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

-------
 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

-------
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

-------
   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

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                                                                                     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

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 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

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 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

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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

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    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

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  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

-------
             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

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  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

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 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

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   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

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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.
                                           58

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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: 1991—648-187/40620

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