EPA/530-SW-89-056
Pollution Prevention
In Metal Manufacturing
Saving Money
Through Pollution Prevention
U.S. Environmental Protection Agency
- Office of Solid Wast*
October 1989
Printed on Recycled Paper
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Preface
Pollution Prevention in Metal Manufacturing is intended to provide you with a brief introduction
to pollution prevention, including what it is, how it can put money back into your company's pocket, what
its basic elements are, and where you can get additional assistance. This booklet also provides a sample
of the various technical options available to a wide range of metal manufacturing facilities. Typical
economics (for example, capital investment* annual savings, and payback periods) are also provided for many
of the options.
The technical and economic information in Pollution Prevention in Metal Manufacturing is intended
to be representative more than comprehensive. The collection and organization of this information is an
ongoing and evolutionary process. The first version of this booklet reflects a sampling of information
readily available at the time of preparation. As more pollution prevention activity takes place and technical
approaches to pollution prevention change, EPA hopes to update and publish follow-up versions of this
booklet.
Pollution Prevention in Metal Manufacturing is only one of many sources of pollution prevention
information available to you from EPA. For additional information about pollution prevention, or to
comment on this booklet, call:
The RCRAySuperfund Hotline, at (800) 424-9346, or
(202) 382-3000;
Myles Morse, of EPA's Pollution Prevention Information *O
Clearinghouse, at (202) 475-7161; or V*
"?A
James Lounsbury, Director of EPA's Waste Minimization J^
Staff, at (202) 382-4807.
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The Purpose of this Booklet
If your metal manufacturing operations generate any wastes, the information in this booklet can
help your firm.
POtLlTTON
CAN:
Significantly reduce your firm's costs, liabilities, and
regulatory burdens associated with waste management; and
Enhance your firm's efficiency, product quality, and public
image.
The United States Environmental Protection Agency (EPA) developed this booklet to help your
firm implement a pollution prevention program. It highlights the various components of a pollution
prevention program. It also provides two tables to help you identify specific pollution prevention options,
based on the types of processes or operations at your facility. The tables contain technical, cost, and waste
reduction information on a variety of options that have actually been used at metal manufacturing facilities.
The information contained in the tables will help you evaluate potential annual savings from numerous
pollution prevention techniques.
The Information in this Booklet
Will Be Helpful to Your Company
This booklet is designed to be most useful to
firms that engage in metal manufacturing
operations. You should read this booklet if your
firm manufactures metal products, or is involved in
any metal manufacturing-type processes.
METAL MANUFACTURING INCLUDES
Cutting or machining
Degr casing
Pickling
Heat treating
Finishing or painting
Equipment and facility
cleanup
Electroplating
This booklet will also be useful if your facility
uses any combustible or Qammabk solvents, strong
acid or alkaline solutions, plating solutions, paints,
cyanide solutions, or any solutions containing heavy
metals. Table I identifies how these materials are
typically used and Table II shows what many
facilities have done to save monev.
Your Company Can Save Money by
Minimizing the Waste it Generates
In addition to relying on traditional waste
management approaches (such as treating or dis-
posing of waste after it has been generated), many
facility managers are finding that by minimizing the
amount of waste their operations generate they can
actually improve their firm's 'bottom line.'
POLLUTION PREVENTION REDUCES
* raw materials
Treatment/disposal costs
Environmental liability and fines
In addition to these economic incentives for
pollution prevention, EPA is taking several steps to
create additional incentives for firms to reduce
their waste generation. Some of EPA's actions
include:
Making technical information available to
help firms identify ways of reducing waste
generation.
Supporting the development of State
programs to assist firms in their waste
reduction efforts.
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Requiring hazardous waste generators, under
the Resource Conservation and Recovery
Act (RCRA), to certify on their hazardous
waste manifests and annual permit reports
that they have a "program-in-place" to
reduce the volume or quantity and toxicity
of their hazardous wastes as much as
economically practical
Requiring generators to describe on their
RCRA biennial reports the efforts they have
undertaken during the year to reduce the
volume and toxicity of their hazardous waste,
and to compare these efforts to previous
years.
What is 'Pollution Prevention?'
Pollution prevention emphasizes reducing or
eliminating any releases of hazardous materials
(including hazardous wastes) into the environment
through the use of source reduction and
environmentally-sound recycling. A pollution
prevention program can be developed by any
business that generates wastes. The program might
include several elements intended to reduce, to the
extent feasible, any air or water discharges, or any
solid or hazardous waste that is generated at the
facility.
Source reduction is intended to minimize or
eliminate the waste at its source, before it is
generated or released. Recvcljnf. on the other
hand, focuses on the use, reuse, or reclamation of
the waste as an effective substitute for a
commercial product or as an ingredient or
feedstock in a process. Recycling by use or reuse
involves returning a waste material to either the
originating process or another process as a
substitute for an input material Reclamation is
the recovery of a valuable material, or removal of
impurities, from a waste.
Because it is significantly more efficient and
less expensive to prevent the generation of waste
in the first place, you should consider source
reduction to be the most preferable waste
management option. Source reduction is followed,
in order of decreasing preference, by recycling,
treatment (for example, incineration or
stabilisation), and land disposal
POLLUTION PREVENTION TERMS
Pollution Prevention - Reducing or
eliminating discharges and/or emissions to
the environment through the use of source
reduction and environmentally-sound
recycling.
Source Reduction - Reducing or
eliminating waste at its point of generation.
Recycling - Reprocessing waste in a way
that makes it useful again Recycling
focuses on the use, reuse, or reclamation
of waste.
Use or Reuse - Returning a waste
material to the original process that
generated the waste or employing it in
another process as a substitute for an
input material.
Reclamation - Recovering valuable
materials or removing impurities from a
waste.
\
Many Pollution Prevention Options Are Available
A pollution prevention program might include
any number of specific pollution prevention
n»<-Kni/jiu»t e^ch with a potentially unlimited range
of pollution prevention options. The options under
each technique that may be appropriate to your
operation are limited only by your ingenuity. Table
II provides suggested pollution prevention options
that have actually been used in industry. The
options are organized by technique. You should
use these suggested options only as a starting point
for your own creativity. Pollution prevention
techniques are described below:
Training and supervision - provide
employees with the information and the
incentive necessary to minimize waste
generation in their daily duties.
This technique may include ensuring
thai employees know and practice
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proper and efficient use of tools and
supplies, and that they are aware of,
understand, and support your
company's pollution prevention goals.
Production planning and sequencing -- plan
and sequence production so that only
necessary operations are performed and that
no operation is needlessly "undone" by a
following operation.
One example is to sort out "reject"
parts pnorto painting or electroplating.
A second example is to reduce the
frequency of having to clean equipment
(e.g., painting all products of the same
color at once). A third example is to
schedule batch processing in a manner
that allows the wastes or residues from
one batch to be used as an mput for
the subsequent batch (e.g., to schedule
paint formulation from lighter shades
to darker) so that equipment need not
be cleaned between batches.
Process or equipment modification - change
the process, or the parameters or equipment
used in that process, to reduce the amount
of waste generated.
You can change to a paint application
technique that is more efficient than
spray painting, reduce overspray by
reducing the atomizing air pressure to
paint spraying equipment, reduce drag-
out by reducing the withdrawal speed
of parts from plating tanks, or improve
a plating line by incorporating dragout
recovery tanks or reactive nnsmg.
Raw material substitution - repla
raw materials with raw materials that will
result in the generation of less waste.
Examples include substituting alkali
washes for solvent degreasers. and
replacing oil with lime or borax soap
as the drawing agent in cold forming
operations.
Loss prevention and housekeeping - per'crm
prcvcotative maintenance and tn,>n;\ge
quipmeni and nutetuis, so as. to rn;- i-.cs/r
jppouuoities for leaks, -.pilis, ;.u?i <***.*'
releases of potentially hazardous wistr-i.
F:
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be clearly affirmed by your top management
in a written statement. This statement
should be circulated among all employees.
Explicit program goals and objectives --
Explicitly identify the goals and objectives
for the pollution prevention program in a
written statement. The goals should include
reducing the volume or toxicity of the waste
as much as is technically and economically
feasible. The objectives should include a
commitment to evaluate technologies,
procedures, and personnel framing
Accurate waste accounting -- Carefully track
changes over time in the types, amounts,
and hazardous constituents of your wastes.
Accurate cost accounting -- Ensure that your
firm uses 'fully-loaded" costs when
accounting for waste management and
disposal (i.e., costs should account for ail
liability, regulatory compliance, permitting,
riding, treatment, and oversight costs).
Involvement of all employees Involve all
appropriate employees in pollution
prevention planning and implementation.
You can use rewards and incentives to en-
courage employee involvement.
Exchange of technology and information --
Encourage exchange of technology and
information both within your firm and
between your firm and others. Firms often
contain a wealth of resources and
information that results from years of
operating experience. Such resources and
information can play a major role in the
efficient development of a pollution
prevention program. Other organizations
you should consult include EPA Region's
and Headquarter's pollution prevention
information clearinghouses, state agencies,
trade associations, universities and colleges,
nonprofit business assistance organizations,
and professional consultants.
Periodic pollution prevention assessment^
- Periodically review individual processes
(or facilities) to identify new or changing
opportunities to undertake pollution
prevention.
Basically, you should develop your own
program for pollution prevention, and wherever
possible, formally define the program in a written
document. You should also develop an
implementation plan for each of your facilities or
processes and periodically review, revise, and
update the program to reflect changing conditions.
You will need a method of tracking changes in
waste generation rates and accounting for sources
of waste. Establishing an effective pollution
prevention program is not difficult, but it does
require commitment from you and all of your
firm's employees, including corporate management.
Where To Go For Information and Help
While it is important that you be actively
involved in establishing and promoting your firm's
pollution prevention program, you may wish to seek
the guidance or help of other experts. Some
organizations that you may wish to contact include:
Trade Associations - Often trade
associations can provide you with pollution
prevention assistance directly, or they can
refer you to someone who can.
State Waste Management Agencies - These
agencies often have staff people who are.
knowledgeable about pollution prevention
and are willing to provide assistance.
Regional Environmental Protection Agency
Offices - There are ten Regional Offices
of the Environmental Protection Agency.
The easiest way to find out which Regional
Office is responsible for your area is to
call the toll free RCRA/Superfund Hotline
(see below) and ask for the telephone
number or address of the Regional Office
responsible for your area.
Environmental Protection Agency - Within
EPA Headquarters you may conveniently
contact any of the following information
sources:
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Hazardous Waste Minimization Staff, at (202)
382-4307, can provide technical waste minimi?*.
tion information;
Waste Minimization Branch, at (513) 569-7529,
can assist you with research and development
activities regarding waste minimization
assessments, innovative technology and pollution
prevention evaluations, and activities of the Waste
Reduction Institute for Scientists and Engineers;
Pollution Prevention Office, at (202) 382-4335,
can assist you in understanding pollution
prevention and provide you with a great deal of
pollution prevention information; and the
Pollution Prevention Information Clearinghouse.
which includes a collection of reference literature
pertaining to pollution prevention, outreach
efforts, the Electronic Information Exchange
System, and the RCRA/Superfund Hotline:
Electronic Information Exchange
System (EIES). at (301) 589-8366, is
an easy-to-use, interactive PC-based
system. Using a personal computer
and a modem, you can access EIES
to obtain a wide variety of pollution
prevention information, including case
studies, a calendar of events, a
directory of experts, a bibliography of
publications, and descriptions of
federal and state pollution prevention
programs. You can use an interactive
message center to pose pollution
prevention questions or provide
comments to other users. The
information in Table II that is followed
by an "EIES Number" has come from
references that are available to you
through EIES. You may examine
these references for additional
pollution prevention information or
ideas.
RCRA/Superfund Hotline, at (800)
424-9346 (or (202) 382-30001 can
answer your pollution prevention
questions, help you access information
in EIES, and assist you in searching
for and obtaining documents.
HAVE YOU TRIED
POLLUTION PREVENTION?
If you have tried, or are planning on
trying any pollution prevention activity at
your facility and would like to share your
ideas or experience, use your personal
computer to access the Electronic
Information Exchange System (EIES) at
(301) 589-8366, and let others know! We
can all learn from your experience!
How To Use the Pollution Prevention Tables
Two tables are included in this booklet as a
quick guide to help you begin identifying specific
pollution prevention options. The ideas
represented in these tabies have been used at
actual facilities, resulting in cost savings. Table I
identifies typical processes and operations in the
metal manufacturing industry. This table also
identifies typical materials used and types of waste
generated for each process.
Table II is also broken down by process and
operation. Table II, however, provides pollution
prevention options for each process and operation.
These puflution pieveuliuu options are organized
by technique, as described in the previous section.
In addition, Table II provides examples of cost and
savings realized by other facilities, and additional
relevant information.1 You should use this
information to help decide which options would
best serve your needs. When properly installed
and maintained, none of the options described on
Table II should adversely affect the quality of your
products and all should reduce your potential
liability from improper waste management. The
entries in Table II that are followed by an 'EIES
Number" have come from references that are
available to you through EIES. You may request
and examine these references for additional
pollution prevention information or ideas.
cost, savings, and waste reduction information provided in Table II is based on actual case studies and
reflects the successes of actual metal manufacturing facilities. Because specific applications are highly variable,
however, you should use this information only as an indicator of how a particular pollution prevention option
may perform under your circumstances.
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TABLE I
TYPICAL METAL MANUFACTURING OPERATIONS
WHICH MAY PRODUCE WASTES
TYPICAL
PROCESS OR
OPERATION
TYPICAL
MATERIALS
USED
GENERAL TYPES
OF
WASTE GENERATED
Metal Cutting or
Machining
Cutting oils
Degreasing and cleaning solvents
Acids
Heavy metals
Acid/alkaline wastes
Heavy metal wastes
Solvent wastes
Waste oils
Degreasing
Pickling
Acid/alkaline cleaners
Organic solvents
Acid/alkaline solutions
Acid/alkaline wastes
[gmtable wastes
Solvent wastes
Still bottoms
Acid/alkaline wastes
Heavy metal wastes
Heat Treating
Acid/alkaline solutions
Cyanide
Oils
Acid/alkaline wastes
» Cyanide wastes.
Heavy metal wastes
Waste oils
Metal Finishing and
Painting Cleanup
Solvents
Paint carrier fluids
Heavy metal paint wastes
Ignitable paint wastes
Solvent wastes
Still bottoms
Facility Cleanup
solvents
Solvent wastes
Still bottoms
Electroplating
Acid/alkaline solutions
Heavy metal bearing solutions
Cyanide bearing solutions
Acid/alkaline wastes
Cyanide wastes
Heavy metal wastes
Plating wastes
Reactive wastes
Wastewaters
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TABLE n
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
METAL CUTTING OR MACHINING
Production
Planning and
Sequencing
Process or
Equipment
Modification
Improve scheduling of processes that require
use of varying oil types in order to reduce
the number of cleanouts.
Standardize the oil types used for machining,
turning, lathing, etc. This reduces the
number of equipment cleanouts, and the
amount of leftover* and mixed wastes.
\
Use specific pipes and lines for each set of
metals or processes that require a specific oil
m order to reduce the amount of cleanouts.
Save on coolant costs by extending machine
coolant life through the use of a centrifuge
and the addition of biocides.
Install a second high speed centrifuge on a
system already operating with a single
centrifuge to improve recovery efficiency
even more.
Install a chip wringer to recover excess
coolant on aluminum chips.
Install a coolant recovery system and
collection vehicle for machine* not OB the
central coolant sump.
Wast* Savings/Redaction*: 25% reduction in plant-wide
waste coolant generation. Product/Waste Throughput
Information: based on handling 20,600 gallons of coolant
per year. [EIES Number 100-101, p. 440)
Capital Investment: $126,000. Payback Period: 3.1 years
ProdxcVWasie Throughput Information: based on handling
20,600 gallons of coolant per year. [EIES Number 100-101,
p. 441]
Capital Investment: $233.500. Payback Period: 0.9 years
Product/Waste Throughput Information: based on handling
20,600 gallons of coolant per year. [EIES Number 100-101.
p. 441]
Capital Investment: $11.000 to S23.000 (chip wringer and
centrifuge system). [EIES Number 101-004. p. 32-6)
Casttel lawwtmcnfc SI04,000. Payback Period: 19 yean.
Product/Waste Throughput Information: based on handling
20,600 gallons of coolant per year. [EIES Number 100-101,
p. 441]
Use a coolant analyzer to allow better
control of coolant quality.
Use an ultrafiltration system to remove
soluble oils from wastewater streams.
Capital Investment: 55,000. Payback Period: 07 years.
Product/Waste Throughput Information: based on handling
20,600 gallons of coolant per year. [EIES Number 100-101.
p. 441]
Annual Savings: 5200,000 (in disposal costs).
Product/Waste Throughput Information: Based on a
wastewater flow rate of 860 to 1,300 gallons per day. (EIES
Number 805-001]
The cost, savings, and waste reduction information provided irr Tatrte-1! is based on actual case studies and reflects the successes of
actual metal manufacturing facilities. Because specific applications are highly variable, however, you should use this information only .is
an indicator of how a particular pollution prevention option may perform under your circumstances.
These options cost les& than 530.000 to implement.
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TABLE n (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
OLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Raw Material
Substitution
Use disk or belt skimmers, to remove way oil
from machine coolants and prolong coolant
life. Also, design sump* for ease of cleaning.
In cold forming or other processes where oil
is used only as a lubricant, substitute a hot
lime bath or borax soap for oil.
Waste Savings/Reduction: Coolant is now disposed once
per year rather than 3-6 times per year. (EIES Number
p. 78)
* Use a stamping lubricant thai can
remain on the piece until the annealing
process, where it is burned off. This
eliminates the need for hazardous degreasmg
solvents and alkali cleaners.
Annual Savings: SI2.000 (results from reduced disposal.
raw material, and labor costs). Waste Throughput
Information: The amount of waste solvents and cleaners
was reduced from 30.000 Ibs. in 1982 to 13.000 Ibs. in 1986.
Employee working conditions were also improved by
removing vapors associated with the old cleaners. [EIES
Number 034-006, p. 5]
Waste
Segregation
and
Separation
If filtration or reclamation of oil is required
before reuse, segregate the used oils in order
to prevent mixing waste*.
" Segregation of metal dust or scrap by
type often increases the value of metal for
resale (e.g., sell previously disposed metallic
dust to a zinc smelter).
Capital Investment: SO. Annual Savings: SI30.000.
Payback Period: immediate. Waste Savings/Reduction:
2,700 tons per year. [EIES Number 306-001. p. 109)
' Improve housekeeping techniques to
prevent cutting oils from becoming
contaminated with 1,1,1-mchloroethane (e.g.,
use care when cleaning cutting equipment to
present tnc uuttucc of cuttmc oil too toe
cleaning solvent).
Capital Investment: SO. Annual Savings: S3.000 in
disposal costs. Waste Savings/Reduction: 60% (30 ions
reduced to 10 tons). [EIES Number 005-043. p. 24]
Recycling
Where possible, recycle oil from cutting/
machining operations. Often oils need no
treatment before recycling:
Capital Investment: SI,900,000. Annual Savings:
$156,000. Waste Throughput Information: 2 million
gallons per year Facility reclaims oil and metal from
process water. [EIES Number 306-001. p. 137]
Oil scrap mixtures can be centhfuged to
recover the bulk of the oil for reuse.
Follow-up magnetic and paper filtration of
cutting fluids, with "^'Tifi^Ttion By so
doing, a much larger percentage of cutting
fluids, can be reused.
Capital Investment: 542,000 (1976). Annual Savings:
S33.800 (1980). [EIES Number 400-072]
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TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
** Perform on-site purification of hydraulic
oils using commercial "off-the-sheir cartridge
filter systems.
Capital Investment- 528,000. Annual Savings:
S17,800/year based on operating costs, avoided new oil
purchase, and lost resale revenues. Payback Period: less
than 2 yean. Prodacl/Waste Throughput Information:
example facility handles 12.300 gallons/year of waste
hydraulic oU. [EIES Number 100-101. p. 144)
'* Use a continuous flow treatment system
to regenerate and reuse aluminum chemical
milling solutions.
Capital Investment: 5465,000. Annual Savings: 3342.000
Payback Period: less than 2 yean. WasU Savings/
Reaction: 90%. [EIES Number 906-001. p. 11]
Use a settling tank (to remove solids)
and a coalescing unit (to remove tramp oil:
to recover metal-working fluids.
DECREASING
Annual Savings: $26,800 (resulting from reduced material,
labor, and disposal costs). [EIES Number 034-009, p. 679]
**
Training and
Supervision
" Improve solvent management by
requiring employees to obtain solvent
through their shop foreman. AJso, reuse
''waste" solvents fium cleaner up-iiveus
operations m down-stream, machine shop-
type processes.
Capital Investment: SO. Annual Savings: $7,200. Waste
Savings/Reduction: 49% (310 tons reduced to 152 tons).
Product/Watte Throughput Information: original waste
stream history: reactive amons- (6-,10* gailons/vr), waste- oils
(1,250 gaUons/yr), hatogenated solvent! (500 gallons/yr).
[EIES Number 005-043, p. 74]
Production
Planning and
Sequencing
Prc-cleaning will extend the life of the
aqueous or vapor degreasing solvent (wipe,
squeeze, or blow part with air, shot, etc.).
Annual Savings: $40,000. Payback Period: 2 yean.
Waste Savings/Reduction: 48,000 gallons of aqueous waste.
Aluminum shot was used to preclean parts. [EIES Number
306-001, p. 239]
Use countercurrem solvent cleaning (i.e.,
nnse initially in prevwusty used, salient and
progres* to new, clean sotveoi).
Cold clean with a recycled mineral spirits
stream to remove the bulk of oil before final
vapor degreasing.
Only degrease parts that must be cleaned.
Do not routinely degrease all parts.
Process or
The loss of solvent to the atmosphere from
vapor degreasing equipment can be reduced
by:
increasing the free board height above
the vapor level to 75% of tank width;
covenng the degreasing unit (automatic
covers are available):
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TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
installing refrigerator coils (or additional
coils) above the vapor zone;
rotating pans before removal from the
vapor degreaser to allow all condensed
solvent to return to degreasmg unit;
controlling the speed at which pans are
removed (10 ft/mm or lest is desirable)
so is not to disturb the vapor line;
installing thermostaiic heating controls
on solvent tanks; and
adding in-line filters to prevent
paniculate buildup in the degreaser.
" Reduce grease accumulation by adding
automatic oilers to avoid. »««« oil
applications. [EIES Number 604-001]
Raw Material
Substitution
** Use less hazardous degreasing agents
such as petroleum solvents or alkali washes.
For example, replace halogenated solvents
(e.g., tnchloroethylene) with liquid alkali
cleaning compounds.
CapiUl Investment: SO. Annual Savings: Si2,000
Payback Period: immediate. Waste Savings/Reduction:
30% of 1,1,1-trichloroethane replaced with an aqueous
cleaner. [EIES Number 034-010. p. 25]
Capital Investment: $438,000. Payback Period: 51 years.
Replaced trichloroethylene degreaser with aqueous cleaner
system. [EIES Number 022-OU. p. 125)
Annual Savings: $2.000. Payback Period: 1.6 year;
Substituted chlorofluorocarbon solvents with proprietary
cleaner. (EIES Number 022-013)
Annual Savings: 38% of cost savings and a 62% return on
investment. Payback Period: 1.6 years. [EIES Number
022-011, p. A-4)
Recycling
Recycle spent degreasing solvents on
site using batch stills.
Capital Investment: $7,200. Annual Savings: $90.000.
Payback Period: 1 month. Waste Savings/Reduction:
10,000 gallons annually of spent solvents by in-house
distillation. [EIES Number 306-001, p. 79]
Capital Investment: S2.600-S4.100 and S4.200-S17.000.
Product Throughput Information: 35-60 gallons per hour
and 0.6-20 gallons per hour, respectively. Two cosi ,md
throughput estimates for distillation units from two vendors
[EIES Number 005-003. p. 70]
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TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Use simple batch distillation to extend
the life of 1,1,1-trichloroethane (l.U-TCA).
Capital Investment: $3.500 (1978). Annual Savings:
$50,400. Product/Waste Throughput Information: facility
handles 40,450 gallons l.U-TCA per year. (EIES Number
100-101. p. 442)
" When on-Jite recycling is not possible,
agreements can be made with supply
companies to remove old solvents.
Capital Investment: S3,250 for a temporary storage
building. Annual Savings: $8,260. Payback Period: less
than 6 months. Waste Savings/Reduction: 38,000 pounds
per year of solvent sent off site for recycling. [EIES
Number 306-001. p. 149J
* Arrange a cooperative agreement with
other small companies to centrally recycle
solvent.
PICKLING
Process or
Equipment
Modification
Increase the number of rinses after each
process bath and keep the rinsing counter-
current m order to reduce ft"g«r" '"t^r
Acids in the wastewaters may be recoverable
by evaporation.
Reduce rinse contamination via dragout by:
slowing and smoothing removal of parts.
rotating them if necessary;
using surfactants and other wetting
a genii,
maximizing drip time;
using drainage boards to direct dripping
solutions back to process tanks;
installing dragoni recovery tanks to
capture dnpping solutions;
using a fog spray nnsing technique
above process tanks;
using techniques such as air knives or
squeegees 10 wipe rMih solutions off of
ihe pan: and
-------
TABLE n (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
changing bath temperature or
concentrations to reduce the solution
surface tension.
Instead of pickling brass pans in mine acid,
place them in a vibrating apparatus with
abrasive glass marbles or steel balls. A
slightly acid additive is used w«h the glass
marbles, and a slightly basic additive is used
with the sted balls.
Capital Investment: S62.300 (1979); 50% less than
conventional mine acid pickling. [EIES Number 400-036]
" Use mechanical scraping instead of acid
solution to remove oxides of titanium.
Annual Savings: SO; cost of mechanical stripping equals
cost of chemical disposal. Waste Savings/Redaction: 100%:
Waste Throughput Information: previously disposed IS
tons/year of acid with metals. [EIES Number 005-043,
p. 32]
For cleaning nickel and titanium alloy,
replace alkaline etching bath with a
mechanical abrasive system that uses a silk
and carbide pad and pressure to clean or
"brighten" the metal.
Capital Investment: S3.250. Annual Savings: S7.500.
Waste Savings/Redaction: 100%. Waste Throughput
Information: previous etching bath waste total was 12.000
tattoos/year. [EIFS Number 005-043, p. 50)
Clean copper sheeting mechanically with a
rotating brush machine that scrubs with
pumice, instead of cleaning with ammonium
persulfate, phosphoric acid, or sulfunc acid
(may generate non-hazardous waste sludge).
Capital Investment: S59.000. Annual Savings: more than
$15,000. Payback Period: 3 yean. Waste Savings/
Reduction: 40,000 pounds of copper etching waste reduced
to zero. [EIES Number 101-028, p. H-3)
Annual Savings: 515,000 in raw materials, disposal. Jnd
labor. Payback Period: 3 years. Wast* Saving*Reduction:
avoids generation of 40.000 pounds per year of hazardous
watte liquid. [EIES Number 803-001)
Reduce molybdenum concentration in
wastewaters by using a reverse
osmosis/precipitation system.
Capital Investment $320,000. Waste Throughput
Information: permeate capacity of 18,000 gallons per day.
Savings Relative to an Evaporative System: installed capital
cost savings: 5510,000; annual operating cost savings:
590,000. [EIES Number 207-001, p. 5]
Raw Material
Substitution
Change copper bright-dipping process from a
cyanide and chromic acid dip to a sulfunc
acid/hydrogen peroxide dip. The new bath is
less toxic and copper can be recovered.
(EIES Number 306-001. p. 130)
' Use alcohol instead of sulfunc acid to
pickle copper wire. One ton of wire requires
4 liters of alcohol solution, versus 2
kilograms of sulfunc at.id.
Capital Investment: SO. [EIES Number 400-069)
- 12 -
-------
TABLE It (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Replace caustic wire cleaner with a
biodegradable detergent. [EIES Number
604-001]
Recycling
Replace chromated desmuttmg solutions with
nonchromated solutions for alkaline etch
cleaning of wrought aluminum.
Sell waste pickling acids as feedstock for
fertilizer manufacture or neutralization/
precipitation.
Annual Savings: $44,541. WasU Savings/Reduction:
sludge disposal costs reduced by 50%. [EIES Number 806-
001, p. 10]
Recover metals from solutions for resale.
Annual Savings: $22,000. Payback Period: 14 months.
Company sells copper recovered from a bright-dip bath
regeneration process employing ion exchange and electrolytic
recovery. [EIES Number 306-001, p. 171]
" Send used copper pictding baths to a
continuous electrolysis process for
and coppar recovery.
Capital Investment: $28,500 (1977). Product Throughput
Information: pickling 12,000 tons of copper copper
icujvery a ax the rue of 200 a/ton of processed copper
[EIES Number 400-097]
" Recover copper from brass bright
dipping solutions using a commercially
available ion exchange system.
Annual Savings: $17.047; based on labor savings, copper
sulfate elimination, sludge reduction, copper metal savings
and bright dip chemicals savings. Product Throughput
Information: example facility processes approximately
215.000 pounds of brass per month. [EIES Number 804-
001]
' Treat industrial waste-water high in
soluble iron and heavy metals by chermcat
precipitation.
Annual Savings: $28.800: based on reduced water and
sewer rarer Waste Throughput Information: wasrewarer
(low from facility's "patening" line is 100 gallons per minute.
[5IES Number 034-013]
HEAT TREATING
Process or
Equipment
Modification
* When refining precious metals, reduce
the acid/metals waste stream by maximizing
reaction time in the gold and silver extraction
process.
Capital Investment: SO Annual Savings: $9.000 Waste
Savings/Reduction: 70% (waste total reduced from 50 tons
to 15 tons). [EIES Number 005-043, p. 73]
Raw Material
Substitution
Replace banuot and cyanide safe heal
treating with a carbonate/chloride cartoon
mixture, or with furnace heat treating.
Replace thermal treatment of metals with
condensation of saturated chlorite vapor* on
i he surface to be heated.
Waste Savings/RfducthHi. tms process is fast, nonouduing.
and uniform: pickling is no longer necessary [EIES
Number 400-1081
-------
TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Replace cyanurated, sail HanVning process
with one using fluidized baths of nitrogen
and corundum.
Relative Savings: nitrogen and corundum hardening costs
60% of the conventional cyanurated salts process, and
generates no waste. [EIES Number 400-071]
Recycling
Oil quench baths may be recycled on site by
filtering out the metals.
Alkali wash life can be extended by skimming.
off the oil layer (this skimmed oil may be
reclaimed).
METAL FINISHING AND PAINTING
Training and
Supervision
Always use proper spraying techniques.
Production
Planning and
Sequencing
Improved paint quality, work efficiency, and
lower vapor emissions can be atutAcd by-
formal training of operators-
Avoid buying too much finishing material at
one time, due to its short shelf life.
Use the correct spray gun for particular
applications:
conventional air spray gun for thm-film-
build requirements;
airless gun for heavy film application;
and
air assisted airless spray gun for a wide
range of fluid output.
Preinspect pans to prevent painting of
obvious rejects.
Process or
Equipment
Modification
Ensure the spray gun air supply is free of
water, col. and dirt.
Replace galvanizing processes requiring higir
temperature and flux with one that is low
lemperature and does not require flux.
Capita* ln»«5lni»nL S96».6e». Arnnnrt Savings: 50% (as
compared 10 conventional galvanizing). Product Throughput
Information: 1.000 kg/h. (TIES Number 400-008]
- U
-------
TABLE n (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Investigate use of transfer methods that
reduce material loss such as:
dip and flow coating;
electrostatic spraying; and
electrodeposition.
Change from conventional air spray to
an electrostatic finishing system.
Annual Savings: $15,000. Payback Period: less than 2
years. [EfES Number 310-001, p. 136)
Use plastic blast media for paint stripping
rather than conventional solvent stripping
techniques.
Waste Savings/Redaction: volume at waste sludge is
reduced by as much as 99% over chemical solvents;
wastewater fees are eliminated. [EIES Number 503-001J
Use solvent recovery or incineration 10
reduce the emission* of volatile orgatucs
from curing ovens.
Annual Savings: £400,000. [EIES Number 306-001. p. 7]
Regenerate anodizing and alkaline silking
baths with contemporary recuperation of
aluminum salts.
Annual Savings: $0.02/m2 of aluminum treated. Annual
Savings: (including sale of the recovered dry aluminum
sulfate) S0.05/m2 Waste Throughput Information: based
on an example plant that previously disposed 180.000 liters
of acid solution per year at S0.07/Iitre. [EIES Number
451-501)
Raw Material
Substitution
Use alternative coatings for solvent
paints to reduce volatile, organic material* use
and emissions, such, as;
high solids coatings (this may require
modifying the painting process; including
high speed/high pressure equipment, a
paint distribution system, and paint
heaters);
Waste Savings/Reduction: 30% net savings in applied costs
per square foot. (EIES Number 038-003)
Waste Savings/Reduction: 41% reduction in VOC
emissions. The VOC of the paint decreased from S.5
Ib/gallon to 3 Ib /gallon. [EIES Number 739-001, p. 182]
water based coatings; and
Waste Savings/Reduction: 87% drop in solvent emissions
and decreased hazardous waste production. [EIES Number
739-001, p. 182)
powder coatings.
Capital Investment: SI.5 million. Payback Period: 2
years. Example is lor a large, wrought iron patio furniture
company. [EIES Nunrfer 73*-«&l. p. 185)
-------
TABLE n (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
* Substitute chromic acid cleaner with
non-fuming cleaners such as sulfunc and and
hydrogen peroxide.
Annual Savings: $10,000 in treatment equipment costs and
$2.50/lb. of chromium in treatment chemical costs. Product/
Wast* Throughput Information: rinse water flowrate of 2
gallons per minute. [EIES Number 101-027, p. H5]
Substitute non-polluting cleaners such as
tnsodium phosphate or ammonia for cyanide
cleaners.
Annual Savings: J 12.000 in equipment costs and S3 00,1b
of cyanide in treatment chemicals costs. Product/Wast*
Throughput Information: rinse water flowrate 2 gallon per
minute. [EIES Number 101-027, p. 115]
Waste
Segregation
and
Separation
Recycling
Segregate non-hazardous paint solids from
hazardous paint solvents and thinner. [EIES
Number 604-001]
Do not dispose of extended shelf life items
that do not meet your facilities'
specifications: They may be returned to the
manufacturer, or sold or donated as a raw
material. [EIES Number 005-043. p. 26}
Recycle metal sludges through metal recovery
vendors. [EIES Number 005-043, p. 27]
Use activated carbon to recover solvent
vapors, then recover the solvent from the
carbon by steam stripping, and distill the
resulting water/solvent mixture.
Capital Investment: $817000 (1973). Waste Savings/
Reduction: releases of solvent to the atmosphere were
reduced from 700 kg/ton of solvent used to 20 kg/ton.
[EIES Number 400-032]
Regenerate caustic sod* oca mint inns for
aluminum by using hydrolysis of sodium
alummate to liberate free sodium hydroxide
and produce a dry, crystalline hydrate
alumina byproduct.
Capital Investment. S260.000. Annum! Savings: S 169.232:
from reduced caustic soda use. income from the sale of ihe
byproduct, and a reduction in the cost of solid waste
disposal. Flyback Period: 1.54 years. Product/Waste
Throughput Information: anodizing operation for which the
surface area is processed at a rate of 200 m2/hour (EIES
Number 505-001]
METAL FINISHING AND PAINTING CLEANUP
Production
Planning and
Reduce equipment cleaning by painting with
lighter colors before darker ones.
Reuse, cleaning solvents for the same resin
system by first allowing solids to settle out of
solution.
- \f> -
-------
TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Flush equipment first with dirty solvent
before final cleaning with virgin solvent.
Waste Savings/Reduction: 98%: from 25.000 gallons c!
paint cleanup solvents to 400 gallons. Company uses
cleanup solvents in formulation of subsequent batches
[EIES Number 034-010. p. 14]
Use virgin solvents for final equipment
cleaning, then as paint thinner.
Use pressurized air mixed with a mist of
solvent to dean equipment.
Raw Material
Substitution
" Replace water-based paint booth filters
with dry filters. Dry filters will double paint
booth life and allow more efficient treatment
of wastewater.
Annual Savings: 51,500. Waste Savings/Reduction: 3,000
gallons/year. [EIES Number 806-001. p. 7]
Loss
Prevention
and
Housekeeping
To prevent spray gun leakage, submerge only
the front end (or fluid section) of the gun
into the cleaning soivem.
Waste
Segregation
and
Separation
Solvent waste streams should be kept
segregated and free from water
contamination.
Recycling
Solvent recovery units can be used to
recycle spent solvents generated in flushing
operations.
Install a recovery system for solvents
contained in air emissions.
Annual Savings: SI.000 [EIES Number 034-010. p 10)
Use batch distillation to recover
isopropyl acetate generated during
equipment cleanup.
Payback Period: : years. [EIES Number 034-010. p. \"\
Use batch distillation to recover xylene
from p»"v "^lupnvm cleanup.
Payback Period: 13 months. Annual Savings: $5.000
(EIES Number 034-010. p. 18]
Use a small solvent recovery still 10
recover spent paint thinner from spray
gun cleanups and excess paint batches.
Capital Investment: $6,000 for a 15 gallons capacity still.
liinual Savings: $3,600 in new thinner savings; $5.400 in
disposal savings. Payback Period: less than 1 year Waste
S«ving*RcdiKtton: 75% (745 gallons of I limner recovered
from 1.003 gallons). Product/Wast* Throughput
Information: 1.500 gallons of spent thinner processed per
year. [EIES Numher 034-006, p. 6|
17
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TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Install a methyl ethyl ketone solvent
recovery system to recover and reuse
waste solvents.
Annual Savings: S43,000/year MEK recovery rate: 20
gallons/day, reflecting a 90% reduction in waste. (EIES
Number 806-001. p. 7]
Arrange an agreement with other small com-
panies to jointly recycle cleaning wastes.
FACILITY CLEANUP
Loss
Prevention
and
Housekeeping
Improve housekeeping practices to reduce
spillage of cleaning solvents.
Install collection/drip pans under machinery
and lubrication operations to recover oils.
Use rags to their full oil absorbing capacity,
and use a laundenng system to clean oil-
laden rags.
ELECTROPLATING
Training and
Supervision
Educate plating shop personnel in the
conservation of water during processing and
m material segregation. [EIES Number 005-
043, p. 20)
Production
Planning and
Sequencing
Prctnspect pans, to prevent proceuing of
obvious rejects.
Process or
Equipment
Modification
Employ countercurrcm rinsing to greatly
reduce rinse water usage. Increase dram
time to allow parts to drain 10 seconds or
more after removal from bath. [EIES
Number 002-016, p. 12]
Add wetting agents to the plating baths to
reduce adhesion of solution to the pans.
[EIES Number 002-01*. p. 12]
Increase bath temperature to reduce viscosity
and improve drainage. [EIES Number 002-
016. p. 13)
. IS -
-------
TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS*
AND OTHER INFORMATION"
Use spray rinsing (o increase rinsing
efficiency for non-complex pan
configurations.
Use air agitation in nnse tanks 10 improve
nnsing efficiency.
Change continuous treatment to a batch
system to account for upsets in effluent
levels.
Capital Investment: 5210,000. Payback Period: 3 years.
Waste Strings/Redaction: reduced water usage from 12.000
gallons per day to SOd gallons per day. [EIES Number 306-
001, p. 133]
Reduce bath evaporation by covering the
surface with a blanket of polypropylene balls.
Continuously filter process baths 10 extend
their life. [EIES Number 005-043, p. 17]
If etching is done only to put a- shine on the
parts, some customers may agree to buy
them unctched. thus, greatly reducing etch
bath wastes. [EIES Number 005-043, p. 22]
" Use low concentration plating solutions
rather than mid-pome concentrations in order
;o reduce the total mass of chemicals being
dragged out.
Annual Savings: SI,300. Product/Waste Throughput
Information: a nickel operation having 5 nickel tanks and
an annual nickel dragout of about 2,500 gallons. [EIES
Number 101-027. p. 121)
Use the Kushner and Providence methods of
double dragpttt followed by treatment or
recycle o/ the concentrated dragout solution
10 minimize rinse water use.
Annual Savings: using the Providence method in lieu of
conventional wafer treatment:
Shop size (gpd): 6.000 36.000 134.000
Annual Savings: SI7,110 S60.080 $44.095
[EIES Number 101-027]
Employ coumercurrem and conductivity
controls to reduce nnse water flows.
Annual Operating Costs: SI0.00/1,000 gallons. Annual
Savings: 1170,000. Waste Savings/Reduction: nnse water
was reduced from 43,000 gallons per day to 8,000 gallons
per day. [EIES Number 806-001, p. 8]
* Use electrolytic cells to recover metals
from waste plating solutions. Applicable to
recovery of gold, silver, cobalt, nickel,
cadmium, copper, ami zinc (root solutions.
wuh 100 mg/1 to 1.000 rag/1 of metal.
Capital Investment: 58,750 - Sl'7,500. Metal Recovery: 1
2 tonnes/yr. Waste Savings/Reduction: metal losses
reduced by a factor of 100. [EIES Number 400-101]
Raw Material
Substitution
Utc less toxic materials whenever possible.
Substitute zinc tor cadmium in
alkali/saline environments.
- 19 -
-------
TABLE II (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Substitute mine or hydrochloric acid for
cyanide in certain plating baths in order
to produce a less hazardous sludge.
(EIES Number 024-001. p. 26]
Substitute zinc chloride for zinc cyanide.
[EIES Number 024-001. p. 26)
Waste
Segregation
ad
Separation
Substitute a non-chlonnated stripper in
place of mwhytewe chloride. [EIES
Number 005-043. p. 16]
Wastewaters containing recoverable metals
should be segregated from other wastewater
streams.
Recycling
Instead of disposing of plating bath when
strength has decreased. Oiler and reconstitute
* * Instead of disposing of process baths,
attempt to make them marketable for resale.
Annual Savings: 516,300. [EIES Number 306-001]
Recycle used nnse waters into bath makeup
solutions tor their respective process baths.
Reduce the quantity and toxicity of
by anpiajrtng. technologies such
evaporation:
Annual Savings: greater than SI00,000. Payback Period:
less than 1 year. Waste Savings/Reduction: from about
8,000 pounds of chromium consumed per month to less than
200 pounds per month. Company used a closed loop
evaporator on the chromium bearing nnse waters. [EIES
Number 450-001, p. 7-6)
Capital Investment: $12,200. Annual Operating Costs:
$24,741. Annual Savings: $60,964. Payback Period: 7
months. Evaporative recovery employed on the company s
nickel plating rinse vwien. [EIES Number 034-011]
2-2.3 years. Waste Savings/Reduction:
84% reduction of chromium usage. 15-20^ sludge reduction
Company iiuulleU an evaporative recovery umr for a
chromium'plating process. (EIES Number 450-001 p ~-6|
- 20 -
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TABLE IJ (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF 1
COSTS AND SAVINGS, I
AND OTHER INFORMATION* j
Capital Investment: $25,000. estimated for evaporaiive
recovery equipment. [EIES Number 005-033. p. C9!
Installed Cost $35.680. Annual Operating Cost 59 160
.Annual Savings: $21,000. System operates for 5.000
hours/year, recovering 9.375 its/year chromic jcid. r^h;
Number 400-047]
Capital Investment- $375,000. Payback Period: 2 vears.
Watte Saving* R*4«cth>au 92% recovery of ton exchange-
treated wastewater for reuse. [EIES Number 310-00!
PF c"--"»l
Payback Period; 5 vean. Nickel sulfate solution :> :rested
by ion exchange and returned to nioccl cUt.ng process.
[EIES Number 306-001. p. TU
Capital Investment: $15 000 > 1981 ':,'. rj,
installed to recover chromium 'f:iF> S;,rrv
P "-5J
InvMimenf: MA (XHi
fnveilawiil- SA2.0OO c$3<»,OOO for ;he --evr
unit i Payback Period: .eis nar .', years.
Companv installed revene osmosis unu and t-.atxir
hsaicrs 10 recover nickel -ind nnse *aiers. E;ES
034-010, 0 2~]
Capital Invesiraenu $8.500 Waste Savings/Reduction
about 85% of the nickel dragout. Company installed reverse
osmosis to recover nickel and nnse water JEIES Number
450-001. p. 7-2)
Capital Investment: $200,000 (330 ft2 membrane). Annual
Operating Co*fc large, due to high pressures in system.
Publication discusses reverse osmosis in general and states
thai it a applicable to many electroplating baths. (EIES
Number 005-033. pp. 29-30)
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TABLE H (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION POLLUTION
PREVENTION PREVENTION
TECHNIQUES OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
Capital Investment: $21.500. Operation Cost $9113.
Gross Annul Savings: $17.464. Annual Savings: $8.351
Payback Period: 2.4 yean. Product/Wast* Throughput
Information: economic information for a watu nickel
plating line with dragout rates greater than one gallon per
hour. [EIES Number 504-001]
electrolysis;
Capital Investment: $8,500. Annual Savings: $26.060 in
chemical usage and process water. Product Throughput
lafannajiaa: 60,000 ft2 /aitminm electroplating, plant.
Company implemented a high surface area (HSA)
electrolytic reactor for cadmium recovery. [EIES.Number
310-001, p. 48]
Capital Investment- $43.000 (1979). Annual Savings:
treatment costs eliminated, between 5 and 14 kilograms each
of silver, nickel, and copper are recovered weekly. Company
used fluidized bed electrolysis to recover metals from
electroplating rinse waters. [EIES Number 450-001, p. 7-6]
electro-dialysis with ion exchange; and
Capital Investment: $21,050 (15-cell-pair unit). Payback
Pcrtod? 9* months'. Company recovers goiil fi'um plating
rinse water using electrodialysis and ion exchange. [EIES
Number 450-001, p. ^-*\
Capital Investment:
$26.000/year (reduc:
Number 400-100]
' '09.600 (1980). Annual Savings:
n detoxification costs). (EIES
Capital Investment: S220.000. Annual Savings: $45.000
A medium sized jewelry plating and manufacturing company;
updating the existing water treatment facility would have cost
556*09* [EIES Number 922-Oil. p-. A-l]
cvanide destruction.
Capital Investment: $20.000-S50,000 for hydrolysis process
Waste Savings/Reduction: Can reduce cyanide from 50.000
mg/1 to less than 30 rag/1. Waste Throughput Information:
300 gallons per day. [EIES Number 005-033, pp. 44-45]
Capital Investment: S10.000-S50,000 for chlorine and
hypochlonte processes. W«sle Throughput Information
TOT gallons per day 20 gallons per minute fF.iES N:,
no 41-1?!
rhroujispuS information:
at » rale of 4. gailoci per TOinui
;."-: 'iminsie T ,'ui o-f 3 plating her :'m>c
Number 034-012 r< ?,79!
(re&c£iv
-------
TABLE n (continued)
POLLUTION PREVENTION PRACTICES FOR PROCESSES
AND OPERATIONS IN METAL MANUFACTURING
POLLUTION
PREVENTION
TECHNIQUES
POLLUTION
PREVENTION
OPTIONS
EXAMPLES OF
COSTS AND SAVINGS,
AND OTHER INFORMATION*
" Use reactive rinsing in nickel plating
operations to reduce nnse water use. improve
plating efficiency, and conserve process
chemicals.
Capful Investment; S250 for plumbing and u-.stallation.
Prodoct/WasU Throughput Information; nnse tanns
operated at rate of 4 gallons per minute (reactive nosing
can eliminate 2 out of 3 plating line nnse tanks). [EIES
Number 034-012, p. 239)
Recover phosphate from aluminum bright
dipping operations by reacting nnse acid with
soda alkalies to yield a tnsodium phosphate
solution. Filter the solution, cool it (so
traodium phosphate crystallizes out), and
recycle the remaining mother liquor with
further batches of nnse acid. [EIES Number
807-001]
OVERALL
Loss
Prevention
and
Housekeeping.
Reduce the number of hazardous materials
purchased for similar purposes, (e.g., from
275 different types of adhesive to 2 or 3).
[EIES Number 005-043. p. 27]
Employ a strict preventative maintenance
system 10 prevent spills and leaks. [EIES
Number 005-043, p. 27]
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