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Wastewater Case Studies 2
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Case Studies: Wastewater 2Alenco
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Effluent from Production area |
Effluent from irrigation Pond |
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BOD |
600 mg/1 |
Less than 10 mg/l |
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COD |
1200 mg/1 |
Less than 200 mg/1 |
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TSS |
600 mg/1 |
Less than 25 mg/1 |
5. COST SAVINGS/BENEFIT
Considering all the factors involved with a completely. segregated water system (independent from municipal wastewater treatment systems) IGP enjoys cost savings in various areas throughout our operation.
One example is IGP's cost per thousand gallons of water. This cost is considerably lower than water purchased from El Paso Water Utilities by about one dollar per thousand. This lower cost includes sewer charges and sewer surcharges which are regularly dealt with by other laundries in El Paso.
In short, rather than purchasing, utilizing, and disposing of perfectly good drinking water down the sewer, IGP is putting non-potable "brackish" water to conscientious use. This brackish water is used to wash blue jeans, treated, then used to irrigate cash crops like alfalfa that return some monies into system. The cost benefit we enjoy are in one way assisting municipal treatment plants by keeping tax rates, water rates, sewer rates, and operating costs down.
Last but not least, can you allocate a cost value to protecting the environment? Our answer would be no! Therefore IGP's commitment towards protecting our valuable water resources, no matter what the cost, will benefit the City of El Paso, the State of Texas, and the whole United States by saving millions of gallons of precious drinking water per week.
ipaper4.95
1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member
Location: Texarkana
Number of Employees: 1,050
Industry: Paper and Paperboard Manufacturing
Waste Reduced: Paper by-products
Process: Recycling
Contact Person: Ken Howorth, (903) 796-1412
2. DESCRIPTION OF PROJECT
International Paper - Texarkana Mill began a cooperative with the Cass County Resource Recovery Facility (CCRRF). To be successful in recycling, CCRRF was in need of a consumer for its fuel pellets made from fiber-based waste materials. The mill realized several advantages to becoming a consumer for fiber-based fuel. Much of the paper produced at the mill is coated with polyethylene. The coating makes the paper difficult to recycle by conventional means. A program was launched to send the coated paper to the CCRRF to be used in the production of a fiber-based fuel. The mill would in turn purchase the fiber-based fuel for their production processes.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The most innovative aspect of the project is the cooperative effort between the Texarkana mill and the Cass County Resource Recovery Facility. Poly-coated paper has previously been difficult to recycle. Pelletizing the paper by-product into a useable product provides energy, reduces landfilling of solid waste, and protects air quality.
4. ENVIRONMENTAL BENEFIT
The project keeps solid waste out of the mill's on-site landfill, approximately 22,000 cubic yards per year. The recycling efforts of the Cass County Resource Recovery Facility reduce solid waste at the regional landfill. Air quality increases by providing the mill with a cleaner burning, renewable fuel source. Burning fiber-based fuels when compared with fossil fuels results in air emission reductions of 21 percent sulfur dioxide, 10-20 percent carbon monoxide, and 67.7 percent nitrogen oxide.
5. COST SAVINGS/BENEFITS
The cost to the mill is essentially zero, CCRRF supplies dumpsters and transportation. The purchase price of pellets is slightly higher when compared to bark, but the mill is expected to break even. The reduction in onsite landfill results in a savings of $220,000 per year.
jonesb1.94
1. GENERAL INFORMATION
Location: Dallas
Number of Employees: 250
Industry: Coatings
Waste Reduced: Wastewater
Process: Water Reuse, Painting
Contact Person: Carlos E. Dorris, (214) 353-1660
2. DESCRIPTION OF PROJECT
Jones Blair has achieved zero discharge of wastewater from its facility of 12 plus acres with a Paint Plant, Resin Plant and Powder Coating unit on site. Jones Blair employees are the key to its success in pollution prevention. They are involved in every step the company takes. The company meets monthly with them in Resin SPC, Paint SPC, Powder Coating SPC, Waste Reduction and Rework committee meetings.
This success has not been without lots of dead ends, but the employees never lose sight of the company's goal (zero discharge). The water treatment plant is designed to treat 5,000 gallons of waste water. Jones Blair reuses and recycles water first; the water treatment plant is the last step. Storm-water is also treated and reused. The presense of the Resin Plant makes any rain water hazardous and must be pretreated before discharge. Instead of discharge the company treat and reuses/recycles the water. Its new hot water latex tank washer has eliminated spoiled batches caused by bacterial contamination.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
No process water or storm water is discharged. All water is recycled and reused.
Cost savings include $17,000/yr. in regulatory fees, $17,500/yr. from reduced water use in cooling towers, and $12,000/yr. in disposal costs.
kelly1.94
1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member
Location: San Antonio
Number of employees: 13,000
Industry: Metal Fabrication
Waste Reduced: Wastewater, Chromate
Process: Chemical Substitution, Aluminum Anodizing
Contact person: Greg Vallery, (210) 925-3100
2. DESCRIPTION OF PROJECT
Kelly AFB Aircraft Directorate has an anodize process located at the bonding shop anodize line in Bldg. 375. This process uses a chromated deoxidizer. Chromium can exist as either trivalent or hexavalent chromium. Hexavalent chromium is a carcinogen and causes a wide range of systemic effects on humans. Chromium causes adverse acute and chronic effects in aquatic organisms. EPA lists chromium as a hazardous waste due to its toxicity characteristic (EPA Waste Code D007) at a concentration of 5 ppm. This project is designed to reduce the use of Chromium which is an EPA 17 ITP chemical by chemical substitution.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The chromated deoxidizer was replaced with a Boeing patented Phosphoric Acid Deoxidizer (PAD).
4. ENVIRONMENTAL BENEFIT
This project eliminated approximately 1,000 pounds/year of sodium dichromate, an EPA 17 ITP chemical, reducing the chromium load on the base Industrial Waste Treatment Plant.
Cost savings on materials alone is approximately $1,100/yr.
kelly3.94
1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member
Location: San Antonio
Number of employees: 13,000
Industry: Metal Fabrification
Waste Reduced: Wastewater, Cyanide Stripper
Process: Equipment Modification, Metal Stripping
Contact person: Dave Leeson, (210) 925-3100
2. DESCRIPTION OF PROJECT
Large amounts of cyanide solutions were used in metal refinishing operations. These included solutions to strip plate metals and other surface coatings form aircraft parts (strippers), to clean and remove smut from parts in preparation for electroplating (cleaners), and to electroplate metals onto parts (plating solutions).
Cyanide strippers have been used commercially to strip a large variety of plate metals and other surface coatings from a number of metallic and nonmetallic substrates. Cleaning solutions use cyanide for the removal of rust, scale, and smut. They become saturated with metals and other contaminants until no longer effective and require replacements. The project involved a material change (chemical substitution).
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The replacement of all cyanide metal strippers with non-cyanide metal strippers has been implemented for nickel and silver strippers (Metalx B-9 nickel stripper and Rosstrip 999-sp electrolytic silver stripper and Clepo 204 metal stripper).
4. ENVIRONMENTAL BENEFIT
This material change reduced the use of Cyanide which is an EPA 17 ITP chemical. Cyanide rinse waters also pose a serious health threat to workers and the environment. By eliminating cyanide strippers, Kelly AFB reduced the amount and toxicity level of its hazardous waste stream.
This project has an economic savings of approximately $100,000/yr in disposal costs alone.
Lone Star Radiator Company, Inc.
lonestar.95
1. GENERAL INFORMATION 1995 Governor's Award
Location: San Antonio
Number of Employees: 12
Industry: Radiator Repair
Waste Reduced: Wastewater, Metals
Process: Water Reuse
Contact Person: David Bippert (210) 732-7558
2. DESCRIPTION OF PROJECT
Water from from our operations contains heavy metals that make the water hazardous. This can no longer be discharged to the city's sanitary sewer and there are few waste haulers able to handle the waste (and it is expensive to have them haul it off).
3. INNOVATIVE APPLICATION OF TECHNOLOGY
Lone Star located a system produced by E/CAR Environmental that utilizes chemical treatment to remove oil products and heavy metals. The heavy metals and other solids drop out of the solution as a sludge and the water can be reused for general cleaning in the shop. The sludge is dried and shipped to a certified recycler (Concorde-Houston) who reclaims the metals. Likewise, the petroleum products are sent to a recycler.
4. ENVIRONMENTAL BENEFIT
This closed loop process eliminated the disposal of hazardous wastewater and reduced water needs by 36,000 gallons a month. Lone Star was the first radiator shop in San Antonio to install this closed loop system.
5. COST SAVINGS/BENEFITS
The entire system cost about $40,000. To dispose of 36,000 gallons of hazardous waste a month would have cost well over $100,000 each month.
murdock 1.92
1. GENERAL INFORMATION
Location: Irving, Dallas County
Number of Employees: 212
Industry: Metal Fabrication
Waste Reduced: Wastewater, Hexavalent Chromium
Process: Recovery, Electroplating
2. DESCRIPTION OF PROJECT
A Hexavalent Chromium Regeneration Unit (HCRU) has been developed and installed on Murdock's sulfuric acid-sodium bichromate deoxidizer process tank which oxidizes trivalent chromium to the hexavalent state and removes extraneous cationic metal contaminants without interfering with production. The HCRU is applicable for eliminating waste streams commonly generated from solutions containing hexavalent chromium in etchants, plating solutions, deoxidizers, anodizing solutions, chem film, and similar processes.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The HCRU utilizes electrodialysis technology whereby an anode cell is fitted on either side with a cationic selective membrane that has an anode suspended inside. The cell is suspended into a tank of catholite solution with a cathode suspended on either side of the anode cell adjacent to the membrane window. The process solution (anolite) is pumped to the bottom of the cell and gravity flows from the top of the cell back to the process tank. As the anolite rises through the cell, a current flow between the electrode plates oxidizes trivalent chromium to the hexavalent state and attracts cationic metal contaminants through the membrane into the catholite solution; thus, the process solution is maintained at a comparable fresh bath state.
The HCRU can be operated intermittently or continuously as needed to maintain solution integrity. It is free standing and is located so as not to interfere with production. All parts are commercially available for ease of servicing.
4. ENVIRONMENTAL BENEFIT
The environmental impact from use of the HCRU is very significant in that the process solution is never depleted due to normal process contaminants.
Specific benefits are:
* Oxidizes trivalent chromium to the hexavalent state
* Extracts dissolved metal contaminants from the process solution
* Maintains consistency of process solution resulting in uniform processing
* Lowers solution viscosity which reduces rinsewater dragout contamination
* Eliminates downtime due to spent solution change out
* Eliminates fresh bath make-up chemical cost
* Eliminates the ever increasing cost of hazardous waste disposal and associated
liabilities
Cost savings associated with use of the HCRU will vary depending on chemical
composition, type and quantity of materials processed, and the volume of process solution.
Typical Performance on Deoxidizer Solution (1988 Data)
* Solution: Sulfuric Acid 37.6-39.3 oz/gal Sodium Bichromate 4.1-5.0 oz/gal
* Temperature: 155-160'F
* Tank Volume: 1870
*Trivalent Chromium: 1.9 percent by weight maximum
Cr+6 Cr+3 A1+3 REMARKS
HCRU Start Up 4 .22 Limit 1.1623 .748 Cr+6 Near low
HCRU Shut Down 4.963 .7519 .653 Cr+6 Near
high limit
Change (percent) +17.6 -35.3 -12.7 Run Time: 74 Hrs.
Cost: Approximately $3.79
Cost prior to HCRU installation: (Low production period)
Chemical Disposal: Approximately $ 9,000
Replacement Chemicals: 2,800
TOTAL $11,800 x an average of twice a year
Production Downtime: Two days
Hazardous Waste Liability: Forever
The HCRU was developed for Murdock's own need and use. After the system was tested and proven in a production environment, Murdock patented the device with the intention of producing HCRUs as a commercial product line.
txeast15.93
1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member
Location: Longview, Harrison County
Number of Employees: 2,700
Industry: Chemicals, Organic
Waste Reduced: Wastewater
Process: Drift Reduction, Cooling Towers
Contact Person: Glenn Phillips, (903) 237-5346
2. DESCRIPTION OF PROJECT
The ethylene glycol department has two cooling towers that cool and recirculate process water streams that contain about 8% ethylene glycol. As the air is pulled through the falling water a small percentage of water and ethylene glycol is released to the atmosphere. Besides being a loss of product, the emissions of ethylene glycol has to be reported.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The department formed a team to look at ways of reducing emissions. They found that new technology existed to reduce drift from cooling towers. The new design allows the drift to impinge on baffles and the droplets that are formed then drop back into the tower instead of going out over the tower. The total cost of the project was $55,000.
4. ENVIRONMENTAL BENEFIT
Ethylene glycol emissions were reduced by 72,000 pound per year with the new drift eliminators.
5. COST SAVINGS/BENEFIT
Sales of recovered ethylene glycol is about $18,000 a year.
txeast6.93
1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member
Location: Longview, Harrison County
Number of Employees: Approximately 2,700
Industry: Chemicals, Organic
Waste Reduced: Wastewater
Process: Water Recovery, Waste Oil Burning
Contact Person: Glenn Phillips, (903) 237-5346
2. DESCRIPTION OF PROJECT
Texas Eastman cracking plants mix large amounts of steam with feedstock before cracking it into ethylene and propylene. After the steam leaves the reactors it is condensed. Because the condensed water contained various oily materials it had to be treated. Utilities also had to purify the water coming into the facility before it could be used in the process. Both fresh water purification and wastewater treatment are expensive.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
A new process water recovery unit was constructed. The unit removes oily contaminant from the condensed water by a DOXTM coalescing unit supplied by Nalco, Inc.. The water is turned back into steam for continuous reuse in the cracking process. The oils from the recovery process are reused as a heat transfer oil and eventually sold as a product.
4. ENVIRONMENTAL BENEFIT
Wastewater treatment was no longer needed for 105 million gallons of wastewater per year. Also, since the oily contaminants are recovered, there is a reduction in VOC emissions by about 60,000 pounds a year.
Costs savings come from reduced treatment of fresh and waste water and from reduced fuel needs for the cracking unit.
62.93
1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member
Location: Sherman, Grayson County
Number of Employees:
Industry: Electronics
Waste Reduced: Wastewater Metals
Process: Wastewater Treatment, Reducing Chelating
Contact Person: Norm Carlson, (903) 868-5722
2. DESCRIPTION OF PROJECT
The project encompassed development and incorporation of a waste treatment process for alkaline soak cleaners used in our aluminum chemical finishing processes.
The chelating agents in our cleaners were tying up the heavy metals (in particular chromium, the major contaminant) in our waste chemical streams. This prevented complete precipitation of the chromium for proper filtration removal in our waste treatment facility.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
The old method of disposal was to have the cleaning solutions either drummed up or placed in a tank truck for off-site disposal. This was not desirable due to trucking/disposal costs and potential liabilities.
Another method of disposing of the solution was suggested by the manufacturer of the cleaning solution. This method involved breaking the chelating effect, thereby rendering the solution treatable through our existing waste treatment facility. The chelating effect was broken by adding calcium oxide (lime), mixing the treated solution for one hour, and finally adding the mixed solution to the waste treatment pH adjust tank at a controlled rate for treatment. While the calcium oxide (lime) treatment process was an alternative, there was the cost of additional process equipment (mixing tank, mixer, metering pump, etc.) and time involved.
Another alternative investigated was reducing the rate at which the cleaner was metered into the waste treatment process. While this did reduce the level of chromium in the effluent, the levels exhibited with practical cleaner flow rates still did not provide chrome levels below 1 ppm (total chrome), as desired.
One final study was initiated. This involved the possible use of nucleation agents to improve the precipitation process. Some of the possible nucleating agents were coprecipitated metals such as copper, nickel, zinc, iron, calcium, aluminum or cationic polymers. Looking for a
naturally occurring source of one of the above metals, the concept for possible use of aluminum, which builds up in our alkaline etch solution was researched.
A 50/50 mix of the waste soak cleaners and alkaline etch solutions, when added at low percentages by volume of reduced chrome solution, provided satisfactory chrome levels in the waste treatment process effluent. This was, in part, due to the dissolved aluminum in the alkaline etch acting as a nucleating agent for more effective precipitation of heavy metals, while reducing the effects of the chelating agents in the cleaners.
4. ENVIRONMENTAL BENEFIT
This use of waste alkaline etch solutions provided an innovative means for improved inhouse treatment of alkaline soak cleaners, thereby eliminating the costs and liabilities of having to transport these waste solutions (some 1600 gallons/year) off-site for disposal.
5. COST SAVINGS/BENEFIT
This process saved some $2300/year in trucking/disposal costs per tank, while being a process which was accomplished without the cost of additional equipment and processing time.
Witco, Inc.: Project 1
witco1.94
1. GENERAL INFORMATION
Location: Marshall
Number of Employees: 60
Industry: Chemicals, Organic
Waste Reduced: Wastewater
Process: Equipment Modifications, Cooling Towers
Contact Person: Bill Childers, (903) 938-5141
2. DESCRIPTION OF PROJECT
Witco installed two automatic chemical controls for blowdown on cooling towers. The system maintains a set conductivity for the water in the tower. It saves water (and chemical additives) over periodically adding fresh water on a timed bases.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
The system has reduced the quantity of blowdown water and chemical additive use by 50%. Approximately 720,000 gallons of water is saved per year.
The two units purchased cost $2,000 each for a total of $4,000. At $0.001/gallon, water use savings amounted to $720 annually. More significantly, chemical additives were reduced saving $3,300 annually. Wastewater disposal costs for clean cooling tower water runs about $0.025/gallon, for a savings of $18,000.
Witco, Inc. Project 2
witco2.94
1. GENERAL INFORMATION
Location: Marshall
Number of Employees: 60
Industry: Chemicals, Organic
Waste Reduced: Wastewater
Process: Equipment Modifications, Tank Cleaning
Contact Person: Bill Childers, (903)938-5141
2. DESCRIPTION OF PROJECT
Process equipment is frequently washed down when switching products. Using the old procedure, the equipment was filled with water, agitated and dropped to waste. Special spray nozzles (designed for cleaning tank cars) were installed to reduce the amount of water needed to clean this equipment.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
The use of the spray heads resulted in reducing water use and disposal of 100,000 gallons a year.
A total of 4 spray heads were purchased at $40 each, for a total cost of $160. Water costs are $0.001/gallon for an annual savings of $100. More significantly, deep well injection of wastewater costs about $0.05/gallon, for an annual savings of $5,000.
Witco, Inc. Project 3
witco I .95
1. GENERAL INFORMATION
Location: Marshall
Number of Employees: 60
Industry: Organic Peroxides
Waste Reduced: Process Cooling Water
Process: Interupt Spray
Contact Person: Bill Childers, (903) 938-5141
2. DESCRIPTION OF PROJECT
Witco produces organic peroxides and peroxyesters for the plastics and fiberglass industry. The product is washed with a KOH solution to remove impurities and separated in a centrifuge. A water mist system is used in the centrifuge to cool the system to prevent product decomposition. The separated water is hazardous for pH and organic content and is sent to deep well injection for disposal. By measuring cooling water use, temperature and product quality it was determined that the continuous water mist could be replaced by an interrupt system reducing water use significantly.
3. INNOVATIVE APPLICATION OF TECHNOLOGY
4. ENVIRONMENTAL BENEFIT
Reducing water use in the cooling system reduced the total quantity of hazardous waste water that was being generated by over 1 million gallons a year.
5. COST SAVINGS/BENEFIT
The interrupt system cost $5,000 to install, but saves Witco $26,000 a year in water use and disposal costs.