EPA/600/2-91/051
September 1991
ACHIEVEMENTS IN SOURCE REDUCTION AND RECYCLING
FOR TEN INDUSTRIES IN THE UNITED STATES
by
Joseph W. Tillman
Science Applications International Corporation
Cincinnati, Ohio 45203
Work Assignment 2-09
EPA Contract No. 68-C8-0062
Technical Project Managers
Anne Robertson
Emma Lou George
Pollution Prevention Research Branch
Risk Reduction Engineering Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
RISK REDUCTION ENGINEERING LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
Printed on Recycled Paper
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DISCLAIMER
The information in this document has been funded wholly or in part by the United States Environmental
Protection Agency under Contract No. 68-C8-0062 to Science Applications International Corporation. It has
been subjected to the Agency's peer and administrative review, and it has been approved for publication
as an EPA document. Mention of trade names or commercial products does not constitute endorsement
or recommendation for use.
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FOREWORD
Waste Minimization (WM) is a policy that was specifically mandated by the U.S. Congress in the 1984
Hazardous and Solid Wastes Amendments to the Resource Conservation and Recovery Act {RCRA). This
mandate, coupled with other RCRA provisions that have led to unprecedented increases in the costs of
waste management, have heightened general interest in WM. A strong contributing factor has been a
desire on the part of generators to reduce their environmental impairment liabilities under the provisions
of the Comprehensive Environmental Response, Compensation and Liabilities Act (CERCLA, or
"Superfund"). Because of these increasing costs and liability exposure, WM has become more and more
attractive economically.
More recently (in early 1989), as part of its effort to reduce the amount of wastes generated, EPA made
source reduction and recycling top priorities for environmental research, development, and implementation
projects sponsored by the Agency. EPA's Risk Reduction Engineering Laboratory (RREL) and Office of
Pollution Prevention (OPP) have taken the lead in this effort.
Implementation of source reduction and recycling has been successful for many companies. By pursuing
research and development of new technologies, or incorporating available new technologies from outside
sources, U.S. Industries have reported the following successes from their efforts:
Cost saving by reducing waste treatment and disposal costs, raw material purchases, and other
operating costs.
Achievement of state and national WM policy goals.
Reduction of potential environmental liabilities.
Protection of public health and worker health and safety.
Protection of the environment.
The increased success of source reduction and recycling efforts has resulted in increased research,
development, and implementation of technologies to achieve source reduction and recycling.
The purpose of this report is to document a sample collection of source reduction and recycling case
studies which were presented to the U.S. EPA as success stories. While the technical and administrative
assessments of these case studies were not exhaustive, we feel that the information contained herein has
considerable utility to similar industries.
iii
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TABLE OF CONTENTS
Disclaimer ii
Foreword \\\
Acknowledgements vi
INTRODUCTION 1
CASE STUDIES 2
Metals Fabrication
Four Star Tool, Inc. - Rosemont, IL 3
Ford Motor Company - Plymouth, Ml 6
Manufacturing of Machinery (non-electric)
Garden Way, Inc. - Troy, NY 9
TRW, Ross Gear Division - Greeneville, TN 12
Lumber Products
Perry Builders, Inc. - Henderson, NC 15
Kinnear Door/Wayne-Dalton Corp. - Centralia, WA '.'.'.'. 17
Electronics
U.S. Dry Cell Battery Manufacturing Industry 20
AT&T Bell Laboratories/AT&T Network Systems -
Princeton, NJ and Columbus, OH 23
Textiles
Burke Mills, Inc. - Valdese, NC 26
Am'rtal Spinning Corporation - New Bern, NC '..['. 29
iv
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TABLE OF CONTENTS (con't)
Page
Petroleum
Chevron Oil Field Research Co. - La Habra, CA 32
Atlantic Richfield Company - Carson, CA 34
Food Products
Maola Milk and Ice Cream Co. - New Bern, NC 37
Mount Dora Growers Cooperative - Mount Dora, FL 40
Chemical Products
Dow Chemical, U.S.A. - Hebron, OH 43
Union Carbide - Seadrift & Texas City, TX 46
Printing and Publishing
Amko Plastics, Inc. - Cincinnati, OH . *...,. 49
Terry Printing - Janesville, Wl ; 52
Transportation Related Industries
Kenworth Truck Company - Chillicothe, OH 55
Southern California Edison Co. - Rosemead, CA 58
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ACKNOWLEDGEMENTS
This report was prepared under the direction and coordination of Ms. Anne Robertson and Ms. Emma
Lou George, EPA's Technical Project Managers in the Pollution Prevention Research Branch of the Risk
Reduction Engineering Laboratory, Cincinnati, Ohio.
This report was prepared for EPA's Office of Research and Development by Mr. Joseph Tillman of
Science Applications International Corporation and for the U.S. EPA under Contract |sjo. 68-C8-0062,
The following are companies and organizations that supplied informatiori (acquired directly or through
published references) used to generate this report. Numerous individuals representing these companies
and organizations aided in gathering information and/or reviewing respective writeups. Therefore, the
names of the primary contacts/reviewers have been included with the actual case study writeups included
in this document. The efforts of all those involved with this document's creation are sincerely appreciated.
COMPANIES ::.,«': : x
AT&T Bell Laboratories - Princeton, NJ
AT&T Quality/Environmental Public Relations -
Basking Ridge, NJ
AT&T Network Systems - Columbus, OH
Am'ttal Spinning Corporation - New Bern, NC
Amko Plastics, Inc. - Cincinnati, OH
Atlantic Richfield Corporation - Los Angeles, CA
- Carson, CA
Betz MetChem Corporation - Horsham, PA
Boyle Engineering Corporation - Orlando, FL
Burke Mills, Inc. - Valdese, NC
Chevron Oil Field Research Co. - La Habra, CA
Chevron Corporation - San Francisco, CA
DOW Chemical, U.S.A. - Hebron, OH
- Midland, Ml
Ford Motor Company - Plymouth, Ml
- Dearborn, Ml
Four Star Tool, Inc. - Rosemont, IL
Garden Way, Inc. - Troy, NY
Kenworth Truck Company - Chillicothe, OH
Kinnear Door/Wayne Dalton Corp. - Centralia, WA
Maola Milk and Ice Cream Co. - New Bern, NC
Mount Dora Growers Cooperative - Mount Dora, FL
Perry Builders, Inc. - Henderson, NC
Sinclair and Valentine,. L.P. - West St. Paul, MN
Southern California Edison Co. - Rpsemead, CA
The Fabricator Magazine - Rockford, IL
Terry Printing, Inc. - Janesville, Wl
TRW, Inc. (Ross Gear Division) - Greeneville, TN
Union Carbide Chemicals and Plastics Co., Inc. -
- Danbury, CT
- Port Lavaca, TX
- Seadrift, TX
- Texas City, TX
vi
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ORGANIZATIONS
American Petroleum Institute - Washington, DC
American Soybean Association - St. Louis, MO
City of Los Angeles Hazardous and Toxic
Materials Project - Los Angeles, CA
EPA, Office of Air Quality Planning
and Standards - Research Triangle Park, NC
Fabricators and Manufacturers Association -
Rockford, IL
Georgia Tech Research Institute -Atlanta, GA
Illinois Hazardous Waste and Information Center -
Champaigne, IL
National Electric Manufacturer's Association -
New York, NY and Madison, Wl
North Carolina State University/Food Science
Extension - Raleigh, NC
State of North Carolina Dept. of Health & Human
Resources/Pollution Prevention Program -
Raleigh, NC
State of Washington Dept. of Ecology -
Olympia, WA
Note: A list of additional companies and organizations that provided contacts or information that aided in
the eventual acquisition of report information are listed below. Their efforts and insight are greatly
appreciated.
Ohio EPA Pollution Prevention Office - Columbus, OH
State Environmental Facilities Corporation - Albany, NY
Waste Reduction Institute for Training and Applications Research - Minneapolis, MN
Wisconsin Department of Natural Resources - Madison, Wl
vii
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INTRODUCTION
The 1984 Amendments to RCRA, the Hazardous and Solid Waste Amendments (HSWA) of 1984,
specifically mandated Waste Minimization (WM) as an objective forthe nation's environmental management
program. One means of implementing this directive has been the encouragement of source reduction and
recycling approaches for both industry and the public. In response to the HSWA, the US EPA developed
an industrial WM program which has sought to assess waste practices and identify WM opportunities. In
early 1989, source reduction was assigned the highest priority within EPA followed by secondary emphasis
on recycling.
This report provides 20 examples of recently successful initiatives by industry to minimize waste through
source reduction and recycling efforts. These examples will help the reader to better understand how
source reduction and recycling can be achieved within the industrial sector. The examples described in
this report can provide other businesses with ideas on how to incorporate source reduction and recycling
into their operations. The ten industry types featured in this document include: metals fabrication,
manufacturing of non-electric machinery, lumber products, electronics, textiles, petroleum, food products,
chemical products, printing and publishing, and transportation related industries.
These examples are presented as concise and easily understandable two- and three-page summaries
containing photographs that supplement the narrative. In certain cases, process flow diagrams, graphs and
summary tables are included. These case summaries should provide valuable information to both technical
and non-technical professionals, including policy makers and industry representatives. The organizations
featured encompass a broad and diverse group, ranging from small companies having less than 50
employees to large industrial sites having over 1,000 employees. The examples featured are all fairly
recent endeavors that were implemented or achieved success within the last 2 to 3 years.
This report was submitted in partial fulfillment of Contract No. 68-C8-0062, Work Assignment 2^09, under
the sponsorship of the U.S. Environmental Protection Agency (EPA). This report covers a period from
August 1989 to April 1991, and work was completed in April 1991.
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CASE STUDIES
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FOUR STAR TOOL, INC.
ROSEMONT, ILLINOIS
Process Modification to Nonhalogenated Degreasing System
Four Star Tool, Inc. located in Rosemont, .Illinois,, is a medium-size fabricating firm that employs
approximately 150 people. The plant manufactures custom tools for a variety of industries and has been
in operation for more than 30 years.
By switching to a new cleaning agent (in 1988), Four Star Tool, Inc. eliminated the generation of
approximately 15 to 20 drums of spent trichloroethylene (TCE) solvent per year. The associated cost
savings that resulted from the switch (mainly from reduction of waste disposal costs) were reported to be
$5,805 per year.
As with most metal fabricating companies, Four Star Tool, Inc. had utilized a halogenated degreasing
solvent for removing oils and greases. Halogenated compounds, although being excellent degreasing
agents, present potential liability concerns due to their toxic and/or carcinogenic effects and bans for
industrial use are being considered via toxic-reduction legislation. The degreasing operation used at Four
Star Tool, Inc. was also labor intensive and, as shown in the photo below, involved hand-dipping a basket
of small parts into an open tank of TCE.
The basket was
hung up to dry
afterwards and any
ferrous parts were
treated with an anti-
rust compound to
preserve the clean
surface until it could
be plated.
Due to increasing
frustration with local
regulators and
increasing concern for
employee health, the
management at Four
Star Tool, Inc. was
determined to make a
change that would
avoid most future
liabilities. Hand-Dipped Basket of Parts
With the aid of the
Illinois Hazardous Waste Research and Information Center (HWRIC), Four Star Tool, Inc. was put in
contact with a local solvent supplier by way of a representative of the Chicago Metal Finishing Institute.
By closely working with this local company (Todco Chemical Co., Inc.), Four Star Tool, Inc. was able
to substitute a non-toxic degreasing agent, d-limonene, for the TCE. D-limonene is a naturally occurring
organic chemical that is extracted from the rinds of citrus. This natural chemical is a member of the
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terpene family and has been used for a variety of applications. D-limonene has been used in hand
cleaners for its orange fragrance; however, it is strong enough to separate oils and greases from most
surfaces and therefore can be utilized in manufacturing processes.
To incorporate the new degreasing system into Four Star Tool, Inc.'s operations, Todco Chemical Co.,
inc. determined the optimum operating parameters of the new process through daily experimentation. One
particular hurdle that had to be overcome was to find a proper heating temperature for the new degreasing
tank so that the potent d-limonene odor of oranges would not be spread over a radius of many blocks.
Also, to accelerate the relatively slower cleaning process of the new solvent (as compared with TCE), the
addition of small amounts of supplementing cleaning chemical (such as surfactants) was found to be
necessary. Four Star Tool, Inc. acquires the new biodegradable degreaser premixed.
The selection and
design process for
the new system took
approximately two
months and an
additional month was
required for
construction and
installation of the new
tanks and plumbing.
Capital costs were
approximately
$10,000 and a
payback on this
investment is
expected in about 2
years.
The new heated
degreasing tank has
a capacity of 400
gallons (see photo at
left). As a result, it
will accommodate
large cleaning loads
and largely overcomes any reduction in speed since the baskets can be hung in the bath while the operator
attends to other responsibilities. Prior to the new system, the baskets were dipped manually in 30-gallon
drums of TCE.
The schematic on the next page shows the layout of the new degreasing system. The proprietary and
limonene-based cleaning agent mixture is added to tap water in a ratio of 1:10 and is then maintained at
100° F. The cleaning agent works best at this modest temperature which can be attained by heat supplied
from a small gas heater. As the degreased oils and particulates are separated from the immersed parts,
they float to the surface and are removed by a skimmer. After degreasing, the baskets are hand-removed,
drained and rinsed in 150° F heated tap water contained in an adjacent tank. Two to three water rinses
within this same tank may occur before rack drying. Plated parts receive an additional rinse in deionized
water heated at 125° F. No residue remains following evaporation. Unplated ferrous items are treated in
a third tank (100 gallons) containing a diluted anti-rust agent heated to 100° F. The d-limonene cleaner
tends to get the parts cleaner than the TCE solvent did.
Non-Halogenated Degreasing System
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Skimmer
\
The residuals from this
operation includes the diluted
cleaning solution in the bath
and the oily material removed
by skimming. The discarded
cleaner (pH of 7) has
approval from the local waste
treatment plant for direct
disposal to the sewer. The
skimmed oily material is put
into barrels and shipped to a
commercial waste handler
who burns the waste.
The d-limonene cleaner is
biodegradable and eliminates
the generation of hazardous
spent solvents, as well as
Sideview of the Four Star Tool Co. Non-Halogenic Degreasing System reducing toxic air emissions
T -,,,,,«.,«« (tnus' reducing exposure to
Source Tanc.g and Wickliff, 1990 operators). The separated
surface oil can be burned for
energy recovery or reclaimed for reuse.
R
U
f
10% Llmonene-based
Cleaning Agent
90% Tap Water
Degreasing Tank
-* 400 Gallons 100° F
f °
|_L_1 l_J
°\ '
\HotA
'I *
i
N f
\ '
Tap Water
1st Rinse Tank
200 Gallons 150° F
|O O||
i
Ir Heating Ducts
.
n
"N
Delonized Water
2nd Rinse Tank
200 Gallons 125° F
JTfo ||
\ Drains
Antirust Tank
-"100 Gallons 100° F
P
f 1 U
1
NOTES:
Company Contact:
John Meyer
Purchasing Agent
Four Star Tool, Inc.
5260 North Otto Ave.
Rosemont, ,IL 60018
(708) 678-6179
References:
"Major Changes Are Coming for
Fabricators, Who use
Degreasers", The Fabricator
Magazine, July/August 1990, Vol.
20, No. 5, pp. 26-27, by W.Tancig
and A.Wickliff (HWRIC)
Illinois Hazardous Waste
Research and Information Center,
Champaign, IL.
(217) 333-8955
Other:
One of ten Illinois organizations
awarded 1989 Illinois Governor's
Pollution Prevention Award
Four Star Tool, Inc.
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FORD MOTOR COMPANY
PLYMOUTH, MICHIGAN
Process Modification for No-Rinse Treatment in Metals Fabrication
One of the operations at the Ford Motor Company's Sheldon Road Plant is the manufacture of aluminum
radiators. The plant, located in Plymouth, Michigan, employs over 1,000 workers and comprises over a
million square feet in area.
In July of 1989, after several years of development and testing, Ford implemented a new cyanide-free
and no-rinse chromate coating process. The waste reductions that have resulted from the switch to the
no-rinse treatment process are summarized below:
Filter Cake Sludge - reduction in volume generated from 20 yards per month to less than 1 yard per
month.
Cyanide Compounds - complete elimination of all forms of cyanide from the process and the resulting
waste sludge.
Water Usage - reduction by approximately 80%, from 14,000-17,000 gallons per day (GPD) to 3,000
GPD (the waste water treatment plant [WWTP], which was previously operated at full capacity every
other day is now
operated
approximately once
every ten days).
As is the case in
most metal fabrication
industries, aluminum
is a desired material
for the automotive
industry due to
several beneficial
properties. One of
these properties is
the natural formation
of aluminum oxides
on the metal surface
that protects against
general corrosion.
These oxides are
formed naturally upon
exposure to the air.
However, the
aluminum oxide layer has very poor adhesion to the metal surface and contains numerous minute cracks
and crevices that lead to localized corrosion. As a result, the aluminum must be pretreated so that the
metal's surface can be converted to an adherent and inert layer.
Up until July 1989, conventional pretreatments, such as chromium chromate and chromium phosphate,
were used at the Sheldon Road plant. However, due to the composition of the chemical products and
nature of the process, two significant disadvantages were evident and include the following:
Spray Application Booth
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1) These conventional pretreatments contain ferricyanide, an extremely stable iron-cyanide complex,
that, although in this form has not been demonstrated to be a particularly hazardous material, is very
difficult to destroy.
2) Conventional pretreatments require rinsing following treatment to halt the chemical reactions and
remove residual reactants and reaction products from the surface.
Aluminum finishes typically remove the residual ferricyanide from rinse water by precipitation in a
wastewater treatment plant with the chemically reduced chromate residual waste. This treatment results
in a waste sludge containing from 0.1 to 0.5% total cyanide, which can not be disposed of in landfills due
to the US EPA Land Disposal Restrictions.
Although it may have been possible to destroy the cyanide in the sludge through chemical reaction with
chlorine at high temperatures over an extended period of time, Ford's approach was to address the iron
cyanide issue at its source, the coating process.
When switching to
the no-rinse coating
process, the Sheldon
Road Plant continued
to utilize the same
large booth that had
always been used for
the spray application
{see photo on
previous page).
However, the new
system allowed for
the elimination of two
rinse stages, thus
allowing room within
the spray booth to
install piping and
collection equipment
that would allow for
collection and
repeated reuse of the
new treatment
chemical. After the
coating product is
applied, it is blown
off, collected and
recycled via gravity
drained PVC piping back into the system. Other modifications included adding controls for automatic
sampling and replenishment of a precise water/chemical mixture; thus, achieving a very consistent
application and minimizing the amount of product used (see photo above). The modification of Ford's
seven zone process for pretreatment of aluminum is shown diagrammatically on the next page as a
comparison to the old system.
Control Panel for Automated System
The switch to a no-rinse treatment process has utilized both source reduction and recycling techniques,
without compromising the integrity of the coating application. Now, as the new mixture is applied, the water
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Original Rinse Process (Before)
,,_,._.. ....,,, nnnTflTnn Ti?Avrt **-»
T T -T
ZONE 1 ZONE 2 ZON
ACID 1st 2n
CLEANER RINSE RIN
(water) (*
E 3 ZONEU ZONE 5
d CHROME 3rd
SE SPRAY RINSE
ater) (water)
1 F~
Counter Flow Connected Counter Flow
Approx. 14,000 - 17.000 GPD Discharge to WTP Approx. 14,000
No-Rinse Process (After)
RADIATOR TRAVFI
/1\ /|\ /|\ IU1U1IUUK IKHVCL^
ZONE 1 ZONE 2 ZONE 3 ZONE1 4 BLOWOFF
ACID 1st 2nd NO-RINSE
CLEANER RINSE RINSE CHROHATE
(water) (water)
1
1
Counter Flow Connected - Computer Controlled
Approx. 3,000 GPD Discharge to WTP
f -t 1\ -^
ZONE 6 ZONE 7 DRY
4th BLOWOFF OVEN
RINSE
(water)
Connected
- 17,000 GPD Discharge to WTP
s**
DRY
OVEN
SHELDON ROAD PLANT
CHROHATE PROCESS FLOW COMPARISON
ALUMINUM RADIATORS
Source: Ford Motor Co., Sheldon Road Plant
evaporates from the surface of the no-rinse treatment, then the coating reacts with itself and with the
substrate to form a coating that tightly adheres to the substrate.
In addition to the amount of waste reduced, Ford Motor Company has offset the increase in chemical
coating cost from the cost avoidance associated with facilities that would have been necessary to safely
destroy the cyanide compounds. Because of the success of the process change at this plant, Ford Motors
has Implemented no-rinse treatments at the Connersville, Indiana and Coclisa, Mexico plants.
NOTES:
Company Contact:
Frank Monahan,
Plant Engineer
Mfg. and Eng. Dept
Climate Control Division
Ford Motor Company
14425 Sheldon Road
Plymouth, Ml 48170
(313)451-9015
References:
"Aluminum Pretreatment Eliminated
Hazardous Waste; High Performance
Finishing For Aerospace and Other
Industries", prepared by J. Favilla
(Betz MetChem), The Fabricator
Magazine, A technology update insert
to July/Aug. 1990 issue, pp. 19-23
Ford Motor Company
8
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GARDEN WAY, INC.
TROY, NEW YORK
Elimination of Solvent Wastestreams in the Manufacturing
of Power Equipment via Switch to Powder Paint Technology
Garden Way, Inc. is a manufacturer of outdoor power equipment and operates manufacturing facilities
in Troy, New York; Lynn, Indiana; and Port Washington, Wisconsin. The Troy, New York plant
manufactures Troy Bilt rototillers, Sickle Bar mowers, Tuff-Cut high wheel mowers, and chipper shredders.
In August of 1990, an additional portion of the company's shredder operations was relocated to Troy, New
York.
By switching to powdered paint technology in December of 1989, Garden Way has accomplished a 95%
reduction in their hazardous wastestreams and has experienced treatment savings of approximately
$25,000 per year. Below is a summary comparison of the old conventional solvent paint system versus
the new system.
Solvent Paint Wastestreams Eliminated
Lead Paint Solid Residues (9600 Ibs/yr)
Paint Line VOCs (63,000 Ibs/yr)
All Caustic Hydroxide & Wash Streams
(4,000 Ib/yr)
Wastestreams of New Powdered Paint System
Non-Hazardous Wastewater (20,000 gal/yr)
Tramp Oil (500 gal/yr)
Waste Plastic Residues (200-500 Ibs/yr)
Non-hazardous Ash (200-250 Ibs/yr)
Note: Quantities of wastestreams are estimated averages.
Because the Garden Way products must endure the rigors of outdoor use, the paints and finishes used
for them must be very durable. For this reason, the company, as well as other manufacturers, used paints
having lead contents exceeding 10,000 ppm (1%). Early efforts by the company reduced lead levels to as
low as 11 ppm, but still above the
regulatory limit of 5 ppm for
leachate.
Garden Way made the major
change in switching to powder
paint technology in late 1989,
because of improvements made in
the durability of the pigment
ranges that the company utilized.
To implement the new technology
a new paint line was constructed
and involved the following:
14,000 square foot addition
new conveyor system
five-stage washer
powder booth (see photo at
left)
future wet booth
dry-off and curing ovens
burn-off oven
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Bringing the new paint line into production took Garden Way approximately 8 months (including
construction time). The capital cost associated with the new system was approximately $1.25 million and
the payback time was originally estimated at 10 years, but may actually be as soon as 5 years.
Initially the project was designed to obtain a higher quality product, improve flexibility and increase
production capacity. The new system afforded Garden Way the improved ability to handle new stocks of
galvanized material for new product lines. Reducing the company's hazardous wastestreams and permit
costs were noted additional benefits. The new system layout consists of a low pH hydroxide wash; clean
tap water rinse; iron phosphate stage; a second rinse; non-chrome sealer; drying off stage (250° F); a
powder booth; and curing oven (400° F). The new powder paint process used at Garden Way is shown
diagrammatically below.
FLOW DIAGRAM OF POWDER PAINT SYSTEM
Overspray (97-98X recycled)
POWDER BOOTH
Powder Paint
Application
via
Electrostatic Gun
Coated
Parts^
Coated Parts
CURING OVEN
400° F
Improperly
Contaminated
Powder
Painted Parts
BURN-OFF OVEN
1200-1400° F
Powder paint, essentially a fine, semi-polymerized polyester dust (3-10 microns), is applied by automatic
and manual electrostatic spray guns. The majority of the overspray (97-98%) is contained within the
powder booth and recycled via an inherent pump system. The collected powder is returned to the fill
hopper and reused. The 2-3% powder that becomes contaminated with dust from outside the spray booth
is collected in a High Efficiency Paniculate Air Filter (HEPA) vac and cured to form a non-hazardous
disposable plastic. The powder coated part is baked so that the coating melts into a durable, high gloss
plastic/polyester finish. Improperly painted parts are cleaned in a 1200° F oven equipped with a 1400° F
afterburner, and the small quantity of non-hazardous ash is sent to a sanitary landfill.
The non-hazardous disposable residues go to a sanitary landfill, as does the ash (the Toxic
Characteristic Leachate Procedure showed the ash to be non-hazardous). The tramp oils are paraffin- and
petroleum-based oils that are present on the metal stocks when received in shipment (for protective
purposes). The oils are collected as float during stock washing operations and are sent to a reprocessor
for recovery and reuse, either as lube oil or for fuel blending.
10
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The photograph above shows the unpainted parts entering the Powder Paint Wash System (foreground)
and finished powder-painted parts leaving the 400-degree F Caving Oven and Cooling Tunnel.
NOTES:
Company Contact:
Paul Hoffmann
Mgr, Environmental Services
Garden Way, Inc.
102nd Street and 9th Ave.
Troy, New York 12180
(518) 235-6010
References:
"Garden Way, Inc., Troy, New York
Plant, Hazardous Waste Reduction-
Powdered Paint Line", by P. Hoffmann,
presented at the New York State Third
Annual Waste Minimization Conference,
June, 1990, Albany, NY.
Garden Way, Inc.
11
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TRW, ROSS GEAR DIVISION
GREENEVILLE, TENNESSEE
Elimination of Hazardous Solvent Waste Generation Via Ultrasonic
Cleaning Technology for the Manufacturing of Hydraulic Components
The Ross Gear Division of TRW Inc. is a manufacturer of hydraulic motors, hydrostatic steering units,
and manual steering gears. The hydrostatic steering units are used in off-highway vehicles such as farm
equipment (e.g., tractors and combines) and the manual steering gears are used in large highway trucks.
The company employs approximately 350 people at the Greeneville Plant, which comprises 281,920 square
feet. The plant has been in operation since June of 1972.
To reduce wastes associated with one of their processes, TRW replaced the method by which they
remove lapping compound from the parts (December of 1987) and more recently (1989) switched to a
water-based lapping solution. As well as eliminating the potential health hazards that were associated with
the old solvent vapor degreasing system, TRW has achieved a 50% reduction in the overall quantity of
hazardous waste generated at the Greeneville plant and has, in turn, significantly decreased disposal costs.
This reduction in hazardous waste generated is shown graphically below.
HAZARDOUS WASTES
TOTAL GENERATED 1981 - 1988
Thousands of Ibs.
70-
60-
50-
40-
59.8
44.2
The fluid power
components
manufactured at the
Greeneville facility are
extremely sensitive to
contamination by dirt
and the abrasive
solutions used to
clean the
components. For
Instance, if hydraulic
motor components
that were not properly
cleaned were
installed in a vehicle,
the entire hydraulic
system of that vehicle
could be affected
since the fluid is
pumped throughout
the entire system.
For this reason, TRW
must meet cleaning specifications that are required by their clients.
To improve the surface finish of their parts, TRW uses an intensive machining process referred to as
lapping. The lapping process utilizes an abrasive media that must be completely removed from the parts
after the finishing operation. The lapping material that had been used at the Greeneville Plant was a slurry
consisting of five-micron silicon grit and an oil carrier.
Prior to late 1987 the company used a solvent vapor degreasing system to remove the lapping
compound from the parts. Trichloroethylene (TCE), the solvent used, worked well but generated
30-
20-
10-
1981
1982 1983 1984 1985 1986 1987
1988
I OTHER WASTES
ITCE WASTES
12
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wastestreams that included (1) hazardous still bottoms from in-house distillation of TCE, (2) hazardous
waste filtration powder (containing residual TCE), and (3) stack and fugitive emissions containing TCE.
The amount of wastes generated by these wastestreams was significant. For instance, in 1987 the
Greeneville plant generated approximately 14,090 pounds of TCE still bottoms, 3,740 pounds of filtration
powder, and an estimated 50,300 pounds of fugitive and stack emissions. The TCE still bottoms were
transported offsite to a hazardous waste treatment and disposal facility and the filtration powder was sent
offsite for incineration.
Because of the health and environmental concerns associated with the TCE, the company began
investigating feasible alternatives to solvent clegreasing in 1986. Extensive research and evaluation
culminated in the discontinued use of TCE in December 1987. The alternative process chosen involved
the use of an aqueous alkaline solution (a cleaning agent) in conjunction with ultrasonic cleaning.
Through a
contractor, TRW
designed and built a
three-stage ultrasonic
system washer. The
system consists of
three primary steps
which include an
ultrasonic cleaner
tank, a water rinse
dip tank, and a rust
inhibitor treatment
tank. The parts are
transported to the
system via a
conveyor line (see
photo to left) and are
placed in the
ultrasonic cleaning
tank where sound
waves are
propagated through an alkaline solution by way of transducers. The transducers are small piezoelectric
devices that are encased in stainless steel and are placed at the bottom and sides of the cleaning tank.
These sound waves, which are in lieu of agitation, impinge on the parts with sufficient energy to
satisfactorily clean the parts. The alkaline solution is a product of Calgon and was chosen after testing the
system with several formulations. A surfactant is a necessary component used in conjunction with TRW's
ultrasonic system to properly loosen the lapping compound from the parts.
The non-hazardous waste from the rinse dip tank is sent to an ultrafiltration unit, which handles
wastestreams from other plant processes as well. Both residuals from the ultrafiltration unit, namely oils
that came from other plant operations, and alkaline solution are non-hazardous. The oils are sent offsite
to a treatment facility and the aqueous solution is discharged to the sanitary sewer.
TRW has continually been refining the new system since it first replaced solvent degreasing. In 1989
the company added more transducers to the ultrasonic cleaning stage to improve the cleaning efficiency.
They also recently switched from an oil-based lapping solution to a water-based aluminum oxide solution.
By making this change, the plant has eliminated the need for using mineral spirits, which were used for the
parts precleaning.
13
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The plant has just
added special filters
to the ultrasonic
cleaning solution
which will stabilize the
amount of particulates
in the cleaning
solution at a level
which is optimum for
the best cleaning
results. As shown in
the photo to the right,
there is one filter for
each of the three
tanks that comprise
the system.
TRW is involved
with the University of
Tennessee Center for
Industrial Services.
Throughthis
organization, TRW has been able to transfer their acquired know-how of ultrasonic cleaning systems to
other companies in the State of Tennessee that have similar cleaning operations.
NOTES:
Company Contact:
Frank Hartman/CHMM
Environmental Coordinator
TRW, Ross Gear Division
P.O. Box 1790
Qreeneville, TN 37744-1790
(615) 639-8151
References:
TRW, Ross Gear Division
Governor's Award Nomination
Information
Other:
Winner of the State of Tennessee
1988 Governor's Award for
Excellence in Hazardous Waste
Management
14
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PERRY BUILDERS, INC.
HENDERSON, NORTH CAROLINA
Process Modification/Procedural Changes for Reduction
of Hazardous Waste Generated in Treatment of Lumber
Perry Builders, Inc.
is a family owned and
operated corporation
that treats lumber
used for building
outdoor structures
that are exposed to
the weather (e.g.,
outdoor decks,
fences, boat docks,
etc.). The Raleigh
Road Plant in
Henderson, NC was
established in July of
1985 and employs
approximately 20
people.
To minimize the accumulation of hazardous wood treatment waste, Perry Builders implemented several
steps involving equipment and process changes, starting in 1987 and continuing up through 1989. These
changes, which have resulted in an annual waste drum reduction from 14 to 2, and associated 80% waste
disposal cost savings, include (1) installation of a vacuum pump to achieve a dryer lumber, thus reducing
drippage; (2) procedural change of paying wood treaters from a per unit to an hourly basis; (3) extension
of the time period for the final vacuum process; and (4) installation of a roof atop the treated lumber storage
area.
The Raleigh Road Plant pressure treats wood products with a mixture of chromated copper arsenate
(CCA), a wood preservative, and water. To minimize worker exposure to the CCA, all functions associated
with the receipt, transfer, storage, and application of the treatment solution are conducted in a contained
area. The treatment application is conducted in a treatment cylinder. This cylinder (shown in the above
photo) is 46 feet in length and 61/4 feet in diameter. "Lumber packs", approximately 2 feet high, are rolled
into the treatment cylinder on "rail cars", the door to the cylinder is closed and the chamber is flooded with
the treatment solution. A computer is utilized for determining the proper amount of treatment solution
added to the amount of wood inserted into the chamber.
During the treatment process, any excess CCA solution that drips off the wood is mixed with sawdust,
wood chips and dirt. As a result, any excess solution that has been contaminated with those particulates
becomes a listed hazardous waste, classified as D004 and D007. This excess flows from a drip pad that
slopes back to the "door pit", which is a concrete pit at the front of the treatment cylinder.
The basis for Perry Builders implementing the three time-related steps (as previously listed above) is
to keep the treatment solution in the treated wood within the cylinder; thus, preventing the solution from
dripping from the wood and coming in contact with the particulates that result in the generation of
hazardous waste. The new vacuum pump installed is very powerful and results in a faster and stronger
15
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vacuum, which in turn results in a reduction of drippings of CCA solution. After the lumber packs are rolled
Into the treatment chamber, the door is closed and the cylinder is flooded with solution and pressure is
applied for 15 minutes to force treatment solution into the wood. Afterwards, the valves on the cylinder are
opened and the vacuum is applied to force any excess treatment solution out of the wood.
Due to the stronger vacuum and increased time applied, the treated wood that exits the cylinder is a
tot dryer than the wood treated by the process used in the past. The management decision to increase
the vacuum time and to pay wood treaters on an hourly basis (rather than a per unit basis as was done
previously) has encouraged the achievement of a dry lumber product.
The fourth step taken, installation of a roof above the treated lumber storage area, is a post-treatment
preventative measure. CCA takes approximately 48 hours to be fixed in the wood cells. Until this time,
the roof prevents any potential leaching of the treatment compound by rain. Once the copper and arsenate
are bonded into the wood cells, the treated wood is virtually leach proof, according to Vice President, Leon
Perry, III.
The volume reduction and associated cost savings from the measures implemented by Perry Builders,
Inc. are summarized below.
SUMMARY OF SOURCE REDUCTION
Year
# of Drums Disposal
Generated Costs
% Saved
1987
1988
1989
14
10
2
$2,380
$1,500
$ 300
37
80
The photo at the right
shows the new vacuum
pump adjacent to the wood
treatment cylinder.
NOTES:
Company Contact:
Leon W. Peny, III, Vice President
Perry Builders, Inc.
Ratetgh Road South
P.O. Box 589
Henderson, NC 27536
(919) 492-9171
Other Contacts:
Gary Hunt & Stephanie Richardson
N. Carolina Dept. of Environmental,
Health and Natural Resources -
Pollution Prevention Program
P.O. Box 27687
Raleigh. NC 27611
(919) 733-7015
References:
Entry Form - State of N.C.
Governor's Award of Excellence
for Outstanding Achievements in
Waste Management
Perry Builders, Inc.
16
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KINNEAR DOOR/WAYNE-DALTON CORPORATION
CENTRALIA, WASHINGTON
Recycling of Wastewater Via Product Substitution of Glue
Formulations in the Lumber Products Industry
Kinnear Door/Wayne-Dalton Corporation, located in Centralia, Washington, is a manufacturer of wooden
parts for overhead garage doors. The company employs as many as 100 workers in the Centralia plant,
which handles approximately 13 to 14 million board feet of lumber annually. Manufacturing processes used
at the plant involve drying, milling, jointing, and gluing wood parts to form the building products.
As a result of several inexpensive measures implemented by Kinnear Door, the company now reuses
much of its glue washdown water to mix up new glue formulations. Prior to this, all of the wastewater was
disposed. At a startup cost of $1,500, for purchase and installation of the new equipment, Kinnear Door
has saved an estimated $1,000 per year in permit fees, $300 per month in sewer fees, $2,000 per year
in landfill disposal fees, and $10,000 a year in pretreatment costs.
The primary
wastestream
associated with the
manufacturing of the
wood parts is
wastewater containing
glue washdown
water. Early in the
company's history,
which dates back to
1963, the wastewater
was disposed of in a
septic system
designed for that
purpose. However,
due to environmental
regulations, the
company began using
the septic tank(s) to
store the wastewater.
It was anticipated that
the wastewater would
eventually be taken
by a septic pumper to
a local landfill and sprayed.
More recent regulations, which prohibited disposal of the wastewater at landfills, eliminated the
aforementioned option. Thus, with the help of the State of Washington Department of Ecology, Kinnear
Door investigated alternative means for disposing of the wastewater that was being generated at a rate of
up to 2,500 gallons per month. Options considered included treatment systems involving settling ponds
and evaporators for pretreatment and ultimate treatment at a local sewage treatment plant.
However, the initial remedies considered were determined to be undesirable. Treatment systems would
have to be evaluated for environmental permitting, and the cost of pretreatment chemicals and the
17
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associated analyses necessary to determine the suitability of disposing of the wastewater at the local
sewage treatment plant was estimated to be $10,000 annually. Ultimately, the solution to the company's
problem came from self-evaluation of the washwater. Because the melamine-urea and PVA glues being
used were water-based, the employees themselves pursued the possibility of reusing the glue washdown
water to mix up their glue (formulations), thus reducing the volume of wastewater generated at the source.
The company decided to purchase dry glues to replace the liquid glues that had always been used. Water
was not added to the already-mixed liquid glues; however, water was needed for mixing up glue
formulations from the dry glues. Thus, the employees figured that a good portion of the mixing water used
could be wastewater.
The system that was developed to implement this change (in October 1989) was fairly simplistic and
Involved two barrels to hold the wastewater, pumps, and a fiberglass settling tank. This glue washwater
recycling system setup is shown in the photo on the previous page.
To extend the pot life of the glue, the employees determined what proportion of fresh water and recycled
water were needed to attain the proper pH. It was determined that 10 pounds of water needed to be added
to the dry glues, 6 pounds could be wastewater and 4 pounds fresh water.
Besides adding the
tanks, the company line
their 3-gallon glue
mixing pots with plastic
trash compactor bags,
which has eliminated
rinsing (see photo at
left). At the end of
each day, the company
now tip the lined pots
upside down and
empty remaining wet
glue into a 55 gallon
drum. Once the glue
sets up in the drum, it
is immobile and can be
sent to a sanitary
landfill. Prior to using
the plastic liners, the
glue pots had to be
rinsed to prevent
buildup of dried glue.
The wet glue
contaminated rinse
water cannot be sent to
a landfill, thus the
plastic liners have
precluded Kinnear Door
from having to
construct expensive
glue/water separation
structures (ie.
evaporation pond).
This photograph shows the lining of a 3-gallon glue mixing pot,
which has eliminated generation of rinse water.
18
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The primary wastestream generated at the manufacturing plant now consists of non-hazardous glue
solids that settle out of the wastewater in the settling tank and are drained out of the glue pots. These
drummed glue solids are sent to a local landfill.
NOTES:
Company Contact:
John Ver Valen
Kinnear Door/Wayne-
Dalton Corporation
2001 Industrial Drive
Centralia, WA 98531
(206)736-7651
Other Contact:
Judy Kennedy
State of Washington
Department of Ecology
PV-11
Olympia, WA 98504-8711
(206) 459-6356
References:
"Success Through Waste
Reduction: Proven Techniques
from Washington Businesses",
Washington State Department of
Ecology, Publication 90-22,
pp. 5-6.
Washington State Department of
Ecology
Kinnear Door/Wayne-Dalton Corp.
19
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U.S. DRY CELL BATTERY MANUFACTURING INDUSTRY
Reduction in Toxicity in Dry-Cell Batteries via Product Substitution
The Dry Battery
section of the
National Electrical
Manufacturing
Association (NEMA)
represents
commercial
household battery
manufacturers located
In the United States.
Members include
such companies as
Eveready Battery
Company, Duracell
USA, Rayovac
Corporation, and
Kodak. Several years
ago, the U.S. battery
industry, in
conjunction with
NEMA, adopted a
source reduction
strategy for reducing the amounts of mercury and cadmium used in battery production
option was preferred over recycling due to logistical and safety concerns relating
facilities.
. A source
to battery
reduction
collection
As a result of the individual efforts of dry-cell battery manufacturers, members of the NEMA Dry Battery
Section have achieved successful source reduction of toxicrty in dry-cell batteries. The table on the next
page shows the steadily decreasing volumes of mercury occurring in batteries over the past six years. The
table also shows how batteries, as a whole, have contained the largest amount of mercury of any product
in the U.S.; thus, the reduction of mercury in batteries will have a significant impact on the amount of
mercury in consumer products.
According to U.S. Bureau of Mines data, the U.S. battery industry decreased its total consumption of
mercury by 91% during the five years from 1984 to 1989, while all other users combined increased their
consumption by 25% during the same time period. In the U.S. production of household batteries (used by
consumers for their personal needs), mercury usage has fallen from 778 tons in 1984 to a projected 62
tons in 1989, a decrease of 92% in just six years. For calendar year 1990, NEMA estimates that the
percentage of total United States mercury consumption going into household battery production will be
around 5%.
Mercury has historically been used in non-rechargeable batteries to coat zinc. Zinc is used as the
negative electrode material in five types of household batteries (shown in the table on the next page).
The zinc anodic material added in alkaline-manganese batteries is in a powdered form. Small amounts
of mercury (an estimated 1-3% by weight) have, in the past, been mixed with the powdered zinc to prevent
the zinc from reacting with other battery ingredients. The mercury combines with the zinc to form a
20
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MERCURY CONSUMPTION, UNITED STATES
1984
1985
1986
1987
1988
1989
Chlorine & caustic soda
Paints
Batteries
Switches, lighting & controls
Other
7,347
4,651
29,700
4,210
8,694
6.804
4,892
27,622
3,909
6,619
7,514
5,087
21,821
4,173
9,982
9,014
5,755
15,462
5,110
6,598
13,199
5,715
12,996
6,004
8,296
12,157
5,528
5,599
3,945
9,613
TOTALS
54,602 49,846 48,577 41,939 46,210
36,840
Source: U.S. Bureau of Mines (Units are in flasks. One flask = 76 pounds
zinc/mercury amalgon. As the
proportion of mercury in the
amalgon increases, there is a
decrease in the rate at which
the zinc oxidizes with the
alkaline electrolyte. This
greatly reduces the generation
of hydrogen gas.
BATTERY TYPES HAVING HISTORICAL USE OF MERCURY
Battery Type Principal Sizes
Alkaline
Carbon Zinc
Mercuric Oxide
Silver Oxide
Zinc Air
D, C, AA, AAA, 9 volt
D, C, AA, AAA, 9 volt
Button cells (hearing aids)
Button cells
Button cells (hearing aids and pagers)
Hydrogen gas is a by-product of the zinc/electrolyte oxidation reaction. Buildup of this gas can weaken
the seals of a cell and cause leakage. Very rapid buildup of hydrogen gas could cause an explosion;
however, the presence of blowout valves at the tip of the battery almost negate this possibility.
Alternative means for controlling the zinc reaction began in the mid-1980's after questions were raised
about the potential environmental impact of mercury found in discarded household batteries. Mercury is
regulated as a hazardous air pollutant under the Clean Air Act (CAA), as a priority pollutant under the
Clean Water Act (CWA), and as a hazardous waste under the Resource Conservation and Recovery Act
(RCRA).
In desiring to lower the toxicity potential of their products, the battery industry was faced with a difficult
problem. Namely, what kind(s) of substitute materials could be used in dry-cell batteries that would provide
a reduction in the amount of hydrogen gas evolving from the anode of alkaline zinc-manganese dioxide
cells, thereby maintaining battery performance, and at the same time reducing the amount of mercury used
in the zinc bearing anodes.
Working independently, the dry-cell battery manufacturers developed their own unique substitute
materials. Just as one example of a clean technology used, Rayovac Corporation, in the summer of 1989,
patented the use of an organosilicate material to reduce the amount of mercury in their anodic gel mixture.
Rayovac initially tested the "gassing" potential of the new gel mixture by covering the mix with mineral
oil within a sealed test tube, via a graduated pipette. Any rise in the mineral oil would reflect the amount
of hydrogen gas that had evolved from the gel and was trapped at the gel/mineral oil interface.
21
-------
TERMINAL CAP
Further testing was
conducted on actual
cylindrical alkaline zinc-
manganese dioxide cells
constructed for testing
purposes (see schematic at
right). Rayovac quantified the
effects of their organosilicate
additives by measuring the
gassing rates of gel mixtures
containing varying
percentages of the additives.
The results are shown in the
table below.
From the results, it was
discovered that the amount of
mercury used in alkaline-
manganese dioxide cells can
be reduced to as little as
0.025% of battery weight.
Rayovac's preferred organosilicate additive compound is called DC-193. The users of this particular
material substitute believe that the organosilicate materials that coat the zinc/mercury amalgon surface
cause a slower evolution of hydrogen gas, either by forming a physical barrier to the evolution of hydrogen
gas or by increasing the efficiency of the mercury in preventing the formation of hydrogen. The mechanism
is not fully understood. DC-193 is believed to have superior, adsorptive film-forming capabilities.
NEGATIVE
CURRENT
COLLECTOR
ANODE GEL
CATHODE RING/
ANODE GEL
SEPARATOR
ANNULAR RINGS-
SEALING DISK ^
INSULATION WASHER,
CONTACT SPRING
STEEL SHELL
COATING
INSULATING
TUBE
TERMINAL CAP
Source: U.S. Patent 4,857,424
Gel Gassing As A Function of Organosiliconate
(uL/gm/Day@ 160°F)
Compound Organosiliconate
40 PPM
160 PPM
A
B
C
D
E
F
DC-193
Polydimethylsiloxane-
Polyoxyethylene
Copolymer
Non-Hyrdolizable
Silteonelycol
Copoiymer
Phosphoate functional
silate
Polydimethylsiloxane
Sodium Dimethylsiloxane
6.03
17.6
12.3
23.3
30.9
39.4
3.82
10.1
3.15
23.8
31.3
24.1
[Gassing of gels without any additive is 14.2]
Source: U.S. Patent 4,857,424
NOTES:
Industry Contact:
Ray Balfour, Spokesman
NEMA-Dry Battery Section
601 Rayovac Drive
P.O. Box 4960
Madison, Wl 53711-0960
(608) 275-4584
References:
. "Household and Other Batteries:
Source Reduction and Recycling",
presented by Ray Balfour at the
9th Annual Resource Recovery
Conference of the U.S.
Conference of Mayors,
Washington, DC, March 30, 1990
U.S. Patent No. 4,857,424
U.S. Bureau of Mines
NEMA
Material Data Safety Sheet
Alkaline Batteries
22
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AT&T BELL LABORATORIES/AT&T NETWORK SYSTEMS
PRINCETON, NEW JERSEY/COLUMBUS, OHIO
Elimination of Postsolder Cleaning in Printed Circuit Board Manufacturing
Via Development of a Low Solid Flux Application Process
AT&T Bell Laboratories (Princeton, NJ) developed a patented process in flux technology which has been
implemented at several AT&T manufacturing facilities, including AT&T Network Systems in Columbus, Ohio
where telecommunications systems are manufactured. The Low Solids Fluxer (LSF), reported to be a
significant advance in flux technology, is available to electronic manufacturing companies other than AT&T.
This technology could aid the entire electronic industry in their effort to phase out worldwide
chlorofluorocarbons (CFCs) production by the year 2000, as part of an international agreement (the
Montreal Protocol).
The Columbus plant was the first AT&T facility to completely convert to the new system (August 1988).
By utilizing the LSF-2000 (shown schematically below) to precisely control and monitor low-solid flux
coatings, the Columbus plant has reoorted the following source reduction benefits:
Main Control Cabinet
Flux Delivery System
ADVANCED APPLICATOR OF LOW SOLID FLUXES (Source: AT&T Bell Laboratories)
elimination of excessive
flux resulting in elimination
of postsolder cleaning
processes;
total elimination of the
perchloro-ethylene (PCE)
postsolder cleaner they
had used (a reduction of
30,000 gallons per year);
and
reduction in product flux
material used (estimated at
2,000 gallons).
These achievements, in conjunction with the elimination of monitoring and reporting of hazardous
materials losses and elimination for the need of solvent recovery and carbon adsorption facilities, have
resulted in cost savings at the Columbus plant estimated at $145,000 per year.
The electronics industry has used solvents containing CFCs and other chlorinated compounds
extensively for cleaning components during manufacturing, most notably for removing excess fluxes from
printed circuit boards. Flux, a cleaning and wetting agent, is applied prior to soldering to enhance
adherence of the solder. Therefore, if application of excess flux can be minimized or eliminated, then the
chemicals (which often include CFCs) used to remove excess flux can be minimized or eliminated.
Several no-clean fluxes are available on the market, and are designed to leave minimal residue. These
fluxes are categorized as low solid fluxes and contain 1-5% nonvolatile material by weight, which is
considerably less than the conventional fluxes that typically contain 25-35% nonvolatile solids by weight.
Although use of these low solid fluxes without special application methods would significantly reduce flux
residues, extensive research by AT&T indicated that even these small amounts of residue may present
23
-------
problems relating to product reliability. Thus, the LSF applicator was designed to eliminate all residues to
Insignificant levels.
AT&T's new process allows flux coatings to be precisely controlled and monitored during application.
Used prior to wave-soldering, AT&T's LSF contains a spray fixture that allows for precise adjustment to
achieve controlled uniform flux coverage. Deposition density and uniformity is critical to the successful use
of low solids flux.
"Stand Alone Model" Low Solids Fluxer
Source: AT&T Bell Laboratories
The LSF is installed inside of or adjacent to existing wave-soldering equipment. The device uses a
mechanism which traverses the flux spray gun perpendicular to the direction of the board to ensure
consistent coverage of predefined flux density across the entire length of the board. This spray fixture
yields a fine, precisely directed spray pattern and traverses back and forth at a speed determined either
by the operator or, as an option, automatically regulated based on conveyor-line speed requirements.
Therefore, traversing speed of the spray fixture can be regulated, in accordance with the conveyor speed
of the production line, to maintain uniform deposition rates as conveyor speed is varied. The operator
controls flux deposition by changing the air pressure applied to the flux tank. The flux deposition range is
adjustable over a wide range.
The LSF consists of two major components, the flux delivery system and the control cabinet. The flux
24
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delivery system which is comprised of a self-cleaning spray gun, traverse mechanism, and exhaust hood
with safety sensors, is mounted in the wave-soldering machine. The free-standing control cabinet contains
all electrical and pneumatic control systems. An easy-to-use operator control panel provides visual and
audible feedback when operator intervention is required.
To control flux vapor, the LSF contains an exhaust system. The LSF's hood is designed to capture and
remove flux overspray. To prevent flux vapor build-up, a sensor automatically shuts down the system when
the exhaust hood is removed and an air-flow sensor shuts down the system when there is no air flow in
the exhaust.
The consistency of AT&T's most advanced flux applicator is reported to allow for a uniformity with ±15%
variation and a repeatability of ±10%. Topside deposition and residue are undetectable. The solderability
of the board is reported to be greatly increased while allowing subsequent soldering processes to yield
consistent topside fillets.
NOTES:
Company Contacts:
Magit Elo-Genther/Head of MTG
Manufacturing Tech Group
(Developer) (609) 639-2238 and
Dr. Leslie A. Guth/Flux Expert
(609) 639-3040
AT&T Bell Laboratories
Engineering Research Center
P.O. Box 900
Princeton, NJ 08540
(609) 639-3040
Girish Parikh, Sr. Engr.
AT&T Network Systems
6200 East Broad Street
Columbus, OH 43213
(614) 860-5594
References:
. "To Clean or Not to Clean? AT&T
Studies the Behavior of Low-Solids
(no-clean) Fluxes", by Leslie A.
Guth, Circuits Manufacturing, Vol.
29, No. 2, p. 59, February 1989.
Nomination Information for Annual
Governor's Award for Outstanding
Achievement in Pollution
Prevention (State of New Jersey),
submitted by AT&T, February
1991.
"Elimination of Perchloroethylene in
Wave Soldering Using Low Solids
Fluxer". Presented by G.D.
Parikh and G.M. Renner at the
National Electric Packaging and
Production Conference, Anaheim,
CA, February 27, 1990.
25
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BURKE MILLS, INC.
VALDESE, NORTH CAROLINA
Minimization of Waste Solvent and Recycling of Solid Waste in
the Textile Industry Through Recovery and Reuse
Burke Mills, Inc. - Frank Gaddy Yarn Division, located in Valdese, North Carolina, is a yarn plant that
employs approximately 325 people. The plant produces high twist filament yarn for the neckwear emblem
and sewing thread industries. The company is also involved in texturing of polyesters and has a dyehouse
for spun yam, filament yarn and stretch nylon.
The plant uses the solvent 1,1,1-trichIoroethane (1,1,1-TCA) for removing greases and oils from yarn
cleaning machinery parts. In the spring of 1985, the company determined that they were contaminating
approximately 450 gallons of 1,1,1-TCA with either the oils and greases, or dyes and chemicals from
cleaning the finished product. Proper disposal of the spent solvent cost $650 per 55 gallon drum.
Through bulk purchasing of the 1,1,1-TCA in 3,000 gallon shipments versus 55 gallon drums, the
company saved approximately $11,330 annually. Improved management practices (e.g., establishment of
a central distribution area) implemented by the company, coupled with the purchase of a distillation unit,
has resulted in better than 90% reclamation of 1,1,1-TCA solvent. As a result, the amount of hazardous
waste being disposed has decreased from 5,400 gallons annually to approximately 55 gallons annually,
with an associated cost reduction from $63,168 annually to $650 annually. Total annual savings was
reported to be $99,964, which resulted in a payback period of less than one month.
The company joined the South East Waste
Exchange in May of 1985 and became aware
of the solvent distilling unit at a seminar. The
company purchased the LS-15 Little Still
(manufactured by Finish Engineering Co., Inc.
of PA) for $6,800 after visiting other industries
that used the apparatus for recycling other
chemicals.
Even prior to purchase of the distiller,
Burke Mills made a significant change in the
purchasing of the solvent. By utilizing 'an
existing 6,000 gallon, stainless steel tank, the
company was able to acquire solvent in 3,000
gallon shipments. By eliminating drum storage
and handling, a central distribution area was
established which improved control over the
chemical and led to safer conditions.
The distilling unit (shown at right) operates at a low pressure and has a 15 gallon capacity per cycle run.
The spent solvent is sent through the recovery process. After completion of the cycle, the reclaimed
solvent is collected into designated containers and is tested by a certified operator before being issued for
use.
In addition to this solvent reclamation project, the Burke Mills plant is also involved in the recycling of
plastic cylindrical tubes that are the base of the yam, dirty and excess waste yarn and cardboard. As a
26
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result they have significantly reduced the solid waste that would go to the Burke County landfill.
The non reusable plastic tubes are sold back to the supplier, are melted and reformed into new yarn
tubes. The dirty and excess yarn is separated, baled and sold to a company in Fairmont, N.C. that chops
up the yarn and uses it for stuffing material (e.g., upholstered furniture, shipping, etc.). According to
company personnel, Burke Mills is one of the very few textile companies that granulates the yarn tubes,
which allows for their reprocessing. The recycling of yarn was initiated approximately two years ago. The
company places approximately 26,000 pounds of waste yarn in dumpsters every 5 to 6 weeks, which is
then sold for reuse. The photographs below and on the next page show the granulated plastic grinder that
processes the plastic to be recycled and the baled waste yarn.
Due to the trend in environmental regulations on halogenated solvents, Burke Mills has decided to
switch to an alternate cleaner that is non-toxic. Currently, the firm is experimenting with a number of
products that could replace the 1,1,1-TCA. By early 1992 the company foresees total elimination of 1,1,1-
TCA use. Their current inventory of the solvent is 860 gallons, which should preclude any further purchase
of the chemical. They continue to use the distillin'g unit to restill all dirty and used cleaning fluids for reuse
in cleaning operations. This process has a recovery rate of 85-90%. This process generates one drum
per year to year and a half of still bottoms. These drums are sent to a hazardous waste facility for
disposal.
The photograph mosaic above shows the granulated plastic grinder system that processes the plastic
for recycling.
27
-------
The photograph below shows the consolidated waste yarn that is reused for other applications.
NOTES:
Company Contact:
Ray Shaping
Burks Mills, Inc. -
Frank Qaddy Yam Division
Sterling St. P.O. Box 190
Vaktese, NC 28690
(704) 874-2261
Other Contacts:
Gary Hunt & Stephanie Richardson
N. Carolina Dept. of Environmental,
Health and Natural Resources -
Pollution Prevention Program
P.O. Box 27687
Raleigh, NC 27611
(919) 733-7015
References:
Entrant Form information submitted
to the State of North Carolina
Governor's Waste Management
Board.
Burke Mills, Inc.
Other:
Winner of 1988 Governor's Award
of Excellence for Outstanding
Achievement in Hazardous Waste
Management - Small Industry
Category.
28
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AMITAL SPINNING CORPORATION
NEW BERN, NORTH CAROLINA
Recycling and Reuse of Process Water/Reduction in
Dyebath Chemical Usage Via Automated Controls
Amital Spinning Corporation is a producer of high bulk acrylic yarn for the sweater trade. The
American/Italian, jointly owned company began its New Bern, North Carolina operation in 1988, and
produces approximately 200,000 pounds of yarn a week. Ninety percent of the yarn is dyed and the
remaining 10 percent consists of heather mixes.
The most significant wastestream generated at the plant in volume is waste water from processing dye
batches of yarn. In 1988 for instance, Amital used^ approximately 320,000 gallons a day to process 12 dye
batches of yarn per day. Water usage and disposal cost the company over $26,000 per month. Thus,
Amital implemented measures to reuse both non-contact cooling water and contact production water. Non-
contact water refers to water that is circulated through the coils, which is necessary to cool the fiber during
critical stages. Amital's dying equipment operates with a four to one water volume to liquor ratio.
The overall water reuse program resulted in a significant cost savings and reduction in waste generation.
The 1990 water volume was 102,000 gallons/day for processing 20 dye batches/day. The water/waste bill
from the City averaged <$13,000/month. The result was a savings of approximately $13,000 per month,
or payback of less than 30 days. It also resulted in a water use/waste generation reduction of 60%, with
an increase in batches produced.
Amital purchased three 5,000-gallon, salvaged, stainless steel tanks and placed them adjacent to dye
vessels (see photo on the next page). The circulated water from the cooling coils is piped to the three
tanks through a temperature activated diverter valve. This valve was set to direct water over 140°F into
these "hot" storage tanks for immediate reuse. These "hot" storage tanks were then piped to the color
kitchen and prep tank. The color kitchen is used for dye weighing and is where dye liquor is prepared.
By using waste heat, steam requirements for generating heat during dying were reduced. Before purchase
of the tanks the heated wastewater was lost to effluent.
The cooling water which is less than 140°F is diverted to a tank farm where existing lines are used to
store it in an on-site aluminum tank of 102,000 gallon capacity. This water is then pumped back into the
water supply line to the dye house at 35 p.s.i. An altimeter switch, installed in the tank, controls the pump
to maintain tank water level at 17 to 21 feet. The city water supply line was installed with a spirex-sacro
pressure reducing valve to step the pressure from 55 p.s.i. to 30 p.s.i. so that the dye house can be run
on the tank water when available, or on city water when not available. The level in the tank is automatically
maintained in this manner.
The contact water is reused as Amital's production requirements will allow and is accomplished by
moving the water from the process tanks back into the preparation tanks. Once the process water is
recovered, the expended chemicals are replenished and the batch is ready for reuse. The company has
successfully recycled the water in this manner on a continuous basis without affecting quality.
Because the New Bern, NC facility is so new, Amital Spinning Corp. has made use of the most modern
technology, which has not only allowed for production efficiency, but has minimized waste as well. For
example, a computer program is used to give complete accuracy in weighing chemicals that are used to
help control the levelness of dye absorption. By automating dyebath flow and temperature for precise
control, a minimal amount of these chemicals (retarders and leveling agents) are used. As a result, the
29
-------
final dyebath exhaust
is essentially clean,
thus eliminating the
need for rinsing after
dying.
Another example
of utilizing modem
technology is the use
of a kier (a dying
machine) that has
packages in a
horizontal
configuration as
opposed to a vertical
configuration. By
using the horizontal
equipment as
opposed to a
conventional vertical
OBEM kier, the
company has reported an estimated 50% reduction in both water and chemicals utilization.
The water reuse implementation at Amital initially cost the company approximately $5,600. As a result
of the contact and non-contact water recycling, Amital's dye house reported a chemical savings of about
$45.00 per batch and reduced heat-up time by 8-10 minutes per cycle. The reduced heat-up time resulted
in fuel usage reduction of approximately 440 gallons per day. Water use was reduced 3,000 gallons per
batch recycled.
In addition to the examples previously mentioned, Amital has more recently (1990) made changes to
reduce fuel consumption and overall energy usage, including:
Reduction in #2 fuel oil consumption by approximately 100 gallons per day. By adjusting the
chilled water temperature set point upward by 6°F, the company was able to balance steam and
chilled water to achieve optimum temperature and humidity parameters. The result was the
operational elimination of one HVAC unit and one air washer and associated fan motors and
pumps.
Installation of a tower recirculation line that allowed towering of tower operation temperature and
improved the efficiency of the chiller. This aided in peak summer month energy savings of
$40,000 per month.
30
-------
Amital's Water Reuse System
X ^N
V ^
Dye
Vessel
/f^S^?*
V^S^L^
\siiy we
To
Cooling
Coils
uei rewu
Pump
.
Mixing Valve
Recovered Water
^^rr=^" w
Dwerier Valve 1
Outside
Storage
Tank
70,000 gal.
Preparation
Tank
Pumped to
Dye Vessel
(pump & line
not shown)
Recovered Water Tanks
30,000 gal. Total
Note: The hottest water returning from coils is stored in 3 tanks which will be used for next dye
cycle to preparation tank. The remaining hot water goes to outside storage to be used again
during cool down.
Source: Amital Spinning Corp.
NOTES:
Company Contact:
Brenda Waters, Director of Dying
Amital Spinning Corporation
P.O. Box 5407
New Bern, NC 28561
(919) 636-3435
References:
Amital Spinning Corporation
"Amital: State-of-the-Art Spinning
and Dying" by G. Robert Turner,
Textile Chemist and Colorist
Magazine, December 1989, pp. 23-24.
31
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CHEVRON OIL FIELD RESEARCH COMPANY
LA HABRA, CALIFORNIA
Equipment Redesign for Reduction of Waste Solvent
in Petroleum Production Research
Chevron Oil Field Research Company (COFRC), a subsidiary of Chevron Corporation, operates close
to 100 laboratories that conduct oil field related experiments for determining factors influencing oil recovery.
"Extraction experiments" are designed to determine the mineral composition and porosity of the core
samples, and yield data used for estimating the potential oil-holding capacity of the reservoir rock and the
ease by which the product can be pumped to the surface.
The extraction
agents used for these
tests include
halogenated
compounds such as
1,1,1 trichloroethane.
When these
compounds are mixed
with traces of oil
during the extraction,
a potential hazardous
waste is generated.
Approximately 300 to
400 gallons of spent
solvent/oil mix were
generated annually.
By recovering the
solvent from the
solvent/oil mix, the
waste reduction
achieved has been
somewhat
phenomenal; from 300 to 400 gallons annually to less than 1 gallon. Actual cost savings from reduced
disposal costs is approximately $2,000 annually.
In a successful effort to reduce the amount of hazardous waste being generated, the lab supervisor in
COFRC's Lab 3151 in La Habra, CA, designed and installed an additional piece of equipment that fits
directly on the existing hydrocarbon extraction unit. This piece of equipment, known as a "solvent saver",
separates oil from the spent solvent enabling recovery of the solvent within the extraction unit itself. The
tubular apparatus, shown as the center tube in the photo above, was crafted with the aid of another
COFRC employee who is the glass blower. The "solvent saver" essentially adds one additional distillation
to the extraction experiment.
The original intention for designing the unit was for recovering the 1,1,1 trichloroethane; however, the
device is reported to have good success with hexane, chloroform-acetone mixtures, and toluene. According
to the developer, the biggest impact of the unit has been reduced worker exposure, which is directly being
attributed to the ancillary device in the hood, thus enabling all recovery to be accomplished within the
confines of the hood.
32
-------
Because of the success of the unit, several of the units have been installed in the company's San
Ramon, California and Algiers, Louisiana laboratories. A patent application has been filed for the device.
Supplemental to the solvent recovery ongoing at the La Habra COFRC facility is a relatively new
computerized chemical inventory used for tracking relevant data for every chemical used throughout
COFRC's labs. The automated data base went on-line in November of 1988 and has led to a procedural
source reduction technique by reducing unnecessary ordering of chemicals and fully utilizing existing
inventories. The system enables researchers to enter an ID number on their desktop computer and retrieve
a comprehensive list of ail other researchers that have that certain desired chemical onsite. The chemical
inventory was expanded in the summer of 1989 and now includes approximately 3,500 chemicals that are
keyed to the particular regulatory list{s) in which the chemical appears.
The photograph at
the left shows the
99% plus pure
solvent being
recovered from the
"solvent saver" device
from within the hood.
The recovered
solvent is pure
enough to be reused
in subsequent
experiments,
whereas, before, it
was discarded.
Collection of Recovered Solvent
NOTES:
Company Contacts:
Bill Campbell/Larry Brooks
Chevron Oil Field Research Company
1300 Beach Blvd.
La Habra, CA 90631-6374
(213) 694-7000
References:
Chevron Save Money and Reduce
Toxics (SMART) Brochure
Chevron Oil Field Research
Company
American Petroleum Institute
33
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ATLANTIC RICHFIELD CORPORATION
CARSON, CALIFORNIA
Process Modification for Production of Substitute
"Emission Control" Fuel for Reduction of Air Pollutants
Although the state of California has the most stringent regulations in the nation for stationary and mobile
sources of air emissions, the air quality in the Los Angeles Basin continues to be the worst in the nation.
As a result, state and local authorities have included use of clean-burning non-gasoline motor fuels as a
mandate in their plans to address the problems. However, conversion to non-gasoline motor fuels will not
take place immediately. Currently, approximately 30% of vehicular pollution in Southern California is
generated by vehicles that lack catalytic converters and operate on leaded regular gasoline. These include
pre-1975 automobiles and pre-1989 trucks. . ,
Atlantic Richfield Corporation (ARCO) has developed a cleaner-burning fuel that can be produced by
current technology for use in these existing vehicles. The new gasoline, Emission Control - 1 (EC-1)
Regular was formulated to reduce carbon monoxide, nitrogen oxide, ozone, and paniculate matter to help
meet federal and state ambient air quality standards.
Based on the
results of exposure
and urban airshed
models (to be
discussed below),
ARCO projected that
if the EC-1 gas
formulation replaced
all leaded gasoline in
Southern California,
there would be a
reduction from 350 to
600 tons per day of
vehicular pollutants
(depending on
misfueling estimates).
This would be
equivalent to
removing 20% (or
320,000) of the old
vehicles from the
roads. Based on
ARCO's market in Southern California, the company estimates that around 100 tons of vehicle pollutant
are reduced daily. There are no cost savings associated with production of EC-1. ARCO reports that they
spend 20 per gallon more to produce EC-1 regular versus leaded regular.
EC-1 was developed between March and August of 1989 by a team of engineers and chemists at the
ARCO Engineering and Technology Center in Anaheim and the ARCO Los Angeles Refinery in Carson.
The team utilized its in-house gasoline component interaction model to define candidate fuel blends and
then employed the services of an outside firm for urban airshed modeling to screen the candidate fuel
34
-------
blends for ozone formation potential. The resulting EC-1 formulation contains no lead, but instead contains
methyl tertiary butyl ether (MTBE), a high octane component blended to a minimum of 1% oxygen.
The ARCO refinery in Carson, California was chosen as the production facility for the EC-1 formulation,
since it supplies the Southern California market which has some of the worst air quality in the nation. To
help generate raw chemicals, a new MTBE production facility was constructed at the Carson Refinery at
a cost of approximately $20 million (see photo on previous page).
This facility supplies all of the blendstock required for the EC-1 production. Other than constructing the
MTBE plant, the changes made at the Carson plant were operational. For instance, to reduce the vapor
pressure of the new gasoline (to reduce volatility), ARCO reduced the amount of butane blended into the
production process. The excess butane was sold or burned for fuel.
The Carson Refinery began producing EC-1 at a rate of 18,000 to 20,000 barrels per day, and the
refinery can produce 36 million gallons of EC-1 per month. The new formulation was introduced to the
public on September 1,1989, and is available at over 700 locations that sell gasoline (e.g. mini markets
tune up centers, and service centers) between Santa Barbara and San Diego. To implement EC-1, ARCO
had to install distinctive dispensers having larger nozzles for leaded gasoline to target the fuel to older
vehicles without catalytic converters and other emission control devices.
The newly formulated gasoline was fleet tested at two independent laboratories, the Southwest
Research Institute (SWRI) and the National Institute for Petroleum and Energy Research (NIPER). EPA
vehicle emission test procedures were strictly adhered to at both laboratories. The fleet consisted of 20
vehicles including 16 passenger cars and 4 light duty trucks. The reported summary of results are shown
below.
Summary of Results
Pollutant Reduction %
Hydrocarbons (exhaust) 5
Hydrocarbons (evaporative) 22
Carbon Monoxide (CO) 10
Nitrogen Oxide (NOx) 6
Benzene 43
Toluene 42
Xylenes 52
It should be noted that oxygenated and olefinic emissions were found to be somewhat hiqher
formaldehyde (+ 17%) and propylene (+ 17%). '
Systems Applications, Inc. (SAI) conducted a study for ARCO to analyze the effects of EC-1 emissions
in Southern California, and to project the consequent effect of those emission changes on episode ozone
levels in the South Coast Air Basin. SAI's urban airshed model (UAM) analysis for ozone air quality used
meteorological conditions occurring from June 5-7, 1985 as a baseline. This is the same episode
emphasized for all ozone modeling done in the development of the ozone portion of the Southern California
Air Quality Monitoring Program (SCAQMP). Their acute ozone exposure findings predicted that use of the
EC-1 fuel would result in 453,997 fewer person-exceedences of the federal ozone standard. Elimination
of on-road non-catalyst (NCAT) emissions was predicted to result in a 28% reduction; which, on an ozone
35
-------
exposure basis, EC-1 was expressed as equivalent to eliminating emissions from 20.5% of on-road NCAT
vehicles.
ARCO recently (September 1990) introduced EC-P gasoline for vehicles having catalytic convenors that
operate on unleaded fuels. Over the next ten years, the company plans to spend an estimated $2 billion
to convert both regular and premium unleaded gasoline lines into "emission control fuels". To make the
EC-P fuel, the Carson Plant reactivated a distillation column that had been out of service for several years.
This "dehexanizer", shown in the photograph below, removes certain carbon compounds in advance of the
catalytic reforming process. The result is a 300 barrels- per-day reduction in benzene production, which,
In turn, reduces benzene in the product fuel (EC-P) without increasing benzene in the other gasoline
grades. EC-P contains a minimum of 1.5% oxygen in the form of MTBE. The refinery purchases MTBE
from an ARCO chemical plant in Houston, Texas to supplement the refinery's production.
NOTES:
Company Contacts:
Doug Elmets, Director/
Media & Public Relations
1055 W. Seventh St
Los Angeles, CA 90017
(213) 486-3181
Mr. Leigh Noda
Mgr. of Refinety Technology
1801 EastSepulveda Blvd.
Carson, CA 90749-6210
(213) 816-8730
References:
« EC-1 Emission Control Gasoline -
Final Report, by L. Cohu, L. Rapp,
and J. Segal (ARCO Products Co.),
September 1989.
Analysis of the Effect of a New
ARCO Gasoline (EC-1) On Ozone
Levels in the South Coast Air Basin,
by Systems Applications, Inc.,
September 30, 1989.
Other:
Winner of Mayor's Award of
Excellence for Significant
Achievement in Pollution
Prevention
New Product Award - First place
California Society of Professional
Engineers
Air Pollution Technology Award -
South Coast Air Quality
Management District
. Product of the Year - Fortune
Magazine
36
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MAOLA MILK AND ICE CREAM COMPANY
NEW BERN, NORTH CAROLINA
Reduction of Dairy Waste Via Minimization of Product
Loss and Process Changes to Reduce BOD5 Load
Maola Milk and Ice Cream Company (Maola) is a multiproduct daiiy producing several milk products
«e;?t?rnilk> chocolate im'ta«on milk drink, etc.), frozen desserts, juices, and fruit drinks. By the end
of 1987, Maola had fully implemented a milk loss program and had completed several process changes
that allowed for the recovery and reuse of ice cream, milk and water.
The initial source reduction measures prevented the loss of an estimated 170,000 Ibs of milk and
decreased the biochemical oxygen demand (BOD5) by 17,000 Ibs. over an approximate 4 month period
,A,!P "u ' )- The resultin9 swings in dollars were estimated at approximately $24,000 per month
When the recovery process changes were included with the milk loss program, the company estimated that
it had saved in excess of $350,000 during 1988. As a gauge of how much waste was being reduced at
its source, the municipal treatment works which receives Maola's waste discharge, reported "profound
results" soon after Maola's efforts were implemented. Influent data to the City of New Bern Treatment Plant
showed a 14.7% reduction in BOD5 per day and a 22.8% decrease in suspended solids over a one-month
period, much of which was attributable to the Maola program. This aided the New Bern Plant in comDlyina
with the National Pollutant Discharge Elimination System (NPDES) requirements. Although difficult to
quantify, Maola's reduced BOD5 load also translated into reduced chemical usage, less sludqe
accumulation, and reduced power requirements for the New Bern Treatment Plant.
Maola's interest in
a planned operation
for reducing waste
began in 1986 with
the formation of a
research team,
consisting of the
co m p a n y
management and
North Carolina State
University (NCSU)
food scientists from
the North Carolina
Agricultural Extension
Service. This project
team conducted a
feasibility study for
reduction of waste
load by the
recovery/reuse of
_ _ process waste. The
Source: Carawan etal. 1987 scope Of the study
included: (1) a plant
sources of milk solids losses from the production processes, (2) identification of methods which coSuS?
used to reduce or recover and reuse the milk solids lost from the system, (3) development of a conceptual
ANIMAL FOOD HECOVERY SYSTEM
37
-------
design for a recovery/reuse system, and (4) evaluation of the costs and payback period for the identified
pollution prevention system.
Most of the waste load from dairy processing plants consist of milk products that are either intentionally
or Inadvertently lost to the sewer system. The survey team thus examined each activity that contributed
to product loss and waste load. Estimated waste loads were calculated from the amount of product lost
and the BODS of the product. Each loss activity was examined for reuse potential, as summarized in the
table below. The research team determined from their survey results (Carawan, et al., 1987) that 2,290
gallons per day (GPD) of high solids product/waste material were recoverable (a potential value of
$400,000 annually if used as ice cream ingredient), and approximately 120 GPD of ice cream could be
recovered (valued at $80,000 annually).
Thus, the research team Judged Maola to have the optimum potential for recovering as much as 2,410
GPD of ice cream ingredient valued at $480,000 annually. Product recovered and not used as an ice
cream ingredient could be beneficially used for animal food. One of the conceptual designs generated for
animal food recovery, from the research study, is shown diagrammatically on the proceeding page.
REUSE POTENTIAL OF MATERIAL
Safe for Incorporation Into
Ice Cream Production
Marginally Useful for Incorporation
Into Ice Cream Production
Suitable Only for Animal Food
Receiving Bay R/W
Heavy Foam from Cream Tanks
Raw Blend R/W
Pasteurizer Surge Tank R/W
Bag Fillers F/R/W
Cream Tanks R/W
Holding Tanks F/R/W
Freezers
Flavor Tank F/R/W
Pasteurized Surge Tank R/W
Jug Fillers F/R/W
Ice Cream Pasteurizer Vats R/W
Ice Cream Blender F/R/W
Raw Processing Tank R/W
Buttermilk Processing Tank R/W
Juice Processing Tank R/W
Clarifier Wash
Separator Wash
R/W - Rinse/Wash F/R/W - Flush/Rinse/Wash
Sourco: Uamwan et aL. 1SS7
From this initial recommendation, Maola has installed a system to recover product-water mixtures from
the High-Temperature-Short Time (HTST) Pasteurizing System (the major contributor to product loss and
waste load) and a raw rinse recovery for the Raw Cleaning-ln-Place (CIP) System. The HTST System,
basically a plate heat exchanger, is the main component of the pasteurizing process. When switching from
the pasteurization of one product to another, to prevent mixing of products, the HTST System must be
rinsed to clean out the remaining product in the system. Maola had in the past used water rinses to clean
out the system for discharge to the sewer. By diverting rinses between products to a recovery tank instead
of discharging the rinses directly to the sewer as was done before, most of the product is now recovered
for animal food. As the table on the next page indicates, about 90% of the rinse water is reused and
approximately 75,000 pounds of dairy solids and butterfat are recovered annually. A recovery tank was
also installed for the Raw CIP System, to hold recovered product from product lines that carry
unpasteurized milk after it arrives from the dairy farm. This recovered product is also used for animal food.
The table on the next page details the material diverted from the wastestream annually at Maola, as
reported by Bullard, et al. (1988).
38
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MATERIAL DIVERTED FROM THE WASTE STREAM ANNUALLY
Recovered
Material (Ib)
Butterfat
Dairy
Solids
HTST Rinse
(Reused)
Other Reusable Material
(Presently Diverted to
Animal Feed; Value Shown
for Reuse)
(Ib)
($)
70)
(Ib)
($)
939,120
245,960
1.4
13,148
18,802
3.5
8,644
12,361
8
61,981
23,555
12.5
22,136
8,412
Ice Cream Plant
(Recovered and Reused
Material)
Unreusable Waste
(Animal Feed)
(%)
(Ib)
($)
(%)
(Ib)
($)
117,000
804,960
8
9,360
13,385
0.5
4,025
0
32
28,080
10,670
4
28,174
0
NOTES:
Contact:
Dr. Roy Carawan
N.C. State - Food Science Ext.
Box 7624
Raleigh, NC 27695
(919) 737-2956
References:
"A Dairy Processor Does It", by
R. Bullard, J. Rushing, and R.
Carawan, Proceedings of the
N.C. Pollution Prevention
Program; Waste Reduction-
Pollution Prevention: Progress
and Prospects Within North
Carolina, Raleigh, NC, March 31,
1988.
"Detailed Plans for the Reduction
In Waste Load from,a Dairy and
Ice Cream Plant", by R. Carawan,
J. Rushing, and R. Bullard, Feb.
1987.
39
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MOUNT DORA GROWERS COOPERATIVE
MOUNT DORA, FLORIDA
Reuse of Washwater for a Fresh Citrus Packinghouse
The Mount Dora Growers Cooperative represents 46 citrus growers in central Florida. The
Cooperative's packinghouse, which has been a landmark in the city of Mount Dora for almost 75 years, is
where oranges, grapefruits, and tangerines are cleaned and prepared for shipment to out-of-state retail
outlets.
In 1988, the Cooperative became
concerned with the amount of wastewater it
generated. On a typical day, the Cooperative
generated 10,000 to 20,000. gallons of
wastewater. With the assistance of Boyle
Engineering Corporation, the Cooperative has
installed (December 1990) a water
pretreatment and reuse system that enables
the packinghouse to reclaim and reuse their
water 20 to 40 times over. The resulting daily
water savings can exceed as much as 19,000
gallons.
Waste washwater is generated from a
number of operations conducted at the
packinghouse, including detergent washing,
disinfection, waxing, and coloring. The
chemicals used in these citrus prep operations
are listed on the next page.
The fruit is first disinfected with a
chlorinated water spray, and then washed with
detergents and wetting agents to remove
pesticides, residuals, sooty mold, and dirt. A
soluble red color additive is then applied to
accentuate an orange color appearance to the actual yellow, yellow-green color of the fruit. The fruit skin
Is coated with an FDA food grade wax emulsion, primarily to seal the porous skin and lessen any
dehydration and help prevent spoilage during shipment. A fungicide is also added to retard spoilage.
The characteristics of the waste water depend on the type of citrus being processed. The water
generally contains residuals of cleaning chemicals, wax and oil, sand, sooty mold, and fruit debris (navels
and leaves). The strength (i.e., amount of chemical additives used) of the washwater is dependent on the
fruit type, time of season, and the condition of the fruit upon arrival from the groves.
The Cooperative had discharged its washwater to the local city waste water treatment plant (WWTP),
but switched to alternative means over concerns about the relative strength of the washwater. Parameters
of primary concern to the city are total Kjeldahl nitrogen (TKN), chemical oxygen demand (COD), total
suspended solids (TSS), oil and grease, and copper.
40
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TYPICAL CHEMICALS USED AT
FRESH CITRUS PACKINGHOUSES
Function
Disinfection
pH Buffer
Mold Stripper
DetergentWetting
Agents
Wax
Fungicide
Color (Early Fruit)
Canker Control
Other
Potassium Hydroxide
Sodium Hydroxide
Glycol Ether
Naphthalene Sultanate
Phenol
Non-Ionic Surfactant
Polyphosphate
Orthophenyl phenol
Ammonlated Wood Resin
Shellac
Thlabendazole
FDA Red Dye #2
Surfactants
Pine Oil
Ammonium Chloride
Quaternary Ammonia
EDTA
Traces of Grove-Applied
Pesticide/Herbicide/Fungicide
Source: Melearand Bouch, 1990
Source: Melear & Bouch, 1990
The Cooperative contracted Boyle
Engineering Corporation of Orlando, to
evaluate pretreatment options for the Coop's
combined washwater flow, which ranged from
10,000-20,000 gpd.
The pretreatment option chosen was a
coagulation, flocculation, and primary
sedimentation system. The pretreatment
system, which was started in October of 1988,
consisted of three primary components: a
10,000 gallon clarifier (see photo, on
proceeding page), a septic tank, and a drain
field. The performance, based on the average
of five monthly composite samples collected
between December 1988 and April 1989, is
shown below.
The modified septic tank system, which
serves as an aerobic digester and sludge
thickener, receives sludge 2-4 times a day.
Supernatant overflows to a drain field;
stabilized solids are removed periodically and
are applied to a local citrus grove owned by
the Cooperative.
The reuse system was developed in conjunction with the pretreatment system and created a clean
technology that allows reclaimed water to be reused approximately 20-40 times before being replaced. The
system includes a 1,100 gallon polypropylene reservoir (see photo, proceeding page), a two HP
recirculation pump, a canister filter with a removable micro-mesh cartridge element, and a chlorinator. A
flow diagram of the Cooperative's washwater reuse facilities is shown on next page.
The effluent drains by gravity into the reservoir, which
provides adequate contact time for chlorination (in accordance
with State regulations - Chapter 17-610, F.A.C.). Chlorination
also minimizes algae growth in the reuse system. If necessary
make-up water is added to the reservoir from the potable water
system. A surfactant is used periodically to reduce foaming
that is caused by the color-add process for early season
oranges.
PRETREATMENT PERFORMANCE
Parameter Removal (%)
Four reported benefits of the new pretreatment and reuse
system are: 1) water conservation, 2) compliance with water
restrictions, 3) use of a viable disposal method and, 4) lower
operating costs.
TSS
COD
BOD
TKN
TP
Copper
OH & Grease
78
60
50
49
63
61
60
The capital cost of the pretreatment system was approximately $15,000, and $5,000 for the reuse
system. Annual operating cost are approximately $8,000. The plant Cooperative spends less than 1 1/2
hours each day on facility operation.
In the citrus growing areas of Florida, water and sewer charges are currently $2.00 - $5.00 per thousand
gallons and are expected to significantly increase in the future. Based on figures accumulated since
41
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MOUNT nnRA RRnuFPS rnnpFRnriVF
Det
CRATED
FRUIT -i
DELIVERY '
CRATE & T
TRAILER.RI
t
Reclaimec
1-2 rag/1 C
REUSE STRE
RESERVO
t \
WASHHATER REUSE FACILITIES
ergent Chlorine Wax Emulsion Red Dye
'-* HASHING-1* DISINFECTION -^> WAXING -f-»COLORATION > DRYING > BOXING
t t t
1 1
| Reclaimed Mater
1-2 mg/1 Chlorine
Quaternary
Amonluffl
RUCK . PACKINGHOUSE . PRETREATMENT ,, REUSE
HS1NG > WASHWAiER A > SYSTEM * SYSTEM
Water 1 10 mg/1 aluminum chloride
hlorine u
0. 5 mq/1 polymer
AH
TO "jPECYCLE PUMP > FILTER >RECLAIMFP WST|:n
^ A A
Hake-up Water
Clilorinu I.HIUI i"=
Surfactant
Note: Dashed (- -) lines indicate processes (i.e. coloration) which are not conducted on late season fruit.
Source: Melearand Bouch, 1990.
system start-up, the Cooperative has estimated a reduction of total water usage and sewer disposal costs
from $750/month to $25/month. Although there are added chemical purchase costs of approximately
$150/month, the Cooperative estimates that it will recover initial capital costs within 2-3 growing seasons.
NOTES:
Company Contacts:
Robert Blairs, General Mgr.
Mount Dora Growers Cooperative
P.O. Box 36
Mount Dora, FL 32757
(904)383-4114
Erik Melear
Boyle Engineering Corp.
320 E. South St.
Orlanda, FL 32801
(407)425-1100
References:
"Pretreatment and Reuse of
Washwater for Fresh Citrus
Packinghouses", by E. Melear and
D. Bouch, presented at the Fourth
Annual Food Industry
Environmental Conference,
November 12-14,1990, Atlanta, GA
(sponsored by Georgia Tech
Research Institute).
42
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DOW CHEMICAL, U.S.A.
HEBRON, OHIO
Source Reduction/Recycling and Reuse of Solid Wastestreams
Associated With Production of Polystyrene and Barrier Films
Dow Chemical's Licking River Film Center, having approximately 130 full time employees, manufactures
polystyrene and barrier films used for a variety of applications. TRYCITE film (produced since 1969) is
used as window film in business envelopes, labels for bottles, and lamination on paper plates and cups.
SARANEX film which is produced by the Barrier Film Department, is used in food and medical packaging
as a barrier of odor and moisture. The primary solid wastes associated with the processing and packaging
of the film include loose film, off-grade film and process related waste.
Beginning in 1989, the Film Center has reduced landfill disposal by 600,000 pounds per year through
process modification, equipment redesigns, and improved quality control. Source reduction applications
have been implemented at the Film Center in conjunction with recycling efforts. Installation of state-of-the-
art winder technology has resulted in computer-controlled tension and consistent roll quality. As a result,
roll scrap is being reduced by 200,000 pounds per year. Installation of proprietary equipment to control
polymer degrading through the process has additionally reduced scrap and has extended process runs.
By reprocessing customer-returned film and off grade film, and resale of film trim, the Barrier Film
Department has reduced landfill disposal costs and total operating costs by $500,000 per year. The
Polystyrene Department has saved an estimated 75,000 pounds per year in landfill volume from the recycle
of resin and film, and an estimated additional 40,000 pounds per year by recycling polystyrene dust.
Also, the plant has reduced water usage by 3 million gallons a year by reducing single-pass cooling
water usage. Cooling water which is needed to cool extruded molten recycled polymer (before the material
can be made into pellets), is now recycled for the plants two largest streams that require cooling. Facility
Source: Dow Chemical, Hebron, OH
43
-------
employees have refined the existing cooling bath system to eliminate single-pass runs. Cooling water, that
was previously discharged to the sewer after one cooling pass is now recooled in heat exchangers and
reused. Other non-process-specific wastes recycled include scrap aluminum, steel, copper, cardboard,
and in-house paper (estimated at 90% recycle).
Waste reduction management was changed at the Film Center in 1990, from a generic recycle program
across their product line to one involving specific recycling practices for specific product lines. To
determine what waste streams within the plant could be targeted for recycling, a waste reduction team was
formed and consisted of production engineers, operating technicians and purchasing personnel. The first
task the team engaged in was the development of a process flow chart listing all raw materials, internal and
external recycle streams, and all discarded process and packaging material. A flow chart showing the
revised management approach for the Polystyrene Film Department is shown on the proceeding page.
After careful evaluation and research into available markets, the following materials were selected for
recycle consideration:
cardboard;
loose film, cut as samples for evaluation of film quality;
polystyrene dust and resin from processing of film;
pallets and end boards used in shipping film rolls;
scrap film and pallets from Licking River Film Center's customers; and
spent cooling water used to cool film production material.
It was determined
that the loose film
and scrap customer
film could be recycled
by the use of grinding
equipment as long as
plant quality
specifications were
met (see photo at
left).
Recovery of loose
film is accomplished
on-line and off-line.
The photograph on
the next page'shows
one type of off-line
film trim recovery
system, which
includes an unwind
stand and a cyclone
separator.
The polystyrene
dust and resin that do not meet plant quality specifications, are now sold to companies that can use the
material in other polystyrene products that do not require high grade clarity (i.e. polystyrene furniture).
Ongoing at the Licking River Film Center is a "Quantifying Waste Program". To fully implement this
program, it is planned to designate ons'rte compactors to a specific category of solid waste (completion is
estimated to be the end of the first quarter of 1991). Also, the center plans to monitor and quantify waste-
streams as related to waste of air, solid waste, hydraulic load, and non-aqueous liquid waste.
44
-------
Off-Line Recovery System
Source: Dow Chemical
NOTES:
Company Contacts:
Marvin Schmehl, Safety and Training
Director & Fred Houdesheli, WRAP
Coordinating Technician
Licking River Film Center
3700 Hebron Road
Hebron, Ohio 43025
(614) 929-5100
References:
Dow Chemical, U.S.A. - Hebron,
OH
Waste Reduction Always
Pays (WRAP) Sheet
Other:
DOW WRAP Program - 1989
Outstanding Achievement
Award Winner
45
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UNION CARBIDE PLASTICS AND CHEMICALS CO., INC.
SEADRIFT/TEXAS CITY, TEXAS
Recovery and Reuse of Raw Materials in Chemical Products/
Elimination of Toxic Metals in Cooling Water Treatment Via Product Substitution
Seadrift Plant
The Union Carbide Seadrift Plant is located along the southeast Texas coast approximately 130 miles
from Houston, Texas. The plant, one of Carbide's largest, employs close to 1,300 people. The plant
produces ethylene, glycols, amines, solvents, polyethylene, and polypropylene.
Seadrift's largest waste stream is a residue that contains high concentrations of vinyl acetate (VA) along
with heavier components such as poly oils. It is characteristically ignitable, making it hazardous under
RCRA. At its peak, this waste stream averaged over 5 million pounds per year.
In late 1987 the plant installed a VA recovery system on their High Pressure 2 Polyethylene Unit. This
recovery system began full-time operation in 1988. The project installation cost of this recovery system
was approximately $1.3 million and took 13 months to complete. After the first full year of operation,
documented raw material efficiency improved 10%. This resulted in a savings of $570,000. The volume
of the hazardous waste stream was decreased by 1.4 million pounds during this reporting period. No
additional manpower was added to operate the recovery system. Operational costs for the new equipment,
such as utilities and maintenance, have been minimal. Over the three year period of its operation the
recovery system has resulted in reported savings of approximately $2 million.
r ' ' >"t«i]n<
* ' '
46
-------
The vinyl acetate recovery system (photograph on previous page) is closed-loop recycle {see flow
diagram on next page). The residue is taken from the reaction system purge column and various
entrainment separators to the Recovery System ("Lights" Column Feed Tank), which operates at fairly low
pressures and temperatures below 100° C. In the feed tank some of the dissolved lights (ethylene and
propylene) are sent to a vent gas suction system. An inhibitor is also added at this point to prevent the
VA from polymerizing.
The residue stream is then fed to the Lights Column where the bulk of the dissolved ethylene and
propylene are taken out. This column contains a number of trays with an integral upward draft condenser.
The column operates under 20 psi and below 100° C.
The lights from the Lights Column go to the Flash Tank for disposal via thermal treatment and the
heavies (vinyl acetate and poly oils) go to the Vinyl Acetate (VA) Recovery Column. The VA Recovery
Column contains 21 trays below 20 psi and below 150° C. The column takes refined VA as an "overhead"
make at a reflux ratio of approximately 2. The recovered vinyl acetate is therefore able to be used as a
raw material in the original process.
Improvements were made to the recovery system during 1989 which resulted in another 10% increase
in efficiency. The calandria was revised to provide better fluid dynamics and heat transfer. Modifications
to recycle piping improved recovery during start-up, shutdown, and reactor upsets. Closer attention to
product scheduling and operating parameters (such as base temperature) have also allowed for
improvements with no additional capital investment. The control panel display has been modified to show
operators the cost savings in a graphic way to encourage optimization.
Texas City Plant
Union Carbide Chemical and Plastics facilities at Texas City, Texas is situated on approximately 120
acres. There are approximately 1500 employees at the location. The principal products produced here
are C2-C8 alcohols, aldehydes, and acids, vinyl acetate, and vinyl chloride monomers. The plant, which
has been in operation since 1941 also serves as a major redistribution point for many other products.
At this plant, chromates had been the preferred corrosion inhibitor in water treatment applications
because of cost and effectiveness. However, in April of 1988, the Energy Systems Department made a
switch in the treatment of the cooling water cycle that eliminated chromates and zinc from the plant waste
water stream. The switch was made to comply with stricter regulations placed on chromatic discharges
by OSHA and EPA and implemented by the Texas Air Control Board and the Texas Water Commission.
Initially, the corrosion rate of the new system was higher than expected. Adjustments were made in the
treatment program and the corrosion rates dropped to an acceptable level. As a result of the change to
the phosphate treatment program the plants discharge of chromates to the waste water system was
reduced to zero.
A stabilized phosphate treatment program by Betz Chemicals, Dianodic II, was chosen after several
water treatment programs were investigated. It's cost is about 2.6 times that of the chromate treatment.
Although this was not the lowest cost program investigated, it was chosen based on its effectiveness, ease
of implementation, and because phosphates are non-regulated chemicals. The switch in the treatment of
the cooling water cycle that eliminated chromates and zinc from the plant waste water stream was made
in April 1988.
The cooling water cycle is comprised of 11 cooling towers of various sizes and loads that contain
approximately 13 million gallons of water. The average blowdown rate of the cycle is 600 gallons per
million (gpm). The conversion was accomplished by allowing the chromates to drop from a normal level
47
-------
fe
Disposal
tad Fro«
wacUm Sjrttei
Rtcoftry
r««< Tank
^-*±!
H
i >
*-
i
Lights
Rnovll
Col urn
i
J
Vinyl Acetate
Recovery
ColUMR
^
Sv
! i» To Vinyl Acetate
Run Tank For Feed
Back To Reaction
avles to Disposal
of 50 ppm to less than 2 ppm by
ceasing the chromate feed.
The phosphates slug feeds to 3
towers. The stabilized phosphate
treatment requires that the pH of the
cycle be maintained between 7.2 and
7.8. The make up water (Brazos
River water) is normally about 8.0 pH,
therefore sulfuric acid has to be added
to control the pH in the required
range. When the cycle reached 12 -
16 ppm phosphate concentration, the
phosphate feed rate was adjusted to
maintain that concentration.
SEADRIFT PLANT
SIMPLIFIED FLOW DIAGRAM
VINYL ACETATE RECOVERY SYSTEM
Source: Union Carbide, Seadrift Plant
1) Feed and Hake Rates Vary With
Reactor Product
2) Operating Conditions Vary Ulth
Reactor Product
3) Major Equipment Only 1s Illustrated
Because the phosphate treatment
program requires tighter control of the
system pH and phosphate
concentration, chemical feed and
monitoring systems (BMAC 1300)
were installed at two cooling towers. Output from the BMACs is transmitted by phone lines to personal
computers in a central control room for data monitoring and tracking.
To monitor the effectiveness of the conversion, a test heat exchanger was installed throughout the cycle.
Plant personnel were able to track and control the heat load on the exchanger and visually inspect the
tubes for corrosion. Corrosion coupons were installed throughout the cycle. The coupons provided a
numerical value and visual indication of-corrosion. Corrosion meters were installed at three cooling towers
and measured instantaneous corrosion rates. Although not absolute the readings were used as data.
Numerous Inspections of various plant heat exchangers were performed as production units were down
for maintenance.
NOTES:
Company Contacts and References:
Seadrift Plant
Kathy Hunt
Sr. Environmental Engr.
Envr. Protection Dept.
P.O. Box 186
Port Lavaca, TX 77979
(512) 553-3058
Seadrift Plant
Mike Gohlke
Sr. Production Engr.
HP-2 Unit
(512) 553-2949
Texas City Plant
Stan Green. Plant Mgr.
Solvent & Coatings Div.
Energy Systems Dept.
Texas City, TX 77592-
0471
(409) 948-5514
Corporate
Henry Ward
Health, Safety and
Environmental Affairs
39 Old Ridgebury Rd.
Danbury, CT 06817-
0001
(203) 794-5270
48
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AMKO PLASTICS,INC
CINCINNATI, OHIO
Process Modification and Product Substitution for VOC Emission
Reduction in the Flexographic Printing Industry
Amko Plastics, Inc., located in Cincinnati, Ohio, is a decorative printer for packaging of consumer
products, retail store packaging and industrial packaging. Examples of printing include product
identification, assembly/use instructions, and advertisements that are typically seen on bags and overwraps
(see photo below).
The company employs approximately 280 people at their flexographic printing plant. Flexographic
printing is a rotary letter-press printing process that is dominant in the decorative polyethylene film printing
industry.
By switching from solvent-based inks to water-based inks, Amko Plastics has minimized their volatile
emissions by an estimated 88%. Due to the drastic reduction of alcohol solvent vapors, there has been
a noticeable improvement in the ambient air quality of the press room. The major costs incurred by Amko
from 1984 to 1987 (exceeding $2 million) have today resulted in the ability to print with quality and
productivity at the same level as U.S. solvent-based printers.
Generally speaking, the printing industry as a whole has been converting from solvent-based to water-
based inks for a variety of common printing operations for several years now. When Amko first began its
49
-------
program however, attempts to do the same for flexographic printing had resulted in little success. Amko
Plastics' conversion to water-based inks has recently attained a level of success that was envisioned as
far back as 1983 when the firm first experimented with water-based inks. From 1984 through mid-1987,
Amko experimented with newly, in-house developed technologies and techniques (many of which are
proprietary), which initially adversely affected their manufacturing operations. The photo below shows a
6-color impression flexographic printing press designed and specified for printing plastic films exclusively
with water-based inks.
For years, alcohol solvent inks have persisted as the preferred inks for printing polyethylene films for
the following reasons:
Alcohol achieves uniform wetting of the polyethylene surface, which prevents streaking, pin holing
and variegated color which diminishes visual quality of the product.
Alcohol dries rapidly after being applied to the substrate. In flexographic printing, inadequate drying
adversely affects the finished print quality and slows production.
The resin in the inks that carries and binds pigment and other ink additives to the substrate is readily
resoluble in alcohol. Poor resolubility of ink solids also diminishes print quality and increases
downtime required for press wash-up.
Although water-based inks for printing on low-density, polyethylene films were not available in 1983,
Amko chose to pursue the ink-switch alternative over alcohol recovery or installation of incinerator control
devices, based on a detailed cost analysis. Not until latter 1987 did Amko make a complete conversion
to new flexographic print technologies that emerged for use on a commercial production scale. Amko
50
-------
experimented with proprietary ink formulations. Following the decision to switch to a water-based acrylic
ink, additional experimental process changes and modifications were evaluated. Some of these included
the following:
to°alcohol-§as?dtintsVater
t0 maintain ink viscosity and Print
a variable not critical
fli d|yer heads between successive color print stations which directed heated air onto
printed film. To enable the increased drying capability needed for drying water-based inks, Amko
had to determine changes to air volume on and away from the printed film, specific air velocity as
the air impinges the film, and the proper amount of heat in the air.
a rfH,S£nf-th£'r ink meterin9 systems for handling a higher strength ink that was needed to achieve
a reduction in the amount of liquid in water ink that would in turn allow for thinner ink application and
reduced drying times (the previously used alcohol inks were applied in thicker layers, but still dried
quickly due to their volatility).
Determination of the optimum shape and number of cells that were needed for the anilox rolls to
achieve quality and productive printing. The anilox rolls transfer ink from the ink fountain transfer
roll to the printing plate. As water-based ink formulation continued to be improved, Amko replaced
its metal anilox rolls, which were having their wear-life drastically reduced as the use of water-based
ink increased, with more expensive ceramic rolls which last longer and offset initial cost increases.
H
roll.
'" the fountain r?," *«tex material to harder durometer rubber to improve wear-life of the
new ceramic rolls had an increased wearing effect on the fountain rolls.
1 systems and I equipment to inversely vary the percentage of resin "slip additive"
blended into the resin as the film was being extruded. Controlling the erucamid slip additive content
was essential for high speed printing with water-based inks, so that the blooming of this slip additive
on the surface of the plastic ("slip blooming") could be reduced. The more slip that blooms on the
surface, the more difficult it is for the water-based ink to adhere to the plastic print media.
n *"$ H rger ^orona tre-ating systems that enabled the electrostatic treatment of
the film surface at the higher surface tension required for water-based inks.
foam ^snjpn "sticky-back" from conventional "sticky-back" to compensate for the
pressure needed to achieve the greater amount of impression, required by water-based
inks, for uniform film wetting and transfer. Sticky-back secures the printing plate to the cylinder in
the press.
Having reduced substantially their VOC's emission, the company is now in the process of designing a
recovery system that will virtually eliminate the costly disposal of the plant's ink press wastes. This system
which is expected to be on-line in early 1991, will enable processing of ink solids for disposal as a non-
hazardous waste and will also enable the treated wastewater effluent to be discharged directly to the
sanitary sewer system. The payback for the recovery system is expected to be one year
NOTES:
Company Contact:
George A. Makrauer,
President and CEO
Amko Plastics, Inc.
12025 Tricon Road
Cincinnati, OH 45246-1792
(513) 671-1777
References:
"Innovations of Flexographic
Printing: Reducing VOCs with
Water-based Inks When Printing
on High-Slip Polyethylene Films",
by George A. Makrauer. Pre-
sented at the 80th Annual
Meeting of APCA, New York, NY,
June 21-26, 1987.
Amko Plastics Inc.
51
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TERRY PRINTING, INC.
JANESVILLE, WISCONSIN
Reduction of VOC Emissions Via Product Substitution and Recycling
of Solid Waste in the Commercial Sheet-Fed Printing Industry
Terry Printing, Inc. is a family-owned, full-service, commercial sheet-fed printer that produces instruction
manuals, sales sheets, catalogs, brochures, annual reports, and greeting cards. The fifty year old company
employs 38 people.
In 1989 Terry Printing replaced their petroleum-based inks with an ink derived from soy beans. The new
ink is used for all of the company's printing operations and has not required any conversions of equipment
for Incorporation (i.e., five-color press shown below).
Although Terry Printing has
not conducted monitoring of
emissions, the soy-based ink
manufacturer has reported
that the ink reduces volatile
emissions into the air by 65-
85%. In addition to changing
to soy-based ink, Terry
Printing implemented a major
paper recycling effort in 1989.
To date, an estimated 80%
reduction of paper and related
solid wastes has been
achieved. Measures to
recover silver film negatives
have resulted in resale of 6-
10 ounces of silver every six
to eight months.
Terry Printing first became familiar with soy-based inks from a Wisconsin advertising firm that works
closely with agribusiness clients. The advertising firm was curious about soy-based inks and requested
the printing company to contact Sinclair & Valentine, a developer of soy heat-set inks for magazines and
glossy paper printing. The developer first received a request for developing a sheet-fed, soy-based ink in
late 1988, and extensive lab work conducted in 1989 resulted in the development of a soy ink with drytime,
gloss and rub characteristics reported to be comparable to most conventional sheet-fed systems.
The major concern of replacing petroleum-based printing inks with the soy-based ink centered around
the drying time of the ink. Unlike newspaper inks, which dry by absorption and evaporation, sheet-fed inks
dry by oxidation. To solve this problem, the ink supplier had to develop a proprietary formulation of soy
Ink, petroleum oil, and dryers. To date, Terry Printing, the first sheet-fed printing company who pioneered
(according to their supplier) the use of soy-based inks in Wisconsin, has not incurred any problems with
delayed ink drying.
Soy ink was originally developed by the American Newspaper Publishers Association in 1985 as a buffer
against oil crises. The ink is made from refined soybean oil, which is the same product as vegetable
cooking oils. Much of the soy-based ink success has been measured in lithographic and letterpress
52
-------
newsprint printing processes in which ink is absorbed by the paper. Soy-based inks for heat-set and sheet-
fed printing, which have only been on the market since 1989, can be run on many types of sheet-fed
presses and are compatible with commonly used fountain solutions.
The environmental benefits of soy inks include reduction of VOC emissions, complete degradability of
the soy-based component, and easier and faster cleanup due to the excellent properties of soy oil.
Soybean oil is edible and is used in products such as vegetable oil, shortening, cosmetics, margarine, and
medicine. Ink manufacturers are producing the color soy oil inks with environmentally compatible non-toxic
pigments and other additives. Sinclair & Valentine, L.P. determined that their soy-based ink reduced VOC
emissions by 65-85% by heating the formulation in a vacuum oven at 110°C for one hour and measuring
the decrease in the formulation's weight (EPA Method 24/ASTM Method D-2369).
Another major drawback to the soy-based inks was the cost to sheet-feed printers. Terry Printing's
Vendor Partnership Programs soon solved the cost difference and is now paying the same price as they
would for conventional petroleum based inks.
Terry Printing is engaged in other waste
;y : reduction activities. The company recently hired a
service company that installed a filtration system
for their film negative wastewater. The system
contains magnetized brillo-like brushes that collect
silver and other heavy metals from the wastewater.
The silver is a commodity that can be resold.
Additional waste reduction measures include:
Introduction and continued use of
ecologically safe materials (i.e., aqueous
plates).
Recycling of aqueous plates and film.
Recycling of all in-house paper. The paper
is stored in large bins (see photo at left) and
approximately 3 tons per week is picked up
by a recycling service.
All self promotion and in-house computer
paper is recycled paper.
Closing the gap towards an alcohol free
pressroom.
53
-------
Tha photo at the right
shows the soy ink being
applied to the top of
a five-color press.
NOTES:
Company Contacts:
John Meyer
Dlr. of Sales and Marketing
Terry Printing, Inc.
1212 Plainfield Ave.
Janesvilta, Wl 53545
(608) 752-1517
Ron Szybatka
Sheet-fed Lab Manager
Sinclair & Valentine. L.P.
245 E. Marie Ave.
West St. Paul, MN 55116
(612)455-12?1
References:
Terry Printing, Inc.
Sinclair & Valentine, L.P.
American Soybean Association
54
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KENWORTH TRUCK COMPANY
CHILLICOTHE, OHIO
Reduction in Paint Waste Via Process Changes and Equipment Modification
Truck Production
1987
Base Year
Waste Paint & Still Bottoms
Pounds Generated
Disposal Costs
Detackified Paint
Pounds Generated
Disposal Costs
Pretreatment Sludge
Pounds Generated
Disposal Costs
Heavy Drums
Pounds Generated
Disposal Costs
88 vs 87
+32.1%
+6.6%
-30.9%
-27.9%
-24.1%
-15.1%
+57.3%
-73.3%
-77.4%
89 vs 88
+11.8%
The Kenworth Truck Company is a Division of PACCAR, Inc. The Kenworth Division consists of two
plants in the U.S., one in the State of Washington, and a facility in Chillicothe, Ohio. The Kenworth-
Chillicothe plant was built in 1973 and began production in 1974 at a low rate. The Chillicothe plant is
located on a 121-acre parcel of land, and current production rate at the facility is several times higher than
the original start-up rate. The plant employs over 850 people.
Kenworth produces class 8 trucks and specializes in custom paint colors and designs. This facility
assembles five different models. The production processes are primarily related to assembly and painting
while the majority of the components of the vehicles are manufactured at other sites.
Kenworth Truck
Company has
achieved a significant
decrease in overall
volume of waste
generated per truck
and associated
disposal and
transportation costs
from improved
housekeeping source
reduction measures.
These amounts are
shown in the table at
the right and take into
account increased
truck production
between 1987 and
1989. As a result of
their efforts,
Kenworth's waste
disposal cost per
truck was reduced by
over 77% from 1987
to 1989.
+29.3%
-74.0%
-46.2%
-41.0%
+24.2%
-30.5%
-100.0%
-100.0%
Source: Kenworth Truck Co.
Production is done on one main assembly line which begins with the chassis (frame rails) and ends with
a ready-to-start truck. Associated assembly/finishing procedures such as cab painting, door assembly,
phosphating of small parts, etc., are done on small assembly lines which incorporate their finished work
in the main assembly line. The assembly line is continuously moving and a tight schedule is required to
produce the required quantities in one 8-hour period.
A large portion of the wastes associated with truck manufacturing center around the painting operations.
Kenworth converted from conventional solvent paints to high solid paints on all trucks in 1989. This
55
-------
conversion includes most primers and top coats for cabs and chassis paints. The decision to use high solid
paints was based on the need to meet standards for volatile organic compound (VOC) air emissions.
Waste generated from the painting operations include 1) oversprayed spray paint, approximately one-
third of total and 2) still bottoms from the distillation of paint gun cleanout solvent, approximately two-thirds
of the total. The oversprayed spray paint is detackified; a process by which paint sludge is rendered non-
adhering and is done to ease handling of the paint waste. Detackified paint waste accumulates in the water
reservoir of four paint booths {3 for painting of cabs and one for painting of chassis). The photograph
below shows one of the cab paint booths; the water reservoir is beneath the steel grate floor.
Because of the relatively high temperature needed to apply single component paints that can damage
the fiberglass and plastic parts of truck assemblies, solvent-based plural (two component) systems are
used. Kenworth had used a "hot potting" method of component mixing which involved premixing two paint
components in the spray painting booth. However, in the spring of 1990 the company converted to use
of equipment which allows the catalyst component (the "activator") to be injected and mixed at the spray
gun during application. Prior to this, the activator was added to the paint in a pot. The activator would
solidify any leftover paint and render it as non-reusable.
fAt
*<*"& '&
OH
The catalyst injection system gives the paints an indefinite life span, thus, any leftover paint can be used
for touchup work. Paints mixed with the hot potting method have a pot life of approximately 3 hours at
72°F and consequently must be discarded if not used within this time period.
56
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In addition to switching to the catalyst injection system, Kenworth converted their paint spray guns in
the chassis booth to high volume-low pressure guns. Listed below were specific measures taken related
to this effort to minimize generation of waste paint.
Fitting the air regulators with locks to prevent operators from using a higher pressure, thus minimizinq
overspray.
Installing new air caps to reduce painting pressures from 60 psi to 40 psi.
Heating of paints to reduce their viscosity to allow use of lower air pressures (chassis paint is heated
to 95° to 100°F and most cab paints are heated to 110°F).
Improved efficiency of the solvent that cleans out the spray guns by injecting the solvent via air at
60 psi. This reduces the volume of solvent required.
NOTES:
Company Contact:
Ken Legner, Environ. Engr.
Kenworth Truck Co.
65 Kenworth Drive
Chillicothe, OH 45601
(614) 774-5227
References:
"Waste Minimization Opportunity
Assessment; A Class 8 Truck
Assembly Plant", Draft Report by
Science Applications International
Corp., 1990.
"Haz Waste Reduction Using
Organic Polymers", by D. Mitchell
and M.Schweers, Pollution
Engineering, March 1989.
Kenworth Truck Company
57
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SOUTHERN CALIFORNIA EDISON COMPANY
ROSEMEAD, CALIFORNIA
Elimination of Tailpipe Emissions and Reduction of Waste Oil Via
Incorporation of Electric Powered Vehicles in Fleet Transportation
THE ELECTRIC G-VAN
Battery Pack
Controller
1
Transmission
Electric Motor
Southern California Edison Company (Edison) provides electric power to over 4 million customers in a
50,000 square mile area of southern California. The company has more than 7,000 vehicles.
In the fali of 1989, Edison
purchased 15 electrically-
powered vans (EVs) and
initiated a loan program
(utilizing 9 of the vehicles) for
interested fleets. In less than
a year's time, over 50 private
and public fleets have
borrowed the vehicles for a
period of 3 weeks. Edison is
planning on as many as 15
EVs in its own fleet in 1991.
These EVs will replace
existing gasoline vehicles
(e.g., mail delivery vans, site
shuttle buses, etc.). Edison's
power plants have the .
capability to easily sustain
over a half million EVs. Source. SCE
FRONT
OF
VEHICLE
Charging Plug
The South Coast Air Quality Management District (SCAQMD) and the
Southern California Association of Governments adopted a 20-year air quality
management plan in 1989 to help the City of Los Angeles meet federal and
state air quality standards. The plan's goal is to have 40% of the new
passenger vehicles purchased by the year 2000 to be low-pollution-emitting
vehicles. Edison estimates that initial incorporation of the 15 EVs will reduce
fleet vehicle NOX emissions by 384 Ibs/yr, VOC emissions by 322 Ibs/yr and
CO emissions by 3,708 Ibs/yr. These figures are based on each vehicle
being driven an average of 50 miles per day, 250 days a year. However,
emission reduction potential has a much greater significance as increased
numbers of electric vehicles are incorporated into its fleet.
The EV utilized by Edison is called the G-Van, which is manufactured
cooperatively by General Motors, Vehma International Inc. and Chloride EV
Systems (a battery and electronics manufacturer). This one-ton
cargo/passenger van was designed for versatile use (e.g. carrying heavy
cargo, van pooling, shuttle services, etc.) and is reported to be an improved
version of the Griffin Van, a forerunner of the G-Van which is currently being
used in England. A schematic of the electric G-Van and a photo of its charging plugs are shown above.
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The G-Van has the following power sources:
Power Source
DC Electric Motor (216 V, 43 kW)
Lead-Acid Battery (216 V, 205 Amp-hrs)
DC Electric Motor (1.6 HP, 216 V)
Auxiliary Battery (540 cold cranking Amps)
Liquid-fueled Heater (diesel)
Off-board Charger (200-250 V, 35 Amps, 60 Hz)
Function
Main Power
Main and Auxiliary Power (i.e., lights, wipers, etc.)
Operation of hydraulic pump (for power
brakes/steering)
Auxiliary Power (115 minute reserve)
Heat in winter
Recharge of lead-acid battery
The G-Van has a range of approximately 60 miles under simulated urban driving, and has a top speed
of 52 m.p.h. Market research has indicated that about 60,000 of the 150,000 commercial fleet, light-duty
vehicles (about 40%) in Southern California travel fewer than 60 miles per day.
The Electric Power Research Institute (EPRI) conducted a study comparing the emission characteristics
of EVs (including the G-Van) with gasoline vans of the same type. According to EPRI, all emissions
associated with EVs come from the power plants that would supply the electricity, with the emission
characteristics dependent on the generation mix of fuels (i.e., coal, petroleum, etc.) used to generate the
electricity.
There are several direct and indirect sources of emissions associated with electrical energy production,
including mining operations, fuel transportation, and electricity transmission and distribution. EPRI used
all generation scenarios in their study, which ranges from fossil-fueled power plants to future cleaner power
plants.
The principal
emissions that
contribute to urban air
quality problems are
VOCs, NOX and
carbon monoxide.
VOCs and nitrogen
oxides are precursors
of ozone. The table
at right compares
California and U.S.
1989 emission
standards for
gasoline-powered
vans to EV emissions
under different
generation scenarios.
Fleet Van Emissions Associated with Urban Air Quality
(grams per mile)
GM Gasoline-Powered Van
Current Emissions
VOCs
NOX
CO
California
0.8
1.1
9.0
U.S.
1.1
1.8
10.0
Electric G-Van
Generation Scenarios
LA Basin
Current
0.02
0.17
0.02
U.S.
Current
0.02
2.5
0.1
U.S. New
Post-1995
0.02
0.7
0.1
Source: EPRI Technical Brief (1989)
EPRI concluded that widespread EV use could contribute only minimally to increased power plant
emissions of SO2 -~
and NOX.
The two primary capital costs associated with EVs are: (1) initial purchase of the vehicle and (2) battery
replacement. The G-Van's current higher initial cost is reported to be partially offset by an increased
vehicle life. Battery life is 4 years or 27,000 to 30,000 miles. Maintenance on the G-Van consists mainly
59
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of filling the lead-acid battery pack with water every three weeks. The vehicle requires approximately 8
hours of charging daily via a 220 volt, 50 amp wall socket.
Fuel and Maintenance Cost Comparison
(over life of vehicle)
Gasoline-
Powered Van
Fuel and Maintenance Costs
($)
An added benefit of the EVs is the
reduction in waste oil generated.
Based on Edison's normal servicing of
their gasoline driven vans, EVs would
result in an annual waste oil reduction
per van of approximately 5 gallons.
As reported by... Edison, there are
considerable fuel and maintenance
cost savings associated with this
alternate vehicle technology, as shown
graphically at the left.
Source: Southern California Edison Co.
NOTES:
Company Contact:
William R. West
Senior Environmental Specialist
Southern California Edison Co.
P.O. Box 800
2244 Walnut Grove Ave.
Rosemead, CA 91770
(818) 302-9534
References:
EPRI Technical Brief
Southern California Edison Co.
60
U.S. Government Printing Office: 1991648-187/40620
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