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witC03.94
1. GENERAL INFORMATION
Location: Marshall, Texas
Number of Employees: 60
Industry: Chemicals, Organic
Waste Reduced: Wastewater
Process: Water Reuse
Contact Person: Bill Childers. (903) 938-5141
2. DESCRIPTION OF PROJECT
Witco collects "clean" wastewater
for reuse in non-critical areas. Boiler, cooling tower blowdown and other
utility area wastewater is collected and reused for services such as floor
sprays and wash water. This eliminates the use of fresh water in these
application and, as a result, reduces the quantity of fresh water use.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
By reusing brown water for non-critical use
Witco reduced water usage by 2,000,000 gallons a year. Some rain water was also
collected in the system, so the total reduction in water disposal was 2,824,000
gallons.
5. COST SAVINGS/BENEFIT
Witco used an existing 5,000 gallon tank to
store brown water. Pump, pipe, controls and other installation costs amounted to
$20,000. Freshwater cost $0.001/gallon saving $2,000 annually. Disposal cost for
"clean" wastewater runs about $0.025/gallon for an annual saving of
$70,600.
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Sandoz1 93
1. GENERAL INFORMATION
Location: Beaumont, Texas
Employees: 300+
Industry: Chemicals, Agricultural
Waste Reduced: Process Chemicals, Chlorinated Organics
Process: Recycling
Contact: Rob Swinney, (409) 722-8061
2. DESCRIPTION OF PROJECT
Our facility manufactures four agricultural
herbicides and one insecticide product. The manufacturing processes generate
both hazardous and non-hazardous waste chlorinated compounds which at one time
were all being transported off site for incineration and landfill. In 1990 an
onsite facility was engineered and constructed to thermally destroy the
chlorinated waste compounds while at the same time recovering the chlorine,
hydrogen, and oxygen to produce 14% aqueous hydrochloric acid for use as a raw
material in one of the manufacturing processes.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Rather than disposing of the waste or just
incinerating the compounds, a useful product is generated in the process which
can be used on site.
4. ENVIRONMENTAL BENEFIT
From 1990 through 1993 the facility generated
over 12,700,000 pounds of waste chlorinated compounds. Over 16,000 tons of
hydrochloric acid was produced from that waste and used as a raw material in the
manufacturing process.
5. COST SAVINGS/BENEFIT
The disposal cost for these compounds would
have been $4,000,000 and the additional purchases of HC I would have amounted to
$2,000,000. The initial cost of the unit was $6.5 million and it has an
operating budget of $1.3 million per year.
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txeast3.92
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Longview, Harrison County
Number of Employees: 2,700
Industry: Chemicals, Organic
Waste Reduced: Wastewater
Process: Recycling, Wastewater Treatment
Contact Person: Neil Quinn, (903) 237-5474
2. DESCRIPTION OF PROJECT
Wastewater from several thermal cracking
plants is pretreated to remove aromatic oil prior to its discharge to the
company's wastewater treatment system. The characteristically hazardous oil was
previously burned for fuel value in the company's boilers. The oil is now being
recycled to another thermal processing plant as a substitute for a commercial
chemical product. This project has reduced the amount of hazardous waste being
burned for fuel.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
This project involved process development work
in order to determine that the oil could be substitute for a commercial chemical
product in another process while still maintaining product quality in the
process.
4. ENVIRONMENTAL BENEFIT
Generation of hazardous waste burned for fuel
value was reduced by 1.9 million gallons per year.
5. COST SAVINGS/BENEFIT
Savings due to reduced purchased of commercial
product less cost of additional natural gas to replace oil for fuel were
approximately $ 800,000 per year.
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txeast2.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Longview, Harrison County
Number of Employees: 2,700
Industry: Chemicals, Organic
Waste Reduced: VOC Emissions, Chloroform
Process: Air Stripping, Wastewater Treatment
Contact Person: Glenn Phillips, (903) 237-5346
2. DESCRIPTION OF PROJECT
Tests determined that natural gas could strip chloroform from
wastewaters and carry it to a hazardous waste incinerator. The wastewater from
the acetaldehyde production facility typically contained 10 ppm chloroform. In
1988 the EPA proposed a regulation that limited chloroform in wastewater to 100
ppb before biological treatment. The chloroform in the wastewater was reduced to
25 ppb by using the gas stripper.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
A pilot study confirmed that natural gas could be used to
extract chloroform from the waste water.
4. ENVIRONMENTAL BENEFIT
The gas stripper reduced the chloroform in the waste water by
400 fold to 25 ppb. It also reduced other waste such as benzene and
dichloromethane by 20 fold.
5. COST SAVINGS/BENEFIT
There are substantial environmental benefits in
emission reductions, but no cost savings.
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ti4.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Stafford, Fort Bend County
Number of Employees:
Industry: Electronics
Waste Reduced: Wastewater
Process: Water Recovery, Parts Cleaning
Contact Person: Cherri Paluch, (713) 274-2043
Patrick Williams, (713) 274-3330
2. DESCRIPTION OF PROJECT
In the Source Rebuild Shop, contaminated parts
are cleaned with a water-based abrasion system. The water is cycled through a
settling tank and the clean water is then recirculated through the process.
The employees from the manufacturing area
decided to address a related solid hazardous waste as a part of the Total
Quality Culture Effectiveness Team program. During their research, they
discovered several areas for waste minimization improvements. The largest
improvement was utilizing the Source Rebuild Shop's hazardous waste compactor to
its full potential. By re-educating the area workers and improving access to the
compactor, the team projects a 80% reduction in volume. The team is also
evaluating improved handling procedures.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
A specialized ionic exchange resin bed was
evaluated, at first, to remove the contamination from the wastewater before its
disposal. While the resin was reasonably effective, it could not meet the low
disposal limits under the site's NPDES permit. The recirculation system and
settling tank was developed as a better alternative.
4. ENVIRONMENTAL BENEFIT
The water recirculating system has reduced
hazardous wastewater generation from the Shop by 2,050 gallons, 97% by volume.
The Effectiveness Team projects an 80% reduction in solid hazardous waste
volume.
5. COST SAVINGS/BENEFIT
The direct disposal cost savings are $59,940
for the wastewater and $85,500 for the solid waste.
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Uanspsv.92
1. GENERAL INFORMATION
Location: Freeport, Brazo County
Number of Employees: 57
Industry: Transportation
Waste Reduced: Wastewater
Process: Wastewater Treatment
Contact Person: Alan W. Dunaway, (713) 474-7621
2. DESCRIPTION OF PROJECT
Bio-treatment of tank cleaning generated
waters.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The application of biological systems for
remediation and control of environmental processes has greatly increased in
recent years. Employing bio-remediation, pollutants are degraded into products
that are part of naturally occurring cycles.
Degradation of hazardous and toxic wastes
employing naturally occurring bacterial cultures go hand in hand. Transport
Service Company has merged this process into an industrial wastewater treatment
system.
Equipment used to facilitate this process
includes: air pumps, fine air diffusers, pH control mechanisms, holding tanks
and a separator for primary treatment.
4. ENVIRONMENTAL BENEFIT
Benefits include the reduced toxicity of
generated wastewaters via naturally occurring organisms.
5. COST SAVINGS/BENEFIT
Financial benefits include reduction of man
hours associated with the previous treatment process. Operational cost have been
substantially reduced. Most importantly, though, are the reduction in surcharges
imposed by the POTW for secondary treatment. These surcharges annually are
$20,000.00.
Payback on project estimated at 1.5 years.
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uncarb1.94
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Port Lavaca, Calhoun County
Number of Employees: 1,150
Industry: Chemicals, Plastic/Resin
Waste Reduced: VOC Emissions
Process: Equipment Modifications
Contact Person: Rick Curtis, (512) 553-2435
2. DESCRIPTION OF PROJECT
Union Carbide's Seadrift Plant has completed
an extensive project to improve our wastewater treatment system. Two earthen
water treatment lagoons have been replaced with modern fully enclosed, 5.5 acre
wastewater treatment reactor. The new system will improve the biodegradation of
organics and will essentially eliminate organic off-gas emissions normally
associated with treatment systems.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The replacement lagoon itself is designed and
constructed in accordance with federal surface impoundment guidelines. While not
mandatory, the system has a 5.5 acre 100 ml floating HDPE cover over the entire
area to contain odors that would be generated.
4. ENVIRONMENTAL BENEFIT
This project benefits the environment as a
result of the protection which it provides for the earth and groundwater, as
well as the air and water. A total reduction of 800 tons/year of hydrogen
sulfide and 12.5 tons/year of VOC's to the air has been achieved.
5. COST SAVINGS/BENEFIT
In addition to the environmental benefit, the
odors from the treatment system are dramatically reduced, which also benefits
employees and near-neighbors.
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valero2.95
1. GENERAL INFORMATION 1995
Governor's Award
Location: Corpus Christi
Number of Employees: 485
Industry: Refining/RFG Gasoline
Waste Reduced: Slop Oil Emulsion Solids
Process: Oil/Water/Solid Separation
Contact Person: Allen Schoen, (512) 289-3285
2. DESCRIPTION OF PROJECT
Valero staff began reviewing waste water
streams in 1992 to determine if there were advantages to processing waste water
prior to entering the waste water treatment (WWT) system. Analysis indicated
that the desalters contributed about 237 gpm of water (221 gpm), solids (6266
ppm) and oil (16.4 gpm) mixture to the WWT system. When the desalter waste water
is mixed with other refinery waste waters in equalization tanks, the slop oil
emulsion solids are dispersed and adhere to more solids suspended in the water.
Tank cleaning requires separation of the slop oil emulsion solids, adding
significantly to the cost of the process and generation of "K" listed
hazardous wastes.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Lion Resources, a Corpus Christi company,
introduced Conoco's Vortoil' Separation Systems to Valero. The system uses a
hydrocyclone principle to remove hydrocarbons and solids from the waste water of
Valero's Residual Hydro-Desulfurization Desalter. The separated oil (21,330 BPY)
is recycled into the refinery. The waste water goes to the WWT system. The
separated solids (85,325 BPY) are treated in Valero's Bioslurry Reactor,
described in a previous case study.
4. ENVIRONMENTAL BENEFIT
The Vortoil' systems expected to reduce the
generation of oily waste water in WWT system; and, the aggregate generation of
hazardous waste in the WWT system equalization tanks by about 350 tons per year.
The oil removal allows Valero to continue to reduce VOC emissions from the WWT
system.
5. COST SAVINGS/BENEFITS
The project was determined to have more than a five year
return based on measurable factors: however, Valero, considered the project to
be "worthwhile" because it could be used to determine the feasibility
of using the technology on other waste water streams of the refinery, it reduced
the mixing with other refinery waste water and redundant separation and the
aromatics removal allows Valero to reduce NESHAP emissions in its WWT system.
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alumax.92
1. GENERAL INFORMATION
Location: Texarkana, Bowie County
Number of Employees: 400
Industry: Aluminum Products
Waste Reduced: Wastewater, Chromium
Process: Electroplating
2. DESCRIPTION OF PROJECT
The source reduction system is for chrome
conversion 6 to chrome 3 by chemical precipitation using sodium metabisulfite at
a 2.0 pH. Magnesium hydroxide is added for pH adjustment along with sodium
hydroxide. Polymers are added to the metal hydroxide solution to facilitate fall
out and filtered through a 6 cubic foot press. This filter cake is then fed to a
JWI sludge dryer at about 70% water content and dried to approximately 30% water
content. This procedure has about a 4:1 ratio of reduction to the sludge being
produced. As a waste being recycled and recovered the 30% water must remain to
be processed. If Alumax did not have this limitation we could reduce the
outgoing waste even further.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
This project has only been facilitated in the
last 60 days. The operation is constantly being refined by using statistical
process control techniques. These developments can produce management control
from the production line all the way to the recycling of the sludge.
4. ENVIRONMENTAL BENEFIT
This type of project allows for the recycling
and reusing of wastes. Since the creation of another waste stream is therefore
prevented, the problems associated with having to landfill are avoided.
5. COST SAVINGS/BENEFIT
Cost savings have been justified by reducing
the sludge volume. The continuing adjustments to fine tune the process will
eventually impact chemical usage and sludge production. In turn, costs will be
lowered. The payback period of the project is forecast at 3 years.
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amoco 1.92
1. GENERAL INFORMATION
Location: Texas City, Galveston County
Number of Employees: 2,200
Industry: Oil Refinery
Waste Reduced: API Separator Sludge
Process: Recycling
Contact Person: S. A. Medley-Perry, (409) 945-1151
2. DESCRIPTION OF PROJECT
The Amoco Oil Company refinery in Texas City
is utilizing a combination of pressure filtration and coking to reduce the
quantity of listed hazardous waste (K048, K051) disposed by 90-95%. The
hazardous wastes (DAF float and API separator sludge) are first pressure
filtered to recover oil and dewater the wastes. The resulting filter cake is
then sent to the refinery coker and converted into fuel-grade coke and oil, in a
proprietary Amoco process.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Although many refineries are using their
cokers to minimize waste disposal, the Amoco process is unique in that it
involves re-slurrying the filer cake to a pumpable material, The filter cake
slurry is then injected into the coker during the coking cycle to recover
additional valuable oil and insure complete conversion of hydrocarbons to coke.
4. ENVIRONMENTAL BENEFIT
This project epitomizes resource conservation
and recovery. A material that would otherwise be incinerated and lost forever is
being recovered and converted into oil and fuel.
5. COST SAVINGS/BENEFIT
Economic savings have been dramatic, with
costs estimated at half the current price for incineration and disposal. Capital
costs of the project were recovered in less than a year.
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aneheuse1.92
1. GENERAL INFORMATION
Location: Houston, Harris County
Industry: Malt Beverage
Waste Reduced: High BOD Water
Process: Wastewater Treatment
Contact Person: Anne Horbaniuk, (713) 678-3713
2. DESCRIPTION OF PROJECT
Prior to installing an eight (8) stage
residuals evaporator, Anheuser-Busch collected several process effluent streams,
centrifuged these streams to remove solids, and then sewered the centrifuge
effluent. This sewered centrifuge effluent was high in BOD and represented 40%
of the plant's total loading.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
To eliminate this portion of our BOD stream,
Anheuser-Busch purchased and installed an eight (8) stage residuals evaporator.
The centrifuge effluent is now pumped to an evaporator feed tank, rather than to
the sewer. From the feed tank, it is metered into the multiple stage evaporator.
Moisture is removed as a condensate stream leaving behind a concentrated thick
syrup with approximately a 50% total solids makeup. This syrup is then sold to a
liquid animal feed producer.
This evaporator application is present
throughout the brewing and distilling industry. Here at Houston, the plant has
been able to bring the evaporator up and operate per design spec within six
months.
4. ENVIRONMENTAL BENEFIT
By installing the residuals evaporator,
Anheuser-Busch reduced the amount of BOD loadings per day to the sanitary sewer
by about 22-23,000 pounds (8 million pounds for 1993). Thus, impacting favorably
the local sewer treatment plant.
5. COST SAVINGS/BENEFIT
The evaporator should yield an annual sewer
savings of approximately $1,500,000. It will increase our fuel, water, and
electric costs. The plant will earn some revenues from the sale of the brewers
condensed solids. Total project payback is five (5) years.
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bellhe1 1.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Fort Worth, Tarrant County
Number of Employees: 4,000
Industry: Metal Parts Fabrication
Waste Reduced: Sludge
Process: Wastewater Treatment, Neutralization
Contact person: Debra L. Rodriguez, (817) 280-8729
2. DESCRIPTION OF PROJECT
Bell Helicopter Textron Inc. has replaced lime
with magnesium hydroxide as a neutralization agent at our wastewater treatment
plants. Bell is saving money, providing a safer working environment for our
employees and reducing our annual hazardous waste sludge.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Metal finishing processes at Bell generate a
variety of acidic waste streams containing dissolved toxic metals. Before the
wastes may be discharged to a sewer or receiving stream, the pH of the solution
must be adjusted to an acceptable level and the metals removed. These acidic
waste streams are commonly neutralized by adding caustic soda or lime, both are
strong bases. Magnesium hydroxide, a fairly weak base, has been used for years
as a neutralizing agent for acids. It is the major ingredient in such medicines
as "Milk of Magnesia", but has rarely been used in wastewater
treatment.
Magnesium hydroxide can be easily purchased as
an aqueous white slurry with a density between 12.3 and 12.5 pounds per gallon.
The slurry is 55-60% magnesium hydroxide by weight and is similar to latex paint
in consistency and appearance.
A convenient way of comparing magnesium
hydroxide to lime or caustic soda is to look at neutralization strength on a
weight basis. Magnesium hydroxide has 27% more hydroxyl ions than lime and 37%
more than caustic soda. Thus, it takes less magnesium hydroxide to neutralize a
given amount of acid or to remove a given amount of metals.
4. ENVIRONMENTAL BENEFIT
Slower reaction time of magnesium hydroxide
produces denser solid particles of metal hydroxides than with lime or caustic
soda. Magnesium hydroxide is a weak base and forms solutions that are buffered
or resistant to changes in pH. Therefore, acids neutralized with magnesium
hydroxide form solutions that are buffered within a pH range of 9.0 to 9.4. This
means that adding too much magnesium hydroxide will not push the pH above the
limits allowed for discharge to most sanitary sewers.
The by-products produced when magnesium
hydroxide neutralizes sulfuric acid is magnesium sulfate (epsom salts) and is
soluble and may be discharged safely to the sanitary sewer.
Bell Helicopter's operators found magnesium
hydroxide was much easier to use and more predictable than lime. Besides saving
time while neutralizing tanks, the lessened volume of hazardous waste greatly
reduced the time required to condition and dry the sludge. The only disadvantage
noted was a slight increase in the amount of flocculating polymer required.
5. COST SAVINGS/BENEFIT
Bell Helicopter has realized a real reduction
in the volume of greater than 50% or 500 tons of hazardous waste sludge per
year. This translates to a net annual savings of over $220,000 and greatly
reduces our liability due to less sludge being disposed of per year.
Bell Helicopter has also gained benefits from
improved safety conditions, reduced maintenance requirements and an easing of
the work load for the wastewater treatment operators. In addition, a
nonhazardous material has been substituted for a very hazardous material.
Magnesium hydroxide is safer for employees and the environment. Bell Helicopter
was able to convert over to magnesium hydroxide with little capital equipment
investment. Our greatest payback is in the fact that Bell's largest and
costliest hazardous waste stream was greatly reduced, thereby reducing our cost
and liability.
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cdc3.93
1. GENERAL INFORMATION
Location: Houston, Harris County
Number of Employees: 90
Industry: Metal Parts Fabrication
Waste Reduced: Wastewater
Process: Recovery
Contact Person: Gary Edwards, (713) 452-6429 ext. 205
2. DESCRIPTION OF PROJECT
CDC Coatings/Dickson Weatherproof Nail Co.
manufactures specialty nails and various metal fasteners. A proprietary
galvanizing process or special paint coatings are added to their products to
provide corrosion protection. These special paints and galvanizing materials
used in their process end up in the wastewater as a result of cleaning
operations. These materials are removed by their wastewater treatment system
prior to discharge.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The wastewater treatment system experienced
difficulty with the settling process during peak production loads. When the
system had problems during peak loads, it was necessary to backwash the filters
more frequently, which requires additional water to be treated. In an effort to
conserve the amount of water being treated, a wastewater recirculation system
was installed on a large receiver to improve the wastewater treatment operation.
4. ENVIRONMENTAL BENEFIT
In the past it was difficult to stay under the
permit limits for daily maximum flow for the treatment system. The added
recirculation system improved the efficiency and reduced the flow through the
system to the point where it is no longer difficult to stay in compliance. As a
result of improved operation, the daily water usage has been reduced 60 % .
5. COST SAVINGS/BENEFIT
The wastewater recirculation system cost less
than $10,000 to install and saved over $156,000 in treatment cost the first
year. The payback period was less than 17 days.
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cmi2.94
1. GENERAL INFORMATION
Location: Nuevo Laredo, Mexico
Number of Employees: 800
Industry: Engine Manifolds
Waste Reduced: Wastewater
Process: Ultrafiltration
2. DESCRIPTION OF PROJECT
CMI produces oily waste water from its cutting
and cleaning operations. The wastewater was sent to Texas for deep well
injection. To eliminate this costly procedure, CMI installed an ultrafiltration
unit to separate the oil and water. After separation, the water can be
discharged and meets regulatory limits for grease and oil. The oil is sent for
energy recovery. CMI is in the process of purchasing an additional reverse
osmosis unit that will produce water clean enough to reuse for cleaning.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
CMI was disposing of approximately 3,000
gallons of oily wastewater per day into deep well injection prior to the
installation of the ultrafiltration unit.
5. COST SAVINGS
CMI is saving over $3,000 a day from reduced
disposal costs. The payback period on the ultrafiltration unit was 4 months.
With other improvements to reduce generation of oily wastewater now on-line, CMI
is still saving over $62,000 a month.
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dupont9.92
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: La Porte, Harris County
Number of Employees: 1,070
Industry: Insecticide
Waste Reduced: VOC Emissions, Methylene Chloride
Process: Stripping
Contact: R. K. Barger, (713) 470-3027
2. DESCRIPTION OF PROJECT
A new wastewater stripping facility was
started up in September 1991 at the du Pont La Porte site. This stripper system
collects process wastewater from an insecticide manufacturing process in tanks
rather than in a pond and removes the volatile organic compounds to ppm levels.
In this facility, all the wastewater streams
containing volatile organics are collected in two large feed tanks and steam
stripped to remove the volatile organics. The stripped organics are burned in an
existing scrubbed incinerator and the volatile-free wastewater is treated in the
plant's biotreatment facilities.
With this system, the amount of volatile
organics being discharged to the air from the wastewater handling facilities is
greatly reduced. The compound of special importance is methylene chloride, a
potential carcinogen.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
Since starting up this unit our TRI reported
air emissions of methylene chloride from the site has been reduced from over
475,000 pound to less than 47,000 pounds.
5. COST SAVINGS/BENEFIT
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dupont2.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: La Porte
Number of Employees: 1,100
Industry: Agricultural Chemicals
Waste Reduced: VOC Emissions
Process: Wastewater Treatment, Stripping
Contact Person: Linda Stegeman, (713) 470-3753
2. DESCRIPTION OF PROJECT
Stripping, which effectively removes VOC's from wastewater is
being used to remove organics (mostly dichloromethane) from a 30-50 gpm
wastewater stream. The stripped organics are treated in our RCRA permitted
incinerator and the remaining wastewater is treated in our NPDES permitted
biotreatment system after testing for organic content. The facility consists of
two pretreatment storage tanks, a stean stripper and two post treatment storage
tanks.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
Since starting up this unit our TRI reported air emissions of
dichloromethane from the site have been reduced from over 475,000 pounds to less
than 84,000 pounds.
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dupontl 1.92
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Orange, Orange County
Number of Employees: 2,000
Industry: Ethylene Production
Waste Reduced: Oil
Process: API Separator
Contact Person: Bich Tran, (409) 886-9227
2. DESCRIPTION OF PROJECT
In the ethylene plant, there are many oily
water waste sources connected to a concrete "API oil/water separator".
These sources include heavy by-products removed from the cracked gas quench
tower, blowdowns from the amine and caustic columns and miscellaneous equipment,
drainage from curbed areas and water decanted from aromatic distillate storage
tanks. In the API separator, most of the oil overflows into a chamber and is
recovered as heavy aromatic distillate product. The water, along with soluble
organics, solids and some oil, underflows to a second chamber. Prior to 1988,
this water was pumped to a settling basin where the water and soluble organics
underflowed to a biopond. Floating oil and solids were removed for costly off
site waste disposal. Nuisance odors were experienced at the basin, and also at
the atmospheric vented API separator because of evaporation of volatile organics
(including benzene).
To reduce waste disposal cost, improved
recovery of oil and solids from the oily water stream was needed prior to
sending the stream to the basin. To accomplish this, a $1 MM capital project was
approved for installation of the following in mid 1988:
* Facilities to combine blowdowns of the amine and caustic
system and allow
neutralization of this stream prior to discharge to the API
separator. C02 is used to
reduce the pH of the caustic rich stream with the help of a pH
control loop. This
improved oil separation in the API separator and provided
adequate pH control of the
water stream exit the separator. Sulfuric acid was considered
as an alternate
neutralizing agent but was ruled out because sulfates degrade
to hydrogen sulfide in
the biopond.
* A dissolved gas flotation (DGF) unit to improve oil
separation of the wastewater
exiting the API separator. The DGF unit uses nitrogen for oil
and solids removal.
This unit consists of a flocculator, flotation cells with
corrugated plates pack, and
high pressure nitrogen saturation system. Water from the API
separator is first
routed to the flocculator which is designed for 45 seconds
retention time under mild
turbulent conditions. In this section, oil and solids
particles flocculate and grow
under gentle agitation. The water then enters a mixing loop
where high pressure
34
nitrogen saturated water is injected. Because
of lower pressure in the mixing loop, the nitrogen is released to form small
bubbles. The water stream then enter the flotation cell where nitrogen bubbles
float to the surface carrying the floc particles of oil and solids with it.
Diagonal corrugated plates provide surface area to improve nitrogen/floc
contact. Floating oil and solids are skimmed off from the top of the water.
Clean water exits the bottom of the DGF cell and is pumped to the settling
basin.
In addition, to reduce atmospheric venting of
benzene and personnel exposure to it, a new vent system was installed on the API
separator at the cost of $70M. This system utilizes a steam ejector to evacuate
vapor in the separator thus creating a slight negative pressure in it and
prevent benzene leaks to atmosphere. Discharge of the steam ejector is routed to
a gas fired steam superheater where the vapor is burned off. To prevent
flashback into the separator, the ejector steam rate was designed to provide a
minimum velocity three times higher than the flame propagation rate, along with
installation of flame arrestor and associated controls.
4. ENVIRONMENTAL BENEFIT
Operation of the DGF allows reduction of over
2MM lb/yr of oily water waste that would otherwise have to be disposed of
off-site. Furthermore, it prepares the waste water stream for further recovery
of benzene utilizing the steam stripping process. The new vent system on the API
separator reduced approximately 8 M lb/yr of organic vapor, including 4M lb/yr
benzene, vented to atmosphere.
5. COST SAVINGS/BENEFIT
After start up of the DGF project, waste
disposal cost associated with the oily water settling basin dropped
significantly. Although this $1 MM project was justified as environmental
necessity project, gross savings on disposal cost was realized at $1.1MM per
year, much higher than expected.
TOP
dupont3.92
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Orange, Orange County
Number of Employees: 2,000
Industry: Ethylene Production
Waste Reduced: Wastewater, Ammonia
Process: Equipment Modification
Contact Person: John F. Griffith, (409) 886-6858
2. DESCRIPTION OF PROJECT
Waste aqueous liquid load was reduced by
25,000 pph by installing a larger calandria (reboiler) on an ammonia stripper
column.
In the original design of the column, 25%, of
the heat input was provided by direct steam injection into the base of the
column. The balance of the heat was head transfer through the calandria.
Installation of the larger calandria provided for all of the heat input through
the calandria which eliminated the direct steam injection. All of the condensate
that resulted from the direct steam injection became aqueous liquid waste that
had to be disposed of, thus elimination of the direct steam injection eliminated
the heat portion of the waste generated.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4 ENVIRONMENTAL BENEFIT
Reduction of 25,000 pph of aqueous liquid
waste that is currently disposed of in a deep well disposal system.
5. COST SAVINGS/BENEFIT
The project payback period was 10 years.
Future savings will be realized through
reduced investment when facilities are installed to dispose of the aqueous
liquid waste by methods other than deep well disposal.
TOP
Gca1.95
1. GENERAL INFORMATION
Location: Pasadena
Number of Employees: 35
Industry: Wastewater Treatment
Waste Reduced: Wastewater
Process: Reuse, Effluent
Contact Person: George Meriwether, (713) 472-5507
2. DESCRIPTION OF PROJECT
The Gulf Coast Authority is a publicly owned waste treatment
authority that operates several treatment facilities in the Houston area. The
Washburn tunnel facility recently constructed a new belt press station to
dewater sludge. The new facility reuses effluent water for belt press process
wash, foam control, primary sludge flow control and general plant wash down.
Reuse of this water significantly reduces the fresh water requirements of the
facility.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
Approximately 530 g.p.m. of plant effluent is used for the
belt press with the plant using approximately 800,000 gallons/day.
5. COST SAVINGS/BENEFITS
If this water supply had to be purchased at the rate of
$0.0021/gallon, the additional costs to GCA would have bee $613,000 per year.
The pumps and associated piping to distribute reuse water plant wide were a
small fraction of this amount.
TOP
gca2.95
1. GENERAL INFORMATION
Location: Pasadena
Number of Employees: 35
Industry: Wastewater Treatment
Waste Reduced: Energy Efficiency
Process: Continuous Monitoring
Contact Person: George Meriwether, (713) 472-5507
2. DESCRIPTION OF PROJECT
The Gulf Coast Authority is a publicly owned
waste treatment authority that operates several treatment facilities in the
Houston area. To control the electrical cost associated with running aerators,
the Washburn tunnel facility installed a continuous Dissolved Oxygen (D.O.)
monitoring system. By optimizing the D.O. concentration in the treatment tanks
and not continuously running aerators, significant energy savings were achieved.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
The reduced use of aerators not only saves the
energy (and the pollutants associated with electrical generation), but also
increases the length of service and decrease wastes generated as a result of
equipment maintenance.
5. COST SAVINGS/BENEFITS
In 1986, before this system was installed GCA
used 1.03 KWhr/# of BOD. In 1994 the rate was 0.86 KWhr/# of BOD. At the 1986
rate this would have cost GCA an additional $270,000 in utility expenditures.
TOP
godan.92
1. GENERAL INFORMATION
Location: Dallas, Dallas County
Number of Employees:
Industry: Transportation
Waste Reduced: Sludge, Heavy Metals
Process: Wastewater Treatment
Contact Person: M. H. Massey, (214) 637-6740
2. DESCRIPTION OF PROJECT
Wastewater pretreatment system: It is a system
for separating precipitated solids from a waste stream. The system consists of
primary units, which together remove the heavy metals from a wastewater system.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The wastewater is collected in the pH adjust
tank. When the tank reaches the permissive level, process pumps feed water from
the adjust tank through the cells. Ferrous ion is added in the cells. The stream
leaving the cell is now essentially a water solution containing metal
hydroxides, which can be precipitated from the water. The water is then passed
to a retention tank were the solids from the high zinc influent are removed.
Polymer is added to overflow from the degassing tank and enters the flash mixing
chamber of the Clarifier. From the flash mixing chamber it passes to the
flocculating chamber. The liquid flows out through the weir at the top of the
Clarifier and is discharged. The slurry transfer pump pulls the solids from the
cone of the Clarifier and pumps them to the slurry holding tank. When the slurry
holding tank is half full, the filter press system is activated. The slurry pump
pumps the solids through the filter press and a thick cake forms in the press.
The outflow water from the press is returned to the equalization tank. The
solids in the filter press are removed from the press and disposed of by EPA
standards.
4. ENVIRONMENTAL BENEFIT
After treatment, results from operating units
show heavy metal levels well within EPA specifications.
5. COST SAVINGS/BENEFIT
Purchase and installation cost: $200,000. Approximate annual
savings: $60,000.
TOP
hoechst2.95
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Bishop, Nueces County
Number of Employees: 1.050
Industry: Chemical/Plastics/Pharmaceuticals Manufacturer
Waste Reduced: Multi-Source Leachate (Hazardous)
Process: Landfill Dome
Contact Person: J. Garza, (512) 584-6000
2. DESCRIPTION OF PROJECT
When rain falls into an open hazardous waste
landfill, the rainwater percolates through the contents of the landfill cell and
is collected via collection headers in the bottom of the landfill. This
collected rainwater, also known as multi-source leachate, is classified by
environmental regulation as a hazardous waste, and must be managed as such.
Before installation of this project, all rainfall (approximately 4.5 million
gallons per year) that contacted the material in the Bishop's hazardous waste
landfill would be collected and sent to the facilities injection wells for
disposal.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
An air-inflated/supported structure (dome) was
installed over the Class IH landfill at the Bishop facility to prevent rainfall
into and rainwater percolation through the landfill cells. The 85ft. high dome,
manufactured by Air Structures American Technologies, Inc. (ASATI), is made of
265,000 square feet of vinyl covered high tensile strength polyester fabric and
is inflated by air blowers. The air inside is exchanged and replaced every two
hours to facilitate work performed by personnel and equipment inside the dome.
When the landfill is full, the dome can be deflated and moved to another
location.
4. ENVIRONMENTAL BENEFIT
Installation of this dome prevents rainfall
into and rainwater percolation through the landfill cells, thereby eliminating
an estimated 4.5 million gallons of hazardous waste generation. This project
also extends the life of the landfill by more than 30% since the need for daily
capping with wind dispersion material was eliminated upon installation of the
dome.
5. COST SAVINGS/BENEFITS
Operating costs avoided by not having to
dispose of this leachate in the facilities injection wells are estimated at
$60,000 per year.
TOP
hoechst2.95
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Bishop, Nueces County
Number of Employees: 1.050
Industry: Chemical/Plastics/Pharmaceuticals Manufacturer
Waste Reduced: Multi-Source Leachate (Hazardous)
Process: Landfill Dome
Contact Person: J. Garza, (512) 584-6000
2. DESCRIPTION OF PROJECT
When rain falls into an open hazardous waste
landfill, the rainwater percolates through the contents of the landfill cell and
is collected via collection headers in the bottom of the landfill. This
collected rainwater, also known as multi-source leachate, is classified by
environmental regulation as a hazardous waste, and must be managed as such.
Before installation of this project, all rainfall (approximately 4.5 million
gallons per year) that contacted the material in the Bishop's hazardous waste
landfill would be collected and sent to the facilities injection wells for
disposal.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
An air-inflated/supported structure (dome) was
installed over the Class IH landfill at the Bishop facility to prevent rainfall
into and rainwater percolation through the landfill cells. The 85ft. high dome,
manufactured by Air Structures American Technologies, Inc. (ASATI), is made of
265,000 square feet of vinyl covered high tensile strength polyester fabric and
is inflated by air blowers. The air inside is exchanged and replaced every two
hours to facilitate work performed by personnel and equipment inside the dome.
When the landfill is full, the dome can be deflated and moved to another
location.
4. ENVIRONMENTAL BENEFIT
Installation of this dome prevents rainfall
into and rainwater percolation through the landfill cells, thereby eliminating
an estimated 4.5 million gallons of hazardous waste generation. This project
also extends the life of the landfill by more than 30% since the need for daily
capping with wind dispersion material was eliminated upon installation of the
dome.
5. COST SAVINGS/BENEFITS
Operating costs avoided by not having to
dispose of this leachate in the facilities injection wells are estimated at
$60,000 per year.
TOP
1. GENERAL INFORMATION
Location: Port Neches
Number of Employees: 1,150
Industry: Petrochemicals
Waste Reduced: Wastewater
Process: Wastewater Treatment
Contact Person: Mike Peters, (409) 723-3351
2. DESCRIPTION OF PROJECT
Two aerobic digesters were constructed and put
in service in June, 1992 for stabilization and reduction of waste activated
sludge from our wastewater treatment facility. This process includes tankage,
aeration, piping, neutralization and mixing equipment. In the process waste
activated sludge is aerated for a period of 20 days, during which time the
microorganisms consume their own protoplasm to obtain energy for cell
maintenance. The majority of cell tissue is oxidized to carbon dioxide, water
and ammonia. The ammonia is oxidized to nitrate as the digestion proceeds.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
Odors associated with our waste activated
sludge have virtually been eliminated. In addition, the quantity of sludge being
disposed has been reduced by over 40% or 1.5 million pounds a year.
5. COSTS SAVINGS/BENEFIT
Since less sludge needs to be disposed, there
is a cost savings of approximately $350,000 per year. The payback period for
this project is about 6 years.
TOP
huntsma1.95
1. GENERAL INFORMATION
Location: Austin
Number of Employees: 225
Industry: Chemical R&D
Waste Reduced Organics in Wastewater
Process: Supercritical Water Oxidation
Contact Person: Dr. Richard Bennett, (512) 483-0934
2. DESCRIPTION OF PROJECT
Huntsman's research laboratory in Austin
generates several organic/water waste streams that were being transported
off-site for incineration. Huntsman decided to build the first Super Critical
Water Oxidation (SCWO) unit to handle it's waste. Eco Waste Technologies of
Austin was contracted to build a 5 g.p.m. unit at the Huntsman facility.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
This is the first commercial application of
SCOW. The 5 g.p.m. unit can handle 15-25% organics in water with almost complete
conversion (99.95% or higher) to C02 and water. The facility is permitted to
discharge water to a publicly owned treatment system, but actual effluent
samples from the system have met drinking water standards. Off gas is primarily
C02 and water vapor (and N2 from amines) with insignificant concentrations of NO
,X particulates, ozone and ammonia.
4. ENVIRONMENTAL BENEFIT
The Huntsman unit has capacity to treat about
2 million lbs./year of organic by-products from the research facility. The water
and gaseous effluent from the process is significantly cleaner than other
treatment systems, and it eliminates the potential hazards associated with
transporting the material off-site incineration.
5. COST SAVINGS/BENEFITS
The operating costs are projected to be less
than $0.20/gallon, once the unit is running at full capacity which will provide
significant waste disposal savings to Huntsman.
TOP
motor1.94
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Oak Hill Facility, Austin
Number of Employees: 3,500
Industry: Electronics
Waste Reduced: Wastewater, HF
Process: Wastewater Treatment
Contact Person: Curtis Wales, (512) 891-6197
2. DESCRIPTION OF PROJECT
One of the key process steps in all
semiconductor manufacturing is the etching of the wafer. Etching refers to the
process of removing materials in specified areas which leaves minute and
intricate patterns on the wafer thereby making a semiconductor. The chemical
predominately used in this industry for etching is Hydrofluoric Acid (HF). HF is
a very hazardous waste and requires a great deal of care to manage and dispose
of it property. In 1992 Motorola generated over 680 tons of HF waste which in
the past was disposed of by deep well injection. In June of 1992 the Motorola
Oak Hill facility installed a Fluoride Waste Treatment System on site to
completely neutralize this very hazardous stream. The treatment method for our
system is a one step chemical reaction of mixing the HF waste and Calcium
Hydroxide, or Lime as it is commonly known, together which neutralizes the acid
and balances the pH at the same time. It forms calcium fluoride, a stable, non
hazardous, and very harmless material.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
In 1993, Motorola expanded the FWTS to keep up
with increased HF usage. The expansion increased our neutralization time and
equipment efficiency by allowing us to filter one of our two reaction tanks
while we are doing a reaction in the other. It also has almost doubled our
capacity to treat HF waste.
4. ENVIRONMENTAL BENEFIT
The benefits for the Flouride Waste Treatment are:
1. The on site treatment system keeps this
very hazardous waste from traveling on our public highways to disposal sites in
different areas. It is completely contained in covered tanks and continuously
monitored for correct operation. All of these benefits represent an extensive
reduction of potential impact to human health and the environment.
2. The FWTS also represents a real waste
minimization effort which will account for a 46% reduction of Motorola's TOTAL
hazardous waste generation and a 99% reduction of our HF waste generation.
3. This sytem could be used industry wide for semiconductor
plants.
176
5. COST SAVINGS/BENEFIT
Motorola spent $378,00 for the initial unit and an additional
$160,000 on the expansion to keep up with increases in production. A cost
savings of over $24,000 for 1992 was determined by comparing the $0.44/gal cost
to deepwell with the $0.29/gal cost to operate the FWTS.
TOP
oxycc 1.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Corpus Christi, Nueces County
Number of Employees: 310
Industry: Chemicals. Organic
Waste Reduced: Waste Water, Copper
Process: Wastewater Treatment
Contact Person: Michael Mudrock, (512) 242-8098
2. PROJECT DESCRIPTION
In 1991, a copper discharge limitation was
added to the facility's wastewater permit. An initial analysis of the wastewater
showed the levels of copper present were much higher than permitted. OxyChem
determined that the plant water supplier (City of Corpus Christi) was dosing the
water with copper sulfate for algae control.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
OxyChem and the City of Corpus Christi Water
Department worked together over a period of more than eight months during 1992
to determine copper removal/alternative treatment methods and implement a
solution. Both parties contributed research efforts. Analytical services to
monitor copper releases at the City's treatment plant were provided by OxyChem.
Chlorine dioxide and potassium permanganate were identified and evaluated as
substitutes for the copper sulfate. In September 1992, the City of Corpus
Christi began utilizing the alternative algicide treatment in lieu of the copper
sulfate.
4. ENVIRONMENTAL BENEFIT
The substitution source reduced copper from
not only OxyChem's water but other industrial customers of the City of Corpus
Christi. Total copper releases to the environment were reduced.
5. COST SAVINGS/BENEFIT
OxyChem avoided the expense of designing,
installing and operating a water pretreatment facility for its process water. In
addition, the water for copper removal would have created additional solid
waste.
TOP
phillip1.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Sweeny
Number of Employees: 1,459
Industry: Petroleum Refining
Waste Reduced: Wastewater
Process: Wastewater Treatment
Contact Person: Dan Hunter, (409) 491-2200 ext 2216
2. DESCRIPTION OF PROJECT
Phillips Petroleum has constructed an
artificial marsh to study the removal of organic chemical waste, heavy metals
and toxicity. The test facility consists of two parallel channels of rooted and
floating aquatic vegetation with design treatment capacities ranging from 20,000
gpd to 100,000 gpd. Cattails and bulrush are contained in one of the channels.
The other was planted with duckweed and torpedo grass. However, the torpedo
grass was overtaken by the adjacent cattails, and our attempt at growing
duckweed was unsuccessful. Additional floating aquatic plants are still being
researched, while testing continues on the channels containing rooted aquatic
plants.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The purpose of this project is to evaluate the
potential of various aquatic plants for treating organic chemical wastewater.
Taking advantage of this new technology could result in cleaner discharge at a
lower cost than the traditional wastewater treatment facility. Biotech
Industries and Dr. B.C. Wolverton of Wolverton Environmental Services are
providing scientific and engineering design services.
4. ENVIRONMENTAL BENEFIT
Phillips has found that the pilot artificial
marsh is capable of reducing BOD by 61 % and NH3-N by 32%. Test results also
show reductions in the concentration of oil, suspended solids and chromium.
Detected increases in phenol may indicate the breakdown of certain aromatic
compounds. Significant reductions in toxicity measured with a microtox are also
consistently observed.
5. COST SAVINGS/BENEFIT
An artificial marsh requires less energy and
is less costly to operate than traditional mechanical treatment systems.
TOP
rhonep11.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Houston, Harris County
Number of Employees: 189
Industry: Chemicals, Inorganic
Waste Reduced: Wastewater, Copper
Process: Wastewater Treatment, Sulfide Precipetation
Contact Person: George Ramsay, (713) 928-3411 ext. 1485
2. DESCRIPTION OF THE PROJECT
Last year the limit for copper in our NPDES
effluent was reduced from a daily average of 0.83 Ib/day to 0.11 lb/day. The
daily maximum was reduced from 1.37 lb/day to 0.11 lb/day. The concentration of
copper in the discharge now could not exceed 10 to 15 ppb, depending on the
flowrate. Much of the copper in the effluent comes from corrosion of copper
alloy heat exchangers, even though the corrosion is low (0.1 mils per year). The
copper in the effluent was being removed by hydroxide precipitation in settling
ponds.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Sulfide-based precipitation was selected for
removing the copper. Retubing with stainless steel would be very expensive and
would reduce the heat transfer of the heat exchangers. Hydroxide precipitation
could not reduce the copper to less than about 20 ppb.
Sodium sulfide and dithiocarbamate were ruled
out because of their known toxicity to our biomonitoring species M,, sepsis
bahia (grass shrimp). Dithiocarbamate attached to insoluble starch was
non-toxic to the shrimp in laboratory tests but seemed to decompose to toxic
compounds in the ponds, possibly due to sun light. Trisodium
trimercapto-triazine was non-toxic in field tests but at times was difficult to
flocculate. A proprietary sulfide-based precipitant called MR-3300 was found to
be non-toxic and reduces the copper to 1 to 10 ppb. By using filtration in
addition to clarification lower copper concentrations are expected. The MR-3300
is sold by Southern Water Treatment, located in Greenville, South Carolina.
4. ENVIRONMENTAL BENEFIT
Reducing the copper in our effluent is
expected to improve the environmental quality of the Galveston Bay.
5. COST SAVINGS/BENEFIT
Meeting the new copper limit increases our
costs by $50,000 to $60,000 per year.
TOP
motor1.94
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Oak Hill Facility, Austin
Number of Employees: 3,500
Industry: Electronics
Waste Reduced: Wastewater, HF
Process: Wastewater Treatment
Contact Person: Curtis Wales, (512) 891-6197
2. DESCRIPTION OF PROJECT
One of the key process steps in all
semiconductor manufacturing is the etching of the wafer. Etching refers to the
process of removing materials in specified areas which leaves minute and
intricate patterns on the wafer thereby making a semiconductor. The chemical
predominately used in this industry for etching is Hydrofluoric Acid (HF). HF is
a very hazardous waste and requires a great deal of care to manage and dispose
of it property. In 1992 Motorola generated over 680 tons of HF waste which in
the past was disposed of by deep well injection. In June of 1992 the Motorola
Oak Hill facility installed a Fluoride Waste Treatment System on site to
completely neutralize this very hazardous stream. The treatment method for our
system is a one step chemical reaction of mixing the HF waste and Calcium
Hydroxide, or Lime as it is commonly known, together which neutralizes the acid
and balances the pH at the same time. It forms calcium fluoride, a stable, non
hazardous, and very harmless material.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
In 1993, Motorola expanded the FWTS to keep up
with increased HF usage. The expansion increased our neutralization time and
equipment efficiency by allowing us to filter one of our two reaction tanks
while we are doing a reaction in the other. It also has almost doubled our
capacity to treat HF waste.
4. ENVIRONMENTAL BENEFIT
The benefits for the Flouride Waste Treatment are:
1. The on site treatment system keeps this
very hazardous waste from traveling on our public highways to disposal sites in
different areas. It is completely contained in covered tanks and continuously
monitored for correct operation. All of these benefits represent an extensive
reduction of potential impact to human health and the environment.
2. The FWTS also represents a real waste
minimization effort which will account for a 46% reduction of Motorola's TOTAL
hazardous waste generation and a 99% reduction of our HF waste generation.
3. This sytem could be used industry wide for semiconductor
plants.
176
5. COST SAVINGS/BENEFIT
Motorola spent $378,00 for the initial unit and an additional
$160,000 on the expansion to keep up with increases in production. A cost
savings of over $24,000 for 1992 was determined by comparing the $0.44/gal cost
to deepwell with the $0.29/gal cost to operate the FWTS.
TOP
Oxy
Petrochemicals, Inc. -Copper
oxycc 1.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Corpus Christi, Nueces County
Number of Employees: 310
Industry: Chemicals. Organic
Waste Reduced: Waste Water, Copper
Process: Wastewater Treatment
Contact Person: Michael Mudrock, (512) 242-8098
2. PROJECT DESCRIPTION
In 1991, a copper discharge limitation was
added to the facility's wastewater permit. An initial analysis of the wastewater
showed the levels of copper present were much higher than permitted. OxyChem
determined that the plant water supplier (City of Corpus Christi) was dosing the
water with copper sulfate for algae control.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
OxyChem and the City of Corpus Christi Water
Department worked together over a period of more than eight months during 1992
to determine copper removal/alternative treatment methods and implement a
solution. Both parties contributed research efforts. Analytical services to
monitor copper releases at the City's treatment plant were provided by OxyChem.
Chlorine dioxide and potassium permanganate were identified and evaluated as
substitutes for the copper sulfate. In September 1992, the City of Corpus
Christi began utilizing the alternative algicide treatment in lieu of the copper
sulfate.
4. ENVIRONMENTAL BENEFIT
The substitution source reduced copper from
not only OxyChem's water but other industrial customers of the City of Corpus
Christi. Total copper releases to the environment were reduced.
5. COST SAVINGS/BENEFIT
OxyChem avoided the expense of designing,
installing and operating a water pretreatment facility for its process water. In
addition, the water for copper removal would have created additional solid
waste.
TOP
phillip1.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Sweeny
Number of Employees: 1,459
Industry: Petroleum Refining
Waste Reduced: Wastewater
Process: Wastewater Treatment
Contact Person: Dan Hunter, (409) 491-2200 ext 2216
2. DESCRIPTION OF PROJECT
Phillips Petroleum has constructed an
artificial marsh to study the removal of organic chemical waste, heavy metals
and toxicity. The test facility consists of two parallel channels of rooted and
floating aquatic vegetation with design treatment capacities ranging from 20,000
gpd to 100,000 gpd. Cattails and bulrush are contained in one of the channels.
The other was planted with duckweed and torpedo grass. However, the torpedo
grass was overtaken by the adjacent cattails, and our attempt at growing
duckweed was unsuccessful. Additional floating aquatic plants are still being
researched, while testing continues on the channels containing rooted aquatic
plants.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The purpose of this project is to evaluate the
potential of various aquatic plants for treating organic chemical wastewater.
Taking advantage of this new technology could result in cleaner discharge at a
lower cost than the traditional wastewater treatment facility. Biotech
Industries and Dr. B.C. Wolverton of Wolverton Environmental Services are
providing scientific and engineering design services.
4. ENVIRONMENTAL BENEFIT
Phillips has found that the pilot artificial
marsh is capable of reducing BOD by 61 % and NH3-N by 32%. Test results also
show reductions in the concentration of oil, suspended solids and chromium.
Detected increases in phenol may indicate the breakdown of certain aromatic
compounds. Significant reductions in toxicity measured with a microtox are also
consistently observed.
5. COST SAVINGS/BENEFIT
An artificial marsh requires less energy and
is less costly to operate than traditional mechanical treatment systems.
TOP
rhonep11.93
1. GENERAL INFORMATION CLEAN
INDUSTRIES 2000 Member
Location: Houston, Harris County
Number of Employees: 189
Industry: Chemicals, Inorganic
Waste Reduced: Wastewater, Copper
Process: Wastewater Treatment, Sulfide Precipetation
Contact Person: George Ramsay, (713) 928-3411 ext. 1485
2. DESCRIPTION OF THE PROJECT
Last year the limit for copper in our NPDES
effluent was reduced from a daily average of 0.83 Ib/day to 0.11 lb/day. The
daily maximum was reduced from 1.37 lb/day to 0.11 lb/day. The concentration of
copper in the discharge now could not exceed 10 to 15 ppb, depending on the
flowrate. Much of the copper in the effluent comes from corrosion of copper
alloy heat exchangers, even though the corrosion is low (0.1 mils per year). The
copper in the effluent was being removed by hydroxide precipitation in settling
ponds.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Sulfide-based precipitation was selected for
removing the copper. Retubing with stainless steel would be very expensive and
would reduce the heat transfer of the heat exchangers. Hydroxide precipitation
could not reduce the copper to less than about 20 ppb.
Sodium sulfide and dithiocarbamate were ruled
out because of their known toxicity to our biomonitoring species M,, sepsis
bahia (grass shrimp). Dithiocarbamate attached to insoluble starch was
non-toxic to the shrimp in laboratory tests but seemed to decompose to toxic
compounds in the ponds, possibly due to sun light. Trisodium
trimercapto-triazine was non-toxic in field tests but at times was difficult to
flocculate. A proprietary sulfide-based precipitant called MR-3300 was found to
be non-toxic and reduces the copper to 1 to 10 ppb. By using filtration in
addition to clarification lower copper concentrations are expected. The MR-3300
is sold by Southern Water Treatment, located in Greenville, South Carolina.
4. ENVIRONMENTAL BENEFIT
Reducing the copper in our effluent is
expected to improve the environmental quality of the Galveston Bay.
5. COST SAVINGS/BENEFIT
Meeting the new copper limit increases our
costs by $50,000 to $60,000 per year.
TOP
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