United States
Environmental Protection
Agency
Office of Research and
Development
Washington DC 20460
EPA/600/R-95/036
March 1995
                                      ••
Pollution Prevention
Case Studies Compendium
2nd Edition

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                                  EPA/600/R-95/036
                                  March  1995
           POLLUTION PREVENTION
         CASE STUDIES COMPENDIUM
                  2nd Edition
                     by

         Diana Kirk and Franklin Alvarez
         Waste Minimization, Destruction
         and Disposal Research Division
      Risk Reduction Engineering Laboratory
             Cincinnati, Ohio 45268
               Project Officers:

         Diana Kirk and Franklin Alvarez
        Waste Minimization, Destruction
        and Disposal Research Division
     Risk Reduction Engineering Laboratory
            Cincinnati, Ohio 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 Unrted S ates
Environmental Protection Agency. It has been subjected to the Agency's peer and fdrnm.strat.ve
review and it has been approved for publication as an EPA document.  Ment.on of trade names or
commercial products does not constitute endorsement or recommendation for use.        ;

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                                         FOREWORD
      Today's rapidly developing and changing technologies and industrial products and practices
frequently carry with them the increased generation of materials that, if improperly dealt with, can
threaten both public health and the environment. The U.S. Environmental Protection Agency is charged
by Congress with protecting the Nation's land, air and water resources.  Under a mandate of national
environmental laws, the agency strives to formulate and implement actions leiading to a compatible
balance between human activities and the ability of natural systems to support and nurture life. These
laws direct the EPA to perform research to define our environmental problems, measure the impacts,
and search for solutions.

        The Risk Reduction Engineering Laboratory is responsible for planning, implementing, and
managing research, development and demonstration programs to provide an authoritative, defensible
engineering  basis in support of the policies, programs, and regulations of the EPA with respect to
drinking water, wastewater, pesticides, toxic substances, solid and hazardous wastes, and Superfund-
related activities.  This publication is one of the products of that research and provides a vital
communication link between the researcher and the user community.

        This report is a second collection of  summaries of pollution prevention demonstrations,
assessments, and research projects conducted by the Pollution Prevention Research Branch.  The
Branch is charged with defining, evaluating, and advancing the technology for; the implementation of a
national pollution prevention program. It also provides technical assistance to other sections of EPA for
the purpose of reducing or eliminating pollution hazards.

        The information contained here will serve  as a reference work and technology transfer vehicle
to disseminate research results and promote the  implementation of pollution prevention activities.

                                   E. Timothy Oppelt, Director
                              Risk Reduction Engineering Laboratory
                                              in

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                                          ABSTRACT
   The Pollution Prevention Research Program encourages the development and adoption of
processing technologies and products in the United States that will lead to reducing the aggregate
generation rates for pollutants entering the various environmental media.  It includes projects to improve
the understanding of environmental problems that might be amenable to pollution prevention
approaches, and projects that demonstrate innovative pollution prevention approaches and',
technologies.  Pollution Prevention Research supports studies and research and demonstration projects
that are designed to further the utilization of source reduction and to a lesser degree recycling as
preferable environmental improvement strategies. Projects within the  program are supported through
in-house activities, contracts with outside organizations, and cooperative agreements with universities
and other government agencies.                ,                                     >

   The Risk Reduction Engineering Laboratory (RREL) serves as the  lead organization within the
EPA's Office of Research and Development for research related to pollution prevention. Spearheading
pollution prevention research within RREL is the Pollution Prevention  Research Branch (PPRB) of the
Waste Minimization Destruction and Disposal Research Division. Efforts cover all sectors identified in
EPA's Pollution  Prevention Strategy (January, 1991), i.e., manufacturing, agriculture, energy and
transportation, municipal water and wastewater, federal facilities and municipal solid waste.  The
program also contains a technology transfer element for incorporating results from other's research and
for disseminating the results of the program's efforts.                                  ;

   As a major part of the effort to disseminate the results of its research, PPRB has produced a second
compilation of case studies. These studies are the culmination of some of the major current research
efforts being conducted in the area of pollution prevention. It  is a compilation of summaries of pollution
prevention demonstrations, assessments and research projects conducted within the Branch.  We hope
that this compendium will facilitate the development and adoption of pollution prevention techniques
throughout the United States and other countries.


   This report covers a period of May  1992 to May 1994 and  work was completed as of February 1995.
                                               iv

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                                       CONTENTS
 Foreword . ..	                                                    :  »:
 Abstract ......	......		'.'.'.'.'.'.'.'.'.'.'.'.........   	" ' '."••'.•'JJ.
 Acknowledgments			..'.....;;!'.'.   	       vi

 Introduction	                                  ^

 Section 1 Waste Reduction Innovative Technology Evaluation Program (WRITE)

 Overview	                      |                      2
 On-Site Solvent Recovery	'.'.'.'.'.'.'.'}'.'.	4
 Ink and Cleaner Waste Reduction Evaluation for Flexographic Printers .. ..^	6
 Replacement of Hazardous Material in Wide Web Flexographic Printing Process   .............   8
 Recycling Nickel Electroplating Rinse Waters by Low Temperature Evaporation and Reverse OsmosislO
 Fluid Sorbent Recycling Device for Industrial Fluid Users	                   12
 NMP-Based Coatings Remover at Tooele Army Depot  	'.''.'.'.'.'.'.'.'.'.'.'.'.'.'.'.    14
 Bicarbonate of Soda Blasting Technology for Aircraft Wheels Depainting  ........ .....       '  16
 Electronic Component Cooling Alternatives: Compressed Air and Liquid Nitrogen  '.'.'.'.'.'.'.'.'.'.'.'.'.'. 18

 Section 2 Waste Reduction Evaluations At Federal Sites Program (WREAFS)

 Overview	                                       20
 Pollution Prevention Opportunity Assessment for Two Laboratories at Sandia National Laboratories   21
 Evaluation of Propylene Carbonate in Air Logistics Center Depainting Operations  .............' 23

 Section 3 University-Based Assessments Program

 Overview	_                                         2c
 Manufacturer of Parts for Truck Engines	..	..	  '..............            26
 Manufacturer of New and Reworked Rotogravure Printing Cylinders  	 	••••••
 Manufacturer of Electrical Rotating Devices	         "      '	29
 Manufacturer of Gravure-Coated Metalized Paper and Metalized Film       •••••••-•	
 Manufacturer of Paints and Lacquers  ..			
 Manufacturer of Surgical Implants		'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.'.	  	34
 Manufacturer of Mountings  for Electronic Circuit Components  ..'.'.'.'.'.'.'.'.'.['.'.'.'.'.'."-	35
Manufacturer of Microelectronic Components		33
Manufacturer of Coated Parts		.............       	40
Manufacturer of Finished Metal and Plastic Parts .-...'.'.'.'.'.'.'.'.	   	  	41
Manufacturer of Battery Separators 	.....'	-'.'.'.	   	'	43
Manufacturer of Folding Paperboard Cartons	-...'.'.'.'.'.'.         	45
Manufacturer of Pharmaceuticals	       	• • • • • • • • • •.
Manufacturer of Food Service Equipment	.I..   	         49

Index	
                               	""	i.	 Oi

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                                    ACKNOWLEDGMENTS
This report was prepared by Mr. Franklin Alvarez and Ms. Diana Kirk, EPA's Project Officers in the
Pollution Prevention Research Branch of the Risk Reduction Engineering Laboratory, Cincinnati, Ohio,
Appreciation is given to the large number of contributors to this report.  Contributions were made by
USEPA's Office of Research and Development, various Federal Departments, state pollution prevention
and research organizations, and members of industry.
                                               VI

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                                        INTRODUCTION
        As a major part of the effort to disseminate the results of its research, the Pollution Prevention
 Research Branch has produced this compilation of case studies. These studies are the culmination of some
 of the major current research efforts being conducted in the area of pollution prevention. It is a compilation
 of summaries of pollution prevention demonstrations, assessments and research projects conducted within
 the Branch.

        The compendium is separated into three sections, featuring three of the Branch's key programs The
 Waste Reduction Innovative Technology Evaluation  (WRITE) Program is a technology demonstration
 program conducted in cooperation with six states and one local government.  The focus of the research is
 to perform technical and economic evaluations of pollution prevention technologies. The Waste Reduction
 Evaluations at Federal Sites (WREAFS) Program focuses on performing waste minimization assessments
 at various Federal facilities.  The University-Based Assessments Program targeits small and medium-sized
 businesses in its assessment program. This program utilizes Waste Minimization Assessment Centers in
 Colorado, Kentucky and Tennessee to conduct waste minimization assessments for businesses which lack
 pollution prevention expertise. The two assessment programs follow the procedures outlined in the EPA
 Waste Minimization Opportunity Assessment Manual (EPA/625/7-88/003, July 1988)

        An overview of each program is provided at the beginning of each section of the compendium. The
 case studies are cross referenced according to key words in an index at the end of the compendium  The
 Information is  also provided on the EPA Project Officer  and the Principal Investigator conducting the
 research.  Case studies of individual EPA project summaries and environmental research briefs  may be
available from EPA's Centerfor Environmental Research Information (CERI):  U.S. Environmental Protection
Agency, Center for Environmental Research Information, 26 W. Martin Luther King Drive, Cincinnati, Ohio
45268.   Information on  obtaining project summaries for other reports is available by contactiha the EPA
Project Officer referenced.

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r
                                                        SECTION 1

                           WASTE REDUCTION INNOVATIVE TECHNOLOGY EVALUATION PROGRAM

                                                          (WRITD   -
              Overview

                     The Waste Reduction  Innovative Technology Evaluation  (WRITE)  Program  is  la  research
              demonstration program designed to evaluate the use of innovative engineering and scientific technologies
              to reduce the volume and/or toxicity of wastes produced from the manufacture, processing, and use of
              materials  It encourages the interaction of government and industry In the demonstrate and evaluate
              of available innovative production and recycling options for reducing waste generation.      .

                     The objectives of the WRITE Program are:

                      (1)     To establish reliable performance and cost information on pollution prevention techniques
                             by  conducting  evaluations or  demonstrations  of the  more promising. Innovative
                             technologies.                                                         !

                      (2)     To accomplish an early introduction of waste reduction techniques into broad commercial
                             practice.

                      (3)     To encourage active participation of small and medium-sized companies in evaluating and
                             adopting pollution prevention concepts by providing support to these companies through
                             State and local government agencies.

                      (4)    To encourage the transfer of knowledge and technology concerning pollution prevention
                             practices between large, medium-sized, and small industries.

                      (5)    To provide solutions to important chemical-, wastestream-, and industry-specific pollution
                             prevention research needs.

                      Under the WRITE Program,  EPA and seven cooperating state and county governments (California,
               Connecticut,  Illinois,  Minnesota, New  Jersey, Washington, and Erie County, New York](evaluate and
               demonstrate  the engineering and  economic  feasibility of selected  waste reducing technologies  in a
               manufacturing or fully operational setting.

                       Research efforts under the WRITE Program focus primarily on source reduction and: the recycling
               and reuse of waste materials.  The WRITE Program has completed, ongoing and/or future technology
               evaluations in the areas  of:  on-site solvent  recovery,  paint mixing/stripping, plating so ution recovery,
               solvent paint remover  substitiutes,  water-based inks as substitutes for solvent based inks, cutting fluid
               recycling, biodegradable solvents, CFC replacement/recovery, fluid sorbent recycling, vacuum  distillation,
               ion exchange, ultrafiltration and others.

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       EPA acknowledges  and appreciates  the  cooperation of the following organizations in the
administration of the WRITE Program:

       California:     California Department of Health Services (DHS)


       Connecticut:   Connecticut Hazardous Waste Management Service (CHWMS)

       Illinois:        Illinois Hazardous Waste Research and Information Center (IHWRIC)

       Minnesota:     Minnesota Technical Assistance Program (MnTAP)


       New Jersey:    New Jersey Department of Environmental Protection (NJDEP)

       Washington:    Washington Department of Ecology
       New York:
Erie County Department of Environment and Planning, Division of Environmental
Erie County, Compliance Services

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TITLE: On-Site Solvent Recovery

INTRODUCTION:  This study evaluated the product quality, waste reduction/pollution prevention and
economic aspects of three technologies for onsite solvent recovery: atmospheric batch distillation, vacuum
heat-pump distillation, and low emission vapor degreasing (LEVD). A comparison of the three units was not
the objective of the study.  Rather, the suitability of each technology to its respective application was
examined.                                                                          ;

BACKGROUND INFORMATION:  This study was performed under the U.S. Environmental Protection
Agency's (EPA's) Waste Reduction and Innovative Technology Evaluation (WRITE) Program.  It was a
cooperative effort between  EPA's Risk Reduction Engineering Laboratory (RREL) and the Washington
Department of  Ecology.  The  objective of the WRITE Program is to evaluate in a typical workplace
environment, examples of prototype or innovative commercial technologies that have a potential for source
reduction or recycling.                                              •'-.["'

TECHNOLOGY DESCRIPTION:  Atmospheric distillation is the simplest technology available to recover
liquid spent solvents. The unit can distill up to 55 gal/batch. Some units can be modified to operate under
vacuum for higher boiling solvents ( >135°C).  The unit was tested on spent methyl ethyl  ketone. The
distillation residue, often a relatively small fraction of the spent solvent is disposed of as hazardous waste.
The vacuum unit is configured similar to a conventional vacuum distillation system. The pump functions as
a heat pump which generates a vacuum  for distillation and compresses vapors for condensation. The
vacuum  unit was tested on spent methylene chloride.  The product quality objective for the two liquid
distillation  units was to show that the recycled solvent was of sufficient quality for reuse  and that the
recycled spent solvent volume was substantially reduced. Both methyl ethyl ketone and methylene chloride
are hazardous chemicals listed on the Toxics Releases Inventory (TRl). These solvents also  are on EPA s
list of 17 chemicals targeted for 33% reduction by 1992 and 50% reduction by 1995.
        Previous studies (Batelle 1992) on conventional open-top vapor degreasers have shown that a large
 part of the solvent (more than 90% in some cases) is lost through air emissions.  These losses can be
 considerable even though vapor degreasers are required to have primary cooling coils (tapwater cooled)
 and a certain freeboard height.  Air emissions are a concern for metal finishers because many solvents used
 in vapor degreasing have been targeted by EPA in the 33/50 Program.                   ;

 TECHNOLOGY EVALUATION: The two distillation units demonstrated that through recycling, large volumes
 of spent solvent waste were reduced to small volumes of distillation residue, which is disposed of as RCRA
 hazardous waste.  Also, the measured parameters showed a significant improvement from spent to recycled
          The main benefit of the low-emission vapor degreasing (LEVD) process is that it is a completely
 enclosed airtight unit. Testing was conducted on the LEVD using perchloroethylene (PCE) solvent. Test
 runs were conducted on machined steel parts with and without cutting oil on the parts. Adding oil to the
 parts did not greatly affect the total cycle time, but the workload mass did. The LEVD reduces air emissions
 by more than 99% compared to air emissions from the typical conventional open-top vapordegreaser.

 ECONOMIC EVALUATION: Compared to disposal, the atmospheric and vacuum distillation units reduced
 operating costs significantly. The estimated payback period for the units was found to be less than 2 years.
 The low emissions vapor degreaser is a slightly higher  capital investment  (with a payback  period  of
 approximately 10 years), but it eliminated the need for other potentially expensive auxiliary equipment that
 conventional vapor degreasers would require to meet comparable pollution prevention objectives.

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CONCLUSION: All three technologies evaluated demonstrated good potential for pollution prevention/waste
reduction. The two solvent distillation technologies reduced large volumes of hazardous solvent to a few
gallons of distillation residue and produced a reusable recycled product.  Onsite recovery is preferable
because of the reduced transportation hazard.  The largest single use for solvents in the United States is
for vapor  degreasing.   The  LEVD reduced air emissions significantly compared to emissions from a
conventional vapor degreaser. Payback periods for the two distillation technologies are less than 2 years.
The LEVD payback period is approximately 10 years.

PRINCIPAL INVESTIGATOR:  Arun R. Gavaskar
                             Batelle
                             Columbus, Ohio 43201

                             Ivars Licis
                             US EPA, RREL
                             Cincinnati, Ohio 45268
                             (513) 569-7718

KEY WORDS:  distillation, atmospheric batch distillation; vacuum heat-pump distillation; low emission vapor
               degreasing;   vapor  degreasing solvents;  methyl  ethyl  ketone;  methylene  chloride;
               perchloroethylene; on-site recovery; air emissions           •  • -.
EPA PROJECT MANAGER:

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TITLE:  Ink and Cleaner Waste Reduction Evaluation for Flexographic Printers

INTRODUCTION: Wastes are generated at most stages of the printing process.  Ink wastes result when
the reservoir, the various rollers, and the printing plate are cleaned at the end of a run. Excess ink in the
reservoir can be collected for reuse,  but the other ink quantities removed during cleaning generally
remain as waste.  Exceptional amounts of waste labels are generated during the production of multicolor
labels because of color registration difficulties.  Also, most printing processes begin with a photographic
negative. Developing the negative generates a number of chemical wastes that usually require special
treatment for either recycling or disposal. In nearly every step of the printing process some volatile
chemicals are released into the air. These volatiles can range from water to various alcohols, plastic
thickeners, homogenizers, and  chemical diluents.  In addition to volatile losses associated with inks,
adhesive and solvent molecules evaporate from the adhesive-coated label surfaces. Cleaning agents
used on the press will also evaporate into the air.

BACKGROUND INFORMATION:  This project originated with the Waste Reduction Innovative
Technology  Evaluation (WRITE) Program and was designed to 1)  quantitatively compare the volume and
toxicity of any waste generated during printing and released as gaseous, liquid, or solid waste before
and after switching to water-based inks and a detergent cleaner and 2) determine the economic effect of
modifying a  traditional printing technology.  The participating firm  was a narrow-web flexographic printer.
MPI Label Systems, Inc., of University Park, Illinois. Several years ago, management directed the
company's eight plants to eliminate the use of all hazardous and toxic materials.  The decision forced
each plant to substitute water-based inks for alcohol-based inks and to change from alcohol solvent
cleaning agents to aqueous-type cleaning agents.                                      !

TECHNOLOGY DESCRIPTION:  Laboratory measurement of solvent loss by evaporation for each ink
was used to estimate the percent volatiles.  By comparison, water-based inks contain less volatiles than
do alcohol-based inks, plus some  of the water (24%)  is bound to the resins and does not evaporate on
drying. The detergent cleaner as compared to the solvent cleaner was mostly water.  The amount of ink
and other materials  disposed of as liquid waste was determined gravimetrically.

TECHNOLOGY EVALUATION: The proportion of alcohol-based ink that evaporated was 48%,
compared with 56%-62% for water-based inks. The press operators at MPI  estimated that aboutthe
same total amount of either ink is required for a job.  Thus, the emission analysis is conservative for the
alcohol-based  ink. A toxicity reduction evaluation was calculated  for four printing scenarios.  For
estimated emissions to the air,  alcohol-based inks and cleaners had relative toxicities about 10 times
higher than  those for the water-based emissions.  Before MPI began using water-based inks|and
detergent cleaner, ft disposed solvent-based waste ink as a hazardous waste.  Although the total amount
of liquid solvent-based waste was  manifested in a year, MPI considered this information proprietary.  For
this reason,  and because MPI no longer uses solvent-based ink and cleaner, it was not possible to
measure the amount of alcohol-based ink and  cleaner wastes. In their experience, the same amount
was generated, but water-based inks aren't considered hazardous.

ECONOMIC EVALUATION:  Annual waste disposal and handling account for at least a savings of
$15,000. The facility saves about $500 each year because of lowered insurance premium based on
improved working conditions.  Savings because of new wiping materials equals about $1,000 annually.
Therefore, the total annual savings is $16,500.
                                               6

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CONCLUSIONS: The results from the change to water-based ink and cleaner are beneficial to MPI
Label Systems.  Solvent emissions to the plant air have been reduced. Toxicity of these emissions has
gone from potentially hazardous to nonhazardous;  And finally, solid waste generated and destined to
landfills has been reduced in volume and is no longer classified as hazardous. In addition, these
changes did not incur capital costs nor increased operational expenses.  Rather, the plant saves a
significant amount with reduced waste disposal, insurance, and cleaning material costs.

PRINCIPAL INVESTIGATOR:  Gary D. Miller
                            Hazardous Waste Research                                  '-'-"
                            and  Information Center                  V
                            Champaign, Illinois 61820

                            Michael J. Plewa
                            University of Illinois
                            Urbana-Champaign Institute for
                            Environmental Studies
                            Champaign, Illinois 61820

EPA PROJECT MANAGER:   Paul M. Randall
                            US EPA, RREL
                            Cincinnati, Ohio 45268
                            (513) 569-7673

KEYWORDS:  ink wastes; waste labels; printing processes; volatiles; alcohols; plastic thickeners;
              cleaning agents; water based inks; alcohol-based inks; detergent cleaner

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TITLE:  Replacement of Hazardous Material in Wide Web Rexographic Printing Process

INTRODUCTION: This study evaluated the effectiveness and applicability of ink substitutions to reduce
waste In a wide web (greater than 16 in. wide) flexographic printing process. This project was
completed under the Erie County/EPA Waste Reduction Innovative Technology Evaluation (WRITE)
Program as a Joint effort by Lustreprint Company (industrial participant).  Lustreprint was required to
submit to the New York State Department of Environment Conservation (NYSDEC) a monthly report
describing VOC emissions from the plant as a result of operations.  In 1974, the NYSDEC approved a
permit for air emissions from Lustreprint's two printing presses. When a 3 shift, 7 day-a-week work
schedule was Implemented in 1989, the total emissions exceeded the baseline criteria of 100 tons/yr of
VOCs.

TECHNOLOGY DESCRIPTION: New York's regulations require that a facility reduce overall plant
emissions to within the compliance level of 100 tons/yr.  As an option,  Lustreprint chose to reduce the
use of solvent-based inks and adhesives.  The first step eliminated solvent-based adhesives used in
laminating. This was followed by a phase-in of water based inks to replace the existing solvent-based
Inks in the printing operation. The company goals were to reduce all volatile organic air emissions to an
extent that would  eliminate the need for costly air abatement and permitting and to eliminate all liquid-
phase solid waste, characterized as hazardous waste at the facility. To achieve these goals, ink use was
monitored over four one-week-long study periods: 3-weeks when both water-based and solvent-based
Inks were used. Historical data for emissions and waste generation were extrapolated for comparison
with the weekly experimental data.                                                     !

TECHNOLOGY EVALUATION: Substituting water-based inks required press modifications.  The
installment of an in-line corona discharge treater  allowed the use of higher surface tension water-based
inks.  VOC emissions were reduced by approximately 72.5%,when compared with those for water-based
solvent. For every 1% increase in water-based ink use, VOC emissions were reduced 14 pounds.
Historically, 424 Ib/wk of solid waste was generated each month.  The  net result in week 1 was an 87%
decrease from normal in solid waste  generation (from 424 Ibs to 55.5 Ibs); a 95% decrease in;week 2 (to
20.0 Ibs); and 100% elimination of solid waste generation in weeks 3 and 4.

ECONOMIC EVALUATION: The payback period for the corona treater and equipment modifications is
2.56 years. The payback period could be further reduced by eliminating the solid waste disposal. With
the complete change over to water inks and the planned purchase of an  ink splitter (absorbs various ink
pigments on a cellulose-based porous material), additional savings for solid waste disposal is possible.
The payback period would then be reduced to 0.54 years. The economic evaluation indicates that the
decision to substitute the water inks for solvent inks was financially beneficial.

CONCLUSIONS:  This project resulted in a double benefit for Lustreprint: they have reduced their VOG
emissions and reduced process costs.  This successful implementation of water-based inks in
flexographic wide web printing should be considered as a VOC source reduction method for similar
printing operations.  Additional benefits from reduced VOC emissions and liquid hazardous waste have
been an Improved working environment: reduced indoor air pollutants,  reduced  handling of hazardous
solvents by employees, and a conscious effort by employees to reduce waste generation.

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PRINCIPAL INVESTIGATOR:  P. B. Kranz
                           Erie County Department of
                           Environment and Planning
        .                   Buffalo, New York 14202      ;          ,

EPA PROJECT MANAGER:   Paul M. Randall                                  -      :
                           US EPA, RREL
                           Cincinnati, Ohio 45268
                    .       (513)569-7673                           :

KEY WORDS:  ink substitutions; wide web flexographic printing process; VOC emissions; adhesives;
              solvent-based; water-based inks; press modifications

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TITLE: Recycling Nickel Electroplating Rinse Waters by Low Temperature Evaporation and Reverse
       Osmosis                                    .                                 :

INTRODUCTION: This project was performed to evaluate, compare, and document the effectiveness of
low temperature evaporation and reverse osmosis technologies for recovery and reuse of water and
plating bath chemicals associated with electroplating rinse waters. These technologies were examined
at a small scale at the HWRIC pilot laboratory facility by using actual rinse water samples collected from
a Graham Plating nickel electroplating line.  Nickel analyses were done to determine how efficiently the
systems removed nickel from the rinse water and concentrated it for potential recycling.  Analyses for
total organic carbon (TOO) were done to indicate the fate of organic constituents in the rinse water.
Electric conductivity was also measured following sample collection.                       ;'.

BACKGROUND INFORMATION: This project was a joint effort of Graham Plating, Chicago, IL, an
electroplating firm; the Hazardous Waste Research and Information Center (HWRIC), a division of the
Illinois Department of Energy and Natural Resources, Champaign, IL; and the Pollution Prevention
Research Branch  of the U.S. Environmental Protection Agency's Risk Reduction Engineering Laboratory,
Cincinnati, OH. Graham Plating will relocate to a new facility that is designed and constructed such that
special features have been installed to facilitate accumulation, segregation, and storage of rinse waters
by principal metal component.  This water can subsequently be treated through a reverse osmosis
system, a low temperature evaporation unit, or both.

TECHNOLOGY DESCRIPTION: Low temperature evaporators heat water under a vacuum to produce
steam at relatively low temperatures. The steam rises into a condenser where distilled water results.
The plating bath chemicals do not rise with the steam and become a concentrated slurry or splution  of
chemicals. Reverse osmosis is a pressure-driven membrane separation process in which a feed stream
under pressure (200-800 psi) is separated into a purified "permeate" stream and a "concentrate" stream
by selective permeation of solution through a  semi-permeable membrane. The pressure required to
force the permeate through the membrane is dictated by the osmotic pressure of the feed stream.

TECHNOLOGY EVALUATION: The low temperature evaporation system exhibited consistent
productivity throughout the tests. This performance feature was unfailing regardless of the chemical
concentrations of the feed solution provided to the system. The nickel concentration in the distillate
produced by the low temperature evaporation system was very low.  Additionally, TOC concentrations in
the distillate were very low.
       The reverse osmosis system exhibited superior productivity at the beginning of the tests, and
productivity dropped off dramatically  after about 60% of the feed solution had been processed.  Beyond
these levels, the productivity of the reverse osmosis equipment decreased dramatically as solids began
to precipitate and foul the membrane.  The reverse osmosis system, however, would probably produce
excess volumes of concentrated rinse water composed of 1.2% to 1.8% nickel. This material would have
to be further processed with the use of an alternative technology such as low temperature evaporation.
TOC concentrations averaged 19.46 to 21.98 mg/L in the permeate solution which suggests that some
of the organic compounds were able to permeate the membrane. Advantages of the reverse |osmosis
system include its relatively high production rates with respect to low concentration feed solutions.
The disadvantage associated with the reverse osmosis system is the lower quality permeate produced
by the system. The concentrate produced by the system does not meet the requirements for the plating
bath.
       The electrical conductivity data obtained in this project were well correlated with nickel
concentration, TOC concentration, and membrane flux characteristics. Accurate assumptions regarding
concentrate, permeate, and distillate could be based on electrical conductivity measurementS;taken
throughout the day.


                                              10

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ECONOMIC EVALUATION: Disadvantages of the low temperature evaporation system include its
relatively high ($140,000) capital cost and high energy requirements.  These costs, however, do not
consider the reduced future liabilities brought about by drastically decreasing the hazardous waste
discharges from the facility.  The reverse osmosis unit, on the other hand, would require lower capital
investment (about $50,000) than a comparably sized low temperature evaporation system.

CONCLUSIONS:  Both the low temperature evaporation and reverse osmosis systems appear to offer
advantages under specific operating conditions.  The reverse osmosis system is; best adapted to
conditions where the feed solution has a relatively low nickel concentration. The low temperature
evaporation system appears to be best adapted to processing solutions with relatively high nickel
concentrations.  Using the equipment within its optimum operating ranges would augment the ability of
the systems to process the rinse water with maximum efficiency while supplying the electroplating
operation with high-quality concentrate, distillate, and permeate solutions for reuse. Since the equipment
would always be functioning within optimum concentration ranges, a combined system of smaller
reverse osmosis and low temperature evaporation units would offer greater advantages than if the units
were used alone.  If this type of combined system were installed at the Graham Plating facility, it would
require a capital investment of $115,000 which would be paid back in 2.8 yr. through a 27.6% implied
rate of return.
PRINCIPAL INVESTIGATOR:
Timothy C. Lindsey
Hazardous Waste Research
and Information Center
Champaign, Illinois 61820
EPA PROJECT MANAGER:    Paul M. Randall
                             USEPA.RREL                         .i
                             Cincinnati, Ohio 45268
                             (513)569-7673                         ;:

KEY WORDS:  low temperature evaporation; reverse osmosis; recovery and reuse of water and plating
               bath chemicals; nickel concentration; rinse waters
                                              11

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TITLE: A Ruld Sorbent Recycling Device for Industrial Fluid Users                        :

INTRODUCTION: In the process of mixing, handling, and packaging of fluids, spills occasionally occur.
Spilled or splattered fluid is removed by hand with sorbent pads made of melt-blown polypropylene.
Once the pads are saturated with fluid, they are drummed for disposal. This study is a cooperative effort
between U.S. Environmental Protection Agency's  (EPA's) Waste Reduction Innovative Technology
Evaluation (WRITE) Program and Cook's Industrial Lubricants, Inc. in Linden, NJ.  The goal of this study
was to evaluate a technology that extracts fluids such as mineral oils, cutting fluids, and solvents from
sorbent pads by roller compression. The Extractor, manufactured  by Environmental Management
Products recovers the fluid by compressing the pads between two gear-driven counter-rotating rollers.
The Extractor has the potential to reduce the number of sorbent pads used and the volume of sorbent
pads and fluids sent to disposal.

TECHNOLOGY DESCRIPTION: Two types of wastes were considered in this study-spent sorbent pads
and waste fluid.  The roller compression method extracts the sorbed fluid and permits reuse of the pads.
The extracted contaminated fluid is then further processed for reuse.  Because fluid removal is
dependent on the fluid viscosity, tests were conducted with three different fluids covering a range of
viscosities. The ability of sorbent pads to leave a clean floor after  use was measured by the fluid pickup
test. The percentage of pickup by a new pad was compared with  that of recycled pads.

TECHNOLOGY EVALUATION:  The sorbent pad  recycling evaluation demonstrated that roller
compression technology can be effectively used to extract low- and medium-viscosity fluids from melt-
blown polypropylene sorbent pads.  The Extractor is particularly useful for low-viscosity fluid applications;
the sorbent pads can be used at least eight times. For medium-viscosity fluids, no more thaatwo to
three reuse cycles are possible.  For high-viscosity fluids, the sorbent pads can only be used once.  The
number of pads disposed of is reduced significantly as is noted  by the number of drums for disposal of
pads reduced from 24 drums to  6.5 or 1.6 drums. The 14 to 16 drums of waste fluids extracted from the
sorbent pads would be processed for  reuse or hauled away for disposal at a waste-to-energy facility.
The fluid pickup tests showed that regardless of fluid types, the sorbent pads effectively removed fluids
from the floor. Moreover, the sorbent pads effectively removed low- and  medium-viscosity fluids even
after they were reused four or eight times.

ECONOMIC EVALUATION:  For low-viscosity fluid, substantial savings occurred as a result of pad
recycling. Savings of up to 51.4% and 75.3% were possible with as few as two and as many as eight
reuse cycles. The cost per use was also greatly reduced, from $4.80 for  single use to $1.19 for eight
uses.  For medium-viscosity fluid, the annual pad  recycling savings were 50.5% and the per use cost
was $2.38 for two uses. Additional savings are unlikely since the sorbent pads became severely
separated and deformed as a result of the extraction process. The capital cost for the Extractor is
relatively insignificant ($699) and the annual savings is substantial,  therefore the payback period of the
investment is 2.8 to 5 weeks.

CONCLUSIONS: The roller compression technology shows potential for reducing sorbent pads used
and volume of sorbent pads and fluids sent to disposal. The sorbent pads exhibited enduring
performance to retain and remove low-viscosity fluids after being compressed repeatedly through the
Extractor.  The sorbent pads were largely separated and deformed after two (and more than three)
extraction cycles when used for  medium-viscosity fluids however.  The sorbent pads soaked with high
viscosity fluids did not pass through the Extractor and therefore, are disposed of after one use. The use
of the Extractor by shops and plants would result in annual savings of 51 %-75%.  Further savings can be
achieved by recycling the extracted  fluids.
                                              12

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PRINCIPAL INVESTIGATOR:  A. S. C. Chen                         ,
        •                   Batelle Memorial Institute               !
     ,                      Columbus, Ohio 43201-2693          •'   ;

EPA PROJECT MANAGER:   Johnny Springer
                           US EPA, RREL                                     ,
                           Cincinnati, Ohio 45268
                           (513)569-7542

KEY WORDS:  spills; mixing, handling and packaging of fluids; roller compression; sorbent pads; fluid
              viscosity; fluid pickup test; extraction cycles
                                            13

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TITLE: NMP-Based Coatings Remover at Tooele Army Depot

INTRODUCTION: The goal of this study is to evaluate a replacement solvent paint remover for
methylene chloride and other hazardous compounds that can be used to remove organic coatings, such
as enamels, lacquers, and varnishes from metal surfaces.  Methylene chloride is a primary component of
many cold paint removers and is one of the substances targeted by the 33/50 Program for use
reduction. U.S. EPA considers methylene chloride to be a hazardous air pollutant because of its low
exposure limit and high volatility. The paint remover to be evaluated is based on n-methyl-2-pyrrolidone
(MNP) and also contains monoethanolamine (MEA). NMP is a highly versatile solvent that has been
used for more than 15 years in the chemical and petrochemical industries.  MEA is used as a co-solvent
that helps accelerate removal of paint and other organic contaminants.                         - -

BACKGROUND INFORMATION:  Tooele Army Depot (TEAD) provided the site for this technology
demonstration. TEAD is a government-owned, government-operated (GOGO)  installation, located in
Tooele, UT, since 1943.  It is one of the 12 depots and 6 depot activities in the Depot System Command
(DESCOM). TEAD's primary function is to overhaul the Army's tactical wheeled vehicles and associated
secondary items, including trucks, trailers, engines and transmissions. TEAD also overhauls and repairs
many other types of troop support equipment, including generators, topographical and surveying
equipment, and reproduction equipment.

TECHNOLOGY DESCRIPTION:  The focus of this study is on the parts Chemical Cleaning
System(PCCS), which is designed for depainting, cleaning and parts and powertrain subassemblies.
Only the nonferrous cleaning line was the subject of this study.  Application of conversion coatings is a
surface preparation method to provide corrosion protection and increase adhesion of the paint coating.
PCCS is designed such that an automated overhead monorail transport baskets of parts through tanks
of paint remover  and various rinses, before applications of conversion coatings. The system employs
automatic controls to regulate tank solution levels, temperatures, agitation tank ventilation, tank heating
and solution filtration.
       This evaluated three objectives. First, the study evaluated the ability of replacement paint
remover to remove paints and compared these  results with those using the old technology (methylene
chloride).  The pollution prevention potential of the new paint remover and rinse water purification
system was evaluated. Finally, the economic potential of the paint removal process was compared with
the cost of using the methylene chloride paint removal system.                          • !
                                                                                  i
CONCLUSION:  To evaluate product quality, test coupons were made and processed through the paint
remover system along with actual parts. An equal number of coupons were coated with heat resistance
or chemical agent resistant coatings, the degree of paint removal from the coupons was qualitatively
evaluated. The baskets of actual parts were evaluated on a pass/fail basis.  To evaluate the pollution
prevention potential of the new paint remover solvent system, three process streams were evaluated.
Qualitative analysis of the test coupons and parts batches indicates that the NMP-based solvent
removed the paint as well as did the methylene chloride paint removal system.
                                              14

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PRINCIPAL INVESTIGATOR:  Bruce Sass
                           Battelle
                           505 King Ave.
                           Columbus, Ohio 43201
EPA PROJECT OFFICER:
Johnny Springer, Jr.
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7542
KEY WORDS:  replacement solvent paint remover; methylene chloride; n-methyl-2-pyrrolidone; rinse
              water purification system
                                            15

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 TITLE: Bicarbonate of Soda Blasting Technology for Aircraft Wheels Depainting

 INTRODUCTION: The goal of this study was to evaluate a bicarbonate of soda depainting technology
 that uses sodium bicarbonate based blasting media to replace chemical solvents, such as
 trichloroethylene C^CE), for stripping paints from aircraft wheels. Specifically, this study evaluated (1)
 effectiveness of this technology, (2) the waste reduction and pollution prevention potentials, and (3) the
 economics.

 TECHNOLOGY DESCRIPTION:  Bicarbonate of soda blasting is a relatively new process that is
 commercially available. Compressed air delivers sodium bicarbonate media from a pressure pot to a
 nozzle where the  media is mixed with a stream of water. The media/water mixture impacts the coated
 surface and removes old coatings from the substrate. The water used dissipates the heat generated by
 the abrasive process, aids the paint removal by hydraulic action, and reduces the amount of dust in the
 air.  As another convenience, the workers do not need to prewash or mask the surface. The dust, unlike
 that of plastic media, is not an explosive hazard, nor is sodium bicarbonate toxic in this form. The
 airborne partlculates generated from the stripping operation, however, can contain toxic elements from
 the paint being removed.                                                              :
        The effectiveness of bicarbonate of soda blasting depends on optimizing a number of operating
 parameters including nozzle pressure, standoff distance,  angle of impingement, media flow rate, water
 pressure, and traverse speed.

 TECHNOLOGY EVALUATION:  The waste reduction was measured in terms of volume reduction and
 pollutant reduction. Volume reduction addressed the gross wastewater such as liquid and solid wastes
 In the vat and wastewater in the rotoclone separator.  Pollutant reduction involved individual pollutants,
 such as oil and grease, total suspended solids(TSS), and heavy metals in the gross wastestream.
 Pollutants reduction addressed the specific hazards of individual pollutants.                 !
        About 30  gal of wastewater was generated  and collected in a vat during each of the blasting
 sessions.  Air emissions were measured in the breathing zone of the operator and analyzed for Cd, Cr,
 Cu, Pb, and Zn.  The cloud of mist created around  the blasting activity was maintained within the work
 area and removed by a ventilation system consisting of an exhaust hood and rotoclone dust separator.

 ECONOMIC EVALUATION: Cost comparison were made for bicarbonate blasting vs. chemical
 stripping.  Blasting times to strip each wheel were measured during the test.  NASA/JSC historical data
 were used to determine chemical stripping times. The capital investment, operating costs, and payback
 period were calculated according to the work sheets provided in the U.S. EPA Waste Minimization
 Opportunity Assessment Manual. The results of the economic analysis indicated that a return on
 Investment(ROI) greater than 15% (which is the cost of capital) could be obtained in 4 years, or payback
 period for NASA/JSC would be 4 years.                                        .        ;      •
                                                                                    i

 CONCLUSION: The bicarbonate of soda blasting evaluation concludes that the blasting technology can
 effectively strip paint from aircraft wheels. The blasting technology substantially reduced the number of
 man-hours required for paint stripping in comparison to chemical stripping.  The time saved Was more
than 95%.  The quantity to be shipped away as hazardous waste was about 7.5 agl/ T-38 aircraft wheel.
The solid waste in the vat contained paint chips and debris, most of which was  insoluble under the
toxlcity characteristic leaching procedure (TCLP) conditions. The wastewater in the rotoclone separator
 could be sewered without treatment. Although convenient for this application and for the existing local
limits, the source reduction of this waste as well as  reuse/recycling should be investigated in greater
depth.
       The blasting technology has good potential for reducing waste and the  consequent waste
disposal costs.  For the application studied, this is  primarily the result of changing the waste from a
                                              16

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RCRA hazardous Category to a nonhazardous category.  Paint stripping shops may find this technology
beneficial, especially as more stringent federal and local regulations are implemented for the disposal of
the toxic solvent-contaminated wastes.
PRINCIPAL INVESTIGATOR:   A.S.C. CHEN
                             Battelle
                             Columbus, Ohio 43201-2693
EPA Project Officer:
Ivars Licis
US EPA
Cincinnati, Ohio 45268
(513) 569-7718
KEY WORDS: bicarbonate of soda, depainting technology; replace chemical solvents; compressed air;
              media/water mixture; gross wastewater; oil;grease; heavy metals; total suspended solids
                                             17

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TITLE:  Electronic Component Cooling Alternatives: Compressed Air and Liquid Nitrogen

INTRODUCTION: This study evaluated the use of cold compressed air tools and liquid nitrogen as
methods for cooling electronic circuits while searching for causes of thermally intermittent circuit failures.
Aerosol cans of refrigerant(f.e., CFC R-12 and HCFC R-22), which commonly have been used in
electronics manufacturing and repair business for this purpose, served as the benchmark for the
evaluation. Six critical parameters were measure for each cooling method: accuracy, electrostatic
discharge risk, cooling capability, technician safety, pollution prevention potential, and economics.

TECHNOLOGY DESCRIPTION:  Aerosol cans of refrigerant, such as R-12 and R-22, are commonly
used in the electronics manufacturing and repair industries for trouble-shooting circuit boards that have
known or suspected thermally intermittent failure modes. Thermally intermittent failures occur-when
temperature changes and material expansion or contraction aggravate the mechanical failure to create
an electrical discontinuity condition. For example, if an electronic device works when first turned on  but
fails as it warms up in operation, a technician may spray refrigerant towards board areas or oh specific
components to reduce temperatures until the device begins to work again. The component that, when
cooled, causes the failure mode to appear or disappear is replaced. If the circuit failure mode still exists,
the troubleshooting process is repeated.                                                :
        The first alternative technology evaluated was a compressed-air tool that provides a continuous
stream of cold air that can be directed towards components. Compressed air enters a tangentially
drilled stationary generator which forces the air to spin  down the long tube's inner walls toward the hot-
air control valve. A percentage of the air, now at a atmospheric pressure, exits through the needle valve
at the hot-air exhaust. The remaining air is forced back through the center of the sonic-velocity
alrstream where it moves at a slower speed, causing a  simple heat  exchange to take place. The inner,
slower-moving air gives up heat to the outer, faster-moving air column. When the slower inner air
column exits through the center of the stationary generator and out the cold exhaust, it has reached an
extremely low temperature. To obtain temperatures in the range of -35 C to -40 C, the tool  requires
clean, dry, room-temperature air flowing at 15 scfm at 100 psi pressure.
        The second alternative technology evaluated uses liquid nitrogen. A 1/2-L Dewar flask can be
used with a release valve that allows a stream of nitrogen gas and liquid  droplets to be directed through
a small-diameter stainless-steel nozzle.  As the valve and the nozzle are cooled by the nitrogen flow, the
portion of the stream that is droplets increases and the output stream drops in temperature. A variety of
valves, nozzles, and heat exchangers are available to tailor the delivery and cooling characteristics of the
stream of nitrogen.  The Dewar flask can be refilled from a bulk container of liquid nitrogen.

TECHNOLOGY EVALUATION: Three factors determine how well a given cooling method will work to
Identify failing circuit board components: accuracy, electrostatic discharge risk, and the cooling rate  and
absolute temperature drop.
        * Accuracy - For this project, accuracy was defined as the  capability of a technician using a
cooling method to Identify a specific component with a thermally intermittent failure mode causing a
circuit board to have a thermally intermittent circuit failure mode. An accurate cooling method provides
a high component identification confidence (CIC) level, which avoids the cost of erroneously replacing
nondefecth/e components, potential damage created during component replacement, and multiple
iterations of testing and repair. The number and variety of test articles identified during the test period
were  not as great as hoped for. Also, the  results of the test article  evaluations do not support
comparisons of the accuracy of the cooling methods.   However, the results do indicate that the
compressed-air method was able to reproduce circuit failures in 12 of 13 test articles.
        * Electrostatic Discharge Risk - The amount of electrostatic charge buildup generated by the
cooling material as it is dispensed is a concern because components can be damaged by electrostatic
discharge. Two experiments were designed to compare the discharges generated.  Averages of each of


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the pairs of measurements indicate that both the compressed air and the liquid nitrogen alternatives
generated lower electrostatic charge buildup than did R-12.

       * Cooling Rate and Absolute Temperature Drop -'They*were measured for each method. The
absolute temperature drop data presented were used for direct comparison of cooling materials; but
cooling rate and temperature difference data were not used for direct comparisons.

CONCLUSION:  Neither alternative is expected to increase safety risks to technician when compared
with those of aerosol refrigerants. Handling of liquid nitrogen presents a safety risk in the form of
exposure to low temperatures. Compressed air generates a small amount of pollution in the forms of
waste compressor oil and filter elements, but the incremental increase in these wastestreams that would
follow adoption of the compressed-air method is not expected to be significant.
PRINCIPAL INVESTIGATOR:
Stephen Schmitt
Battelle
Columbus, Ohio 43201-2693
PROJECT OFFICER:
Johnny Springer, Jr.
US EPA
Cincinnati, Ohio 45268
(513)569-7542
KEY WORDS: cold compressed air tools; liquid nitrogen; accurate cooling method: electrostatic
              discharge risk; cooling capability; technician safety; aerosol cans; trouble-shooting
              circuit boards                                       .,
                                              19

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                                         SECTION*

                WASTE REDUCTION EVALUATIONS AT FEDERAL SITES PROGRAM

                                          (WREAFS1
Overview
       The Waste Reduction Evaluations at Federal Sites (WREAFS) Program consists of a series of
demonstration and evaluation projects for waste reduction conducted cooperatively by the U.S.
Environmental Protection Agency (EPA) and various parts of the Department of Defense, Department of
Energy, and other federal agencies.  The WREAFS Program focuses on waste minimization research
opportunities  and technical assessments at federal sites. The objectives of the WREAFS Program
Include: (1) conducting waste minimization workshops; (2) performing waste minimization opportunity
assessments; (3) demonstrating waste minimization techniques or technologies at federal facilities; and
(4) enhancing waste minimization benefits within the Federal community.

       The WREAFS Program facilitates the adoption of pollution prevention/waste minimizatipn
practices through technology transfer. New techniques and technologies for reducing waste generation
are identified through waste minimization opportunity assessments and may be further evaluated through
joint research, development, and demonstration projects.  The waste minimization opportunity
assessments follow the procedures outlined in the EPA Waste Minimization Opportunity Assessment
Manual (EPA/625/7-88/003, July 1988).  The major phases of a WREAFS assessment are:

       (t)     Planning and Organization: organization goaf setting

       (2)     Assessment: careful review of a facility's operations and wastestreams and the
               identification and screening of potential options to minimize waste

       (3)     Feasibility Analysis: evaluation of the technical and economic feasibility of the options
               selected and subsequent ranking of options and

       (4)     Implementation: procurement, Installation, implementation, and evaluation (at the
               discretion of the facility surveyed).
                                              20

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 TITLE: Pollution Prevention Opportunity Assessment for Two Laboratories at Sandia National
 Laboratories
                                                                   •ii " -              -
 INTRODUCTION: Sandia National Laboratories (SNL) is a federally owned DOE facility located in
 Albuquerque, NM. Sandia's primary mission is national security, with principle emphasis on nuclear
 weapons development and engineering.  As by-products of production, research and development, and
 environmental restoration activities, Sandia generates a variety of waste materials that are carefully'
 controlled during operations and regulated by the federal government and state and local agencies.
 Under the purview of the WREAFS Program, SNL and EPA conducted pollution prevention opportunity
 assessments (PPOAs) for two laboratories within the SNL complex. The PPOAs were conducted at the
 Geochemistry Laboratory (GL) aand the Manufacturing and Fabrication Repair Laboratory (MFRL) at
 DOE's SNL facility as part of EPA's WREAFS Program.

 BACKGROUND INFORMATION: The United  States government, through legislative and executive
 actions has mandated waste minimization as a national environmental policy. Federal statutes, such as
 the Resource Conservation and Recovery Act Amendments of 1984 and the Pollution Prevention Act of
 1990 affect all waste generators, including federal facilities.  To support pollution prevention activities at
 federal facilities, EPA has established the WREAFS Program.  WREAFS provides funding and technical
 assistance for pollution prevention efforts at a wide variety  of federal facilities

 TECHNOLOGY DESCRIPTION: The GL performs analysis of earth materials and simulates earth
 conditions. The types of research performed by the GL fall into three major categories differing in
 research control. The largest waste stream by volume, generated by the GL is Polaroid film backs from
 Scanning Electron Microscopy (SEM) photography. The use of prior waste generation data is not an
 optimal indicator of future waste generation to  measure the success of pollution prevention projects.
        The MFRL typically repairs printed circuit board assemblies (mother boards) for use in satellite
 systems.  Approximately 683 Ib/yr of waste are generated from the MFRL.  Bulk solvent accounts for
 approximately 88% of the waste generated. Wastes and  input materials are primarily related to board
 repair, but a portion results from repair of box  assemblies and cables.

 TECHNOLOGY EVALUATION:  The number of laboratories at SNL and the nature of laboratory work
 result in a large number of small quantity waste streams being generated.  This presents certain
 obstacles to pollution prevention initiatives.  The feasibility of pollution prevention opportunities
 discussed in the report is largely dependent on the attitude and confidence of SNL's researchers.  For
 the GL Laboratory, significant reductions in waste generation  can be achieved through education and
 training.  Building pollution prevention into research proposals is one of the most feasible initiatives.
 Site-wide pollution prevention opportunities offer the greatest  potential for waste reduction.  The site-
 wide options  identified are technically feasible.  The repair  room, vapor degreasing  room, and storage
 room for the MFRL were evaluated. Several options were identified for each waste stream.  Rinse water
 was tested to determine its toxicity and, therefore to determine its use for other non-potable purposes.
 Nonflammable, contaminated laboratory trash is placed in Zipiock bags. The Ziplock bags contain
 mostly air.  By keeping  a lined 20-gal polyethylene container in the  vapor degreasing room, the use of
 Ziplock bags  could be eliminated. Uncontaminated end-of-swab sticks could be reused by the
 technician after breaking off the contaminated ends. Eliminating bench cleaning would reduce the
 amount of solvent- and  flux-contaminated lab trash generated. In addition the number of wipes and
 swabs expended would be less.

 ECONOMIC EVALUATION: For the GL laboratory, increased costs are incurred initially, but the
 increase is offset by savings in disposal costs.  The rinse water testing results in annual savings of
$139.50.  The raw material cost savings from not having to  purchase Ziplock is estimated at $100.  A net

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annual savings of $128.40 would be achieved and the payback period is 0.24 years.  The net annual
savings for reusing swabsticks would be $22.28. The raw material cost savings are $26.15 for     ,
eliminating bench cleaning.  The expected net annual savings is $89.26 with a payback period of zero
years.  Therefore, the small savings from many laboratories can result in significant savings over the long
run.

CONCLUSIONS: For the GL laboratory, implementation of concepts identified during this WREAFS
project would further enhance SNL's pollution prevention program. EPA recommendations to DOE     ^
SNL include but are not limited to 1) building pollution prevention into research projects from the start 2)
escrowed closeout money can be set aside at the beginning of a project so that potential reuse, proper
characterization, and appropriate management of chemicals can be maximized, and 3) funding of site
wide projects to make the system more effective. These alternatives provide promising turnouts but the
recommendation with the largest potential for pollution prevention gains is to continue SNL's education
and training.  Of the four options evaluated  in detail for the MFRL, eliminating Ziplock bags appears to
be the most promising. The waste reduction achieved from any of the options evaluated is small, but
are easily implemented and savings could be gained quickly.
 PRINCIPAL INVESTIGATOR:  Science Applications International Corporation
                              Cincinnati, Ohio 45203
 EPA PROJECT OFFICER:
James S. Bridges
US EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7683
 KEY WORDS: geochemistry laboratory; manufacturing and fabrication; repair laboratory; earth
               materials; satellite systems; bulk solvent; small quantity waste streams; rinse water;
                                               22

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TITLE:  Evaluation of Propylene Carbonate in Air Logistics Center Depainting Operations

INTRODUCTION: The Strategic Environmental Research and Development Program (SERDP) was
established two years ago in order to sponsor cooperative research, development and demonstration
activities for the environmental risks reduction.  Funded with the Department of Defense(DoD) resources,
SERDP is an interagency initiative between DoD, DOE and epa.  SERDP seeks to develop environmental
solutions for federal activities that are applicable across the public and private sectors.

BACKGROUND INFORMATION: In September 1992, EPA completed a study of the use of 1,1,1 -
trichloroethane(methyl chloroform), xylene, and methyl ethyl ketone(MEK) (2-butanone) in aerospace
operations, due to their widespread use through the industry.  Considerable research on solvent
substitution for methyl chloroform is Ongoing due to this chemical's schedule phaseout in year end 1995
as a result of the Montreal Protocol. MEK and xylene are considered volatile organic compounds
(VOCs) and are listed as Hazardous Air Pollutants under the Clean Air Act. Various contacts within the
aerospace and defense community indicate that MEK and its regulatory and disposal issues are
significant problems within the industry and worthy of immediate research activities.

       MEK is a solvent used for depainting aircraft radomes at the Oklahoma City Air Logistics Center
(OCALC) at TAFB. TAFB removes paint from radomes on KC-135, EC-135, B-52, B-1, and E-3A aircraft.
In a large ventilated booth, MEK is applied to "depaint" the radome. The MEK attacks the primer
through scribed breaks in the topcoat. The paint starts to bubble after 30 minutes Of continuous
showering. As the primer dissolves, the topcoat is flushed away from the radome by MEK shower.
Topcoat residue is filtered from the MEK The solvent then flows to a sump for recycle back to the
spray header. The operation typically takes 1.5 to 3 hours. According to TAFB, a large percentage of
MEK is lost to the atmosphere through the booth exhaust system because of the chemical's high
volatility.  After the MEK application, any remaining paint residues are removed by hand sanding.
Topcoat chips are captured in a sump and disposed as hazardous waste. In 1991, 719 pounds of
topcoat chips were disposed, and an estimated 8,250 gallons of MEK evaporated to the atmosphere.

       From a  review of alternative paint stripping chemicals on the market, n-methyl-2-pyrrolidone
(NMP) has demonstrated potential for removing paint from structures with composite substrates. The
physical properties of NMP that make it favorable for the use in paint stripping are its low flammability,
low evaporation rate, solvency power, ease in blending with other solvents, and its potential
biodegrability.

TECHNOLOGY DESCRIPTION:  From its research and in cooperation with Texaco, RREL identified
solvent formulations based on PC and NMP as possible alternatives for MEK.  Texaco Chemical
Company demonstrated unique abilities in the area of solvent applications research and volunteered to
assist in the research.  For pre-screening, Texaco used a computer program to predict  properties of
various solvent blends and to select potential blends, based on criteria entered into the program.  The
selection criteria for the PC solvent blends included:
               * Nonhazardous  mixture
               * Low volatility
               * Safe to handle                                      ;
               * Flashpoint > 140 F
               * Biodegradable

       After lab scale testing , three solvents formulations demonstrated favorable performance
characteristics and were selected for a screening performance with MEK to determine which solvent
blend would undergo further testing. One formulation designated "PC Blend 2" was chosen because of


                                             23

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its effectiveness and speed in removing .the coating.
              * 25% PC
              * 50% NMP
              * 25% DBE
PC Blend 2's composition is:
CONCLUSIONS:  Currently EPA is reviewing the data from this study and is preparing a report and
technical article for publication.  Although the data have not yet cleared the Agency's quality assurance
review, the potential of the PC blends encourages further investigation.  Interim results suggest that a
formulation of PC, NMP and DBE can be produced to remove paint in comparable time to the MEK.  For
solvent properties, the PC blend promises to compare favorably with MEK with minimimal effects on the
environment and health and safety. The anticipated benefits include the elimination of 33/50 toxic
chemical, MEK, from the radome depainting operation, along with the VOC air emissions.
PRINCIPAL INVESTIGATOR:  Ann Marie Hooper
                 Foster Wheeler USA Process Plants Division
                 Clinton, NJ 08809
 EPA PROJECT MANAGER:  Johnny Springer, Jr. and Kenneth R. Stone
               US EPA, RREL
               Cincinnati, Ohio 45268
                         (513) 569-7542
 KEYWORDS:  solvent substitution; methyl chloroform phaseout; 1,1,1-tri-
               chloroethane; methyl ethyl ketone; n-methyl-2-pyrroiidone; alternatives to remove paint
                                              24

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                                          SECTIONS               fi

                         UNIVERSITY-BASED ASSESSMENTS PROGRAfr
                                    Philadelphia. Pennsylvania

Overview

       The University-Based Assessments Program is a pilot project between EPA and the University
City Science Center (UCSC) to assist small and medium-size manufacturers who want to minimize their
formation of hazardous waste but who lack the in-house expertise to do so. Under agreement with the
Risk Reduction Engineering Laboratory of the U.S. Environmental Protection Agency, UCSC's Industrial
Technology and Energy Management (ITEM) division has established three waste minimization
assessment centers (WMACs) at Colorado State University in Fort Collins, the University of Louisville
(Kentucky), and the University of Tennessee in Knoxville. Each WMAC is staffed by engineering faculty
and students who have considerable direct experience with process operations in manufacturing plants
and who also have knowledge and skills needed to minimize hazardous waste generation.

       The WMACs conduct waste minimization assessments for small and medium-size manufacturers
at no  out-of-pocket cost to the client.  To qualify for the assessment, each client must meet the following
criteria:

       *     Standard Industrial Classification Code 20-39              j

       *     Gross annual sales of not more than $75 million

       *     No more than 500 employees

       *     Lack of in-house expertise in waste minimization

       The potential benefits of the pilot project include minimization of the amount of waste generated
by manufacturers, reduced waste treatment and disposal costs for participating plants, valuable
education experience for graduate and undergraduate students who participate in the program, and a
cleaner environment without more regulations and higher costs for manufacturers.
       The waste minimization assessments require several site visits to each client served.  In general,
the WMACs follow the procedures outlined in the EPA Waste Minimization Opportunity Assessment
Manual (EPA/625/7-88/003, July 1988). The WMAC staff locate the sources; of hazardous waste in each
plant and identify the current disposal or treatment methods and their associated costs. They then
identify and analyze a variety of ways to reduce or eliminate the waste.  Specific measures to achieve
that goal are recommended and the essential supporting technological and economic information is
developed.   Finally, a confidential report which details the WMACs findings and recommendations
including cost savings, implementation costs, and payback times is prepared for each client. UCSC
conducts follow-up interviews with the client to determine actual costs and benefits of the
recommendations.  Research Briefs are prepared and distributed by EPA to transfer the technical
information to others.  These Research Briefs are available from EPA's Center for Environmental
Research Information. The full reports on this research are available from the University City Science
Center, Philadelphia, PA 19104. At the completion of this pilot  effort with UGSC, one  hundred facilities
will have waste minimization opportunity assessments with documented results of findings and
recommendations.
                                              25

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TITLE: Manufacturer of Parts for Truck Engines                                        '.

PLANT BACKGROUND: The plant manufactures turbochargers, fan drives, and vibration dampers for
truck engines.  It operates approximately 6,000 hr/yr to produce more than 600,000 units annually.

MANUFACTURING PROCESS: The major raw materials used by the plant are iron, aluminum,
magnesium, and steel castings. Other raw materials include bearings, finger sleeves,  bands, studs, and
rubber strips.                                                                       ;
       For the production of turbocharges, steel castings undergo a vapor degreasing operation and
friction welding.  In parallel operations, the steel castings, aluminum castings, and iron castings are
turned, drilled, tapped, and sent through an alkaline cleaner. The finished parts are assembled into
complete turbocharger units, packaged, and shipped.                                   :        •
       In the fan drive production line, aluminum, magnesium, iron, and steel castings are turned,
drilled, and tapped, resulting in rotors, shafts, and bearing housings.  Rotors are sandblasted, vapor
degreased, spray-coated with a wear-resistant formulation, and heated in a curing oven.  The shafts and
bearing housings, after an alkaline cleaning, are assembled with the finished rotors. The finished
product Is packaged and shipped.                                                   :

EXISTING WASTE MANAGEMENT PRACTICES:  This plant already has implemented the following
techniques to manage and minimize its waste:
       * Onsite solvent recovery units are used to distill spent degreasing solvent for reuse.
       * Several waste streams, Including an anti-rust treatment and cleaning chemicals have been
         eliminated from the production process.
       * A heat pump evaporator has been purchased for drying of wastewater sludge.
       * Waste cardboard is baled  and sold to a recycler.
       * Waste metals are compacted into blocks and sold as scrap.

WASTE MINIMIZATION OPPORTUNITIES:
       *  Reduce the frequency of leaks and spills of hydraulic oil.
       *  Dispose of spent coolant through a method other than the onsite wastewater treatment plant.

PRINCIPAL INVESTIGATOR:   University City Science Center                           i
 EPA PROJECT OFFICER:     Emma Lou George
                             U.S. EPA,  RREL
                             Cincinnati, Ohio 45268
                             (513) 569-7578
 KEY WORDS:  turbochargers; fan drives; vibration dampers; vapor degreasing operation; friction
               welding; rotors; sandblasted; spray-coated; on-site solvent recovery; heat pump
               evaporator
                                              26

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TITLE:  Manufacturer of New and Reworked Rotogravure Printing Cylinders                    •'•*• " '•

PLANT BACKGROUND: The plant produces chrome-plated engraved copper-plated steel and
aluminum cylinders for rotogravure printing from new stock and custbmer returns.  It operates 6,240
hr./yr to produce over 7,000 cylinders annually.

MANUFACTURING  PROCESS: Rotogravure printing cylinders are produced from new stock (primarily
steel or aluminum) and from used cylinders requiring reworking.

        New cylinders are cleaned and degreased before processing. Then the aluminum cylinders are
passivated in a wash tank containing an acid mixture, and zincated in a zinc oxide solution. Next, all
aluminum and steel  cylinders are nickel-plated and then copper-plated. The  plated cylinders then
undergo lathing, polishing, and grinding.

        Customer-provided art work is used to create plating images which are then mechanically
engraved on the surfaces of the cylinders. The engraved cylinders are cleaned, polished, and chrome-
plated.

        Cylinders are then tested in the proofing department. Those cylinders that pass inspection are
packaged and shipped.  The cylinders that fail inspection are stripped of chrome (using acid) and are
either replated with chrome or lathed and returned to the copper-plating baths for reprocessing.

EXISTING WASTE MANAGEMENT PRACTICES: This plant already has taken the following steps to
manage and minimize its wastes:
        * Metal shavings from turning, polishing, and electronic engraving are recovered and sold for
         reclamation.
        * Cylinders are rinsed with deionized water directly above the tanks after nickel and copper
         plating in order to eliminate drag-out of plating solution.  ,
        * Nickel plating has been substituted for cyanidin prior to copper-platting thereby eliminating the
         generation of cyanide wastes.                                  i
        * Film with a very low silver content is used  in image processing in order to reduce the amount
         of waste silver generated.
        * Silver is recovered onsite by electrolytic deposition.
        * Recovered silver and waste film are sold to a recycler.
        * Electronic engraving is used for etching cylinders in order to eliminate the wastes that would
         be generated using chemical etching.
        * Cylinders are rinsed over the planting tanks and fume scrubber water is reused as plating bath
         make-up in order to eliminate the need for chromium removal from wastewater.
        * Chromic acid fume losses are reduced through the use of tank covers and floating ball
         insulation.

WASTE MANAGEMENT OPPORTUNITIES:
        * Reduce or eliminate spill over from the nickel and copper-plating by installing plastic guards
         around the tank edges.
        * Evaluate the necessity for and standardize the use of solvents for the cleaning of cylinders.
        * Recover chromium or hydrochloric acid from the spent acid stripper solution.
        * Replace disposable filters used for filtering nickel and copper-plating solutions with reusable
         stainless steel filters.
                                              27

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PRINCIPAL INVESTIGATOR:  University City Science Center
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7578
KEY WORDS:  rotogravure printing; chrome-plating; engraved copper-plated steel; aluminum cylinders;
              polishing; electronic engraving; nickel plating; electrolytic deposition; chromic acid fume
                                             28

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TITLE: Manufacturer of Electrical Rotating Devices

PLANT BACKGROUND: Several varieties of electrical rotating devices are manufactured by this plant.
It operates over 4,000 hr/yr to produce more than 250,000 units annually.

MANUFACTURING PROCESS:  Carbon and stainless steel, aluminum, brass ami copper bar stock,
nickel strip stock, plastic powder, fiberglass pellets, powdered metal are the principal raw materials used
in production.
        The various types of metal, bar stock are machined into component parts using automatic screw
machines.  Metal shafts that are produced are sent to the four-stage aqueous cleaner consisting of an
alkaline wash tank, two rinse tanks, and a rust inhibitor rinse tank for carbon  steel parts. Other parts
produced by the screw-machines are machined further and then washed in the four-stage cleaner.
Stainless steel and aluminum parts undergo surface treatment after cleaning.
        Almost all of the stainless steel parts and all of the aluminum parts undergo a protective surface
treatment to prevent corrosion.  The stainless steel  parts are submerged in a passivating bath,  rinsed,
dried, and cleaned in an ultrasonic vapor degreaser. Aluminum parts are submerged in a chromium
dioxide solution and rinsed.
        Laminations, which are used individually in  rotor assembly and stack«jd and fixed together in
stator and stepper assemblies, are produced in the plant also. Individual laminates are cut from strip
stock in a punch press and then washed in the four-stage washer and heat treated.  The laminations are
either transferred individually to the rotor assembly area or to spray painting,  or are  stacked and then
held in the place by shrink wrap or by welding.  The welded laminates are then sent to painting, and
unwelded stacks are transferred to the stator and stepper area.
        In the rotor and stator assembly line, individual laminations are pressed onto metal shafts. The
resulting rotors and  stators are machined, washed in the four-stage cleaner and in an ultrasonic vapor
degreaser, and transferred to final assembly.  The completed  units are tested,, the motor housings are
wiped clean and stamped with identifying markings, and the finished parts are packaged and shipped

EXISTING WASTE MANAGEMENT PRACTICES: This plant already has implemented the following
techniques to manage and minimize its wastes.
        * Distillation units are used to recover usable TF-Freon from contaminated Freon from the
         plant's vapor degreasers.
        * An in-drum waste compactor is used to reduce the volume and disposed cost of paper towel
         waste.

WASTE MINIMIZATION OPPORTUNITIES: The quantities of waste currently generated by the plant
and possible waste reduction depend on the production level  of the plant.  It  should be noted that the
economic savings of the minimization opportunity, in most cases, result from  the need for less raw
material and from  reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable by this study include  a wide variety of possible future costs related to
changing emissions standards, liability, and employee health.  It also should be noted that the savings
given for each opportunity reflect the savings achievable when Implementing each waste minimization
opportunity independentiy arxJ do not reflect duplication of savings that may result when the
opportunities are Implemented in a package.
                                              29

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PRINCIPAL INVESTIGATOR:   University City Science Center
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7578
KEY WORDS:  electrical rotating devices; four-stage aqueous cleaner; rinse tanks; ultrasonic vapor
              degreaser; laminations; distillation units; in-drum waste compactor
                                             30

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TITLE:  Manufacturer of Gravure-Coated Metalized Paper and Metalized Film.

PLANT BACKGROUND;  The plant produces gravure-coated metalized polypropylene and polyester film
for use in labeling and wrapping food products. It operates 8,760 hr/yr to produce over 14 million
pounds of product annually.

MANUFACTURING PROCESS: The plant's products are manufactured from raw paper and film
received in bulk rolls.  Other raw materials include water-based and solvent-based coatings mixtures,
aluminum wire (for vapor deposition coating), liquid nitrogen, and diluting solvents.
        Diluting solvents are received in bulk quantities and stored. The organic-solvent-based coating
mixtures are diluted with methyl ethyl ketone (MEK) as required and transported to the pre-coater.
Water-based coating mixture is diluted with isopropanol to either the pre-coater or top-eoater.
        Raw white coated paper is processed in the pre-coater where coating is applied to enhance the
gloss of the paper and provide a good  surface for aluminum adhesion during later vacuum metalization.
Two coatings are applied to the paper,  and in some cases, both sides of the paper are coated.  One of
the three organic-solvent-based coatings or the water-based coating is used for each coating
application; the first and second coating applications may or may not use the same coating mixture.
Following coating, the paper is dried in the pre-coater oven.
        Each coated paper roll from the pre-coater is transported to one of two vacuum metalizers.
Rolls of polypropylene and polyester film are processed in a specialized vacuum metalizer. A thin layer
of aluminum is deposited on the paper  and film through vapor-deposition. About half of the metalized
film is cut to specification  in the metalizer and sent directly to shipping. The rest of the film is sent to the
finishing, rewind, and slitting area of the plant prior to shipping.
        The metalized paper is transported to the top-coater where coating is applied to the metalized
surface in the same manner that the initial coating was applied in the pre-coater. The top  coat acts as a
printing primer and provides a clear protective layer. The coated paper is dried  in the top-coater oven
and sent to the finishing, rewind, and slitting area prior to  shipping.

EXISTING WASTE MANAGEMENT PRACTICES: This plant operates an onsite solvent recovery still to
recover MEK from solvent wastes.  Recovered solvent is used for diluting coating mixtures and clean-up.

WASTE MINIMIZATION OPPORTUNITIES:  The quantities of waste currently generated by the plant
and possible waste reduction depend on the production level  of the plant. It should be noted that the
economic savings of the minimization opportunity, in most cases, result from the need for  less raw
material and from  reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable  by this study include a wide variety of possible future costs  related to
changing emissions standards, liability,  and employee health.  It also should be noted that the savings
given for each opportunity reflect the savings achievable when implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.

PRINCIPAL INVESTIGATOR:   University City Science Center
                                                                     I
EPA PROJECT OFFICER:     Emma  Lou George
                             U.S. EPA, RREL
                             Cincinnati, Ohio 45268
                             (513)569-7578

KEY WORDS:  gravure-coated metalized polypropylene and polyester film; water-based and solvent
               based coating mixtures; diluting solvents;  vacuum metalizer; on-site solvent recovery


                                              31

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TITLE:  Manufacturer of Paints and Lacquers.

PLANT BACKGROUND:  This plant manufactures lacquers and consumer and industrial water-based
and solvent-based paints.  It operates 4,000 hr/yr to produce approximately 1.5 million gallons of paint
and lacquer annually.

MANUFACTURING PROCESS: The raw materials used by this plant include pigments, resins, fillers,
plasticlzers, dryers, preservatives, solvents, and water. Water-based paints represent about one-third of
the total production; the remainder is solvent-based.  The production processes for water-based and
solvent-based products are very similar; the major distinction between the processes is the u?e of water
or solvent.                                                                           ;
        Specified amounts of  raw materials are prepared for batches of product in the pre-batch area.
Those Ingredients, other additives, and solvent or water are blended at one of several mixing stations.
Pigment dispersion is checked and if it is unacceptable, the mixture is ground in a sand-mill or a pebble-
mill.  If lacquer is being manufactured, the liquid from the mills is sent to a separate building where
additives are  added and the resulting mixture is pumped into drums.                      ;
        For products other than lacquer, the mixture is pumped from the mixing station or from the mills
to one of several let-down tanks where additives, tint, resins.and solvent are added. The viscosity, dry
gloss, translucency, color, and other physical properties of the product are tested in the laboratory and
adjustments are made as needed.  The product is pumped from the let-down tanks through filters to an
automated filling unit or gravity-fed to drums and tankers.

EXISTING  WASTE MANAGEMENT PRACTICES:  This plant has implemented the following techniques
to manage and minimize its wastes:
        * When possible, cleaning solvents are reused in  paint formulation.
        * Plastic liners are used in steel pails to reduce cleaning wastes.
        * Obsolete products and products returned by customers are blended into new products when
         feasible.
        * Plant personnel are evaluating the possible purchase of a distillation unit for the recovery of
         spent solvents that are currently shipped  off-site.                               '

WASTE MINIMIZATION OPPORTUNITIES: The quantities of waste currently generated by the plant
and  possible waste reduction depend on the production level of the plant. It should be noted that the
economic savings of the minimization opportunity,  in most cases, result from the need for less raw
material and  from reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable by this study include a wide variety of possible future costs related to
changing emissions standards, liability, and employee health.  It also should be noted that the savings
given for each opportunity reflect the savings achievable when implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.
                                               32

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PRINCIPAL INVESTIGATOR:  University City Science Center
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513)569-7578
KEY WORDS:  lacquers; consumer and industrial water-based and solvent-biased paints; pigment
              dispersion; viscosity; dry gloss; translucency; color; physical properties; plastic liners;
              distillation unit
                                           33

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TITLE:  Manufacturer of Surgical Implants

PLANT BACKGROUND: This plant manufactures surgical implants. Nearly four million parts are
produced each year during 4,160 hours of operation.

MANUFACTURING PROCESS:  Fasteners and plates are manufactured from stainless steel and
titanium sheets, rectangles, and round stock.
        The first step in the plate manufacturing process is the sanding and cutting to size of stainless
steel stock.  Computer numerically controlled (CNC) mills are used to mill the sides of the plate, and
another mill finishes the top and bottom of the plate.  Lathes, drills, broaches, and additional mills are
used for further machining operations. Then the parts are placed in one of several vibratory polishers
that utilize aluminum oxide chips and water for additional finishing.  Sand blasting may be used in place
of vibratory polishing for some parts.  The final finishing step is eiectropolishing, which uses an alkaline
cleaner, a hot water rinse, a cold water rinse, a phosphoric acid solution, a hot water rinse and hold,
eiectropolishing solution, and delonized water rinse. After the part dries, a logo and serial number are
etched  chemically onto its surface. Finally, the parts are passivated in a nitric solution, inspected,
boxed,  and shipped.
        Fasteners are manufactured in a separate area of the paint.  Cylindrical metal blanks are cut and
machined to form a screw head on one end. Centerless grinders are used to shape the head and
reduce the outside diameter.  Threads are cut into the blanks using mills.  The fasteners are polished in
the vibratory polishers, electropolished, and passivated. The finished products are inspected, packaged,
and shipped.

EXISTING WASTE MANAGEMENT PRACTICES: This plant already has implemented the following
techniques to manage and minimize its wastes.
        * An aqueous, citric-based cleaner has replaced solvents used for
          cleaning machined plates prior to  polishing.
        * Water meters have been installed on all aqueous waste streams that are discharged to the
          treatment unit to monitor and control water usage.
        * Scrap metal is shipped offsite for  recycling.                                    ,
        * Centrifuges have seen installed on many of the machines used in fastener fabrication to
          separate metal chips from the oil-based cutting fluid, thereby extending the fluid's life and
          reducing waste generation.

 WASTE MINIMIZATION OPPORTUNITIES: The quantities of waste currently generated by the plant
 and possible waste reduction depend on the production level of the plant.  It should be  noted that the
 economic savings of the minimization opportunity, in most cases, result from the need for less raw
 material and from reduced present and future costs associated  with waste treatment and disposal.
 Other savings not quantifiable by this study include a wide variety of possible future costs related to
 changing emissions standards, liability, and employee  health. It also should  be rioted that the savings
 given for each opportunity reflect the savings achievable when implementing each waste minimization
 opportunity Independently and do not reflect duplication of savings that may result when the
 opportunities are implemented in a package.
                                                34

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PRINCIPAL INVESTIGATOR:  University City Science Center
EPA PROJECT OFFICER:     Emma Lou George
                            U.S. EPA, RREL
                            Cincinnati, Ohio 45268
                            (513)569-7578          .    ".  -       f..

KEY WORDS:  surgical implants; computer numerically controlled (CNC) mills; electropolishing
              passivation; aqueous, citric based cleaner; centrifuge; metal chips; oil-based cutting fluid
                                             35

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TITLE:  Manufacturer of Mountings for Electronic Circuit Components

PLANT BACKGROUND: This plant produces ceramic mountings for electronic circuit components.
Approximately 600,000 mountings are produced each year by the plant, which operates 4,160 hr/yr.

MANUFACTURING PROCESS:  Several types of mountings or "packages," varying in size and number
of ceramic layers and connectors, are manufactured by the plant. The unit operations used to produce
the plant's products are described below:

* Ceramic Tape Production                                                           ',
        A ceramic slurry is mixed from dry and liquid ingredients and deairated. The slurry is poured
into a thin film on a conveyor and cured in an oven. The resulting soft ceramic tape is cut and rolled
onto cores. Tape rolls that pass inspection are pressure-and heat-stabilized and then pouched and cut
automatically.
* Tungsten Paste Mixing
        Tungsten paste is produced from dry and liquid ingredients.
jars for storage until required for production.
Finished paste is poured into small
* Screening
        Ceramic tape that has been cut into sheets is loaded onto a screening machine where the
insides of holes that have been punched are coated with tungsten paste. A circuit board pattern is
automatically applied and dried in another screening machine. The screened sheets are transferred to a
metal press where they receive a dielectric coating as needed to prevent plating in certain areas. Some
of the sheets are transferred to the laminating process and then all screens are scored or cut, cured,
inspected and transferred to the nickel-plating process.                                 \

*Laminating
        Those sheets that require laminating are moved through a booth where they are sprayed with
adhesive. The individual  screens are stacked, indexed, and placed in a press to bond the stacked
sheets.

* Nickel Plating
      t The packages are nickel  plated using  one of three automated operations-electrolytic, vapor
deposition, or electroless. Packages that have been electrolytically nickel plated are transferred  to
electrolytic gold  plating, brazing,  or to a sintering furnace and then to electrolytic gold plating. The
packages that undergo vapor deposition are transferred to electroless gold plating or to brazing. After
electroiess nickel plating, packages are transferred to electroless gold-plating.

* Gold Plating
        Packages are gold-plated in one of two electroless plating lines or in an electrolytic plating line.
After electroless  gold plating, packages are taken to brazing or inspected and shipped.  Packages from
brazing and packages from electrolytic nickel-plating are gold-plated electrolytically, brazed, and
shipped.

* Brazing                                                                          ;
       Whether or not a package is brazed and at what stage it is brazed depends on the product
being produced. After brazing, the packages are inspected and returned to one of the gold plating
processes.
                                               36

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EXISTING WASTE MANAGEMENT PRACTICES: This plant already has implemented the following
techniques to manage and minimize its waste.


       * A citric-based cleaning solution is used instead of toluene for clean-ilip in the screening area.
       * Most of the off-specification ceramic tape and cuttings from ceramic tape is recycled onsite.
       * Toluene is decanted and reused in the cleaning processes.
       * Sodium hydroxide and hydrochloric acid solutions from alkaline cleaning tanks in the plating
         process are used to adjust wastewater pH levels in the onsite wastewater treatment system.
       * Rags wetted with citric-based cleaning solution are washed in-house         and reused.

WASTE MINIMIZATION OPPORTUNITIES:  The quantities of waste currently generated by the plant
and possible waste reduction depend on the production level of the plant.  It-should be noted that the
economic savings of the minimization opportunity, in most cases, result from the need for less raw
material and from reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable by this study include a wide variety of possible future costs related to
changing emissions standards, liability, and employee health. It also should be noted that the savings
given for each opportunity reflect the  savings achievable when implementing each waste minimization
opportunity independently and  do not reflect duplication of savings that may result when the
opportunities are implemented  in a package.
       Since one  or more of these approaches to waste reduction may increase in attractiveness with
changing conditions in the plant, they were brought to the plant's attention for future consideration.
       * Compact the contaminated nickel plating solution filters prior to    s1
        disposal to reduce the volume of space they occupy and the associated removal cost.
       * Install a natural gas-fired dry-out oven to reduce the amount of water contained in the sludge
         from the  onsite wastewater treatment plant.
       * Automate the measuring and delivery process of solvents to the mixing chambers in the tape
        production area to reduce evaporative losses.
       * Recover evaporated solvents from tape production, tungsten paste mixing, and clean-up for
         reuse.
       * Substitute a nonhazardous cleaner for the solvent cleaners used in the tape production and
         tungsten paste mixing lines.                                    ;
        * Substitute a nonhazardous  cleaner for 1,1,1-trichloroethane used for clean-up in the screening
         area.  '-                  -  -    -     -..-•'.•".•    -  :         •; -    -  .."    - •      '.

PRINCIPAL INVESTIGATOR:  University City Science Center
 EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513)569-7578
 KEY WORDS: ceramic mountings; citric-based cleaning solution; nature gas-fired dry-out oven; tape
               production; tungsten paste mixing; 1,1,1 trichloroethane; laminating; brazing; screening;
               gold/nickel plating
                                               37

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TITLE:  Manufacturer of Microelectronic Components

PLANT BACKGROUND:  This plant manufactures monolith and hybrid amplifiers and integrated circuit
assemblies.  Over 100,000 assemblies are produced annually by the plant during approximately 5,000
hours of operation.
                                                                             •  '  i
MANUFACTURING PROCESS: Thin-film circuitry is generated on sheet-alumina substrates using
photolithography for pattern generation and vacuum-chamber vapor deposition to form circuit
components. Photoresist is applied to the substrate, dried, exposed to ultra-violet light, and developed
to leave polymerized material on areas to be protected during subsequent vapor deposition- Remaining
photoresist is removed with a resist stripper. These process may be repeated several times to add
circuit elements in a sequential manner.  Resistors are trimmed to specific values using laser machines.
        Assembly of the products involves attaching integrated circuits and other components to the
ceramic substrates. Much of the process is automated. The resulting products are tested,  inspected,
packaged, and shipped.                                                           ;

EXISTING WASTE MANAGEMENT PRACTICES: This plant already has implemented the following
techniques to manage and minimize its waste.
        * Waste acetone from the stagnant bath for photoresist removal is reused in the ultrasonic acid
         bath in the same line.
        * Waste tri-iodine stripping solution is shipped offsite for gold recovery.
        * Water-based solder .fluxes are  replacing solvent-based solder fluxes.
        * A close-loop rinse is used for cleaning following stripping and etching.
        * Acetone and isopropyl alcohol baths and waste drums are kept covered to reduce
         evaporation.

WASTE MINIMIZATION OPPORTUNITIES:  The quantities of waste currently generated by the plant
and possible waste reduction depend  on the production level of the plant. It should be noted that the
economic savings of the minimization  opportunity, in most cases, result from the need for less raw
material and from reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable by this study include a wide variety of possible future costs related to
changing emissions standards, liability, and employee health. It also should be noted that the savings
given for each opportunity reflect the savings achievable when implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.
        Since one or more of these approaches to waste reduction may increase in attractiveness with
changing conditions in the plant, they were brought to the plant's attention for future  consideration.
        * Reuse the laser cooling water  instead of sewering it after use.
        * Use delonized water and a hot air dryer to replace acetone and isopropyl alcohol  used for
         drying wafers  after initial cleaning.
        * Continue to use the tri-iodine gold  stripper for a longer period of time before disposal.
                                              38

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PRINCIPAL INVESTIGATOR:   University City Science Center
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA.RREL
Cincinnati, Ohio 45268
(513)569-7578
KEY WORDS:  amplifiers; integrated circuit assemblies; ceramic substrates; photoresist removal- waste
              tr-iodine; water-based solder fluxes; laser cooling water; vapor deposition
                                          39

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TITLE: Manufacturer of Coated Parts

PLANT BACKGROUND: This plant produces specially coated aluminum, steel, and plastic parts. It
operates 2,210 hr/yr to produce approximately 1 million units.

MANUFACTURING PROCESS: The plant operates as a job shop to apply special purpose surface
coatings to customer-supplied parts. Coatings applied to the parts include chromate-conversion, zinc
phosphating, and organic coatings.              •             .  •_     .  „  ..   .  t.  ,  L^
       Parts that receive conversion coatings are first cleaned in a heated alkaline bath, rinsed,    _
desmutted, and rinsed again. Then the parts are immersed in a heated chromic acid solution, rinsed
again, and air dried.

EXISTING WASTE MANAGEMENT PRACTICES: This plant already has implemented the following to
manage and minimize its wastes.
        *  High volume, low pressure paint guns are used for most painting to reduce overspray.
        *  Operations use care in raising parts bins slowly from process solutions and allow sufficient
         drainage time to reduce drag-out.                                           ;
        *  Some solvents are recovered on-site for reuse.                               ;

WASTE MINIMIZATION OPPORTUNITIES:  The quantities of waste currently generated by the plant
and possible waste reduction depend  on the production level of the plant.  It should be noted that the
 economic savings of the minimization  opportunity, in most cases, result from the need for less raw
 material and from reduced present and future costs associated with waste treatment and disposal.
 Other savings not quantifiable by this  study include a wide variety of possible future costs related to
 changing emissions standards, liability, and employee health.  It also should be noted that the savings
 qiven for  each opportunity reflect the  savings achievable when implementing each waste minimization
 opportunity independently and do not reflect duplication of savings that may result when the
 opportunities are implemented in a package.

 PRINCIPAL INVESTIGATOR:  University City Science Center
 EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati,'Ohio 45268
(513) 569-7578
  KEY WORDS:  coated aluminum, steel, plastic parts; chromate-conversion coating; zinc phosphating
                coating;  organic coatings; high volume, low pressure paint; on-site solvent recovery
                                               40

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 TITLE:  Manufacturer of Finished Metal and Plastic Parts
  .n8,? C,KGR°UND: ™s P'ant is a l°b shop that applies coatings to metal and plastic components
 supplied by its customers. It operates 4,940 hr/yr to produce approximately 234,000 sq ft of product
 3nnudiiy.                                                           ..  ;
 MANUFACTURING PROCESS:  Prefabricated .aluminum, steel, and plastic parts are supplied to the
 plant by rts customers who specify the coating or paint that is to be applied.  The plant performs several
 different coating operations, but the ones that generate consistent and appreciable amounts of waste are
 anodizing of aluminum parts, ehromating of aluminum parts, painting of plastic and metal parts.

        * Anodizing: Aluminum parts to be anodized are first immersed in a caustic solution and then
         an etching solution to remove surface contaminants. Smut that remains on the parts after
         etching is removed using an acidic deoxidizing solution. A surface oxide layer is then formed
         on the parts in an aqueous electrolytic bath that contains sulfuric acid.  The anodized parts are
         then dyed one of five colors or left undyed. Next, an aqueous nickel fluoride solution is used
         to seal the oxide layer.  The last step is rinsing  of the finished parts.  The anodized parts are
         then assembled if necessary, packaged, and shipped back to the customer.

        * Chromating:  Chromate conversion coatings are applied to aluminum parts by first immersing
         the parts in a series of aqueous solutions for cleaning, etching, and acidic deoxidizing The
         parts are then immersed in the chromate conversion solution and rinsed  The finished parts
         are then painted if required, inspected, assembled if necessary, package, and shipped back to
         the customer                           :    .,;              . •'..  ••.         r~ ,,- .    i.

        * Painting: Parts that require painting are painted in one of three spray booths Water-based
         solvent-based, and powder coatings are used by the plant according to the customer's     '
         specifications.  Special tooling supplied by the customer is used to mount the parts to be
         painted. After the  coating has been applied, the parts are placed in an oven for curing and
         drying. The completed parts are inspected, packaged, and shipped back to the customer.

EXISTING WASTE MANAGEMENT OPPORTUNITIES: This plant already has implemented the
following techniques to manage and minimize  its waste.

       * Flow reducers have been installed on all flowing rinses in the anodizing and ehromating lines
         A solvent distillation unit is used to recover paint-related solvents which are then reused bv the
         plant.                                                                            '
       * The use of water-based instead of solvent-based paints is significant and is increasing  Plant
         personnel encourage customers to specify water-based and powder-based paints
         Operators use care in raising parts racks slowly from the process solutions and allowing
         sufficient drainage time to reduce drag-out in the anodizing and ehromating lines
         Water used to cool Freon in the chillers associated with the anodizing tanks is reused as  rinse
        water.
                                             41

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WASTE MINIMIZATION OPPORTUNITIES: The quantities of waste currently generated by the plant
and possible waste reduction depend on the production level of the plant.  It should be noted that the
economic savings of the minimization opportunity, in most cases, result from the need for less raw
material and from reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable by this study include a wide variety of possible future costs related to
changing emissions standards, liability, and employee health. It also should be noted that the savings
given for each opportunity reflect the savings achievable when implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.                          ,        •   »   *•    «,,,,!th
        Since one or more of these approaches to waste reduction may increase in attractiveness with
changing conditions in the plant, they were brought to the plant's attention for future consideration.
        * Modify the onsite solvent distillation unit in order to raise the temperature and the recovery
         factor.
 PRINCIPAL INVESTIGATOR:   University City Science Center
 EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7578
 KEY WORDS:  metal and plastic components; coatings; anodizing; chromating; painting; flow reducers;
                solvent distillation unit; water-based paints; sufficient drainage time; freon; recovery
                factor
                                                42

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 TITLE:  Manufacturer of Battery Separators

 PLANT BACKGROUND: This plant manufactures two types of automotive battery separators.  It
 operates approximately 8,400 hr/yr to produce almost 3.5 billion square feet of polyethylene/silica
 separators and over 2 billion vinyl rib separators annually.

 MANUFACTURING PROCESS: Automotive battery separators, which are thin sheets placed between
 battery electrodes, to keep them from shorting out, are manufactured by this plant. The production
 processes for the two types of separators manufactured-polyethylene/silica sheet and vinyl rib-will be
 described here.                                                        !..'...•

        * Polyethylene/Silica Sheet:
          Polyethylene/silica sheet  is manufactured from a mixture of high density polyethylene,
          ultrahigh molecular weight polyethylene, silica, oil, and other ingredients. The raw materials
          are blended together and the resulting mixture is extruded through a die bar into a sheet and
          calendared.  The oil, which prevents the silica from damaging the extruder and provides
          porosity to the product, is then removed by countercurrent extraction with TCE. After oil
          removal, the sheet passes through a drying oven for TCE removal and  enters a bath where a
          wetting agent is added to change the electrical properties of the sheet.  The sheet is then
          dried again for water and  further TCE removal and is inspected, wound onto a roll and slit
          Recovered oil and TCE are reused by the plant.                 ,

         * Vinyl Rib Separators:
         A latex batch containing latex, saline, water, and other ingredients iis mixed  in two steps and
         placed in a dip tank.  Plastisol, which is composed  of diethylhexyl phthalate, polyvinyl
         chloride, mineral spirits, and other ingredients, is mixed separately for use in extrusion
         through the rib dip bar.                                              ,   .        ,,

       In order to produce the vinyl rib separators, fiberglass sheet paper is dipped into the dip tank
squeezed between rollers to remove excess latex, and then passed under the rib die bar where plastisol
is extruded onto the sheet to form the ribs. The resulting product sheet is dried in an  oven  cut into
squares,  inspected,  and packaged.

EXISTING WASTE MANAGEMENT  PRACTICE: This plant already has implemented the following
techniques to manage and minimize its waste.
       * Waste fiberglass paper from vinyl rib production is used to adsorb spills from      :
         polyethylene/silica sheet production thus reducing the quantity of adsorbents purchased
       * Trichloroethylene fugitive emissions are reduced as a result of the extraction pans, turnaround
         drier, wetting agent bath, and water drier being welded together.
       * Disposable cotton wound cartridge filters are being replaced by
         reusable metal mesh strainers on the still feed lines.
       * Recovered materials such as oil and TCE are reused extensively onsite.
       * Equipment to regrind blacksheet trim for reuse in the polyethylene/silica sheet production line
         has been purchased.
       * Roll cores from the fiberglass sheet used in the vinyl rib production line is returned to the
         supplier for reuse.
                                              43

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WASTE MINIMIZATION OPPORTUNITIES:  The quantities of waste currently generated by the plant
and possible waste reduction depend on the production level of the plant. It should be noted that the
economic savings of the minimization opportunity, in most cases, result from the need for less raw
material and from reduced present and future costs associated with waste treatment and disposal.
Other savings not quantifiable by this study include a wide variety of possible future costs related to
changing emissions standards, liability, and employee health.  It also should be noted that the savings
given for each opportunity reflect the savings achievable when  implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.                                          _
        Since one or more of these approaches to waste reduction may increase in attractiveness with
changing conditions in the plant, they were brought to the plant's attention for future consideration.
        * Identify a suitable alternative for trichloroethylene currently used for oil removal.
        * Identify an alternative oil for use in the process, thereby making it possible to use a different
         solvent for extraction.
        * Grind waste black sheet for reuse onsite.
        * Replace the steam stripper used for oil recovery on one of the  process lines with a newer,
         more efficient unit.
        * Install  a backup centrifuge to take the place of the primary centrifuge when it is not working.
        * Regenerate the carbon beds with nitrogen instead of steam in order to eliminate the
         generation of wastewater containing TCE.
        * Recover dactyl phthalate from stack gases prior to incineration by carbon bed adsprption and
         condensation.
        * Reuse empty gaylords internally and/or obtain shipments received  in paper bags
         with shipments in returnable bulk bags.
 PRINCIPAL INVESTIGATOR:  University City Science Center
 EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7578
 KEY WORDS:  automotive battery separators; polyethylene/silica separators; vinyl rib separators; waste
                fiberglass paper; trichloroethylene fugitive emissions; cartridge filters; regrind blacksheet
                trim; steam stripper; backup centrifuge; dactyl phthalate
                                                44

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  TITLE: Manufacturer of Folding Paperboard Cartons

  PLANT BACKGROUND: This plant manufactures folding paperboard cartons.  It operates
  approximately 2,200 hr/yr to produce about 1,200 tons of cartons annually.
     otorm,             PaPerboard rolls of various gauges are cut to specific sheet sizes in the
 shee ter machine. If required, the paper sheets are sent to the hydraulic cutter for trimming to smaller
 sheet sizes. The sheets are stacked on pallets and assigned a labeling code in preparation -for printinq
         For the past several years, the plant has used its six-color press for printing exclusively  Two
 other presses a iwo-color and a three-color-are also available.  Printing plates are developed onsite
 using a recently installed photolithographic process. Printing plates are attached to five of the six press
 cylinders. Each cylinder transfers a different color to each sheet as it passes through the press  The
 sixth and final cylinder is used exclusively to apply a clear aqueous coating to the sheet, which gives the
 prmted sheet a glossy appearance.  Printed sheets are attached at the end of the press to await die
 cuninQ.

 Chnot thTh6 S^"1? lhe!,tS f re,CUt int° Carton sheets by one of the die cutters-  Tne die cutter feeds the
 sheet through, cuts the desired carton pattern, applies the fold impression.  Die patterns used by the die
 cutters are produced onsite from metal strips and wood arranged on polywood stabs.  Excess strips of
 paper are removed from cartons manually after die cutting  in the striping area.  The stripped sheets are
 attached on pallets and sent to either windowing or folding and gluing.
        The large and small windower machines are used to apply a clear plastic film to cover carton
 openings.  A glue wheel is used to apply a glue pattern on  the carton to affix the film.  Cartons are sent
 to one of three folding and gluing machines in which the carton sides are glued together  Glue is
 applied using a glue pads in two of the machines and automatically in the third machine.  Completed
 cartons are boxed and stored to await shipping.

 EXISTING WASTE MANAGEMENT PRACTICES: This plant already has implemented the following
 techniques to manage and minimize its wastes.
        * Ink is collected from the color presses at the end of the day, returneld to its proper container
         and stored for reuse.                                                                 '
        * Waste film from the photolithographic process is collected and shipped offsite for recyclina
         Waste paperboard instead of new paperboard is fed through the printing press at start-up until
         the printing quality meets specifications to avoid the generation of additional waste
         paperboard.
        * Printed and non-printed waste paperboard is  baled and shipped offsite for recycling.

 WASTE MINIMISATION OPPORTUNITIES:  The quantities  of waste currently generated by the plant
 and  possible waste reduction depend on the production level of the plant. It should be noted that the
 economic savings of the minimization opportunity, in most cases, result from the need for less raw
 material and from reduced present and future costs associated with waste treatment and disposal
 Other savings not quantifiable by this study include a wide variety of possible future costs related to
 changing emissions standards, liability, and employee health.  It also should be  noted that the savinas
nnnnrtnni^? H°PPOf "« V "?? ** ^'^ achievable when implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.
phanriin?ince °"e or.m°re °f these approaches to waste reduction may increase in attractiveness with
changing condrt,ons in the plant, they were brought to the plant's attention for future consideration
         Install a silver recovery unit onsite to recover dissolved silver from spent photographic fixer
        and wash water.                                                       .
                                              45

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       * Improve the existing paperboard recycling program. Suggested improvements include
        standardizing the type of board manufactured; improving the sorting of various types of waste
        board; automating the collection and baling operations; reducing the size of waste; bales;
        and moving the waste board storage and baling unit outdoors.                 ,

PRINCIPAL INVESTIGATOR:  University City Science Center                         ;
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7578
KEY WORDS: paperboard cartons; printing plates; die cutter; windower machines; photolithographic
              process; silver recovery unit; waste paperboard recycling
                                               46

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 TITLE:  Manufacturer of Pharmaceuticals                                ,,,,.,:„,,,'

 PLANT BACKGROUND:  This plant manufactures intermediates for pharmaqeuticaJs and other
 miscellaneous chemicals.  Over six million pounds of product are produced annually during 8 640 hr/yr
 of operation.                                                                               ''

 MANUFACTURING PROQESS:  Production is performed by the plant in batches and is structured into
 campaigns. The required  raw materials and pre-processed materials are received from a sister plant
 The production of the Pharmaceuticals requires several reaction and purifying steps that are combined
 to make up a single batch. Batches isolate either intermediate or final products.  Several intermediates
 may be required to get to  the final product stage.

 EXISTING WASTE MANAGEMENT PRACTICES:  This plant has implemented the  following techniques
 to manage and minimize its wastes.
        * The Responsible Care program of the Chemical Manufacture's Association is used as the
          plant's waste minimization vehicle.  The program emphasizes pollution prevention at the source
          rather than end-of-pipe solutions.
        * An average of 95% of solvents are reused by the plant.
        * Clean, used solvents are incinerated onsite to produce required steam,  thereby reducing fuel
          consumption.
        * Off-specification  batch materials are reused.
        * Enclosed centrifuges are used for dedicated processes to reduce aiir .emissions volatile organic
          compounds from solvents.
        * A policy has been implemented for the chemists to eliminate new production processes that
          require metallic compounds or chlorinated solvents.
        * A site reduction plan for air  emissions that includes a mass spectrometer  used  to monitor air
         emissions throughout the plant has been implemented.
        * Since initial site visit by the WMAC assessment team, some of the production steps for one of
         the products have been revised thereby reducing the generation rate of  waste acetone
         dramatically.

WASTE MINIMIZATION  OPPORTUNITIES: The quantities of waste currently generated by the plant
and possible waste reduction depend  on the production level of the plant.  It should be noted that the
economic savings of the minimization  opportunity, in most cases, result from the need for less raw
material and from reduced  present and future costs associated with waste treatment and  disposal
Other savings not quantifiable by this study include a wide variety of possible future  costs related to
changing emissions standards, liability, and employee health.  It also should be noted that the savings
given for each opportunity  reflect the savings achievable when  implementing each waste minimization
opportunity independently and do not  reflect duplication of savings that may result when the
opportunities are implemented in a package.
       Since one or more  of these approaches to waste reduction may increase  in  attractiveness with
changing conditions in the  plant, they  were brought to the plant's attention for future consideration
         Reuse the water from the onsite wastewater treatment plant as make-up water for the coolinq
        tower.  .                                                •    '  ,
       * Install suitable storage tanks, piping, and a pump to permit onsite reuse of waste hexane
         Install a sludge dryer to remove water from the wastewater treatment sludge
       * Extend the life of  the solvents used for tank cleaning by implementing staged cleaning
         Install a small solvent recovery unit to distill small volumes of waste solvent for reuse onsite
                                             47

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PRINCIPAL INVESTIGATOR:  University City Science Center
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268, (513) 569-7578
KEY WORDS:  intermediates; batches; solvent reuse; solvent incineration; enclosed centrifuges; mass
              spectrometer; sludge dryer; staged cleaning
                                              48

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 TITLE:  Manufacturer of Food Service Equipment

 PLANT BACKGROUND:  This plant manufactures commercial food service equipment storaae bins
 cabinets, and other miscellaneous sheet metal products. Sixty employees produce one-half million'
 annual?           St6el and painted steel Products during approximately 2,200 operating hours


 MANUFACTURING PROCESS:
        * Specialty Sheet Metal Fabrication:  Food service equipment, counter tops, case work 'and
          other products required on a job-shop basis are produced in the custom shop area of  the
          p ant  Raw  materials used include stainless steel,  mild steel, aluminum, and copper and brass
          Stainless and mild steel arrive at the plant in sheets of precut blanks that are trimmed to size '
          using hydraulic shears.  Operations performed include plasma cutting, forming, bending
          custom welding, polishing, finishing/and assembly.
        * Ice Storage Equipment Fabrication:  The other production activity at this plant is the
         fabrication of ice storage equipment. Trimmed sheet metal received from the shearing
         operation is  cut, formed, welded, finished/prepared for painting, painted, and insulated with
         polyurethane foam.
                                               This plant already has implemented the following
EXISTING WASTE MANAGEMENT PRACTICES:
techniques to manage and minimize its wastes.
       * Scrap stainless steel is collected and sold to a scrap metal dealer for reuse
         A citrus-based cleaner is used instead of solvents in some wipe-down cleaning operations
         Most of the ice storage products are coated using powder coating technology rather than
        conventional painting.
       * The nozzle of the foam insulation application system is cleaned with ethylene glycol rather
        than methylene chloride.
  Hnh,            OPP5RTUNITIES:  The quantities of waste currently generated by the plant
and possible waste reduction depend on the production level of the plant.  It should be noted that the
economic savings of the minimization opportunity, in most cases, result from the need for less raw
material and from reduced present and future costs associated with waste treatment and disoosal
Other savings not quantifiable by this study include a wide variety of possible future costs related to
changing emissions standards, liability, and employee health. It also should be noted that the savinqs
nnn"rt  f? /PPTn'fy refleCt the ^'^ achievable when implementing each waste minimization
opportunity independently and do not reflect duplication of savings that may result when the
opportunities are implemented in a package.

ehanninn ^nLT ^ "T °! *?*? aPProacnes to waste reduction may increase in attractiveness with
changing condrt.ons in the plant, they were brought to the plant's attention for future consideration
         Install a solvent recovery unit to recover waste toluene  generated during parts cleaning and
        wipe-down in the painting area.                                 ;
       * Install an enclosed spray gun washer in order to reduce solvent air emissions associated with
       paint gun cleaning.
                                             49

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PRINCIPAL INVESTIGATOR:  University City Science Center
EPA PROJECT OFFICER:
Emma Lou George
U.S. EPA, RREL
Cincinnati, Ohio 45268
(513) 569-7578
KEY WORDS:  sheet metal fabrication; ice storage equipment fabrication; citru-based cleaner; powder
              coating; foam insulation application system; solvent recovery unit; enclosed spray gun
              washer                                                         ;
                                             50

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                                                     INDEX
B
     acetone, reuse 38
     acid stripper 27
     adhesives, solvent based 8
     aerosol refrigerants 19
     alcoho! cleaning solvent 6
     aluminum, vapor deposition of 31
     amplifier manufactory 38
    battery separator manufactory 43
    bicarbonate of soda 16
    cabinet/bin manufactory 49
    cartons, folding paperboard 45
    centrifuge
        enclosed 47
        separation 34
    ceramic tape 36
    circuitry
        board assembly waste 21
        ceramic mounting for 36
        integrated assemblies 38
        thin film 38
        troubleshooting 18
    cleaner
        alkaline 26, 34
        aqueous, four stage 29
        citric based 34, 37, 49
        detergent, water based 6
        ethylene glycoj 49
        toluene 37
   cleaning
        enclosed spray gun washer 49
        solvents 32
        wastes, use of plastic liners 32
   coating 40, 41, 49 (see also painting)
   compactor 29
   compressed air, refrigerant alternative 16
   cutting fluids 12


   degreasing
       low-emission vapor  4
       ultrasonic vapor 29
       vapor 26      v
  depainting (see palnl removal)
      die cutter 45
      distillation
           atmospheric batch 4
           Freon recovery 29
           solvent recovery 41
               vacuum heat pump 4
           dragout 27, 40, 41
      education and training to reduce waste 21
      electronic circuitry (see circuitry)
      electroplating rinse waters 10
      electropolishing 34
      engraving 27
      evaporation, low temperature 10
      evaporator, heat pump 26
      extraction, countercurrent 43
      Extractor (roller extraction) 12


      fan drive manufacturing 26
      fiber glass, spill absorber 43
      film, metalized 31
      filters, stainless steel  27
      flow reducer 41
      fluids - mixing, handling, packaging 12
      food service equipment manufactory 49
 H
     heat pump evaporator 26
     hexane, reuse 47
     ice storage equipment manufactory 49
     ink
         reuse 45
         solvent based 6, 8
         waste reduction 6
         water based 6, 8
     integrated circuit assemblies 38
J

K
                                                    51

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M
    labels
         gravure-coated, metalized 31
         waste 6
    liquid nitrogen, refrigerant alternative 18
    makeup water, reuse 47
    manufacturory/industry
         battery separators 43
         cartons, folding paperboard 45
         coated metal and plastics 41
         coated parts (aluminum, steel, plastic) 40
         electrical rotating devices 29
         electronic circuit components 36
         electronics 18
         electroplating 10
         fluids-mixing, handling, packaging 12
         food service equipment 49
         labels 31
         microelectronic amplifier components 38
         paint removing 14,16, 23
         paints and lacquers 32
         paper and film 31
         pharmaceutical 47
         printing 6, 8
         rotogravure printing on cylinders 27
         surgical Implants 34
         truck engine parts 26
      metalizer, vacuum 31
      methyl chloroform 23
      methyl ethyl ketone (MEK) 4, 23, 31
      n-methyl-2-pyrolidone (MNP) paint remover 14
      microelectronic components 38
      mineral oil 12
      monoethanolamlne (MEA) 14
  N
      nickel electroplating rinse water 10
      oil, reuse 43
      paint
           manufacturing 32
           powder based 41, 49
           solvent based 32,  41
           water based 32, 41
paint remover                I
    alternative 23
    bicarbonate of soda 16
    methylene chloride replacement 14
    propylene carbonate evaluation 23
painting (see also coating)
    finished metal 41
    high volume low pressure ;(HVLP) 40
    plastic 41          .     ;
paperboard  cartons, folding 45
payback period
    bicarbonate blasting 16
    evaporation, low temperature 10
     onsite solvent recovery 4
     reverse osmosis 10
     small stream waste prevention 21
     sorbet-pad recycling 12
     water-based ink use 8
 perchloroethylene (PCE) 6
 pharmaceutical  manufacturing ;47
 photography                :
     chemical waste 6
     Polaroid film backs 21
     scanning electron microscopy 21
 photolithography 38, 45
 printing
     color 45
     narrow-web flexographic 6
     photolithography 45     ;
     plates 45               :
     rotogravure cylinders 27
     waste labels 6
     wide-web flexographic 8
 propylene carbonate (PC) paint remover 23
  recovery
      chromium from acid stripper 27
      dactyl phthalate 44     j
      distillation unit 32
      Freon 29
      gold from stripping solution 38
      hydrochloric acid 27
      oil 43
      Silver 27, 45
      solvent 4, 31, 32, 36, 41, 47, 49
      sorbet pad 12
  recycling
      film waste 45
      paperboard waste 45
                                                        52

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       rinse water 10
       sorbet pad fluid 12
  refrigerant alternative 18
  refrigeration
       carbon beds 44
       cutting fluid 34
  reverse osmosis, recycling rinse water 10
  reuse
       acetone 38
       blacksheet43
       gaylords 44
       hexane 47
       ink 45
       makeup water 47
      off-specification material 47
      oil 43
      rinse water 41
      solvent, Incineration 47
      toluene 36
      trichloroethane 43
      waste paperboard 45
 rinse
      close loop 38
      nickel electroplating 10
      tank 29
      water, purification system 14
      water, recycling 10
      reuse 41
 rotating device, electrical, manufactory 29
W
     surgical implant manufactory 31
     total organic carbon (TOO) 10
     1,1,1,-trichloroethane (methyl chloroform) 23
     trichloroethylene (TCE)
          removal 43
          reuse 43
          substitute needed for 16, 36
     truck engine parts manufactory 26
     tungsten paste 36
     turbocharger manufactory 26
 vapor
     degreaslng, low emission (LEVD) 4
     depositing 38
 vibration damper manufactory 26
 vinyl rib separator 43
 volatile organic compound (VOC) (see specific)


 Waste Minimization Assessment Centers 25
 Waste Reduction Evaluations at Federal Site
     Programs (SREAFS) 20
 Waste Reduction Innovative Technology Evaluation
     Program (WRITE) 2
welding friction 2(5
windower machine 45
 sandblasting 26
 separation process
     centrifuge 34
     reverse osmosis 10
 separators for batteries 43
 sheet metal fabrication 49
 silver recovery 27
 sludge dryer 41
 small waste stream, prevention 21
 sodium flux, water based vs. solvent based 38
 solvent (see also specific)
     degreasing 4, 26
     distillation 4
     recovery 4, 31, 32, 36, 40, 41, 47, 49
sorbent pads, polypropylene 12
spills
     fluid pickup 12
     nickel and copper plating 27
strainer, metal mesh 43
    xylene 23
                                                  53
  •kv.S. GOVERNMENT PRINTING OFFICE: 19*5 - 650406/00248

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