TECHNICAL REPORT
EPA REGION III POLLUTION PREVENTION
OPPORTUNITY ASSESSMENT
LEONARD'S PLATING, INC.
ST. ALBANS, WEST VIRGINIA
NVIRONMENTAL RISK MANAGEMENT
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TECHNICAL REPORT
EPA REGION III POLLUTION PREVENTION
OPPORTUNITY ASSESSMENT
LEONARD'S PLATING, INC.
ST. ALBANS, WEST VIRGINIA
October 15, 1990
Prepared for:
Mr. James Hemby
U.S. Environmental Protection Agency
Region III
MS-3ES43
BUI Chestnut Building
Philadelphia, Pennsylvania 19107
Prepared by:
Versar Inc.
6850 Versar Center
Springfield, Virginia 22151
EPA Contract No.: 68-C8-0062, Work Assignment No. 1-13
SAIC Project No.: 1-832-03-953-00
Subcontract No.: 16-900010-89
Versar Task 15253.5.1
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DISCLAIMER
This report has been reviewed by the U.S. Environmental Protection
Agency, Region III, and approved for publication. Approval does not
signify that the contents necessarily reflect the views and policies of
the U.S. Environmental Protection Agency, nor does mention of trade names
or commercial products constitute endorsement or recommendation for use.
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TABLE OF CONTENTS
Paee
SECTION 1 - PROJECT OVERVIEW 1
1.1 Purpose 1
1.2 Procedures 1
1.3 Organization of Report 2
SECTION 2 - SITE DESCRIPTION 5
2.1 General Description of Leonard's Plating, Inc.,
St. Albans, West Virginia 5
2.2 Waste Management at Leonard's Plating 10
2.3 Description of Operations Selected for the
Waste Minimization Assessment 11
SECTION 3 - ASSESSMENT PHASE RESULTS 12
3.1 Summary of Assessment Phase 12
3.2 Description of Rinsewater Volume Reduction
Option 13
3.3 Description of Options for Potential Recovery
of Nickel and Chromium 15
3.3.1 Nickel 15
3.3.2 Chromium 18
3.4 Description of Potential Trivalent Chromium
Substitution Option 21
SECTION 4 - FEASIBILITY ANALYSIS RESULTS 23
4.1 Summary of Feasibility Analysis Phase 23
4.2 Waste Minimization Options Recommended for
Implementation 24
SECTION 5 - OBSERVATIONS THAT MAY BE GENERALLY APPLICABLE
TO THE BUMPER PLATING INDUSTRY 25
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APPENDICES
Appendix A - Trip Report on Detailed Site Inspection of
Leonard's Plating Facility
Appendix B - Waste Minimization Worksheets 2-16
Appendix C - Material Safety Data Sheets for Chemicals Used at
Leonard's Plating Facility
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SECTION 1
PROJECT OVERVIEW
1.1 PURPOSE
The purpose of this project was to support the pollution prevention
program of Region III of the U.S. Environmental Protection Agency (EPA)
by performing a pollution prevention opportunity assessment at one site
within the Region. After a Region-wide solicitation, Leonard's Plating,
Inc., a job shop bumper recycling operation in St. Albans, West Virginia,
was selected to serve as the host site for the planned assessment. The
assessment was intended to develop pollution prevention options for the
principal hazardous waste-generating areas at the Leonard's Plating
operation. The resulting case study is to be used to encourage other
industrial sites to employ waste minimization as a tool in pollution
prevention.
1.2 PROCEDURES
This project was initiated when the Versar assessment team received
preliminary operational data from Leonard's Plating on its bumper plating
operation, as well as data on the plant's wastewater discharge. These
data were reviewed by the assessment team, and a detailed site inspection
was then carried out at Leonard's Plating as part of the overall
pollution prevention opportunity assessment. Following completion of
this site inspection, the assessment team carried out the remaining steps
in the pollution prevention opportunity assessment, including options
generation and review, feasibility analysis, and the preparation of
recommendations for Leonard's Plating on implementation of selected
options.
aSee Trip Report, Appendix A, for a report on the site inspection
results.
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The procedures described in the EPA Waste Minimization Opportunity
Assessment Manual are used in this effort. This manual provides a
systematic methodology for identifying ways to reduce or eliminate waste.
The EPA manual contains a set of 19 worksheets designed to facilitate
the pollution prevention opportunity assessment procedure. Table 1 lists
the worksheets and provides a brief description of the purpose of each.
Worksheets 2 through 16 were completed for the Leonard's Plating project
and are presented in Appendix B for the three waste streams studied.
Leonard's Plating plans to implement one or more of the pollution
prevention options developed in the current project in its automobile and
truck bumper recycling operation if these options are found to be useful
and cost-effective. This implementation effort would be part of Phase II
of the present project, with the current pollution prevention assessment
considered to be Phase I.
1.3 ORGANIZATION OF REPORT
This report contains four sections and three appendices. Section 1
provides an overview of the project. Section 2 describes the Leonard's
Plating facilities, the industrial activities surveyed during this
project, and the waste management procedures currently employed at this
site. Section 3 presents the results of the assessment phase, including
the selection of pollution prevention options. Section U discusses the
results of the feasibility analysis phase, including the recommendations
made. Appendix A contains the Trip Report covering the 1-day detailed
site inspection at Leonard's Plating. Appendix B contains Waste
Minimization Worksheets 2-16, completed for the hazardous wastes of
concern. Appendix C contains the Material Safety Data Sheets on the
chemicals used in the Leonard's Plating bumper plating operations.
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TABLE 1 LIST OF WASTE MINIMIZATION ASSESSMENT WORKSHEETS
Worksheet
Number and Title
Purpose/Remarks
1 Assessment Overview
Summarizes the overall assessment procedure.
2 Program Organization
Records key members in the WMA program task force and the WM
assessment teams Also records the relevant organization.
3. Assessment Team Makeup
Lists names and duties of assessment team members. Includes a
list of potential departments to consider when selecting the
teams.
4 Site Description
5 Personnel
Lists background information about the facility, including
location, products, and operations.
Records information about the personnel who work in the area
to be assessed
6 Process Information
7 Input Materials Summary
Serves as a checklist of useful process information to look
for before starting the assessment
Records input material information for a specific production
or process area Includes name, supplier, hazardous component
or properties, cost, delivery and shelf life information, and
possible substitutes
8 Products Summary
Identifies hazardous components, production rate, revenues,
and other information about products.
9 Individual Waste Stream
Characterization
10. Waste Stream Summary
Records source, hazard, generation rate, disposal cost,
and method of treatment or disposal for each waste stream
Summarizes all of the information collected for each waste
stream Also used to prioritize waste streams for future
waste minimization assessments.
11 Option Generation
12 Option Description
Records options proposed during brainstorming or nominal group
technique sessions Includes the rationale for proposing each
option
Describes and summarizes information about a proposed option
Also notes approval of promising options
13 Options Evaluation by
Weighted Sum Method
Used for screening options using the weighted sum
method
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TABLE 1 (CONTINUED)
Worksheet
Number and Title
Purpose/Remarks
14 Technical Feasibility
IS Cost Information
Serves as a detailed checklist for performing a technical
evaluation of a WM option Divided into sections for
equipment-related options, personnel/procedure-related
options, and materials-related options
Includes a detailed list of capital and operating cost
information for use in the economic evaluation of an option
16 Profitability Worksheet
#1 Payback Period
17 Profitability Worksheet
#2 Cash Flow for NFV
and IRR
Calculates the payback period, using the capital and
operating cost information developed from Worksheet IS
Used to develop cash flows for calculating NPV or IRR
18 Project Summary
19 Option Performance
Summarizes important tasks to be performed during the
implementation of an option These include deliverable,
responsible person, budget, and schedule
Records material balance information for evaluating the
performance of an implemented option
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SECTION 2
SITE DESCRIPTION
2.1 GENERAL DESCRIPTION OF LEONARD'S PLATING, INC., ST. ALBANS,
WEST VIRGINIA
Leonard's Plating, Inc., is an automobile and truck bumper recycling
operation located in St. Albans, West Virginia, a suburb of Charleston.
This plant has been in continuous operation since 1961, with the present
owner, Mr. Leonard Reed, having purchased the facility in 1985.
The principal activity of Leonard's Plating is the refurbishing and
replating of damaged car and truck bumpers obtained mainly from auto body
shops and, to a lesser extent, from private individuals. Thus, the
operation is a job shop, dependent almost entirely on a supply of
customers' damaged bumpers as feedstock to the plant. Mr. Reed indicated
that his facility is a relatively small shop in terms of bumper recycling
operations. This shop processes about 15 to 20 car and truck bumpers per
day on average, with 30 to 35 bumpers per day considered to be the
plant's maximum output.
The Leonard's Plating plant layout (as supplied by the facility) is
shown in Figure 1. This figure also indicates the sole sampling point
for rinsewater from the plating operations prior to discharge of the
stream to the St. Albans publicly-owned treatment works (POTW). The
one-story plant (no basement) occupies a total of 6,600 square feet, with
approximately 1,000 square feet devoted to bumper straightening,
540 square feet allocated to bumper grinding and polishing operations,
and about 1,200 square feet for the plating line area. The entire
plating area is enclosed by a cinder block wall, which serves to minimize
the possibility of tank leakage or spills into the other plant areas or
into the local sanitary sewer system.
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Ul
s
Sample
Point
n | n I n~r n i rrn
< i _3
9
7 .
Plating Line
Grinding
and
Straightening
Plating
Tank
Number
1
2
3
4
5
6
7
8
9
Chromium Stripping
Alkaline Electrocleaning
Alkaline Rinse
Acid Pickling
Pickling Rinse
Nickel Plating
Nickel Rinse
Chromium Plating
Not Used
*•
&
*
n
Office
FIGURE 1. LAYOUT OF PRINCIPAL OPERATIONS CARRIED OUT AT
LEONARD'S PLATING FACILITY, ST. ALBANS, WEST VIRGINIA
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The bumper recycling operation, which is performed on an 8-hour
shift, 5 days per week, consists of the following steps in sequence:
1. Bumper straightening, in which the dented mild steel bumpers are
straightened using hand tools.
2. Bumper stripping, in which the straightened bumpers are
chemically stripped of the outer chrome layer in a stripping tank
containing alkaline solution at a temperature of approximately
130°F. The stripping solution is heated via a steam line
running through the tank.
3. Grinding of the stripped bumpers using two grinding wheels
surfaced with coarse and fine abrasive, respectively. In this
operation, small dents, cracks, and grinding lines are removed.
4. Alkaline electrocleaning, in which reverse current
electrocleaning of the bumpers in an alkaline detergent medium is
carried out at temperatures around 130°F. The "scrub" solution
is heated using a steam line running through the solution tank.
The bumpers from Step 3 are immersed in the scrub tank for
30 seconds, after which they are suspended above the tank and
spray-rinsed, with the rinsings flowing back to the tank.
5. Following the scrub tank, a running rinse step in which
0.5 gal/min of tap water (no agitation used) flows through the
tank and removes the balance of the alkaline detergent solution
on the bumper surfaces. The rinsewater discharge is wasted to
the St. Albans sanitary sewer.
6. Acid pickling, in which a solution of approximately equal amounts
of 20°Baumea muriatic acid (HC1) and water is maintained in a
fiberglass tank. The bumpers are immersed in this tank for a few
minutes at ambient temperature.
7. Following the pickling tank, immersion of treated bumpers in a
running rinse tank in which about 0.5 gal/min of tap water flows
through the tank to the St. Albans sanitary sewer. The pickled
bumpers are immersed in this tank for several minutes to rinse
off all traces of muriatic acid.
8. Suspension of the pickled rinsed bumpers in one of two nickel
plating tanks (used alternately) equipped with nickel anodes and
containing a nickel sulfate plating solution in which the clean
mild steel bumpers are the cathodes. The bumpers are suspended
in
aA measure of the specific gravity of the HC1 solution.
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the bath for about 50 minutes at a temperature of 150-170°F with
solution agitation provided by compressed air spargers. The
plated bumpers are lifted out of the bath and suspended over it.
Spray rinsing over the tank causes most of the adhering nickel
plating bath solution to return to the plating tank.
9. Spray rinsing, in which the nickel-plated bumpers are suspended in
a tank and sprayed with tap water from the four sides of the
tank. The accumulated spray liquor at the bottom of this tank is
periodically pumped back to one of the nickel plating tanks, as
appropriate.
10. Plating of a layer of chromium metal over the nickel layer already
on the bumper. A single chrome plating tank is equipped with lead
anodes (which last in excess of 3 years before having to be
replaced) with the nickel-plated bumpers as cathodes. The chromium
is plated out of chromic acid solution. The nickel-plated bumpers
are immersed in the chromic acid solution for about 3 minutes,
after which they are lifted out of the bath and suspended above
it. Excess plating solution is then rinsed back into the tank
using hand-held water spray nozzles. During the plating cycle,
the tank is covered with a hood from which a flexible duct
exhausts any chromic acid vapors through the roof of the plating
shop. Any chromic acid in the mist leaving at the roof exhaust
could be collected in a chevnon-type or mesh-type canister and
periodically returned to the chromium plating tank.
Figure 2 is a simplified schematic of the sequence of operations
discussed above.
Following this sequence of bumper cleaning and plating steps, the
replated bumper is examined for imperfections in the plated finish. If
any imperfections are found, the bumper is put through the chemical
stripper (Step 2) to remove some of the surface chromium and then is
freshly replated with chromium to ensure the proper bumper surface
characteristics. Mr. Reed indicated that the average bumper reject rate
is roughly 10 percent. Bumpers may be poorly plated for the following
reasons:
• Improper rectifier operation affecting plating efficiency;
• Low chromic acid concentration in the plating bath; and/or
• Improper bumper preparation in the alkaline and acid cleaning
baths.
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To Grinding
Operations
Evaporation Alkaline Tap Water
(maintains tank stripper Rinse Over
water level) (1 dr/yr) Tank
From Grinding
Operations
Work Flow
t ,.
(Straightened
Bumpers)
Tap Water
Rinse
ALKALINE CHROME
STRIP TANK
1.000 gallons, 130 °F
Spray Rinse on Chrome-Stripped
Bumpers
H H
Tap Water
Evaporation
(maintains tank
water level)
ALKALINE REVERSE
CURRENT ELECTROCLEANING
TANK
8 00 gallons, 130 °F
Tap Water
Rinse
(1/2 gpm)
i
ALKALINE RINSE
TANK
700 gallons
ay Rinse on Plated Bumpers
Nickel Anodes
& Nickel Sulfate
1^ Solution(added
intermittently)
Tap Water
Rinse
(1/2 gpm)
NICKEL PLATING TANKS
(TWO TANKS USED ALTERNATELY)
800 & 1.000 gallons, 150-170 °F
Bag or Cartridge
Fitter
Filtered
Solution
Recirculated
to Nickel
PlatingTank
SPRAY RINSE TANK
800 gallons
ACID RINSE
TANK
700 gallons
\ I
IMOC I ^ *
J
Hydrochloric Acid(HCI) & Water
(added intermittently) I
PICKLING TANK
(MURIATIC ACID SOLUTION)
1,300 gallons
Collected Nickel
Spray Rinse
Intermittently
Recirculated
to Plating Tank \
Evaporation
(maintains
chrome solution
level)
Spray Rinse on Plated Bumpers
Tap Water
Rinse
L
J!L
t
\
I I I i— Chromic Acid Solution
X * V V Y (added imermittent|y)
CHROME PLATING TANK
800 gallons, 112-118 °F
To Inspection, Packing,
and Shipping
Filtered Solids
& Spent Cartridges to Municipal Landfill
Rinsewater Discharge to POTW
(about 1 gpm)
FIGURE 2. PRECLEANING & PLATING AREA:
Bumper Recycling Operations at Leonard's Plating,
St. Albans, West Virginia
Legend:
Work Flow
Water & Chemicals Flow
Solid Waste Flow
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2.2 WASTE MANAGEMENT AT LEONARD'S PLATING
Based on the information available to Versar during the onsite
inspection, the following findings are believed to be applicable to the
wastes generated in the bumper recycling operation:
Floor sweepings from the bumper straightening and grinding
operations are disposed of at the local sanitary landfill on an
intermittent basis. This material was found, through analysis, to
be nonhazardous.
Wastes are generated in the chromium stripping operation. The
solid wastes collecting at the bottom of this tank have not been
removed during the 5 years that the installation has operated
under Mr. Leonard Reed's ownership. Evaporation from this tank
prevents liquid overflow. When the contents of this tank are
finally discharged, its chromium content will probably cause this
material to be classified as RCRA D007 hazardous waste, requiring
discharge to a hazardous waste landfill unless Mr. Reed chooses to
attempt recovery/recycle of the chromium residuals in these solids.
The rinsewater discharges from the alkaline and acid rinse tanks
(see Figure 2) are not treated by the generator and therefore are
not F006 hazardous waste. Review of the available analyses of
these wastes (combined as a wastewater stream discharged from the
plant) indicates that there are no reportable levels of Toxicity
Characteristic Leaching Procedure (TCLP)-toxic (i.e., chromium)
sufficient to classify this stream as TCLP-toxic. The combined
wastewater stream is discharged to the St. Albans, West Virginia,
POTW and meets the local POTW pretreatment standards.
There are no reported discharges of liquid or solid wastes from
the plating and follow-on rinsing sections of the operation (see
Figure 2).
Chromium-bearing emissions discharged to the roof vent over the
chromium plating tank are not quantified; i.e., there is no
permitted air pollution control device (APCD) in place at this
location so the quantity (if any) of these emissions has not been
measured. These emissions are discussed under item 10 on page 9
of this report.
Nickel-bearing sludges filtered out of the recirculating nickel
plating solution (see Figure 2) have been found to have no
RCRA-reportable quantities of EP-toxic metals. (TCLP tests have
not been performed on these wastes, however.) These sludges are
accumulated in a 55-gallon drum, and in the past they have been
discharged to the local sanitary landfill about once per year
(about 400-500 Ib/yr).
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In summary, the detailed site inspection at the Leonard's Plating
site carried out by the Versar assessment team indicates that potential
hazardous waste discharges are eliminated through careful attention to
retention of chromium and nickel plating solution dragout in the plating
tanks, as well as retention of chromium-bearing solids and solutions in
the bumper stripping tank.
2.3 DESCRIPTION OF OPERATIONS SELECTED FOR THE WASTE MINIMIZATION
ASSESSMENT
Since none of the bumper plating operations at Leonard's Plating
generate any rinsewater wastes that require discharge, the only operation
that appeared to be amenable to waste minimization option analysis was
the rinsewater discharged from the alkaline cleaning and acid pickling
bumper pretreatment steps. In addition to this operation, two other
pollution prevention opportunities seemed to be worth analyzing since
these opportunities are potentially of interest to the bumper plating
operation. These two opportunities were the recovery of nickel and
chromium from solid residuals potentially generated in the bumper plating
operation and the substitution of trivalent chromium plating for
hexavalent chromium plating in order to reduce potential waste toxicity.
All three pollution prevention opportunities are analyzed in detail in
Section 3.
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SECTION 3
ASSESSMENT PHASE RESULTS
3.1 SUMMARY OF ASSESSMENT PHASE
The assessment phase includes data collection, selection of potential
areas of waste minimization, data review, and options generation and
screening. The results of the assessment phase for Leonard's Plating
include three potential waste minimization options. Data and
calculations relating to these options are shown on Worksheets 2 through
16 (Appendix B). The three options are as follows:
1. Rinsewater reuse;
2. Recovery of nickel and chromium from solid residuals; and
3. Substitution of trivalent chromium plating for hexavalent
chromium plating to reduce waste toxicity.
Option 1 was fully evaluated. Option 2 was only partially evaluated
because the volume of residuals is only about 55 gallons of nickel solids
per year, and no chromium-bearing solids have been discharged since
1985. It is believed that the cost of transporting the 55 gal/yr of
residual nickel-bearing solids to a metal recovery operation would exceed
the cost incurred as a result of the facility's current disposal
practice, i.e., removal to a local municipal landfill. Option 3 was not
evaluated because both wastewater discharge regulations and hazardous
waste regulations require control of total chromium discharges, not
hexavalent chromium. Hence, there would be no advantage to discharging
trivalent chromium. Further, the effect of using trivalent chromium on
product quality and costs is not known although at least one decorative
3758g
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chrome plating operation has been known to use trivalent chromium
successfully.
3.2 DESCRIPTION OF RINSEWATER VOLUME REDUCTION OPTION
As noted in Figure 2, 0.5 gal/min of tap water is used for the
immersion rinse after the alkaline electrocleaner, and another
0.5 gal/min is used for the immersion rinse after the hydrochloric acid
(HC1) pickling bath. The overflows from both these rinse tanks are
combined and discharged without treatment to the St. Albans, West
Virginia, publicly-owned treatment works (POTW). (See Figure 2.) No
heavy metal concentrations are detectable except nickel, which has never
exceeded 1.2 mg/1, as compared to the State of West Virginia permit limit
of 2.38 mg/1 for a monthly average.
It was suggested that a simple plumbing change be made to cut the
overflow from the above two rinse tanks in half. This change is not
expected to adversely affect product quality and may, in fact, lessen the
amount of HC1 use. Figure 3 shows this change, which involves
disconnecting the HC1 rinse overflow to the sewer and repiping it to the
electrocleaner rinse tank inlet. At the same time, the 0.5-gal/min tap
water flow into the electrocleaner rinse would be turned off. The effect
of this change would be to rinse the bumpers in the overflow from the HC1
rinse after alkaline electrocleaning. Such an approach would, in fact,
be advantageous when compared to rinsing in tap water because the HC1
rinsewater would be slightly acidic and would rinse the alkali from the
bumpers better than would tap water. The modification would also mean
that less alkali would be dragged out of the alkaline electroclean rinse
into the HC1 bath, thereby lengthening the time between additions to the
HC1 bath.
aValley Plating, Los Angeles, California, as referred to in
Environmental Progress, Vol. 9, No. 2, p. 11.
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Evaporation
(maintains tank
water level)
To Grinding
Operations
Tap Water I
Rinse Over!
From Grinding
Operations
Alkaline Tap Water
Stripper Rinse Over1
(1 dr/yr) Tank
Work Flow,
(Straightened
Bumpers)
f * t
ALKALINE CHROME
STRIP TANK
1,000 gallons, 130 °F
Spray Rinse on Chrome-Stripped
Bumpers
H H
Tap Water
Evaporation
(maintains tank
water level)
ALKALINE REVERSE
CURRENT ELECTROCLEANING
TANK
800 gallons, 130 °F
ALKALINE RINSE
TANK
700 gallons
Spray Rinse on P
^- Spray Rins
Tap Water I I
Rinse W V
'lated Bumpers
I T '
f
Nickel Anodes
& Nickel SuHate
Solution(added
intermittently)
Tap Water
Rinse
(1/2 gpm)
Acid Rinse
Overflow
NICKEL PLATING TANKS
(TWO TANKS USED ALTERNATELY)
800 & 1,000 gallons, 150-170 °F
Bag or Cartridge
Filter
Hydrochloric AckJ(HCI) & Water
(added intermittently) I
Filtered
Solution
Recirculated
to Nickel
PlatingTank
SPRAY RINSE TANK
800 gallons
PICKLING TANK
(MURIATIC ACID SOLUTION)
1.300 gallons
Collected Nickel
Spray Rinse
Intermittently
Recirculated
to Plating Tank
Spray Rinse on Plated Bumpers
Tap Water
Rinse
Evaporation
(maintains
chrome solution
level)
III
t
••
il I .— Chromic Acid Solutioi
1 WWW (added intermittently)
CHROME PLATING TANK
800 gallons, 112-1188F
To Inspection, Packing,
and Snipping
Filtered Solids
Rinsewater Discharge to POTW
(about 1/2 gpm)
& Spent Cartridges to Municipal Landfill
FIGURE 3. SUGGESTED WASTE MINIMIZATION OPTION:
PLATING RINSEWATER REDUCTION
Bumper Recycling Operations at Leonard's Plating,
St. Albans, West Virginia
Legend:
Work Flow
Water & Chemicals Flow
Solid Waste Flow
Recommended New Rinsewater Line
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3.3 DESCRIPTION OF OPTIONS FOR POTENTIAL RECOVERY OF NICKEL AND
CHROMIUM
3.3.1 Nickel
Nickel is plated in two baths (one of which is shown in Figure 4,
Photographs 1 and 2). Insoluble sediment and impurities build up in
these baths and would affect product quality if not removed. To remove
the impurities, the contents of the nickel bath are circulated
continuously from the baths, through filters, and back to the nickel
plating tanks. The filter for the larger plating tank is a large
bag-type filter (shown in Figure 5, Photograph 3). The filter for the
smaller plating tank is a smaller cartridge-type filter (also shown in
Figure 5, Photograph 3). The solids collected in these filter bags, and
ultimately the bags themselves, are placed in a 55-gallon drum (shown in
Figure 5, Photograph 4). The drum is typically filled and disposed of at
the local municipal landfill once annually. The cartridges (also shown
in Figure 5, Photograph 4) from the smaller filter are removed when they
become plugged and are disposed of in the same manner. An analysis for
all EP-toxic metals was performed on the filtered solids, and only barium
was found to be present at detectable concentrations (0.04 mg/1 in the EP
leachate). Hence, the solids are unlikely to fit the definition of a
"characteristically" hazardous waste under EPA 40 CFR 261
regulations.a The waste also does not meet the definition of the
hazardous waste F006. F006 is "wastewater treatment sludges from
electroplating operations. ..." At Leonard's Plating "wastewater" is
not being treated to generate the solids. Only process water is
filtered. Further, there is no technical reason to believe that
aAt this time the EP leach test has been replaced as the regulatory
standard by the TCLP leach test. However, it is unlikely that
"characteristic" metals in a TCLP leachate of these filtered nickel
solids would violate regulatory standards.
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PHOTOGRAPH 1
SPRAY RINSE NOZZLES
NICKEL PLATING BATH
PHOTOGRAPH 2
Figure 4. Leonard's Plating Tank Operations
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NICKEL BATH FILTERED SOLIDS
NICKEL BATH FI1 PER CARTRIDGES
PHOTOGRAPH 3
PHOTOGRAPH 4
HANDRINSING OVER HOT CHROMIUM
STRIPPING TANK
PHOTOGRAPH 5
Figure 5. Leonard's Plating - Plating Solution Filtration and Rinsing Operations
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significant quantities of "characteristic" metals (barium, arsenic,
cadmium, lead, chromium, selenium, silver, and mercury) would be present
in the filtered nickel plating bath solids. Consequently, because the
waste is not hazardous by current Federal definition, it could continue
to be disposed of at the local municipal landfill at relatively low cost.
Clearly, the filter bath solids must have relatively high
concentrations of nickel (not a "characteristic" hazardous metal),
although total concentration analyses have not been performed for any
metals. Various high-temperature metals recovery techniques are
practiced by a number of commercial firms. (Table 2 lists the names of a
number of these firms.) Some of these processes purportedly will recover
nickel if the waste has a sufficiently high nickel concentration.
However, based on contacts with recovery firms, it is unlikely that one
55-gallon drum of solids per year could be recovered as economically as
the manner in which Leonard's Plating is currently disposing of the
material. (Also, it is unlikely that the cartridges would be amenable to
nickel recovery in any case because they are predominantly inorganic
fiber material.)
3.3.2 Chromium
Solids of unknown chemical composition (other than the expected
presence of chromium metal) are accumulating at the bottom of the warm
alkaline tank used for stripping chromium (see Figure 2), although the
solids level appears to be only a few inches high and the solids have not
been disposed of since 1985, when the ownership of Leonard's Plating
changed. The tank has no overflow. Rinsing over the tank balances
evaporation (see Figure 5, Photograph 5).
In addition, no solids have ever been disposed of from the chromium
plating tank (see Figure 6, Photograph 6), nor does that tank overflow.
Rinsing over the tank balances evaporation. The Versar assessment team
3758g
- 18 -
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TABLE 2. FIRMS THAT RECOVER METALS FROM
SOLID WASTE RESIDUALS
Company Name
Location
Telephone Number
World Resources Corporation*
Recontek
Eticam*
CP Chemicals
Encycle
Inmetco*
McLean, Virginia
San Diego, California
Warwick, Rhode Island
Ft. Lee, New Jersey
Corpus Christi, Texas
Elwood City, Pennsylvania
(703) 734-9800
(619) 581-3331
(800) 541-8673
(201) 944-6020
(800) 443-0144
(412) 758-5515
*These firms were contacted by Versar by telephone.
3758g
- 19 -
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VENTILATION HOOD (IN OPEN POSITION)*
CHROMIUM PLATING BATH \
PHOTOGRAPH 6
NICKEL BATH FIl ER PUMP
PHOTOGRAPH 7
Figure 6. Leonard's Plating - Auxiliary Operations in Plating Area
- 20 -
-------
was advised that any solid impurities buildup is removed daily by
stirring the tank and chromium plating a "dummy" for about 15 minutes.
The plating on the "dummy" incorporates the solid impurities. According
to plant personnel, the "dummies" themselves have never been disposed of.
If solids from these tanks were disposed of, they would most likely
be the "characteristically" hazardous waste D007 (waste that is capable
of leaching chromium at greater than 5.0 mg/1, using the TCLP test). As
such, they could be disposed of after treatment, only at a permitted
hazardous waste landfill. Since such disposal would probably be
relatively expensive, chromium recovery, like nickel recovery, might be
economically feasible. However, no solids have been generated from
either tank, nor do plant personnel anticipate that they will be
generated in the foreseeable future. Hence, recovery of chromium from
solid wastes at Leonard's Plating is of only academic interest.
3.4 DESCRIPTION OF POTENTIAL TRIVALENT CHROMIUM SUBSTITUTION OPTION
After nickel is plated on bumpers at Leonard's Plating, chromium is
plated over the nickel (see chromium plating bath shown in Figure 6,
Photograph 6). The chromium bath consists of conventional hexavalent
chromium compounds. In recent years plating technology has developed
chromium plating systems using trivalent chromium compounds. Trivalent
chromium is believed by most toxicological authorities to be a less toxic
form of chromium. Hence, any discharges of chromium from trivalent
chromium plating operations would be less RCRA hazardous than those from
similar hexavalent chromium plating operations.
Leonard's Plating discharges minimal amounts of chromium to the
environment, only to the atmosphere, through a ventilation system (see
hood in Figure 6, Photograph 6). The ventilation system is not the
3758g
- 21 -
-------
subject of an air pollution permit; hence, the form of chromium is not an
issue. Likewise, with no solids or wastewater chromium discharges, the
form of chromium is not an issue for these media.
Additionally, even though Leonard's Plating does not discharge
chromium in its wastewater, the facility's wastewater discharge permit
regulates total chromium and does not distinguish between the forms of
chromium. Hazardous waste regulations also do not differentiate between
forms of chromium, but regulate only total chromium.
Because of the above findings, there is no basis for recommending
trivalent chromium plating. In addition, the effects of trivalent
chromium plating on product quality, plating process design, or waste
generation are not known.
3758g
- 22 -
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SECTION 4
FEASIBILITY ANALYSIS RESULTS
4.1 SUMMARY OF FEASIBILITY ANALYSIS PHASE
The purpose of the feasibility analysis phase is to prepare a
technical and economic evaluation of the pollution prevention (PP)
options developed and to select options worthy of implementation.
The technical feasibility evaluation initially determines the nature
of the PP option, i.e., whether it is equipment-related, personnel/
procedure-related, or materials-related, or a combination of these
factors. For each of the three types of PP options, specific information
and data are required. For equipment-related options, the information
requirements relate to the state of technology, availability of
equipment, performance specifications, testing, space and utilities,
production effects, and training. For personnel/procedure-related
options, the required information relates to training and operating
instruction changes. For materials-related options, the required
information relates to production impacts, storage and handling,
training, and testing.
As noted in Section 3, three pollution prevention options were
considered for the Leonard's Plating facility. Only one, rinsewater
reuse (an equipment-related PP option), was subjected to a feasibility
analysis. The other two suggested options were rejected for the reasons
discussed in Section 3.
The rinsewater reuse option involves minor equipment and plumbing
modifications whose capital costs are estimated to be under $200. Annual
savings are expected to be about $300, which represents savings on water
and sewer use fees. These savings represent a capital payback period of
only 8 months. More detail is available on the worksheets in Appendix B.
3758g
- 23 -
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4.2 WASTE MINIMIZATION OPTIONS RECOMMENDED FOR IMPLEMENTATION
It is recommended that the water reuse option be implemented at the
Leonard's Plating facility as this option involves very low costs and
rapid capital payback.
3758g
- 24 -
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SECTION 5
OBSERVATIONS THAT MAY BE GENERALLY APPLICABLE
TO THE BUMPER PLATING INDUSTRY
Leonard's Plating has developed a successful bumper recycling
operation that includes stripping and replating of mechanically repaired
auto and truck bumpers. Of potential interest to this industry is the
Leonard's Plating achievement of zero discharge of RCRA hazardous metal
pollutants generated in the bumper plating operations, i.e., no discharge
of chromium. Both the protective coating of nickel plated on the steel
bumper substrate and the decorative chromium subsequently plated on the
nickel are handled in the plating operations such that the adhering
plating chemical dragout on the bumpers is either rinsed back into the
plating tank (in the case of chromium) or both rinsed back and recycled
back as additional rinsewater to the plating tank (in the case of
nickel). There is no rinsewater discharge from either of these
operations, and the plating solution level is maintained without
overflow. In addition, the quality of the nickel and chrome plates on
the bumper appears to be satisfactory with the operation having achieved
an acceptable bumper reject rate (as claimed by the owner).
This technique may prove useful to other bumper plating operations
that have a hazardous rinsewater discharge following the plating
operations and can tolerate some buildup of impurities in the respective
plating tanks. The nickel plating solution filtering operation and the
use of "dummies" to remove impurities in the chrome plating tank seem to
have helped Leonard's Plating to maintain adequate quality control.
3758g
- 25 -
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APPENDIX A
LEONARD'S PLATING TRIP REPORT
3758g
-------
TRIP REPORT
Site: Leonard's Plating, Inc., St. Albans, West Virginia
Attendees: Marvin Drabkin, Stephen Schwartz
Subject: Detailed Inspection of Onsite Bumper Replating Operations at
Leonard's Plating as Part of a Waste Minimization Opportunity
Assessment (WMOA) at This Facility
The Versar personnel listed above visited the Leonard's Plating Inc.
facility in St. Albans, West Virginia, on August 21, 1989. Dr. Drabkin
and Mr. Schwartz comprised the team assigned by Versar to perform a WMOA
(under EPA sponsorship) at this site. Leonard's Plating was the facility
chosen by EPA Region III for a WMOA as part of its effort to encourage
pollution prevention at industrial sites within the Region. Region III
hopes to encourage other industrial sites to use waste minimization as a
tool in pollution prevention. Versar was selected as the WMOA contractor.
The principal points of contact at this facility are Mr. Leonard Reed,
owner and president of the company, and Mr. Mark Reed, the owner's son
and Assistant Manager. Mr. Leonard Reed and Mr. Mark Reed can be reached
at (304) 727-2905.
The principal activity at this plant is the refurbishing and
replating of damaged car and truck bumpers obtained principally from auto
body shops, and to a lesser extent from private individuals. Thus the
operation performs as a job shop, dependent almost entirely on a supply
of customer's damaged bumpers as feed stock to the plant. Mr. Leonard
Reed asserted that his facility is a small shop in terms of a bumper
recycling operation. This shop processes about 15-20 car and truck
bumpers per day on average, with 30-35 bumpers per day considered to be
maximum output from the plant.
As part of the WMOA at Leonard's Plating, Versar was to perform a
detailed site inspection at this facility. The detailed site inspection
afforded the Versar assessment team an opportunity to obtain firsthand
knowledge of the bumper plating operations (including taking pictures of
these operations), obtain waste quantity and characterization data, and
gain insight into the plant's housekeeping and quality assurance
procedures. The plant operation is labor intensive, with all movement of
the bumpers to the various stages of reprocessing (including each of the
plating tanks) being carried out by hand. Most of the mechanical
operations (e.g., bumper straightening) involve the use of hand tools.
Motorized abrasive-coated wheels are used for grinding purposes.
0773i
-------
The bumper recycling operation is performed on an 8 hour shift, 5
days per week, and consists of the following steps in sequence:
1. Bumper straightening, where the dented mild steel bumpers are
straightened using hand tools.
2. Bumper stripping, where the straightened bumpers are chemically
stripped of the outer chrome layer in a stripping tank
containing alkaline solution.
3. Grinding of the stripped bumpers using two grinding wheels
surfaced with coarse and fine abrasive, respectively. In this
operation, small dents, cracks, and grinding lines are removed.
4. Alkaline electrocleaning, or "scrub" tank, in which reverse
current electrocleaning of the bumpers in an alkaline detergent
medium is carried out at temperatures around 130°F. The
bumpers from Step (3) are immersed in the tank for 30 seconds,
after which they are suspended above the tank and spray-rinsed,
with the rinsings flowing back to the scrub tank.
5. Following the scrub tank a running rinse step in which 0.5 gpm
of tap water (no agitation used) flows through the tank and
serves to remove the balance of the alkaline detergent medium on
the bumper surfaces. The rinsewater discharge is wasted to the
St. Albans sanitary sewer.
6. Acid pickling, in which a solution of approximately equal
amounts of 20°Be muriatic acid (HC1) and water is maintained
in a fiberglass tank. The bumpers are immersed for a few
minutes in this tank at ambient temperature.
7. A running rinse tank following the pickling tank in which about
0.5 gpm of tap water flows through the tank to the St. Albans
sanitary sewer. The pickled bumpers are immersed in this tank
for several minutes to rinse off all traces of muriatic acid.
8. Two nickel plating tanks (used alternately) equipped with nickel
anodes, and containing a nickel sulfate plating solution, in
which the clean mild steel bumpers are the cathodes. The
bumpers are suspended in the bath for about 50 minutes at a
temperature of 150-170°F with solution agitation provided by
compressed air spargers. The plated bumpers are lifted out of
the bath and suspended over it. Spray rinsing over the tank
serves to return most of the adhering nickel bath solution back
to the plating tank.
0773i
-------
9. Spray rinsing, in which the nickel-plated bumpers are suspended
in a tank and sprayed with tap water from the four sides of the
tank. The accumulated spray liquor at the bottom of this tank
is periodically pumped back to one of the nickel plating tanks,
as appropriate.
10. A single chrome plating tank where a layer of chromium metal is
plated over the nickel layer already on the bumper. This tank
is equipped with lead anodes (which last in excess of 3 years
before having to be replaced) with the nickel-plated bumpers as
cathodes. The chromium is plated out of chromic acid solution.
The nickel-plated bumpers are immersed in the chromic acid
solution an average of 3 minutes, after which they are lifted
out of the bath and suspended above it. Excess plating solution
is then rinsed back into the tank using a hand-held water spray
nozzle. During the plating cycle, the tank is covered with a
hood from which a flexible duct exhausts any chromic acid vapors
through the roof of the plating shop.
Figure 1 is a simplified schematic of the sequence of operations
discussed above.
Following this sequence of bumper cleaning and plating steps, the
replated bumper is examined for imperfections in the plated finish. If
any imperfections are found, the bumper is put through the chemical
stripper (Step (2)) to remove some of the surface chromium, and then
freshly replated with chromium to ensure the proper bumper surface
characteristics. Mr. Leonard Reed indicated that the average bumper
reject rate is in the neighborhood of 10 percent. Bumpers may be poorly
plated for the following reasons:
• Improper rectifier operation affecting plating efficiency
• Low chromium acid concentration in the plating bath
• Improper bumper preparation in the alkaline and acid cleaning
baths
Based on the information available to Versar during the onsite
inspection, the following information is believed to be applicable to the
wastes generated in the bumper recycling operation:
• Floor sweepings from the bumper straightening and grinding
operations are disposed of - analyzed as nonhazardous.
0773i
-------
• Muds generated in the chemical stripping operation - these
solid wastes have not been removed from the stripper tank in the
4-5 years that the installation has operated under Mr. Leonard
Reed's ownership. Evaporation from this tank prevents liquid
overflow. When the contents of this tank are finally
discharged, the chromium content of this material will probably
cause this material to be classified as RCRA D007 hazardous
waste.
• The rinsewater discharges from the alkaline and acid-rinse
tanks (see Steps (5) and (7) above) are not treated by the
generator and therefore are not F006 hazardous waste. Review of
the available analyses of these wastes (combined as a wastewater
stream discharged from the plant) indicate that there are no
reportable levels of TCLP-toxic metals (i.e., chromium)
sufficient to classify this stream as TCLP-toxic. The combined
wastewater stream is discharged to the St. Albans, West
Virginia, POTW and meets the local POTW pretreatment standards.
• There are no reported discharges of liquid or solid wastes
from the plating and follow-on rinsing sections of the
operation, i.e., Steps (8) through (10) above.
• Chromium-bearing emissions discharged to the roof vent over
the chromium plating tank are not quantified, i.e., there is no
permitted air pollution control device (APCD) in place at this
location so that the quantity (if any) of these emissions has
not been measured.
• Nickel-bearing sludges filtered out of the recirculating
nickel plating solution (Step (8) above) have been found to have
no RCRA-reportable quantities of EP-toxic metals. (TCLP tests
have not been performed on these wastes.) These sludges are
accumulated in a 55-gallon drum, and in the past have been
discharged to the local sanitary landfill about once per year
(about 400-500 Ib/yr).
In summary, the detailed site inspection at the Leonard's Plating
site carried out by the Versar assessment team indicates a reasonably
well-run operation in terms of production and housekeeping practices.
Elimination of potential hazardous waste discharges is accomplished
through careful attention to retention of chromium and nickel solution
dragout in the plating tanks. The only potential waste minimization
measure immediately obvious to Versar was the reduction of the combined
alkaline/acid rinsewater waste through shutting off of the fresh water
flow to the alkaline rinse tank (Step (5) above) and instead using the
rinsewater discharge from the acid rinse tank (Step (7) above). Details
of this proposed waste minimization measure as well as any other Versar
waste minimization proposals will be provided in the forthcoming
assessment report.
0773i
-------
To Gnnding From Grinding
Operations Operations
Work Flow
Straightened Bumpers)
STRIP TANKS
(130F)
Tap Water
Spray Rinse on Plated Bumpers
'I II
ALKALINE REVERSE
CURRENT ELECTRO-CLEANING
TANK
Tap Water
I
ALKALINE RINSE
TANK
-^» Spray Rinse on Plated Bumpers
I I I I
NICKEL PLATING TANK
NKS USED ALTERNATELY)
(150-170 F)
Tap
Water
Sprays
SPRAY RINSE TANK
PICKLING TANK
(MURIATIC ACID SOLUTION)
Collected Nickel
Spray Rinse Recirculated
to Plating Tank
Spray Rinse on Plated Bumpers
I I I I
•••
CHROME PLATING TANK
(112-118 F)
To Inspection. Packing,
and Shipping
Rinsewater Discharge to POTW
FIGURE 1. PRECLEANING& PLATING TANK AREA:
Bumper Recycling Operations at Leonard's Plating,
St. Albans, West Virginia
-------
APPENDIX B
EPA WASTE MINIMIZATION ASSESSMENT
WORKSHEETS COMPLETED FOR THE
LEONARD'S PLATING FACILITY
3758g
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PROGRAM ORGANIZATION
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ASSESSMENT
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SITE DESCRIPTION
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INDIVIDUAL WASTE STREAM
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2.
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liquid
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-------
Cirvn
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WORKSHEET
9b
Waste Minimization Assessment
Proc Un"t/Op9r . . .
Pmj Kin
Pr
Cl
SI
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
soared By
larked By
wet .2_ of 4 Page • ol
4>EPA
6. Waste Origins/Sources
Fill out this worksheet to Identify the origin of the waste. M the waste Is a mixture of waste
streams, fill out a sheet for each of the Individual waste streams.
Is the waste mixed with other wastes?
D
Yes
No.
Check
Describe
Formulation/Removal of Undesirable Compound
of
LJ Unconverted Hazardous Raw Materials or Additive
I I Accumulation of Inert Impurity
I I Depletion of Key Component(s).
D
Equipment Cleaning
n
Obsolete Stock.
LJ Spoiled Batch/Production Run
a
Spill/Leak Cleanup
a
Evaporative Loss
a
Breathing/Venting Losses.
n
Other.
-------
Firm
Sita
Data
Waste Minimization Assessment
Pror Unit/Oper
Pmj No
Prepared By
Checked By
Sheet 3 of 4 Page of
WORKSHEET
9c
INDIVIDUAL WASTE STREAM Q CD A
CHARACTERIZATION W C KM
(eonUnuad)
Waata $traam
7.
Management Method
Leaves stte In
bulk
roll off bins
55 gal drums
other (describe)
Disposal Frequency
Applicable Regulations1
Regulatory Classification2
Managed
Recycling
commercial TSDF
own TSDF
other (describe)
direct use/re-use
lVtv. • "i"
p
offsite
combusted for energy content
redistilled
LJ other (describe)
reclaimed material returned to site?
D Yes LD No C] used by others
residue yield
residue disposal/repository
Note1 list federal, state & local regulations, (e.g., RCRA. TSCA, etc.)
Note2 list pertinent regulatory classification (e.g.. RCRA - Listed K011 waste, etc.)
-------
Site
r-0 C
Waste Minimization Assessment
Proc. Unit/Oper.
Proj. No.
Prepared By S
Checked By
Sheet ±_ of _4_ Page
WORKSHEET
9d
7.
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
vvEPA
Waste Stream
Management Method (continued)
Treatment
D biological -
CD oxidation/reduction
LJ incineration -
pH adjustment
LJ precipitation
CH solidification
LJ other (descrfte)
residue disposal/repository
Final Disposition
Costs as of
EH landfill
EH pond
LJ lagoon
LJ deep well
LJ ocean
other (describe)
(quarter and year)
Cost Element:
Onsite Storage & Handlino
Pretreatment
Container
Transportation Fee
DisDOsal Fee
Local Taxes
Slate Tax
Federal Tax
Total Disposal Cost
Unit Price ¥
f par 1000 OM
*£**
Reference/Source:
v ^ 1 •" , !—„ /pc«.-
3v>'-' .-,i- ^ j«-— ,c "-, J T >v -»' r?^^, ,u=c
0
-------
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Site
/
Waste Minimization Assessment
Proj No I^~^S~3>°3«/
Prepared By ^. M ^.c.fciEPA
Stream Number.
2.
Waste Characteristics
n
gas
CD liquid
Isold I \ mixed phase
Density, tb/cutt
Viscosity/Consistency
pH 0,/Jk .Flash Point
Waste Leaves Process as:
LJ air emission LJ waste water
. % water
,
<
[solid waste
n
hazardous waste
4. Occurrence
I — I continuous.
discrete
discharge triggered by I I chemical analysis
t2Tother (describe)
Type:
length of period:
UlJ periodic
I—I sporadic (irregular occurrence)
I I non-recurrent
5. Generation Rate
Annual
Maximum -
Average -
Frequency.
Batch Size-
<-(oo
,. J
average
Ibs per year
Ibsper
Ibs per
batches per
range
-------
Firm
Site
Date
Waste Minimization Assessment
Pmc. Unrt/Oper. W
Proj. No.
Prepared By S
Checked By
Sheet _EL of i_ Page 10_ at J¥_
WORKSHEET
9b
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
x>EPA
(eonumwd)
6. Waste Origins/Sources
Fill out this worksheet to Identify the origin of the waste. If the waste Is a mixture of waste
streams, fill out a sheet for each of the Individual waste streams.
Is the waste mixed with other wastes?
D
Yes
Check
Describe
Formulation/Removal of Undesirable Compound
I I Unconverted Hazardous Raw Materials or Additive
^-
Accumulation of Inert Impurity F^>^TT-J> * -^ r^^- -1 ^ . £; v . *Lc u=*» - ^ r^ ^^
I I Depletion of Key Component(s)
Lki Equipment Cleaning Occfc-t-j^fi. rc^^^^ CF froT-rpnrv^ FKU>- /'J<- I U.-T
n
n
n
n
n
n
Obsolete Stock.
Spoiled Batch/Production Run
Spill/Leak Cleanup
Evaporative Loss
Breathing/Venting Losses.
Other.
-------
Firm
Date
' J t-^-L-
Waste Minimization Assessment
Proc.
Proj. No.
Prepared By ^ M ..c'-".V-^~
Checked By
Sheet _a_ of 4_ Page _L/ of J±L
WORKSHEET
9c
Waste Stream
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
&EPA
7. Management Method
Leaves site In
bulk
roll off bins _
LJ 55 gal drums
other (descrtoe)
Disposal Frequency
-rv- •; /-• '• <•*:
Applicable Regulations'
/)c .- - \\T- -• — — — E — i
c' '
Regulatory Classification8
Managed
onsfte
commercial TSDF
ovwi TSDF
CU other (describe)
offsite
'- "* f'f V '• 1
Recycling
direct use/re-use
D
l~1 combusted for energy content
D redistilled
EH other (describe)
reclaimed material returned to site?
Yes C] No CU used by others
residue yield
residue disposal/repository
Note1 list federal, state & local regulations, (e.g.. RCRA, TSCA, etc.)
Notea list pertinent regulatory classification (e.g., RCRA - Listed K011 waste, etc.)
-------
Firm '
Site
.tuiiN*^ s P r.~^v,
-r ,'_. >C_ 00
WORKSHEET
9d
Waste Minimization Assessment
Pmr tlnit/Opar /Jj^€trfc Pu^- SiOC
Pmj No 1 ^"^r^,. _5". /
Pri
Ch
Sh
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
spared By <, -re ^ re-> ) f/\ V/x-ilX/ ^t
ackadBy
set 4 of 4 Page ! 2^bf N
x>EPA
7.
(eonllm»d)
Waste Stream
Management Method (continued)
Treatment
Final Disposition
LU biological .
[_J oxidation/reduction
LJ incineration
LJ pH adjustment
LJ precipitation
EH solidification
I 1 other (describe) —
residue disposal/repository
landfill
D pond
LJ lagoon
LJ deep well
LJ ocean
other (describe)
Costs as of
(quarter and year)
Cost Element:
Onsite Storage & Handling
Pretreatment
Container
Transportation Fee
Disrjosal Fee
Local Taxes
State Tax
Total Disposal Cost
Unit Price
S oer
Reference/Source:
-------
p;rm L-£joc5A-ec>s r^-^^i 0
Site
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Waste Minimization Assessment
Praj No ' ^2-^3. .S"- /
Prepared By ^ A> SiCN-J^H?^*
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Sheet JL of •* Page 3. of /JF
WORKSHEET
9a
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
* EPA
1. Waste Stream Name/ID:.
Process Unit/Operation
Stream Number.
2.
3.
Waste Characteristics
n
gas
CD liquid
Density. Ib/cuft
Isofid d mixed phase
A
Viscosity/Consistency
pH '*>/*- .Flash Point r* /*- ; % Water
Waste Leaves Process as:
I I air emission I I waste water L^J solid waste I—I
IPX
A -.-. ..vf'-:v.
. j v
hazardous waste
4. Occurrence
I—I continuous-
discrete
discharge triggered by I—I chemical analysis
0 other (describe) -^±
Type: Lkj periodic length of period:
[ I sporadic (irregular occurrence)
non-recurrent
5. Generation Rate
Annual
Maximum .
Average -
Frequency.
Batch Size-
Ibs per year
tosper
tosper
batches per
average
range
-------
Firm
Site
Waste Minimization Assessment
Proc.
Proj. No.
Prepared By
By
Sheet_2_ of _4_ Page -of
WORKSHEET
9b
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
SEPA
6. Waste Origins/Sources
nil out this worksheet to Identify the origin of the waste. If the waste Is a mixture of waste
streams, fill out a sheet for each of the Individual waste streams.
Is the waste mixed with other wastes?
Yes
No.
Cheek
Describe
Formulation/Removal of Undesirable Compound _
LJ Unconverted Hazardous Raw Materials or Additive
l£\J Accumulation of Inert Impurity -
LJ Depletion of Key Component(s).
Equipment Cleaning
Obsolete Stock.
D
Spoiled Batch/Production Run
LJ Spill/Leak Cleanup
n
D
Evaporative Loss.
Breathing/Venting Loa
D
Other.
-------
Firm
Site
Date
Waste Minimization Assessment
Proc. Unit/Oper..
Proj. No.
Prepared By
Checked By
Sheet JL_ of 4_ Page of
WORKSHEET
9c
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
Wasta Straam
O CD A
W C KM
7.
Management Method
Leaves site In
LJ bulk
EH roll off bins
LJ 55 gal drums
other (describe)
IV
Disposal Frequency
Applicable Regulations'
Regulatory Classification3
Managed
VV-C -
Recycling
onsite
commercial TSDF
CH own TSDF
other (describe)
n
offsite
direct use/re-use
combusted for energy content
CH redistilled
other (describe)
reclaimed material returned to site?
Yes D No CI used by others
residue yield
residue disposal/repository
Note1 list federal, state & local regulations, (e.g., RCRA. TSCA, etc.)
Note2 list pertinent regulatory classification (e.g.. RCRA - Listed K011 waste, etc.)
-------
Firm
Site
Date
Waste Minimization Assessment
Proc. Unrt/Oper
Proj. No
Prepared By
Checked By
Sheet _4_ of _4_ Page of
WORKSHEET
9d
7.
INDIVIDUAL WASTE STREAM
CHARACTERIZATION
(continued)
Waste Stream
Management Method (continued)
Treatment
Final Disposition
biological
LJ oxidation/reduction
I — I incineration _
I — 1 pH adjustment _
LJ precipitation _
— I solidification _
CJ other (describe) _
residue disposal/repository
D landfill
pond
lagoon
LJ deep well
LJ ocean
other (describe)
3 o .A v
Costs as of
(quarter and year)
^ K * 0 j
Cost Element:
Onsrte Storage & Handling
Pretreatment
Container
Transportation Fee
Disposal Fee
Local Taxes
State Tax
Federal Tax
Total Disposal Cost
Unit Price
S oer
Reference/Source:
-------
Firm U-tO fOP- ( ''l/t-*— ^/iO
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WORKSHEET
10
Waste Minimization Assessment
Pm fn . ^c^^JD^iC ^
eckedBv
set 1 of 1 Page ^/of /V
SEPA
Attribute
Waste ID/Name:
Source/Origin
Component/or Property of Concern
Annual Generation Rate (units )
Overall
Component(s) of Concern
Cost of Disposal
Unit Cost
^L
Notes: 1 . For example, sanitary landfill, hazardous waste landfill, onslte recycle, Incineration, combustion
with heat recovery, distillation, dewaterlng, etc.
2. Rate each stream In each category on a scale from 0 (none) to 10 (high).
*j «
f 1" l\ ' • f l^-i: 7 '
-------
Firm
Site
Date rr^s P-OG-
^ V_
Waste Minimization Assessment
Proc. Unrt/Oper.
Proj. No. _L
Prepared By PI- - ' o . . / -.7 ) -/>--v~' — ' -
U^=^ - - • — .<•'<-, rr,-
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WORKSHEET
12
Dotlon Name:
j-~-zhc.
>
uW
T
Waste Minimization Assessment
Proc. Unit/Op«r
Proj. No. ' S">^3. S'. '
OPTION DESCRIPTION
/E?oEPA
Briefly describe the option
. ^***v* (
-' .' /-.^' •--- c. ''-''(•')[-. A'
;PPA
tif" P.
Waste Stream(s) Affected:
Input Materlal(s) Affected:
Product(s) Affected:
Indicate Type:
Originally proposed by:
Reviewed by:
Approved for study?—tL:
Source Reduction
jt^T Equipment-Related Change
Personnel/Procedure-Related Change
Materials-Related Change
Q' Recycling/Reuse
Onslte
Off stte
Material reused for original purpose
Material used for a lower-quality purpose
Material sold
Material burned for heat recovery
'i
Date:
Date:
yes
no, by:
Reason for Acceptance or Rejection
-------
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Site
Date
(
f £. ~ '.- 1
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WORKSHEET
12
Dptlon Name: ^
| ^txf-^ >if\>(
o
>:^,"-
•N
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Waste Minimization Assessment
Proc. Unft/Ope''
Proi. No. l£~~i"^*> <^ '
OPTION DESCRIPTION
;=CW,^ +ii,.,.. ,
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Sheet 1 of 1 Page of
vvEPA
^ /;,.r.,. -;..._
Briefly describe the option
?t , i V .r * 9 -. Pi {• -r
Waste Stream(s) Affected:
PC- -
Input Materlal(s) Affected:
Product(s) Affected:
Indicate Type:
Originally proposed by:
Reviewed by:
Approved for study?
LJ Source Reduction
Equipment-Related Change
Personnel/Procedure-Related Change
Materials-Related Change
Recycling/Reuse
Onslte
Material reused for original purpose
Material used for a lower-quality purpose
Material sold
Material burned for heat recovery
Date:
Date:
yes
no, by:
Reason for Acceptance or Rejection
-------
Firm UaAcx^'v, £W=AC
SZU06 -X3131 • OOOE-OSt tEOtl -BNUHdS
Site
Date 7-3 f^G Gs§
Waste Minimization Assessment
131 • tSIZZ VINIOHIA Ql^ldONIUdS • 6VSI
Proc. Unrt/Oper
Proj. No. 157x^3.^.1
ygJCCPflEAri.RLI hia<-i uwouaA HCOQ
Checked By
Sheet 1 of 1 Paae of
WORKSHEET
12
Option Name:
OPTION DESCRIPTION
&EPA
Brlefly describe the option
Cf-c* ,-T
-_J,,
f. -rf 7
-,V C<-fl,--.-Jr,,
WasteStream(s) Affected:
Input Material(s) Affected:
--.ei.
Product(s) Affected:
ri c3 •-....
Indicate Type:
Originally proposed by:
Reviewed by:
Approved for study?
Ld Source Reduction
_ Equipment-Related Change
_ Personnel/Procedure-Related Change
_ Materials-Related Change
LJ Recycling/Reuse
— Onslte
- Offslte
Material reused for original purpose
Material used for a lower-quality purpose
Material sold
Material burned for heat recovery
Date;
Date:
*-V-
yes
no, by:
•Reason for Acceptance or Rejection —
M*
-------
Firm I
Sila
Data
WORKSHEET
13
Waste
Proc. U
Proj Nc
Minimization Assessment
nrt/Oper
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Sheet J
OPTIONS EVALUATION BY
WEIGHTED SUM METHOD
Criteria
Reduction
Reduction
Reduction
Reduction
In
of
of
of
waste's hazard
treatment/disposal costs
safety hazards
Input
material costs
Extent ol current use In Industry
Effect on product quality (no effect = 10)
Low capital cost
Low 0 & M cost
Short Implementation period
Ease of Implementation
0 - N11"* ' '
11 ,'.' : f
2^>
7-1^
y-rt>
1
r^
«2 Option
/K/f'r RfP* I'.f.s
1 1
R
s
o
o
o
J?
10
10
£
0
1
RxW
\6
0
o
0
10
loo
|oo
40
n
°,
TO
^
^A
*3 Option
R
^
0
5
0
J
3
8
2,
g
g
RxW
G
o
(*
0
G
fa
9>o
IX
lo
40
3&\
3
,y*
Page _L
tmi^^mi^^mm
*^m^^*m^mm
(R)
.ol J_
m^^mm^^^^^
ft
EPA
#4 Option
R
RxW
«5 Option
R
RxW
-------
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WM
WORKSHEET
14a
Option Description '-
Waste Minimization Assessment
Proc Llnit/Opflr
Pmj. No. I 'T- c Lc '^ . '
Prepared By S>- /h SC^^S^L
Checked Bv
Sheet 1 of 6 Page of
TECHNICAL FEASIBILITY ^ EPA
X /Cr fc^-M-
1. Nature of WM Option
Equipment-Related
LJ Personnel/Procedure-Related
I—I Materials-Related
2. If the option appears technically feasible, state your rationale for this.
•"ff' \ • c
-ro C-'c. ^j-^^r-P-."^.^- ,-f^.-_ ,-
Vi-f/W /' ~=>3/K - 1 -=-. M^V-c: -7
•>jv;* -^<.->rM--/F-f.vv i-t^ £*.«:v^,.*v. •--,- --.^- --,,('-.r „--- • , •• •-/-/- -nr^/teo,i
Is further analysis required? P^f Yea I I NO.
worksheet If not, skip to worksheet 15.
3. Equipment - Related Option
Equipment available commercially?
Demonstrated commercially?
In similar application?
Successfully?
Describe closest industrial analog '•"
(Poofe"^
Describe status of development Q.c-r.-
•;.'. •;- «-• -....<-^r
If yes, continue with this
YES . NO
pf | | i^ i . - 1 -/
PI f^f P.?:>-:-Ulv «OT-
r/f n
>sr
, j-rr J '.*- )(-~^-'^1~\!.\,G- T i . / /- i " -
r\ > ' . • -f ~'-! „ -- r ' ',
Prospective Vendor
' •/->. 3- >-'- . f j:' - '• f* , I^»J r •
JIr)i.-*--C.O
^T^t-^-rA
c? av-^-^-c
Working Installatlon(s)
VeS-
YfcS.
Ol"! |")OJ.^
j i j>: rj>-*-i«-i
Contact Person(s)
T*< f - 1 ' «• -'.n--".
Pr"' .LJ32. l/^ --'--^C-
().., ' . — -•"• f.'i <•.
.,
Date Contacted 1.
2^ S.SP ^0
'-' & z--J
1. Also attach filled out phone conversation notes, Installation visit report, etc.
-------
Firm L* & *\-« -c, S Kt-i----^ G-
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Hat0 "2- 2» .f^1^ * / 0
Waste Minimization Assessment
Proc. Unrt/Oppr
Proj. No. ' ci 1'5> Lo oTo
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Sheet 2 of 6 Paae of
WORKSHEET
14b
WM Option Description
TECHNICAL FEASIBILITY
C r
(eeminiMd)
••-•-../-.r"
SEPA
3. Equipment-Related Option (continued)
Performance Information required (describe parameters):
VQ L
Scaleup Information required (describe):
Testing Required: |_J yes
Scale: CH bench 1 1 pilot
Test unit available? 1 1 yes
Test Parameters (list)
D no
n /O/A
1 1 no
Number of test runs:
Amount of materlal(s) required:
Testing to be conducted:
n
In-plant
Facility/Product Constraints:
Space Requirements
Possible locations within facility
-------
Firm
Site
Waste Minimization Assessment
Proc. Unil/Oper
Proj. No. T^St»S\'
Prepared By S- fr
Checked By
Sheet _3_ of 6 Page of
WORKSHEET
14C
TECHNICAL FEASIBILITY
WM Option Description
X Cr- V-
(COMllMMd)
2. Equipment-Related Option (continued)
Utility Requirements:
Electric Power Volts (AC or DC)
Process Water Flow
kW
Pressure
Cooling Water
Quality (tap, demln, etc.)
Row Pressure.
Temp. In
Coolant/Heat Transfer Fluid —
Temp. Out
Temp. In
Duty —
Temp. Out
Steam
Pressure
Duty
Temp.
_ now
* EPA
Fuel
Plant Air .
Inert Gas.
Type
Flow.
Duty.
Flow
now
Estimated delivery time (after award of contract).
Estimated Installation time
Installation dates
Estimated production downtime.
will production be otherwise affected? Explain the effect and Impact on production.
Will product quality be affected? Explain the effect on quality.
-------
Firm '^*OeiWLVSTtm,x;
SitA
Oat*
WORKSHEET
14d
Waste Minimization Assessment
Proc Unrt/Oper
Pmj. No.
Pi
Cl
SI
TECHNICAL FEASIBILITY
•epared By
flecked Bv
leet 4 of 6 Page of
vvEPA
WM Option Description
C.
3. Equipment-Related Option (continued)
Will modifications to work flow or production procedures be required? Explain..
Operator and maintenance training requirements
Number of people to be trained
Onstte
D Offslte
Duration of training
Describe catalyst, chemicals, replacement parts, or other supplies required.
Item
Rate or Frequency
of Replacement
Supplier, Address
Does the option meet government and company safety and health requirements?
Yes d No Explain
How Is service handled (maintenance and technical assistance)? Explain
What warranties are offered?
-------
Firm Lt_» t^<^-{i -J 5> Puf-^THiC
Site
Date
Waste Minimization Assessment
Pme. Unrt/Opflr
Proj. No.
Prepared By
Checked Bv
Sheet S of 6 Rape of
WORKSHEET
14e
TECHNICAL FEASIBILITY
(carnimMd)
4>EPA
WM Option Description.
3. Equipment-Related Option (continued)
Describe any additional storage or material handling requirements.
Describe any additional laboratory or analytical requirements.
Personnel/Procedure-Related Changes
Affected Departments/Areas
Training Requirements
Operating Instruction Changes. Describe responsible departments.
5. Materials-Related Changes (Note: If substantial changes In equipment are required, then handle the
option as an equipment-related one.) Xea Mfl
Has the new material been demonstrated commercially? I I O
In a similar application? CD ED
Successfully? CU
Describe closest application.
-------
Firm
Site
Date
Waste Minimization Assessment
Proc. Unit/Oper
Proj. No.
Prepared By
Checked By
Sheet _§_ of _g_ Page ol
WORKSHEET
14f
TECHNICAL FEASIBILITY
&EPA
(eontifMMd)
WM Option Description
u r
C
4. Materials-Related Changes (continued)
Affected Departments/Areas
Will production be affected? Explain the effect and Impact on production.
Will product quality be affected? Explain the effect and the Impact on product quality.
Will additional storage, handling or other ancillary equipment be required? Explain.
Describe any training or procedure changes that are required.
Decrlbe any material testing program that will be required.
-------
Firm L ? c>
Site
Waste Minimization Assessment
Proc. Unit/Oper
Proj. No.
Prepared By S. (Y\
Checked By
Sheet _1_ of _fi_ Page - of
WORKSHEET
14a
TECHNICAL FEASIBILITY
oEPA
WM Option Description
op
1. Nature of WM Option Q Equipment-Related
LJ Personnel/Procedure-Related
[^Materials-Related
2. If the option appears technically feasible, state your rationale for this.
Is funher analysts required? EH Yes [3 No.
worksheet If not, skip to worksheet 15.
~
3. Equipment • Related Option J *
Equipment available commercially?
Demonstrated commercially?
In similar application?
Successfully?
Describe closest industrial analog
If yes, continue with this
1ES
D
n
n
n
Nfl
n
n
n
n
Describe status of development
Prospective Vendor
Working Installatlon(s)
Contact Person(s)
Date Contacted 1.
1.
Also attach filled out phone conversation notes, Installation visit report, etc.
-------
Firm
Site
Date
fr-QC
Waste Minimization Assessment
Proc. Unit/Oper.
Proj. No. _
Prepared By ^ /h
Checked By
Sheet J_ of _g_ Page of
WORKSHEET
14a
WM Option Description
TECHNICAL FEASIBILITY
Equipment-Related
LJ Personnel/Procedure-Related
1. Nature of WM Option
Materials-Related
2. If the option appears technically feasible, state your rationale for this.
Is further analysis required? LU" Yes LJ No. If yes, continue with this
worksheet. If not, skip to worksheet 15.
3. Equipment • Related Option
Equipment available commercially?
Demonstrated commercially?
In similar application?
Successfully?
Describe closest industrial analog
D
D
n
Descnbe status of development
''" ' ^ ( -
Prospective Vendor
Working Installatlon(s)
Contact Person(s)
Date Contacted 1,
1. Also attach filled out phone conversation notes, Installation visit report, etc.
-------
Firm
Site
Date
Waste Minimization Assessment
Proc. Unrt/Oper
Proj. No.
fa -^ c f ^>w?-3^.
Prepared By
Checked By _
Sheet _2_ of 6 Page _ of _
WORKSHEET
14b
WM Option Description
TECHNICAL FEASIBILITY
(eenuruMd)
3. Equipment-Related Option (continued)
Performance Information required (describe parameters):
Scaleup Information required (describe):
Testing Required: I I yes
Scale: CH bench I I pilot
Test untt available? I I yes
Test Parameters (list)
no
D
no
Number of test runs:
Amount of matertal(s) required:
Testing to be conducted:
EH In-plant
D
Facility/Product Constraints:
Space Requirements
Possible locations within facility
I > />
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Firm
Site
Date
Waste Minimization Assessment
Proc. Unrt/Oper.
Proj. No.
Prepared By ^ ft • ^c. ^•.Of'-f-^.
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Sheet _3_ of JL Page of
WORKSHEET
14C
TECHNICAL FEASIBILITY
WM Option Description
2. Equipment-Related Option (continued)
Utility Requirements: \} oiYl_ ^z>: -
Electric Power Volts (AC or DC)
Process Water Flow
^ 7~S"G
kW
Pressure
Cooling Water
Quality (tap, demln, etc.)
Flow Pressure
Temp. In
Coolant/Heat Transfer Fluid —
Steam
Temp. In
Duty
Pressure
Duty
Temp. Out
Temp. Out
Temp.
- Flow
SEPA
Fuel
Plant Air .
Inert Gas.
Type
Flow.
Duty.
Flow
Flow
Estimated delivery time (after award of
Estimated Installation time _
Installation dates _ f^ f- P
-r>rr n
ft M: s.
Estimated production downtime.
\
Will production be otherwise affected? Explain the effect and Impact on production.
Will product quality be affected? Explain the effect on quality.
-------
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Site
Date
Waste Minimization Assessment
Proc. Unit/Oper..
Proj. No
Prepared By ^ A^
Checked By
Sheet 4_ of 6 Page of
WORKSHEET
14d
TECHNICAL FEASIBILITY
WM Option Description
3. Equipment-Related Option (continued)
Will modifications to work flow or production procedures be required? Explain..
|Q Q
Operator and maintenance training requirements
Number of people to be trained f
CH Onslte
Offslte
Duration of training
Describe catalyst, chemicals, replacement parts, or other supplies required.
Hem
lO o a-*^
Rate or Frequency
of Replacement
Supplier, Address
Does the^eptlon meet government and company safety and health requirements?
0Yes CH No Explain
How Is service handled (maintenance and technical assistance)? Explain
What warranties are offered?
-------
Firm
Site
Date
Waste Minimization Assessment
Proc. Unit/Oper
Proj. No
Prepared By 5L -A\ S>
Checked By
Sheet _5_ of 6 Page of
WORKSHEET
14e
TECHNICAL FEASIBILITY
(coral nu«d)
WM Option Description
3. Equipment-Related Option (continued)
Describe any additional storage or material handling requirements. /OX&
Describe any additional laboratory or analytical requirements.
AJ-fJ '
4. Personnel/Procedure-Related Changes
Affected Departments/Areas
Training Requirements
Operating Instruction Changes. Describe responsible departments.
Materials-Related Changes (Note: If substantial changes In equipment are required, than handle the
option as an equipment-related one.) (0 /K ^fll Wfl
Has the new material been demonstrated commercially? LJ LJ
In a similar application? LJ
Successfully? D
Describe closest application
D
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Firm
Site
Date
Waste Minimization Assessment
Proc. Unit/Oper
Proj. No.
Prepared By c. A ^ c
Checked By
Sheet £_ of 6 Page of
WORKSHEET
14f
TECHNICAL FEASIBILITY
(continued)
WM Option Description
4. Materials-Related Changes (continued)
Affected Departments/Areas
Will production be affected? Explain the effect and Impact on production.
Will product quality be affected? Explain the effect and the Impact on product quality.
Will additional storage, handling or other ancillary equipment be required? Explain.
Describe any training or procedure changes that are required.
Decribe any material testing program that will be required.
-------
Firm
Site
Date_L2>
C '?
Waste Minimization Assessment
Proc. Unit/Oper
Proj. No. I
Prepared By ^ fl/ 5,
Checked By
Sheet _i_ of _6_ Page of
WORKSHEET
15a
COST INFORMATION
4>EPA
WM Option Description.
t-
CAPITAL COSTS • Include all costs as appropriate.
LJ Purchased Process Equipment
Price (fob factory)
Taxes, freight, Insurance
Delivered equipment cost
Price for Initial Spare Parts Inventory
Estimated Materials Cost
Piping
Electrical
Instruments
Structural
Insulation/Piping
TOTALS
LJ Estimated Costs for Utility Connections and New Utility Systems
Electricity _
Steam _
Cooling Water _
Process Water _
Refrigeration _
Fuel (Gas or OH) _
Plant Air _
Inert Gas _
Estimated Costs for Additional Equipment
Storage & Material Handling
Laboratory/Analytical
Other
LJ Site Preparation
(Demolition, site clearing, etc.)
Estimated Installation Costs
Vendor
Contractor
In-house Staff
-------
Firm L-fr:-.-VK
Site
Date
Wast* Minimization Assessment
Proc. Unrt/Oper
Proj. No.
Prepared By C, /< -^r
Checked By .
Sheet 2_ of _6_ Page of
WORKSHEET
COST INFORMATION
&EPA
CAPITAL COSTS (Cent)
Engineering and Procurement Costs (In-house & outside)
Planning _
Engineering _
Procurement _
Consultants _
TOTALS
LJ StarMip Costs
Vendor
Contractor
In-house
LJ Training Costs
Permitting Costs
Fees
In-house Staff Costs
Initial Charge of Catalysts and Chemicals
ttem m
Kem*2
Working Capital [Raw Materials, Product, Inventory, Materials and Supplies (not elsewhere specified)].
Item f 1.
Item*?.
Kem«3.
ltem«4.
O Estimated Salvage Value (If any)
-------
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Pmj No
Pre
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Sh
WORKSHEET
15c
COST INFORMATION
soared Bv £ ft S."-"N r'7-^
eckedBy
set 3 of 6 Page of
&EPA
CAPITAL COST SUMMARY
Cost Item
Purchased Process Equipment
Materials
Utility Connections
Additional Equipment
Site Preparation
Installation
Engineering and Procurement
Start-up Cost
Training Costs
Permitting Costs
Initial Charge of Catalysts and Chemicals
Fixed Capital Investment
Working Capital
Total Capital Investment
Salvage Value
Cost
"~ loo
Mo,
^'O'i
^ 7^^
U
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15d
Waste Minimization Assessment
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Pre
Ch
Sh
COST INFORMATION
spared By S • fa ^c'-^v*^:"71^
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eet 4 of 6 Page of
vvEPA
CH Estimated Decrease (or Increase) In Utilities
Utility
Electricity
Steam
Cooling Process
Process Water
Refrigeration
Fuel (Gas or Oil)
Plant Air
Inert Air
•b^j-.^x'c O^-
Unit Cost
S per unit
1s0 / *
<*•' /(OooCfrV
SflZ, /
J/ /'3C»:>v
Decrease (or Increase) In Quantity
Unit per time
5000CH- /£,) —
S~Oco ^f". ////") -i:
Total Decrease (or Increase)
$ par time
^r-^ -<•* /
' > — / >— -
^ -^- -PA--
INCREMENTAL OPERATING COSTS
D
D
include all relevant operating savings. Estimate these costs on an incre-
mental basis (i.e., as decreases or increases over existing costs).
BASIS FOR COSTS
Annual
Quarterly
Monthly
Dally
Other
Estimated Disposal Cost Saving
Decrease In TSDF Fees
Decrease In State Fees and Taxes
Decrease In Transportation Costs
Decrease In Onstte Treatment and Handling
Decrease In Permitting, Reporting and Recordkeeplng
Total Decrease In Disposal Costs
Estimated Decrease In Raw Materials Consumption
o
Materials
\ . f- -' v -- :-• - • , • » , ^
•
Unit Cost
$ per unit
• , .'\ I;
i ^^y '-^
Reduction In Quantity
Units per time
£0 — HV r~ —> >-
"
Decrease In Cost
$ per time
T/ff- ''^
-i-
^0
-------
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Site
Date
Waste Minimization Assessment
Proc. Unit/Oper
Proj. No.
Prepared By S (•> . S^c ^
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Sheet _5_ of _6_ Page of
WORKSHEET
15e
COST INFORMATION
(cantkNMd)
v>EPA
D
Estimated Decrease (or Increase) In Ancillary Catalysts and Chemicals
CatalyaVChamteal
Unit Coat
Spar unit
Daeraaaa (or Increase) ki Quantity
Unttpartima
Total Dacraaaa (or IncraaM)
$ par tlma
f]
<*0
LJ Estimated Decrease (or Increase) In Operating Costs and Maintenance Labor Costs
(Include cost of supervision, benefits and burden).
fj. 'i.
Estimated Decrease (or Increase) In Operating and Maintenance Supplies and Costs.
D
Estimated Decrease (or Increase) In Insurance and Liability Costs (explain)
LJ
Estimated Decrease (or Increase) In Other Operating Costs (explain).
INCREMENTAL REVENUES
Estimated Incremental Revenues from an Increase (or
By-products (explain).
/) 'A.
) In Production or Marketable
-------
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PTOC. Unft/Oper
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WORKSHEET
15f
COST INFORMATION
4>EPA
(conUniMd)
INCREMENTAL OPERATING COST AND REVENUE SUMMARY (ANNUAL BASIS)
Decreases In Operating Cost or Increases In Revenue are Positive.
Increases In Operating Cost or Decrease In Revenue are Negative.
Operating Cost/Revenue Item
Decrease In Disposal Cost
Decrease In Raw Materials Cost
Decrease (or Increase) In Utilities Cost
Decrease (or Increase) In Catalysts and Chemicals
Decrease (or Increase) In O & M Labor Costs
Decrease (or Increase) In O & M Supplies Costs
Decrease (or Increase) In Insurance/Liabilities Costs
Decrease (or Increase) In Other Operating Costs
Incremental Revenues from Increased (Decreased) Production
Incremental Revenues from Marketable By-products
Net Operating Cost Savings
$ per year
-•LSO^
i
* 3^ o -
-------
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Site
Date
Waste Minimization A
Proc. Unft/Oper
Proj. No. I -?-vs"b. s-.i
nt
Prepared By ^=- fa
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Sheet J_ of _6_ Page of
WORKSHEET
15a
COST INFORMATION
vvEPA
WM Option Description .
/
Jl$,Lr
f.< y: - ,.... ^
CAPITAL COSTS -include all costs as appropriate.
I~~I
U Purchased Process Equipment
Price (fob factory)
Taxes, freight, Insurance
Delivered equipment cost
Price for Initial Spare Parts Inventory
Estimated Materials Cost
Piping
Electrical
Instruments
Structural
Insulation/Piping
=>./f--L
" TOTALS
"*"*
^ /v.
Estimated Costs for Utility Connections and New Utility Systems
Electricity
Steam
Cooling Water
Process Water
Refrigeration
Fuel (Gas or Oil)
Plant Air
Inert Gas
Estimated Costs for Additional Equipment
Storage & Material Handling _
Laboratory/Analytical _
Other _
LJ Site Preparation
(Demolition, site clearing, etc.)
Estimated Installation Costs
Vendor _
Contractor _
In-house Staff _
-------
Rrm L
-to-OM^S ?^^^C
fiilA
Date
1,1 C^OC'lfl
Waste Minimization Assessment
Pm<« llni^Opflr
Prnj No |-s-^5"b'r. I
Pre
Ch
Shi
WORKSHEET
15a
COST INFORMATION
loared By *==• • ^ • ^uv^^a-^.
BdcedBy
aet1 of 6 Rape of
.
SEPA
0
WM Option Description
CAPITAL COSTS • Include all costs as appropriate.
LJ Purchased Process Equipment
Price (fob factory)
Taxes, freight, Insurance
Delivered equipment cost
Price for Initial Spare Parts Inventory.
Estimated Materials Cost
Piping
Electrical
Instruments
Structural
Insulation/Piping
r/'O/rcT'M?-1,'
fog,
e/j\/r/-v)/
TOTALS
.Jo
LJ Estimated Costs for Utility Connections and New Utility Systems
Electricity
Steam
Cooling Water
Process Water
Refrigeration
Fuel (Gas or OH)
Plant Air
Inert Gas
Estimated Costs for Additional Equipment
Storage & Material Handling _
Laboratory/Analytical _
Other _
LJ Site Preparation
(Demolition, site clearing, etc.)
Estimated Installation Costs
Vendor _
Contractor _
In-house Staff _
-------
Pirm LSjaiV-K^'i ^l/V-3^5
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Waste Minimization Assessment
Pro<; IJnft/Opflr
Proj Ma /S^Si. So )
Prepared By S> ^ - S£<-Li-^?t27:?r
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Sheet 1 of 1 Page of
WORKSHEET
16
PROFITABILITY WORKSHEET # 1
PAYBACK PERIOD
&EPA
Total Capital Investment ($) (from Worksheet 15C)
Annual Net Operating Cost Savings ($ per year) (from Worksheet 1st).
Payback Period (In years):
Total Capital Investment
Annual Net Operating Cost Savings
O
-------
APPENDIX C
MATERIAL SAFETY DATA SHEETS
PRECLEANING AND PLATING CHEMICALS
USED AT LEONARD'S PLATING FACILITY
3758g
-------
NO. 8120
fftacDermid
Incorporated
MACDERMID® 8120
WATERBUR)
. MR l314J.862r57Cq — .LOS Ar.
acPerrriTd nickel plating
<213] 240-9573
solubilizes certain metallic impurities thus preventing or minimizing such problems as rough-
ness, anode bag plugging, and anode polarization caused by certain metallic impurities. Mac-
Dermid 8120 thus provides an economical way to operate MacDermid nickel plating baths
which have become contaminated with iron. It is particularly effective for bumper replaters
and tubular furniture platers and any other steel work with recessed areas.
Use of MacOermid 8120 does not necessitate any changes in equipment or operating condi-
tions. See data sheet for MacDermid nickel process being used for recommendations on equip-
ment and operating conditions. MacOermid 8120 will solubilize rust so holes in linings could
cause holes in equipment more rapidly than previously encountered.
CONCENTRATION
The required concentration of MacDermid 8120 depends on the amount of metallic impuri-
ties present or dragged into the nickel plating bath. Use the following data as a guide.
Each 1% by volume MacDermid 8120 will theoretically solubilize approximately the following
amounts of impurities individually at pH 3 to 5:
256 ppm
186 ppm
Mg4"1" 112 ppm
NOTE: Dark recesses caused by copper or zinc contamination are not eliminated by the use of
MacDermid 8120. Copper and zinc, therefore, should be removed by electrolytic
treatment, chemical purification, or by adding MacDermid Nickel Purifier (Data Sheet
No. 8190).
CONTROL
To maintain an adequate level of MacDermid 8120 in the working bath, add 1/2 gallon (1/2
I./1000 I.) per week of MacDermid 8120 per 1000 gallons of nickel plating solution to rack
baths, and 1 gallon (1 I./1000 I.) per week of MacDermid 8120 per 1000 gallons of plating
solution to barrel baths, based on 8 hours per day and 5 days per week of operation. Increase
the amount of MacDermid 8120 for longer production periods; for example, double the above
additions for 16 hours per day of operation.
The iron complexed and solubilized by MacDermid 8120 is removed from the nickel solution
by electrodeposition. The iron codeposits with the nickel, forming a nickel/iron alloy.
JMI-'ORTANT Please note disclaimer on page 2 Also read carefully warning and safety information on the last page
This data sheet contains technical information required for safe and economical operation of this product READ IT THOROUGHLY
PRIOR TO PRODUCT USE EMERGENCY DIRECTORY ASSISTANCE en fs a (313)644-5626
-------
& WARNING INFORMATION
MacDermid 8120 is a slightly acidic product. Wear protective gloves, goggles, and clothing. Oo
not take internally. Avoid contact with skin and eyes. Flush exposed areas immediately with
clean, cold water. Contact a doctor immediately in case of injury. OSHA 20 Forms are avail-
able on request from MacDermid Incorporated.
WASTE DISPOSAL
See data sheet for MacDermid nickel plating process being used for recommendations. Follow
local waste disposal regulations.
STORAGE
MacDermid 8120 should be stored at temperature above 32°F. (0°C.). If frozen, warm solu-
tion to about 80°F. (27°C.) and shake or mix to re-dissolve.
STANDARD PACKAGE: 55 gallon container
MACDERMID INCORPORATED
WATERBURY, CONNECTICUT
Page 2 of 2 - SK-A
MacDermid 8120
MacDermid is a registered trademark of MacDermid Incorporated.
All statements, technical information and recommendations contained herein are based on
tests we believe to be reliable, but the accuracy or completeness thereof is not guaranteed. No
statement or recommendation shall constitute a representation unless set forth in an agreement
signed by officers of seller and manufacturer. NO WARRANTY OF MERCHANTABILITY OR
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE. The following war-
ranty is made in lieu of such warranties and all other warranties, express, implied or statutory.
Products are warranted to be free from defects in material and workmanship at the time sold.
The sole obligation of seller and manufacturer under this warranty shall be to replace any pro-
duct defective at the time sold. Under no circumstances shall manufacturer or seller be liable
for any loss, damage or expense, direct or consequential, arising out of the use of or inability
to use, the product.
No suggestion for product use nor anything contained herein shall be construed as a recom-
mendation to use any product in infringement of any patent rights, and seller and manufac-
turer assume no responsibility or liability for any such infringement.
1. - *•> / S». f t »-, \ «. f f= e- /••• *•», /w«
; .;".•:. u- - .*•« B4-4-ob^6
DIRECTCRY ASSIST^ivr:
I
I
-------
MATERIAL SAFETY DATA SHEET
R 10/13/86
CODE 13120
SECTION 1
Manufacturer's Name
MacDenaid Incorporated
EMERGENCY TELEPHONE
203-575-5700
ADDRESS (Number. Street, City, State, Zip Code)
526 Huntingdon Avenue Waterbury, CT. 06708
CFR-49 - DOT Proper Shipping Name Non Hazardous
MFSA EMERGENCY 24 HOUR
HOTLLNE: (MEDICAL)
(313) - 644 - 5626
CHEMICAL NAME AND SYNONYMS
N/A
TRADE NAME AND SYKOMYM.
NiMac Iron Control 5120
CHEMICAL FAMILY
Polyhydroxy carboxylic acid
FORMULA
Mixture
SECTION II - HAZARDOUS INGREDIENTS
PAINTS, PRESERVATIVE
& SOLVENTS
N/A
TLV (D3ITS)
ALLOYS & METALLIC
COATINGS
..VA
TLV (UNITS)
PIGMENTS
BASE METAL
CATALYST
ALLOYS
VEHICLE
METALLIC COATINGS
SOLVENTS
FILLER METAL PLUS
OR CORE FLUX
ADDITIVES
OTHERS
OTHERS
HAZARDOUS MIXTURES OR OTHER LIQUIDS. SOLIDS. OR GASES
TLV (UNITS)
Non Applicable
SECTION III - PHYSICAL DATA
SOILING POINT (F )
Approx. 212
SPECIFIC GRAVITY
1)
1.04
VAPOR PRESSURE (MM. HG.)
PERCENT VOLATILE BY VOLUME ( Z )
Aqueous
known
VAPOR DENSITY (AIR =1)
Unknown
EVAPORATION RATE (
1)
Un^noua
SOLUBILITY IN WATER
Complete
APPEARANCE AND ODOR
yellow solution
SECTION IV = FIRE Am) EXPLOSION HAZARD DATA
-tf&fc,
FLASH POINT (METHOD USED)
won flammable
FLAMMABLE LIMITS
K/A
EXTINGUISHING MEDIA
Waterspray. CO^. dry chemical, foam
SPECIAL FIRE FIGHTING PROCEDURES
Wear self-contained breathing apparatus and protective clothing when
fighting chemica fires.
UNUSUAL FIRE AUD EXPLOSION HAZARDS
Itone
-------
SECTION V - HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE
Hot established for product. Ingredients are FLiA recognized foou aoaicives anj are net
considered toxic.
EFFECTS OF OVEREXFOSURE - UNLESS OTHERWISE STATED, CHRONIC OR LONG-TERM HEALTH EFFECTS
ulKNOWN!
May be irritating to eyes.
EMERGENCY AND FIRST AID PROCEDURES
Eyes: Wash wicu water for 15 minuets, contact pnysician if irritation persists.
Skin: Wash off with water.
Inhalation: Remove to fresh air.
SECTION VI - REACTIVITY DATA
UNSTABLE
STABLE
INCOMPATIBILITY (H
Oxidizing material
X
CONDITIONS
N/A
ATERIALS TO AVOID)
s
TO AVOID
HAZARDOUS DECOMPOSITION PRODUCTS
Oxides of carbon under thermal conditions
iiAZARDOUS POLYMERIZATION
HAY OCCUR
HILL NOT OCCUR
CONDITIONS TO AVOID
N/A
SECTION VII - SPILL OR LEAK PROCEDURES
STEPS TO 3E TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED - WEAR PROTECTIVE CLOTHING iIEVER
DISCHARGE DIRECTLY INTO SEWERS OR WATERWAY.
Neutralize with soda ash and wash to chemical drain with cold water.
WASTE DISPOSAL METHOD - ALWAYS CHECK & COMPLY WITH GOVERNMENT DISPOSAL REGULATIONS
Neutralize to pH 6.0 - 3.0 and discnarge to sewer. Material is biodegradable.
SECTION VTII - SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (SPECIFY TYPE)
IJot required
VENTILATION
LOCAL EXHAUST
MECHANICAL (GENERAL)
PROTECTIVE GLOVES
Rubber
X
N/A
SPECIAL
n'/A
OTHER
X/A
EYE PROTECTION
Splash proof socles
OTHER PROTECTIVE EQUIPMENT
Protective clothing
SECTION IX - SPECIAL PRECAUTIONS
PRECAUTIONS TO BE TAKEN Ii4 HANDLING AND STORING
tCeep in closed containers in a cool, diy area.
OTHER PRECAUTIONS - AVOID EYE AND SKIN CONTACT - ALWAYS WASH CLOTHING BEFORE RE-USE
None
PREPARED 5Y: Cherrie D. Gillis
DATE: W13/36
113120
-------
NO. 0201
fVlcicDermicI ANODEX*
Incoroorated REVERSE CURRENT CLEANERS
FOR STEEL AND COPPER
WATERBURY. CT (203) 57S-57OO - FERNDALE. Ml (313) 399-3553 - LOS ANGELES. CA (818) 240-9573
ANOOEX COMPOUNDS PRODUCE BRIGHT, SNOT-FREE WORK
MacDertnid Anodex compounds are all alkaline, detergent, highly
conductive cleaning materials used for electrocleaning. Used
under the proper conditions and with the right cleaning cycle,
Anodex cleaning compounds assure you a bright, smut-free surface
for subsequent electrodeposits. The brightness and uniformity of
the electrodeposit is improved because Anodex compounds remove all
organic and inert films from pores of the basis metal. Because
Anodex removes all surface contaminants, there is no drag-in of
materials into plating solutions. Therefore, they will not
require purification as often, resulting in substantial savings in
brightener costs and labor.
ADVANTAGES OF USING ANODEX COMPOUNDS
1. High speed cleaning.
2. High conductivity.
3. Increases uniform plating.
4. Softens and removes buffing residues.
5. Free rinsing.
6. May be used in automated line.
Anodex Description
Anodex NP No. 2 is recommended for oily steel because of its
unique wetting system. In cases where the solution surface area
of the cleaner tank is small and the current requirements (amperes
/gallon) are high, a foam blanket produced by Anodex NP No. 2
allows the normally developed gasses to escape without exploding.
Anodex 61X is highly effective for cleaning buffed copper without
destroying the luster of the base metal. It is also best for use
in hard water areas for cleaning steel, copper, or a combination
of both.
,...r .-.- .-N' Rifcrse note disclaim-:-'on rzr.r-o Alsc rear, caiefuiiy w?-.mg arc^afety information en the last page ODTr>
This riaia s,neet contains technical information required for safe and economical operation ot this product READ IT T HUriuuiaMLY KMIUK i u
-cn<- i,—r..cr EMERGENCY DIRECTORY ASSISTANCE m/Sfl (313> 640-5626
-------
Anode x U (unwetted) is used when there is excessive drag-in of the
preceding soak cleaner or when the user wants to control the foam
blanket and detergency with wetter additions.
All Anode x compounds may be used to strip chromium from nickel
plated work.
Anodex compounds operate over a wide range of conditions; however,
for the most efficient cleaning, we recommend the following.
OPERATING CONDITIONS AMD EQOIPMENT
Tank and Heating Coil
Concentration
Temperature
Polarity
Current Density
Time Required
Voltage
Cathodes
Steel*
8-16 oz./gal. (60-120 g/1)
190-210°F ( 87.8-98.8°C)
Reverse current; i.e./ work as
anode
50 to 125 amps/sq. ft. (5.4 to
13.5 amps/sq. dm.) at 6 volts
1 to 3 minutes (additional time
not detrimetal)
6 to 9
Nickel plated steel (perforated)
A minimum current density of 25 amps/sq. ft. (2.7 amps/sq. dm.) is
essential for effective cleaning. Reverse cleaning has the
advantage of removing smut and other films which may contribute to
roughness, poor corrosion resistance, cloudy electrodeposit, and
poor adherence. Therefore, the elimination of these films results
in maximum adhesion and luster. In all cases, the use of remov-
able nickel plated electrodes is recommended. The electrodes are
removed periodically and cleaned to remove deposits of soil.
MAKE-UP
Considerable heat is generated when Anodex is dissolved in water.
A new solution should be prepared by filling the tank half full of
warm water, 120-130°F (48.9-54.4°C) and slowly adding Anodex while
continuously stirring. After solution is complete, bring the tank
to volume with cold water. Heat or cool to operating temperature
before use. Goggles should be worn to protect the eyes.
*A tank design incorporating a dam overflow weir, grease trap, and
recirculating pump is highly recommended.
Page 2 of 7
Anodex
MacDermid Incorporated
>5 "OH AP*fc'».,i .*
or statutory
•' ifiuctsarr ••T'Jinieii lotio i.ue hom aeferis m '-
h'WIive 31 '"** • m** sold Uncter norircunislances
D'OduCl
ipspons H'W Of lubtlily »Of any such •nlnngemenl
-------
Typical Cycle for Cleaning Steel - Anodex NP No. 2
1. Anodex NP No. 2, 12 oz./gal. (90 g/1) , 180°F (82.9°C), 75
amps/sq. ft. (8.1 amps/sq. dm.), 6 volts/ 1 to 2 minutes
reverse current.
2. Water rinse.
3. 1 to 2 Ibs./gal. (120-240 g/1) Metex Acid Salt M-629
(Data Sheet No. 3001), room temperature.
4. Water rinse.
5. Water rinse.
6. Anodex NP No.2, 12 oz./gal. (90 g/1), 180°F (82.9°C), 75
amps/sq. ft. (8.1 amps/sq. dm.), 6 volts, 30 seconds to 1
minute, reverse current.
7. Water rinse.
8. 1 to 2 Ibs./gal. (120-240 g/1) Metex Acid Salt M-629,
room temperature.
9. Water rinse.
10. Electroplate.
The above double cleaning cycle is the most effective to use when
substantial quantities of surface contaminants are to be removed.
It is the most foolproof procedure to use for cleaning when
removing carbon, smut, scale, rust or other inorganic materials.
Where the material is not as difficult to remove, the cycle can be
shortened so that Step 5 can be followed by electroplating.
In all cases if the electrocleaning time for Step 1 above exceeds
two minutes, it is good practice to use two separate tanks so that
the first tank takes off the bulk of the material being removed.
When it is time to dump the cleaners, the first cleaner can be
dumped and the second one pumped into the first tank. The second
cleaner is madeup fresh. This procedure reduces the cleaning cost
and assures free, easy rinsing out of the second cleaner.
Typical Cycle for Cleaning Buffed Copper - Anodex 61X
1. Preclean, if necessry. (Consult your MacDermid
representative.)
2. Anodex 61X, 8 oz./gal. (60 g/1), 180°F (82.2°C), 75
amps/sq. ft. (8.1 amps/sq, dm.), 6 volts, 1 minute,
reverse current.
Page 3 of 7 MacOermid Incorporated
Anodex
-------
3. Water rinse.
4. Metex Acid Salt M-629, 1 Ib./gal. (120 g/1), room
temperature.
5. Water rinse.
6. Rocheltex copper strike (Data Sheet No. 6561-A), 1
minute.
7. Water rinse.
8. Water rinse.
9. Electroplate.
When the cleaning time for Step 2 above exceeds 2 minutes, it is
advisable to have two reverse current Anodex tanks for the first
operation rather than one large one. The benefits of this double
cleaning cycle are explained fully in the section above, "Typical
Cycle for Cleaning Steel".
The use of solvent degreasing prior to the electrocleaning is not
recommended unless the work has deep recesses or crimped over
edges. Whenever possible, we suggest the degreasing operation be
performed prior to polishing rather than prior to the cleaning
operation.
For Stripping Chromium from Nickel
1. Anodex, 8 oz./gal. (60 g/1), 180°F (82.2°C), 6 volts,
work anodic.
2. Cold water rinse.
3. Dry.
TROUBLESHOOTING
1. Determine if the polarity is correct. Cleaning problems
have been traced to the use of incorrect polarity.
2. Burning of work in electrocleaners may be due to one or
more of the following factors:
a. Low temperature or concentration.
b. High voltage.
c. High current density.
d. Improper cleaning compound for basis metal.
3. Check the cleaning current density. A low current
density may be due to polarized cleaning electrodes. The
electrodes should be removed and cleaned periodically.
Page 4 of 7 MacDermid Incorporated
Anodex
-------
CONTROL PROCEDURE
MacDermid Test Kit Factors are:
Anodex U 0.50
Anodex 61X 0.53
Anodex NP No. 2 0.53
Test kits are available, at no charge, upon request to
MacDermid Incorporated. The accuracy oE the test kit
procedure is within about 10%. If an analytical
procedure is desired for greater accuracy/ use the
following.
By Titration:
a. Pipette a 10.0 sample into a 250 ml Erlenmeyer
flask, and dilute with 50 ml H2O.
b. Add 3 to 5 drops phenolphthalein indicator solution.
c. Titrate with 0.5 Normal hydrochloric acid until pink
color just disappears.
d. Calculations:
ml of Q.5N HC1 x 0.34 = oz./gal. Anodex U
(ml of 0.5N HC1 x 2.55 = g/1 Anodex U)
ml of 0.5N HC1 x 0.36 = oz./gal. Anodex NP No. 2
(ml of 0.5N HC1 x 2.70 = g/1 Anodex NP No. 2)
ml of 0.5N HC1 x 0.35 = oz./gal. Anodex 61X
(ml of 0.5N HC1 x 2.62 = g/1 Anodex 61X)
NACDERNID INCORPORATED
HATERBURY, CONNECTICUT
Page 5 of 7 - CI-F
Anodex
This data sheet is a revision of Issue E, which is now obsolete
and should be destroyed.
Anodex, Metex, and Rocheltex are registered trademarks of
MacDermid Incorporated.
-------
w/////////////////////////////////////^^^
g SAFETY & WARNING INFORMATION p
/5 HANDLING PRECAUTION y
s, ANODEX IS A STRONG ALKALINE MATERIAL AND SHOULD BE USED /f
fy ACCORDINGLY. AVOID SKIN, ORAL, AND EYE CONTACT. PROTECT EYES ^
Yf WITH GOGGLES AND SKIN WITH RUBBER GLOVES AND OTHER ALKALINE ^
2 V
YJ RESISTANT CLOTHING. FLUSH EXPOSED AREAS IMMEDIATELY WITH CLEAN, ^
fy COLD WATER. CONSULT A DOCTOR IN CASE OF INJURY. /f
JZ WARNING A
fy ANODEX COMPOUNDS ARE ALKALINE MATERIAL. IF SPLASHED INTO THE /*
Y. BYES, FLUSH IMMEDIATELY WITH COLD WATER FOR 20 MINUTES, CONTACT A ^
V /y
J/ PHYSICIAN. IF SPLASHED ON CLOTHING OR SKIN, REMOVE SOILED //
^ CLOTHING, FLUSH WITH COLD WATER FOR 20 MINUTES, CONTACT A Zj
dt PHYSICIAN FOR TREATMENT OF BURNS. IF TAKEN INTERNALLY, GIVE Xj
6 WATER, CONTACT A PHYSICIAN. %,
OSHA 20 FORMS ARE AVAILABLE FROM MACDERMID INCORPORATED. fa
// ELECTROCLEANERS, WHEN IN USE, GENERATE HYDROGEN AND OXYGEN GAS. A %
Yj HYDROGEN GAS EXPLOSION (OR IMPLOSION) CAN OCCUR IF THE GASSES Yf
7> 7,
'A TRAPPED IN THE FOAM BLANKET ON THE SURFACE OF THE ELECTROCLEANER f/,
V< ARE IGNITED BY A SPARK GENERATED AT ELECTRICAL CONTACT POINTS. IF J/
^ SUFFICIENT HEAT IS GENERATED AND OIL OR OTHER COMBUSTIBLE V
'/. MATERIALS ARE PRESENT, FIRES CAN START. THESE IMPLOSIONS CREATE A //
y. LOUD NOISE THAT MAY BE HARMFUL TO HEARING. OPERATING CONDITIONS /X
Y, THAT CAN CREATE IMPLOSIONS SHOULD BE AVOIDED. //
Y. HYDROGEN EXPLOSIONS CAN BE PREVENTED BY KEEPING ELECTRICAL CONTACT ^
Y POINTS AWAY FROM FOAM LEVELS AND BY INSTALLING AN OIL TRAP IN THE ^
/? CLEANING TANK. /jt
// PAGE 6 OF 7 MACDERMID INCORPORATED
ANODEX
# (31 3) 644-5626
^ vmtesssa* //
'SS//S//S//S//S//////S/////S///////S////////////SS
-------
SAFETY & WARNING INFORMATION
WASTE DISPOSAL ^
•f SOLUTIONS OF ANODEX ARE ALKALINE. NEUTRALIZE TO pB 6 TO 8 WITH AN %
// YJ
Yt ACID AND DISCHARGE TO SEWER, STREAM, OR LAGOON. ADD ACID SLOWLY />
K
WITH CAUTION. THIS REACTION GENERATES HEAT. USE CAUTION. WEAR />
%
GOGGLES AND PROTECTIVE CLOTHING. CHECK LOCAL AUTHORITIES FOR //
V
. WASTE DISPOSAL IN YOUR AREA. ^
<
1 I
? I
X> /s
I l
/.
•y
•
// PAGE 7 OF 7 MACDERMID INCORPORATED /^
•/, ANODEX %
ty/////////////////^^^^
-------
MATERIAL SAFETY DATA SHEET
R 11/22/89
CODE 10203
SECTION 1
Manufacture's Name
MacDermid Incorporated
EMERGENCY TELEPHONE
203-575-5700
ADDRESS (Number, Street, City, State, Zip Code)
526 Huntingdon Avenue Waterbury, CT. 06720
CFR-49 - DOT Proper Shipping Name Sodium Hydroxide Dry, Solid
Mixture Corrosive Material UN1823
MFSA EMERGENCY 24 HOUR
HOTLINE:
(313) - 644 - 5626
CHEMICAL NAME AND SYNONYMS
N/A
TRADE NAME AND SYNOMYMS
Anodex NP-2
CHEMICAL FAMILY
Alkali
FORMULA
Mixture
SECTION II - HAZARDOUS INGREDIENTS
PAINTS, PRESERVATIVE
& SOLVENTS
N/A
TLV (UNITS)
ALLOYS & METALLIC
COATINGS
N/A
TLV (UNITS)
PIGMENTS
BASE METAL
CATALYST
ALLOYS
VEHICLE
METALLIC COATINGS
SOLVENTS
FILLER METAL PLDS
OR CORE FLUX
ADDITIVES
OTHERS
OTHERS
HAZARDOUS MIXTURES OR "OTHER LIQUIDS. SOLIDS. gR GASES
TLV (UNITS)
Sodium Hydroxide (1310-73-2) PEL - 2 mg/M
50-60
2 mg/M
SECTION III - PHYSICAL DATA
BOILING POINT (F )
N/A
SPECIFIC GRAVITY
1)
N/A
VAPOR PRESSURE (MM. HG.)
PERCENT VOLATILE BY VOLUME ( Z )
N/A
0
VAPOR DENSITY (AIR = 1)
EVAPORATION RATE (
1)
N/A
N/A
SOLUBILITY IN WATER
Appreciable
APPEARANCE AND ODOR
Off-white granular powder/no odor
SECTION IV = FIRE AND EXPLOSION HAZARD DATA
-tfifc
-BEfc
FLASH POINT (METHOD USED)
Non-flammable
FLAMMABLE LIMITS
N/A
EXTINGUISHING MEDIA
As appropriate for surrounding materials
SPECIAL FIRE FIGHTING PROCEDURES
Always wear self-contained breaching apparatus and full protective
clothing when fighting fires involving chemicals.
UNUSUAL FIRE AND EXPLOSION HAZARDS
Will cause evolution of heat, possible spattering, when mixed with water.
-------
SECTION V - HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE
Not established for produce.
See Section II.
EFFECTS OF OVEREXPOSURE-UNLESS OTHERWISE STATED, CHRONIC OR LONG-TERM HEALTH EFFECTS UNKNOWN!
Will cause severe burns to eyes, skin and mucous membranes. Direct eye contact may
result in permanent damage.
EMERGENCY AND FIRST AID PROCEDURES
EYES: Flush with water for 15 minutes. Contact physician immediately!
SKIN: Wash with soap and water.
DIGESTION: Give water or milk. Do not induce vomiting. Contact physician immediately!
INHALATION; Remove to fresh air. Contact physician if irritation results.
SECTION VI - REACTIVITY DATA
UNSTABLE
STABLE
CONDITIONS TO AVOID
N/A
INCOMPATIBILITY (MATERIALS TO AVOID)
Acids, aluminum, zinc
HAZARDOUS DECOMPOSITION PRODUCTS
Oxides of carbon, disodium oxide
HAZARDOUS POLYMERIZATION
MAY OCCUR
WILL NOT OCCUR
CONDITIONS TO AVOID
N/A
SECTION VII - SPILL OR LEAK PROCEDURES
STEPS TO BE TAKEN IN CASE MATERIAL IS RELEASED OR SPILLED. WEAR PROTECTIVE CLOTHING, NEVE
DISCHARGE DIRECTLY INTO SEWER OR WATERWAYS.
Sweep up dry material and collect into proper containers. Flush area with cold water to
chemical drain.
WASTE DISPOSAL METHOD-ALWAYS CHECK & COMPLY WITH GOVERNMENT DISPOSAL REGULATIONS.
Dispose of as solid waste in secure, approved landfill. Alternate method: Dissolve in
cold water, adjust pH to 6 to 8 with dilute acid, and discard to waste treatment system.
SECTION VIII - SPECIAL PROTECTION INFORMATION
RESPIRATORY PROTECTION (SPECIFY TYPE)
NIOSH-approved dust mask
VENTILATION
LOCAL EXHAUST
N/A
MECHANICAL (GENERAL)
X
SPECIAL
N/A
OTHER
N/A
PROTECTIVE GLOVES
Rubber
EYE PROTECTION
Face shield/safety goggles
OTHER PROTECTIVE EQUIPMENT
Rubber apron/boots
SECTION IX - SPECIAL PRECAUTIONS
PRECAUTIONS TO BE TAKEN IN HANDLING AND STORING
Store in cool dry area in tightly closed containers away from acids. Do not wear contact
lenses when handling this product.
OTHER PRECAUTIONS - AVOID EYE AND SKIN CONTACT -.ALWAYS WASH CLOTHING BEFORE RE-USE.
Contains SARA Title 313 substance - See Section II.
PREPARED BY: MacDermid Incorporated
DATE: 11/22/89
10203
-------
fftacDermid
Incorporated
NO. 0311
METALEX® W SPECIAL
ALL PURPOSE CLEANER
Metalex W Special is a mildly alkaline general purpose cleaner with a high percentage of
wetting agent. It is especially compounded to counteract the bad effects of hard water. It is
also a free rinsing cleaner and tolerates long transfer times.
EFFECTIVE SOAK OR CATHODIC CLEANER FOR STEEL
Metalex W Special is used as a soak cleaner for steel to remove oils and certain type buffing
compounds. It is usually followed by a reverse current (work anodic) electrocleaner. When
Metalex W Special is used as an electrocleaner, it is generally used with direct current (work
cathodic). MacDermid Anodex (Data Sheet No. 0201) compounds are recommended for
reverse current cleaning of steel.
GOOD COMPATIBILITY
Metalex W Special is compatible with all MacDermid alkaline cleaners. Therefore, it can be
incorporated into the most effective cycle. Drag-in of Metalex W Special into Anodex will not
affect the action of that electrocleaner nor the following rinse.
BARREL OR TUMBLE CLEANER
For all basis metals other than aluminum, Metalex W Special may be used as a tumble cleaner
prior to barrel plating or for other metal finishing.
It will effectively remove light oils. However, if heavy oil contamination is to be removed, the
recommended material is Metex T-103 (Data Sheet No. 0113).
BRASS, SOAK, OR ELECTROCLEANER
Metalex W Special finds wide application in cleaning brass. It may be used as a soak, director
reverse current cleaner. With reverse current, time should not exceed 10 seconds.
FOR COLOR BUFFED OR BRIGHT NICKEL PRIOR TO CHROME PLATING
In this application, Metalex W Special may be used as a soak or direct current cleaner. In addi-
tion to the cleaning action, it will activate bright nickel plate or buffed nickel before chrome
plating. The resulting plate will be bright and stain-free.
c •,-. ^BJANT t;:.vase ncie disclaims 01 page 2 Also read carefully warning & safety info'inaiion on the last page
7m:, data sheet contains technical information required for safe and economical operation of Ihis product READ IT THOROUGHLY
PRI'^R TO
-------
Brass With Oil and Buffing Compound
1. Metalex W Special, soak or direct, followed by 3 to 5 seconds reverse, 4 to 5 volts.
2. Metalex W Special, 3 to 5 seconds reverse current, 4 to 5 volts.
3. Water rinse.
4. Metex Acid Salt M-629.
5. Water rinse.
6. Electroplate.
Stainless Steel - Chrome Plating Cycle
1. Soak clean, Metalex W Special, 8 oz./gal. (60 gm./L), 160-190°F. (72-87°C.).
2. Spray rinse.
3. Anodic clean at 5 to 50 amps./sq. ft. (0.5 to 5.5 amps./sq. dm.), Anodex NP-2, 6 to
8 oz./gal. (45 to 60 gm./l.), 45 seconds, 3 to 6 volts, 170°F. (76°C.).
4. Spray rinse.
5. Acid dip, Metex Acid Salt M-629, 1 Ib./gal. (120 gm./l.), room temperature.
6. Rinse.
7. Rinse.
8. Chrome plate, chromic acid, 42 oz./gal. (315 gm./l.) and sulfuric acid, 0.5 oz./gal.
(3.8 gm./l.), 120°F. (48°C.), 4 minutes.
9. Rinse.
10. Rinse.
11. Hot rinse and dry.
Barrel Plating
Tumble clean - all basis metals - Metalex W Special, 8 oz./gal. (60 gm./l.), prior to barrel
plating
1. Metalex W Special.
2. Water rinse.
3. Metex Acid Salt M-629.
4. Water rinse.
5. Barrel plate.
MAKE-UP PROCEDURE
When preparing a fresh solution of Metalex W Special which will be operated at the low
temperature range, it is advisable to follow this procedure.
Slowly add the full amount of cleaner to at tank filled 3/4 full of warm water. Heat this solu-
tion to 150°F. (65°C.). After a few minutes, add the remainder of the water and adjust to the
desired temperature. This procedure will insure complete solubility.
CONTROL PROCEDURE
1. MacDermid Test Kit Factor
Metalex W Special = 1.00
-------
USER BENEFITS OF METALEX W SPECIAL
Feature
General purpose cleaner
Specially formulated for hard water
High wetting agent content
Easily rinsed
Low alkalinity
Compatible
Simple control
Benefit
- Reduced inventory - one material for
many jobs
- Hard water will not affect its cleaning
ability nor life
- Results in better cleaning
- Following solutions not contaminated
- Will remove soils which are not affected
by high alkalinity cleaners, such as lime
and stearic acid base compounds
- Can be used in best place in cycle with
other materials
- Easy to keep at proper concentration
for maximum efficiency
METHOD OF USE
Concentration
Temperature
Time
Soak or direct current
Reverse current on brass
8 to 10 oz./gal. (60 to 75 gm./l.)
150-200°F. (65-94°C.)
1 to 3 minutes
3 to 5 seconds
20 to 40 amps./sq. ft. (2.2 to 4.4 amps./sq. dm.)
4 to 6
Steel tank and heating coil*
Current density
Voltage
Equipment
SUGGESTED CYCLES
Steel - Oil and Buffing Compound Removal
1. Metalex W Special, soak or direct.
2. Water rinse.
3. Anodex.
4. Water rinse.
5. Metex Acid Salt M-629 (Data Sheet No. 3001 ).
6. Water rinse.
7. Electroplate.
*A tank design incorporating a dam overflow weir, grease trap and recirculating pump is highly
recommended.
i«l .ill ui hoi vtiirr,ii if-. t'MMi'ts tinpueti o> st^.i^'-ir ,
r MUI is.ifO«arfdn.t*iilot'eiri'GtrQn i i ..... ..... i-s .,,,r- 1 -I . • ,
» nl it »-,*n\ [iffjfJuut rtplcriivenl the imit* snlc 'i» • • ' i r"< i n • i i- "• V. ' * i il if •uf»f or • on™ t<* ' '.'i* t')' IP. loss m «c • n> • «(i • -' ' Tlft ' "" ' t'1' • •' '
• MIUI -HI' it! ihp u>e of Of mahthly to use the tjf*' »' >
No suaqestion for oroduct use nor anything contained npi ein shall be construed as a recommendritinn to use any proluct m nlrmr* mpot o» any oatnnt nqhtb anj SL
•••irf mnniifjclurrr assume no '••spnnsihihlv or Mml *\ • ^ mv siir.h in^ino^rnen'
-------
Test kits are available, at no charge, upon request to MacOermid Incorporated.
The accuracy of. the test kit procedure is within about 10%. If an analytical proce-
dure is desired for greater accuracy, use the following.
2. By Titration
a. Pipette a 10 ml. sample into a 250 ml. Erlenmeyer flask and dilute with 50
ml. H2O.
b. Add 3 to 5 drops of phenolphthalein indicator solution.
c. Titrate with 0.5 Normal hydrochloric acid until pink color disappears.
d. Calculations:
ml. 0.5N HCI x 0.68 - oz./gal. Metalex W Special
(ml. 0.5N HCI x 5.10 = gm./l. Metalex W Special)
TROUBLESHOOTING
1. Determine if the polarity is correct. Cleaning problems have been traced to the use of
incorrect polarity.
2. Burning of work in electrocleaners may be due to one or more of the following
factors:
a. Low temperature or concentration.
b. High voltage.
c. High current density.
d. Improper cleaning compound for base metal.
3. Check the cleaning current density. A low current density may be due to polarized
cleaning electrodes. The electrodes should be removed and cleaned periodically.
WARNING
Metalex W Special is a dry alkaline material and should be stored in a dry area away from
acids. If the material is spilled, sweep up the dry powder and flush the area with cold water.
Wear protective gloves, goggles, and clothing. Flush exposed areas immediately with clean, cold
water. Contact a doctor in case of injury. OSHA 20 Forms are available from MacOermid
Incorporated.
WASTE DISPOSAL
Solutions of Metalex W Special are alkaline and contain phosphates and are biodegradable.
Neutralize to pH 6 to 8 with an acid and discharge to sewer or lagoon. Add the acid slowly
with caution. The reaction generates heat. Wear goggles and protective gloves and clothing.
Use caution. Check local authorities for waste disposal regulations for your area.
Page 4 of 5 MacDermid Incorporated
Metalex W Special
-------
STANDARD PACKAGE: 375 Ib. drum
MACDERMIDINCORPORATED
WATERBURY, CONNECTICUT
Page 5 of 5 - CI-D
Metalex W Special
This bulletin is a revision of Issue C, which is now obsolete and should be destroyed.
Metalex and Anodex are registered trademarks of MacDermid Incorporated.
All statements, technical information and recommendations contained herein are based on
tests we believe to be reliable, but the accuracy or completeness thereof is not guaranteed. No
statement or recommendation shall constitute a representation unless set forth in an agreement
signed by officers of seller and manufacturer. NO WARRANTY OF MERCHANTABILITY OR
WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS MADE. The following war-
ranty is made in lieu of such warranties and all other warranties, express, implied or statutory.
Products are warranted to be free from defects in material and workmanship at the time sold.
The sole obligation of seller and manufacturer under this warranty shall be to replace any pro-
duct defective at the time sold. Under no circumstances shall manufacturer or seller be liable
for any loss, damage or expense, direct or consequential, arising out of the use of or inability
to use, the product.
No suggestion for product use nor anything contained herein shall be construed as a recom-
mendation to use any product in infringement of any patent rights, and seller and manufac-
turer assume no responsibility or liability for any such infringement.
-------
MATERIAL SAFETY DATA SHEET
A/29/87
CODE 10311
SECTION I
Manufacture's Uaae
MacDemid Incorporated
EMERGENCY TELEPHONE
203-575-5700
ADDRESS (Number, Street, City, State, Zip Code)
526 Huntingdon Avenue Uaterbury, CT. 06708
CFR-49 - DOT Proper Shipping Name Sodium Hydroxide, Dry Solid
Mixture, Corrosive Material UN1823
MFSA EMERGENCY 24 HOU1
HOTLINE:
(313) - 644 - 5626
CHEMICAL NAME AND SYNONYMS
N/A
TRADE SAME AND SYIIOMY1
Metalex W Special
CHEMICAL FAMILY
Inorganic Alkaline Mixture
-4-
FORMULA
Mixture
SECTION II - HAZARDOUS INGREDIE:iTS
PAINTS, PRESERVATIVE
& SOLVE3TTS
Z
N/A
TLV (UNITS)
ALLOYS & METALLIC
COATINGS
TLV (UMTS;
PIGMENTS
BASE METAL
CATALYST
ALLOYS
VEHICLE
METALLIC COATIKGS
SOLVENTS
FILLER METAL PLUS
OR CORE FLUX
ADDITIVES
OTHERS
OTHERS
HAZARDOUS MIXTURES OR OTHER LIQUIDS. SOLIDS, OR GASES
TLV (UNITS;
Sodium Hydroxide (1310-73-2)
Sodium Mctasillcate (6834-92-0)
SECTION III - PHYSICAL DATA
BOILING POINT (F )
N/A
SPECIFIC GRAVITY (H20 = 1)
VAPOR PRESSURE (MM. HG.)
N/A
PERCENT VOLATILE BY VOLUME ( Z )
VAPOR DENSITY (AIR = 1)
EVAPORATION RATE (
= 1)
N/A
SOLUBILITY IN WATER
Appreciable
APPEARANCE AND ODOR
White granular powder
SECTION IV ° FIRE AND EXPLOSION HAZARD DATA
-fcWr-
FLASH POINT (METHOD USED)
Non-flammable
FLAMMABLE LIMITS
N/A
EXTINGUISHING MEDIA
As for surrounding materials
SPECIAL FIRE FIGHTING PROCEDURES
Wear self contained breathing apparatus.
UNUSUAL FIRE AND EXPLOSION HAZARDS
ic reaction when brought in cuntacc with water
-------
SECTION V - HEALTH HAZARD DATA
THRESHOLD LIMIT VALUE
;:«t asiabliahed for product. Sc-.t Section I£.
EFFECTS OF OVEREXPOSURE-UNLESS OTHERWISE STATED, C3RONIC OR LOKG-TERM HEALTH EFFECTS UXKXOUK!
Can cause irrimtion and burns t« «.yas, skin an-i mucouo
EMERGENCY AND FIRST AID PROCEDURES
£y«5: Flush with water for 15 minutes. Contact doctor.
Skin:.Flush with water. Wash with vinegar.
Internal: Drink diluted vinegar, loaon or orange juice,
physician.
Do not induce
SECTION VI - REACTIVITY DATA
UNSTABLE
STABLE
CONDITIONS TO AVOID
N/A
INCOMPATIBILITY (MATERIALS TO
Avoid contact with acid or acidic materials.
HAZARDOUS DECOMPOSITION PRODUCTS
Unknown
HAZARDOUS POLYMERIZATION
MAY OCCUR
WILL NOT OCCUR
CONDITIONS TO AVOID
N/A
SECTION VII - SPILL OR LEAK PROCEDURES
STEPS TO BE TAKEN IB CASE MATERIAL IS RELEASED OR SPILLED
Scoop up excess material. Flush with water to chemical, drain.
WASTE DISPOSAL METHOD
Neutralize to pll i>.G - C.O and discard. Contains
Consult local iff.ulaLions before discarding.
SECTION' VIII - SPECIAL PROTECTION IltFORMATIOK
RESPIRATORY PROTECTION (SPECIFY TYPE)
Dust mask
VEKTILATION
LOCAL EXHAUST
\VA
MECHANICAL (GENERAL)
SPECIAL
OTHEE
N/A
PROTECTIVE GLOVES
Rubber
EYE PROTECTION
Face
OTHER PROTECTIVE EQUIPMENT
Rubber apron
SECTION IX - SPECIAL PRECAUTIONS
PRECAUTIONS TO BE TAKEB IN HANDLING AND STORING
in dry area, in ti^litly closed containers
OTHER PRECAUTIONS
None known
PREPARED BY: MacDenaid Incorporated
DATE:
------- |