3m – prairie du chien 2013 shwec internship kara klubertanz
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3M – Prairie du Chien2013 SHWEC Internship
Kara Klubertanz
Outline•Sustainability Background (3P)•Project Objectives•Water Reduction
▫Process A▫Process B
•Discharge Investigation•Site Wide Water Management
Pollution Prevention Pays (3P)•Pollution Prevention Pays (3P) program in
1975. ▫Goal - eliminate or reduce sources of
pollution in 3M products and processes
•10,000 3p projects since 1975. ▫Prevented > 3.8 billion lbs of pollution ▫Saved > $1.7 billion in their first year.
Project Objectives•Assess water management for potential
reuse or reduction▫Noncontact and contact cooling water
Main focus Process A Process B
Water Reduction• Background
▫Two processes Process A
Extrudes resin to form very thin nylon or polyester fibers
Process B Extrudes resin to form vinyl
or Nylon/polyester webbing material
▫Significant opportunity to improve water management
Process A
Process A•Current water usage
▫Extruder 10 GPM
▫Quench Tanks 1 tank = 6 GPM All 8 tanks = 48 GPM Each tank vol.= 45 Gal.
▫Orient Tank Volume = 278 Gal.
Gal/yr Ft3/yr
Extruder 2,764,800 369,654
Quench Tanks
13,271,040
1,744,338
Orient Tank
26,688 3,568
Total 16,062,528
2,117,560
Process A•Suggestion
▫Reduce flow rate in Quench Tanks by 15%▫Decrease each Quench Tank volume by 1/3
Evaluate tank design
Process A •Water Reduced
▫2,003,136 gal/yr•CO2 Emission Reduction
▫6.016 Tons CO2/yr•Cost Savings
▫$10,867/yr
Process A•Potential future projects
▫Automatic valves▫Reuse Quench Tank discharge to supply
Orient Tank
Process B
Process B•Current water usage
▫Extruders 44 GPM
▫Quench Tank 6-12 GPM
Temperature dependent
435 gallon tank
Gal/yr Ft3/yr
Extruders 12,165,120
1,626,477
Quench Tank
1,658,880- 3,317,760
221,792- 443,585
Total 13,824,000-
15,482,880
1,848,269-2,070,062
Process B•Replace non-contact
cooling water with an Air Cooled Oil Cooler▫Cools oil in extruders
•Implement in 4.5” extruder
Process B – Heat Exchanger•Water Reduction
▫6,082,560 gal/yr•CO2 Emission Reduction
▫ 16.843 tons CO2/yr•Average Cost Savings
▫$10, 540/yr
Discharge Investigation•Problem
▫2Q water bill increased•Research Highlights
▫Discharge Monitoring Reports
▫Production Schedules Inconsistent with
chart recorder▫Maintenance
Preparing Fire Water Tanks for inspection
Discharge Investigation•Conclusion
▫Meter Possible obstruction or mechanical upset
▫Evaluate data more frequently▫Cost Savings
$43,181
Site Wide Water Management•Accurately meter & evaluate usage•Improve as products and operations
expand
Thank you to all 3M-PdC employees and to SHWEC
Special thanks toDavid Liebl and Mary
Prisby
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