&EPA
United States Office of Pollution
Environmental Protection Prevention and Toxics
Agency
EPA/560/8-92/001 A
January 1992
Pollution Prevention
Options In Metal
Fabricated Products
Industries
A Bibliographic Report
Printed on Recycled Paper
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POLLUTION PREVENTION OPTIONS
IN METAL FABRICATED PRODUCTS INDUSTRIES
A BIBLIOGRAPHIC REPORT
January 1992
This report was developed by U.S. EPA's Office of Pollution Prevention and Toxics, under the
direction of:
David A. Hindin
William M. Burch
Special Projects Office
and
Daniel L. Fort
Economics and Technology Division
U.S. Environmental Protection Agency
401 M. Street, S.W.
Washington, D.C. 20460
This report was prepared under EPA contract number No. 68-WO-0027
by Science Applications International Corporation.
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TABLE OF CONTENTS
SECTION I.
INTRODUCTION
Overview
What is Pollution Prevention? . . .
Information on Pollution Prevention
Purpose of this Report
Limits of this Report
1
2
3
4
5
SECTION H. OVERVIEW OF METAL FABRICATED PRODUCTS
Introduction to Metal Fabricated Products Industries
Wastes of Concern
Metal Fabricated Products Manufacturing Processes
6
8
8
SECTION HI.
METAL SHAPING OPERATIONS
Metal Shaping Processes
Wastes Generated
General Source Reduction and Recycling Techniques
10
10
12
12
SECTION IV.
SURFACE PREPARATION OPERATIONS
Surface Preparation Processes
Wastes Generated
General Source Reduction and Recycling Techniques
16
16
17
18
SECTION V.
SURFACE FINISHING OPERATIONS
25
Surface Finishing Processes 25
Wastes Generated 28
General Source Reduction and Recycling Techniques 29
SECTION VI. POLLUTION PREVENTION DOCUMENTS AND REFERENCES
42
SECTION VII.
APPENDIX A
Compendiums and Guides 42
Additional Pollution Prevention References 45
BIBLIOGRAPHY
RELEASES OF THE 17 CHEMICALS FROM 1988 TRI DATA
52
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LIST OF TABLES
Page
Table 1. Metal Fabricated Products Industries 6
Table 2. Typical Metal Fabricated Products Operations Which May Produce Waste 9
Table 3. Metal Shaping Operations 10
Table 4. Examples of Source Reduction and Recycling Options for Metal Shaping Operations 13
Table 5. Types of Surface Preparation Operations 16
Table 6. Examples of Source Reduction and Recycling Options for Surface Preparation Operations .. 19
Table 7. Types of Surface Finishing Operations 25
Table 8. Examples of Source Reduction and Recycling Options for Plating Operations 30
Table 9. Examples of Source Reduction and Recycling Options for Finishing Operations 37
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POLLUTION PREVENTION OPTIONS IN METAL
FABRICATED PRODUCTS INDUSTRIES:
A BIBLIOGRAPHIC REPORT
SECTION I:
INTRODUCTION
Overview
The United States Environmental
Protection Agency (EPA) developed this
bibliographic report to assist metal fabricated
products companies in implementing pollution
prevention practices. This report is intended to
help metal manufacturers identify and implement
cost-effective pollution prevention practices to
reduce or eliminate their releases of the 17
chemicals targeted for reductions in EPA's 33/50
Program. In addition, EPA developed this report
to educate its own staff and State personnel on
pollution prevention opportunities in these
industries. EPA hopes this report also will assist
the public, engineering and business students, and
other interested persons in learning about pollution
prevention.
The 33/50 Program is EPA's voluntary
pollution prevention initiative to reduce national
pollution releases and off-site transfers of 17 toxic
chemicals by 33 per cent by the end of 1992 and by
50 per cent by the end of 1995. The Agency is
inviting companies to participate in this voluntary
program by examining their own industrial
processes to identify and implement cost-effective
pollution prevention practices for these chemicals.
The Program aims, through voluntary pollution
prevention activities, to reduce releases and off-site
transfers of a targeted set of 17 chemicals from a
national total of 1.4 billion pounds in 1988 to 700
million pounds by 1995, a 50% overall reduction.
While EPA is seeking to reduce aggregate
national environmental releases of the 17 chemicals
by 50 per cent by 1995, individual companies are
encouraged to develop their own reduction goals to
contribute to this national effort. EPA also
encourages companies to reduce releases of other
TRI chemicals and to extend these reductions to
their facilities outside the United States. EPA will
periodically recognize those companies that have
committed to reduce their releases and transfers of
the targeted chemicals, and publicly recognize the
pollution prevention successes these companies
subsequently achieve.
POLLUTION PREVENTION CAN:
Reduce a company's costs and legal liabilities associated with
waste treatment and disposal;
Reduce production costs by conserving raw materials, water, and
energy; and
Protect the environment and public health.
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THE 17 CHEMICALS TARGETED FOR REDUCTIONS IN THE 33/50
PROGRAM:
Benzene
Cadmium and Compounds
Carbon Tetrachloride
Chloroform
Chromium and Compounds
Cyanide and Compounds
Lead and Compounds
Mercury and Compounds
Methylene Chloride
Methyl Ethyl Ketone
Methyl Isobutyl Ketone
Nickel and Compounds
Tetrachloroethylene
Toluene
1,1,1 -Trichloroethane
Trichloroethylene
Xylenes
These chemicals were selected fronr the Toxics Release-inventory - (TRI). The
TRI is a computerized data base containing public information on the annual
releases and transfers of approximately 300 toxic chemicals reported by U.S.
manufacturing facilities to EPA and the States. Since 1987 federal law has
required facilities to report the amount of both routine and accidental releases of
the 300 listed chemicals to the air, water and soil, and the amount contained in
wastes transferred off-site. As required by the Pollution Prevention Act of 1990,
TRI industrial report requirements will be expanded, beginning in calendar year
1991, to include information on pollution prevention.
What is Pollution Prevention?
Pollution prevention (sometimes referred to
as source reduction) is the use of materials,
processes, or practices that reduce or eliminate the
creation of pollutants or wastes at the source.
Pollution prevention includes practices that reduce
the use of hazardous materials, energy, water or
other resources, and practices that protect natural
resources through conservation or more efficient
use.
Pollution prevention should be considered
the first step in a hierarchy of options for reducing
the generation of pollution. The next step in the
hierarchy is responsible recycling of any wastes
that cannot be reduced or eliminated at the source.
Wastes that cannot be recycled should be treated in
accordance with environmental standards. Finally,
any wastes that remain after treatment should be
disposed of safely.
EPA is promoting pollution prevention
because it is often the most cost-effective option to
reduce pollution and the environmental and health
risks associated with pollution. Pollution
prevention is often cost effective because it may
reduce raw material losses, reduce reliance on
expensive "end-of-pipe" treatment technologies and
disposal practices, conserve energy, water, chem-
icals, and other inputs, and reduce the potential
liability associated with waste generation. Pollution
prevention is environmentally desirable for these
very same reasons: pollution itself is reduced at
the source while resources are conserved.
Perhaps the best way to understand
pollution prevention is to consider a few examples
of some possible types of pollution prevention
techniques and processes. (Specific examples of
pollution prevention techniques that have been used
successfully by metal manufacturers are described
in Sections III, IV, and V of this report). Some
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general examples of pollution prevention techniques
are described below:
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 prior to painting or
electroplating. A second example is to
reduce the frequency of cleaning
equipment by painting all products of the
same color at the same time. 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 input 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, parameters or
equipment used in that process, to reduce
the amount of waste generated. For
example, you can change to a paint
application technique that is more efficient
than spray painting, reduce overspray by
reducing the atomizing air pressure, reduce
dragout by reducing the withdrawal speed
of parts from plating tanks, or improve a
plating line by incorporating dragout
recovery tanks or reactive rinsing.
Raw material substitution or elimination
replace existing raw materials with other
materials that produce less waste, or a
non-toxic waste. Some examples include
substituting alkali washes for solvent
degreasers, and replacing oil with lime or
borax soap as the drawing agent in cold
forming.
Loss prevention and housekeeping
perform preventive maintenance and
manage equipment and materials so as to
minimize opportunities for leaks, spills,
evaporative losses and other releases of
potentially toxic chemicals. For example,
clean spray guns in a manner that does not
damage leather packings and subsequently
causes the guns to leak; or place drip pans
under leaking machinery to allow recovery
of the leaking fluid.
Waste segregation and separation avoid
mixing different types of wastes, and
mixing hazardous wastes with non-
hazardous wastes. This technique makes
the recovery of hazardous wastes easier by
minimizing the number of different
hazardous constituents in any given waste
stream. Also, it prevents the
contamination of non-hazardous wastes.
For example, segregate scrap metal by
metal type, and segregate different kinds
of used oils.
Closed-loop Recycling - use or reuse of a
waste as an ingredient or feedstock in the
production process on-site. Recycling in
which a waste is recovered and reused in
the production process on-site as an input
is a form of pollution prevention. One
example is using a small on-site still to
recover and re-use degreasing solvents.
Training and Supervision provide
employees with the information and the
incentive to minimize waste generation in
their daily duties. For example, this might
include ensuring that employees know and
practice proper and efficient use of tools
and supplies, and that they are aware of,
understand, and support the company's
pollution prevention goals.
Information on Pollution Prevention
One good source of information on
pollution prevention is EPA's Pollution Prevention
Information Clearinghouse ("PPIC"). PPIC
contains technical, policy, programmatic, legis-
lative, and financial information on pollution
prevention efforts in the United States and abroad.
The FPIC may be reached by personal computer
modem ("PIES"), telephone hotline or mail.
Associated with the PPIC is the PIES, or Pollution
Prevention Information Exchange System, a free
24-hour computer bulletin board consisting of
message centers, technical data bases, issue-specific
"mini-exchanges", and a calendar of pollution
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prevention events. The PIES allows a user to
access the full range of information in the PPIC.
For information on how to use the PPIC/PIES call
(703) 821-4800. To logon to the PIES system
using a modem and a PC call (703) 506-1025 (set
your communication software at 8 bits and no
parity). Many of the documents referenced in this
report are available through the PPIC/PIES.
While the PPIC provides a centralized
information source, you may wish to seek the
guidance or help of pollution prevention 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. Many states now
have pollution prevention programs which may be
able to offer information and sometimes technical
assistance on pollution prevention.
Regional Environmental Protection Agency Offices
There are ten Regional Offices of the U.S.
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 respon-
sible for your area.
EPA Office of Research and Development Pollution
Prevention Research Branch, as (513) 569-7215 can
also provide technical and engineering pollution
prevention information.
Environmental Protection Agency Within U.S.
EPA Headquarters you may conveniently contact
any of the following information sources:
EPA Waste Minimization Branch, at (703) 308-
8402, can provide you with technical waste
minimization information;
Pollution Prevention Division, at (202) 260-3557,
can assist you in understanding pollution prevention
and provide a great deal of pollution prevention
information; and the
RCRA/Superfund Hotline, at (800) 424-9346 (or
(202) 260-3000), can answer your pollution
prevention questions, help you access information
in PIES, and assist you in searching for and
obtaining documents.
A comprehensive, national listing of
pollution prevention resources, documents, courses,
and programs, including names and phone
numbers, is contained in an annual EPA
publication. Copies of this document Pollution
Prevention Resources and Training Opportunities in
1992 - may be obtained by calling the PPIC/PIES
support number at (703) 821-4800.
Purpose of this Report
This report is intended to help metal
fabricated products manufacturing companies
develop and implement pollution prevention
practices to reduce their releases of the 17
chemicals targeted for reductions in the 33/50
Program, as well as other pollutants and wastes
generated. In addition, this report is intended to
assist EPA staff, state environmental agencies, and
other interested persons in learning about pollution
prevention opportunities. The remainder of this
report provides:
An overview of the various metal
fabricated products manufacturing
processes and the wastes they produce;
A quick reference to pollution prevention
options applicable to many of these
processes, including summaries of
economic benefits; and
An annotated bibliography of references
that describe additional information on
potentially useful pollution prevention
options, procedures, techniques, as well as
waste recycling options.
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Limits of this Report
or
This report provides an overview of the
pollution prevention and recycling alternatives that
may be available in the metal fabricated products
industry. This report is only a starting point to
assist the user in his or her preliminary research
and development of pollution prevention options.
Of course, each company remains responsible for
identifying, evaluating and implementing pollution
prevention practices that are appropriate for its
particular situation.
EPA has compiled this report as an
information dissemination and exchange service.
The information is intended to inform companies
and the public about pollution prevention practices,
options, and references. By compiling and
distributing this report EPA is not recommending
the use of any particular processes, raw materials,
products, or techniques in any particular industrial
setting. Compliance with environmental,
occupational and safety and health laws, as well as
all applicable federal, state, and local laws and
regulations is the responsibility of each individual
business and is not the focus of this document.
The information contained in this report is
intended to be a fairly comprehensive bibliography
of the documented information on pollution
prevention and recycling practices for the metal
fabricated products industry. However, the
collection, organization and dissemination of
pollution prevention information is a relatively new
undertaking, as well as an ongoing and evolutionary
process. In addition, there are limits to any
bibliography, including this bibliography. Thus,
this bibliography may not contain every relevant
article on pollution prevention and recycling for
metal manufacturers. EPA encourages all users
who discover, in the literature or in the field,
pollution prevention options that are not cited in
this report to share this information with EPA.
Please submit any corrections, updates, or
comments on this report to:
Pollution Prevention Information Clearinghouse
Science Applications International Corporation
7600-B Leesburg Pike
Falls Church, VA 22043
Special Projects Office (TS-792A)
Office of Pollution Prevention and Toxics
U.S. EPA
401 M Street, S.W.
Washington, D.C. 20460
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SECTION H:
OVERVIEW OF METAL FABRICATED PRODUCTS INDUSTRIES
Introduction to Metal Fabricated
Products Industries
Metal or equipment manufacturing
encompasses a wide variety of industries. This
report includes those industries that produce
fabricated metal products. The raw materials used
by these industries are metals that range from
common copper and steel to expensive high grade
alloys and precious metals. The metal fabricated
products manufacturing processes are integral parts
of aerospace, electronic, defense, automotive,
furniture, domestic appliance, and many other
industries. Table 1 identifies the types of industries
that conduct metal fabricated products
manufacturing operations (74).
These industries typically utilize processes
that fabricate products from ferrous and non-ferrous
metal materials. There are many types of
operations that are used in this category. Due to
the large scope, however, this discussion will be
limited to the processes that are common to the
majority of the industries. This report will provide
a general overview of the major processes, the
wastes typically generated, and set a foundation on
which to begin a pollution prevention approach.
Table 1. Metal Fabricated Products Industries
SIC 34 FABRICATED METAL PRODUCTS, EXCEPT MACHINERY AND TRANSPORTATION
EQUIPMENT
This major group includes establishments engaged in fabricating ferrous and nonferrous metal
products, such as:
Metal cans
Tinware
Handtools
Cutlery
General hardware
Ordnance (except vehicles
and guided missiles)
Nonelectric heating apparatus
Metal forging
Metal stampings
Fabricated structural metal products
Metal and wire products, not elsewhere
classified.
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Table 1. Metal Manufacturing Industries (continued)
SIC 35 INDUSTRIAL AND COMMERCIAL MACHINERY AND COMPUTER EQUIPMENT
This major group includes establishments engaged in manufacturing industrial and commercial
machinery and equipment and computers. Included are the manufacture of:
Engines and turbines Metalworking machinery
Farm and garden machinery Special industry machinery
Construction, mining, and Computer and peripheral equipment
oil field machinery and office machinery
Elevators & conveying equipment General industrial machinery
Hoists, cranes, monorails, industrial
trucks and tractors
Refrigeration and service industry machinery
SIC 36 ELECTRONIC AND OTHER ELECTRICAL EQUIPMENT AND COMPONENTS, EXCEPT
COMPUTER EQUIPMENT
This major group includes establishments engaged in manufacturing machinery, apparatus, and
supplies for the generation, storage, transmission, transformation, and utilization of electrical
energy. Included are the manufacturing of:
Electricity distribution equipment
Electrical industrial apparatus
Household appliances
Electrical lighting and wiring equipment
Radio and television receiving equipment
Communications equipment
Electronic components and accessories
Other electrical equipment and supplies
SIC 37 TRANSPORTATION EQUIPMENT
The Transportation Equipment Manufacturing category includes all industries involved in the
manufacture of equipment for transportation of passengers, and/or cargo by land, air, and water.
Included in this industry are manufacturers of:
Motor vehicles
Aircraft
Guided missiles and space vehicles
Railroad equipment
Miscellaneous transportation equipment, such as motorcycles, bicycles, and snowmobiles
Individual vehicle systems, parts, and some related accessories
Ships
Boats
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Table 1. Metal Manufacturing Industries (continued)
SIC 38 MEASURING, ANALYZING, AND CONTROLLING INSTRUMENTS;
PHOTOGRAPHIC, MEDICAL AND OPTICAL GOODS; WATCHES AND CLOCKS
This major group includes establishments engaged in manufacturing a wide array of
instruments for measuring, testing, analyzing, and controlling, and their associated sensors
and accessories. Industries in this group are manufacturers of:
Search, detection, navigation, guidance, aeronautical, and nautical systems, instruments, and
equipment
Laboratory apparatus and analytical, optical, measuring, and controlling instruments
Surgical, medical, and dental instruments and supplies
Ophthalmic goods
Photographic equipment
Watches, clocks, clockwork operated devices, and parts
SIC 39 MISCELLANEOUS MANUFACTURING INDUSTRIES
This major group includes establishments primarily engaged in manufacturing products not
classified in any other manufacturing major group. Industries in this group fall into the following
categories:
Jewelry, silverware, and plated ware
Musical instruments
Dolls, toys, games, and sporting and athletic goods
Pens, pencils, and artists' materials
Buttons, costume novelties, miscellaneous notions
Brooms and brushes
Caskets
Other miscellaneous manufacturing industries
Wastes of Concern
Metal fabricated products industries were
selected for the 33/50 Program because these
industries release significant quantities of the 17
chemicals of concern. Appendix A lists the
releases associated with each of these five SICs.
Appendix A demonstrates that release of
chlorinated solvents and the generation of metal-
and cyanide-bearing wastes are of concern for these
industries. The processes responsible for these
releases are described in the sections that follow.
Metal Fabricated Products
Manufacturing Processes
Metal fabricated products manufacturing
operations can be classified into three major
operations: metal shaping, surface preparation and
surface finishing. Each of these operations may
consist of various processes used in different
combinations or sequences to achieve the desired
product. To understand the metal manufacturing
process with respect to use and release of the 17
chemicals of concern and methods to reduce these
emissions, requires an investigation of each of these
types of operations and their component processes.
Table 2 provides a quick reference list of the
processes to be examined in the remainder of this
paper.
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Table 2. Typical Metal Fabricated Products Manufacturing Operations
Which May Produce Wastes
Typical Process or
Operation
Typical Materials Used
General Types of Wastes Generated
Metal Shaping Including:
Machining
Cutting oils
Degreasing and cleaning solvents
Acids
Heavy metals
Acid/alkaline wastes
Heavy metal wastes
Solvent wastes
Waste oils
Surface Preparation Including:
Solvent Cleaning
Pickling
Heat Treating
Acid/alkaline cleaners
Organic solvents
Acid/alkaline solutions
Acid/alkaline solutions
Cyanide salts
Oils
Acid/alkaline wastes
Ignitable wastes
Solvent wastes
Still bottoms
Acid/alkaline wastes
Heavy metal wastes
Acid/alkaline wastes
Cyanide wastes
Heavy metal wastes
Waste oils
Surface Finishing Including:
Electroplating
Surface Finishing
Facility Cleanup
Acid/alkaline solutions
Heavy metal bearing solutions
Cyanide bearing solutions
Solvents
Paint carrier fluids
Cleaning solvents
Acid/alkaline wastes
Cyanide wastes
Heavy metal wastes
Plating wastes
Reactive wastes
Wastewaters
Heavy metal paint wastes
Ignitable paint wastes
Solvent wastes
Still bottoms
Solvent wastes
Still bottoms
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SECTION HI:
METAL SHAPING OPERATIONS
Metal Shaping Processes
Shaping operations take raw materials and
alter their form to make the intermediate and final
product shapes. There are two phases of shaping
operations: primary and secondary. Primary
shaping consists of forming the metal from its raw
form into a sheet, bar, plate, or some other
preliminary form (2). Examples of the most
common metal shaping operations are described in
Table 3. More detailed descriptions of these
operations can be found in standard engineering
references as well as many of the pollution
prevention references listed in this document. EPA
also has provided some general information on the
types of wastes commonly associated with these
processes. For many processes, however, EPA
does not have descriptive or quantitative
information concerning process wastes.
Secondary shaping consists of taking the
preliminary form and further altering its shape to
an intermediate or final version of the product.
This step typically involves operations such as:
stamping,
turning,
drilling,
cutting and shaping,
milling,
reaming,
threading,
broaching,
grinding,
polishing, and/or
planing.
These operations are primarily used to remove
metal to develop a specific form from the
unfinished piece.
Table 3. Types of Metal Shaping Operations
Process
Abrasive Jet Machining
Casting
Cladding
Description
Cutting hard brittle materials through a process similar to sand blasting. Abrasive
jet machining, however, can use much finer abrasives carried at high velocities
(500-3000 fps) by a liquid or gas stream. The process can result in wastewater
from solution dumps, spills, leaks or wash downs of work area. Wastes may
contain abrasive fines, metals and oils.
Filling shaped containers or molds with molten metal so that upon solidification,
the shape of the mold is reproduced. Types of casting methods: stationary casting
(or pig casting, air cooled in molds); direct chill casting (continuous solidification
of the metal while it is being poured); continuous casting (sheet or strip); semi-
continuous casting (molten metal is poured down a trough and into vertical billet
molds).
Creating a composite metal containing two or more layers that have been bonded
together. Bonding may have been accomplished by roll bonding (co-rolling),
solder application (brazing), or explosion bonding.
10
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Table 3. Types of Metal Shaping Operations (continued)
Process
Description
Drawing
Pulling the metal through a die or succession of dies to reduce its diameter, alter
the cross-sectional shape, or increase its hardness. Typically used to manufacture
tube, rod, bar, and wire. May be conducted hot or cold. Intermediate annealing is
frequently required between draws to restore the ductility lost by cold working of
the drawn product.
Electrical Discharge Machining
Removal of metal from the workpiece surface with stringent dimensional control.
The machining action is caused by the formation of an electrical spark between an
electrode, shaped to the required contour, and the workpiece. Rinsing of machined
parts and work area cleanups can generate wastewaters which also contain base
materials. These wastewaters contribute to the common metals and oily waste
types.
Electrochemical Machining
Process based on the same principles used in electroplating except the workpiece is
the anode and the tool is the cathode. Electrolyte is pumped between the electrodes
and a potential applied which results in removal of the metal. In addition to
standard chemical formulations, inorganic and organic solvents are sometimes used
as electrolytes for electrochemical machining and with the basis material being
machined, can enter waste streams via rinse discharges, bath dumps, and floor
spills. Waste generated can contain metals, cyanide, and solvents depending upon
specific precvs!:
Electron Beam Machining
Thermoelectric process whereby heat is generated by high velocity electrons
impinging on part of the workpiece. At the point where the energy of the electrons
is focused, it is transformed into sufficient thermal energy to vaporize the material
locally to alter or cleave surfaces. The operation is generally under vacuum.
Extruding
Applying high pressures to a cast metal billet, forcing the metal to flow through a
die orifice. Two types: direct and indirect. Heat treatment is often used after
extrusion to attain the desired mechanical properties.
Forging
Deformation of metal, usually hot, with compressive force into desired shapes with
or without dies. Five types: closed die, open die, rolled ring, impacting, and
swaging. In each, pressure is exerted on dies or rolls, forcing the heated stock to
take the desired shape. The first three are hot working, the other two are cold.
Impact Deformation
Applying impact force to a workpiece such that it is permanently deformed or
shaped. Wastes containing metals and oils may result from cleaning the impacted
parts.
LASER Beam Machining
Process whereby a highly focused monochromatic collimated beam of light is used
to remove material at the point of impingement on a workpiece. Laser beam
machining is a thermoelectric process with material removal largely accomplished
by evaporation, although some material is removed in the liquid state at high
velocity.
Plasma Arc Machining
Removal of material from shaping of a workpiece by a high velocity jet of high
temperature ionized gas. A gas (e.g., nitrogen, argon, or hydrogen) is passed
through an electric arc causing it to become ionized and raised to temperatures in
excess of 16,649 °C (300,000 °F). The relatively narrow plasma jet melts and
displaces the workpiece material in its path.
Applying force (at a slower rate than at impact force) to permanently deform
shape a workpiece. Cleanup wastes may contain metals and oils.
Pressure Deformation
11
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Table 3. Types of Metal Shaping Operations (continued)
Process
Rolling
Sand Blasting
Thermal Cutting
Ultrasonic Machining
Description
Reducing cross-sectional area of metal stock, or otherwise shaping metal products,
through the application of pressure by rotating rolls. Cylindrical rolls produce flat
shapes; grooved rolls produce rounds, squares, and structural shapes. Employs hot
or cold working techniques depending on the kind of metal or alloy. Hot rolling is
generally rolling at temperatures above the recrystallization temperature. Cold
rolling is defined as rolling below the recrystallization temperature of the metal.
Heat treatment is usually required before and between stages of the rolling process.
Annealing is typically required between passes or after cold rolling to keep the
metal ductile and remove the effects of work hardening.
Removing stock, including surface films, from a workpiece by the use of abrasive
grains pneumatically impinged against the workpiece. Waste blasting media can
contain metals and residues from the surface of the metal.
Cutting, slotting or piercing a workpiece using an oxyacetylene oxygen lance or
electric arc cutting tool. Water may be used for rinsing or cooling of parts and
equipment following this operation.
Mechanical process designed to effectively machine hard, brittle materials. It
removes material by the use of abrasive grains which are carried in a liquid
between the tool and the work, and which bombard the work surface a high
velocity and are agitated using high energy ultrasonic waves.
Wastes Generated
Each of the metal shaping processes can
result in wastes that may contain chemicals of
concern (depending on the metal being used). In
general, there are two categories of waste generated
in metal shaping operations: scrap metal and
metalworking fluids/oils. Scrap metal may consist
of metal removed from the original piece as well as
amounts of metalworking fluids used prior to and
during the metal shaping operation that generates
the scrap.
Metalworking fluids are applied to either
the tool or the metal being tooled to facilitate the
shaping operation (3). The metalworking fluid is
used to:
keep tool temperature down and aid
lubrication;
keep the workpiece temperature down and
aid lubrication;
provide a good finish;
wash away chips and metal debris; and
inhibit corrosion or surface oxidation.
These metalworking fluids typically become spoiled
or contaminated with extended use and reuse. In
general, metal working fluids can be petroleum-
based, oil-water emulsions, and synthetic emulsions
(4). When disposed, these oils, often handled as
hazardous, may contain levels of contaminants of
concern including metals (cadmium, chromium, and
lead) depending on the metal being tooled. Many
fluids may contain chemical additives such as
chlorine, sulfur and phosphorus compounds,
phenols, cresols, and alkalies. In the past, such
oils have been commonly mixed with used cleaning
solvents and fluids (including chlorinated solvents).
General Source Reduction and Recycling
Techniques
As described above, metal forming results
in two types of waste: scrap metal and spent
metalworking fluids. The most common
management of these materials is either disposal or
recycling. Facilities
12
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commonly recycle scrap metals that have value and
defined recycling markets. Metals without
significant value or without a defined recycling
market, or metals that are not recyclable are
commonly disposed. Table 4 provides examples of
source reduction and recycling options that might
be applied to various metal shaping operations.
Contaminated and spoiled metalworking fluids are
the largest source of waste from machining
operations (3). Water- and animal fat-based oils
can spoil without proper management and storage.
All fluids can become contaminated with metals,
packing and lubricating oils, and cleaning materials
(including chlorinated solvents). The life of
metalworking fluids can be increased (thus
decreasing waste) through the source reduction and
recycling techniques described in Table 4. This
table provides examples of source reduction and
recycling alternatives that are discussed further in
documents referenced in Section VI.
Table 4. Examples of Source Reduction and Recycling Options
for Metal Shaping Operations
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Production Planning and
Sequencing
Improve scheduling of processes that
require use of varying oil types in order to
reduce the number of cleanouts.
Process or
Equipment Modification
Standardize the oil types used for
machining, turning, lathing, etc. This
reduces the number of equipment
cleanouts, and the amount of leftovers and
mixed wastes.
Use specific pipes and lines for each set of
metals or processes that require a specific
oil in 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
Waste Savings/Reductions: 25 %
reduction in plant-wide waste coolant
generation. Product/Waste Throughput
Information: based on handling 20,600
gallons of coolant per year. [Reference
Install a second high speed centrifuge on a
system already operating with a single
centrifuge to improve recovery efficiency
even more.
Capital Investment: $126,000. Payback
Period: 3.1 years. Product/Waste
Throughput Information: based on
handling 20,6000 gallons of coolant per
year. [Reference #82]
Install a chip wringer to recover excess
coolant on aluminum chips.
Capital Investment: $233,500. Payback
Period: 0.9 years. Product/Waste
Throughput Information: based on
handling 20,600 gallons of coolant per
year. [Reference #82]
13
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Table 4. Examples of Source Reduction and Recycling Options
for Metal Shaping Operations (continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Process or equipment
modification (continued)
Capital Investment: $11,000 to $23,000
(chip wringer and centrifuge system).
[Reference #81]
Install a coolant recovery system and
collection vehicle for machines not on a
central coolant sump.
Capital Investment: $104,000. Payback
Period: 1.9 years. Product/Waste
Throughput Information: based on
handling 20,600 gallons of coolant per
year. [Reference #82]
**Use a coolant analyzer to allow better.
control of coolant quality.
Capital Investment: $5,000. Payback
Period: 0.7 years. Product/Waste
Throughput Information: based on
handling 20,600 gallons of coolant per
year. [Reference #82]
Use an ultrafiltration system to remove
soluble oils from wastewater streams.
Annual Savings: $200,000 (in disposal
costs). Product/Waste Throughput
Information: based on a wastewater flow
rate of 860 to 1,800 gallons per day.
[Reference #81]
Use disk or belt skimmers to remove way
oil from machine coolants and prolong
coolant life. Also, design sumps for ease
of cleaning.
Waste Savings/Reduction: coolant is now
disposed once per year rather than 3-6
times per year. [Reference #6]
Raw Material
Substitution
In cold forming or other processes where
oil is used only as a lubricant, substitute a
hot lime bath or borax soap for oil.
**Use a stamping lubricant that can remain
on the piece until the annealing process,
where it is burned off. This eliminates the
need for hazardous degreasing solvents and
alkali cleaners.
Annual Savings: $12,000 (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. [Reference #7]
Waste Segregation and
Separation
If filtration or reclamation of oil is required
before reuse, segregate the used oils in
order to prevent mixing wastes.
"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: $0. Annual Savings:
$130,000. Payback Period: immediate.
Waste Savings/ Reduction: 2,700 tons per
year. (Savings will vary with metal type
and market conditions.) [Reference #19]
14
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Table 4. Examples of Source Reduction and Recycling Options
for Metal Shaping Operations (continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Waste Segregation and
Separation (continued)
"Improve housekeeping techniques and
segregate waste streams (e.g., use care
when cleaning cutting equipment to prevent
the mixture of cutting oil and cleaning
solvent).
Capital Investment: SO. Annual Savings:
S3,000 in disposal costs. Waste
Savings/Reduction: 60% (30 tons reduced
to 10 tons). [Reference #81]
Recycling
Where possible, recycle oil from cutting/
machining operations. Often oils need no
treatment before recycling.
Capital Investment: $1,900,000. Annual
Savings: $156,000. Waste Throughput
Information: 2 million gallons per year.
Facility reclaims oil and metal from
process water. [Reference #19]
Oil scrap mixtures can be centrifuged to
recover the bulk of the oil for reuse.
Follow-up magnetic and paper filtration of
cutting fluids with ultrafiltration. By so
doing, a much krger percentage of cutting
fluids can be reused.
Capital Investment: $42,000 (1976).
Annual Savings: $33,800 (1980).
[Reference #81]
Perform on-site purification of hydraulic
oils using commercial "off-the-shelf
cartridge filter systems.
Capital Investment: $28,000. Annual
Savings: $17,800/year based on operating
costs, avoided new oil purchase, and lost
resale revenues. Payback Period: less
than 2 years. Product/Waste Throughput
Information: example facility handles
12,300 gallons/year of waste hydraulic oil.
[Reference #82]
**Use a continuous flow treatment system
to regenerate and reuse aluminum chemical
milling solutions.
Capital Investment: $465,000. Annual
Savings: $342,000. Payback Period:
less than 2 years. Waste Savings/
Reduction: 90%. [Reference #81]
**Use a settling tank (to remove solids)
and a coalescing unit (to remove tramp
oils) to recover metal-working fluids.
Annual Savings: $26,800 (resulting from
reduced material, labor, and disposal
costs). [Reference #20]
*The cost, savings, and waste reduction information provided in Table 4 is based on actual case studies and
reflects the successes of actual metal fabricated products manufacturing facilities. Because specific applications
are highly variable, however, you should use this information only as a indicator of how a particular pollution
prevention option may perform under your circumstances.
**These options cost less than $30,000 to implement.
15
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SECTION IV:
SURFACE PREPARATION OPERATIONS
Surface Preparation Processes
Surface preparation is an integral step in
the metal fabricated products manufacturing
industry and is typically used in all metal fabricated
products manufacturing processes. Virtually all
fabricated metal products require some form of
physical and/or chemical surface preparation prior
to finishing to remove unwanted surface materials
or to alter the chemical or physical characteristics
of the surface. Some surface preparation
operations also may be desired prior to some
shaping operations. As a result of the initial and
intermediate shaping processes, the metal surfaces
usually have become oxidized or coated with grease
and machining oils that may interfere with the
finishing processes. Some products may require
only the removal of rough surfaces and/or edges.
There are a number of surface preparation
methods that are used depending on the nature of
the surface requirements. The major surface
preparation methods include those listed in Table 5
(2). More detailed descriptions of these operations
can be found in standard engineering references as
well as many of the pollution prevention references
described in the reference list included in this
document.
Table 5. Types of Surface Preparation Operations
Process
Solvent Cleaning:
Emulsified Solvent Degreasing
Ultrasonic Vapor Degreasing
Vapor Degreasing
Wiping
Paint Stripping
Chemical Treatment:
Acid Cleaning
Description
Organic solvents are used to remove lubricants (oils and greases) and paints applied
to the surface of metals during mechanical forming operations. Methods for
degreasing include (5):
Cleaning where the solvent and contaminants are suspended in water. The piece is
either sprayed with or immersed in the emulsified solvent.
Cleaning of parts using high energy sound waves and a solvent immersion bath.
Cleaning of small parts by exposure to solvent vapors. Vapors are generated by
heating a solvent reservoir. The surface is cleaned by the flushing action of solvent
that condenses on the part. Different types of vapor degreasing include:
immersion-vapor degreasing and spray-vapor degreasing.
Manual cleaning of metal objects that are too large for immersion operations.
Removal of organic coatings (paint) from a workpiece. The stripping of such
coatings is usually performed with caustic, acid, solvent, or molten salt using
processes similar to those for degreasing operations.
Treatment performed as an integral part of forming processes to alter the surface of
the metal. Operations include:
Removing oxides and minor corrosion from metal surfaces. Acid cleaners are used
in spraying, wiping, and electrolytic processes.
16
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Table 5. Types of Surface Preparation Operations (continued)
Process
Description
Alkaline Cleaning
Removing soils, grease, oil, and casting materials from forged, heat-treated and
machined metal parts. Alkaline cleaners can be used in immersion, spray, and
ultrasonic systems (described above). In addition, alkaline cleaners are compatible
with steam and electrocleaning processes. Steam processes rely upon water vapor
as the cleaning medium for the alkaline detergent. In electrocleaning, the metal
part acts as the anode in an alkaline bath. Water is decomposed with hydrogen
forming on the surface of the metal part. Hydrogen formation bubbles surface
contaminants off of the metal part.
Etching
Corroding the metal surface as a means to remove surface contaminants. Etching
can also be used to develop a design or pattern on the metal. Etching includes:
bright dipping and chemical polishing which relies upon mixtures of acids to
remove surface contaminants and/or corrosion; and chemical milling and etching
whereby designs are created on the surface by controlled immersion in etching
solutions.
Pickling
Another form of acid or alkaline cleaning operation, relying on a high
concentration (5 to 25 percent) acid or alkaline solution to remove heavy scale and
rust. Nitric, sulfuric, hydrochloric, and chromic acids are commonly used in
pickling operations.
Mechanical Surface
Treatment:
Altering the surface of formed metals using processes that include machining,
grinding, polishing, tumbling (barrel finishing), and burnishing. Mechanical
shaping operations are similar to metal parts shaping operations (see Section 3) in
principle but are used to only change the nature or texture of the surface (not the
gross form) of the object.
These operations are used to change or prepare the
surface of the object for additional shaping or
plating. These types of operations result in various
types of waste, as described below.
Wastes Generated
Surface preparation operations primarily
generate wastes contaminated with solvents and/or
metals depending on the type of cleaning operation.
Specifically, concentrated solvent-bearing wastes
and releases may arise, in general, from degreasing
operations. Degreasing operations may result in
solvent-bearing wastewaters, air emissions, and
solid-phase wastes. That is, solvents may. be rinsed
into wash waters and/or spilled into floor drains.
Air emissions may result through volatilization
during storage, fugitive losses during use, and
direct ventilation of fumes. Any solid wastes (e.g..
wastewater treatment sludges, still bottoms,
cleaning tank residues, machining fluid residues,
etc.) generated by the operation may be
contaminated with solvents.
Chemical treatment operations can result in
wastes that contain the metals of concern.
Alkaline, acid, mechanical, and abrasive cleaning
methods can generate waste streams such as spent
cleaning media, wastewaters, and rinse waters.
Such wastes consist primarily of the metal
complexes or particles, the cleaning compound,
contaminants from the metal surface, and water. In
many cases, chemical treatment operations are used
in conjunction with organic solvent cleaning
systems. As such, many of these wastes may be
cross-contaminated with solvents.
The nature of the waste will depend upon
the specific cleaning application and metal
fabricated products manufacturing operation.
Wastes from surface preparation operations may
17
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contribute to commingled waste streams such as -
wastewaters discharged to centralized treatment.
Further, such operations can result in direct
releases such as fugitive emissions and easily
segregated wastes such as cleaning tank residues.
General Source Reduction and Recycling
Techniques
Surface preparation processes can result in
various types of wastes depending on the specific
nature of the manufacturing process. In many
cases, alternative cleaning operations may be
available that rely on less- or non-toxic cleaning
agents. In cases where no alternative exists, source
reduction and recycling may be used to extend
solvent life and/or reduce solvent emissions. In
general, identification of these opportunities relies
upon the systematic identification of:
methods to reduce solvent usage - solvents
can be lost through volatilization. Further,
improper or careless management of
solvents can require premature
contamination and replacement.
opportunities to eliminate specific cleaning
steps - that is, by controlling factors that
contribute to surface contamination, the
need for cleaning can be reduced or
eliminated.
less hazardous cleaning media - in most
cases, there are several cleaning solvent
systems that may perform the desired
operation. In such cases, the solvent that
poses the least risk to human health and
the environment should be considered.
methods to maximize cleaning efficiency -
for cleaning operations that cannot be
eliminated, the amount of cleaning material
used to achieve the desired cleanliness
should be minimized.
procedures to segregate cleaning wastes -
for cleaning wastes, segregation is an
important part of proper management.
Specifically, segregation is needed to allow
and promote recycling of solvent-based
cleaners. Further, segregation will help to
reduce the amounts of toxic components
from cleaning solvents that eventually
collect in metal manufacturing wastes
(e.g.. wastewater treatment sludges, used
machining fluids, etc.).
opportunities to reuse cleaning solvents -
many cleaning materials can be recycled or
reused. Reuse can be increased through
procedures to reduce losses. Recycling
operations can be increased through
improved capture of chemicals released
during the cleaning operation.
opportunities to recycle cleaning solvents -
once cleaning solvents are segregated, on-
site and off-site recycling can be used to
reduce waste and raw material
consumption.
Table 6 provides examples of source reduction and
recycling techniques applicable to surface
preparation operations. Table 6 provides a small
sample of source reduction and recycling
alternatives that are contained in the references
identified in Section VI. Facilities that want
additional information should access the PPIC
directly. Further, facilities that would like to share
their pollution prevention successes are encouraged
to submit their information directly to the PPIC.
18
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Table 6. Examples of Source Reduction and Recycling Options
for Surface Preparation Operations
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information'"
SOLVENT CLEANING
Training and Supervision
Production Planning and
Sequencing
"Improve solvent management by
requiring employees to obtain solvent
through their shop foreman. Also, reuse
"waste" solvents from cleaner up-stream
operations in down-stream, machine shop-
type processes.
Pre-cleaning will extend the life of the
aqueous or vapor degreasing solvent (wipe,
squeeze, or blow part with air, shot, etc.).
Use counter-current solvent cleaning (i.e.,
rinse initially in previously used solvent
and progress to new, clean solvent).
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.
Capital Investment: $0. Annual Savings:
$7,200. Waste Savings/Reduction: 49%
(310 tons reduced to 152 tons).
Product/Waste Throughput Information:
original waste stream history: reactive
anions (6,100 gallons/yr), waste oils (1,250
gallons/yr), halogenated solvents (500
gallons/yr). [Reference #23]
Annual Savings: $40,000. Payback
Period: 2 years. Waste
Savings/Reduction: 48,000 gallons of
aqueous waste. Aluminum shot was used
to preclean parts. [Reference #19]
19
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Table 6. Examples of Source Reduction and Recycling Options
for Surface Preparation Operations (continued)
Pollution Prevention
Techniques
Process or Equipment
Modification
Process or Equipment
Modification (continued)
Raw Material
Substitution
Pollution Prevention Options
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 100% of
tank width;
covering the degreasing unit
(automatic covers are available);
installing refrigerator coils (or
additional coils) above the vapor
zone;
rotating parts before removal
from the vapor degreaser to allow
all condensed solvent to return to
degreasing unit;
controlling the speed at which
parts are removed (10 ft/min or
less is desirable) so as not to
disturb the vapor line;
installing thermostatic 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 excess oil
applications.
Use plastic blast media for paint stripping
rather than conventional solvent stripping
techniques.
Use less hazardous degreasing agents such
as petroleum solvents or alkali washes.
For example, replace halogenated solvents
(e.g., trichloroethylene) with liquid alkali
cleaning compounds. (Note that
compatibility of aqueous cleaners with
wastewater treatment systems should be
ensured.)
Examples of Costs and Savings,
and Other Information'*'
Waste Savings/Reduction: volume of waste
sludge is reduced by as much as 99% over
chemical solvents; wastewater fees are
eliminated. [Reference #81]
Capital Investment: $0. Annual Savings:
$12,000. Payback Period: immediate.
Waste Savings/ Reduction: 30% of 1,1,1-
trichloroethane replaced with an aqueous
cleaner. [Reference #7]
Capital Investment: $438,000. Payback
Period: S.I years. Replaced
trichloroethylene degreaser with aqueous
cleaner system. [Reference #26]
20
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Table 6. Examples of Source Reduction and Recycling Options
for Surface Preparation Operations (continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Raw Material
Substitution (continued)
Annual Savings: $2,000. Payback Period:
1.6 years. Substituted chlorofluorocarbon
solvents with proprietary cleaner.
[Reference #81]
Annual Savings: 38% of cost savings and a
62% return on investment. Payback
Period: 1.6 years. Substituted
chlorofluorocarbon solvents with
proprietary cleaner. [Reference #81]
"Substitute chromic acid cleaner with
non-fuming cleaners such as sulfuric acid
and hydrogen peroxide.
Annual Savings: $10,000 in treatment
equipment costs and 52.50/lb. of chromium
in treatment chemical costs. Product/Waste
Throughput Information: rinse water
flowrate of 2 gallons per minute.
[Reference #81]
Substitute non-polluting cleaners such as
trisodium phosphate or ammonia for
cyanide cleaners.
Annual Savings: $12,000 in equipment
costs and $3.00/lb. of cyanide in treatment
chemical costs. Product/Waste Throughput
Information: rinse water flowrate of 2
gallons per minute. [Reference #81]
Recycling
**Recycle spent degreasing solvents on site
using batch stills.
Capital Investment: $7,500. Annual
Savings: $90,000. Payback Period: 1
month. Waste Savings/Reduction: 10,000
gallons annually of spent solvents by in-
house distillation. [Reference #19]
Recycle spent degreasing solvents on site
using batch stills.
Capital Investment: $2,600-$4,100 and
$4,200-$17,000. Product Throughput
Information: 35-60 gallons per hour and
0.6-20 gallons per hour, respectively. Two
cost and throughput estimates for
distillation units from two vendors.
[Reference #81]
Use simple batch distillation to extend
the life of 1,1,1-trichloroethane (1,1,1-
TCA).
Capital Investment: $3,500 (1978).
Annual Savings: $50,400. Product/Waste
Throughput Information: facility handles
40,450 gallons 1,1,1-TCA per year.
[Reference #82]
When on-site recycling is not possible,
agreements can be made with supply
companies to remove old solvents.
Capital Investment: $3,250 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. [Reference #19]
21
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Table 6. Examples of Source Reduction and Recycling Options
for Surface Preparation Operations (continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information"*
Recycling (continued)
Arrange a cooperative agreement with
other small companies to centrally recycle
solvent.
CHEMICAL TREATMENT
Process or Equipment
Modification
Increase the number of rinses after each
process bath and keep the rinsing counter-
current in order to reduce dragout losses.
Unmixed acids in the wastewaters may-be
recovered by evaporation.
Reduce rinse contamination via dragout by:
slowing and smoothing removal
of parts, rotating them if
necessary;
using surfactants and other
wetting agents;
maximizing drip time;
using drainage boards to direct
dripping solutions back to process
tanks;
installing dragout recovery tanks
to capture dripping solutions;
using a fog spray rinsing
technique above process tanks;
using techniques such as air
knives or squeegees to wipe bath
solutions off of the part; and
changing bath temperature or
concentrations to reduce the
solution surface tension.
Process or Equipment
Modification
Instead of pickling brass parts in nitric
acid, place them in a vibrating apparatus
with abrasive glass marbles or steel balls.
A slightly acid additive is used with the
glass marbles, and a slightly basic additive
is used with the steel balls.
Capital Investment: $62,300 (1979); 50%
less than conventional nitric acid pickling.
[Reference #81]
*Use mechanical scraping instead of acid
solution to remove oxides of titanium.
Annual Savings: $0; cost of mechanical
stripping equals cost of chemical disposal.
Waste Savings/Reduction: 100%. Waste
Throughput Information: previously
disposed 15 tons/year of acid with metals.
[Reference #81]
22
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Table 6. Examples of Source Reduction and Recycling .Options
for Surface Preparation Operations (continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information"1
Process or Equipment
Modification (continued)
**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: $3,250. Annual
Savings: $7,500. Waste
Savings/Reduction: 100%. Waste
Throughput Information: previous etching
bath waste total was 12,000 gallons/year.
[Reference #81]
Clean copper sheeting mechanically with a
rotating brush machine that scrubs with
pumice, instead of cleaning with
ammonium pcrsulfate, phosphoric acid, or
sulfuric acid (may generate non-hazardous
waste sludge).
Capital Investment: $59,000. Annual
Savings: more than $15,000. Payback
Period: 3 years. Waste Savings/
Reduction: 40,000 pounds of copper
etching waste reduced to zero. [Reference
Annual Savings: $15,000 in raw materials,
disposal, and labor. Payback Period: 3
years. Waste Savings/Reduction: avoids
generation of 40,000 pounds per year of
hazardous waste liquid. [Reference #81]
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: $510,000;
annual operating cost savings: $90,000.
[Reference #81]
**When refining precious metals, reduce
the acid/metals waste stream by
maximizing reaction time in the gold and
silver extraction process.
Capital Investment: $0. Annual Savings:
$9,000. Waste Savings/ Reduction: 70%
(waste total reduced from 50 tons to 15
tons). [Reference #81]
Raw Material
Substitution
Change copper bright-dipping process from
a cyanide and chromic acid dip to a
sulfuric acid/hydrogen peroxide dip. The
new bath is less toxic and copper can be
recovered.
"Use alcohol instead of sulfuric acid to
pickle copper wire. One ton of wire
requires 4 liters of alcohol solution, versus
2 kilograms of sulfuric acid.
Capital Investment: $0. [Reference #81]
Replace caustic wire cleaner with a
biodegradable detergent.
Replace chromated desmutting solutions
with nonchromated solutions for alkaline
etch cleaning of wrought aluminum.
Annual Savings: $44,541. Waste
Savings/Reduction: sludge disposal costs
reduced by 50%. [Reference #81]
23
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Table 6. Examples of Source Reduction and Recycling Options
for Surface Preparation Operations (continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information1"
Replace barium and cyanide salt heat
treating with a carbonate/chloride carbon
mixture, or with furnace heat treating.
Replace thermal treatment of metals with
condensation of saturated chlorite vapors
on the surface to be heated.
Waste Savings/Reduction: this process is
fast, nonoxidizing, and uniform; pickling is
no longer necessary. [Reference #81]
Recycling
Sell waste pickling acids as feedstock for
fertilizer manufacture or
neutralization/precipitation.
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.
[Reference #19]
**Send used copper pickling baths to a
continuous electrolysis process for
regeneration and copper recovery.
Capital Investment: $28,500 (1977).
Product Throughput Information: pickling
12,000 tons of copper; copper recovery is
at the rate of 200 g/ton of processed
copper. [Reference #81]
**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 225,000 pounds of brass per
month. [Reference #81]
**Treat industrial wastewater high in
soluble iron and heavy metals by chemical
precipitation.
Annual Savings: $28,000; based on
reduced water and sewer rates. Waste
Throughput Information: wastewater flow
from facility's "patening" line is 100
gallons per minute. [Reference #81]
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).
"The cost, savings, ana waste reduction information provided in Tab e 4 is based on actual case studies and
reflects the successes of actual metal fabricated products manufacturing facilities. Because specific applications
are highly variable, however, you should use this information only as a indicator of how a particular pollution
prevention option may perform under your circumstances.
""These options cost less than $30,000 to implement.
24
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SECTION V:
SURFACE FINISHING OPERATIONS
Surface Finishing Processes
Surface finishing may include one or a
combination of methods and materials.
Specifically, surface finishing may include a
combination of five metal deposition operations and
21 finishing operations (80). The finishing
operations consist of procedures used to assemble
or complete the item. In many cases, surface
preparation methods are included with these
additional operations because they are often an
integral portion of the finishing process.
Table 7 describes types of surface finishing
operations. More detailed descriptions of these
operations can be found in standard engineering
references as well as many of the pollution
prevention references described in the reference list
included in this document. EPA has also provided
some general information on the types of wastes
commonly associated with these processes. For
many processes, however, EPA does not have
descriptive or quantitative information concerning
process wastes.
Table 7. Types of Surface Finishing Operations
Process
Description
METAL DEPOSITION OPERATIONS:
Anodizing
An electrochemical process which converts the metal surface to a coating of an
insoluble oxide. Aluminum is the most frequently anodized material. The
formation of the oxide occurs when the parts are made anodic in dilute sulfuric or
chromic acid solutions. The oxide layer begins formation at the extreme outer
surface and as the reaction proceeds, the oxide layer penetrates further into the
metal surface.
Conversion Coating
Any operation that includes chromating, phosphating, metal coloring and
passivating. In chromating, a portion of the basis metal is converted to a
component of the protective film formed by the coating solutions containing
hexavalent chromium and active organic or inorganic compounds. Phosphate
coatings are formed by the immersion of steel, iron, or zinc plated steel in a dilute
solution of phosphoric acid plus other reagents to condition the surfaces for further
processing. Metal coloring involves the chemical method of converting the metal
surface into an oxide or similar metallic compound to produce a decorative finish.
Passivating is the process of forming a protective film on metals by immersion into
an acid solution, usually nitric acid or nitric acid with sodium dichromate.
Electroless Plating
The chemical deposition of a metal coating on a workpiece by immersion in an
appropriate plating solution in which electricity is not involved. Copper and nickel
electroless plating for printed circuit boards are the most common operations.
Immersion plating, considered a type of electroless plating, produces a metal
deposit by chemical displacement.
25
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Table 7. Types of Surface Finishing Operations (continued)
Process
Electroplating
Etching and Chemical Milling
Description
The production of a thin surface coating of one metal upon another by
electrodeposition. Ferrous or nonferrous materials may be coated by a variety of
common (copper, nickel, lead, chromium, brass, bronze, zinc, tin, cadmium, iron,
aluminum or combinations thereof) or precious (gold, silver, platinum, osmium,
indium, palladium, rhodium, indium, ruthenium, or combinations thereof) metals.
In electroplating, metal ions supplied by the dissolution of metal from anodes are
reduced onto the workplaces (cathodes). Depending on the metals involved,
electroplating cells use acidic, alkaline, or neutral solutions.
Operations used to produce specific design configurations or surface appearances
on parts by controlled dissolution with chemical reagents or etchants. Chemical
etching is the same process as chemical milling except the rates and depths of metal
removal are usually much greater in chemical milling.
FINISHING OPERATIONS:
Assembly
Brazing
Burnishing
Calibration
Electroplating
Electrostatic Painting
The fitting together of previously manufactured parts or components into a
complete machine, unit of a machine, or structure.
The joining of metals by flowing a thin, capillary thickness layer of nonferrous
filler metal into the space between them. Bonding results from the intimate contact
produced by the dissolution of a small amount of basis metal in the molten filler
metal, without fusion of the basis metal. The term "brazing" is used where the
temperature exceeds 425 °F (800 °F). This operation is commonly followed by
quenching, cooling or annealing in a solution of water or emulsified oils.
The finish sizing or smooth finishing of a workpiece (previously machined or
ground) by displacement, rather than removal, of minute surface irregularities.
Wastes may come from spills, leaks, process solution dumps and post- finish rinsing
and could contribute to the common metals, precious metals, and oily waste types
depending upon the basis material finished. In addition, sodium cyanide (NaCN)
may be used as a wetting agent and rust inhibitor (for steel), thus contributing
cyanide wastes from this operation.
Adjustment of the workpiece to dimensions needed to function as designed and
within appropriate tolerances.
Coating a workpiece by either making it anodic or cathodic in a bath that is
generally an aqueous emulsion of the coating material. Electropainting is used
primarily for primer coats because it gives a fairly thick, highly uniform, corrosion
resistant coating in relatively little time. Ultrafiltration is used in connection with
electropainting to concentrate paint solids. Wastewaters from these unit operations
can result in wastes containing metals (including hexavalent chromium) and
solvents.
Application of electrostatically charged paint particles to an oppositely charged
workpiece followed by thermal fusing of the paint particles to form a cohesive
paint film.
26
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Table 7. Types of Surface finishing Operations (continued)
Process
Description
Flame Spraying
Application of metallic coating to a workpiece using finely powdered fragments of
wire, together with suitable fluxes, which are projected through a cone of flame
onto the workpiece. This operation is followed by quenching, cooling or annealing
in a solution of water or emulsified oils. Wastes produced can contain metals and
oil.
Heat Treating
Modification of the physical properties of a workpiece through the application of
controlled heating and cooling cycles. Wastewater is generated through rinses,
bath discharges, spills, and leaks, and often contain the solution constituents as well
as various scales, oxides, and oils.
Hot Dip Coating
Coating a metallic workpiece with another metal to provide a protective film by
immersion in a molten bath. Galvanizing (hot dip zinc) is the most common hot
dip coating. Water is used for rinses following precleaning and sometimes for
quenching after coating. These wastewaters can contain metals.
Laminating
Adhesive bonding layers of metal, plastic, or wood to form a part. Water is not
often used in this operation; however, occasional rinsing or cooling may occur in
conjunction with laminating. The wastes generated from these processes may
include solvents and metals.
Mechanical Plating
Deposition of metal coatings on a workpiece via the use of a tumbling barrel, metal
powder, and usually glass beads for the impaction media. The operation is subject
to the same cleaning and rinsing operations that are applied before and after the
electroplating operation.
Painting
Application of an organic coating to a workpiece. Painting processes result in
solvent waste, paint sludge wastes, paint-bearing wastewaters and paint solvent
emissions.
Polishing
Abrading operation used to remove or smooth out surface defects (scratches, pits,
tool marks, etc.) that adversely affect the appearance or function of a part. Area
cleaning and washdown can produce metal-bearing wastewaters.
Sintering
Forming a mechanical part from a powdered metal by fusing the particles together
under pressure and heat. The temperature is maintained below the melting point of
the basis metal.
Soldering
Joining metals by flowing a thin (capillary thickness) layer of nonferrous filler
metal into the space between them. Bonding results from the intimate contact
produced by the dissolution of a small amount of basis metal in the molten filler
metal, without fusion of the basis metal. The term soldering is used where the
temperature range falls below 425 °C (800 °F). This operation is followed by
quenching, cooling or annealing in a solution of water or emulsified oils.
Sputtering
Covering a metallic or non-metallic workpiece with thin films of metal. The
surface to be coated is bombarded with positive ions in a gas discharge tube, which
is evacuated to a low pressure.
27
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Table 7. Types of Surface Finishing Operations (continued)
Process
Thermal Infusion
Tumbling (Barrel Finishing)
Vacuum Metalizing
Vapor Plating
Welding
Description
Applying fused zinc, cadmium, or other metal coating to a ferrous workpiece by
imbuing the surface of the workpiece with metal powder or dust in the presence of
heat.
Controlled removal of burrs, scale, flash, and oxides as well as to improve surface
finish. Barrel finishing produces a uniformity of surface finish not possible by
hand finishing and is generally the most economical method of cleaning and surface
conditioning. Wastewater is generated by rinsing of parts following the finishing
operation and by periodic dumping of process solutions. Wastewaters may contain
metals (including hexavalent chromium), cyanide, and oily waste depending upon
the chemical solutions employed. ...
Coating workpieces with metal by flash heating metal vapor in a high-vacuum
chamber containing the workpiece. The vapor condenses on all exposed surfaces.
Decomposition of a metal or compound upon a heated surface by reduction or
decomposition of a volatile compound at a temperature below the melting point of
either the deposit or the base material.
Joining two or more pieces of material by applying heat, pressure or both, with or
without filler material, to produce a localized union through fusion or
recrystallization across the interface. This operation is followed by quenching,
cooling or annealing in a solution of water or emulsified oils. Welding wastes may
contain metals.
Wastes Generated
In general, surface finishing and related
washing operations account for the largest volumes
of wastes associated with these processes. These
wastes fall into two groups: plating-related wastes
and painting wastes. Specifically, metal plating and
related processes account for the largest volumes of
metal (e.g.. cadmium, chromium, lead, mercury,
and nickel) and cyanide-bearing wastes. Painting
operations account for the generation of solvent-
bearing and direct release of solvents (including
benzene, MEK, MIBK, toluene, and xylene). Paint
cleanup operations may contribute to the release of
chlorinated solvents (including carbon tetrachloride,
methylene chloride, 1,1,1-trichloroethane, and
perchloroethylene). The nature of the wastes
produced by these processes is discussed next.
Metal Deposition Operation Wastes
Electroplating operations can result in solid
and liquid wastestreams that contain the chemicals
of concern. Liquid wastes result from workpiece
rinsing and process cleanup waters. In general,
most surface finishing (and many surface
preparation) operations contribute to liquid
wastestreams. Centralized wastewater treatment
systems are common to this industry and can result
in solid-phase wastewater treatment sludges. In
addition to these wastes, spent process solutions
and quench bathes are discarded periodically when
the concentrations of contaminants inhibit proper
function of the solution or bath. When discarded,
process bathes usually consist of solid- and liquid-
phase wastes that may contain high concentrations
of the constituents of concern, especially cyanide
(free and complexed).
28
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Related operations, including all non-
painting processes, can contribute wastes including
scrap metals, cleaning wastewaters, and other solid
materials. The nature of these wastes will depend
on the specific process, the nature of the
workplace, and the composition of materials used
in the process. However, due to the potentially
diverse nature of these wastes, the remainder of
this discussion focuses primarily on the plating
operations which are similar among all metal
fabricated products manufacturing industries.
Finishing Wastes
Painting operations result in emissions to
the atmosphere as well as the generation of solid
and liquid wastes. Atmospheric emissions consist
primarily of the organic solvents used as carriers
for the paint. Emissions result from paint storage,
mixing, application, and drying. In addition, clean-
up processes can result in the release of organic
solvents used to clean equipment and painting
areas. In many cases, chlorinated solvents are used
in clean-up operations. Solid and liquid wastes can
be generated throughout the painting operation.
Sources of solid- and liquid-phase wastes include:
paint application emissions control devices
(e.g.. paint booth collection systems,
ventilation filters, etc.),
equipment washing,
disposal materials used to contain paint
overspray (e.g.. paper, cloth, etc.), and
excess paints discarded upon completion of
a painting operation or after expiration of
the paint shelf-life.
These solid and liquid wastes may contain metals
from paint pigments and organic solvents such as
paint solvents and cleaning solvents).
General Source Reduction and Recycling
Techniques
As described above, surface finishing
operations can result in two types of waste: plating
and related operations, and painting operation
wastes. Source reduction and recycling techniques
for each of these materials are described below
(81).
Metal Deposition Operations
Plating wastewaters are composed
primarily of metallic species in aqueous solution.
Plating sludges are generated from the treatment of
wastewater and consist of complexed metal
precipitants and water. In general, the key to
reducing plating wastes includes:
reuse of metal-bearing materials prior to
discharge to centralized wastewater
treatment, and/or
segregation, reclamation, and recycling of
metals from metal-bearing materials in
place of discharge to centralized
wastewater treatment.
Various strategies and techniques for reusing metal-
bearing materials have been developed and
implemented by metal fabricated products
manufacturing facilities. Examples of source
reduction and recycling techniques are listed in
Table 8.
Other, non-painting, finishing operations
such as polishing and sintering also can result in
waste metals that might provide similar source
reduction and recycling opportunities. These
operations are similar to those discussed in previous
sections. This discussion focuses primarily on
source reduction and recycling techniques that have
been applied to plating processes. Additional
information on source reduction and recycling
techniques for these operations can be found in
documents identified in the reference list provided
in this document.
There are many strategies for reducing the
generation and/or release of solvents and paint
29
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residues to the environment. Several examples are
presented in Table 9.
Both Tables 8 and 9 provide a small
sample of source reduction and recycling
alternatives that are discussed further in the
references identified in Section VI. Facilities that
want additional information should access the PPIC
directly. Further, facilities that would like to share
their pollution prevention successes are encouraged
to submit their information directly to the PPIC.
Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information1"
METAL DEPOSITION OPERATIONS
Training and Supervision
Educate plating shop personnel in the
conservation of water during processing
and in material segregation.
Production Planning and
Sequencing
Preinspect parts to prevent processing of
obvious rejects.
Process or Equipment
Modification
Employ countercurrent rinsing to greatly
reduce rinse water usage. Increase drain
time to allow parts to drain 10 seconds or
more after removal from bath.
Add wetting agents to the plating baths to
reduce adhesion of solution to the parts.
Increase bath temperature to reduce
viscosity and improve drainage.
Use spray rinsing to increase rinsing
efficiency for non-complex part
configurations.
Use air agitation in rinse tanks to improve
rinsing efficiency.
Change continuous treatment to a batch
system to account for upsets in effluent
levels.
Capital Investment: $210,000. Payback
Period: 3 years. Waste
Savings/Reduction: reduced water usage
from 12,000 gallons per day to 500
gallons per day. [Reference #19]
Reduce bath evaporation by covering the
surface with a blanket of polypropylene
balls.
30
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Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information1"
Continuously filter process baths to extend
their life.
If etching is done only to put a shine on
the parts, some customers may agree to
buy them unetched, thus, greatly reducing
etch bath wastes.
"Use low concentration plating solutions-
rather than mid-point concentrations in
order to reduce the total mass of chemicals
being dragged out.
Annual Savings: $1,300. Product/Waste
Throughput Information: a nickel
operation having 5 nickel tanks and an
annual nickel dragout of about 2,500
gallons. [Reference
Use the Kushner and Providence methods
of double dragout followed by treatment or
recycle of the concentrated dragout solution
to minimize rinse water use.
Annual Savings: using the Providence
method in lieu of conventional water
treatment: Shop size (gpd): 6,000,
36,000, and 184,000; Annual Savings:
$17,110, $60,080, $44,095. [Reference
Employ countercurrent and conductivity
controls to reduce rinse water flows.
Annual Operating Costs: $10.00/1,000
gallons. Annual Savings: $170,000.
Waste Savings/Reduction: rinse water
was reduced from 43,000 gallons per day
to 8,000 gallons per day. [Reference #81]
**Use electrolytic cells to recover metals
from waste plating solutions. Applicable to
recovery of gold, silver, cobalt, nickel,
cadmium, copper, and zinc from solutions
with 100 mg/1 to 1,000 mg/1 of metal.
Capital Investment: $8,750 - $17,500.
Metal Recovery: 1-2 tons/yr. Waste
Savings/Reduction: metal losses reduced
by a factor of 100. [Reference #81]
31
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Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Raw Material
Substitution
Use less toxic materials whenever possible.
Substitute zinc for cadmium in
alkali/saline environments.
Substitute nitric or hydrochloric
acid for cyanide in certain plating
baths in order to eliminate
cyanides in waste sludges= This
substitution however, may not
apply to all systems and may
decrease the efficiency of certain
waste water treatment systems.
Substitute zinc chloride for zinc
cyanide.
Substitute a non-chlorinated
stripper in place of methylene
chloride.
Waste Segregation and
Separation
Wastewaters containing recoverable metals
should be segregated from other
wastewater streams.
Recycling
Instead of disposing of plating bath when
strength has decreased, filter and
reconstitute it.
Instead of disposing of process baths,
attempt to make them marketable for
resale.
Annual Savings: $16,300. [Reference
#81]
Recycle used rinse waters into bath makeup
solutions for their respective process baths.
Reduce the quantity and toxicity of waste-
waters by employing technologies such as:
evaporation;
Annual Savings: greater than $100,000.
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 rinse waters.
[Reference #81]
32
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Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Recycling (continued)
reverse osmosis;
ion exchange;
evaporation;
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
waters. [Reference #7]
Payback Period: 2-2.5 years. Waste
Savings/Reduction: 84% reduction of
chromium usage, 15-20% sludge
reduction. Company installed an
evaporative recovery unit for a chromium
plating process. [Reference
Capital Investment: $25,000, estimated
for evaporative recovery equipment.
[Reference #81]
Installed Cost: $35,680. Annual
Operating Cost: $9,160. Annual Savings:
$21,000. System operates for 5,000
hours/year, recovering 9,375 Ibs/year
chromic acid. [Reference 081]
Capital Investment: $375,000. Payback
Period: 2 years. Waste
Savings/Reduction: 92% recovery of ion
exchange-treated wastewater for reuse.
[Reference #81]
Payback Period: 5 years. Nickel sulfate
solution is treated by ion exchange and
returned to nickel plating process.
[Reference #19]
Capital Investment: $15,000 (1981).
exchange unit installed to recover
chromium. [Reference #81]
Ion
Capital Investment: $1.3 million. Annual
Savings: $1.2 million. Product/Waste
Throughput Information: 350,000 m'/year
of wastewater. [Reference #57]
33
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Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information"'
Recycling (continued)
reverse osmosis;
electrolysis;
Capital Investment: $16,000. Payback
Period: 20 months. Waste
Savings/Reduction: almost 100% of lost
chemical and 90% of wastewater
recovered. Waste Throughput
Information: 260 liters per hour of
wastewater. [Reference #81]
Capital Investment: $62,000 ($39,000 for
the reverse osmosis unit). Payback
Period: less than 2 years. Company
installed reverse osmosis unit and
evaporative heaters to recover nickel and
rinse waters. [Reference #31]
Capital Investment: $8,500. Waste
Savings/Reduction: about 85% of the
nickel dragout. Company installed reverse
osmosis to recover nickel and rinse water.
[Reference
Capital Investment: $200,000 (330 ft2
membrane). Annual Operating Cost:
large, due to high pressures in system.
Publication discusses reverse osmosis in
general and states that it is applicable to
many electroplating baths. [Reference
#81]
Capital Investment: $21,500.. Operation
Cost: $9,113. Gross Annual Savings:
$17,464. Annual Savings: $8,351.
Payback Period: 2.4 years.
Product/Waste Throughput Information:
economic information for a watts nickel
plating line with dragout rates greater than
one gallon per hour. [Reference #81]
Capital Investment: $8,500. Annual
Savings: $26,060 in chemical usage and
process water. Product Throughput
Information: 60,000 ft2 cadmium
electroplating plant. Company
implemented a high surface area (HSA)
electrolytic reactor for cadmium recovery.
[Reference #81]
34
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Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information*
Recycling (continued)
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.
[Reference #81]
electrodialysis with ion exchange;
and
Capital Investment: $21,050 (15-cell-pair
unit). Payback Period: 9 months.
Company recovers gold from plating rinse
water using electrodialysis and ion
exchange. [Reference
Capital Investment: $109,600 (1980).
Annual Savings: $26,000/year (reduction
in detoxification costs). [Reference #87]
Capital Investment: $220,000. Annual
Savings: $45,000. A medium sized
jewelry plating and manufacturing
company; updating the existing water
treatment facility would have cost
$500,000. [Reference #81]
cyanide destruction.
Capital Investment: $20,000-$50,000 for
hydrolysis process. Waste
Savings/Reduction: can reduce cyanide
from 50,000 mg/1 to less than 30 mg/1.
Waste Throughput Information: 300
gallons per day. [Reference #81]
cyanide destruction (continued)
Capital Investment: $10,000-$50,000 for
chlorine and hypochlorite processes.
Waste Throughput Information: 200
gallons per day - 20 gallons per minute.
[Reference #81]
Capital Investment: $300,000 for ozone
oxidation. Product/Waste Throughput
Information: rinse tanks operated at a rate
of 4 gallons per minute (reactive rinsing
can eliminate 2 out of 3 plating line rinse
tanks). [Reference #81]
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Table 8. Examples of Source Reduction and Recycling Options for Plating Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information"1
Recycling (continued)
**Use reactive rinsing in nickel plating
operations to reduce rinse water use,
improve plating efficiency, and conserve
process chemicals.
Capital Investment: $250 for plumbing
and installation. Product/Waste
Throughput Information: rinse tanks
operated at rate of 4 gallons per minute
(reactive rinsing can eliminate 2 out of 3
plating line rinse tanks). [Reference #81]
Recover phosphate from aluminum bright
dipping operations by reacting rinse acid
with soda alkalies to yield a trisodium
phosphate solution. Filter the solution,
cool it (so trisodium phosphate crystallizes
out), and recycle the remaining mother
liquor with further batches of rinse acid.
"The cost, savings, and waste reduction information provided in Table 4 is based on actual case studies and
reflects the successes of actual metal fabricated products manufacturing facilities. Because specific applications
are highly variable, however, you should use this information only as a indicator of how a particular pollution
prevention option may perform under your circumstances.
""These options cost less than $30,000 to implement.
36
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Table 9. Examples of Source Reduction and Recycling Options for Finishing Operations
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information"'
FINISHING OPERATIONS
Training and
Supervision
Production Planning
and Sequencing
Process or Equipment
Modification
Always use proper spraying techniques.
Improved paint quality, work efficiency, and
lower vapor emissions can be attained by
formal training of operators.
Avoid buying excess finishing material at one
time, due to its short shelf-life.
Use the correct spray gun for particular
applications:
conventional air spray gun for thin-
film-build requirements;
airless gun for heavy film
application; and
air assisted airless spray gun for a
wide range of fluid output.
Preinspect parts to prevent painting of
obvious rejects.
Ensure the spray gun air supply is free of
water, oil, and dirt.
Replace galvanizing processes requiring high
temperature and flux with one that is low
temperature and does not require flux.
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.
Use solvent recovery or incineration to reduce
the emissions of volatile organics from curing
ovens.
Capital Investment: $900,000. Annual
Savings: 50% (as compared to
conventional galvanizing). Product
Throughput Information: 1 ,000 kg/h.
[Reference #81]
Annual Savings: $15,000. Payback
Period: less than 2 years. [Reference #81]
Annual Savings: $400,000. [Reference
#81]
37
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Table 9. Examples of Source Reduction and Recycling Options for Finishing Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information1"
Process or Equipment
Modification
(continued)
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)
$0.05/m2. Waste Throughput Information:
based on an example plant that previously
disposed 180,000 liters of acid solution per
year at $0.07/litre. [Reference #81]
Raw Material
Substitution
Use alternative coatings for solvent based
paints to reduce volatile organic materials 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.
[Reference #32]
Waste Savings/Reduction: 41 % reduction
in VOC emissions. The VOC of the paint
decreased from 5.5 Ib./gallon to 3
Ib./gallon. [Reference #81]
water based coatings; and
Waste Savings/Reduction: 87% drop in
solvent emissions and decreased hazardous
waste production. [Reference #81]
powder coatings.
Capital Investment: $1.5 million. Payback
Period: 2 years. Example is for a large,
wrought iron patio furniture company.
[Reference #81]
Waste Segregation and
Separation
Segregate non-hazardous paint solids from
hazardous paint solvents and thinner.
Recycling
Do not dispose of extended shelf life items
that do not meet your facility's specifications.
They may be returned to the manufacturer, or
sold or donated as a raw material.
Recycle metal sludges through metal recovery
vendors.
38
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Table 9. Examples of Source Reduction and Recycling Options for Finishing Operations
(continued)
Pollution Prevention
Techniques
Recycling (continued)
Pollution Prevention Options
Use activated carbon to recover solvent
vapors, then recover the solvent from the
carbon by steam stripping, and distill the
resulting water/solvent mixture.
Regenerate caustic soda etch solution for
aluminum by using hydrolysis of sodium
aluminate to liberate free sodium hydroxide
and produce a dry, crystalline hydrate
alumina byproduct.
Examples of Costs and Savings,
and Other Information*
Capital Investment: $817,000 (1978).
Waste Savings/Reduction: releases of
solvent to the atmosphere were reduced
from 700 kg/ton of solvent used to 20
kg/ton. [Reference #81]
Capital Investment: $260,000. Annual
Savings: $169,282; from reduce caustic
soda use, income from the sale of the
byproduct, and a reduction in the cost of
solid waste disposal. Payback Period:
1.54 years. Product/Waste Throughput
Information: anodizing operation for which
the surface area is processed at a rate of
200 m2/hour. [Reference #81]
METAL FINISHING AND PAINTING CLEANUP
Production Planning
and Sequencing
Raw Material
Substitution
Loss Prevention and
Housekeeping
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.
Flush equipment first with dirty solvent
before final cleaning with virgin solvent.
Use virgin solvents for final equipment
cleaning, then as paint thinner.
Use pressurized air mixed with a mist of
solvent to clean equipment.
**Replace water-based paint booth filters with
dry filters. Dry filters will double paint
booth life and allow more efficient treatment
of wastewater.
To prevent spray gun leakage, submerge only
the front end (or fluid control) of the gun into
the cleaning solvent.
Waste Savings/Reduction: 98%; from
25,000 gallons of paint cleanup solvents to
400 gallons. Company uses cleanup
solvents in formulation of subsequent
batches. [Reference #31]
Annual Savings: $1,500. Waste
Savings/Reduction: 3,000 gallons/year.
[Reference #81]
39
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Table 9. Examples of Source Reduction and Recycling Options for Finishing Operations
(continued)
Pollution Prevention
Techniques
Waste Segregation and
Separation
Recycling
Pollution Prevention Options
Solvent waste streams should be kept
segregated and free from water
contamination.
Solvent recovery units can be used to recycle
spent solvents generated in flushing
operations.
Install a recovery system for
solvents contained in air emissions.
Use batch distillation to recover
isopropyl acetate generated during
equipment cleanup.
Use batch distillation to recover
xylene from paint equipment
cleanup.
Use a small solvent recovery still to
recover spent paint thinner from
spray gun cleanups and excess paint
batches.
Install a methyl ethyl ketone solvent
recovery system to recover and
reuse waste solvents.
Arrange an agreement with other small com-
panies to jointly recycle cleaning wastes.
Examples of Costs and Savings,
and Other Information*
Annual Savings:- $1,000: [Reference 031]
Payback Period: 2 years. [Reference #31]
Payback Period: 13 months. Annual
Savings: $5,000. [Reference #31]
Capital Investment: $6,000 for a 15
gallons capacity still. Annual Savings:
$3,600 in new thinner savings; $5,400 in
disposal savings. Payback Period: less
than 1 year. Waste Savings/Reduction:
75% (745 gallons of thinner recovered from
1,003 gallons). Product/Waste Throughput
Information: 1,500 gallons of spent thinner
processed per year. [Reference #81]
Annual Savings: $43 ,000/year; MEK
recovery rate: 20 gallons/day,' reflecting a
90% reduction in waste. [Reference #81]
40
-------
Table 9. Examples of Source Reduction and Recycling Options for Finishing Operations
(continued)
Pollution Prevention
Techniques
Pollution Prevention Options
Examples of Costs and Savings,
and Other Information'1'
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 laundering system to clean oil-laden
rags.
"The cost, savings, and waste reduction information provided in Tab
e 4 is based on actual case studies and
reflects the successes of actual metal fabricated products manufacturing facilities. Because specific applications
are highly variable, however, you should use this information only as a indicator of how a particular pollution
prevention option may perform under your circumstances.
**These options cost less than $30,000 to implement.
41
-------
SECTION VI:
POLLUTION PREVENTION DOCUMENTS AND REFERENCES
Compendiums and Guides
Table 10 contains a listing of some key
guides and compendiums on waste minimization,
pollution prevention and recycling that may be of
particular interest or use for metal fabricated
products industries. In many instances, these
documents may provide a firm with important
information as it begins to explore
pollution prevention options for its operations.
Copies of documents with EPA document numbers
may be obtained from EPA or the Pollution
Prevention Information Clearinghouse (PPIC).
Copies of documents with PIES numbers may be
obtained through PPIC/PIES.
Table 10. Recommended Compendiums and Guides
Title
Date
Author &
Reference
Abstract
1. Guides to Pollution
Prevention. The Fabricated
Metal Products Industry
1990
USEPA, Office of
Research and
Development
EPAy625/7-90/006
An overview of metal fabrication waste
generating processes and strategies for
waste reduction and recycling. The
Guide describes integral processes of
aerospace, electronic, defense,
automotive, furniture, domestic
appliance, and other manufacturing
industries. For these industries, the
Guide summarizes source reduction
and recycling alternatives for oily
wastes, surface treatment and plating
residues, and painting operation
wastes.
2. Waste Minimization in Metal
Parts Cleaning
1989
USEPA, Office of Solid
Waste and Emergency
Response
EPA/530-SW-89-049
A summary of source reduction
opportunities associated with metal
parts surface preparation operations.
The review includes descriptions of
source reduction options including
solvent substitutes, mechanical devices,
alternative cleaning systems, and
recycling options.
42
-------
Table 10. Recommended Compendium and Guides (continued)
Title
Date
Author &
Reference
Abstract
3. Meeting Hazardous Waste
Requirements for Metal
Finishers
1987
USEPA, Center for
Environmental Research
Information
EPA/625/4-87/018
An overview of techniques and
strategies for meeting waste regulations
applicable to metal fabricated products
manufacturing industries. The
document summarizes the information
presented in three seminars presented
in 1986. The document includes
discussions of source reduction and
materials recycling options that might
be used'to meet compliance standards.
4. Waste Audit Study - Metal
Finishing Industry
1988
California Alternative
Technology Section and
USEPA
PIES 0005-073-A
Description of waste audit protocol for
metal finishing operations. The
protocol is based upon audits at three
small- to medium-sized operations.
The manual includes discussions of
common processes, wastes, and
applicable source reduction and
recycling techniques.
5. Waste Audit Study - Printed
Circuit Board Manufacturers
1987
California Alternative
Technology Section and
USEPA
PIES #005-006
Summary of protocol developed to
support printed circuit board
manufacturers in identification of
source reduction and recycling
opportunities. The manual includes
discussions of processes and wastes
common to the industry as well as
applicable source reduction and
recycling techniques. The effort
focuses primarily on techniques
applicable to small- and medium-sized
facilities but describes source reduction
and recycling applications that might
be used throughout the industry.
6. Case Studies from the
Minnesota Technical Assistance
Program and the Oregon
Hazardous Waste Reduction
Program
1989
State of Minnesota, State
of Oregon, and USEPA
Compendium of case studies that
describe source reduction and recycling
techniques that have been used in metal
fabricated products industries in
Minnesota and Oregon. Case studies
provide technical and economic
information on proven techniques and
technologies.
43
-------
Table 10. Recommended Compendiums and Guides (continued)
Title
7. Case Summaries of Waste
Reduction by Industries in the
Southeast
8. Source Reduction of
Chlorinated Solvents -
Electronic Products Manufacture
and Solvent Cleaning
9. Waste Minimization
Opportunity Assessments
Manual
10. Waste Minimization and
Pollution Prevention: Metal
Finishing A Self Audit Manual
Date
1989
1990
1988
September
1990
Author &
Reference
North Carolina Pollution
Prevention Program
PIES #112-003-A
Metropolitan Water
District of Southern
California and the
Environmental Defense
Fund
PIES 0609-008-A and
PIES 0609-005-A
USEPA, Office of
Research and
Development
EPA/625/7-88/003
Connecticut Hazardous
Waste Management
Service
State of Connecticut
Abstract
Compendium of case studies that
describe source reduction and recycling
techniques that have been used in metal
fabricated products industries in the
USEPA Region IV States (North
Carolina, South Carolina, Tennessee,
Alabama, Georgia, Kentucky,
Mississippi, and Florida). Case studies
provide technical and economic
information on proven techniques and
technologies.
Two volumes of a twelve volume set
that focus on methods to reduce wastes
associated with processes that result in
chlorinated solvent-bearing wastes.
Each document provides process
descriptions and specific source
reduction alternatives for the industry
of concern (electronic products
manufacturing and solvent cleaning
operations).
A description of a procedure to identify
waste reduction opportunities for
industrial processes. While the manual
is not specific to any particular
industries, it is designed to provide a
systematic assessment strategy to any
industrial generator.
A step by step procedure of how to
perform a self audit of a metal
finishing operation. Contains forms to
collect and organize data and a list of
good operating practices for
electroplaters.
44
-------
Table 10. Recommended Compendiums and Guides (continued)
Title
Date
Author &
Reference
Abstract
11. Hazardous Waste
Minimization Manual for Small
Quantity Generators in
Pennsylvania
1989
Center for Hazardous
Materials Research
PIES #101-004
An overview of general waste
reduction concepts as well as
discussions of waste minimization
strategies appropriate for small
industries including metal fabricated
products manufacturing operations.
This document provides a detailed
study on source reduction and
recycling techniques as they apply to
small metal fabricated products
industries in the State of Pennsylvania.
Additional Pollution Prevention
References
EPA has identified additional documents
that discuss pollution prevention concepts,
techniques and technologies as they apply to metal
fabricated products manufacturing operations.
These documents are contained in the PPIC/PIES
repository (indicated by a PIES number).
Documents may be available through the PPIC
depending on copywrite status and the desires of
the author and/or publisher. The following list of
references is divided by manufacturing process
types to provide the user with some ideas on the
specific topic of the document. A document does
not appear in more than one section, eventhough it
may discuss more than one of the processes
described below.
MACHINING
Metalworking fluids
12. J.T. Johnson, Cincinnati Milacron Products Division. "A Comprehensive Strategy for an Overall
Program of Metal Working Fluid Management". Cincinnati, OH, 1985.
PARTS CLEANING/DECREASING
Surface Preparation
13. R. Schecter and G. Hunt, North Carolina Pollution Prevention Pays Program. "Case Summaries of
Waste Reduction by Industries in the Southeast". Raleigh, NC. 1989. Page 40. (PIES #112-003-A)
45
-------
Solvent Usage
14. L. Traverse, Massachusetts Office of Safe Waste Management. "Creative Source Reduction
Techniques". Third Annual Massachusetts Hazardous Waste Source Reduction Conference
Proceedings. Boston, MA. October 23, 1986. (PIES #022-012)
15. R. Schecter and G. Hunt, North Carolina Pollution Prevention Pays Program. "Case Summaries of
Waste Reduction by Industries in the Southeast". Raleigh, NC. 1989. Page 39. (PEES #112-003-A)
16. C. H. Fromm, S. Budaraju and S. A. Cordery, Jacobs Engineering Group. "Minimization of Process
Cleaning Waste". Solvent Waste Reduction Alternatives Seminar. Speaker Papers. Washington, DC.
March 1988. (PIES #005-012-A-000)
17. E. A. Rodzewich. "Source Reduction - Parts Cleaning". Solvent Waste Reduction Alternatives
Seminar. Speaker Papers. March 1988. (PIES #005-012-A-000)
18. Jacobs Engineering Group, Inc. for USEPA, Hazardous Waste Engineering Research Laboratory,
Office of Research and Development. Waste Minimization Audit Report: Case Studies of Solvent
Wastes from Parts Cleaning and from Electronic Capacitor Manufacturing Operations. Cincinnati, OH.
(PIES #010-003-A)
19. Institute for Local Self-Reliance. "Engine and Plumbing Parts Manufacture, Case Study 60", Proven
Profits from Pollution Prevention: Case Studies in Resource Conservation and Waste Reduction,
Volume II. Washington, D.C. 1989. (PIES #306-001-A)
20. North Carolina Department of Environment, Health, and Natural Resources: Pollution Prevention
Program. Managing and Recycling Solvents in the Furniture Industry. Raleigh, NC. May 1986.
(PIES #034-018-A)
21. Hackney, Pollution Prevention Challenge Grant Program, North Carolina Department of Natural
Resources. "Pilot Study of Solvent Recovery for Use in Paint Equipment Cleanup". December 1986.
(PIES #034-050-A-000)
22. N. H. Frick and G. W. Gruber, PPG Industries, Inc. Solvent Waste Minimization by the Coatings
Industry. Pittsburgh, PA. March 1988. (PIES #800-01)
23. California Department of Health Services, Alternative Technology Section, Toxic Substances Control
Division, Waste Audit Study: Automotive Paint Shops. January 1987. (PIES #005-005)
24. M. Drabkin and P. Sylvestri, USEPA Hazardous Waste Engineering Research Laboratory, Office of
Research and Development. Waste Minimization Audit Report: Case Studies of Minimization of
Solvent and Electroplating Wastes at a POD Installation. Cincinnati, OH. 1989. (PIES #101-036-8)
Aqueous Cleaners
25. K. B. Patterson and D. E. Hunt, U.S. Air Force, AGMC/MAQSE, Newark Air Force Base, OH.
"The Cyl-Sonic Cleaner: Aqueous Ultrafiltration Cleaning Using Biodegradable Detergents". Proc
46
-------
Technology '88: The Key to Hazardous Waste Minimization. Air Force Logistics Command.
Sacramento, CA. August 15-18, 1988. (PIES #100-100-D)
26. T. Smietana, Office of Safe Waste Management "Trichloroethylene Elimination Case Study: Electric
Furnace #2 Bright Anneal Line Industrial Metals Department of Texas Instruments, Inc.," , Third
Annual Massachusetts Hazardous Waste Source Reduction Conference Proceedings. October 23, 1986.
(PIES #022-012)
Wastewaters
27. Massachusetts Department of Environmental Management, Office of Safe Waste Management.
Preliminary Report: Phase I Source Reduction Activities. Southeast Platers Project. Case Study B.
July, 1988. Page 3. (PIES # 022-003-A)
28. North Carolina Department of Natural Resources and Community Development. "Water Conservation
for Electroplaters: Counter-Current Rinsing". Raleigh, NC. 1985. (PIES #034-024A)
29. North Carolina Department of Natural Resources and Community Development "Water Conservation
for Electroplaters: Rinse Tank Design". Raleigh, NC. 1985. (PIES #034-026A)
30. Office of Safe Waste Management, Massachusetts Department of Environmental Management. "The
Robbins Company: Wastewater Treatment and Recovery System, A Case Study." Raleigh, NC. 1985.
(PIES #034-0268)
Degreasing
31. G. Hunt, North Carolina Department of Natural Resources and Community Development.
"Accomplishments of North Carolina Industries - Case Summaries". Raleigh, NC. January 1986, p.
22. (PIES #034-010)
32. Hazardous Waste Reduction Program of the Oregon Department of Environmental Quality. "The
Tektonix Payoff". Salem, OR. June 1988. (038-003-A-OOO)
33. United Nations, Economic and Social Council, Economic Commission for Europe. "Compendium on
Low-and Non-Waste Technology: Elimination of Chlorine by the Use of Fumeless In-line Degreasing
in the Aluminum Industry". Geneva, Switzerland. 1983. (PIES #400-103)
34. New Jersey Hazardous Waste Facilities Siting Commission, Hazardous Waste Source Reduction and
Recycling Task Force. A Study of Hazardous Waste Source Reduction and Recycling in Four Industry
Groups in New Jersey. Newark, NJ. April 1987. Case study D4.1, p. 30.
(PIES #031-001-A)
35. S. P. Evanoff, et. al. "Alternatives to Chlorinated Solvent Degreasing - Testing, Evaluation, and
Process Design" Process Technology '88. Sacramento, CA. August 15-18, 1988. (PIES #100-100-D)
47
-------
SURFACE TREATMENT AND PLATING
Electroplating
36. G. Hunt, et al., North Carolina Department of Natural Resources and Community Development.
"Accomplishments of North Carolina Industries - Case Summaries". Raleigh, NC. January 1986, p.
22. (PIES #034-010)
37. United Nations, Economic and Social Council, Economic Commission for Europe'Compendium on
Low- and Non-Waste Technology: A Low-Waste Electroplating Process". Geneva, Switzerland. 1985.
(PIES #400-125)
38. D. Huisingh, L. Martin, H. Hilger, N. Seldman, The Institute for Self-Reliance. "Proven Profit from
Pollution Prevention". Washington, D.C. 1985, case study 26, Page 103. (PIES #306-001-A)
39. G. F. McRae. "In-Process Waste Reduction: Part 1 - Enviroscope," Plating and Surface Finishing.
June 1988.
40. David Wigglesworth, et.al., Alaska Health Project. "Waste Reduction Assistance Program (WRAP)
On-Site Consultation Audit Report: Electroplating Shop". Anchorage, Alaska. April 7, 1987, pp. 17.
(PIES #002-016-A-001)
41. Edward Saltzberg, Ph.D., Science Applications International Corporation. "Methods to Minimize
Wastes From Electroplating Facilities", Process Technology '88: The Key to Hazardous Waste
Minimization. Air Force Logistics Command. Sacramento, CA. August 15-18, 1988. (PIES #100-
100-D)
42. Hubbard Enterprises, San Diego County, Department of Health Services. "Minimizing Waste from an
Electroplating Operation", Pollution Prevention, A Resource Book for Industry. San Diego, CA.
1990. (PIES #005-079-A-000)
43. Jerome Kohl, et. al., North Carolina State University, School of Engineering. "Reducing Hazardous
Waste Generation with Examples from the Electroplating Industry". Raleigh, NC. 1986.
44. Office of Safe Waste Management, Massachusetts Department of Environmental Management. "Source
Reduction Recommendations for Precious Metal Platers." Boston, MA. April 1988. (PIES #002-012)
Electroplating - Chromium
45. D. Achman, Minnesota Technical Assistance Program. "Reducing Chromium Losses from a
Chromium Plating Bath", Minnesota Technical Assistance Program Summer Intern Report. Summer
1987. (PIES #709-030)
46. United Nations Economic and Social Counsel. "Use of an Evaporator in Chromium Electroplating",
Compendium on Low and Non-waste Technology. Monograph ENVAVp.2/5/Add.47. Geneva,
Switzerland. 1988. (PIES #400-125)
48
-------
Electroplating - Cyanide-containing wastes
47. L. E. Vaaler, Office of Safe Waste Management. "Prospects for Developing Substitutes for Cyanide-
Containing Electroplating Baths", Third Annual Massachusetts Hazardous Waste Source Reduction
Conference Proceedings. Boston, MA. October 23, 1986. (PIES #022-012)
48. USEPA Research and Development, Risk Reduction Engineering Laboratory. "Waste Minimization
Audit Report: Case Studies of Minimization of Cyanide Waste from Electroplating Operations",
Project Summary. Cincinnati, OH. January 1988. (PIES #101-023-8)
Electroplating - Nickel
49. Minnesota Technical Assistance Program. Metal Recovery: Metal Finishing Shop. Minneapolis, MN.
September 1988. (PIES #709-017)
SO. P. Pajunen, Eco-Tech Ltd., and E. Schneider, Hewlett Packard, American Electroplaters and Surface
Finishing Society and U.S. EPA. "Copper and Nickel Removal in Printed Circuit Board Processing by
Ion Exchange and Electroforming", Ninth AESF/EPA Conference on Environmental Control for the
Metal Finishing Industry. January 25-29, 1988.
51. T. Nadeau, et. al.. "Copper, Nickel and Chrome Recovery in a Jobshop to Eliminate Waste Treatment
and Sludge Disposal", Third Annual Massachusetts Hazardous Waste Source Reduction Conference
Proceedings, Office of Safe Waste Management. Boston, MA. October 23, 1986. (PIES #022-012)
52. Minnesota Technical Assistance Program. Metal Recovery: Ion Exchange. Minneapolis, MN.
September 1988. (PIES #709-019)
53. T. V. Tran, et al. "Recovery of Nickel Salts by Electrodialysis Reversal Process," Presented at 73rd
Annual AESF Technical Conference and Exhibit of Surface Finishing. The American Electroplaters
and Surface Finishers Society Bulletin: TP 334-ST. June 23, 1986. (PIES #222-00l-A-001)
Electroplating - Cadmium
54. North Carolina Pollution Prevention Program. "Potential Recovery and Reuse of Cadmium from an
Electroplating Bath". Pollution Prevention Challenge Grant Program. Raleigh, NC. December 1987.
(PIES #034-050-A-000)
Electroplating - Zinc
55. Hazardous Waste Reduction Program, Oregon Department of Environmental Quality. Guidelines for
Waste Reduction and Recycling: Metal Finishing. Electroplating. Printed Circuit Board Manufacturing.
Eugene, OR. July 1989. (PIES # 038-010)
Electrowinning
56. Tom Nadeau, et. al. "Copper, Nickel and Chrome Recovery in a Jobshop to Eliminate Waste
Treatment and Sludge Disposal", Third Annual Massachusetts Hazardous Waste Source Reduction
49
-------
Conference Proceedings, Office of Safe Waste Management. Boston, MA. October 23, 1986. (PIES
#022-012)
Continuous Hardening
57. United Nations, Economic and Social Council, Economic Commission for Europe. "Compendium on
Low- and Non-Waste Technology: Continuous Hardening and Zinc-Coating". Geneva, Switzerland,
1981. (PIES #400-103)
Zinc Coating
58. United Nations, Economic and Social Council, Economic Commission for Europe "Compendium on
Low- and Non-Waste Technology: Continuous Hardening and Zinc-Coating". Geneva, Switzerland,
1981. (PIES #400-103)
Brite Dip Baths
59. Institute for Local Self-Reliance. "Engine and Plumbing Parts Manufacture, Case Study 60", Proven
Profits from Pollution Prevention: Case Studies in Resource Conservation and Waste Reduction,
Volume II. Washington, DC. 1989. (PIES #306-001-A)
60. Minnesota Technical Assistance Program, University of Minnesota. "Metal Recovery: Etchant
Substitution". Minneapolis, MN. 1989. (PIES # 709-014-A-OOO)
61. A. Boyce, Tekronix, Inc. and D. J. Kavanaugh, CH2M Hill Industrial Design Corporation.
"Electrolytic Regeneration of Chromic/Sulfuric Acid Etchant," Ninth AESF/EPA Conference on
Environmental Control for the Metal Finishing Industry. American Electroplaters and Surface
Finishing Society and U.S. EPA, Washington, DC. January 25-29, 1988.
62. V. R. Sellers. "Waste Management Alternatives for Electroplating and Printed Circuit Board
Manufacturing Operations", Third Annual Massachusetts Hazardous Waste Source Reduction
Conference Proceedings, Office of Safe Waste Management. Boston, MA. October 23, 1986. (PIES
#022-012)
63. Thaddeus Smietana. "Trichloroethylene Elimination Case Study: Electric Furnace #2 Bright Anneal
Line Industrial Metals Department of Texas Instruments, Inc.", Third Annual Massachusetts Hazardous
Waste Source Reduction Conference Proceedings, Office of Safe Waste Management. Boston, MA.
October 23, 1986. (PIES #022-012)
50
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Chrome conversion
64. New Jersey Hazardous Waste Facilities Siting Commission, Hazardous Waste Source Reduction and
Recycling Task Force. "A Study of Hazardous Waste Source Reduction and Recycling in Four
Industry Groups in New Jersey", Case study D6.1, p.33. Newark, NJ. April 1987. (PIES #031-001-
A)
Painting
65. K. Weigel. "Developments in Powder Coating Technology", Metal Finishing. April 1989, pp. 41-44.
66. D. S. Tyler, Volstatic, Inc. "Electrostatic Powder Coating: Finishing for the Future", Metal
Finishing. January 1985, pp. 23-26.
67. Hans Sutler, Umweltbundesamt. "Low-waste Technologies in-the Federal Republic of Germany", The
Environmental Professional. Volume U, pp. 190-198. Berlin, Germany. 1989. (PIES #458-006-A-
001)
68. North Carolina Department of Environment, Health, and Natural Resources: Pollution Prevention
Program. Managing and Recycling Solvents in the Furniture Industry. May 1986. (PIES #034-018-A)
69. Hazardous Waste Reduction Program of the Oregon Department of Environmental Quality. "The
Tektonix Payoff. Salem, OR. June 1988. (PIES #038-003-A-000)
70. Mark Manzione, Brown and Caldwell Consulting Engineers. "Waste Minimization for Electroplating
and Aircraft Paint-Stripping Wastewater Treatment", Process Technology '88: The Key to Hazardous
Waste Minimization, Air Force Logistics Command. Sacramento, CA. August 15-18, 1988. (PIES
#100-100-D)
71. Hackney, Pollution Prevention Challenge Grant Program, North Carolina Department of Natural
Resources. "Pilot Study of Solvent Recovery for Use in Paint Equipment Cleanup". Raleigh, NC.
December 1986. (PIES #034-050-A-000)
72. California Department of Health Services, Alternative Technology Section, Toxic Substances Control
Division. Waste Audit Study: Automotive Paint Shops. Sacramento, CA. January 1987. (PIES #005-
005)
73. United States Environmental Protection Agency, Hazardous Waste Engineering Research Laboratory,
Office of Research and Development Waste Minimization. Audit Report: Case Studies of Minimization
of Solvent Waste from Parts Cleaning and from Electronic Capacitor Manufacturing Operations.
Cincinnati, OH. November 1987. (PIES #101-008-A).
51
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SECTION VH:
BIBLIOGRAPHY
In addition to the documents identified in Section VI, the following documents were used to develop
this report.
74. Office of Management and Budget. "Handbook of Standard Industrial Classifications." Springfield,
VA. 1987.
75. United States Environmental Protection Agency, Office of Water. "Development Document for
Effluent Limitations Guidelines and Standards for the Nonferrous Metals Forming and Metal Powders
Point Source Category." Washington, DC. 1986.
76. United States Environmental Protection Agency, Office of Research and Development. "Guides to
Pollution Prevention - The Fabricated Metal Products Industry." Washington, DC. 1990.
(EPA/625/7-90/006)
77. Franklin Associates for the United States Environmental Protection Agency. "Composition and
Management of Used Oil Generated in the United States." Mission, KS. 1984.
78. United States Environmental Protection Agency, Office of Solid Waste. "Industrial Resource Recovery
Practices: Fabricated Metals Production, Machinery Manufacturing/Non-Electrical, and Manufacturing
of Electrical Machinery." McLean, VA. 1982.
79. United States Environmental Protection Agency, Office of Solid Waste. "Waste Minimization in Metal
Parts Cleaning." Washington, DC. 1989. (PIES #101-056-A)
80. United States Environmental Protection Agency. "Development Document for Effluent Limitations
Guidelines and Standards for the Metal Finishing Point Source Category. Washington, DC. 1983.
81. United States Environmental Protection Agency, Office of Solid Waste. "Pollution Prevention in Metal
Manufacturing - Saving Money Through Pollution Prevention (DRAFT)." Washington, DC. 1989.
(PIES #101-054-A)
52
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APPENDIX A
-------
Releases of the 17 Chemicals of Concern
By Metal Manufacturing Industries (in pounds)
SIC 34
Chemical
Benzene
Cadmium
CC1<
CH2C12
CHC13
Chromium
Cyanide
Lead
MEK
Mercury
MIBK
Nickel
TCE
PCE
Toluene
Xylene
111 TCE
Land +
Injection
0
106000
0
0
0
1100789
27250
110378
168310
0
0
22066
4
26965
34517
31234
32898
Air
132
4750
0
3682720
0
104280
78742
98624
7783053
0
2221038
108118
10971337
3864849
9141163
16247570
12086091
Water
0
278
0
262
0
7160
4353
2898
500
0
0
16046
1388
10
67
276
535
Other Transfers
250
631430
0
558261
0-
3550057
813464
1458406
3192717
0
593975
2444351
1397660
652884
1775865
2187671
1676409
Total
382
636458
0
4241243
0
4762268
923809
1670306
11144580
0
2815013
2590581
12370389
4544708
10951612
18466751
13795933
-------
Releases of the 17 Chemicals of Concern
By Metal Manufacturing Industries (in pounds) cont.
SIC 35
Chemical
Benzene
Cadmium
CC14
CH2C12
CHC13
Chromium
Cyanide
Lead
MEK
Mercury
MIBK
Nickel
TCE
PCE
Toluene
Xylene
111 TCE
Land +
Injection
0
1
0
0
0
543
0
32007
250
0
0
785
1100
0
0
27624
0
Air
62317
3300
0
1753930
0
36976
2000
16642
2342567
0
353834
24096
5979064
1681180
4084061
7065077
6585150
Water
0
1
0
0
0
2296
1
80
6
0
161
501
2730
0
250
40
40597
Other Transfers
500
638
0
314892
0
2907984
6083
54627
519165
0
36545
932448
345792
98021
497932
537092
752644
Total
62817
3939
0
2068822
0
5855783
8084
103356
2861988
0
390540
957830
6328686
1779201
4582243
7629833
7378391
-------
Releases of the 17 Chemicals of Concern
By Metal Manufacturing Industries (in pounds) cont.
SIC 36
Chemical
Benzene
Cadmium
CC14
CH2C12
CHC13
Chromium
Cyanide
Lead
MEK
Mercury
MIBK
Nickel
TCE
PCE
Toluene
Xylene
111 TCE
Land +
Injection
0
8800
0
250
0
837
0
282000
2
250
0
11013
734
0
2
12442
7737
Air
0
1159
0
10858010
2150
59600
7289
195711
14633707
1681
519978
14511
6017921
3760992
9848899
13362826
13178506
Water
0
284
0
1433
0
351
1250
0379
250
1
1
1988
1537
282
1519
1534
1261
Other Transfers
0
203943
0
1907897
0
376356
40993
3355740
1300256
59510
59252
1063540
789576
879625
990906
1550351
2060735
Total
0
205386
0
1276790
2150
437144
49532
3839830
15934215
61442
11252
1091052
1393639
38240899
10841326
1547530303
15248239
-------
Releases of the 17 Chemicals of Concern
By Metal Manufacturing Industries (in pounds) cont.
SIC 37
Chemical
Benzene
Cadmium
CC1<
CH2C12
CHC13
Chromium
Cyanide
Lead
MEK
Mercury
MIBK
Nickel
TCE
PCE
Toluene
Xylene
111 TCE
Land +
Injection
0
250
0
1739
0
55490
0
24632
60905
0
0
40750
250
27000
39942
0
5950
Air
360529
1351
0
8237059
26910
54571
2065
113919
13510807
0
4912197
77388
6072105
7727503
16411671
37960496
17617966
Water
263
125
0
623
5
4523
132
1508
1429
0
0
2316
3
1634
750
250
16922
Other Transfers
13463
45223
0
602430
1709
2899431
119924
1535438
3881378
0
895230
655590
702710
399602
2847173
4507721
995896
Total
374255
46699
0
8841851
28624
3014015
122121
1675497
17454519
0
5808427
776044
6775068
8155739
19299536
42468467
18636734
------- |