on the topics of hazardous waste and chemical safety.
      In 1993 he was appointed by the National Research Council to
subcommittees on Mixed Waste and Pollution Prevention to help draft parts of
Prudent Practices in the Laboratory: Handling and Disposal of Chemicals (1995).
      Mr. Reinhardt has a B.S. in Biochemistry (with a concenitration in
toxicology) from the University of Wisconsin-Madison, and an M.A. in Public
Policy and Administration (Environmental Risk Policy focus) from the UW-
Madison's Robert M. La Follette Institute of Public Affairs.

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                       K. Leigh Leonard,  CHMM
           University of Wisconsin System Administration
Ms.  Leonard is the Associate  Environmental/  Occupational Health and Safety
Manager for the University  of Wisconsin System,  which includes  twenty-six
campuses.  She provides policy development and technical oversight for the UW's
hazardous  waste management  program.    She  works with  a  multi-agency
committee  to administer the  State of Wisconsin's mandatory hazardous waste
services contract.  In this capacity,  she monitors the hazardous  waste  market,
conducts hazardous  waste facility inspections, and recently worked on a rebid of
the contract that resulted in a 50 percent cost savings to the State.  Ms. Leonard's
role  in the  State's contract earned her a State of Wisconsin award  for Excellence
in Purchasing in 1995.

Other professional specialties include  laboratory waste minimization, management
of high hazard  wastes, chemical safety, safety in the  arts, and biosafety.  Leigh
has worked in environmental  health &  safety at the University  for  over eight
years.
Professional Affiliations

O     Certified Hazardous Material Manager (CHMM).

O     Federation of Environmental  Technologists  (FET)  a Wisconsin-based
       organization dedicated to the  education  of environmental compliance
       professionals (co-founder and past officer of Madison Chapter).


Publications

O     Reinhardt, Leonard, and Ashbrook, ed.  1995.  Pollution Prevention and
       Waste Minimization in Laboratories.  Lewis Publishers.  New York.


Education

O     Master's degree from University  of Wisconsin-Madison in Urban and
       Regional Planning with a concentration in environmental planning (1989);
       Bachelor's degree from Oberlin College in Biology (1982).

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                What Is  Different About
      Pollution  Prevention  In  Laboratories?

    ... and  how  to  take advantage  of the differences

               by Peter A. Reinhardt1 and K. Leigh Leonard2
                        University of Wisconsin

                             presented at
 U.S. EPA Region 5 Waste Minimization and Pollution Prevention Conference
                      Chicago,  February 26,  1997

Pollution prevention presents unique challenges for laboratories. We've noted
in our book that, "Laboratory operations  are notoriously difficult to prescribe
waste minimization solutions for. Their waste types are numerous, and
usually small in volume...  These challenges are  further compounded in pure
research labs where there is a high frequency of change in experimental
procedures and reagents used. Just when you have found a way to minimize
a wastestream from a particular protocol, the study or project comes to an
end."3
The way people work in laboratories tends to be different than in
manufacturing. Scientists and researchers rely on widely established,
published protocol, which may have been developed without regard to
environmental  impact. People who work in labs tend to have considerable
discretion  with regard to their laboratory operations.  Due to the nature of
laboratory operations, researchers can change their procedures quickly and
drastically as their results open new paths of investigation. Factors that
motivate and inhibit pollution prevention activities are different in the
laboratory environment, especially in acadennia. Scientists mak ng decisions
at the laboratory benchtop are more insulated from understanding the
environmental  impacts and costs of their operations. This is because  waste
disposal expenses, compliance responsibilities,  and sometimes product costs
1 Peter A. Reinhardt is the Assistant Safety Director at the University of Wisconsin-
Madison, 30 N. Murray St.,  Madison, Wl 53715-2609, (608) 262-9735, FAX: (608)
262-6767, peter.reinhardt@mail.admin.wisc.edu.

2 K. Leigh Leonard is the Associate Manager of Environmental Health and Safety for
the University of Wisconsin  System Administration, P.O. Box 8010, Madison, Wl,
53708-8010 (608)  263-4419, FAX: (608) 263-4400, @.

3 Pollution Prevention and Waste Minimization in Laboratories, Reinhardt, P. A.,
Leonard, K. L., Ashbrook, P. A., eds., CRC Press/Lewis Publishers (1996), p.  4.

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What is Different about Pollution Prevention in Laboratories?              26 February 1997
are managed centrally at many institutions, and not allocated back to the
laboratory unit.
As a result, the systematic pollution prevention framework developed for
industrial processes does not work well when planning and implementing
pollution prevention in laboratories. The comprehensive planning approach
does not lend itself to the  laboratory setting where major process changes
occur overnight. In particular, systems analyses and production or activity
indices are difficult to apply due to number and variability of processes. Unit
cost allocations are  generally not meaningful to the people who work in labs
and make  choices about laboratory operations and chemicals used.

National  Survey of Laboratory Chemical Waste  Minimization
The findings of our National Survey of Laboratory Chemical Waste
Minimization practices underscore the points made above. 4 The survey
gathered waste minimization data from Howard Hughes Medical Institute
member institutions (mostly academic labs) and firms with members of the
American  Chemical  Society's Division of Chemical Health and Safety (private
labs). 120 total respondents provided information on their laboratory waste
management activities in 1993.
The survey found over 90%  of the labs engaged in waste minimization
activities.  However, many of these labs do not have a plan, and few labs
have stated  goals for waste minimization. Very few laboratories have
accounted for the money they saved from waste minimization activities.
The popularity of laboratory waste minimization methods was also surveyed;
substitution with a with less hazardous material was listed most often.
Reducing scale (e.g., microscale) manage inventory management were given
by respondents as their most beneficial waste minimization methods.
Chemical inventory  management included procedures to purchase smaller
quantities and control purchases, and redistribution of surplus laboratory
chemicals.
As shown in our survey, laboratories have found that certain pollution
prevention activities are more likely to succeed than others. When considered
together, these activities can be used as a "toolbox" by laboratory managers
and staff to apply as appropriate in their changing laboratory environment
and unique culture.
4 Chapter 2 of our book provides detailed results of our survey.

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What is Different about Pollution Prevention in Laboratories?               26 February 1997
              Laboratory Pollution Prevention "Toolbox'
    Substitute with Less Hazardous Product
    Reduce Scale
    Chemical Inventory Management

    >•   purchase less

    >•   control/ monitor purchases

    >•   redistribute excess product
A Strategy for Lab Pollution  Prevention Strategy
Considering the limitations of the traditional pollution prevention approach
and the survey results described above, a reasonable strategy for pollution
prevention in laboratories would include:
•   Replicate the success of proven methods (i.e., the "Lab Pollution
    Prevention Toolbox");
•   Take advantage of the inherent discretion and empowerment of  people
    who work in labs;
•   Take advantage of the flexibility of lab processes;
•   Take advantage of trends that facilitate Pollution prevention;
•   Evaluate and consider emerging and new lab processes.

What You Can Do to Facilitate Laboratory  Pollution Prevention
There are several things  institutions and firms can do to facilitate laboratory
pollution prevention. Environmental Health & Safety and other support staff
facilitate pollution prevention by providing resources to initiate change (e.g.,
loaning or funding equipment such as a solvent still or a non-mercury
thermometer). They can  also make available timely consulting services for
specific decisions. Because processes need to be evaluated quickly  in the
laboratory, a "back-of-the-envelope" cost-benefit analysis will us;ually suffice
for evaluating opportunities. To abbreviate the analysis, focus on high risk or
volume wastes, occupational safety concerns, the cost and difficulty  of
waste disposal, or the ease of implementing a proposed solution.
A pollution prevention facilitator will benefit by becoming familiar with
laboratory processes. In  doing so, they will gain the confidence of people

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What is Different about Pollution Prevention in Laboratories?               26 February 1997


who work in laboratories. This positions the facilitator to provide timely and
concise assistance and is in keeping with the "customer service" and
Continuous  Quality Improvement impulse of many organizations today.
Scientists are often willing  to understand the  environmental impacts and
costs of their activities, and the benefits of pollution prevention, but do not
want to invest time in assembling the appropriate data. Interest in pollution
prevention and  proven methods will grow when successes are rewarded and
publicized. When convinced, laboratory staff and researchers often have the
requisite tools and expertise to quickly adopt  new procedures that prevent
pollution.
Some unrelated trends in laboratory operations have pollution prevention as a
byproduct. Institutions and firms that assist these trends will facilitate
pollution prevention. The ability to detect and study chemicals in increasingly
small quantities has enabled the miniaturization of laboratory experiments.
Reduced scale has the added advantages of reducing the cost of sampling,
the use of valuable product, and personnel exposures. Undergraduate
chemistry laboratories  have embraced those microscale experiments that are
safer, faster and less costly.
There is a heightened awareness and concern of the occupational risks of
laboratory chemicals. When less toxic chemicals are substituted, they usually
create less toxic waste and emissions.
Affordable database applications and bar coding make it easier to manage the
inventory  of many chemicals. The incentive for doing so includes reducing
chemical purchasing costs  as well as reducing disposal costs. Because of
these new capabilities, purchase controls have expanded, as have
redistribution programs for surplus chemicals.

Performance Indicators  for Lab  Pollution Prevention
It is important to measure progress  in any pollution prevention program.
Documentation will help other laboratories prioritize their efforts and help
convince administrators that waste minimization is worthwhile. Laboratories
again present a special challenge. Indicators that can work include waste
stream goals specific to a stable process, and measures of publicity, training
and consultation. An indicator pollution  prevention acceptance would be
particularly  important for researchers who have great discretion in the
products,  techniques and procedures they choose.

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What is Different about Pollution Prevention in Laboratories?
                                                          26 February 1997
                 Pollution Prevention in Laboratories
           Examples of Performance Indicators and Metrics
                    "What gets measured gets done."
Performance Indicator: A quantifiable attribute of an enterprise's activities
that characterizes the potential implications of these activities with respect
to the environment (EPRI definition).
Metric: A chosen method for quantifying a specific Environmental
Performance Indicator (EPRI definition).
   Performance Indicator
                                               Sample Metrics
Waste Stream Goals Specific to Stable
Process
    Example: reduction in hazardous
    solvents wastes in histology
    procedure due to substitution with
    non-hazardous substitute.
                                        gallons per year OR pounds per
                                        month
                                        # of P2 seminars per semester

                                        # of attendees per session
                                        # of labs per semester receiving
                                        fact sheet
Training and Information Exchange

    (Example: seminars, informational
    fact sheets.)
P2 Consultation Effort
    (Examples: phone or in-lab
    consultation and degree of follow-
    through.)
                                        # lab staff assisted per year
                                        # of lab procedures modified
 Help for Laboratory  Pollution Prevention

 Laboratories would benefit from a more active exchange of information on
 methods and substitutes that prevent pollution. Our book acts as an
 information clearinghouse for one point in time, but ongoing data collection
 and dissemination would be of great benefit.
 EPA's Green Chemistry Challenge was successful in promoting pollution
 prevention techniques  for chemical manufacturing. A Green Chemistry
 Challenge for laboratories might produce similar gains.
                                                              P2EPA7F.DOC

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Peter A.  Reinhardt & K. Leigh Leonard, University of Wisconsin
            1
©What Is Different
  About Pollution Prevention
  In Laboratories?
    ... and how to take advantage of the differences
QHow Labs Differ From Industry
    • Great number of chemicals used result in...
      - numerous waste types
      - small in volume
    • Many processes that change often and radically...
      - lead to variable waste streams
QPeople who work in labs...
    • Tend to rely on widely established, published protocol...
    • ...but do have discretion/empowerment for benchtop decisionmaking
    • Tend to be insulated from environmental impacts and costs
CD Limitations of Traditional P2 Approaches in Laboratories
    • Systematic planning is too time consuming
    • Process analysis takes too long for processes that change often
    • Production/activity indices are difficult to apply due to number and
      variability of processes
    • Unit cost allocation not meaningful to people who work in labs
QNational Survey of Laboratory Waste Minimization
   Profile of Respondents
    m Howard Hughes Medical Institute member institutions (mostly
      academic labs)
    • Firms with ACS DivCHAS members
      (private labs)
    • 120 total respondents
©National Waste Minimization Survey
   Summary of Findings
    The Good News:
    • Over 90 % of labs are engaging in waste minimization activities!

©National Survey Results
   The "Lab P2 Toolbox"
    Most popular:
    • Substitute with less hazardous material
 1/17/97

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Peter A. Reinhardt & K. Leigh Leonard,  University of Wisconsin
            10
            11
            12
QP2 Strategies for Laboratories
     • Replicate the success of proven methods
      (The "Lab P2 Toolbox")
     • Take advantage of the inherent discretion and empowerment of
      people who work in labs
     • Take advantage of the flexibility of lab processes
     • Take advantage of trends that facilitate P2
     • Evaluate and consider emerging and new lab processes (check your
      radar screen)
^Facilitating Implementation of Lab P2
     • Get close to the "customer" to:
      - understand lab processes
      - gain the confidence of people who work in labs
      - ...to thereby P2 empower them
[^Facilitating Implementation of Lab P2, cont.
     • Back-of-the-Envelope C-B Analysis
      - high risk or volume
      - occupational safety
      - cost and difficulty of waste disposal
      - ease of implementation (are the tools and expertise already there?)
     • Publicize and reward successes
QP2 Empower People
   Who Work in Labs
     • Explain the environmental impacts and costs
     • Explain the benefits of P2
     • Provide P2 Information and  Toolbox
     • Consult for specific decisions
     • Provide resources to overcome inertia
ZJ Trends Are Already In Place
   that facilitate P2
     m Miniaturization
       - Reducing scale
       - Microscale chemistry
     • Safer substitutes tend to be greener
     • Inventory Management
       - Less is better
       - Purchase controls
 1/17/97

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Peter A. Reinhardt & K. Leigh Leonard, University of Wisconsin
            13
            14
       - Redistribution of surplus chemicals
J Performance Indicators for Lab P2
   Goal-setting and Measuring Progress
    • Waste stream goals specific to a stable process
    • Publicity and training effort
    • P2 consultation effort
    • P2 acceptance
    Documentation will help other labs prioritize their efforts and help
       convince administrators that waste minimization is worthwhile
JHelp for Laboratory P2
    • Information clearinghouse for greener methods and substitutes
       - Pollution Prevention and Waste Minimization m Laboratories, Reinhardt. Leonard and
        Ashbrook, eds , CRT/Lewis. 1996
    • Green Chemistry Challenge for research and analysis laboratories
 1/17/97

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         Daniel P. Reinke





Environmental Resources Management

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                EFFLUENT COMPLIANCE THROUGH
                    POLLUTION PREVENTION IN
                 ASSEMBLY/TESTING OPERATIONS

                            Daniel P. Reinke, P.E.
                              Branch Manager
             Environmental Resources Management - North Central
                        289 East Fifth Street, Suite 201
                         Saint Paul, Minnesota 55101
INTRODUCTION

This case study presents the results of work at a machinery manufacturer to reduce
the amount of zinc in wastewater from assembly and testing operations. Facility
operations include assembly, welding, product testing and packaging. The facility
also houses repair operations for products sent in by customers. These repair and
rebuild operations include aqueous cleaning, simple machining and painting.

In the 1980s, wastewater was generated from a number of operations at the site. At
that time, products were assembled, tested, cleaned using a manual pressure washer,
and painted using a solvent-based paint in a water wall paint booth.  During the
products testing process, there would be occasional leaks of the machine
lubricant/coolant. This lubricant would drain into trenches which were connected
to an oil/water separator.  The test cells would be regularly cleaned with water
which also drained through the trenches. The trenches were covered with
galvanized metal screen material to catch dropped bolts and other small parts.
Cleaning in the rebuild area was accomplished using petroleum distillate soak
cleaners in which parts often had to sit overnight to loosen stubborn carbon deposits,
oils and greases. Process wastewater was generated from the product testing area,
discharge of water from the wet paint booths and general floor cleaning. Site
wastewater discharges averaged 11,000 gallons per day of a mixed process and
sanitary flow.

In the midst of a major redesign of the products and manufacturing process, the
plant was notified by the local control authority and the zinc discharge limits in the
discharge permit were to be significantly reduced from 0.42 milligrams per liter
(mg/1) to 0.05 mg/1 to accommodate a lack of zinc loading capacity at the publicly
owned treatment works (POTW). The company worked with their environmental
consultant to assist in identifying zinc sources within the facility and to jointly
develop a plan to attain compliance through pollution prevention rather than
expensive end-of-pipe treatment.

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METHODOLOGY

The strategy for effluent compliance through pollution prevention included the
following steps:

   •  Source sampling and analysis
   •  Data evaluation
   •  Strategy development
   •  Pilot testing
   •  Final design
   •  Implementation and training
   •  Continuous improvement

The activities taken under each step are described below.

Source Sampling and Analysis

This initial task included evaluating all wastewater sources to determine the
contribution of each process to the overall facility wastewater loading. To get an
accurate evaluation of the sources, multiple samples were collected and analyzed for
zinc and chemical oxygen demand (COD) from the following areas:

   •  Incoming water at several locations
   •  Trench water
   •  Oil/water separator effluent
   •  Floor cleaning water
   •  Compressor lubricants

Sample analysis was completed using colormetric test kits to allow for immediate
test results. Select samples were also sent off site for laboratory analysis.

Data Evaluation

The data collected was evaluated to determine the relative significance of the various
wastewater sources. There were several interesting findings.

The first finding was that the product lubricants contained significant levels of zinc
and that when the lubricants were mixed with water, the water would pick up zinc
at levels above the discharge limits.

A second finding was that a new, more biodegradable lubricant mat was being used
had a specific gravity of 0.99, which was too high to allow effective removal through
an oil/water separator. Fluid suppliers were contacted and it was found that low
levels of zinc were added to the materials to increase lubricity. While reformulation
may have been possible to eliminate this source of zinc, the more logical approach
was to eliminate the discharge of any lubricants to the wastewater. This strategy

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was consistent with the product and process redesign activities which were aimed to
eliminate all machine leaks and rework processes.

A third finding was that while incoming zinc levels were significant, 0.03 to 0.06
mg/1, in one area of the building where there had been extensive remodeling, the
incoming water was found to contain 0.56 mg/1 of zinc. We suspected that galvanic
action was causing erosion of new galvanized water supply piping where it was
connected with older copper lines. This piping was immediately replaced with
copper piping.

A fourth finding was  that the water from the trenches and the oil/water separator
contained especially high levels of zinc at the beginning of the day. What we
determined was that dropped galvanized fasteners were dissolving in the trenches,
releasing zinc into the wastewater. We also found that there was a buildup of
sludge in the oil/water separator which also contained high levels of zinc and
released this material into the wastewater.  Levels were highest in the morning at
startup and decreased through the day. The trenches and the oil/water separator
were cleaned out, lowering zinc levels in the discharge. Regular cleaning of the
trenches and the oil/water separator was added to the facility preventative
maintenance program to prevent further buildup.

Strategy Development

Based on this evaluation, which included calculations of total mass loading of
contaminants from industrial processes, a strategy was developed to meet POTW
loading requirements. This strategy was developed in conjunction with the local
control authority which was very supportive of the plant's desire to address the
issue through pollution prevention rather than extensive end-of-pipe metals removal
equipment. The strategy was as follows:

   1.  Segregate industrial flows from sanitary flows and reduce the permit flow
      limit from 14,000 gpd to 5,000 gpd.

   2.  Increase zinc limits on a concentration basis to reflect the lower permit flow
      rate.

   3.  Eliminate lubricant leaks and discharges wherever possible through
      improved product and process design and increased employee awareness.

   4.  Perform regular cleaning of trenches and the oil/water separator to reduce
      sludge buildup.

   5.  Purchase a non-chelated cleaner for use in floor cleaning.

   6.  Investigate the use of plastic screens over the trenches to eliminate the
      galvanized material. The trenches were later eliminated in the redesign of the
      product test area.

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   7.  Investigate the use of an ultrafiltration system to remove any oil and high
      COD contaminants that would come from the product test area, floor cleaning
      and new aqueous cleaning systems.

As part of an overall objective to reduce the environmental impact of the
manufacturing operations, the facility tested and purchased several high pressure
cabinet washers for use in rebuild and manufacturing operations.  These washers
significantly reduced the amount of time and labor required in these operations,
reduced the generation of hazardous waste from the facility and reduced employee
exposure to hazardous chemicals.

Another significant change was the elimination of painting operations through the
use of prepainted parts.  The use of prepainted sheet stock gives a better product
appearance and also allows these sheets to be coated more efficiently, reducing
manufacturing costs. The elimination of all production painting at the facility also
reduces the impact of air permitting requirements, reduces the generation of
hazardous waste and reduces employee exposure to chemical solvents.  All of these
items reduce the cost of manufacturing  at the facility.

Pilot Testing

Testing the impact of the procedural changes was completed by thoroughly cleaning
out the trenches and oil/water separator, and repeating the source sampling and
analysis.  Operators were trained to prevent the discharge of product lubricants to
the drains. These changes were found to effectively eliminate zinc contributions
from the test area operations.

While the procedural changes alone may have been able to maintain regular
compliance, facility management personnel were concerned that there was no
effective system to remove lubricants from the wastewater. Since the new, more
biodegradable fluid had a specific gravity close to water, the oil/water separator
was not able to reduce the oil and grease and COD loadings thai would result from a
machine leak in the test areas.  Membrane technologies were tested, first on a bench
scale and later with a pilot scale system, to determine the potential of this method to
reduce these loadings.

The bench and pilot testing showed that ultrafiltration was effective in reducing
COD loadings of wastewater containing lubricant by approximately 80 percent.
Since these fluids also contain low levels of zinc, it was expected that this technology
could reduce zinc loadings from any fluid leaks. Pilot equipment performed well,
and facility personnel were able to easily maintain the system with minimal labor
requirements.

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Final Design

Based on the results of the pilot testing, a final design for installing an ultrafiltration
system was submitted to, and approved by, the local control authority. Due to a lack
of adequate space in the existing oil/water separator area, a new building was
designed to house storage tanks and the ultrafiltration system. This new building
included secondary contaminant for spill protection and a sprinkler system.

Implementation and Training

The product and process redesign involved a total revision of the manufacturing
facility layout. Quality teams assisted in improving the designs to simplify the
manufacturing process. New test areas were built and the old trench system was
eliminated.

The ultrafiltration system was installed in 1992 and has allowed the facility to
remain in compliance with the new discharge standards. One process modification
was made to bubble air through the wastewater holding tank to prevent the buildup
of anaerobic bacteria. Prior to this modification, the smell from the stagnant water
would build up, especially over weekend shutdown periods.

Continuous Improvement

The facility is dedicated to a total quality management program that stresses
continuous improvement in all of the operations.  This program has had a
measurable impact on product quality and manufactured cost.
RESULTS

 Since implementation of the process changes, the facility has been in full compliance
with effluent discharge limits, including the zinc discharge limits.  Average process
wastewater flows are 2,000 gallons per day. The most recent effluent analysis gave
the following results:

                  BOD       83 mg/1
                  TSS        8 mg/1
                  Zinc        0.01 mg/1
CONCLUSION

Pollution prevention techniques were successful at this facility in addressing
stringent zinc discharge limitations proposed by the local control authority. While
some treatment was necessary to assure COD loadings would be within standards,
the product and process modifications that were completed successfully kept zinc
out of the wastewater. These modifications, which were initially developed to

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reduce manufacturing costs and improve product quality, had the following
environmental impacts:

   •  Significantly reduced generation of hazardous waste, to below small quantity
      generator limits.

   •  Effectively eliminated the volatile organic compound (VOC) emissions from
      the facility, reducing air permitting requirements.

   •  Effectively eliminated employee exposure to solvents.

   •  Allowed compliance with stringent zinc discharge limits without the
      investment in a major end-of-pipe treatment system.

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Patricia Sheller





 3M Company

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Presenter. Patricia Shelter, 3M Cordova Plant

Title of talk: 3M's Pollution Prevention Pays (3P): Plant applications

Quick background on the corporate 3P award system.

Brief description of 3M Cordova plant: two divisions, one with one major product
line, one with hundreds of products, both supplying mostly other 3M plants.

Top-down interest in pollution prevention: From CEO on down, our management
is very interested in seeing the plant continue to get large numbers of 3P awards.

Bottom-up interest in pollution prevention: Plant engineers and operators have become
vividly aware that waste disposal is the single most controllable part of their product costs.

Waste  disposal costs are directed back to the products generating wastes. In addition,
we track quarterly what all our wastes are - outside disposal, wastewater, air emissions,
etc. This is also a tool for addressing major changes at the plant - how will they affect
this balance?  Monthly reports go to our operating units telling them which products are
generating the most waste.

Many of our past successes have come from actions the plant could take on its own using
this information.  Most of the easy stuff has already been done. The biggest future
opportunities are in developing new or replacement products that are inherently less
wasteful. The Governor's Award the plant got was an example of this approach.

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  Kendal R. Smith





Enviro Filtration, Inc.

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           BIOGRAPHICAL INFORMATION FOR KENDAL SMITH
Kendal Smith is the chief engineer for Enviro Filtration (1-800-368-4763). He has a BS in
chemical engineering from Rose-Hulman Institute of Technology and a MBA from the
University of Michigan. He is a member of the American Filtration and Separations Society,
the Society of Automotive Engineers, and The Maintenance Council oi'the American Truck
Association. His work experience  includes product management with Cummins Engine
Company and research and production engineering with Amoco Oil Company. The author
has presented  papers on  various technologies for pollution prevention at EPA Waste
Minimization conferences, the National Pollution Prevention Roundtable,  and the Joint
Service Pollution Prevention Conference.

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                           The 96,000 Mile Oil Change Innovation:
                       The Enviro High Efficiency Secondary Oil Filter
                                  Kendal R. Smith, Chief Engineer
                                         Enviro Filtration
                                        4719 Roosevelt St.
                                         Gary, IN 46307
                                          800-368-4763

Executive Summary
        Cost pressures, government regulations, and environmental responsibility continue to drive
American industry toward waste stream reduction and financial efficiency.  Yet these concerns cannot impede
mission performance.  For fleet maintenance managers this means reducing waste oil generation, cutting costs,
and enhancing vehicle reliability.  A solution to this challenge is an extended oil drain program. New oil
formulations and advances in filtration technology are creating opportunities to extend significantly and safely
oil drain intervals, resulting in less waste generation, lower costs, and increased engine protection. One such
technology offering high returns is the Enviro high efficiency secondary(HES) oil filter. The Enviro HES oil
filter removes the most damaging contaminants in the oil and maintains the oil's additive package enhancing oil
life and performance.  This technology has demonstrated in military and commercial field evaluations the ability
to increase drain intervals 400% to 800%, decrease waste oil generation 70-80%, and reduce operating costs
40-50%. There is no magic here.  The effectiveness of the HES oil filter results from understanding the effects
of engine operation on oil quality and applying purification technology to minimize the adverse effects. The
technical basis for the effectiveness of HES oil filtration, results of commercial and military field evaluations,
and suggestions for achieving extended oil drains follow.

The Challenge - The Opportunity
        According to the RCRA Hotline of the EPA over 1,000,000,000 gallons of used oil  were generated in
1991.  The cost to industry and consumers to replace this oil is estimated to be $640 million annually. This does
not include disposal, clean-up, or  liability costs.  In addition, American industry continues to cut costs and
strive for efficiency. Environmental projects must be cost effective.  Finally, costs  and environmental concerns
need to be balanced against mission performance. How does a maintenance or environmental manager reduce
waste stream significantly and costs without jeopardizing mission performance?  The answer is high efficiency
secondary (HES) oil filtration for internal combustion engines. The Enviro HES oil filter enables engine oil
drain intervals to be extended substantially without compromising engine protection.

Why Change the Oil - Additive Depletion and Contamination
        "Additive depletion and contamination are really the only two reasons that oil needs  to be changed."
That's what Don Johnson, Vice President of Product Engineering for Pennzoil Products Co., wrote in the
September 1995 issue of the National Oil and Lube News.  Dirt,  metal particles, and combustion by-products
accumulate in the oil and wear engine parts. For diesel engines, particles in the range of 0-10 microns cause the
most wear. According to a Cummins Engine Company study, particles between 0-5 microns and 5-10 microns
exhibit wear rates 3.4 times and 3.6 times higher than the wear rates of 10-20 micron size particles.  To protect
the engine properly these particles must be removed.
        Oil also needs to be changed when oil quality suffers from additive depletion.  Elements of the oil's
additive package such as acid neutralizes, anti-oxidants, detergents, and dispersants are consumed protecting
the engine and oil.  When the additives are depleted, the oil is no  longer able to protect the engine properly.

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            Effect of HES Filter on Oil Cleanliness
                      New vs. Used Oil
5000 T

4000

3000

2000

1000

   0



<»6UB



2080

2907

688

       Because of these reasons, oil was changed routinely. The existing technology did not adequately
address these problems.  For example, OEM primary, or full flow, filters remove effectively only the 20-40
micron size particles, leaving the most damaging particles in the oil. In addition, they fail to maintain or
replenish the additive package.

HES Oil Filters - The Enabling Technology
       The Enviro HES oil filter affects both the accumulation of damaging particles and the depletion of the
oil's additive package enabling oil drains to be extended significantly while increasing engine protection. As the
name implies, the HES oil filter is a high efficiency filter. That means it removes a significant amount of the
0-10 micron particles,
over 99% in a single
pass.  The effect of the
Enviro HES oil filter on
oil cleanliness is
presented in the figure
to the right. Particle
counts for new oil are
compared with those of
oil used in vehicles
equipped with the HES
oil filter.  As illustrated,
the used oil after 247
hours and 471 hours
had fewer particles than
the new oil out of the
drum.  In the  critical
zone of 5-10 microns, the oil used 247 hours and 471 hours contained 57% and 40% fewer particles
respectively, than the new oil. Fewer particles mean less wear and better engine protection.
       The HES oil filter also maintains and replenishes the oil's additive package. Since most of the
particulate contamination is captured in the filter, the demand on detergents and dispersants is lower.
Neutralizers are preserved because the HES oil filter removes moisture from the oil preventing the formation of
sulfuric and nitric acid.  Finally, the additive package is replenished when make-up oil is added at the time of the
HES filter change.
       Examples of the impact of the filter on oil quality are demonstrated by its effect on total base
number(TBN) and
viscosity. The effect
on TEN is presented
in the figure to the
right. TBNisa
measure of the oil's
acid neutralizing
capability. The
figure shows TBN as
a function of miles on
oil. The TBN of the
new oil was 7.4.
After 130,000 miles
               5 to 10                      10 to 15

                       Particle Size, microns

             j New Oil     CH Used 247 hrs (Z3 Used 471 Hrs
9i
8
7
T «.
B 4
N 3
2
1
oJ


7.4
0


Effc
8.1
30
ctofH
Miles
ES Filt
7.9
90
on Oil, 1
eronl
OOO's
^BN
7.3
130
4
Lower Limit

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on oil the TBN was 7.3, well above the suggested minimum of 4.0. As a basis for comparison, the typical oil
change interval for this type of application is 16,000 miles.
       The effect of
the HES filter on
viscosity is presented
in the figure to the
right. TheSAE
viscosity of the new
oil was 43. After
130,000 miles the
SAE viscosity had
dropped only to 37,
still within the
recommended range
of 35 to 45.
50 1
S 40
A
E 30
T *
s
10
0


43
0
Efl
42
30
recto!
	 I 	
•HES
41
90
Miles
Filtei
on Oil,
•onV
37
130
LOOO's
iscosil
Lo
ty
35
werLin

lit Uj
45
iperLin

lit
Field Results - The 96,000 Mile Oil Change Interval
        A field test was begun in 1991 with a major on-highway, heavy-duty truck fleet. After accumulating
approximately 2.5 million miles on test, the oil change intervals are averaging 95,000 miles. Vehicles not
equipped with an HES oil filter average 16,000 miles. Oil analysis is used to monitor oil quality. The average
waste reduction is 79%.  If the technology were applied to the entire fleet, 40 million quarts of oil would be
saved every year!  The estimated payback is 1 year.  For the remainder of the evaluation, the fleet has
established a PM at 96,000 miles for an oil change. HES cartridges are changed every 16,000 miles, and the
primary filter is changed every 48,000 miles.
        An evaluation of HES oil filters was also conducted by the Air Force's Material and Equipment
Evaluation Project. An Enviro HES oil filter was installed in June of 1992 on an aircraft refueling vehicle. The
test was terminated in June of 1994.  The oil remained in excellent condition throughout the test period.  The
maximum oil drain interval possible with the HES oil filter was not determined, since the test was terminated
before the oil needed to be changed. The standard oil change interval for aircraft refueling  vehicles is  6 months.
Among the conclusions drawn by MEEP from the testing are:
        "All preliminary results indicate these filters perform exactly as advertised
        & could revolutionize the automotive repair industry if properly used."
                                                           - MEEP Management Office
                                                             Project Update, 2/95

        "Based on what we have seen over the past two years, we are strongly
        recommending that these filters be considered for use on Air Force vehicles
        as a method of reducing engine wear, oil depletion trends, and used oil
        disposal difficulties."
                                                           - Jake Detweiler, MEEP Chief
                                                             Minutes from 9 May 95
                                                             meeting with WR-ALC/LV

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As a result of this and other USAF testing, HES oil filters have been authorized for use on PACAF
vehicles. An evaluation to assess the impact of the Enviro HES oil filter on tactical vehicles is being
conducted by the USMC.

Reducing the Risk - Suggestions for Implementing Extended Oil Drains;
       We have learned many things through our experience with extended oil drains and HES filtration.
Below are seven tips which will aid you in safely and sensibly implementing an extended oil drain program.

1.  Use an HES oil filter capable of removing 5-10 micron particles efficiently (>99%).
2.  Monitor oil quality using oil analysis conducted by a reputable lab.
3.  Increase drain intervals gradually.
4.  Use an oil formulated for longer drain intervals.
5.  Start with vehicles offering the highest potential savings.
6.  Seek help from a consultant specializing in extended oil drain to establish your
  program.
7.  Refer to the TMC's RP 318 Used Oil Analysis and RP 1403 Determining Engine: Oil
  Change Intervals for Light- and Medium Duty Vehicles.

Conclusion
       The extension of oil drain intervals holds enormous environmental and financial potential. The key to
realizing this potential is HES oil filtration.  The enviro HES oil filter removes the most damaging particles in
the oil and maintains the additive package ensuring high oil quality and enabling oil drain extension.  Through
the use of HES filters, oil drain intervals increase 400 to 800%, waste oil generation decreases 70 to 80%, and
operating costs decrease 30 to 40%. As a win-win financially and environmentally, HES oil filtration is an ideal
pollution prevention tool.
About the Author: Kendal Smith is the chief engineer for Enviro Filtration(l-800-368-4763).  He
has a BS in chemical engineering from Rose-Hulman Institute of Technology and a MBA from the
University of Michigan.  He is a member of the American Filtration and Separations Society, the
Society of Automotive Engineers, and The Maintenance Council of the American Truck Association.
His -work experience includes product management with Cummins Engine Company and research
and production engineering with Amoco Oil Company.  The author has presented papers on various
technologies for pollution prevention at EPA Waste Minimization conferences, the National Pollution
Prevention Roundtable, and the Joint Service Pollution Prevention  Conference.

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      John L. Stanberry





General Services Administration

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         BIOGRAPHICAL INFORMATION FOR JOHN L. STANBERRY
Dr. John L. Stanberry  is the General Services Administration's  (GSA) Environmental
Executive. He is responsible for coordinating all GSA environmental programs in the areas
of procurement and acquisition, standards and specification review, facilities management,
waste prevention and recycling, and logistics. He previously was responsible for the design
and implementation of GSA's nationwide recycling program.

Dr. Stanberry has spent most of his Government career with GSA, holding such positions as
Deputy Associate Administrator for Operations, Assistant Commissioner for Public Utilities,
and Deputy Assistant Commissioner for Procurement. Prior to working for GSA, he held
responsible positions with NASA and the Air Force. John  is a member  of the Federal
Government's Senior Executive Service.

He is a registered professional engineer, holding BS and MS degrees in Industrial Engineering
and Management and a Ph.D. in Business Administration.

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      George Strapko





Sinclair Mineral & Chemical

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          BIOGRAPHICAL INFORMATION FOR GEORGE STRAPKO
Mr. Strapko is a Career Marketing Professional serving the Industrial Sector developing new
products/processes for the Surface Finishing and Parts Cleaning markets. Primary areas of
focus have been on emerging technology which is Environmentally conscious and effective.
He currently  represents the premier manufacturers of Industrial Finishing & Cleaning
Equipment and related supplies.

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 CASE STUDIES OF SUCCESSFUL SOLVENT REPLACEMENT IN
              INDUSTRIAL CLEANING APPLICATIONS
 I.  BRIEF OVERVIEW OF AQUEOUS CLEANING PROCESS

II.  CASE HISTORIES

    1.  A. Screw machine parts
          1/2"OD x 4"OAL x (3" deep blind hole 1/4" NPT)

       B. Old process (agitated dunk tank with solvent)

       C. New cleaning process (Cyclojet 1)

       D. Benefits: chip removal, oil seperation, increased production,
          environmental safety

    2.  X-Ray equipment overhaul

       A. Meehanite castings, various shapes, sizes

       B. Old Process (Solvent Sinks)

       C. New Process (Jet Washing)

       D. Benefits: labor savings, degree of cleanliness, thru-put environmental safety

    3.  Precision Valve Assemblies

       A. Stainless stems, carbide seats

       B. Old Process (Solvent Sinks)

       C. New Process (Jet Washing)

       D. Benefits: labor savings, thru-put, environmental safety

III.  Question & Answer

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      Better Engineering  Mfg.,  Inc. supplies  a line  of  aqueous
degreasing equipment designed to replace solvents in most cleaning
applications.   These machines have been  widely  accepted  as  an
alternative to solvents  at hundreds  of U. S. Military Bases across
the country and on foreign soil.

      Better Engineering's "Jet Washers" use a heated, recirculated
detergent and water solution instead of  solvents.  This solution is
constantly filtered,  skimmed of  oil,  and  used again  and again.
Parts are  placed  on  a  rotating  turntable  and as  the  turntable
rotates within the sealed cabinet,  the  parts are blasted from all
sides with the 180° F detergent and water solution.

      Machines  are available  in  a  full  range  of  sizes.    Our
smallest  unit,   the  "Impulse"  is  designed  as  a  unit-by-unit
replacement  for  the typical  solvent sink.   Larger  equipment  is
available to accommodate motor vehicle  engines and transmissions,
weapon  systems,  aircraft  wheels,  etc.,  up to entire  jet engine
assemblies.  All units clean  automatically, reducing parts washing
labor to simply loading and unloading parts.

      Better Engineering's Jet Washers are available  with  wash,
rinse,  and dry  cycles,  as well as a full  complement of options,
including automatic level  controls,  additional  filtration,  auto-
steam exhaust, and small parts baskets.

      Better Engineering  also supplies a  full  line  of detergent
products.

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      Better  Engineering  Mfg.,  Inc.  supplies  a line  of  aqueous
degreasing equipment designed to replace solvents in most cleaning
applications.   These machines  have been  widely accepted  as  an
alternative to solvents at hundreds  of U. S. Military Bases across
the country and on foreign soil.

      Better Engineering's "Jet Washers" use a heated, recirculated
detergent and water solution instead of solvents. This solution is
constantly filtered,  skimmed of oil,  and  used again  and again.
Parts are  placed  on  a rotating turntable  and as  the  turntable
rotates within the sealed cabinet,  the parts are blasted from all
sides with the 180° F detergent and water solution.

      Machines  are available  in  a  full  range of  sizes.    Our
smallest  unit,  the  "Impulse"  is  designed  as  a  unit-by-unit
replacement  for  the typical  solvent  sink.   Larger  equipment  is
available to accommodate motor vehicle engines and transmissions,
weapon  systems,  aircraft  wheels,  etc.,  up to  entire  jet engine
assemblies.  All units clean automatically, reducing parts washing
labor to simply loading and unloading parts.

      Better  Engineering's Jet  Washers are available  with  wash,
rinse,  and dry cycles,  as well as a  full  complement of options,
including automatic level  controls,  additional  filtration,  auto-
steam exhaust, and small parts baskets.

      Better  Engineering  also supplies a full  line  of detergent
products that is on the QPL for  Mil-Spec No. MIL-C-29602 (cleaning
aircraft components).

      Better Engineering machines and detergents are available on
GSA Contract #GS07F-5778A.

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 toilette Sun





Motorola, Inc.

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             Promoting A  Pollution  Preventive Culture

                    Colette Sun, Mary Beth Northrup
                        Motorola, Plantation, FL

To be presented at the EPA Region 5 Waste Minimization/Pollution Prevention
Conference, Chicago, III., Feb. 25-27, 1997

Introduction
Over the last two decades, corporate environmental programs have undergone a
steady evolutionary process.  There were few environmental regulations in the
1970's, and public awareness and corporate environmental programs were
limited in scope. Exponentially-increasing environmental regulations, as well as
rapidly escalating public concern during the  1980's, spurred the development of
compliance-based corporate  environmental  programs.

As we approach the next century, companies are awakening to the fact that good
environmental practices are consistent with the goals of good management.  The
concept of "total quality management" is embraced and integrated into business
operations.  Likewise, environmental management systems, with emphasis upon
environmental proactivity and pollution prevention, are being developed which
look beyond compliance  and  into protecting  the resources of future generations.

As environmental professionals, we undertand the benefits of preventing
pollution: decreased negative environmental impact, reduced  cost,  improved
public image, and so on.  Most of the information published explains the technical
approaches to preventing pollution in "how to" guides for specific processes.  But
seldom does the literature address how to move the responsibility for pollution
prevention from the Environmental Department to the process areas; how to
promote a corporation culture that embraces and supports the  concept of
preventing pollution in all aspects of the business.

Establishing A Proactive  Culture - Commitment from the Top
Motorola is one of the world's leading providers of wireless communications,
semiconductors, and advanced electronic systems and services for  worldwide
markets. Our major equipment businesses include two-way radio, cellular
telephones, paging and data communication, personal communications,
automotive, defense and space electronics, and computers.  Motorola is
comprised of a number of individual business groups and sectors with
manufacturing facilities throughout the Americas, Europe and the  Asia-Pacific
Region.

Our Corporate Environmental Health & Safety  (EHS) vision is "to be a recognized
global corporate leader for progressive and  best-in-class EHS practices."
Support from all levels of management is the key to any EHS program's success.
Motorola's commitment to quality, continuous improvement and global leadership
in developing electronics products also extends to protecting and promoting
environmental, health and safety values.  Motorola's EHS policy is "to conduct all
operations  in a  responsible manner, free from recognized hazards; to respect the
environment, health and  safety of our employees,  customers, suppliers, and
                                  -1 -

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community neighbors; and to comply with all applicable environmental, safety,
and industrial hygiene laws and regulations of countries where we conduct
operations." Site or Business Group General Managers are held accountable for
ensuring that this policy is followed.

From  Pollution Abatement  to  Pollution Prevention
In the 70's, the pollution prevention focus was at the "end  of the pipe," controlling
or abating emissions from waste streams generated by industrial processes.
Growing public awareness of the impact of pollution to air and water supplies
drove regulators to pass laws requiring industry  to throttle  back emissions. This
was accomplished  by installing a wide range of pollution abatement devices (air
scrubbers, waste water treatment plants, and the like) to meet regulatory emission
limits.  This all was viewed strictly as a cost drain by industry, a necessary
expense, a cost of  doing business.

By the 1980's, industry began to recognize that rapidly growing waste disposal
costs (with its associated  long term liability) was increasingly impacting
profitability.  It was  in the best interest of business, from a cost standpoint, to
reduce the quantity of waste generated. Thus, a new concept was introduced --
waste minimization. Here the goal was not just to treat what spit out of the pipe,
but to try to reduce the quantity and toxicity of waste being generated. Often this
could be achieved  by relatively simple means such as proper waste segregation,
improved housekeeping and better process control.  Still, the focus was primarily
en-of-pipe rather than upstream in  the process itself.

In the last few years, the concept of "minimizing waste" has evolved into the
concept of "preventing pollution." Rather than just trying to reduce the volume of
waste generated, pollution prevention seeks to avoid the creation of pollutants or
waste altogether.  This may necessitate fundamental process changes requiring
the invention or implementation of new technologies.

From a philosophical viewpoint, we are transitioning from  outside the process,
further upstream into the production process itself.


Management Approaches To  Pollution Prevention
The following case studies illustrate an evolution in  management style and
approach to pollution prevention projects at the Motorola Plantation, Florida
facility.

Case #1: Management mandate -  Freon  elimination
In the late 1980's, it became increasingly clear that the use of ozone depleting
substances was compromising  the Earth's ozone layer protection, and that
aggressive action was needed  to stop continued destruction.  In 1988, The Chief
Executive Office passed a mandate that all Motorola operations, world wide,
would eliminate the use of Freon 113 in manufacturing operations by the end of
1992.

At the time, Freon 113 (trade name Freon TF) was as widely used in the
electronics manufacturing business as water. When originally introduced, Freon
TF appeared to be the ideal solution for many applications; a highly effective,
                                    -2-

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nonflammable, relatively nontoxic agent.  However, scientific evidence mounted
indicating that the use of Freon had potentially devastating, but previously
unrecognized, global impact.  Motorola leadership acted proactively to issue a
mandate, and a substitute would have to be found.

The best research engineers in Motorola were tasked with developing process
alternatives to eliminate the use of Freon.  Depending upon the particular process
involved, a variety of different solutions were implemented. Most sites
transitioned to alternative aqueous or semi-aqueous degreasing agents to meet
the 1992 deadline. And we did meet the deadline. Here in the Plantation facility,
we implemented a cleaning process using a naturally-occurring citrus-based
product as an alternative to Freon. Ultimately, as a result of continued research
efforts, the cleaning process step has been completely eliminated. The resulting
manufacturing process is cleaner, faster, and better.

There is no doubt that a mandate from the top is one effective method for
accomplishing a pollution prevention goal.

Case 2: Linking Process with  Environment - Phosphoric acid cleaner reduction
A few years ago, plating area production volumes were increasing and the
discharge rate of a particular cleaning bath  - one that was phosphoric acid based
- had increased substantially. Once spent, this bath required treatment to meet
effluent discharge standards and this treatment process generated a substantial
quantity of waste water treatment sludge. As a result a significantly higher
quantity of hazardous waste sludge was being generated, driving up disposal
costs.

Process engineers were aware only of the relatively minimal cost to purchase
and use this cleaning bath.  As manufacturing volumes increased, chemical
usage had simply been increased proportionally.  What the process engineers
didn't see was the cost impact of waste chemical treatment and disposal. After
both pieces were connected, it became apparent that the total cost of use was
much higher than previously realized. When the process engineers  rigorously
characterized the process, they discovered  that the chemical  use rate could be
decreased to one-fourth the previous rate without  impacting product quality.  The
end result was cost savings at every step: decreased virgin material use, less
time  spent handling  and treating the chemical, and a reduction in the quantity of
hazardous waste generated.

In  this case, simply looking at the bigger picture and bringing it to the attention of
those in control  of the process, was enough to prompt investigation which
resulted in change.

Case 3: Working together as a team - Environmental Awareness Team
Increasing plating production volumes also required increased usage of
photoresist developers and strippers which contained glycol ether and
monoethanolamine.  These organic compounds contributed to our waste water
discharge levels for Biological Oxygen  Demand (BOD)  and Total Kjeldahl
Nitrogen (TKN).  Our onsite waste water pretreatment system is designed to treat
for metals (primarily copper and nickel), not organics. Therefore,  any organics
introduced into the system simply pass through. At the projected rate of
                                   -3-

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production use, we saw that we would exceed our local waste water discharge
permit limits for those two parameters if nothing was changed.

We formed a cross-functional team to work on the problem, with members from
the environmental group, process engineering and production.  Together, we
developed a short term strategy (reduction in chemical use) and a long term
strategy (glycol ether elimination).  The end result was implementation of a  new
chemistry that totally eliminated the use of glycol ether and greatly reduced the
use of monoethanolamine. The chemistry was actually less expensive to use
and was easier to control, which improved the overall process.

An environmental requirement provided the catalyst for change, but the change
resulted in a better process, saved money, AND ensured compliance.

We used the Motorola TCS (Total Customer Satisfaction) team program as  a
forum to internally publicize our positive results.  The TCS program is a quality
teaming program in which teams form to work on projects using a defined
problem-solving process.  When results have been achieved, teams have the
opportunity to present their projects in "showcases." High scoring teams are
selected to advance to successively higher level showcases (site, group, Sector)
all the way up to the Corporate Showcase - the highest level of recognition.
Rewards ranging from T-shirts, to dinners, to trips to exotic locales (in this case,
Hawaii) are built into the system as incentives.

The Environmental Awareness Team advanced through all levels to the
Corporate TCS Showcase in Chicago in January 1995.  The team won a gold
medal (the highest award given) AND a special merit award for "Outstanding
Process Creativity." This was especially significant in that this was the first gold
medal ever awarded to a team whose project had an environmental focus - let
alone for pollution prevention. This sent a message to the entire corporation that
environmental  issues - and pollution prevention - were recognized as being an
important means of achieving Motorola's key initiatives.

In this case study, the key was working together as a team to view all sides of the
issue and come up with the best solution,  and that the solution made good
business sense, as well.

Case 4: Grass roots effort - water use reduction
With the success of the Environmental Awareness Team, interest was high  in
launching other environmentally-oriented  projects. Several members of the
plating area advanced the idea of a water conservation team and asked the
environmental  group to mentor the team.  Upon closer examination,  it was
surprising to learn that water was the second highest material cost, second only
to the plating substrate itself.  This was due to the cost of first purchasing city
water, then processing it to meet production specifications, treating the resulting
waste water and disposing of both treated water and hazardous waste sludge.
Substantial cost savings could be realized by reducing water consumption.

After studying the rinsing process and rates of water consumption, one of the
team members came up with a concept for an on-demand rinsing module to
replace free-flowing cascade rinses. We  built and piloted a model, and ultimately
replaced all of the cascade rinses with these modules. As a result, overall water
use decreased by about 50%, saving over 6 million gallons  of water per year.
                                   -4-

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Surprisingly, another benefit of standardizing the rinsing process was enhanced
product yield. The new module actually produced a better rinse with less water,
reducing blistering defects and thus reducing process scrap. We realized more
cost savings from reduced scrap than reducing water consumption!

Again, teamwork was the key to finding the solution - and the best ideas came
from the owners of the process. The result was cost savings, process
improvement, AND resource conservation.

Fitting Pollution Prevention Into  Environmental Management
Systems
The four case studies illustrate an evolution in not only "how" projects were
managed to develop innovative solutions but also "why" and "how" they were
selected. Although the solutions found were proactive, the project selection in the
first three examples was driven by "reactive" concerns. A problem existed that
had to be addressed.  Certainly, involving all parties was effective in finding the
solution, but disconnects still existed in the process which sometimes contributed
to creating the problems in the first place. In the final case study, we have an
example of true proactivity. No "problem" existed, simply an opportunity for
improvement.

The evolution of pollution prevention mirrors the evolution of the environmental
management system as a whole.  It can also be compared to the quality
movement -- originally measured at the finished product by "quality inspectors," it
became clear that quality could only be achieved when built into the entire
process and by everyone involved.

So, too, with pollution prevention. Environmental Management started as
reactive, "end of pipe", driven by regulatory edicts. Pollution prevention, and
environmental management systems as a whole, function best when  integrated
into the overall business management systems and involve everyone at all levels.
As  it becomes part of the culture, pollution prevention simply becomes another
tool to use in achieving the fundamental business objectives of quality, cost, cycle
time, and customer satisfaction.


How  To Drive  The  Culture?
Changing the pollution prevention culture is no different than changing any
culture. It requires a change in how people think and act in their job.

Attitude roadblocks are often encountered -

Fear:
        "I don't really understand how the process works, but it is working so
        DON'T MESS WITH IT!"
        "It will negatively impact (pick one) cycle time, cost, quality, production,
        my job."
        "I will have to change."

                                   -5-

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Lack of resources:
       "We have insufficient money, expertise, equipment, time to implement."

Short Term Thinking:
       "I gotta get production out the door right now; I'll take care of tomorrow,
       later."

So, how to overcome the barriers?

Fight fear with facts.  Spread the message that preventing pollution is not just a
"feel good"  program for bunny huggers, it just makes good  business sense.
Select  projects that will yield true business improvements and publicize the
results.

Use the same problem solving tools as you use for quality issues. Go after the big
cost items, get the most bang for your effort. But look at TOTAL cost -- short-term
and long-term. Only do it if it makes sense.

Use all available resources: vendors, trade associations,  consulting services, and
the internet.  Don't reinvent the wheel, benchmark what others have done. You
may well find a drop in replacement has been rolled out just last month to
accomplish exactly what you need.

Don't dismiss the simple things.  Sometimes  a fresh perspective can reveal
something so obvious it was overlooked.  Pollution prevention doesn't have to be
a doctoral thesis project. Get only as detailed as makes sense to evaluate
alternatives, identify opportunities, and  implement process enhancements.

Make it a team effort. Several minds are (usually) better than one.

Use reward and recognition systems that exist in your firm to promote
environmental and pollution prevention successes.  Put pollution prevention on
the map, remind, encourage others to look for opportunities. Success builds
upon success.

Environmental Evolution  Continues
As in all aspects of business, the evolutionary process continues.  We have
already moved from "end of pipe" up the pipeline into  the process and are poised
to embrace the total life cycle of our products. We soon may have "cradle to
grave"  responsibility for our products as well  as our processes and wastes.
Customers in Europe are  already beginning to require less-toxic products and
product end-of-life take back programs. Total product stewardship and designing
for the  total product life cycle is the next frontier in our quest for better, cheaper,
faster,  and more environmentally-friendly.

As environmental systems management evolves toward integration into all
aspects of the operation,  the environmental  professional has more opportunity
than ever to provide value to the business by lending  our special expertise to all
phases of the product life  cycle.

1/13/97
                                   -6-

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  Greg Terdich





A.T. Kearney, Inc.

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        Suzanne T. Thomas





Rust Environmental & Infrastructure

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                    Information Management: Key to a P2 Action Plan

                              Suzanne T. Thomas, P.E., QEP
                                 Senior Program Manager
                            Rust Environment & Infrastructure
                                     15 Brendan Way
                                   Greenville SC 29616
                            (864)234-3016 FAX (864)234-3069
Introduction
       Pollution Prevention (P2) plans have had a change in status over the last several years. P2 at
one time meant mandatory hazardous waste minimization plans and/or optional EPCRA one-liners
for TRI chemicals but, now, P2 is the core of existing and future environmental regulatory compliance
programs within the commercial/industrial and federal sector.  The main reason for this shift was in
response to the spiraling costs of waste disposal, additional regulations requiring a P2 focus, and
executive orders demanding P2 programs - and a realization that fundamental changes in how
compliance issues are handled was necessary for true cost-effective compliance.  The P2 plans are
now plans for action - action at both the management level and at the shop level.

       This sounds great in theory - but when we sit down to write our P2 plans, we face a plethora
of data and information that has been collected over the years at great expense.  Data which relates
to our end-of-the-pipe mentality but which, although necessary, does not really fit well into our P2
culture. How do we manage all of the old data and information - and what new data and information
should we  be collecting - simply and inexpensively - and how should it become the basis for
responsible action?

       The construction of a P2plan is an exercise in information and data management. If you have
the correct data and can manage it easily, you can have effective action plans to prevent  waste and
to ensure compliance.

Data/ Information Relationships

       Every facility - whether industrial/commercial or federal - has invested significant resources
into acquiring data to address wastewater issues, air emissions, hazardous waste, TRI chemicals,
ODS usage  and substitutes, and EPA-17 materials.  In addition, many other types of environmental
data must be  collected and managed;  data,  such as, groundwater and  soil characteristics for
remediation activities, wastewater quality data, and solid waste characterization data.  Then, as we
look outside the environmental arena, most facilities track their raw material purchases and their
product shipments. Many of these tracking systems are geared towards the procurement issues and
accounting practices. This data can be useful to P2 actions - but it often doesn't go far enough to be
useful. For  example, many accounting systems may track the total purchase of solvent ABC but they
often do not track who the actual users of the solvent are or, even more specifically,  where the
solvent is being used in the process.

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       What are the common denominators? Environmental data is usually media-specific, i.e., soil,
groundwater, wastewater, or air; and it is usually location-specific, i.e., end-of-the-pipe, wastewater
sump,  stack sampling port, or fence line.  Environmental data is specific to a target compound or
material or characteristic which is responsible for the undesirable environmental impact. Purchasing
information is component-specific - meaning it usually identifies the compounds or materials which
can eventually be directly or indirectly associated with the undesirable impact. In addition, purchasing
information may identify the users of the materials and, in some rare instances, the uses may also be
identified. All of this information is related and can be connected. The one component that is missing
in these  relationships described is in identifying the generating source.  If the  components in
purchased materials can be tracked to their end-user and the environmental data can also be linked
with the generator across all media (air, water and land) - then closure can be ensured based on a
mass balance at the source. With  the introduction of mapping and location coordinates, data also
begins to provide an added dimension.

Management of Information

       Connections and relationships between data can be used to create roadmaps - roadmaps for
action.  Several examples of data collections and connections versus information roadmaps are
described below for various industries.   These  collectively illustrate how the management of
information is crucial to effective action. By managing data and information and their relationships,
we can effectively develop solutions for many of our environmental problems. Understanding the
relationships, we can also predict the impact of future activities. This is the fundamental principle of
P2.

Case Studies

       It should be noted that all of the examples to follow assume that pollution prevention is the
objective of the study rather than strict compliance with end-of-the-pipe standards.  The presentation
portion of this paper will include graphics which further illustrate these examples.

1, Water Use/Wastewater

       The first example is a food/beverage facility with discharges to a POTW.  The cost to
discharge has become outrageously expensive because of surcharges for BOD and flow. There are
no hazardous or toxic components in the wastewater discharges therefore no significant  risk to the
community is involved. Table 1 shows the data collected when a traditional approach is used versus
the desirable data for the information roadmap.  The traditional data is end-of-the-pipe data on the
parameters  against which compliance will be judged. But the more valuable information is obtained
when a water balance is developed with process-specific water usage and wastewater generation data.
With the water balance as a basis, effective water use reduction can be the first priority followed by
reuse and recycle solutions. Ultimately, this approach will reduce wastewater discharges which in turn
will reduce the need to collect end-of-pipe data to track compliance - a win-win situation with
resulting cost reductions in materials management and energy usage.

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2. Ventilation/air toxics

       The second example is a battery manufacturing facility which has high air toxic levels at the
property boundary.  Again, in Table 1, we see the traditional approach would be to perform stack
sampling to collect data being emitted from the building.  This data can then be used as input to air
dispersion modeling.  What-if analysis can then lead to the specification of air pollution control
efficiencies necessary to comply with standards at the property line. The alternate approach involves
obtaining a deeper understanding of the process areas and their chemistry, the construction of mass
balances to differentiate point sources from fugitive releases,  and an accurate set of production
procedures which identify the "how" and "why" for the releases. Analysis of this information leads
to identification of waste reducing measures within the plant rather than  end-of-pipe control
equipment.  Cost savings result from  an integration of information which can segregate streams and
treat the air toxic components at the point of generation where the volumes which must be treated
are much smaller and more manageable.
3.  Ventilation/visible emissions

       The third example involves a textile operation with visible oil emissions being produced at the
calendar hoods. Stack sampling carried out in the past produced extremely variable results; the use
of these results as a design basis for add-on control equipment would result in over-design and
additional cost since each line would require control.  An alternate approach involves examining the
calender operation and the individual raw material/product scenarios. In this case, this examination
revealed a relationship between the quantity of oily emissions being generated and the different types
of products being run.  The  end-result was the development of an emission rate equation which
calculated emission rate as a function of product type and machine data. Subsequently, segregation
of product lines was implemented such that product lines with problematic emission levels were
assigned to machines with newly-designed air pollution control equipment. Savings in capital and
operating  cost were realized by installing control  only on those lines running the problematic
emission-generating products.

4.  Multi-media compliance/pollution prevention

       The fourth example involves a federal DOD base  with a high level of industrial activity.
The single-media compliance focus had resulted in many separately-funded projects awarded to
different contractors with considerable overlap in data collection and data organizational activities.
In addition,  P2 projects and compliance projects were separately funded when they, in fact,  had
identical objectives and focus. For example, hazardous waste reduction projects aimed at  reducing
the use of chlorinated solvents in cleaning operations were funded separately from NESHAPs
compliance projects which were intent on reducing the toxic air emissions from the use of chlorinated
solvents in the same  cleaning operations.  Although compliance projects have additional elements
which needed to be addressed, such as record keeping and monitoring, the best outcome from these
projects  should meet all  requirements. A cost effective approach involves  a multi-media data
collection activity by process or by shop - with all raw material and production data  collected
alongside waste disposal data to all media (air, water and land). The organization of data into a mass

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balance becomes the information roadmap around each logical  process unit  which will allow
assessment of all potential options for reduction or elimination of materials and for all compliance
issues.  This not only saves time and money in data collection but also ensures that all media and all
compliance issues are addressed.  If the data is further organized into database format by location,
it can be accessed for multiple uses.

Conclusions

       In past years, more available data meant better information to address environmental
problems.  Today, 'more data' is not necessarily 'better information'; solving environmental problems
requires the correct mix of data to create an information 'roadmap'.  These types of roadmaps are
action-oriented and lead to quicker and cheaper environmental compliance and reduced environmental
impacts on production costs.
                        Table 1: Data/Information Relationships
 EXAMPLE
DATA COLLECTED
INFORMATION/DATA
COLLECTED
 Beverage/Food
Wastewater: BOD, COD,
Flow, TSS, TDS
Water balance process;
process specific BOD,
TSS/TDS and flow loadings
 Battery Manufacturer
Stack emissions
Production logs, procedures,
fugitive activities, chemical
usage and reaction kinetics,
mass balances on key
pollutants.
 Textile Operation
Stack emissions
Production schedules and
procedures, usage of
processing materials and
components.
 Federal Facility
Single media data:
wastewater discharge data
for flow, BOD/COD, TSS;
stack emissions data;
hazardous waste shipment
logs.
Process-specific generation
rates for all media; process-
specific production and
throughput information; costs
for tracking compliance on
each media.

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 Peter Wise





Illinois EPA

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          David W. Wolfe





Rust Environmental & Infrastructure

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           BIOGRAPHICAL INFORMATION FOR DAVID W. WOLFE
Mr. Wolfe is a Senior Project Engineer and Manager of Engineering and Industrial Services
for the Harrisburg, Pennsylvania office of RUST Environment and Infrastructure, Inc.  He has
over 20 years of environmental engineering and environmental management experience. Prior
to his current consulting position, he managed a corporate environmental compliance program
for 13 plants involved in the organic and inorganic chemical, nonferrous metals, and energy
industries.

Mr. Wolfe is responsible for projects related to water, wastewater, and hazardous waste
management engineering design.  He has managed projects involving RCRA corrective action,
waste minimization audits,  engineering feasibility studies, environmental permitting,  and
conceptual,  preliminary, and detailed engineering designs.  His experience includes most
recently, manager for the design and construction of a $15,000,000 industrial wastewater
recovery project.

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       Patrick Wooliever





PRC Environmental Management

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               Reducing Dragout from
             Electroplating Operations
             with Spray Rinse Systems
                      Patrick Wooliever
                     PRC Environmental
               Overview
              Applications
              Types of spray nozzles
              Design considerations
              Maintenance
              Case study: All American Manufacturing
              Company
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems

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Hierarchy of P2 and Waste Management
Strategies for Metal Finishing
\
\
\
v_
v
i — \:
Recycling
(In-Process or Other)
1

Material Substitution
Extend Bath Life
Reduce Dragout
Recover Dragout
Reduce Rinse Water
Reuse Spent Baths
Reuse Rinse Water /
k /
\ Recycle Process /
\ Bath and Rinse Water /
\Segregate /
Waste Streams /
\ Improve /
\ WWTS /

/
/}
7 Source

/ 1


Improved
Treatment
1

                   Frequency of Spray Rinses
              NAMF National Survey on Pollution Prevention


              Only 39% of respondents that pursued rinse
              water reduction used spray rinses
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems

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                  Why Consider Spray Rinses
                   Reduce and recover dragout
                   > Over plating tank
                   > Over stagnant tank
                   > Hand held
                   Improve rinsing quality
                   > Improve finish quality
                   > Reduce drag in between processes
                   Reduce water use
                  Design Considerations
                   Operating conditions:
                    >Type
                    > Pressure
                    > Spray pattern and angle
                    > Flow rate
                   Evaporation rate
                   Timing and actuation
                   Material and compatibility
                   Placement
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems

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                  Spray Nozzles
                 Hydraulic: Water only

                 Air Atomizing: Water with compressed
                 air; air increases impact and affects
                 droplet size
                  Air Atomizing Spray Nozzle
Reducing Dmgoutfrom Electroplating Operations
•7nH-h 
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                   Spray Patterns
                         Hollow cone
                         Full cone
                         Flat spray
                         Fine spray
                   Hollow Cone
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems

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                      Full Cone
                      Flat Spray
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems

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                     Fine Spray
                     Spray Rinse Flow Rate
                 Flow rate = evaporation rate
                 Estimating evaporation rate - chart
                  >• Temperature of solution
                  > Surface area
                 Flow at virtually any rate (0.01 to 142 gpm)
                 Flow rate determined by nozzle design and water
                 pressure
                 Droplet size and impact determined by nozzle
                 design, air pressure, and water pressure
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems

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                     Spray Pattern and Angle
                 Maximize coverage
                 Spray with downward angle to knock dragout off parts
                 Use spray pattern to target certain areas
                 Use offset spray position to spray interior surfaces of
                 parts
                 Overlap patterns to concentrate spray in areas of high
                 dragout
                 >• Rough surfaces
                 > Areas with "pockets"
                     Evaporation Rate
              + For dragout recovery, spray rinse flow rate should equal
                plating bath evaporation rate (to avoid need for an
                evaporator)

              + Still tank evaporation rate (gal/hr/ft2) = e<°-03236T-7-2>

              4> Agitated tank evaporation rate (gal/hr/ft2) = e(0-02655T-595>
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems

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                   Evaporation Rate
                              .60
                              .40
                              .20
                             . .10
                            « •°8
                            J .06
                            o M
                              .02
                              .01
                                 80 100 120 140 160 180 200220
                                 TEMPERATURE °F
                   Timing and Actuation
                    Manual operation
                    > Hand-operated
                    xFoot pedal-operated
                    Conveyor actuated solenoids/timers
                    Common problems with timing and
                    actuation
                    > Response time
                    > Line drainage
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems

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                     Check Valves
                     Specifications
                      >• Crack pressure
                      > Shutting pressure
                     Adjustable
                      > Change springs
                      > Rotate screw
                     Durability of Nozzles
                     Durability
                      >- Corrosion resistance
                      > Heat resistance
                      >• Strength
                     Materials
                      xPVC
                      > PVDF thermoplastic
                      > Polypropylene
                      > Stainless Steel
                      > Brass
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems
10

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                    Placement Issues
                     Corrosion
                     Caking

                     Exposure to damage by operator or hoist

                     Accessibility for service
                    Maintenance
                 Nozzle wear characterized by:
                  >• Decrease in system operating pressure
                  > Deterioration in spray pattern
                 Regular inspection
                  > Spray pressure
                  > Spray pattern
                  > Flow rate
                  >• Nozzle alignment
                  > Product quality
                 Remove nozzle and check for deposits
                 Clean with compressed air or water
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems
U

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               Common Causes of
               Spray Nozzle Problems
                Erosion and wear
                Corrosion
                Clogging
                Caking
                Temperature damage
                Improper reassembly
                Accidental damage
                Improper worker training
                     All American
              Manufacturing Company
                    Los Angeles, CA
                        John Norton
                          President
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
12

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                  All American
               Metal stamping of plumbing parts

               Decorative chrome and nickel plating
                  Motivation for Pursuing P2
               Competitive market: high volume, low profit
               margin
               Process control and efficiency
               Cost of raw materials and waste
               Compliance with wastewater limits
               Company TQM program
               Good environmental citizen
Reducing Dragoutfrom Electroplating Operations
with Spray Rinse Systems
13

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                  Two-Phase Approach
               Phase I: Reduce dragout; need to reduce
               loading first to stay under the POTW
               discharge limits

               Phase II: Once loading has been reduced,
               water use can be reduced on running rinses
                  Phase I
               Reduce dragout volume through spray rinses
                >Over plating tanks (nickel and chrome)
                vln dragout tanks (nickel)
                > Over rinse tanks (chrome)
               Measure dragout reduction due to spray
               systems
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
14

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                        Nickel Plating Tank Layout
                Racks
                                                                   To Chrome Plating
                                   Racks and Drag-out

                                     1            1       I    1
                                I     T ^^  ^K I    T       «    T
                                     Spray Dragout
                                        Tank
                   Dragout
                    Tank
                       Flowing
                       Rinse
                                      	f.	
                                      Recycle
                                 t
                                POTW
                        Chrome Plating Tank Layout
                            Racks
                          and Drag-out
                                                                          To Dryer
                           I	1      I	1      I	1      I	1      I	1
                           IX      1  w      I  i/^fVvX^XI  A/^\/^N I   Jr
                           »    Y      >  T      '  T      *  T      IT
                              yV^V>V^_A  [A_/^A^^A| 1/^VAvVyM
                  Chrome Plating Tank
Dragout
 Tank
                               T^T
Stagnant
 Rinse
Flowing
Rinse
Rowing
Rinse
Stagnant
 Rinse
                          Recycle
     Recycle
                                                  T
                                                  POTW
               Recycle

               Recycle
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
                                                            15

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                   Spray Rinses Over
                   Nickel Plating Tanks
               Nozzles
                > Hydraulic
                > Flat pattern
                > 84° angle
                > 0.5 gpm/nozzle at 40 psi
               Configuration
                >• 6 nozzles per tank
                > Configured in two rectangles, 3 nozzles per long side
                > Installed 2 inches above process solution
                   Spray Rinses Over
                   Nickel Plating Tanks
                Sprays parts from four sides to form plane of
                rinsing through which parts pass
                Total spray flow = 4.0 gpm for 3 seconds;
                activated with timer
                Spray directed into the tank to minimize
                overspray and maximize dragout recovery

                Pressure relief valves and shutoff rate
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
16

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                  Spray Rinses In Dragout Tanks
                     Two nickel dragout tanks

                     Nozzles
                      > Air atomizing
                      > Flat pattern
                      > 84° angle
                      > 0.29 gpm/nozzle at 40 psi
                   Spray Rinses In Dragout Tanks
                Configuration
                > Eight nozzles in each tank
                >3 nozzles per long side, one nozzle per short side
                > Nozzles installed below tank lip level
                > Back-side nozzles several inches higher to spray
                 at more of a downward angle
                Total spray flow = 2.3 gpm for 5 seconds
                Hang time of up to 1 minute
                All rinse water returned to process tank
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems

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                rm
Spray Rinse In Dragout Tanks
                    Spray Rinses Over
                    Chrome Plating Tank
                   Mist spray rinse - 0.04 gpm/nozzle
                   Configuration
                    > Six nozzles evenly spaced along length of tank
                    > One nozzle for each rack
                   Location
                    > Above chrome plating tank
                    > In front of and slightly below vibrating hang bar
                   Timer activated by placing rack on vibrating
                   hang bar
                   Stratification in plating tank
                   Work environment improvement          J
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
                                                       18

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             i/_  Spray Rinses Over
                   Chrome Plating Tank
             %_  Spray Rinses Over
             \    Flowing Rinse Tanks
                Two chrome rinse tanks
                > Dragout reduced through vibrator and impact
                Purpose
                > Conserve water
                > Improve rinsing effectiveness
                Nozzles
                > Hydraulic
                > Full cone pattern
                > Two over each tank
                Quick-connect exchangeable nozzles
                > 3.5 to 8.5 gpm                           J
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
19

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                    Spray Rinses Over
                    Flowing Rinse Tanks
                    Spray Rinse Results
                Spray system performance was determined
                by measuring the decrease in dragout due to
                the spray systems
                Approach:
                 > Under identical conditions (same part number and same
                   worker), operate plating line with spray rinses on and
                   off
                 > Measure the conductivity increase in a stagnant rinse
                   tank following the spray rinses (|iS/rack)
                 > Relate conductivity increase to volume of dragout over
                   time (gallons of dragout/month)
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
20

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                    Nickel Spray Rinse Results
                  Process order:
                   1) Nickel plating with spray rinse
                   2) Spray rinse dragout tank
                   3) Stagnant rinse with conductivity meter
                  Conductivity increase
                  with both spray rinses off   =  5.50 jiS/rack
                  Conductivity increase
                  with both spray rinses on   =  2.35 jiS/rack
                  Dragout reduction          =  58%
                   Spray Reduce Nickel Dragout by 58%
                  250
                 -200
                 ;150
                 
-------
                  Chrome Spray Rinse Results
               Process order:
                1) Chrome plating with mist spray over hang bar
                2) Stagnant rinse with conductivity meter
               Dragout volume
                    With sprays off   =  63.1 gallons/month
                    With spray on    =  23.0 gallons/month
               Dragout reduction     =  63%
                  Other Positive Impacts
                 Positive feedback from platers about air
                 quality
                 Reduced evaporator use
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
22

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                      Monthly Savings from
                      Dragout Reduction
                                                 $200/month
                                                   savings
                                                      $115
                                 Nickel
                                Solution
Chrome
Solution
                      Spray Rinse Results
                                      Without
                                       Sprays
   With     Monthly
  Sprays    Savings
               Nickel Solution Dragout  50.0 gal/mo    20.8 gal/mo
               Chrome Solution Dragout 63.1 gal/mo    23.0 gal/mo
               Rinse Water*           380,000 gal/mo 152,600 gal/mo
                             Total Cost Savings = $8,376/year
                                  Total Cost = $4,890
                                Payback Period = 0.6 year
               *Estimated based on dragout reduction
              $313
              $200
              $185
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
                                23

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                    The Next Step:  Phase II
                 Generate calibration curves for nickel and chrome
                 Calculate the actual decrease in dragout volume
                 associated with the conductivity measurements
                 Reduce rinse water use on flowing rinses while
                 maintaining nickel and chrome discharge levels
                 below POTW limits
                 Train workers and continuously monitor dragout as
                 part of company TQM program
Reducing Dragout from Electroplating Operations
with Spray Rinse Systems
24

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                  Catherine Zeman





Iowa Waste Reduction Center, University of Northern Iowa

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