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PROFITS OF POLLUTION PREVENTION

A Compendium of Nor th Carol ina Case S t u d i e s i n Resource Conservat ion and Waste Reduct ion

MAY 1985

P r e p a r e d f o r t h e Nor th C a r o l i n a Board o f S c i e n c e and Technology

by

Donald H u i s i n g h , Ph.D., P r o f e s s o r , D i v i s i o n of U n i v e r s i t y S t u d i e s , NCSU, R a l e i g h , N.C.

Helene Hi lger , I n s t r u c t o r , Depar tment of C i v i l E n g i n e e r i n g , UNC-C, C h a r l o t t e , N.C.

Sven Thesen , Resea rch A s s i s t a n t L a r r y M a r t i n , Resea rch A s s i s t a n t

ACKNOWLEDGEMENTS

OUR GRATEFUL APPRECIATION TO THE N.C. GENERAL ASSEMBLY FOR THEIR SUPPORT OF THE BOARD OF SCIENCE AND TECHNOLOGY'S POLLUTION PREVENTION PAYS PROGRAM, WHICH WE ACKNOWLEDGE FOR THE SUPPORT OF THIS PROJECT. WE WOULD ESPECIALLY LIKE TO RECOGNIZE THOSE INDUSTRIES AND CONCERNS WHO HAVE PARTICIPATED IN THIS ENDEAVOR BY COOPERATING IN OUR RESEARCH AND AGREEING TO BE INCLUDED AS A CASE STUDY IN THE COMPENDIUM. THEY ARE TRULY NORTH CAROLINA'S "PROPHETS" OF POLLUTION PREVENTION.

iii

PREFACE

I n May o f 1982 t h e c o n c e p t s , p r o c e d u r e s and b e n e f i t s of p o l l u t i o n p r e v e n t i o n were p r e s e n t e d i n a symposium i n Winston Salem t o more t h a n 200 i n d u s t r i a l i s t s , g o v e r n m e n t a l o f f i c i a l s , e d u c a t o r s , s t u d e n t s and concerned c i t i zens . S i n c e t h a t t i m e many c o n f e r e n c e s and workshops have been h e l d t o f u r t h e r t h e d i s s e m i n a t i o n o f i n f o r m a t i o n a b o u t p o l l u t i o n p r e v e n t i o n t o most key i n d u s t r i a l s e c t o r s o f Nor th C a r o l i n a .

Wi th i n s i g h t s g a i n e d t h r o u g h t h e s e e d u c a t i o n a l e f f o r t s and because o f r i s i n g cos ts a n d e n v i r o n m e n t a l r i s k s o f b u r i a l of h a z a r d o u s wastes, many i n d u s t r i a l l e a d e r s have been m o t i v a t e d t o d e v e l o p and implement p o l l u t i o n p r e v e n t i o n s t r a t e g i e s r a t h e r than t o r e l y s o l e l y upon p o l l u t i o n c o n t r o l s t o meet e f f l u e n t s t a n d a r d s a n d t o u t i l i z e s a f e , cost e f f e c t i v e waste managemen t pract ices .

I n t h e summer o f 1983, t h e N . C . L e g i s l a t u r e a l l o c a t e d f u n d s t o t h e Nor th C a r o l i n a Board of Science and Technology w i t h t h e mandate t h a t t h e Board g r a n t t h e money to r e s e a r c h e r s t o d e v e l o p a d d i t i o n a l e d u c a t i o n a l m a t e r i a l s d e s i g n e d t o in fo rm i n d u s t r y and government a b o u t ways and means by which t h e s t a t e ' s i n d u s t r i a l sec tor c a n d e c r e a s e i t s p r o d u c t i o n of h a z a r d o u s wastes.

Among t h e p r o j e c t s funded , one e n t i t l e d , A Compendium of P o l l u t i o n P r e v e n t i o n P a y s P ro jec t s i n Nor th Ca ro l ina was submi t - t e d bv two o f U S . Donald Hu i s inoh and Helene Hilaer . The - compeniium and of o u r e f f o r t s t o document t h e " P o l l u t i o n P r e v e n t i o n Pays" s u c c e s s e s o f Nor th C a r o l i n a i n d u s t r i e s .

you a r e . n o w r e a d i n g is t<e r e s u l t o f t h a t s u p p o r t

i v

TABLE OF CONTENTS

page #

Preface i v

Table of Contents V

Chapter 1. INTRODUCTION 1

b Pollution Prevention Concepts and Approaches .......... 3 a Development of the Pollution Prevention Ethic in N.C.. 1

c North Carolina Assistance Programs for Pollution Prevention Program Development......................... 4

Chapter 2. PURPOSE AND USE OF THIS DOCUMENT 6

a Purposes of This Pollution Prevention Compendium.. .... 6 c Identification of Potential Industrial Respondents .... 8 d Preparation of Individual Case Study Entries.......... 8 e Responses to Our Requests for Information

From Industry..........................................lO f Discussion of Methodology........,....................lO

Commonly Used Abbreviations..................... ...........] 3

Literature Cited...........................................l4

Chapter 3 . CASE STUDIES, organized by industry group

b Methodology for Preparation of This Compendium ........ 6

a AgKiCUltUral and Related Products case study I, Choplin Farm......................]5 case study 2, Dunbar Foods......................lg case study 3 , Miller Brewing Company............23

case study 4, Coty...... ...................,....27 case study 5, Daly-HeKring. ..................... 28 case study 6, IAC ............................... 35 case study 7, IC1 Americas......................39

case study 8 , United Globe......................43

case study 9, Data General......................48 case study 10, Emerson Electric..................55

case study 11, Florida Steel.....................62 case study 12, Scovill- Hamilton Beach...........66

b Chemicals

c Furniture

d High Tech

e Metals Plating/Working

case study 1 3 , Stanadyne ......................... 70 f Photography

case study 14, PCA..........................,.....84 case study 15, Rexham-Matthews, NC...............89

g Printing case study 16, Rexham-Greensboro, NC.............94

h Textiles

V

CONTENTSl CONTINUED

case study 17. American Enka ..................... 99 case study 18. Hampshire Hosiery ................. 103 case study 19. West Point Pepperell .............. 107 case study 21. Duke Power ......................... 115 case study 22. Hickory-Newton-Conover ............ 123 case study 23. Morganton ......................... 128 case study 24. Natural Power ..................... 149 case study 25. New Hanover County ................ 154

i Utilities and Municipal Services case study 20. Carolina Power and Light .......... 111

Chapter 4 . ABSTRACTS CROSS REFERENCING CASE STUDIES- MATERIALS

a Agricultural/Food Processing Wastes .................. 161 b Fly Ash & Bottom Ash ................................. 162 c Low Level Radioactive Wastes ......................... 163 d Metals and Other Inorganic Chemicals ................ 164 e Municipal Wastes ..................................... 166 f Process water ........................................ 167 g Solvents and Other Organic Chemicals ................. 168

Chapter 5 . ABSTRACTS CROSS REFERENCING CASE STUDIES- PROCESSES

a Adsorption ................ ...,.. ..................... 173 b Distillation ......................................... 174 c Electrolytic Reactions ............................... 175 d Equipment Operation .................................. 176

g Incineration/Heat Recovery ........................... 181

e Filtration ........................................... 178 f Housekeeping ......................................... 179

h Ion Exchange ......................................... 18~ i Land Application ..................................... 1 ~ 4 j Management Initiatives ............................... 185 k Material Substitution ................................ 187 1 Recycle. Reuse & Recovery ............................ 188

APPENDIX ................................................... 191

v i

Chapter 1. INTRODUCTION

DEVELOPMENT O F THE POLLUTION PREVENTION ETHIC I N NORTH CAROLINA

I n 1981 , Nor th C a r o l i n a ranked e l e v e n t h o u t of t h e f i f t y s t a t e s i n t h e g e n e r a t i o n o f h a z a r d o u s w a s t e s and f o u r t h i n t h e g e n e r a t i o n of l o w - l e v e l r a d i o a c t i v e wastes. Governor H u n t ' s t a s k f o r c e o n w a s t e management, a f t e r e x t e n s i v e s t u d y o f t h e o p t i o n s , s u b m i t t e d i t s r e p o r t on F e b r u a r y 1981. T h e i r v e r y f i r s t recommendat ion was:

"A comprehens ive was te management sys t em be d e v e l o p e d which e m p h a s i z e s p r e v e n t i o n , resource conserva t ion and r e c o v e r y and m i n i m i z e s t h e volume o f waste t o be d i s p o s e d o f . "

T h i s recommendat ion u n d e r s c o r e d t h e t a s k force 's c o n v i c t i o n t h a t r e l i a n c e upon land-based " d i s p o s a l " p r a c t i c e s o f t h e p a s t is n o t t h e e c o l o g i c a l l y sound s o l u t i o n t o Nor th C a r o l i n a ' s h a z a r d o u s waste management problems t h e y wanted. A d d i t i o n a l l y , e l e m e n t s o f t h e t a s k f o r c e r e p o r t r e c o g n i z e d t h a t e c o n o m i c a l l y , t h e l a r g e scale w a s t i n g o f materials was a g r o s s i n e f f i c i e n c y , and t h a t i n t h e l ong term, " d i s p o s a l " c o u l d l i k e l y g e n e r a t e more costs t h a n r e p r e s e n t e d by i n i t i a l i n v e s t m e n t s i n sound resource s t e w a r d s h i p . They r e a l i z e d , based upon t h e successes o f s e v e r a l i n d u s t r i a l companies t h r o u g h o u t t h e n w o r l d , t h a t p r e v e n t i o n of t h e p r o d u c t i o n o f t h e w a s t e s , or a t l e a s t , m i n i m i z a t i o n o f t h e p r o d u c t i o n of t h e wastes is t e c h n i c a l l y f e a s i b l e i n many in s t ances . F u r t h e r , t h e y l e a r n e d t h a t s u c h emphases can a l s o be p r o f i t a b l e , f r e q u e n t l y p a y i n g f o r t h e p r o c e s s m o d i f i c a t i o n i n v e s t m e n t s i n a c o m p a r a t i v e l y s h o r t time from t h e m a t e r i a l s and e n e r g y saved and from t h e w a s t e d i s p o s a l costs n o t i n c u r r e d . S i m u l t a n e o u s l y t h e s e a p p r o a c h e s r e d u c e t h e human h e a l t h and e n v i r o n m e n t a l risks.

Among t h e c o r p o r a t e examples t h a t h e l p e d c o n v i n c e t h e t a s k f o r c e of t h e d i r e c t i o n Nor th C a r o l i n a ' s haza rdous waste management e f f o r t s s h o u l d t a k e , were t h e r e s u l t s of t h e world- wide 3 - M c o r p o r a t i o n . The c o r p o r a t e l e a d e r s h i p w i t h i n 3 - M h a s been a p a c e s e t t e r s i n c e i t i n i t i a t e d i t s " P o l l u t i o n P r e v e n t i o n Pays" program i n 1975. By 1980 3 - M had saved $80 m i l l i o n and by O c t o b e r 1984 i t h a s saved $192 m i l l i o n . The Company h a s a n n u a l l y p r e v e n t e d t h e d i s c h a r g e o f more t h a n 90,000 tons of a i r p o l l u t a n t s , 1 0 0 , 0 0 0 t o n s of w a t e r p o l l u t a n t s and 140 ,000 t o n s o f s l u d g e , much of which i s h a z a r d o u s ; and p r e v e n t e d t h e product ion o f one b i l l i o n g a l l o n s of wastewater. A d d i t i o n a l l y , 3 - M s a v e s t h e e n e r g y e q u i v a l a n t o f 254,000 b a r r e l s of o i l a n n u a l l y ( B r i n g e r , 1 9 8 4 ) .

By p l a c i n g emphas i s upon p o l l u t i o n p r e v e n t i o n , 3 - M h a s n o t o n l y a c h i e v e d t h e g o a l s o f t h e p o l l u t i o n c o n t r o l l a w s , b u t t h e y have , i n many c a s e s , s u r p a s s e d t h e r e q u i r e m e n t s of t h e s e laws .

Furthermore, they have accomplished this and simultaneously increased profits, illustrating the truth of the old adage, "An Once of Prevention is Worth a Pound of Cure." In this case, pollution prevention is much more efficient and effective than sole emphasis upon pollution control.

It i s noteworthy that 3-M received the "International Corporate Environmental Award" on May 10, 1985 in Washington D.C. The award was presented by the World Environment Center for 3-M's outstanding corporate leadership in making pollution prevention Pay-

It has been said, "Well that's great that a giant multi-national corporation like 3-M with its large financial and technical resource base can accomplish such impressive reductions in the production of pollutants of all types and at the same time improve their net profitability; but what about the smaller, more localized firms, can they also successfully employ the pollution prevention pays concepts?"

In late 1982 a few leaders within N.C. believed that some of our companies were already utilizing pollution prevention approaches. In order to obtain specific examples and to provide industries the opportunity to tell their own stories, the Governor's Waste Management Board initiated an annual competition for the "Governor's Award for Excellence in Hazardous Waste Management.

Now, after three years of this competition, it can definitely be stated, "The same types of successes that big companies like 3-M have documented, are also being demonstrated by smaller firms within North Carolina.

This compendium provides details of 25 corporate and municipal proofs that pollution prevention pays. The case studies are based upon information supplied to us by each company or agency in response to our phone calls, their filling out our questionnaire ( see copy of questionnaire in appendix) and our follow-up letters, phone calls and site visits.

2

POLLUTION PREVENTION CONCEPTS AND APPROACHES

Investigations of resource conservation and waste reduction in private and public enterprises have identified nine general approaches which have been implemented to achieve the goal of pollution prevention. They can be classed into three categories, assessment and planning, technical modification, and by-product/ residual processing.

In assessment and planning, the ENVIRONMENTAL AUDIT and MANAGEMENT STRATEGIES are implemented to characterize the waste streams, to quantify the wastes being produced, to determine alternative approaches €or their reduction, and to generally establish suitable frameworks for promoting pollution prevention efforts. A preliminary step is the environmental audit. The audit should identify waste streams which are candidates for the application of pollution prevention or waste reduction strategies. A management strategy will naturally precede any waste management. innovations, but €or purposes of classification "management strategies" will refer more specifically to programs, personnel motivation, and such endeavors as marketing. Management strategies are characterized by initiatives such as "environmental compliance committees", "employee incentive cost savings programs", "chemical waste management programs", and improved "housekeeping" practices. The key element in this phase of planning and implementing a pollution prevention program is gaining the attitude that waste reduction and resource conservation are desirable €or both economic and environmental ends.

Technical modifications are pollution prevention innovations to the manufacturing process, and include CHEMICALS SUBSTITUTION, PRODUCTION PROCESS CHANGES, and VOLUME REDUCTION. These innovations are generally modifications to the manufacturing process which effect a reduction in either the waste stream, in its toxicity, or both. The modifications may be actual alterations or additions to existing equipment, but are often much simpler strategies such as stricter monitoring and reduced usage of resources (i.e. water in the animal processing and metals plating industries). A modification receiving increasing usage is the substitution of less hazardous or more easily recycled substances for those identified as presenting a hazardous waste management problem. A key element in this phase of pollution prevention strategies is to locate materials or stages in the manufacturing processes which can be modified to achieve waste reduction.

By-product and residuals processing are often linked closely to the other two categories of pollution prevention strategies. Assessment, planning, and technical modifications may be directed toward making a manufacturing by-product more easily "processed". Included in this pollution prevention category are the following strategies: SEPARATION OF WASTE STREAMS, RESOURCE RECOVERY,

3

RECYCLING and REUSE- including the WASTE EXCHANGE concept, and INCINERATION & HEAT RECOVERY. Common processes characteristic of by-product and residual processing include; adsorption (i.e. carbon), distillation, electrolytic separation, electro-dialysis, ultra-filtration, ion exchange, land application, reverse osmosis, incineration for recovery of energy, and other chemical and physical treatments. A key element in this pollution prevention strategy is to stop thinking of process by-products as wastes, and to begin a creative process whereby the by-products become resources for other manufacturing processes, or even end products themselves. Several case studies document how companies have immediately eliminated waste disposal costs, and even realized new "product" sales profits by simply identifying markets for their process by-products and treatment residuals.

It is o u r hope that this compendium's examples will serve to inform and inspire many to develop and implement these same types of waste reduction and pollution prevention approaches in their organizations. Their firms will benefit financially, and their employees will usually experience fewer risks of exposure to toxic substances, and we will all benefit from having utilized our limited resources more efficiently and safely. Hopefully as more and more N.C. industries implement pollution prevention technologies, we will see a dramatic decline in the quantities of hazardous waste and low level radioactive wastes produced, and therefore have less that must be "disposed of". We will have made real progress in the direction envisioned by the Governor's task force.

NORTH CAROLINA ASSISTANCE PROGRAMS FOR POLLUTION PREVENTION PROGRAM DEVELOPMENT

Elements of the pollution prevention program supported by North Carolina tax revenues can be found in The Board of Science and Technology under the auspices of the Governor's office, the Division of Environmental Management (DEM) of the Department of Natural Resources and Community Development, (NRCD) and in the University of North Carolina Industrial Extension Service.

The Pollution Prevention Pays Program in NRCD is the lead program in coordinating the state's efforts in waste reduction and pollution prevention. The program promotes pollution prevention efforts across the State through providing and coordinating technology transfer, research, financial assistance and technical assistance. NRCD's services to industry include; ___ publications such as a Pollution Prevention Bibliography, A Directory of Resource Recovery Firms, An Environmental Auditing Guide, and a series of industry specific Technical Guides; the Small Business Initiative Program, which funds research and ~

demonstration projects to assist small businesses and communities ~

with pollution prevention initiatives: and the assistance of the State-wide DEM staEf i n the development of pollution prevention strategies. Challenge Grants are also now available to concerns

4

i n t e r e s t e d i n d e v e l o p i n g p o l l u t i o n p r e v e n t i o n t e c h n i q u e s f o r s p e c i f i c waste s t r e a m s and f a c i l i t i e s . Matching g r a n t s of up t o $5000 may be awarded t o s u p p o r t p r o j e c t s i n c l u d i n g : e n v i r o n m e n t a l a u d i t or w a s t e s u r v e y : marke t s u r v e y o f p o t e n t i a l r e c o v r y or

p r e v e n t i o n / r e d u c t i o n t e c h n o l o g i e s ; and d e t a i l e d , i n - p l a n t p r o c e s s s t u d i e s f o r w a s t e r e d u c t i o n o p p o r t u n i t i e s .

waste exchange o p t i o n s : d e m o n s t r a t i o n p r o j e c t s o f

The Board o f S c i e n c e and Technology a d m i n i s t e r s a research a n d e d u c a t i o n program f o r p o l l u t i o n p r e v e n t i o n . Monies p r o v i d e d by t h e N . C . G e n e r a l Assembly have been a p p l i e d t o d e v e l o p i n g a r e s e a r c h program t o promote p o l l u t i o n p r e v e n t i o n o p p o r t u n i t i e s i n Nor th C a r o l i n a . The Board h a s funded r e s e a r c h , i n c l u d i n g t h i s Compendium, s p o n s o r e d a se r ies o f p o l l u t i o n p r e v e n t i o n s e m i n a r s , c o n f e r e n c e s , and work-shops, and worked toward e s t a b l i s h i n g a f i r m f o u n d a t i o n of p o l l u t i o n p r e v e n t i o n e x p e r t i s e on which t o b u i l d a n e f f e c t i v e w a s t e r e d u c t i o n and r e s o u r c e c o n s e r v a t i o n e t h i c f o r Nor th C a r o l i n a .

The I n d u s t r i a l E x t e n s i o n S e r v i c e h a s a l s o s p o n s o r e d workshops p romot ing p o l l u t i o n p r e v e n t i o n . T h e i r s e r v i c e h a s been more s p e c i f i c a l l y d i r e c t e d to problem a r e a s i n d i s t i n c t i n d u s t r i e s . As a n i n t e g r a l component, t h e E x t e n s i o n S e r v i c e h a s p u b l i s h e d a t e c h n i c a l g u i d e f o r r e d u c i n g waste, f o c u s i n g o n i n d u s t r i e s which u t i l i z e s o l v e n t s . The E x t e n s i o n S e r v i c e o f f e r s a s s i s t a n c e t o i n d u s t r y as i t s resources p e r m i t .

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Chapter 2 . PURPOSE AND USE OF THIS DOCUHENT

PURPOSES OF THIS POLLUTION PREVENTION COMPENDIUM

There are two principle purposes for this pollution prevention compendium. First, to create an educational and promotional document to explain and publicize the economic and ecological benefits of utilizing pollution prevention and pollution reduction technologies. Although North Carolina has made significant strides in familiarizing the state's industrial leaders with the concept that "pollution prevention pays", the phrase is still perceived by many as a theoretical concept with little practical application. The compendium allows u s to put forth detailed examples of successful applications that utilize pollution prevention approaches. These case studies also demonstrate that technical solutions are not the only way to solve a pollution problem. Management attitudes, policies and strategies can also be used to accomplish pollution prevention goals.

A second purpose in developing the compendium was to use case studies to attack the inertia problem. There is a natural hesitancy on the part of any individual firm to be the first to experiment with a new approach, technology or product unless some of the perceived risks have been removed. If a new low-waste method of production does not prove as cost effective as predicted, or if the product is altered in an undesirable way, then the firm that instituted the alteration is left at a competitive disadvantage. There is a tendency to take a "wait and see" attitude toward new pollution prevention schemes because they are considered peripheral to the main purpose of the firm and not worthy of the financial risk involved to implement them. The case studies in this document provide a sense of safety and encouragement to firms considering such changes but are unwilling to risk being the first to work through the necessary development and experimentation processes.

METHODOLOGY FOR PREPARATION OF THIS COMPENDIUM

The two faculty project leaders obtained advisory input in the planning and development phases from representatives of many private and educational groups and from members of the following state government agencies:

a. The Governor's Waste Management Board b. The Pollution Prevention Pays section of the Department

of Natural and Economic Resources c. The Solid and Hazardous Waste Management Branch of the

Department of Human Resources d. The N.C. Board of Science and Technology

6

These representatives provided useful input in identifying potential industrial firms that would be likely to participate in the proposed study.

Early in the project, a detailed assessment was done to determine the potential users of the compendium. The following were considered to be the ones most likely to benefit and to use this document:

a. b.

d. e. E. 4. h.

C.

State government monitoring agency field representatives Industrial firms Trade association personnel Consulting firms The North Carolina Industrial Extension Service The Piedmont Waste Exchange Universities and technical colleges Concerned citizens

The information to be solicited from respondents was then tailored to meet the anticipated needs of each group. After numerous revisions, the final questionnaire emphasized the following major categories of information, in addition to identification and demographic information about each firm. See the Appendix for a copy of the questionnaire.

a. Description of PPP application, including technological

b. Economic analysis of capital, operational, maintenance, and management components

and indirect costs and savings, including the payback per iod

c. Evaluation of any attitudinal changes required to implement the project

d. Assessment of transferability of each project to other firms in the same SIC and firms in other SICS

e. Description of other benefits such as nonquantifiable environmental benefits and reduction in health risks

f. Identification of legal issues, including permits, and insurance liabilities

g . Recommendations for possible improvements, modifications or adaptations of the project for the use in other firms

The form was designed with the assumption that the initial contact with potential respondents would be by phone or letter, with a mailed questionnaire to follow if a firm agreed to participate. Recipients of the questionnaire were then contacted by phone to determine if they had any questions about the form. __ Often this phone call enhanced the enthusiasm and quality of the response. In many cases, the call made the difference between a response and no response from the firm. Once the completed forms were returned, we evaluated them to determine if further phone ~

contacts and/or on-site plant visits were necessary or desirable. ~

Numerous follow up letters and phone calls were made to solicit additional, more detailed information. Site visits were performed at nine of the firms included as case studies.

7

IDENTIPICATION OF POTENTIAL INDUSTRIAL RESPONDENTS

Several activities were initiated to identify potential respondents. The most ready source of contacts came from a list of firms that had nominated themselves for "The Governor's Award for Excellence in Waste Management", granted annually during the last three years to recognize and honor firms that have demonstrated exceptional hazardous waste management practices. The state monitoring agencies also generated lists of firms judged to be good candidates for case study presentations. Announcements describing the project and soliciting examples were placed in various newsletters published by state government agencies, trade associations, Chambers of Commerce, and the Piedmont Waste Exchange. Letters were sent to consulting firms across the state asking for their cooperation in suggesting candidates among their clients. Announcements describing o u r project were made at several technical conferences sponsored by the N.C. Industrial Extension Service.

PREPARATION OF INDIVIDUAL CASE STUDY ENTRIES

The development of a standardized format for the case studies was considered to be a major component of the project. Numerous drafts were developed, modified, and finally the one included in this compendium was agreed upon. Each case study entry is comprised of the following types of information in varying degrees of detail, depending upon what we were able to obtain from the firms and from supportive literature.

a. b. C.

d.

e.

f.

4.

h.

i.

Type of industry Name, address, business contact and phone number The Standard Industrial Classification (SIC), or the product type, if the firm manufactures products in a number of SIC categories A "modifications" section that highlights the types of process modifications the firm has implemented An abstract, designed to concisely summarize the main PPP approaches employed and the consequent pollution prevention that has been realized Annual Cost Savings, designed to present quantitative data on the financial benefits derived from implementation of the PPP technologies Payback period, a measure of the length of time required to pay for the process modification investments through the increased efficiency of operations and from waste disposal cost minimization Time to implement, as the time from initial planning to the time the new procedure/s is functioning Transferability, designed to suggest ways the process modifications incorporated by the case study firm may be applicable to firms in similar and/or different manufacturing categories

a

j. Environmental and health benefits, included to indicate the less environmental and health benefits resulting from the new processes

technical aspects of the process modifications, the problems encountered and the costs and benefits that have resulted

1. The process dimensions table, located at the end of each case study is designed to be: 1) a concise qualitative summary of the affects of the respective modifications on the overall process 2 ) a complete as possible quantitative cost/savings assessment of the modifications

k. The project description, designed to detail the

There are thirteen descriptive "dimensions" in the table. Of these, some are not always pertinent for a modification in any given case study. In those cases, "not applicable" was entered for that dimension. Additionally, information was not always made available for reasons discussed elsewhere in this chapter. The dimensions are largely self explanatory, however the following dimensions are discussed briefly to ensure they are understood thoroughly. WASTES GENERATED generally refers to the dhanges in the facilities waste stream, a reduction in toxicity or reduced wastes are illustrative. The other qualitative dimensions are: PRODUCTIVITY, PRODUCT QUALITY and NET BENEFITS.

The remaining dimensions are designed to summarize costs and savings resulting from the respective modifications. FACILITIES and EQUIPMENT are similar in that they both refer to the capital investment for the modification. They are separate entries so as to better indicate the nature of the investment. WASTE DISPOSAL is a description of the costs or savings associated with the management of residuals. This may take the form of waste management costs or savings resulting from the respective modification, as contrasted with "wastes generated" which is discussed above. POLLUTION CONTROL is designed to describe the costs or savings resulting from the modification associated with equipment outmoded or installed to meet regulatory or voluntary standards for the facilities' emissions. The other quantitative dimensions are RAW MATERIALS, WATER, ENERGY, and PERSONNEL/MAINTENANCE.

9

RESPONSES TO OUR REQUEST FOR INFORMATION FROM INDUSTRY

The highest frequency of responses came from applicants for the Governor's Award for Excellence in Waste Management. This was not surprising, since these firms had already made the decision to come forward and seek acknowledgement and publicity for their waste management activities. The lower response level from newly identified firms reflected a variety of circumstances. Several firms did not want to participate because they feared regulatory repercussions. Similarly, there was a hesitancy by some firms to draw attention to applaudable waste reduction operations because they feared "guilt by association" if linked in any way with the hazardous waste issue. Among certain industrial groups, confidentiality and preservation of trade secrets was of major concern, and this prevented them from providing detailed accounts of their pollution prevention practices. A related problem was that some firms that had realized significant cost savings from their projects did not want to share these methods with their peers for they did not want to loose the competitive edge they had gained by implementing these approaches. Several firm's engineers and plant managers were eager to share information but were advised to not do so by the corporate lawyers.

The level of detail reported on the completed questionnaires varied considerably. In large part, this resulted from the amount of time devoted by the respondent in working with us. The size of the firm tended to determine the quality o€ the completed questionnaire, with the larger companies being more easily able to assign knowledgeable personnel to the task of responding than the smaller companies with limited staff. The lack of good quantitative information, especially cost data, often prevented the respondent from providing detailed information even when the opportunity for an on-site interview was given.

Additionally, the time of year when the information was requested influenced response. Firms involved in the production of ayricultural or other seasonal products were unwilling or unable to participate during the busy summer months.

DISSCUSSION OF METHODOLOGY

Based on our activites in preparing the compendium, we make the following observations regarding the results obtained by our me t hod0 1 og y .

( 1 ) Much effort was devoted to ensuring that the final product will be used. Although this recommendation may seem obvious, there are numerous state and federal government documents which can be offered as evidence that apparently this is not always done. It is important to devote time to the identification of target user groups and to keep their needs in mind thoughout the development of the project. It is equally important to enlist the assistance of those in immediate contact

10

with industry and other targeted users in directing the activities of the project.

( 2 ) Several references were consulted in the design of the questionnaire to ensure that no descriptive elements were overlooked in its preparation. Although each desciptive parameter is not always pertinent for all case studies, overall, the parameters have been determined to meet all contingencies for characterizing the modifications presented here. Examples of several good resources used in preparing the questionnaire are: Campbell (1982), Huisingh (1982), Royston (1979), U.N. Compendium (1982), Chambolle (1982).

( 3 ) The method of collecting information will affect the level of detail and length of the form. Although on-site interviews are direct, they usually preclude the opportunity €or the respondent to search out certain data or provide thoughtful responses to the questions. Because on-site interviews are very expensive, such interviews limit the number of firms that can be contacted. We found that the questionnaire, prefaced and followed by telephone calls was satisfactory and allowed u s to contact a broad spectrum of potential participants. When mailings are used, it is important that the questions be succinct and yet directive enough to result in some uniformity of answers among resopondents. A review of the questionnaire by the targeted users is essential to ensure that the questions are understood and interpreted as intended. It is important to be realistic about the amount of time that will be spent by the respondent completing the questionnaire and, therefore, it is essential that the form was made as brief as possible and consistent with the goal of obtaining the essential information about the case study. Follow-up letters and phone calls, and in some cases, site visits, were essential to obtain as much information as possible. (note that many firms do not have or will not release detailed quantitative data for the reasons cited in a previously.

( 4 ) When approaching potential respondents, it was helpful to get one's "foot in the door" by preceding a request for completion of the questionnaire with a less imposing request, such as a response to a letter or phone call. It is critical that the questionnaire be received by the person in the firm who is knowledgeable, willing, and who has the authority to complete it. Our experience has led us to conclude this initial activity is worth a significant time investment which will result in a greatly improved response rate.

( 5 ) It is important to be thorough in explaining the pollution prevention philosophy to potential respondents. This helps them conceptualize their case study in terms that emhpasize __ the pollution prevention features one is trying to illustrate. It is not uncommon to find firms using PPP methods who have not identified them as such. It is particularly helpful to remind respondents that management approaches such as employee incentive award programs can also be effective parts of a pollution prevent ion program .

~

11

( 6 ) R e q u e s t s f o r case s t u d i e s emphas ized t h e p o s i t i v e aspec ts of p a r t i c i p a t i o n . A s e r i o u s e f f o r t was made t o "sel l" t h e c a n d i d a t e s o n t h e i d e a t h a t t h e i r company's s t o r y belongs i n t h e compendium as a case s t u d y . P o t e n t i a l r e s p o n d e n t s m u s t be conv inced t h a t i t i s w o r t h t h e i r time t o comple t e t h e q u e s t i o n n a i r e and t h a t i n c l u s i o n o f t h e i r c a s e s t u d y i n a document s u c h as t h i s conpendium w i l l b e n e f i t t h e company. P e r c e i v e d b e n e f i t s i n c l u d e p u b l i c i t y f o r t h e i r p r o d u c t and improved p u b l i c r e l a t i o n s w i t h t h e g e n e r a l p u b l i c o r among t h e i r i n d u s t r i a l g r o u p . T h e r e seem t o be t w o p redominan t p h i l o s o p h i e s among i n d u s t r i a l l e a d e r s . Some v iew t h e m s e l v e s a s p a r t o f a " b u s i n e s s community" and are in t e re s t ed i n c o o p e r a t i n g because t h e y c a n c o n t r i b u t e t o t h e w e l f a r e o f t h e i r community. O t h e r s see t h e i r i n t e r a c t i o n s w i t h p e e r s a s one-on-one c o m p e t i t i o n , and are more h e s i t a n t to s h a r e t h e i r s u c c e s s s tor ies .

( 7 ) When c o l l e c t i n g i n f o r m a t i o n , t h e i s s u e of c o n f i d e n t i a l i t y and t r a d e secrets m u s t be a d d r e s s e d . Al though some f i r m s may n o t o f f e r t h i s e x p l a n a t i o n €or t h e i r re fusa l to p a r t i c i p a t e , i t may be r e s p o n s i b l e f o r a large number of u n r e t u r n e d q u e s t i o n n a i r e s . W e o f f e r e d t o p r e s e n t case s t u d i e s w i t h o u t i d e n t i f y i n g t h e f i r m i n v o l v e d , and t o p r e s e r v e t r a d e secrets; we made i t c lear we would a c c e p t examples e v e n i f c e r t a i n i n f o r m a t i o n was o m i t t e d . W e f e e l t h i s is c o n s i s t e n t w i t h ou r i n t e r e s t i n o b t a i n i n g as many examples a s p o s s i b l e , b u t may n o t be a c c e p t a b l e f o r ce r t a in p u r p o s e s which r e q u i r e d e t a i l e d e x p l a n a t i o n s of process p a r a m e t e r s .

(8) Telephone c a l l s were be used t o monitor t h e p r o g r e s s of t h e q u e s t i o n n a i r e c o m p l e t i o n p r o c e s s a t e a c h f i r m . I t is n e c e s s a r y t o t a k e t h e l e a d i n communicat ion w i t h r e s p o n d e n t s ; i f t h e y have q u e s t i o n s t h e y w i l l a s k them i f c o n t a c t e d , b u t t h e y w i l l r a r e l y t a k e t h e t i m e t o p u r s u e them w i t h you on t h e i r own i n i t i a t i v e .

12

EPA- BTU- BOD- COD- TSS- GAL/FII N- MGD- RCRA- NPDES- KWH- PSIG-

LIST OF COMMONLY USED ABBREVIATIONS

U.S. Environmental Protection Agency British Thermal Units Biological Oxygen Demand Chemical Oxygen Demand Total Suspended Solids Gallons per Minute Million Gallons per Day Resource Conservation and Recovery Act National Permit Discharge Elimination System Kilowatt Hour Gage Pressure, Pounds per Square Inch

13

Literature Cited

1. Bringer, Robert, P. and Sara Zoss, 1 9 8 4 , 3P: An Environmental Protection Program that Works. Paper presented at the "Low and Non Waste Technology conference" held in Tashkent, USSR, October 15-19, 1984 .

2. Campbell, Monica, E. and William M. Glenn, 1982 , PROFIT FROM POLLUTION PREVENTION. Published by the Pollution Probe Foundation, Toronto, Ontario, Canada. pp 404.

3. Chazelon, Jean-Claude, 1 9 8 2 . LES TECHNIQUES PROPRES DANS L'INDUSTRIE FRANCAISE. Published by La Societe Objective, 1 9 Rue Vaugelas, Paris, France.

4 . COMPENDIUM ON LOW AND NON-WASTE TECHNOLOGY, 1982 , Produced by the Economic Commission for Europe and the United Nations Environmental Programme, Geneva, Switzerland.

5. Huisingh, Donald and Vicki Bailey, (eds), 1982 , MAKING POLLUTION PREVENTION PAY: ECOLOGY WITH ECONOMY AS POLICY. Published by Pergamon Press, Elmsford, N.Y.. pp 156.

6 . Royston, Micheal, G., 1979, POLLUTION PREVENTION PAYS. Published by Pergamon Press, Elmsford, N.Y.. pp 197.

14

CASE STUDY 1

TYPE OF INDUSTRY: Swine Product ion NAME OF FIRM: The Choplin Farm ( 9 1 9 / 5 5 6 - 2 3 8 3 ) LOCATION: Wake Forest, North Carolina SIC: 0 2 1 3 & 0 1 1 5

~

MODIFICATIONS

1) THE USE OF SWINE WASTES AS A FERTILIZER 2 ) APPLICATION OF A COMPREHENSIVE SOIL AND WATER

CONSERVATION PROGRAM

ABSTRACT: In 1982 the Choplin farm saved $8,000 in fertilizer costs by spraying swine wastes on crops with a standard irrigation gun. They also reduced organic material losses by 1,6708, total nitrogen losses by 490%, and total phosphorus losses by 5 2 5 % through the integrated use of conservation tillage, parallel terracing, grassed waterways and cover crops. The reuse of these agricultural wastes and the management initiative to incorporate conservation practices in the farm operation resulted in corn crop yields that were 300% above the county average.

1 5

ANNUAL COST SAVINGS: $107,000

PAYBACK PERIOD: 6.5 years

TIME TO IMPLEMENT: Information not provided

TRANSFERABILITY:

ENVIRONMENTAL AND HEALTH BENEFIT:

Applicable to animal farming operations in conjunction with land farming

conservation of nutrients and water: decrease in soil erosion, reduction in non-point sources of pollution: decrease in risk of drinking water contamination

16

PROJECT DESCRIPTION: The Choplin Farm is a swine raising operation. Throughout the year, animal wastes are collected in a slurry pit, and in early spring, soil samples are taken for analysis. Based on the results, particularly the nitrogen and phosphorus concentrations in the slurry, the wastes are diluted to the desired concentration with water from ponds used to store runoff. The diluted swine waste is pumped underground to stations distributed around the farm and applied periodically to

practice saved $8,000 in fertilizer costs and provided management of the wastes in an environmentally sound fashion.

the crops by a traveling hard nose sprayer. During 1982, this ~~

In concert with swine waste application, the following Best Management Practices are being used to decrease non-point source pollution: 1) Soil and water conservation practices such as grassed waterways, parallel terraces, field borders, winter cover crops, and conservation tillage are employed to reduce sediment runoff. 2) Three ponds are available to store stormwater runoff for seasonal irrigation needs. 3) Soil is tested annually to assess nutrient and lime requirements. 4) Irrigation is scheduled based on crop and soil moisture cond it ions.

As a result of these practices, the farm operation reports: 1) Stormwater runoff has been reduced from 176,OO gallons per acre to 93,000 gallons/acre. 2) Sediment losses have been reduced from 14.7 ton/acre to 0.05 ton/acre. 3) Organic material loss from soil has been reduced from 1,370 lb/acre to 82 lb/acre. 4) Total nitrogen loss from soil has been reduced from 38.2 lb/acre to 7.8 lb/acre. 5 ) Total phosphorus loss from soil has been reduced from 12.6 to 2.4 lb/acre.

These modifications have improved crop yields. The Choplin Farm produced the State's 4th largest corn yield in 1981, 214 busheldacre.

17

PROCESS DIMENSIONS:

WASTES GENERATED Reduced sediment, organic & nutrient loadinq to surface water

PRODUCTIVITY Improved

PRODUCT QUALITY Improved

DOWN TIME No Change

FACILITIES No Change

EQUIPMENT $71,000 One-time cost

RAW MATERIALS $8,00O/yr savings

WATER 83,400 gal/acre saved

ENERGY Increased savings

WASTE DISPOSAL Decrease in disposal problems

POLLUTION CONTROL Decrease in control costs

PERSONNEIJMAINTENANCE Detailed Information Not Provided

NET BENEFITS Increased yield & reduced costs decreased soil erosion and surface water pollution

For more information, refer to Agricultural Nonpoint Source Control Case Studies In North Carolina, IX. Wake County Demonstration Farm, by B. Atkins, Biological and Agricultural Engineering Department; North Carolina State University, Raleigh, North Carolina, May 1984, 119 pp.

"Irriyation/Hog Waste Slices Fertilizer Bill 80%", by F. Jeter, in Progressive Farmer, Febuary 1983 p. G-14.

"No-Till Makes the Grade", by D. L. Comis, in - - - Soil and Water Conservation News, July 1983 p. 6-7 .

"Pollution Control and Production Efficiency", by J. B. Atkins, in Extension Review Spring 1983 p. 47.

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18

CASE STUDY 2

TYPE OF INDUSTRY: V e g e t a b l e P r o c e s s i n g f a c i l i t y NAME OF FIRM: Dunbar Foods

LOCATION: Dunn, Nor th C a r o l i n a SIC: 2033

(Wayne D a i l 919-892-3175)

MODIFICATION

LAND APPLICATION OF FOOD PROCESSING WASTES

ABSTRACT: Dunbar Foods p r o c e s s e s canned p e p p e r s and sweet p o t a t o e s . They have d e v e l o p e d a s p r a y i r r i g a t i o n land a p p l i c a t i o n s y s t e m f o r t h e i r food p r o c e s s i n g wastes. P r o c e s s water c o n t a i n i n g v e g e t a b l e wastes is r e u s e d t o i r r i g a t e and f e r t i l i z e g r a s s l a n d owned by t h e Company.

19

ANNUAL COST SAVINGS: Information not provided

PAYBACK PERIOD: Information not provided


TRANSFERABILITY:

ENVIRONMENTAL AND HEALTH BENEFITS:

This modification would be suitable for any firm producing large quantities of high BOD wastewater that does not contain toxic materials. Because Dunbar Foods was constrained by the capacity of their local municipal treatment facility, this innovative method was cost effective if they were to expand their operation. Firms in regions where the publically owned treatment plant could handle the required loading might find it more cost effective to use municipal wastewater treatment and pay a sewer use charge. In either case, additional activities might include a review of processes generating wastewater €or possible ways to reduce the waste strength or volume.

Excessive organic loading to the municipal treatment plant is prevented: reduced risk of inefficient municipal wastewater treatment and a consequent high pollution load to the receiving stream. Monitoring revealed no deleterious changes in nearby groundwater quality, availability of oxygen to soil microbes, or runoff water quality due to landspreading activities. Conservation of water, land and material resources: less municipal wastewater sludge to manage, less fertilizer and potable water required for crop production. Maintenance of a monitoring program is required to ensure consistent system performance. __

20

PROJECT DESCRIPTION: Dunbar Foods p r o c e s s e s d i c e d p e p p e r s and sweet potatoes f o r s a l e t o m a r k e t . They became t h e f i r s t i n d u s t r y i n Nokth C a r o l i n a t o employ a l a n d a p p l i c a t i o n s p r a y i r r i g a t i o n wastewater t r e a t m e n t sys tem. The sys t em was o r i g i n a l l y d e v e l o p e d by t h e Company's e n g i n e e r i n 1971 t o allow e x p a n s i o n o f t h e f i r m ' s c a p a c i t y w i t h o u t o v e r t a x i n g t h e m u n i c i p a l w a s t e w a t e r t rea tment f a c i l i t y . Dunbar Foods expanded a g a i n i n 1982 , and because o f t h e s p r a y i r r i g a t i o n s y s t e m , t h e y have n o t r e q u i r e d t h e u s e of t h e m u n i c i p a l t r e a t m e n t p l a n t . P r o c e s s water f low from t h e f i rm ' s c l e a n i n g and c a n n i n g o p e r a t i o n s c u r r e n t l y t o t a l s a b o u t 7 . 5 m i l l i o n g a l l o n s p e r day. All o f t h i s f l ow is screened f o r s o l i d s removal and l a n d a p p l i e d to g r a s s l a n d owned and m a i n t a i n e d by Dunbar. Because Dunbarrs o p e r a t i o n is s e a s o n a l , t h e i r major a c t i v i t y o c c u r s f rom J u l y t h r o u g h December. The wastewater is a p p l i e d o v e r v a r i o u s f i e l d s of t h e 85 acres o f g r a s s l a n d owned by t h e Company. The f i e l d s are mowed p e r i o d i c a l l y t o m a i n t a i n a maximum 9- inch growing h e i g h t .

T h e i r i n n o v a t i v e sys t em f o r h a n d l i n g h i g h BOD i n d u s t r i a l wastewater h a s been s t u d i e d by t h e S t a t e Depar tment o f N a t u r a l R e s o u r c e s and Community Development. Over a t h r e e y e a r p e r i o d of o b s e r v a t i o n and t e s t i n g , t h e y found no e v i d e n c e of g roundwate r c o n t a m i n a t i o n , odor, r u n o f f , or o t h e r p rob lems , and a f t e r t e n Y e a r s of o p e r a t i o n , t h e r e h a s been no i n d i c a t i o n of a n a e r o b i c

o f t h e w i t h i n

- - a c t i o n i n t h e s o i l , and no change i n t h e q u a l i t y g r o u n d w a t e r i n numerous o b s e r v a t i o n s from test wells b o t h t h e i r r i g a t e d a r e a and on i ts p e r i m e t e r .

Dunbar a l s o r e c y c l e s p r o c e s s water used f o r c Recyc led water is s c r e e n e d a n d c h l o r i n a t e d b e f o r e r e u s e . r i n s e w a t e r a n d water f o r c a n n i n g a r e n o t r e u s e d .

e a n i n g . F i n a l

21

PROCESS DIMENSIONS:

WASTES GENERATED Eliminated 7.5 million gal/day loading to municipal system

~~ ~

PRODUCTIVITY No change

PRODUCT QUALITY No change

DOWN TIME No change

FACILITIES Information not provided

EQUIPMENT Information not provided

RAW MATERIALS No Change

WATER Information not provided

ENERGY Information not provided

WASTE DISPOSAL Information not provided

POLLUTION CONTROL Information not provided

PERSONNEL/MAINTENANCE Information not provided

NET BENEFITS Permitted plant expansions otherwise precluded by limited municipal wastewater treatment capacity

22

CASE STUDY 3

TYPE OF INDUSTRY: Brewer NAME OF FIRM: Miller Brewing Company

LOCATION : 8 6 3 East Meadow Road (Kenneth R. Croft 919/627-2100)

P. 0. Box 3327 Eden, North Carolina 27288

SIC: 2 0 8 2

MODIFICATION

SALE OF TREATED BREWERY WASTES FOR AGRICULTURAL LAND APPLICATION

ABSTRACT: - Food processing wastes generated during the brewing operation at Miller Brewina Company are treated and made - - a;ailable farmers €or land application. The by-product is used for liming and as a nitrogen supplement. The reuse of this previously landfilled material has eliminated disposal costs for Miller, provided an inexpensive substitute for standard agricultural liming material, and preserved valuable landfill capac i ty .

23

ANNUAL COST SAVINGS: $ 8 8 , 0 0 0

PAYBACK PERIOD: N/A

TIME TO IMPLEMENT: 1 year

TRANSFERABILITY: The important features of the Miller Brewery wastes are that they are non- toxic, solid, and contain material suitable for agricultural purposes. These characteristics are common to many food processing wastes and, therefore, this modification may have wide application. The feasibility of this modification for other firms will depend on an analysis of the composition of the waste and availability of users. One important market option that should not be overlooked is the use of a waste exchange brokerage for transfer of wastes. Although Miller's wastes are in a solid form, a slurry could also be used for land application. The Miller wastes have distinct value for soil pH adjustment and as a source of usable nitrogen, however, even materials that are limited to improving soil texture would be valuable for agricultural and horticultural purposes.

ENVIRONMENTAL AND HEALTH BENEFITS: Conservation of land resources

24

PROJECT DESCRIPTION: Miller Brewing Company's Eden Brewery '

Wastewater Treatment Facility is a 5-million gallon per day activated sludge treatment plant. Wastewater is routed to the treatment plant from the brewing, packaging and utilities areas of the brewery complex. Domestic sewage from the brewery is treated through the City of Eden municipal treatment system.

During the activated sludge process, daily amounts of excess biomass are removed as waste sludge. The excess biomass is dewatered through high pressure plate and frame filters after conditioning with lime and related dewatering compounds. After the filtration process is completed, the biomass has a consistency of moist earth and is lime-rich. The company generates approximately 13,500 tons of waste sludge each year (wet weight). Until recently, this material has been buried in the Rockingham landfill, costing the firm $88,00O/year in hauling and landfill fees.

Miller Brewing Company had the biomass analyzed, and they determined it could be registered as an agricultural product. They offered the biomass to local agricultural and farm operatioRS as a "byproduct liming material with nitrogen" for land application. Seven and one half tons of the byproduct material are equivalent to 1 ton of standard agricultural lime.

Numerous ' farmers have asked to purchase this material for application to cropland. Miller Brewing Company is providing a desired material to local farm and agricultural operations at no cost. Thls method of pollution control creates a beneficial use for a once worthless material, reduces hauling and landfill fee expenses, and preserves landfill space for future use.

Miller Brewing Company also maintains an incentive awards program for employee suggestions which improve operations and/or reduce costs.

25

PROCESS DIMENSIONS:

WASTES GENERATED Eliminated 13,000 tons waste sludge/yr



DOWN TIME No change

FACILITIES No change

EQUIPMENT No change

RAW MATERIALS No change

WATER No change

ENERGY No change

WASTE DISPOSAL $88,00O/yr saved

POLLUTION CONTROL No change

PERSONNEL/MAINTENANCE Informatiop not provided

NET BENEFITS Annual cost savings and providing soi ls annendment material

26

CASE STUDY 4

TYPE OF INDUSTRY: Cologne, toilet water & perfume production NAME OF FIRM: The Coty Division of Pfizer, Inc.

LOCATION: P. 0. Box 1 0 2 6 (R. R. Clarke 919/774-8800)

Sanford, North Carolina 2 7 3 3 0 SIC: 2 8 4 4

MODIFICATION

HEAT RECOVERY FROM WASTE IGNITABLES

ABSTRACT : The Coty Division of Pfizer, Inc. has developed a method of incineration/heat recovery from waste organic chemicals. The ignitable hydro-alcoholic wastes are mixed with fuel oil and burned to produce steam and hot water. The company saves over 1000 gallons of fuel oil a year, and an unspecified amount of natural gas. The cost of hazardous waste disposal has been e 1 imi nated.

27

ANNUAL COST SAVINGS: $2800



TRANSFERABILITY:


Although the boiler modifications required were specific to this rather unique fuel source, the fundamental concept of using waste materials with fuel potential for heat recovery has numerous applications. I€ a match of fuel source and heat requirements cannot be made internally, a waste exchange contact might make such savings possible for two compatible firms.

Elimination o f threat to groundwater quality: conservation of land and fuel resources: elimination of fire hazard during transport and at the landfill- site

~

28

I

PROJECT DESCRIPTION: The Coty plant has historically had a small percentage of hydro-alcoholic products that become damaged or outdated and eventually must be destroyed. Prior to the Resource Conservation and Recovery Act of 1976, bottles of colognes, perfumes, and toilet waters were crushed, and the residual liquids, as well as the crushed containers, were trucked to a landfill for disposal. However, because hydro-alcoholic products are ignitable and constitute a hazardous waste according to RCRA, an alternative to landfill disposal was sought.

Several management strategies have helped to reduce the quantity of hydro-alcoholic waste. Substantial reductions have been accomplished through strong marketing campaigns, refurbishing of product returned from customers, and sales through employee and outlet stores. For the small percentage of waste hydro-alcoholic products remaining, it was decided to make use of their heat value, which is approximately two-thirds as great as that of fuel oil.

A unique system for collecting, distributing and burning the hydro-alcoholics was designed by Coty personnel. With minor modifications to the existing system and hot water boilers, construction of a collection apparatus, and installation of a special feed system, the hydro-alcoholics are burned'as a 20% mixture with fuel oil. This fuel mixture burns well, and for every gallon of hydro-alcoholics consumed, two-thirds of a gallon of fuel oil is conserved.

Coty has been using the system since November 1980 and reports savings of over 1,000 gallons of fuel oil and an unspecified amount of natural gas per year. The initial cost of the project was $ 7 , 5 0 0 , with a payback period of about 2.7 years. There are some minimum operating expenses, but the company is saving about $2,800 annually since it has eliminated all other waste treatment o r disposal costs. There are no hazardous air pollutants released from the boiler, and the current system has also eliminated the environmental and health risks associated with landfilling ignitable wastes.

29

PROCESS DIMENSIONS:

WASTES GENERATED Hydro-alchoholic wastes eliminated



DOWN TIME No change


EQUIPMENT $7500 one time cost


WATER No change

ENERGY $2800/year savings

WASTE DISPOSAL $2800/year savings


PERSONNEL/MAINTENANCE Minor cost increase

NET BENEFITS Relief from RCRA regulations; disposal cost savings

30

CASE STUDY 5

TYPE OF INDUSTRY: P e s t i c i d e P r o d u c t i o n NAME OF FIRM: Daly-Herr ing Company

LOCATION: P. 0. Box 428, N e u s e Road

SIC: 2879

( D . W. C r a i g 919/527-8001)

K i n s t o n , Nor th Caro l ina 28501

MODIFICATION

SEPARATION OF WASTE DUST STREAMS TO PERMIT REUSE OF DUST

ABSTRACT: Daly-Herr ing Company a l t e r e d t h e i r d u s t collection equ ipmen t operat ion so t h a t waste streams c o n t a i n i n g organic c h e m i c a l s f rom v a r i o u s p r o d u c t i o n areas are now c o l l e c t e d s e p a r a t e l y r a t h e r t h a n mixed i n a s i n g l e bag house . The c o l l e c t e d mater ia ls are n o l onge r c o n t a m i n a t e d by a l t e r n a t e waste streams, and e a c h is r e c y c l e d back t o t h e p r o c e s s where it was g e n e r a t e d . The f i r m h a s e l i m i n a t e d over $9 ,000 i n a n n u a l d i s p o s a l costs and es t imates t h e r e c o v e r e d m a t e r i a l is w o r t h more t h a n $2000/year .

31


PAYBACK PERIOD: 1 0 months

TIME TO IMPLEMENT: I n f o r m a t i o n n o t p r o v i d e d

TRANSFERABILITY:


T h i s p r o j e c t d e m o n s t r a t e s t h e u s e of w a s t e s t r e a m s e p a r a t i o n t o r e d u c e waste p r o d u c t i o n and d i s p o s a l costs . T h i s c o n c e p t c a n be a p p l i e d across i n d u s t r i e s , processes, and m a t e r i a l s . Whenever s e v e r a l w a s t e s t r e a m s a r e c u r r e n t l y b e i n g mixed , t h e r e is t h e o p p o r t u n i t y t o d e t e r m i n e i f s e p a r a t i o n c a n r e d u c e t h e t o t a l amoun t of h a z a r d o u s m a t e r i a l r e q u i r i n g d i s p o s a l , o r w h e t h e r , a s i n t h i s case, any of t h e s e p a r a t e d w a s t e stream components can be r e c y c l e d t o t h e p r o c e s s t h a t g e n e r a t e d them.

Reduced t h r e a t t o so i l and g r o u n d w a t e r , c o n s e r v a t i o n of m a t e r i a l s ; r educed r i s k t o employees r e q u i r e d t o h a n d l e , s to re and t r a n s p o r t waste mater ia ls

32

PROJECT DESCRIPTION: Daly-Herring Company manufactures pesticides and generates approximately 45,000 pounds/year of pesticide dust from two major production systems in the- plant. Until recently, the dust was collected in a single baghouse and was unsuitable for reuse because it contained a mixture of several pesticides. Approximately 112 drums of waste dust per year were landfilled at a cost of $28 per drum. Transportation, disposal, and labor costs totalled over $9,000 a year.

In April 1983 the firm replaced the single baghouse collection system with two separate vacuum air baghouse systems specific to the two production lines. Dust from the respective production areas is now collected separately into independent baghouses. The filtered dust is automatically shaken down into a hopper which augers the dust back to the production area where it was generated. The returned dust is classified as inert filler in the final product because of the costly quantitative analytical testing which would otherwise be required to characterize it as an active ingrediant. The recycling results in reduced raw material costs for production, and the elimination of dust/waste disposal costs. The payback period for the $9,600 new equipment investment and renovations was less than one year.

33

PROCESS DIMENSIONS:

WASTES GENERATED 45,000 l b / y e a r w a s t e d u s t e l i m i n a t e d

S l i g h t i n c r e a s e PRODUCTIVITY

PRODUCT QUALITY No Change

N o Change DOWN TIME


EQUIPMENT $ 9 , 6 0 0 One t i m e cost

RAW MATERIALS $2000/year s a v i n g s

WATER No Change

ENERGY No Change

WASTE DISPOSAL $9,00O/year s a v i n g s

POLLUTION CONTROL I n f o r m a t i o n n o t p r o v i d e d

PERSONNEL/MAINTENANCE No Change

NET BENEFITS Annual cost s a v i n g s and reduced l i a b i l i t y r i s k s

34

CASE STUDY 6

TYPE OF INDUSTRY: Production and sale of trace elements

NAME OF FIRM: Industrial and Agricultural Chemicals, Inc

LOCATION : Route 2

to the fertilizer industry

(Randall F. Andrews 919/843-2121)

SIC: Red Springs, North Carolina 28377 287

MODIFICATION

SUBSTITUTION OF INDUSTRIAL BY-PRODUCTS FOR VIRGIN RAW MATERIALS

ABSTRACT: Industrial and Agricultural Chemicals Inc. (IAC) uses materials substitution to reduce their raw material costs in the manufacture of trace element fertilizer formulations. Suitable inorganic chemical wastes are received from firms that would otherwise pay to landfill the materials. This arrangement constitutes a reuse of by-products which would conventionally be treated as wastes. Three examples are cited describing the utility of this arrangement to both IAC and the waste material donor.

35


PAYBACK PERIOD: W A

TIME TO IMPLEMENT: W A

TRANSFERABILITY:


This case study demonstrates the utility of the waste exchange concept. In all three examples cited, wastes to be landfilled by one firm were salvaged for recoverable material by another firm.

Prevention of groundwater contamination risks due to landfilling, conservation of land and material resources

36

PROJECT DESCRIPTION: Industrial and Agricultural Chemicals, Inc.(IAC) produces trace element €ormulations €or sale to the fertilizer industry. The elements they market include copper, boron, manganese, zinc, and magnesium. In several instances they have been able to reduce their production costs by substituting waste materials from other firms for virgin raw materials in their manufacturing processes. These substitutions include both on-going receipt of material such as copper sulfate and magnesium oxide wastes, and single-event acceptance of a batch of magnesium chloride which had become contaminated with copper chloride. In each case, the waste materials were otherwise destined for landfill disposal. IAC, therefore, obtains raw materials at no cost, and the firms donating material eliminate their disposal costs, which are often substantial. Furthermore, useable chemicals are not discarded, which saves land and material resources and reduces health and environmental risks.

IAC has realized a significant increase in the number of opportunities it has to accept free industrial wastes with the advent of the Piedmont Exchange. IAC representatives claim that waste exchanges have improved their profitability through increased opportunity to reduce their raw material costs.

37

PROCESS DIMENSIONS:

WASTES GENERATED Variable, no change

PRODUCTIVITY Improved


~~

DOWN TIME N/A


EQUIPMENT No Change

RAW MATERIALS Reduced

WATER No Change

ENERGY No Change

WASTE DISPOSAL Reduced disposal requirements

-

of donors

POLLUTION CONTROL No Change

PERSONNEL/MAINTENANCE No Change

NET BENEFITS C o s t Savings, resource conservation

38

CASE STUDY 7

TYPE OF INDUSTRY: Agricultural Chemical Research & Development Group

NAME OF FIRM: IC1 Americas Inc. (Paul Ekoniak 9 1 9 / 7 3 1 - 5 2 0 0 ) LOCATION: Goldsboro, North Carolina SIC: 2879

MODIFICATIONS

: 1) ESTABLISHMENT OF AN ENVIRONMENTAL COMPLIANCE COMMITTEE : 2 ) IMPROVED HOUSEKEEPING : 3 ) SOLVENT RECOVERY

ABSTRACT: IC1 Goldsboro, as a research and development Eacility, does not produce a large amount of waste. However, to manage the waste it does generate, a management initiative was undertaken in 1 9 8 1 to form an Environmental Compliance Committee to review issues and activities at IC1 that impact on the environment. Emphasis is first on early planning to minimize waste production, second on attempting to recycle or treat the waste whenever possible so that there is zero discharge. Measures recommended by the Committee and implemented include improved housekeepinq

distillation. The Committee's recommendations saved the Company an estimated $37,000 in waste disposal costs in 1984.

improvements and the initiation of waste solvent recovery by

39

ANNUAL COST SAVINGS: E s t i m a t e d $ 3 7 , 0 0 0 i n 1984 compared w i t h c o n d i t i o n s i n 1981

PAYBACK PERIOD: Immediate

TIME TO IMPLEMENT: On-go ing p r o c e s s

TRANSFERABILITY: T h i s approach t o c o n t r o l l i n g t h e g e n e r a t i o n of waste is b r o a d l y a p p l i c a b l e t o many waste g e n e r a t o r s . A waste a u d i t , good "housekeep ing" a n d s t r i n g e n t s e g r e g a t i o n o f w a s t e s t r e a m s w i l l u s u a l l y y i e l d a n e t r e d u c t i o n of w a s t e s r e q u i r i n g t r e a t m e n t . These e f f o r t s a r e v a l u a b l e f i r s t s t e p s i n waste r e c y c l i n g and m i n i m i z a t i o n , e s p e c i a l l y f o r t h e many s m a l l e r g e n e r a t o r s o f h a z a r d o u s was te who have been r e c e n t l y b r o u g h t under t h e RCRA r e g u l a t o r y framework. Such generators are c h a r a c t e r i s t i c a l l y less ab le t o m a k e l a r g e c a p i t a l i n v e s t m e n t s €or process m o d i f i c a t i o n s o r r e c y c l i n g equipment .

ENVIRONMENTAL AND HEALTH BENEFITS: Reduced t h r e a t t o a i r and g roundwate r

q u a l i t y : c o n s e r v a t i o n of r e s o u r c e s ; improved h e a l t h and s a f e t y c o n d i t i o n s f o r p l a n t p e r s o n n e l .

40

PROJECT DESCRIPTION:

I C I , Go ldsboro is i n v o l v e d i n r e s e a r c h and development o f a g r i c u l t u r a l c h e m i c a l s . They g e n e r a t e a v a r i e t y o f w a s t e s t r e a m s , h u t t h e t o t a l a m o u n t of waste produced is n o t v e r y l a r g e . T h e Company's wastes are f lammable non-ha logenated s o l v e n t s a n d non-flammable h a l o g e n a t e d s o l v e n t s w i t h RCRA c lass i - f i c a t i o n s F 0 0 2 , F 0 0 2 , F003, F 0 0 5 , DO01 and U057.

Waste management a c t i v i t i e s a t I C 1 have f o c u s e d o n t h e e v a l u a t i o n and p l a n n i n g o f any new p roposed p r o j e c t s i n order t o min imize o r p r e v e n t waste genera t ion . An Env i ronmen ta l Compliance C o m m i t t e e was formed t o o v e r s e e t h e s e a c t i v i t i e s and d e v e l o p and implement p r o c e d u r e s t o m i n i m i z e p r o d u c t i o n o f w a s t e s r e q u i r i n g l a n d f i l l i n g . The C o m m i t t e e c o n s i s t s of n i n e p e r s o n s w i t h v a r i o u s t y p e s o f e x p e r t i s e , and a s a r e s u l t o f t h e i r e f f o r t s , I C 1 r e p o r t s s i g n i f i c a n t reduct ion i n h a z a r d o u s w a s t e s s e n t o f f - s i t e f o r b u r i a l .

Al though t h e r e was no p r e v i o u s l y e x i s t i n g " p r o c e s s " w i t h which t o m a k e cost s a v i n g s c o m p a r i s o n s , i n d i c a t i o n s are t h a t a s i g n i f i c a n t r e d u c t i o n o f h a z a r d o u s wastes s e n t o f f - s i t e f o r management h a s o c c u r r e d . I n t h e l a s t 3-4 y e a r s t h e I C 1 g r o u p h a s more t h a n doubled i t s r e s e a r c h w o r k . I n t h e same p e r i o d , I C 1 h a s e s s e n t i a l l y r educed t h e amount o f h a z a r d o u s waste g e n e r a t e d by 70%.

I n 1981 t h e r e was no concerted e f f o r t t o r e d u c e t h e g e n e r a t i o n of waste; 1 0 0 55 -ga l lon drums were s e n t o f f - s i t e f o r treatment, r e c y c l i n g , o r b u r i a l ( a t a n a v e r a g e cost of $130/drum). I n 1984 o n l y 6 0 drums were s e n t o f f - s i t e ( a t a n a v e r a g e cost o f $266/drum). Tak ing i n t o a c c o u n t doub led o u t - p u t a t t h e l a b s , and r o u g h l y a 1 0 0 % i n c r e a s e i n treatment and d i s p o s a l costs per drum of h a z a r d o u s wastes o v e r t h e p a s t 3-4 y e a r s , I C I ' s waste p r e v e n t i o n s t r a t e g y h a s saved a n estimated $37,000 i n 1984 h a z a r d o u s w a s t e management costs.

F o l l o w i n g a r e examples of new p r a c t i c e s t h a t have been implemented t o h e l p r e d u c e t h e p r o d u c t i o n o f waste:

1) S p e n t c h l o r i n a t e d and n o n - c h l o r i n a t e d s o l v e n t s a r e now s e g r e - g a t e d t o allow o f f - s i t e d i s t i l l a t i o n and r e c o v e r y . S i n c e I C 1 u s e s a p p r o x i m a t e l y 55 g a l l o n s o f s o l v e n t / w e e k , t h i s h a s r e s u l t e d i n a cost s a v i n g s f o r t h e f i r m .

2 ) I n l a r g e s c a l e l a b o r a t o r i e s , s e p a r a t e waste c o n t a i n e r s are __ d e s i g n a t e d for non-hazardous and h a z a r d o u s was te . T h i s r e s u l t s i n less h a z a r d o u s w a s t e by r e d u c i n g c r o s s - c o n t a m i n a t i o n o f t h e non-hazardous w a s t e by h a z a r d o u s was te .

3 ) Unused p o r t i o n s o f c h e m i c a l s u s e d i n t h e a g r i c u l t u r a l r e s e a r c h E i e l d s a r e r e t u r n e d t o t h e cen ter f o r r e u s e o r r e f o r m u l a t i o n .

41

PROCESS DIMENSIONS:

WASTES GENERATED Reduced 70% (140 x 55 gal/year)



DOWN TIME No change


EQUIPMENT Minimal


WATER No change

ENERGY No change

WASTE DISPOSAL Estimated savings of $37,000 in 1 9 8 4

POLLUT$ION CONTROL No change

PERSONNEL/MAINTENANCE No change

NET BENEFITS Reduced waste disposal costs and conservation of resources

42

CASE STUDY a TYPE OF INDUSTRY: F u r n i t u r e M a n u f a c t u r e r NAME OF FIRM: Uni t ed Globe Corporation

LOCATION: P . 0. Box 907

SIC: 2 5 1

(Wayne Kennedy 704-246-5961)

L e x i n g t o n , Nor th Carol ina

MODIFICATION

INCINERATION O F FURNITURE MANUFACTURING WASTES FOR ENERGY AND HEAT RECOVERY

ABSTRACT: TWO major w a s t e streams g e n e r a t e d d u r i n g Un i t ed G l o b e ' s f u r n i t u r e m a n u f a c t u r e are i n c i n e r a t e d t o produce steam and h e a t . S o l i d s f rom t h e ragwash and s p r a y b o o t h process water wastes are t h i c k e n e d u s i n g d i s s o l v e d a i r f l o t a t i o n . The r e s u l t i n g s l u d g e is mixed w i t h woodchips , d r i e d , and f e d w i t h s e m i - s o l i d and l i q u i d f i n i s h i n g wastes t o t h e p r i m a r y combust ion chamber of a two-s tage i n c i n e r a t i o n sys t em. High BTU s o l v e n t wastes a r e f e d t o t h e s e c o n d a r y combust ion chamber. The steam produced is used €or s p a c e h e a t i n g , r agwash ing /d ry ing o p e r a t i o n s , and t h e s l u d g e d r y e r . U s e of t h e i n c i n e r a t o r h a s reduced Un i t ed G l o b e ' s waste volume by 95%, and t h e a s h produced is n o t h a z a r d o u s . D i s c h a r g e l o a d i n g t o t h e m u n i c i p a l sewer sys t em h a s d e c r e a s e d d r a m a t i c a l l y , a s have h a z a r d o u s waste t r a n s p o r t and d i s p o s a l costs .

43

ANNUAL COST SAVINGS: $905,00O/year

PAYBACK P E R I O D : L e s s t h a n 3 y e a r s

TIME TO IMPLEMENT: 1 y e a r

TRANS FE RAB I L I TY : The m o d i f i c a t i o n s made by U n i t e d Globe r e q u i r e a waste f u e l s o u r c e o f s u f f i c i e n t volume and BTU c o n t e n t t o o f f s e t t h e c a p i t a l cost of t h e i n c i n e r - a t o r u n i t . The wastes must a l so be f r e e o f h a l o g e n s . F i r m s smaller t h a n U n i t e d Globe which c a n n o t j u s t i f y t h e cost o f a n i n h o u s e u n i t c a n minimize t h e i r d i s p o s a l costs by s a l e o f t h e i r wastes f o r o f f s i t e i n c i n e r a t i o n . A c o o p e r a t i v e a r r a n g e m e n t among s e v e r a l s m a l l f i r m s m i g h t a l s o a l low the p u r c h a s e o f a n in- c i n e r a t o r f o r t h e g r o u p .

ENVIRONMENTAL AND HEALTH BENEFITS :

C o n s e r v a t i o n o f e n e r g y and m a t e r i a l r e s o u r c e s : r educed t h r e a t o f s u r f a c e or g roundwate r c o n t a m i n a t i o n by l a n d f i l l l e a c h a t e : r educed t h r e a t o f s u r f a c e water c o n t a m i n a t i o n by i n a d e q u a t e muni- c i p a l t r e a t m e n t of f u r n i t u r e m a n u f a c t u r i n g wastes: r e d u c e d t h r e a t o f a c c i d e n t d u r i n g h a z a r d o u s waste t r a n s p o r t .

44

PROJECT DESCRIPTION: I n October 1984 B u r l i n g t o n I n d u s t r i e s sold t h e i r f u r n i t u r e d i v i s i o n t o a p r i v a t e o w n e r , and The D i v i s i o n was renamed Uni t ed Globe C o r p o r a t i o n . U n i t e d Globe reports h e r e i n on a s i g n i f i c a n t w a s t e r e d u c t i o n m o d i f i c a t i o n which was implemented b e f o r e t h e y assumed ownersh ip , b u t which c o n t i n u e s t o p r o v i d e b e n e f i t s t o t h e on-going o p e r a t i o n .

U n i t e d Globe C o r p o r a t i o n ( f o r m e r l y B u r l i n g t o n I n d u s t r i e s F u r n i t u r e D i v i s i o n ) had two major s o u r c e s o f was te : ragwash and s p r a y b o o t h wastewater and semi-solid and l i q u i d f i n i s h i n g wastes. The fo rmer were d i s c h a r g e d t o t h e C i t y of Lex ing ton w a s t e w a t e r t r e a t m e n t p l a n t , and t h e l a t t e r were drummed and s e n t t o a l a n d f i l l i n S o u t h C a r o l i n a . Some o f t h e high-BTU l i q u i d w a s t e s were s e n t o f f - s i t e for i n c i n e r a t i o n and e n e r g y r e c o v e r y .

The ragwash and s p r a y b o o t h w a s t e s are g e n e r a t e d a t t h r e e o f t h e Company's f u r n i t u r e p l a n t s , and t h e y c o n t a i n o i l s , f i n i s h res idues and s o l i d s . The C i t y of Lex ing ton r e q u e s t e d t h a t t h e s e wastes be p r e t r e a t e d b e f o r e r e l e a s e i n t o t h e c i t y sewer sys t em. The s e m i - s o l i d and l i q u i d wastes are g e n e r a t e d a t s i x of B u r l i n g t o n ' s f u r n i t u r e f i n i s h i n g o p e r a t i o n s , and t h e y i n c l u d e up t o 4000 g a l l o n s / y e a r o f waste s o l v e n t . Much o f t h e s o l v e n t comes from f u r n i t u r e s t r i p p i n g . I t is a m i x t u r e o f t o l u e n e , x y l e n e , acetone, e t h a n o l , b u t a n o l , i s o p r o p y l a l c o h o l , n a p t h a , m e t h y i e t h y l k e t o n e , and esters. These wastes are u s u a l l y c o n t a m i n a t e d w i t h s t a i n s , f i l l e r s , g l a z e s , a n d n i t r o c e l l u l o s e . A small amount o f w a s t e s o l v e n t comes from equ ipmen t c l e a n - o u t or c o n t a m i n a t e d b a t c h e s of f i n i s h i n g material ,

I n o r d e r to a v o i d t h e h i g h costs of h a z a r d o u s waste s t o r a g e , t r a n s p o r t and d i sposa l , t h e Company s o u g h t a n a l t e r n a t i v e method of w a s t e management. P l a n t and c o r p o r a t e p e r s o n n e l worked o n a g e n e r a l s o l u t i o n , t h e n c o n s u l t e d w i t h equipment vendors before se lec t ing p a r t i c u l a r p i e c e s o f equipment . A c e n t r a l f a c i l i t y was c o n s t r u c t e d to house a n i n c i n e r a t o r and d e w a t e r i n g equipment . T o t a l cost f o r t h e b u i l d i n g and equipment was $1 .5 m i l l i o n .

A small i n c i n e r a t o r bo i le r package , manufac tu red by Consumat, w a s selected which c o u l d burn b o t h s o l i d and l i q u i d w a s t e and p r o d u c e steam f o r u s e a s h e a t and f o r ragwash o p e r a t i o n s . The i n c i n e r a t o r o p e r a t i o n c a l l e d f o r p l a n t w a s t e s t o be s e g r e g a t e d i n t o f o u r g roups : s o l i d s , heavy l i q u i d s , s l u d g e s , and s o l v e n t s . A c e n t r a l treatment sys t em f o r t h e Company's ragwash and s p r a y b o o t h wastewater was a l s o d e v e l o p e d t o s e p a r a t e t h e s o l i d mater ia l s from t h e w a s t e w a t e r .

As t h e sys t em c u r r e n t l y o p e r a t e s , s p r a y b o o t h and ragwash wastewater p a s s e s t h r o u g h a n o i l /water s e p a r a t o r and t h e n i n t o a mixing t a n k w h e r e i t is dosed w i t h a c i d and polymer t o promote f o r m a t i o n o f p r e c i p i t a t e . The p r e c i p i t a t e is t h e n removed i n a Baker d i s s o l v e d a i r f l o t a t i o n u n i t . The r e s u l t i n g s l u d g e is

45

m i x e d w i t h woodchips a n d o t h e r h i g h - m o i s t u r e s l u d g e and f u r t h e r d e w a t e r e d i n a H o l o f l i t e s l u d g e d r y e r . The d r i e d s l u d g e s a r e t h e n burned i n t h e lower chamber o f t h e i n c i n e r a t o r . Drums of low m o i s t u r e c o n t e n t s l u d g e s and v a r i o u s p l a n t w a s t e s are loaded by a s k i p loader t o a ram f e e d e r f o r t h e lower chamber.

Waste s o l v e n t s , a r e burned i n t h e uppe r chamber , which uses No. 2 f u e l o i l a s i t s p r i m a r y f u e l . The u p p e r chamber r u n s a t a t e m p e r a t u r e o f 1800 degrees F. The h e a t from t h e i n c i n e r a t o r f i r e s a b o i l e r t o m a k e steam which is used t o wash and d r y r a g s . I n w i n t e r , excess h e a t is used t o supp lemen t t h e p l a n t ' s s p a c e h e a t . T h e i n c i n e r a t o r a s h is non-hazardous and is s e n t t o t h e c o u n t y l a n d f i l l . S i n c e incinerator e x h a u s t s are w e l l w i t h i n e m i s s i o n s t a n d a r d s f o r t h e S t a t e , no s c r u b b e r is needed.

~~

Two w e l l t r a i n e d p e o p l e o p e r a t e t h e i n c i n e r a t o r , m o n i t o r i ts o p e r a t i o n , and p e r f o r m r o u t i n e p r e v e n t a t i v e ma in tenance . S p r a y b o o t h w a s t e w a t e r and drummed s o l v e n t w a s t e s are p icked ~p a t t h e v a r i o u s U n i t e d G l o b e ' s p l a n t s and t r a n s p o r t e d t o a c e n t r a l f a c i l i t y f o r dewatering and i n c i n e r a t i o n .

The i n c i n e r a t o r began f u l l o p e r a t i o n i n 1982, and b u r n s a p p r o x i m a t e l y 1.5 m i l l i o n pounds o f waste e a c h y e a r . The Company h a s decreased i t s h a z a r d o u s waste d i s p o s a l r e q u i r e m e n t s by 95% and based on 1981 d a t a , a v o i d e d d i s p o s a l costs of a p p r o x i m a t e l y $9 0 5,00O/year . The f i r m a l so r e c e i v e s s p e n t s o l v e n t wastes from smaller f u r n i t u r e companies f o r i n c i n e r a t i o n a t a c h a r g e of $29.00 per drum which g e n e r a t e s a d d i t i o n a l r evenue . The cost o f t h e i n c i n e r a t o r is e x p e c t e d t o have a payback p e r i o d of a p p r o x i m a t e l y t h r e e y e a r s , depend ing o n m a r k e t c o n d i t i o n s .

The i n c i n e r a t o r s y s t e m h a s a l so had m u l t i p l e e n v i r o n m e n t a l b e n e f i t s . The C i t y of L e x i n g t o n wastewater treatment f a c i l i t i e s have been r e l i e v e d o f a heavy p o l l u t i o n load, no h a z a r d o u s w a s t e is t r a n s p o r t e d o r b u r i e d i n a l a n d f i l l , and e n e r g y resources a re c o n s e r v e d .

46

" I

PROCESS DIMENSIONS:

WASTES GENERATED 95% volume reduction of Burlington wastes 1.5 million pounds/year hazardous waste (Burlington plus others) eliminated



DOWN TIME No change

FACILITIES Included with equipment costs

EQUIPMENT $1.5 million One-time cost



ENERGY $36,00O/yr fuel cost

WASTE DISPOSAL $905,00O/yr. savings


PERSONNEL/MAINTENANCE $60,00O/yr cost

NET BENEFITS Relief from hazardous waste management costs; relief from compliance pressure from municipal treatment facility, annual cost savings

47

CASE STUDY 9

TYPE OF INDUSTRY: M a n u f a c t u r e r of p r i n t e d c i r c u i t b o a r d s NAME OF FIRM: Data G e n e r a l C o r p o r a t i o n

LOCATION: S t a t e Road 42E ( S t a n T a y l o r 919/553-5076)

SIC: C l a y t o n , Nor th C a r o l i n a 27520 3573,3679

MODIFICATIONS

1. IDENTIFICATION OF MARKETS FOR SALE OF

2 . PROCESS CHANGES TO OBTAIN MARKETABLE SLUDGES FOR

3. LAND APPLICATION OF PRETREATED METAL PLATING

UNTREATED WASTES

COPPER RECOVERY

WASTES

ABSTRACT: Data General C o r p o r a t i o n g e n e r a t e s s eve ra l h a z a r d o u s w a s t e s t r e a m s d u r i n g t h e m a n u f a c t u r e o f p r i n t e d c i r c u i t b o a r d s . Most of these w a s t e s a r e c h a r a c t e r i z e d by h i g h heavy metal c o n c e n t r a t i o n s . I n 1981 t h e Company l aunched a vigorous program t o r e d u c e t h e i r reliance o n h a z a r d o u s waste l a n d f i l l s . A management i n i t i a t i v e t o d e v e l o p m a r k e t s f o r t h e i r w a s t e s r e s u l t e d i n $9000/year i n d i s p o s a l cost s a v i n g s and r e v e n u e from sa le o f u n t r e a t e d wastes. T r e a t m e n t o f o t h e r w a s t e s u s i n g new p r o c e s s c h e m i s t r y , i n c l u d i n g changes i n equipment d e s i g n or o p e r a t i o n , r e n d e r e d a d d i t i o n a l mater ia l s u i t a b l e f o r s a l e f o r metal r e c o v e r y . A f i l t r a t i o n sys t em f o r process water y i e l d s a n e f f l u e n t c l e a n enough f o r - l a n d a p p l i c a t i o n on company-owned f o r e s t l a n d . Data G e n e r a l p s program to p roduce s a l e a b l e w a s t e s and m a r k e t t h o s e wastes h a s r educed t h e h a z a r d o u s ma te r i a l t h e y l a n d f i l l by over 400 t o n s / y e a r and y i e l d e d a cost s a v i n g s o f $180,00O/year.

48

ANNUAL COST SAVINGS: $18 0,O OO/yea r

PAYBACK PERIOD: 1.5 months

TIME TO IMPLEMENT: 3 years

TRANSFERABILITY: The strategy of focusing on sale of wastes at their current l e v e m generation rather than reduction of waste volumes is feasible if the wastes contain materials which are valuable and for which the recovery technology exists. Use of a waste exchange might help a generator to evaluate potential markets and determine what treatments might be necessary to make wastes saleable. The use of a consultant or assistance from a trade association might also be helpful in making these determinations. Some of the treatment methods developed by Data General resulted in significant waste volume reduction, even though this was not their primary objective.

plating wastewater is not widely used, and the feasibility of such a system would require significant engineering evaluation, land availability, and willingness to maintain a careful monitoring program. Data General has shared data from their operation with the North Carolina Agricultural Extension Service, which might also serve as a resource for other firms considering this modification. The advantages of such a system are that it reduces the pollution load on municipal treatment facilities and allows the wastewater to serve a s a supplementary source of irrigation.

Land application of treated

ENVIRONMENTAL AND Reduced risk of soil and groundwater HEALTH BENEFITS: pollution by heavy metals; conservation

of land and material resources. Because of the potential for accumulation of metals in the soil, frequent monitoring __ of treated effluent, soil, plants, and groundwater is required to ensure a land application system is functioning properly.

49

PROJECT DESCRIPTION: Data G e n e r a l C o r p o r a t i o n i n C l a y t o n , Nor th C a r o l i n a m a n u f a c t u r e s p r i n t e d c i r c u i t b o a r d s f o r computers . The wastes from t h e f a b r i c a t i o n , a s sembly , and t e s t i n g of t h e c i r c u i t b o a r d s i n c l u d e s p e n t e t c h a n t and p l a t i n g b a t h s , s t i l l bottom wastes f r o m s o l v e n t c l e a n e r r e c l a m a t i o n , and process w a t e r c o n t a m i n a t e d w i t h metals such as c o p p e r , n i c k e l , and l e a d . Many of these wastes a r e h a z a r d o u s and are g e n e r a t e d i n s i g n i f i c a n t volume. I n 1 9 8 1 , t h e f i r m se t a g o a l t h a t l a n d f i l l d i s p o s a l s h o u l d be used o n l y a s a method of l a s t r e s o r t . They s e t o u t a n a m b i t i o u s p l a n of a c t i o n as follows:

1) A l l w a s t e s t r e a m s t h a t have a monetary v a l u e and t h a t c a n be e c o n o m i c a l l y r e c o v e r e d s h o u l d be r o u t e d t o some r e c o v e r y p r o c e s s , o n or o f f - s i t e . 2 ) Remaining waste s t r e a m s s h o u l d be m o d i f i e d by m a n u f a c t u r i n g o r waste t r e a t m e n t p r o c e s s changes so t h a t t h e y c a n be r e n d e r e d m a r k e t a b l e o r a r e no l o n g e r h a z a r d o u s by d e f i n i t i o n and c a n be d i s p o s e d o f i n t h e l oca l l a n d f i l l . 3 ) Wastes which c a n n o t meet t h e g o a l s s t a t e d above s h o u l d be r e n d e r e d s u i t a b l e for d i s p o s a l i n a p r o p e r l y d e s i g n e d and l i c e n s e d i n c i n e r a t o r . 4 ) If a l l else f a i l s , t h e volume of w a s t e r ema in ing s h o u l d be r e d u c e d t o a minimum and b u r i e d i n an approved h a z a r d o u s waste l a n d f i 11.

T h i s program r e q u i r e d t h a t a l l p h a s e s of t h e Data G e n e r a l o p e r a t i o n be e v a l u a t e d . T h e Company p o i n t s o u t t h a t t h e i r s t r a t e g y i n v o l v e s p l a c i n g p r i m a r y emphas is on t h e of s p e n t c h e m i c a l s and s l u d g e s , no t on r e d u c i n g o r e l i m i n a t i n g the p r o d u c t i o n o f t h e s e w a s t e s . They b e l i e v e t h i s removes t h e r i s k o f s a c r i f i c i n g p r o d u c t q u a l i t y o r q u a n t i t y €or improved p o l l u t i o n c o n t r o l . They have m o d i f i e d c e r t a i n m a n u f a c t u r i n g p r o c e s s e s t o s e r v e t h e waste t rea tment program, b u t o n l y w i t h t h e f u l l s u p p o r t of t h e p r o c e s s e n g i n e e r . Data G e n e r a l r e p o r t s t h a t a p p r o x i m a t e l y 15% of t h e t o t a l p r i n t e d c i r c u i t board f a b r i c a t i n g process e n g i n e e r i n g e f f o r t o v e r t h e l a s t two y e a r s h a s been devoted t o t h e waste management program. T h i s h a s i n c l u d e d m a r k e t i n g a c i t i v i t i e s t o f i n d b u y e r s f o r t h e i r w a s t e s , o p e r a t i o n a l r e v i s i o n s and development of new p r o c e s s c h e m i s t r y , and s e v e r a l e f f o r t s to share t h e i r program w i t h s t a t e p e r s o n n e l and u n i v e r s i t y e x t e n s i o n a g e n t s .

S a l e o f U n t r e a t e d Wastes -- M a r k e t s were i d e n t i f i e d f o r t h e f o l l o w i n s u n t r e a t e d waste -

s t reams :

1 ) S p e n t c u p r i c c h l o r i d e e t c h a n t 2 ) S p e n t p l a t i n g b a t h s

a ) Acid c o p p e r b a t h b ) P a l l a d i u m c a t a l y s t b a t h c ) S p e n t s u l f u r i c a c i d f rom t h e e t ch -back process on t h e

electroless copper l i n e 3 ) Copper s u l f a t e c r y s t a l s f rom r e g e n e r a t i o n of t h e s u l f u r i c -

p e r o x i d e b a t h

50

, ,

4 ) S p e n t ammonia e t c h a n t 5 ) S p e n t n i c k e l p l a t i n g b a t h 6 ) S t i l l bottoms from t h e l , l , l - t r i c h l o r o e t h a n e r e c o v e r y process.

These w a s t e s are s h i p p e d e i t h e r a t no cost or f o r p r o f i t t o b u y e r s , y i e l d i n g t h e f i r m a p p r o x i m a t e l y $9,00O/year i n d i s p o s a l cost s a v i n g s and r evenue . The wastes t o t a l a p p r o x i m a t e l y 90,000 pounds /yea r .

Sale o f T r e a t e d Wastes -- S e v e r a l wastes were t r e a t e d t o p u t them i n a s a l e a b l e form:

1) S p e n t e lectroless copper b a t h is t reated i n a b a t c h p r o c e s s f o r c o p p e r removal . By r a i s i n g t h e pH o f t h e b a t h a n d a d d i n g fo rma ldehyde a s a r e d u c i n g a g e n t , t h e c o p p e r i n s o l u t i o n is d e s t a b i l i z e d . The b a t h is s e e d e d w i t h f i n e l y powdered c o p p e r s ludge g e n e r a t e d i n a p r e v i o u s p r o c e s s , and t h e d e s t a b i l i z e d c o p p e r p r e c i p i t a t e s o u t as e l e m e n t a l c o p p e r . The r e s u l t i n g s l u d g e is 90% me ta l l i c c o p p e r . T h i s p r o c e s s is soon t o be r e v i s e d t o i n c l u d e t h e a d d i t i o n o f s p e n t a c i d c o p p e r - b e a r i n g b a t h s , s u c h a s t h e s u l f u r i c p e r o x i d e e t c h a n t , to be added t o t h e above m i x t u r e . The r e v i s e d t r e a t m e n t o p e r a t i o n w i l l e l i m i n a t e a p p r o x i m a t e l y 151 ,800 pounds /year of waste s l u d g e a t a s a v i n g s of a p p r o x i m a t e l y $16,30O/year .

2 ) P r o c e s s water from p r i n t e d c i r c u i t board f a b r i c a t i o n , a s s e m b l y , and t e s t i n g is t r e a t e d u s i n g a c r o s s - f l o w f i l t r a t i o n water p u r i f i c a t i o n sys t em m a n u f a c t u r e d by B a k e r B r o t h e r s , I n c . The f i l t e r s were p h y s i c a l l y m o d i f i e d so t h a t t h e membrane f i l t e r b u n d l e s c o u l d b e c l e a n e d q u i c k l y and e a s i l y , and t h e waste f low p a t t e r n and p r o c e s s c h e m i s t r y were a l t e r e d t o e l i m i n a t e t h e u s e o f f e r r o u s s u l f a t e c o a g u l a n t . The wastes are reduced w i t h sodium h y d r o s u l f a t e and t h e n p r e c i p i t a t e d o u t of s o l u t i o n . A f t e r t h e f e r r o u s s u l f a t e was removed, t h e heavy metal h y d r o x i d e s l u d g e no l o n g e r c o n t a i n e d i r o n , and it c o u l d be s u c c e s s f u l l y p r o c e s s e d f o r copper r e c o v e r y .

Waste streams which are n o t t r e a t a b l e i n t h e c o n t i n o u s water p u r i f i c a t i o n s y s t e m (WPS) or which c o n t a i n s t r o n g c h e l a t i n g a g e n t s or are h i g h i n o r g a n i c compounds which i n t e r f e r e w i t h t h e WPS p r o c e s s are b a t c h - t r e a t e d u s i n g s o d i u m s u l f i d e . The s u l f i d e s l u d g e is v e r y f i n e , and c a r e f u l c o n t r o l of t h e p r o c e s s is n e c e s s a r y t o p roduce a s l u d g e which can be removed i n a f i l t e r p r e s s . M o n i t o r i n g is a l s o r e q u i r e d t o p r e v e n t t h e f o r m a t i o n o f hydrogen s u l f i d e and t h e r e s u l t i n g o d o r problems. I n order t o m a i n t a i n a h i g h c o p p e r f r a c t i o n i n t h e s l u d g e , no c o a g u l e n t s u c h ~

as l i m e o r f e r r o u s s u l f a t e is used . An o r g a n i c polymer is used t o h e l p improve s l u d g e c h a r a c t e r i s i t i c s and t h e s u l f i d e s l u d g e is o f t e n b l ended w i t h t h e metal h y d r o x i d e s l u d g e from t h e WPS t o improve f i l t r a t i o n c h a r a c t e r i s i t i c s d u r i n g f i l t e r press d e w a t e r i n g . The b a t c h t r e a t m e n t p r o c e s s e l i m i n a t e s t h e sh ipmen t ~

o f a p p r o x i m a t e l y 18 ,000 g a l l o n s / y e a r of s l u d g e f o r l a n d f i l l d i s p o s a l , y i e l d i n g a b o u t $16,50O/year i n d i s p o s a l cost s a v i n g s and r e v e n u e .

~

51

Separation of waste streams and the changes in process chemistry described decreased reagent costs $74,00O/year and cut sludge volume in half. Transport and disposal costs totalling $56,00O/year were eliminated, and Data General receives $7200/year revenue from sale of the sludge. Equipment costs for the modifications totalled $17,500.

Sludges from the W S and the batch sulfide precipitation are dewatered in a filter press. The addition of an air blow-down line to the press was accomplished at minimal cost, and the solids concentration of the filter cake has increased from 15% to 60% solids. Depth filters which were previously used to polish the press effluent were eliminated after the press operation was improved. The depth filters had previously generated 300 pounds/month of spent filters which required landfill disposal.

On-Site Reuse of Treated Wastes The copper-laden sludge from the process water filtration

system is treated and sold for copper recovery, as described above. The treated process water is disposed of by land application on forest land owned by the Company. This site was the first land application site for pretreated metal plating waste in North Carolina.

There are approximately 27 acres of land committed to the system. The Company discharges about 200,000 gallons/day to the area, and they are permitted to deliver no more than two inches per week of irrigation flow to the site. Copper is the limiting constituent of their wastewater, and their permit regulates the amount of copper tlhey may apply.

Data General has a comprehensive monitoring program for the site. Surface watlers above and below the system are sampled, and two monitoring wellls were drilled for groundwater testing. The Company has exper'ienced no problems with the system, and they anticipate the site will remain suitable for cropland after Data General has ceased the land application operation.

Incineration of Treated Wastes Data General has begun incineration of oil and flux waste from

the wave folder operation to avoid hazardous waste land disposal of the lead-containing wastes.

In summary, Data General is aggressively pursuing its goal of eliminating their use of hazardous waste landfills. In the process, they have developed new methods (land application of pretreated metal plating wastes; sulfide precipitation for strongly chelated wastes; and treatment of chelated process rinse waters without conventional coagulants which results in reduced sludge volumes), and they have reduced their disposal costs by over $80,00O/year. They estimate their total process cost savings for the several modifications to be over $100,00O/year. Capital investment for the sludge recovery program was less than $50,000.

52

I ,

They are b e g i n n i n g p i l o t t e s t i n g of new equ ipmen t d e s i g n e d t o remove copper from s o l u t i o n e l e c t r o l y t i c a l l y . A woven f i b e r c a t h o d e w i l l p r o v i d e i n c r e a s e d s u r f a c e area f o r p l a t i n g , and t h e c o p p e r w i l l be s t r i p p e d from t h e c a t h o d e e l e c t r o l y t i c a l l y o n t o a s t a r t e r s h e e t . Because t h e sys t em uses a c a p t i v e e l e c t r o l y t e , no l i q u i d waste s o l u t i o n is g e n e r a t e d d u r i n g t h e c a t h o d e s t r i p p i n g . The equipment is manufac tu red by Metal Removal Sys tems, a D i v i s i o n of PCK T e c h n o l o g i e s i n N e w Y o r k . Data G e n e r a l a n t i c i p a t e s t h e p r o c e s s w i l l be much more economica l and w i l l

c o p p e r s l u d g e r e q u i r i n g f u r t h e r c o p p e r r e c o v e r y o p e r a t i o n s .

~~

produce a metal shee t which c a n be s o l d f o r s c r a p , r a the r t h a n a -~

53

PROCESS DIMENSIONS:

WASTES GENERATED Eliminated process water waste; reduced wastes requiring burial by 400 tons/year



DOWN TIME



RAW MATERIALS Conserved, reduced cost

WATER No change

ENERGY No change

WASTE DISPOSAL $80,00O/year savings

POLLUTION CONTROL $100,00O/year savings


Decreased 75%

NET BENEFITS Relief from hazardous waste management costs; annual cost savings

54

CASE STUDY 10

TYPE OF INDUSTRY: Metal Finishing-Manufacturer of Stationary

NAME OF FIRM: Emerson Electric Company Power Tools

Special Products Division (Layton Schuh 704/837-5101)

Murphy, North Carolina 28209 LOCATION: Route 1, Box 549

SIC: 35,36

MODIFICATIONS

USE OF A WATERBORNE ELECTROSTATIC PAINT SYSTEM INSTEAD OF CONVENTIONAL ORGANIC SOLVENT ELECTRO- STATIC PAINT SYSTEM INSTALLATION OF A COMPUTERIZED ROBOTIC ELECTRO- PLATING SYSTEM INSTALLATION OF AN ULTRAFILTRATION SYSTEM FOR OIL AND PROCESS CHEMICAL RECOVERY INSTALLATION OF A COMPUTERIZED ENERGY MANAGEMENT SYSTEM DEVELOPMENT OF A COMPREHENSIVE CHEMICAL WASTE MANAGEMENT PROGRAM INTRODUCTION OF AN INCENTIVE PROGRAM FOR NEW COST REDUCTION OR PRODUCT IDEAS

:

ABSTRACT: Emerson Electric Company has made a series of modifications which have significantly decreased operating costs; increased productivity; reduced solvent, paint solids and plating chemical costs; conserved energy; improved product quality; provided a safer working environment; and conserved raw materials. Several of the improvements involved the purchase of new equipment which allowed automation of their electroplating process and energy management system. Conversion from an organic solvent-based paint system to a water-based system reduced paint solvent and paint sludge losses by 4 0 % . The addition of an ultrafiltration system for their wastewater stream has allowed the recovery of oil and process chemicals. As a result, the load to the wastewater treatment system has been reduced, and $11,000 __

management initiative to develop a program to oversee all waste management activities has also been instituted. Several housekeeping improvements have resulted from this program and yielded __ significant cost and environmental benefits. ~

in raw materials are returned to the production processes. A -

55

ANNUAL COST SAVINGS: $1.8 million/year

PAYBACK PERIOD: 1) 1.1 years 2 ) 1.1 years 3 ) 2 years 4 ) 5 years

TIME TO IMPLEMENT:

TRANSFERABILITY:


1 year

The most important feature of this set of mod if ica t ions is the comprehensive nature of Emerson's pollution prevention activities and the significant savings they were able to realize as a result of their efforts. Changes were made in several finishing processes which reduced the amount of wastes requiring treatment in their on-site system. Several of the modifications required significant capital expenditures which might not be cost- effective at smaller facilities. The housekeeping activities demonstrate the savings that can be achieved by consistently monitoring all phases of a manufacturing operation and keeping abreast of new product development.

Conservation of material resources: conservation of energy: elimination of oil spill risks: reduction of oil and chemical loading to effluent stream: Reduced employee exposure to organic solvents, acids and caustics.

56

. I

PROJECT DESCRIPTION: Emerson Electric Company manufactures stationary power tools, which require both metal finishing and painting operations. Chemical processes in operation include the f ol lowing : 1) An electrostatic paint system with a seven stage metal pretreatment line to finish 75,000 square feet per day of parts. 2 ) A black penetrate and zinc electroplating line to finish 10,000 pounds of small parts/day. 3) An aluminium die casting facility to produce 30,000 pounds of par ts/day . 4 ) A paint stripping line to strip paint from 1,000 square feet of parts/day. 5) A two stage small parts washer that cleans 3,000 pounds/day of ware. 6) A vibratory finishing line to process 4,000 pounds per day of parts. 7 ) A machining center that contains 2,000 gallons of machine coolant and generates 10,000 pounds of miscellaneous sludge and 7 5 gallons of spent chemicals/day.

When Emerson installed an automated metal electroplating system to replace their manual operation, annual productivity increased $200,000, and system down-time decreased from 8% to 4 % . Chemical consumption has decreased 25%, resulting in an annual reduction of $8,00O/year in raw material costs. Water costs have been reduced by $1,100 per year, and plating wastes, including acids, caustic, and oils, have decreased from 450 to 360 pounds/day. Treatment costs for the process water used in the plating operation have been reduced 25%. Annual personnel and maintenance cost savings attributable to the new system are $35,00O/year. The automated system has also eliminated worker exposure to acids and caustics, which was required with the previous ma nua 1 operation.

A second major revision to the metal finishing operation was the substitution of a water-based anodic electrostatic immersion paint system for an existing organic solvent paint system. As a result the quality of the paint application has been greatly improved, and annual productivity has increased by $1,000,000. Down-time for the new system has decreased from 3% to 1%. The water based system allows 99.5% recovery and reuse of paint. Consequently, raw material paint costs have decreased $600,000 /year. Instead of generating 3000 pounds/day of aromatic, chlorinated waste solvent and 7 0 pounds/day of paint solids, daily waste quantities have decreased to 150 pounds/day of non- reactive solvent and 2 pounds/day of paint solids. As a result of these changes, hazardous waste disposal costs have been reduced from $10,00O/year to only $300 per year. Personnel and maintenance costs for the new paint system have been decreased by 4 0 % , and worker exposure to organic paint solvents has been eliminated.

57

The wastewater from the manufacturing process, which contains oil and process chemicals, is treated on-site in a 5 5 , 0 0 0 gallons/day NPDES permitted wastewater treatment plant. The plant includes neutralization, polymerization, dissolved air flotation, sand filtration, and carbon adsorption processes. The effluent is discharged to a Class I1 stream. The addition of a $65 ,000 oil skimmer and ultrafiltration system has allowed the recovery of oil worth $8,00O/year. Twenty-f ive hundred gallons/month of reusable alkaline cleaning solution are also recovered, saving approximately $3,00O/year. About 370 pounds/month of BOD are removed by the ultrafiltration unit. The reduced organic loading to the treatment system has cut water treatment costs by $10,00O/year. The new filtration process has also saved the firm from having to install additional water treatment capacity.

~~

In addition to these specific process modifications, a broad-based chemical waste management program has been developed at Emerson. The program was initiated throughout the Special Products Division of Emerson Electric with the President and Vice President of Operations taking personal action. The program was initiated because the Company had a number of specific waste management problems, including:

1) Continual oil spills at the scrap loading site. The oil contaminated the surrounding surface water which ultimately drained to the adjacent creek. Approximately 20 gallons/week of water soluble, petroleum-based oil was released to the environment. 2 ) Continual oil spills from the aluminum die casting facility contaminated an adjacent waterway. Approximately 4 5 gallons/week of water soluble and water insoluble petroleum-based and synthetic oils were released to the environment. 3 ) Weekly episodes of unauthorized dumping of process chemicals into the water treatment system. This practice overloaded the treatment system8s organic removal capacity and resulted in subsequent inefficient metal removal. 4 ) Monthly overloads of the wastewater treatment system by dumping of spent concentrated alkaline cleaner solution. As a result of this practice, the effluent exceeded allowable limits for organics and metals. 5 ) Improper labeling and storage of hazardous and non-hazardous chemical wastes which could enter an adjacent waterway if spilled. At one time 20,000 pounds of unidentified chemical wastes were being stored outside. 6 ) Excessive use of chlorinated solvents in degreasing operations which impacted the wastewater treatment system. Approximately 1800 pounds/month of solvent were used, half of which was introduced to the wastewater treatment plant. 7 ) Improper use of zinc chromates as an algacide in the ~

gallons/minute of continual blowdown containing zinc chromates were discharged to the storm drain.

__

evaporative cooling water systems. Approximately 4 ~

58

After the waste management program was begun, the Company reports :

1) $25,000 were invested in a die cast sump and pumping facility and in a scrap loading facility. All oils were previously being lost from die cast and the scrap loading site, approximately 65 gallons/week are now recovered. The improvements save approximately $8,00O/year. 2 ) All unauthorized dumping of waste chemicals to the wastewater treatment plant has been discontinued. Operation of the treatment facility has improved, and effluent guidelines are being protected. 3 ) $3,000 were invested in drum storage and handling. All hazardous chemical wastes are properly labeled, stored, manifested and managed by an EPA approved vendor. No hazardous wastes are stored outside; they are properly stored and specially treated or picked up by proper vendors. 4) Degreasing with chlorinated solvents has been reduced by 80%. A steam cleaner was purchased for $5,000, and degreasing is accomplished by using an alkaline detergent and steam. This has reduced the toxic organic loading to the wastewater treatment plant, and the treated effluent is meeting the current proposed guidelines. 5) The algacides in the cooling water systems were reformulated and the zinc chromates removed. Chlorinators for the cooling towers were purchased for $1000.

The management program remains ongoing and is monitored by the in-plant Process Engineer. The continuing goals of the program are:

1) To improve the daily operations and effluent of the wastewater treatment plant by eliminating unauthorized dumping of spent chemicals. 2 ) To secure the safety of employees by educating them about the proper disposition of all waste process chemicals. 3 ) To prevent chemical spills on plant grounds. 4) To comply with the pertinent RCRA regulations and other relevant environmental laws.

Process technicians maintain daily log sheets. All plant personnel who have designated responsibilities in the program have been properly informed and have access to the management booklet. Any violations of the stated procedures are reported to the Plant Manager.

Emerson also maintains an incentive awards program to encourage new ideas for cost savings or new product development. Items such as color televisions, radios, and stereos are awarded - to acknowledge employee contributions.

__

A final installation of which saves the

modification reported by Emerson was the a $100,000 computerized energy management system firm $145,000 in electrical costs and has reduced

59

I ,

personnel and maintenance costs an additional $2,00O/year.

PROCESS DIMENSIONS:

WASTES GENERATED 1) Elimination of 3000 lbs/day of aromatic chlorinated solvent waste (paint system)

2) Reduction of paint solids waste from 70 to 2 lbs/day (paint system)

3 ) Reduction of plating acid, caustic and oil from 450 lbs/day to 360 lbs/day (plating system)

4 ) Elimination of 65 gallons/ . day of waste oil (ultrafiltration)

chlorinated solvents from 900 to 180 lbs/month (degreasing)

chromate discharge to storm drains (cooling water)

5) Reduction of waste

6) Elimination of zinc

PRODUCTIVITY 1) Increase of $1,000,000/year (paint system)

(plating system) 2) Increase of $200,00O/year

PRODUCT QUALITY Improved paint coverage,

DOWN TIME 1. Reduced from 3% to 1% by

uniformity of coat_inq thickness

new paint system 2. Reduced from 8% to 4 % by new plating system

FACILITIES $200,000 One-time cost

EQUIPMENT $674,000 One time cost


WATER $ 2,200/yr savings

ENERGY $145,00O/yr savings ___

WASTE DISPOSAL $ 52,70O/yr savings

POLLUTION CONTROL $380,00O/yr cost

PERSONNEL/MAINTENANCE $157,00O/yr savings

60

. I

NET BENEFITS Annual cost s a v i n g s ; improved o n - s i t e waste treatment e f f i c i e n c y ; reduced r e g u l a t o r y p r e s s u r e s , decreased worker ~

exposure to o r g a n i c s o l v e n t s ~

61

CASE STUDY 11

TYPE OF INDUSTRY: Stee l Smelting NAME OF FIRM: Florida Steel Corporation

Charlotte Steel Mill Division (Dennis E. Tebby 704/596-0361)

LOCAT ION : I P. 0. Box 31067

S I C : Charlotte, North Carolina 28231 3312

I I I I

: W D I F ICATIDU :

SALE OF WASTE DUST FOR ZINC RECOVERY

ABSTRACT: Florida Steel Corporation sells metal dust collected from furnace fumes to a zinc smelter. This practice has reduced their disposal costs by almost half and allows reuse of the metal rather than disposal.

62


PAYBACK PERIOD: Immediate

TIME TO IMPLEMENT: N/A

TRANSFERABILITY: Any firm producing significant quantities of metallic dust could pursue opportunities for sale or donation of the dust to reduce disposal costs and risks. Pertinent information to such an investigation would include composition analysis of the waste, possible alternative uses, and availability of marketg. One important market option that should not be overlooked is the use of a waste exchange brokerage. * , I 8

ENVIRONMENTAL AND Conservation of land and material HEALTH BENEFITS: resource@; reduced threat of heavy metal

contamination to surface water and groundwater from landfill leachate

63

PROJECT DESCRIPTION: Florida Steel Corporation produces steel in two electric arc furnaces. Scrap steel is the predominant raw material and includes such items as shredded automobiles, machine shop turnings, and heavy plate. The fumes emitted from the furnaces are ducted to baghouses where the gas is filtered. Approximately 2700 tons of waste dust are collected from the furnace each year. Because electric furnace dust has been categorized as a hazardous waste by the EPA, the Company has been unable to landfill the waste dust on-site, as had been done in the past. The waste material was deposited in a hazardous waste landfill in South Carolina at a cost of $109 per ton, which included transportation, disposal fees, and charges imposed by the state of South Carolina.

Chemical analyses of the waste dust revealed high concentrations of zinc. The firm has recently arranged to ship the furnace dust to a zinc smelter for metal recovery at a cost o f $61 per ton. This has resulted in significant cost savings to Florida Steel, elimination of the pollution risks associated with the landfilling of zinc, and recovery of a useable material, zinc oxide .

64

PROCESS DIMENSIONS:

Reduced WASTES GENERATED



DOWN TIME No chanqe


EQUIPMENT No change

N o change

WATER No change

ENERGY No change

WASTE DISPOSAL $129,60O/yr s a v i n g s


PERSONNEL/HAINTENANCE N o change

NET BENEFITS

RAW MATERIALS

R e l i e f from h i g h hazardous waste management costs

65

CASE STUDY 12

TYPE OF INDUSTRY: Small Appliance Manufacture NAME OF FIRM: Hamilton Beach Division; Scovill, Inc.

LOCATION: Clinton, North Carolina SIC: 36

(Guy Tilford 919/592-0121)

MODIFICATIONS

1) SOLVENT RECYCLING 2) SUBSTITUTION OF WATER-BASED CLEANERS FOR ORGANIC

SOLVENT- BAS ED CLEANERS

ABSTRACT: Hamilton Beach Division of Scovill, Inc. manufactures small electric appliances. Their operation requires 1-1-1- trichloroethane solvent to degrease metal stampings. Solvent wastes are collected in 55 gallon drums and housed in a storage building designed to contain spills if they occur. The drums are picked up by a company that distills 1-1-1 trichloroethane from the wastes and returns it to Scovill for reuse. The recycled solvent costs about half as much as the virgin material. The company has also experimented with material substitution of water soluble synthetic cleaners, and they have consequently reduced their use of organic solvents by 30%. A management initiative to reward other ideas from employees for waste reduction and cost savings projects is also a part of Hamilton Beach's program for pollution prevention.

66



TIME TO IMPLEMENT: 3 months

TRANSFERABILITY: The use of distillation to recover spent solvent is a feasible alternative for most degreasing solvents

The quality of wastes generated may determine whether recycling can be done in-house or off-site. An off- site recovery arrangement like the one used by Scovill eliminates the need for capital expenditures for distillation equipment or the maintenance and operating costs associated with such equipment. The drawback to such an arrangement is the liability the generator must assume both for the material during transport and for the burial of still bottom residues. Be- cause off-site recycling can sometimes result in contamination of recovered solvent with a substance from another user's process, it is to the generator's advantage to arrange an agreement to have their solvent segregated during distillation.

agents for organic solvents is becoming more commonplace, since the latter are expensive, and they present serious health risks to workers.

Employee incentive programs are also becoming popular, since many waste reduction projects involve changes in housekeeping practices or equipment operation and maintenance -- modifications most readily noticed by production personnel rather than management.

because of their low boiling points. ~.

The substitution of other cleaning


Reduced threat to air and groundwater quality; conservation of resources; improved health and safety conditions __ for plant personnel

67

PROJECT DESCRIPTION: Scovill uses 1-1-1 trichloroethane solvent to degrease metal stampings produced in their manufacturing process. Until implementation of their recycling program, the company had been accumulating waste solvent in 55 gallon drums. In order to avoid the responsibility 'and expense of landfilling the wastes, Scovill collaborated with the Fayetteville Office of the North Carolina State Solid and Hazardous Waste Management Branch to develop a plan to recycle the waste solvent. Ashland Chemical Company was contracted to recycle 27 drums of accumulated waste and all future waste, which is expected to be generated at a rate of about 38,000 pounds/year.

A $3,000 storage building was constructed to house the wastes, and a central recessed floor section was installed to minimize the pollution impact of an accidental spill. The structure can contain up to 220 gallons of spillage. Other miscellaneous equipment for the storage building includes sand, oil/dry, shovels, and fire extinguishers at a total cost of about $250. Personnel and maintenance'costs for the system run about $100/year.

The Company reports that substitution of the recycled solvent for the virgin product has reduced their overall raw material costs from $0.41/lb to $0.27/lb, yielding an annual savings of $5,320 per year. Scovill also eliminated all previous waste disposal costs, estimated to be about $0.08/lb, or $3,04O/year. The result was an annual cost savings of $8260 and a payback period of under 6 months. In addition to financial savings, the new storage building and the elimination of landfill requirements reduce the potential for health and environmental risks. Although the firm is subject to RCRA cradle-to-grave accountability for their wastes, the reduction of waste volume significantly reduces their liability risks.

Scovill also tested a water soluble synthetic cleaner as a possible substitute for the 1-1-1 trichloroethane organic solvent degreaser. The cleaner is manufactured by Cincinnati Milacron Company of Cincinnati, Ohio. After some experimentation, they found the cleaner is suitable for some of their applications, and they have been able to reduce their 1-1-1-trichloroethane use by 30%. The water soluble cleaner is not suitable for all applications because it can corrode galvanized parts. Scovill reports a $12,00O/year savings from this substitution.

Scovill has also instituted an employee incentive cost savings program which they hope will lead to other pollution prevention projects. Six-member teams are randomly selected, and the team membership is changed each year. The team responsible for the greatest annual cost savings to the company receives bonus checks. No waste management projects have resulted from this program yet, but Scovill is considering an in-house recycling program, which would be a project eligible for the bonus award.

68

PROCESS DIMENSIONS:

WASTES GENERATED Reduced 38,000 lb/yr (less substitutions)



DOWN TIME No change

FACILITIES $3000 One-time cost

EQUIPMENT $250 One-time cost


WATER No change

ENERGY No change

WASTE DISPOSAL $3040/yr savings


PERSONNEL/MAINTENANCE $100/yr cost

NET BENEFITS Annual cost savings, resource conservqtion and reduced risk of RCRA liability

69

CASE STUDY 13

TYPE OF INDUSTRY: Plumbing Products Manufacture NAME OF FIRM: Stanadyne, Inc., Moen Group

(George McRae 919/258-3341) LOCATION : 2609 Cox Mill Rd.

Sanford, North Carolina SIC: 3432

MODIFICATIONS

MATERIAL SUBSTITUTION TO REDUCE SLUDGE VOLUME CHANGE IN EQUIPMENT AND OPERATION TO REDUCE CYANIDE CONCENTRATIONS IN WASTE REVISED RACK DESIGN TO REDUCE DRAGOUT INSTALLATION OF EQUIPMENT TO RECYCLE METALS IN PLATING BATH IMPROVEMENTS IN FILTRATION EQUIPMENT OPERATIONS TO REDUCE WASTE INSTALLATION OF A FILTER PRESS TO REDUCE WASTE SLUDGE VOLUME INSTALLATION OF NEW WATER PURIFICATION SYSTEM TO IMPROVE EFFLUENT QUALITY USE OF HOUSEKEEPING IMPROVEMENTS TO REDUCE WASTE INCORPORATION OF POLLUTION PREVENTION CRITERIA IN NEW EQUIPMENT SELECTION DEVELOPMENT OF A PROGRAM TO PROMOTE POLLUTION PREVENTION

ABSTRACT: The Stanadyne Company undertook a comprehensive and systematic review of their electroplating processes in order to reduce or eliminate waste generation. The result of their efforts has been a broad spectrum of activities which has saved the firm money and minimized pollution. A sulfuric/peroxide materials substitution for chromic acid reduces ~ sludge production from their parts cleaning operation. The Company also - - found they could operate their cyanide copper and chrome- piating baths at lower concentrations, saving both raw material and sludge handling costs. Other equipment design operation changes which reduced dragout volumes and rack recoating costs also improved plating efficiency. Tanks were installed before the rinsing operation to recycle valuable metals back to the plating baths. A change in plating bath filtration equipment operation drastically reduced solution losses and resulted in a 93% cost reduction in filter media. A filter press operation for sludge dewatering minimized the cost of sludge transport and disposal. A new wastewater and sand filtration system has improved the treated wastewater quality. Housekeeping improvements led to leak elimination and a preinspection program which prevents plating of defective parts. Stanadyne also

70

incorporated pollution prevention goals in their recent plant expansion, which resulted in the selection of a new degreaser which has significantly lowered solvent costs. Finally, the Company has undertaken numerous manpgement initiatives to promote pollution prevention within their firm, among other ~

electroplaters, and among the State's citizens at large. ~

7 1


PAYBACK PERIOD: W A

TIME TO IMPLEMENT: Ongoing, 1982-1985

TRANSFERABILITY: The most important feature of the Stanadyne modifications is the commitment the firm has made to waste reduction, and the on-going, systematic approach they have used to achieve this goal. Once they identified the two major sources of pollution--dragout and spent process solutions, they focused their efforts on these features of their operation.

modifications described, the following comments are offered:

The success of changes in solution make-up will depend on what materials compose the plating bath and the thickness and deposit quality of the coating required.

Dragout recovery was a low-cost modification for Stanadyne. Some kind of dragout recovery system can usually be used after most heated plating baths. However, some applications may be limited by a build-up of degraded organic additives and metallic contaminants or heat sensitivity of some of the components. Some systems might require prohibitive capital costs or energy costs. Use of this modification may also require additional floor space to accomodate extra tanks.

The housekeeping activities and filter media changes are demonstrations of savings that can be achieved by consistently monitoring equipment use and keeping abreast of new product development. One of the most important features of the Stanadyne program is the company's commitment to pollution reduction and the willingness of management to devote personnel time to both in-house and public activities aimed at achieving this goal.

With respect to specific


Conservation of land, water, and material resources; reduced threat of ground and surface water contamination Reduced personnel exposure to cyanide

72

PROJECT DESCRIPTION: The Stanadyne Plant in Sanford, North Carolina is a manufacturer of plumbing products, principally the Moen faucet. Some of the operations that are essential to the production of a quality faucet that is marketable also result in the production of waste material. These operations include: plating, brite dipping, stripping, and degreasing. The Company has adopted a comprehensive and systematic approach to reducing waste generation. They began with the question: "HOW can

electroplating process?", and proceeded to carefully review their operation with this question in mind.

pollution be prevented without adversely affecting the ~~

The plumbing products they manufacture are plated with copper, nickel, and chrome. These finishes are applied to zinc, or brass parts to resist corrosion, and it was important that the finish quality not be compromised. The Company also wanted to avoid any increase in plating defects or contamination of plating baths which could ultimately lead to more rather than less waste production.

The modifications reported herein come from all phases of their operation including: parts surface cleaning, the plating operation, rinsing, stripping, and waste treatment. Their pollution prevention program also incorporates consideration of waste reduction potential in new equipment and facility design, active participation of employees in carrying out the program goals, and strong leadership by Stanadyne personnel in pi-omoting these activities among other industries.

Pay~ts Surface Cleaning

The cleaning of brass and copper parts which have been brazed together is accomplished in a brite dipping operation. This operation, cleaning of metal surfaces with acids and oxidizers, is a major waste producer. A sulfuric/peroxide brite dip is used to avoid the high sludge production associated with chromic acid brite dip. A side tank, which will be used as an electrolytic cell, has been ordered for plating out copper which builds up in the bath. Redesign of the racks which carry the parts will also be considered in 1985.

Plating Operation

Plating is accomplished on two return-type machines (Udylite Cyclemasters). As parts are lifted out of the plating bath, the solution that clings to the part is called dragout, which becomes __ pollution in the rinsing process. Minimization of dragout should be involved with the investigation of four areas: solution makeup, machine motion, part and rack design, and solution ~

maintenance.

73

Solution Makeup

Different shaped parts require different chemical makeups of plating baths to achieve required thickness and deposit qualities. In formulating their cyanide copper and chrome plating baths, Stanadyne determined that lower concentrations of chemicals could be used. By running the potassium cyanide concentration at 2.5 oz./gallon instead of 3.5 oz./gallon, the cyanide dragout concentration has been reduced by 28% without any adverse affect on plating quality. Savings accrue from using less cyanide and less bleach for cyanide destruction. In the chrome baths the chromic acid levels are maintained at about 29 oz./gallon instead of 32 oz./gallon. This 9% reduction results in savings due to reduced raw material requirements including chromic acid; sodium bisulfite, which is used to reduce hexavalent chrome to trivalent chrome; and sodium hydroxide, which is used to precipitate metals; and to reduced sludge handling costs.

Machine Motion

The motion of the Udylite Cyclemaster plating machine is repetitious and automatic. Work is moved through a tank, lifted out, indexed over and lowered into the next tank.

By introducing a pause before indexing in the up position, a significant portion of the dragout is able to drip back into the process tank. Specific savings due to this change have not been calculated. In making this change, care was taken to avoid an excessive increase in "hang time". Depending on the base metal and process, dry-ons or passivation of nickel could result.

Part and Rack Design --- Stanadyne adopted a program of rack redesign for

minimization of drag out after attending the "Pollution Prevention Pays in the Electroplating Industry" Workshop in 1983 (sponsored by the State). Although savings are difficult to calculate, significant savings in process chemicals, pollution control chemicals, reduction of dropped parts, and reduction in future rack coating costs have been achieved. The first consideration for rack redesign was a change from horizontal to vertical orientation. Instead of running tips off horizontal cross-members, tips were connected directly to vertical splines (see Figure 1). Several advantages were gained by this change: 1) reduced dragout because the solution slides off the rack instead of clinging to horizontal cross members; 2 ) reduced rack area, which provides less surface area for dragout to cling on; 3 ) fewer electrical resistance points since splines are direcly connected to rack hooks: 4 ) reduced shading of low current density areas by each rack spline; 5 ) reduced plating on backs of parts which are not exposed surfaces and therefore require less protection, and; 6 ) reduced cost of recoating racks because of reduced rack area. The changes in rack design were undertaken

74

d u r i n g t h e r e g u l a r rack r e c o a t i n g p r o c e s s . I n i t i a l cos t was somewhat h i g h e r t h a n a s i m p l e recoat b u t t h e change w i l l q u i c k l y pay f o r i t s e l f .

Wide s h e l f a r e a s , cups, and b l i n d h o l e s were e l i m i n a t e d whereve r p o s s i b l e . The o r i e n t a t i o n of e a c h p a r t on t h e r a c k was r ev iewed . By a n g l i n g p a r t s t o one s i d e , "cups" were e l i m i n a t e d , and d r a g o u t was r educed . The l o n g e s t l i n e s o f e a c h p a r t are racked v e r t i c a l l y whenever p o s s i b l e t o allow d r a g o u t to s l i d e o f f ~~

i t more e a s i l y .

S o l u t i o n Main tenance

S t a n a d y n e rev iewed t h e p l a t i n g s o l u t i o n f i l t r a t i o n p r o c e s s f o r waste r e d u c t i o n o p p o r t u n i t i e s . P l a t i n g s o l u t i o n s must be f i l t e r e d t o p roduce h i g h q u a l i t y f i n i s h e s which are f r e e from r o u g h n e s s . F i l t e r media must be changed whenever p r e s s u r e b u i l d s up and r e t a r d s t h e ra te of f i l t r a t i o n . During f i l t e r c h a n g e s , s p i l l a g e or o u t r i g h t dumping c a n o c c u r which c a n be a s i g n i f i c a n t s o u r c e o f p o l l u t i o n and/or p r o c e s s water t r e a t m e n t problems. I n l a t e 1982 and e a r l y 1983, a l l f i l t e r s which were s l e e v e t y p e f i l t e r s were r e p l a c e d by h o r i z o n t a l p l a t e f i l t e r s , which u s e paper d i s k s a s f i l t e r media . The new Mefiag f i l t e r s are m a n u f a c t u r e d by Baker B r o t h e r s . The payback p e r i o d f o r t h e new f i l t e r s w a s less t h a n two y e a r s . The m o s t s t a r t l i n g s a v i n g s o c c u r r e d i n cost o f media f o r f i l t e r changes . The cost o f f i l t e r media p e r change r e s u l t e d i n a 93% d i r e c t cost s a v i n g s . A r e d u c t i o n i n s o l u t i o n losses and l a b o r t i m e needed to change t h e f i l t e r was a l so r e a l i z e d .

A method o f r e d u c i n g s o l u t i o n losses d u r i n g f i l t e r changes was recommended by Dave Gibson , o f B a k e r B r o t h e r s , and i n s t i t u t e d a t S t a n a d y n e i n 1984. An a i r hose from t h e l o w p r e s s u r e a i r blower is c o n n e c t e d to t h e b l e e d - o f f hose o f t h e f i l t e r . A i r is i n t r o d u c e d i n t o t h e f i l t e r and t h e s o l u t i o n can be blown i n t o a s l u r r y o r s t o r a g e t a n k . The l o n g e r t h e f i l t e r is blown down, t h e d r i e r it becomes. Using t h i s method, s o l u t i o n loses were almost e l i m i n a t e d , and f i l t e r changes a r e easier and s a f e r . T h i s is e s p e c i a l l y h e l p f u l when h a n d l i n g c y a n i d e s o l u t i o n .

S t a n a d y n e h a s o b s e r v e d a 20% r e d u c t i o n i n c h e m i c a l c o s t s / h o u r a s a r e s u l t o f t h e z i n c dye cast p l a t i n g m o d i f i c a t i o n s . T h i s t r a n s l a t e s t o o v e r $lO,OOO/year cos t s a v i n g s .

Dragout Recovery - and R i n s i n g

By c a p t u r i n g d r a g o u t i n s t i l l t a n k s b e f o r e r i n s i n g and r e c y c l i n g i t t o t h e p l a t i n g t a n k s , v a l u a b l e chemicals can be s a v e d and t r e a t m e n t and d i s p o s a l costs e l i m i n a t e d . Dragout ~

r e c o v e r y r e q u i r e s s t r i c t c o n t r o l o f t h e c o n t a m i n a n t s i n t h e ~

p l a t i n g s o l u t i o n t o p r e v e n t c o n c e n t r a t i n g them, which would r e s u l t i n p l a t i n g d e f e c t s .

A s i m p l e d r a g o u t r e c o v e r y sys t em was i n s t a l l e d on t h e 75

n i c k e l p l a t i n g machine f o r z i n c d i e c a s t i n g . A d i a g r a m o f t h e l a y o u t i s shown i n F i g u r e 2 . L e s s t h a n $1000 was i n v e s t e d f o r t h e s torage t a n k . The d r a g o u t is r e c y c l e d once a week . The n i c k e l is r e c o v e r e d a t a c o n c e n t r a t i o n o f 3 .2 o z / g a l l o n , which r e s u l t s i n a 30 pound/week s a v i n g s i n raw materials. A t t h e c u r r e n t m a r k e t p r i c e o f $2.80/pound, t h i s s y s t e m s a v e s t h e f i r m $4200/year . The r e c o v e r y o p e r a t i o n a l s o r e d u c e s t h e n i c k e l s l u d g e volume generated by 9500 pounds /year .

P l a n s are now underway to r e c y c l e chrome d r a g o u t . The s y s t e m w i l l n o t r e c o v e r 100% o f t h e chrome loss b u t w i l l a t t e m p t t o r e a c h a n 80%-90% r e c o v e r y r a t e . S i n c e t h e e v a p o r a t i o n from t h e chrome t a n k is too l o w to a l l o w d i rec t r e t u r n o f chrome d r a g o u t , a n e v a p o r a t o r t a n k w i l l be used t o r e d u c e t h e volume b e f o r e pumping it d i r e c t l y back t o t h e chrome t a n k . S u l f a t e a n d c a t i o n c o n c e n t r a t i o n s w i l l be m o n i t o r e d f o r p o s s i b l e p r o b l e m a t i c b u i l d u p s .

C o u n t e r f l o w r i n s i n g and f low c o n t r o l s t o r inse t a n k s are s t a n d a r d p r a c t i c e s a t S tanadyne . Water r e u s e , b o t h p r e - t r e a t m e n t a n d p o s t - t r e a t m e n t , a r e b e i n g c o n s i d e r e d b u t have n o t y e t been i n s t i t u t e d .

Waste T r e a t m e n t

The r e d u c t i o n o f s l u d g e volume is a c h i e v e d by r e d u c i n g t h e water c o n t e n t o f t h e s l u d g e . S l u d g e r e s u l t s f rom removal o f metals from r i n s e waters i n t h e form of metal h y d r o x i d e , a h a z a r d o u s waste. S ludge volume r e d u c t i o n is a c h i e v e d a t S t a n a d y n e t h r o u g h t h e u s e o f a f i l t e r press. Dewater ing w i t h t h e press r e s u l t s i n a 25%-30% s o l i d s s l u d g e . The reduced s l u d g e volume d e c r e a s e s s h i p p i n g and d i s p o s a l costs.

A f u r t h e r r e d u c t i o n is c u r r e n t l y b e i n g pu r sued t h r o u g h p u r c h a s e of a JWI, J-Mate, s l u d g e d r y e r . T h i s p i e c e o f equ ipmen t , which is c u r r e n t l y on order, r e p r e s e n t s new t e c h n o l o g y i n t r o d u c e d i n J u l y 1984. The d r y e r w i l l d r i v e t h e r ema in ing 65%- 70% water o f h y d r a t i o n from t h e s l u d g e . The r e s i d u a l s o l i d s w i l l have a s i g n i f i c a n t metal c o n t e n t , 30%-40%, which may be r e c o v e r a b l e , i f n o t now, i n t h e f u t u r e .

Wastewater T r e a t m e n t Improvements

The a d d i t i o n o f a sand f i l t e r t o t h e i r w a s t e w a t e r t r e a t m e n t s y s t e m h a s h e l p e d S tanadyne p roduce a h i g h e r q u a l i t y wastewater. The "DynaSand" f i l t e r , which cost a b o u t $40 ,000 , i n c o r p o r a t e s t h e new i d e a o f a moving, c o n t i n u o u s l y - c l e a n e d sand f i l t r a t i o n bed which s i g n i f i c a n t l y r e d u c e s t h e volume o f water requi red f o r backwashing. Numerous o t h e r smal l c h a n g e s were made i n t h e s y s t e m to improve water q u a l i t y : a n improved p o l y e l e c t r o l y t e pumping s y s t e m , a changed p r o c e d u r e f o r h a n d l i n g s p e n t c l e a n e r , and i n s t a l l a t i o n o f m e t e r i n g pumps on col lect ion p i t s t o e l i m i n a t e s y s t e m o v e r l o a d s .

Wi th a 15% i n c r e a s e i n p l a t i n g o n z i n c , a 56% increase i n 76

plating on brass, and a 35% increase in brite dipping, a 20% reduction in wastewater treatment chemical costs and only a 2 % increase in sludge generation was acheived in 1983-84 as a result of Stanadyne's pollution prevention modification. The chemical cost reductions resulted in a net savings of $5000/year.

Stripping

Stripping nickel and chrome of f brass parts is a rework operation designed to save the expensive brass base metal. Until recently, immersion stripping was used to remove nickel and chrome. An immersion stripper loses efficiency as it is used. The bath slows down as metal loading increases, and ultimately it must be "dumped" and remade.

The Company installed a new electrolytic nickel stripper, Udystrip 8000, by Udylite, which deplates nickel from the part. Nickel sludge builds up on the electrodes and on the tank bottom and can be removed by pulling the electrodes or by decanting the bath, removing the sludge, and pumping the bath back. A volume of liquid equal to the volume of sludge removed is then added to the bath. This bath does not have to be dumped, and rinse waters are waste-treatable. The new stripper resulted in an 81% reduction in chemical costs/hour, which translated to approximately $5000/year savings. Cost savings are also realized in reduction of waste for treatment and disposal, and in having a more scientific and predictable operation. Initial capital costs are higher since a rectifier must be purchased, but long-term costs were significantly reduced, with savings greater than 50%. Chrome is stripped in a 75% muriatic acid dip immersion stripper.

Housekeeping

Recognizing that plating a defective part creates the same amount of waste as plating a good one, Stanadyne began preinspecting work to be plated. Parts that would obviously be scrapped are eliminated from the plating operation, resulting in direct waste reduction. Elimination of leaks also resulted in waste reduction.

Plant Expansion

During 1983, Stanadyne expanded its plant, increasing its capacity by 25 percent. Additional plating and degreasing capacity was included in the expansion. Each of these operations is a source of hazardous waste generation, and extensive __ planning of equipment layout, operation, and design was undertaken to maximize pollution prevention.

- Platina Machine

In planning the layout for a new plating machine, an effort was made to minimize pollution sources and rinse water flow and to include features which would ease future recovery opportunities. Rinsing on the machine was designed with double

77

counterflow rinses and, where possible, triple counterflow rinses. In addition, the plating tanks (nickel and chrome) were followed by dragout tanks to allow some direct recycling of solutions which would otherwise be wasted. The design of the floor layout included additional room in a chrome reduction unit pit to permit the installation and cost effective operation of a simple chrome recovery system currently under design.

Deg rease r

A similar approach was used during the purchase of a new totally-enclosed, automatic "degreaser. After analyzing the different machines that were available, a unit manufactured by Finishing Equipment, Inc. of St. Paul, Minnesota was selected. Pollution prevention and energy efficiency were major factors in the decision to purchase this particular unit. Stanadyne selected the unit based on the following features:

1 ) The chiller system is run continously to keep the solvent in the machine where it belongs. Major solvent losses usually occur when a degreaser is not in production. By running the chiller system continuously, these losses are eliminated.

2 ) No water is used in the system for cooling or rinsing. This reduces water costs and ultimately helps the community by limiting the need for expansion of the municipal wastewater treatment plant.

3 ) Waste heat from the chiller is used to heat the degreaser unit, resulting in an energy savings and conservation of resources.

4 ) The machine design offers two major pollution prevention features: (a) the parts are continuously rotated, which facilitates drainage and prevents solvent dragout; (b) the chip removal system design eliminates solvent loss during chip removal and eliminates a major safety hazard for employees.

5 ) The use of methylene chloride in the degreaser system reduces solvent waste because its stability allows it to be distilled many times before it degrades. It also has a low boiling point which saves energy.

6 ) The system is designed with a large amount of distillation capacity. This allows the still bottoms to be reduced to a 6-10% solvent content. __

The features which led to the purchase of this unit are paying dividends. Solvent usage has dropped from an average of 7 drums/month to only 1.5 drums/month. Air emissions and hazardous waste generation have been reduced substantially ~

~

Management In i ti at ives

Stanadyne believes one of the major strengths of their 78

pollution prevention program is the involvement of all the employees working in plating and pollution control operations. The staff is trained to appreciate the contribution each job makes to the overall success of the program.

The enthusiastic backing of pollution prevention projects by the firm's corporate management has led to company participation in numerous environmental programs, boards and committees to explain and promote Stanadyne's activities. Stanadyne was instrumental in organizing workshops throughout the State on "Making Pollution Prevention Pay in the Electroplating and Metal Finishing Industries." They have also made their plating operation available to professional associations for plant tours. On September 12, 1983 a film crew from U.N.C.-TV visited Stanadyne to film a report on hazardous waste management in North Carolina. Plant Manager, John Carney, led a tour of the plant and answered questions for the program.

In September of 1982, George McRae, plating manager at Stanadyne, proposed the formation of a Lee County Industrial Waste Committee, now called the Lee County Waste Managers Association. The purpose of the association is to trade ideas and information, coordinate waste shipments, and to offer an opportunity for discussion of issues related to the Lee County Waste Board. The association initially met monthly to give the waste managers a chance to become acquainted and discuss ideas and problems. A tangible benefit resulting from the association was the initiation of shared waste shipments. During the past year, Stanadyne has shared waste loads with another Lee County company on four occasions. This arrangement has allowed both companies to move their waste in a cost effective manner in less than 90 days. Stanadyne and the company with which it shares loads have both been delisted as storers under the RCRA guidelines. The savings occurs because transportation of waste is computed on a per mile hauled basis. This means that the charge for transportation is the same whether the truck carries 20 drums or 80 drums. At $3.20/loaded mile, it definitely pays to send a full truck load. George McRae currently serves as association chairman.

79

PROCESS DIMENSIONS:

WASTES GENERATED Reduced 4 6 % (plating bath compositions, filter media change, dragout recovery system, sludge filter press, stripping operation, cleaning)

PRODUCTIVITY Improved (rack design)

PRODUCT QUALITY Improved (rack design)

DOWN TIME Reduced (filter media change, stripping operation

FACILITIES Expanded, cost information

EQUIPMENT New plating solution filters,

not provided

sludge filter press, nickel stripping system, dragout recovery tank, process water filtration system Cost information not provided

RAW MATERIALS $15,00O/year savings (cyanide, bleach, chromic acid, sodium bisulfite, sodium hydroxide, other plating solution chemicals, stripping

WATER Costs minimized (New degreaser) Complete Information not


WASTE DISPOSAL Reduced transport and disposal

POLLUTION CONTROL $5000/year savings

PERSONNEL/NAINTENANCE Reduced rack coating costs, Reduced filter media replacement costs, Increased initial rack coating costs during redesign

80

NET BENEFITS Annual cost s a v i n g s : improved product q u a l i t y ; reduced r e g u l a t o r y p r e s s u r e ~~

~

81

P t

Figure 1 . Rack Redesign

L I

v- , ,

I. . \# *, '

r " ,. I

I ,, .\

r * ' I ./ /. . .

OLD DESIGN

SPOUT & DECK

Ii NEW DESIQN

1-H 6 2-HU'LAV

m mn DESIGN

SPOUT 6 DECK

82

F i g u r e 2 . N i c k e l D r a g o u t R e c o v e r y S y s t e m

A NICKEL PLATING TANK

B DRAGOUT TANK

C PUMP

D STORAGE TANK

E F I L T E R

83

CASE STUDY 14

TYPE OF INDUSTRY: Mass Portrait Photography NAME OF FIRM: PCA International, Inc.

LOCATION: Matthews, North Carolina SIC: 7395

(Fred Monroe 704/847-8011)

MODIFICATIONS

1) ELECTROLYTIC SILVER RECOVERY 2 ) DEVELOPER REGENERATION BY ION EXCHANGE

ABSTRACT: PCA International generates several waste streams during their color portrait processing operations. They have developed a number of modifications to reduce their waste volume. Electrolytic recovery is used to remove silver from film and paper solutions. The silver is 96% pure and the fixer can be replenished and reused. - Ion exchange columns are used to remove the inorganic chemical, bromide, from the color developer solution. This system has allowed 85% reuse of the color developer. Spent bleach solution is restandardized by chemical addition and recycled, allowing 90% reuse.

84

ANNUAL COST SAVINGS:

PAYBACK PERIOD:

TIME TO IMPLEMENT:

TRANSFERABILITY:


Variable due to fluctuating silver prices

Electrolytic Recovery -- 1 year Ion Exchange -- less than 1 year Information not provided

Optimum silver recovery is desirable because the metal has a high market value and, if left unrecovered in a waste stream, is a pollutant. The cost of in-house recovery equipment is high, however, and a small firm may elect to send waste solutions out-of-house for metal recovery or form a cooperative to purchase and share one set of equipment. Out-of-house recovery requires more bookkeeping and transportation risks. The water and solution regeneration/reuse modifications undertaken by PCA, pioneered these activities for the industry nation- wide. Equipment manufacturers can assist small firms evaluate the potential payback for similar installations on a reduced scale.

Reduced pollutant load to munici- Pal sewage treatment system; conservation of water and materials; reduced threat of silver compounds entering surface and groundwater

85

PROJECT DESCRIPTION: PCA International is a color portrait processing company. Their waste stream is characterized by high BOD and COD concentrations. When their Matthews facility was first constructed in 1972, it was a goal of PCA management to minimize the pollution load contributed to the small municipal wastewater treatment fa’cility. The result has been the development of several projects which have significantly reduced waste generation and yielded annual savings for the company.

An electrolytic silver recovery process is used to recover silver from color negative film fixer solutions and the paper fixer solutions. Spent fixer solutions from both processes are mixed and are passed into a continuous flow silver recovery unit. A large cathode rotates in the solution, and a low voltage current (3-4 volts) is applied. The silver collects on the cathode. once a week the cathodes are removed and the silver knocked off in chunks. The desilvered solution is aerated, returned to full strength, and pumped back to the processing units. The system allows approximately 96% reuse of the fixer solution, and raw material costs have been reduced about $25,00O/year. The silver chip obtained is about 96% pure, and approximately 2200 troy ounces/week of silver are recovered each week.

Waste overflow fixer solution is collected in a tank and subjected to a batch electrolytic silver recovery process. Effluent is then passed through 5-gallon cannisters containing steel wool for a final polishing. In the presence of thiosulfate complex in the fixer, the iron in the steel wool becomes soluble, and the silver from the complex precipitates out as metallic silver. The cannisters can usually recover about 80-85% of the silver in solution, and the original fixer solution silver concentration is reduced from 1500 g/1 to 0.02 g/1 after passing through both recovery systems. About 24 cannisters are used each year at a cost of $35/cannister. The spent cannister systems are sent to a refiner for silver recovery, and each yields approximately 150 troy ounces of silver.

The cartridge silver removal systems are also used to remove silver from one of the paper processing rinses. The rinse, called the “slow wash”, is the first wash following the fixer solution, and is performed at a lower flow than the other wash operations. Slow wash water is collected and passed through two cartridges in series, yielding 6-8% silver recovery. The wash water then exits to the municipal sewer system.

A second modification undertaken by PCA was the regeneration of color developer using ion exchange. As photographic materials are developed, they release bromide into the developer solution. This release can inhibit the development process, and requires replacement of the solution when the bromide levels get too high. PCA has been able to regenerate spent color developer from paper by removing excess bromide with ion exchange columns. Developer solution containing 0.8-1.0 g/1 bromide is passed through a sand filter, then through an absorption resin to remove contaminants,

86

I ,

and finally through two sets of ion exchange columns for bromide removal. The effluent contains 0.07 g/1 bromide. It is readjusted to the required concentration before returning it to the processing tanks. The ion exchange columns are regenerated on-site using an 8% sodium chloride solution. This system has allowed 8 4 % reuse of the color developer solution.

PCA uses approximately 8500 gallons/week of color developer solution for paper. The ability to regenerate spent solution has reduced their costs from $1.4O/gallon to $0.57/gallon, saving about $360,00O/year.

Spent color developer from film processing is collected and stored for a short time in case it is needed for reuse. It is not routinely recycled at this time.

Spent bleach solution is restandardized by the addition of necessary chemicals and reused. Ninety percent of the bleach solution can be recycled by using the rejuvenation process, saving over $2.50/gallon in raw material costs.

PCA uses countercurrent flow for their rinse water flow in order to minimize the number of washes required and enhance product quality. They also have a well-developed housekeeping program to minimize spillage and loss of chemicals. In the rinse operations rubber "squeegees", similar to automotive windshield wipers are used to remove water and chemicals adhering to the film. This reduces the dragout from tank to tank and maintains solution integrity as long as possible. The "squeegees" are wrung dry regularly to maintain their efficiency.

Other housekeeping features include careful labeling of chemicals; dedication of pumps to certain chemicals to reduce cleaning operation wastes: direct pumping rather than manual transfer of bulk chemical$ to reduce risk of spillage, use of drum lifts to minimize spillage and accidents, and use of larger drums for chemical storage to reduce spillage and cost.

Over the past 10 years, PCA has also experimented with several other modifications to reduce waste generation. These have included:

( 1 ) Use of reverse osmosis units to recycle rinse waters from film and paper processing. Abandoned because of reduced product quality.

( 2 ) Silver recovery from concentrated wastes collected on the RO __ system by electrolytic recovery preceded by ion exchange. Wastes were passed through a strong anion exchange column which increased the silver concentration from 0.5 g/1 to 5 g/l. Electrolytic silver recovery was then performed on the solution, ~

resulting in 97% pure silver chip. ~

(3) Concentration of wastes collected on the RO system using spray evaporators. A spray film evaporator system received the

a7

wastewater a t a ra te o f 15 ,000 g a l l o n s p e r day . S o l c o n c e n t r a t e d from 5% to 30% on a s i n g l e p a s s t h r o u g h t h e F u r t h e r c y c l e s t h r o u g h t h e sys t em y i e l d e d a 60-708 s o l which c o u l d t h e n be s o l d f o r s i l v e r r e c o v e r y .

PROCESS D I M E N S I O N S 1

d s were sys t em.

d s cake

~- ~~

WASTES GENERATED Removed 115,000 Troy Ounces S i l v e r / y r from wastes E l i m i n a t e d approx . 1700 g a l / d a y color d e v e l o p i n g waste E l i m i n a t e d approx . 19 g a l / d a y s p e n t f i x e r w a s t e E l i m i n a t e d approx . 1200 g a l / d a y s p e n t b l e a c h waste

PRODUCTIVITY N o change


DOWN TIME N o chanqe

FACILITIES $24 ,000 ( E l e c t r o l y t i c Recove ry ) Complete i n f o r m a t i o n n o t p r o v i d e d

EQUIPMENT $96,000 ( E l e c t r o l y t i c Recove ry ) Complete i n f o r m a t i o n no t p r o v i d e d

RAW MATERIALS $360,00O/yr s a v i n g s ( d e v e l o p e r ) $25,00O/yr s a v i n g s ( f i x e r ) $780,000 / y r s a v i n g s ( b l e a c h )

WATER No change

ENERGY $200/year cost ( E l e c t r o l y t i c

WASTE DISPOSAL I n f o r m a t i o n n o t p r o v i d e d

POLLUTION CONTROL I n f o r m a t i o n n o t p r o v i d e d


Recovery)

NET BENEFITS I n c r e a s e d r e v e n u e from s i l v e r recovery, cost sav ings from s o l u t i o n reuse

88

CASE STUDY 15

TYPE OF INDUSTRY: Lamination and Coating of Specialized

NAME OF FIRM: Rexham Corporation

LOCATION: Matthews, North Carolina SIC: 3861

Paper, Rilm and Foil Products

(Gordan Miller 704/847-9171)

MODIFICATIONS

1. DEVELOPMENT OF A COMPREHENSIVE MANAGEMENT PROGRAM TO REDUCE WASTES REQUIRING LANDFILL DISPOSAL

2 . SEGEGATION OF SPENT CLEANING SOLVENTS FOR REUSE 3 . RECOVERY AND SALE OF SOLVENT VAPORS COLLECTED BY

4. OFF-SITE DISTILLATION OF WASTE SOLVENT FOR REUSE 5. SOLVENT LNCINERATION FOR HEAT RECOVERY

I

CARBON ADSORPTION

ABSTRACT: The Rexham Corporation facility in Mathews North Carolina laminates and coats specialized paper, film, and foil substrates for the photography industry. A management initiative to develop a comprehesive waste management plan for the firm has resulted in several pollution prevention modifications. The initiation of new housekeeping practices which require the segregation of spent toluene solvent by ink color and type has resulted in almost 100% reuse of liquid toluene. Toluene-laden vapors are collected in a carbon adsorption-based air pollution control system and sold for use in the coatings industry. Off-site distillation of spent solvent mixtures has allowed reuse of methyl ethyl ketone solvent for washup operations. Methyl ethyl ketone vapors are removed from the air and incinerated for heat recovery.

89


PAYBACK PERIOD: Information not provided

TIME TO IMPLEMENT: Installed during facility construction

TRANSFERABILITY: Organic vapor recovery is an expensive modification for which the payback may be realized in terms of improved air quality and personnel safety rather than annual cost savings. New systems are now available that do not require the personnel commitments needed for the Rexham unit. Use of a carbon adsorption system will depend on the retentivity of the solvent vapors on the carbon particles, the amount of vapor generated, and the capacities of the systems available.

The practice of segregating spent cleaning solvents is particularly applicable when it allows the reuse of the material in-house, as Rexham has done. Even if there is no other in- house use for such materials, segregation of waste streams may result in material suitable for use in other firms. Participation in a waste exchange might help identify other users and reduce disposal costs.

Off-site solvent recovery by distillattion can significantly reduce raw material costs and waste disposal costs and risks. Several vendors in North Carolina which provide such services.

air for incineration is an excellent way to reduce health risks to workers and reduce operating costs. Use of such a system requires sufficient concentration of solvent vapors and a use for the heat generated.

The removal of solvent vapors from


Improved air quality, reduced reliance on landfill disposal, conservation of energy and material resources: improved health and safety conditions for plant personnel

__

~

90

PROJECT DESCRIPTION: The Rexham Corporation facility in Matthews, North Carolina is part of the Company's Industrial Division. They are involved in the laminating and coating of paper, film, and foil products, and in printing film substrates for the photography industry. Their waste streams are generated from several routine operations as well as from intermittent or one- time only services for customers.

Rexham has made a firm commitment to waste reduction activities. They view good hazardous waste management practices as a way to maintain evnironmental integrity, ensure worker safety and expand to Qrovide new job opportunities and profitability. The Industrial Division has developed an on-going comprehensive program to review and improve safety and waste management practices throughout their operations. A meeting is held annually for representatives from the several division facilities to review safety contingency plans, hazardous waste handling practices and discuss waste management problems of mutual concern.

At the Matthews plant, a Manager of Safety and Environmental Affairs oversees a number of activities to monitor and reduce waste generation. A hazardous waste manual has been developed for use by plant personnel. The manual sets forth Rexham's contingency plan for accidents and spills and identifies the response teams activities. The plant's major waste streams are also reviewed in the manual, including a description of what constituents are present in each stream, what constituents are not permitted in a given stream, and how each stream is to be handled. All waste materials are tracked through the system to ensure proper handling and to identify possible problems.

Because much of their work involves on-going product development research, the variety of chemicals used at the Matthews plant is very large, in excess of 1300 unique chemicals. Management procedures call for the Manager of Safety and Environmental Affairs to sign-off on all incoming materials. This practice permits a review of all new chemicals and allows special waste handling arrangement to be made if necessary. Periodic internal exchanges of surplus chemicals between product development groups has also been organized so that excess chemicals are not wasted or allowed to become outdated.

Rexham reports four major pollution prevention projects that have contributed to the success of their waste management program: segregation of spent toluene solvent to allow reuse; recovery and sale of toluene vapors; off-site recovery of methyl ethyl ketone from spent solvent mixtures: and incineration of waste solvent vapors for heat recovery. The capital improvements associated with these projects were made during construction of an additional adjacent manufacturing facility.

Liquid toluene is used for print and roller cleanup operations on various printing lines. 5y segregating the used

91

t o l u e n e a c c o r d i n g t o color and t y p e o f i nk c o n t a m i n a n t , e a c h b a t c h c a n be r e u s e d f o r t h i n n i n g t h e same i n k t y p e and color. T h i s s y s t e m h a s a l l o w e d almost 100% r e u s e of l i q u i d t o l u e n e .

U s e o f t o l u e n e s o l v e n t i n a n o t h e r o p e r a t i o n g e n e r a t e s l a r g e q u a n t i t i e s of t o l u e n e s o l v e n t v a p o r s . I n 1979, Rexham i n s t a l l e d a c a r b o n a d s o r p t i o n r e c o v e r y u n i t t o c a p t u r e these v a p o r s . The c a r b o n b e d s are r e g e n e r a t e d in-house t o remove t h e t r a p p e d t o l u e n e which is t h e n so ld f o r u s e i n t h e c o a t i n g s i n d u s t r y a s a

a n d Rexham se l l s t h e reclaimed s o l v e n t a t a b o u t h a l f t h e p r i c e of v i r g i n s o l v e n t .

T h e s o l v e n t r e c o v e r y u n i t was a major c a p i t a l i n v e s t m e n t and i t r e q u i r e s a f u l l t i m e operator. A s u p e r v i s o r and t h r e e s t a f f p e r s o n n e l a re employed t o o v e r s e e t h e o p e r a t i o n . The c a r b o n bed w i l l e v e n t u a l l y r e q u i r e complete r e p l a c e m e n t , b u t t h i s w i l l be a n i n f r e q u e n t expense . Rexham r e p o r t s a small f i n a n c i a l r e t u r n of 1 t o 1 1/2% per y e a r from t h e s y s t e m , b u t t h e major b e n e f i t s have come from improved a i r q u a l i t y and increased o p p o r t u n i t y f o r Rexham t o expand i t s o p e r a t i o n s . Before t h e r e c o v e r y s y s t e m went o n - l i n e , t h e Company released up t o 5000 tons o f h y d r o c a r b o n s i n t o t h e a tmosphe re e a c h y e a r . The c a r b o n a d s o r p t i o n s y s t e m h a s r educed t h e s e e m i s s i o n s t e n f o l d t o o n l y 4 8 5 t o n s / y e a r .

Ano the r major waste stream a t Rexham's Matthews f a c i l i t y is a s o l v e n t mix i n which m e t h y l e t h y l k e t o n e u s u a l l y p r e d o m i n a t e s . About 7 0 0 drums/year of s u c h wastes are p roduced , and t h e y are s e n t o f f - s i t e for me thy l e t h y l k e t o n e r e c o v e r y by d i s t i l l a t i o n . Rexham c u r r e n t l y c o n t r a c t s w i t h Seaboard Chemical Co. i n Jamestown, N o r t h C a r o l i n a f o r t h e p r o c e s s i n g and a p p r o x i m a t e l y 60-65% r e c o v e r y is a c h i e v e d . Rexham u s e s t h e r e c l a i m e d s o l v e n t f o r washup o p e Y a t i o n s , and Seaboa rd i n c i n e r a t e s t h e s t i l l bot toms. Rexham is c u r r e n t l y l o o k i n g a t in-house d i s t i l l a t i o n a s a way t o r e d u c e t h e i r w a s t e management costs and perhaps a c h i e v e improved r e c o v e r y e f f i c i e n c y .

A i r c o n t a i n i n g me thy l e t h y l k e t o n e v a p o r s is v e n t e d t h r o u g h a c o n t i n u o u s f l o w REECO r e t h e r m u n i t f o r h e a t r e c o v e r y . The a i r / v a p o r m i x t u r e is p a s s e d t h r o u g h columns f i l l e d w i t h a r e f r a c t o r y material where s o l v e n t i s p r e h e a t e d and t h e n i n c i n e r a t e d . The c l e a n e d a i r is p u l l e d t h r o u g h t h e s y s t e m and d i s c h a r g e d t h r o u g h a s t a c k t o the ambien t a i r . The h e a t produced is u s e d i n one o f Rexham's d r y i n g o p e r a t i o n s .

A new o p p o r t u n i t y fo r i d e n t i f y i n g and implement ing improved waste management p r a c t i c e s a t Rexham came w i t h t h e r e c e n t e s t a b l i s h m e n t o f weekly 1 h o u r d e p a r t m e n t a l g r o u p m e e t i n g s . The m e e t i n g s were i n s t i t u t e d t o allow employees to pa r t i c ipa t e i n s o l v i n g some of t h e w o r k - r e l a t e d problems t h a t a f f e c t them. The g r o u p s a d d r e s s a v a r i e t y o f t o p i c s , i n c l u d i n g s a f e t y p r a c t i c e s and i d e a s f o r improvements i n p r o d u c t q u a l i t y , waste management ~

pract ices o r of f ice p r o c e d u r e s

t h i n n e r . The s o l v e n t r e c o v e r y u n i t s a c h i e v e about 90% r e c o v e r y , ~~

__

~

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PROCESS DIMENSIONS:

WASTES GENERATED Reduced air emissions (4515 tons/yr collected in carbon adsorption system)

PRODUCTIVITY Increased plant capacity was possible with new air pollution controls


DOWN TIME No chanae



RAW MATERIALS Reduced due to recycling, reuse


ENERGY Reduced due to heat recovery

WASTE DISPOSAL Reduced due to recycling, reuse

POLLUTION CONTROL Increased cost (solvent recovery unit)

PERSONNEL/MAINTENANCE 3 employees for solvent recovery unit

NET BENEFITS Annual cost savings; opportunity for plant expansion: decrease in worker exposure to solvents: significant improvement in air quality

93

CASE STUDY 16

TYPE OF INDUSTRY: Printing and Manufacture of Specialized

NAME OF FIRM: Rexham Corporation

LOCATION: Greensboro, North Carolina SIC: 275

Printing labels

(William J. Klein, Jr. 919/292-9911)

MODIFICATIONS

1. SUBSTITUTION OF WATER-BORNE INKS FOR SOLVENT-

2. RECLAMATION OF WASTE INK SOLVENTS BY IN-HOUSE

3 . USE OF A CLOSED LOOP WASTEWATER SYSTEM FOR

4 . SEGREGATION OF SPENT CLEANING SOLVENTS FOR REUSE 5. RECOVERY AND SALE OF VAPORS COLLECTED FROM

BASED INKS

DI STI LLATION

HEAT RECOVERY

OIL-BASED SOLVENTS

ABSTRACT: The Rexham Corporation facility in Greensboro, North Carolina is involved in the manufacture and printing of specialized product labels. They have made several modifications in their printing operations at various North Carolina facilities to reduce hazardous waste production. A water-borne ink material substitution for some of their alcohol/acetate ink applications reduced the volume of spent solvent requiring disposal and lowered air emission levels. The Company also installed a distillation unit to reclaim n-propyl alcohol from their waste inks. The unit reduced their hazardous waste disposal costs by 7 4 % and decreased their raw material costs by 16%.

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ANNUAL COST SAVINGS: $15,000 (Distillation system)

PAYBACK PERIOD: Less than 1 year (Distillation

TIME TO IMPLEMENT: 3 months (Distillation system)

TRANSFERABILITY: The suitability of water-borne inks

system)

will depend on the material receiving print and the gloss and quality required. Some printing speed must also be sacrificed. Water-based ink suppliers can be a useful resource for assistance in determining optimum conditions for various applications.

In-house solvent recovery using distillation is an excellent investment for many firms using sufficient volumes of solvent to justify the equipment costs. When transportation, insurance, and service fees are included, in-house systems are often quite competitive with off-site recycling arrangements. In-house recovery also eliminates the risk of spills and accidents in transit.


Reduced threat to air and groundwater quality: conservation of resources: improved health and safety conditions for plant personnel

95

. I

PROJECT DESCRIPTION: Rexham Corporation in Greensboro North Carolina manufactures and prints product labels. Several of the waste streams from their pkocesses are hazardous, including spent solvents. Because the company management felt a strong commitment to comply with the spirit of the provisions of RCRA, as well as its technical requirements, the firm began to look in a comprehensive way for opportunities to limit the amount of waste produced. The Greensboro plant made two major modifications to achieve these goals.

Rexham investigated the substitution of water based inks for the traditional alcohol/acetate based inks used in their flexographic printing process. They found there were several technical problems with the substitution, but for many applications, operator retraining was sufficient to achieve excellent product quality. The water-based ink operation reduced both spent solvent volume and air emissions of solvents. The substitution did result in a decrease of the printing speed, and cannot be used if gloss is required in the final product. However, Rexham is optimistic the ink companies will overcome some of these problems in the near future.

To reduce the waste solvent volumes generated from press and roller cleanup, Rexham installed a Cardinal Distillation Unit. The unit receives a solvent blend consisting mainly of normal propyl alcohol and a small percentage of normal propyl acetate. The unit was placed in a corner of a materials storage room with a special block wall built around it to ensure that all materials being redistilled were properly contained. The unit boils the solvent out of a 55 gallon drum of press washup and recondenses the clean solvent vapor into another drum for reuse. Total solvent reclamation is not possible because the 55 gallon drum of press washup is heated by use of a band heater wrapped around the bottom of the drum. Even heat distribution inside the drum cannot be achieved. The press washup at the outside edge of the drum is hotter than that at the center. The residue from this unit is a flammable hazardous waste.

Total cost of the distillation unit and the structural modifications was approximately $16,000. The distillation unit recovers 85% of the solvent in the waste stream, resulting in a savings of $15,000 per year in virgin solvent costs and $22,800 in hazardous waste disposal costs. After implementation of the solvent recovery process, Rexham sends 7 2 drums of waste per year to the hazardous waste landfill as opposed to 300 or 350 per year previously. The reclaimed alcohol/acetate mixture is reblended with virgin materials to provide the required composition for new ink batches and for cleanup. The still bottoms are transported off-site for incineration at a cost of approximately $98.50 per drum.

Rexham plans to add a further distillation unit in order to recover the remaining 15% of the solvents in the sludge wastes. They are investigating the purchase of a "second generation"

96

solvent reclamation unit distributed by Activation, Inc. in Charlotte, North Carolina. This unit is very similar to the Cardinal Unit except instead of evaporating the solvent out of a 5 5 gallon drum, a special holding tank is used. The special holding tank is shallow and is part of the distillation unit. Heat coils run through the sides and the bottom of the tank. This greatly increases the heated surface area and allows an almost total recovery of solvent from the press washup. The residue resulting from this second distillation unit should be non-hazardous waste that can be sent to a sanitary landfill. The new unit is especially appealing because it will allow the Greensboro plant to become declassified as a hazardous waste generator. The Company believes relief from not having the training, verification, reporting and inspection costs tied up with hazardous waste management is in itself a great savings. Once the Activation Unit is installed, Rexham will use a two stage method of solvent reclamation. They will utilize the Cardinal Unit as the first reclaiming stage. This arrangement will allow the purchase of a smaller Acitivation Unit, and cut the capital investment required by two-thirds.

The Greensboro plant also employs a closed loop wastewater system. Heat is extracted from an equipment cooling process and is used to heat the firm's warehouse.

~

97

, ,

PROCESS DIMENSIONS:

WASTES GENERATED Reduced spent solvent volume (13,000 gal/yr due to distillation unit)

PRODUCTIVITY Slight loss of print speed with water-based ink

PRODUCT QUALITY Sacrifice some quality with water-based ink

DOWN TIME Information not provided

FAC I LIT I E S $4,000 One-time cost for distillation equipment

EQUIPMENT $12,000 One-time cost for distillation operation

RAW MATERIALS $15,00O/year savings from distillation operation



WASTE DISPOSAL $22,80O/yr savings from


PERSONNEL/MAINTENANCE Slight increase in cost due to

distillation operation

distillation operation

NET BENEFITS Annual cost savings; reduced RCRA liability and other regulatory concerns

98

CASE STUDY 17

TYPE OF INDUSTRY: Nylon Yarn Production and Research Facility NAME OF FIRM: America Enka Company (John Ray 704/667-7351) LOCAT I ON : Enka, North Carolina SIC: 2824

MODIFICATION

SOLVENT RECYCLING

ABSTRACTS American Enka Company is a nylon yarn production and research facility. They require isopropyl alcohol solvent to produce a polymer film product. They have found it is economically profitable and environmentally sound to recycle their waste isopropyl alcohol solvent in-house rather than having it recycled by an outside firm. They purchased a used distillation unit and, with appropriate modifications, American Enka is now saving $90,00O/yr. They have also been able to reuse the still bottom residues as an asphalt emulsifier in another product line.

99


PAYBACK PERIOD: 1 month

TIME TO IMPLEMENT: 3 months

TRANSFERABILITY:


In-house solvent recovery using distillation can be competitive with off-site vendors. Important variables in determining the suitability of implementing this technology include volume of solvent (to justify equipment costs), contaminants, boiling points and other chemical characteristics. When transportation, liability insurance, and service fees are included in off-site recycling, on-site recovery economics are considerably enhanced.

Reduced threat to air and groundwater quality from prior waste disposal; conservation of resources: Reduced risks of transportation related accidents and environmental contamination

100

PROJECT DESCRIPTION: American Enka Company is a nylon yarn production and research facility. One of their processes uses isopropyl alcolhol as a solvent for a fatty amine. The end product is a porous film of polymer. They previously employed an outside firm to distill their waste isopropyl alcohol. They then bought it back for reuse in their production line. Average distillation losses were 15%, but losses as high as 40% had occurred. Also, due to improper cleaning of the distillation column between runs, the isopropyl alcohol returned was often unusable due to contamination with Dowtherm, benzene, ethyl benzene, methyl benzene, various chlorinated hydrocarbons, and other organic constituents. Each batch of recycled isopropyl alcohol had to be analyzed for contamination, and, if found unsuitable, required disposal arrangements and fees.

To solve this problem, American Enka purchased a used distillation unit for $7500 and modified it to redistill the isopropyl alcohol in-house. This resulted in a savings of $90,00O/year, since it is less expensive to distill the alcohol on-site than to contract these services. In addition, the in-house distillation is more efficient, recovering 90% of the isopropyl alcohol as opposed to the outside firm’s efficiency of 85%. Not only does American Enka reuse the pure isopropyl alcohol the distillation unit produces, but they also utilize the still bottoms as an asphalt emulsifier in another product line. The payback period for this project was approximately one month.

101

PROCESS DIMENSIONS: ( 1 9 8 3 d o l l a r s )

WASTES GENERATED Reduced By 1 0 , 0 0 0 g a l l o n s / v r

PRODUCTIVITY N o Change

PRODUCT QUALITY No Chanqe

DOWN TIME No Change

FACILITIBS No Change

EQUIPMENT $ 7 , 5 0 0 one - t ime cost

RAW MATERIALS $90,00O/yr s a v i n g s

WATER $81 /y r cost

ENERGY $5,52O/yr cost

WASTE DISPOSAL No Change

POLLUTION CONTROL No Change

PERSONNEL/MAINTENANCE S l i g h t increase i n cost

NET BENEFIT Annual cost s a v i n g s , improved q u a l i t y c o n t r o l

102

CASE STUDY 18

TYPE OF INDUSTRY: Hosiery Manufacture NAME OF FIRM: Hampshire Hosiery (Ellen Knitting Mills)

LOCATION : Spruce Pine, North Carolina 28777 SIC: 2251

(George Beauvais, Sr. 704/765-9011)

MODIFICATIONS

1) USE OF A HEAT EXCHANGE SYSTEM TO REDUCE WASTE EFFLUENT TEMPERATURES AND REDUCE ENERGY COSTS

2) REPLACEMENT OF AN OIL-FIRED FURNACE WITH A WOOD- FIRED SYSTEM

ABSTRACT: Hampshire Hosiery manufactures women's pantyhose. They have made several modifications to reduce their energy costs and improve the quality of effluent discharged to the minicipal sewer system. A - heat recovery system was installed to capture heat from spent dye solutions and preheat subsequent dye operations. In addition to energy savings, the exchanger system lowers the temperature of effluent entering the municipal sewer system from 130 degrees F to 70 degrees F. A change in furnace equipment now permits the recycling of locally generated saw dust as a fuel source. The plant's oil-fired steam boiler was replaced with a wood-fired system capable of using sawdust from nearby lumbermills as fuel. The new boiler operation saves the firm $200,000 per year in fuel costs.

103


PAYBACK PERIOD: 2 years 4 years

heat exchanger) wood-f ired boiler)

TIME TO IMPLEMENT: 3 years

TRANSFERABILITY: The use of a heat exchanger to capture waste heat is cost effective if a sufficient flow of water at a sufficiently high temperature is available to justify the capital equipment costs. Equipment manufacturers would be a good resource for making this de- termina t ion. Use of a wood-fired furnace may be limited by the availability and cost of fuel, and the age and performance of existing equipment.


Reduced thermal pollution; reduced air pollution; conservation of energy and material resources

104

t

PROJECT DESCRIPTION: E l l e n K n i t t i n g Mills, a D i v i s i o n of Hampshire Hosiery, was d i s c h a r q i n g s p e n t d v e b a t h w a t e r t o t h e _ - _ m u n i c i p a l sewer sys t em. The t e m p e r a t u r e of t h e d i s c h a r g e w a t e r was 130 d e g r e e s F , which c a u s e d b r e a k a g e o f t h e t e r ra c o t t a sewer p i p i n g . I n 1981 , t h e Company i n v e s t e d $100,000 i n a hea t e x c h a n g e s y s t e m t h a t lowered t h e e f f l u e n t water t e m p e r a t u r e t o 7 0 degrees F. Spent dye water is d i s c h a r g e d i n t o a h o l d i n g v a t f rom which it e n t e r s t h e s t a i n l e s s s t e e l h e a t e x c h a n g e r . The e x c h a n g e r is composed o f f i v e 3 0 - f o o t l o n g 8 - i n c h d i a m e t e r p i p e s . I n s i d e e a c h pipe is a b u n d l e of smaller t u b e s which allow t h e heat t r a n s f e r .

Heat removed from t h e w a t e r is used to p r e h e a t incoming f e e d water f o r t h e d y e t u b s from 55 d e g r e e s F to a b o u t 1 0 5 d e g r e e s F. The p r e h e a t i n g o p e r a t i o n s a v e s a b o u t 5 2 , 0 0 0 g a l l o n s o f f u e l o i l per y e a r , and t h e h e a t exchange s y s t e m had a payback p e r i o d o f o n l y t w o y e a r s .

The Company made a second major m o d i f i c a t i o n which h a s a l s o r e s u l t e d i n s i g n i f i c a n t e n e r g y s a v i n g s and reuse o f waste materials. I n 1982 E l l e n M i l l s p u r c h a s e d and i n s t a l l e d a s a w d u s t f i r e d s t e a m g e n e r a t i n g p l a n t f o r a p p r o x i m a t e l y $800,000. The u n i t c o n s i s t s o f a 1 2 ton r e c e i v i n g h o p p e r , a c o n v e y o r t ranspor t s y s t e m , a h o g g e r , a 200 t o n s t o r a g e s i l o , a d u t c h oven c o m b u s t i o n chamber , an a u x i l i a r y o i l b u r n e r , and a 400 h o r s e power HRT b o i l e r .

I n t h e v i c i n i t y o f S p r u c e P i n e , N o r t h C a r o l i n a t h e r e are s e v e r a l local sawmills and a r e a d y s u p p l y o f waste s a w d u s t . The s a w d u s t is t r u c k e d t o t h e M i l l , where it is dumped i n t o t h e r e c e i v i n g h o p p e r , p a s s e d by c o n v e y o r b e l t u n d e r a magnet t o remove metals, and on t o a h o g g e r where it is ground t o a u n i f o r m s ize . The s a w d u s t is t h e n l i f t e d by a b u c k e t e l e v a t o r t o t h e top of t h e storage s i l o , which h o l d s a n 8 d a y s u p p l y o f f u e l .

Sawdus t e x i t s t h e s i l o from t h e b o t t o m , where i t is c o l l e c t e d i n a m e t e r i n g b i n which d i s p e n s e s it t o a screw c o n v e y o r l e a d i n g t o t h e b o i l e r . The m e t e r i n g b i n h a s s e n s i n g d e v i c e s t o monitor t h e s t e a m p r e s s u r e i n t h e b o i l e r and releases s a w d u s t as needed t o m a i n t a i n a c o n s t a n t p r e s s u r e . The measu red charge of s a w d u s t is blown i n t o t h e d u t c h oven where c o m b u s t i o n t a k e s p l a c e . The h e a t p roduced by t h i s combus t ion is i n t r o d u c e d i n t o t h e bo i l e r where t h e steam is g e n e r a t e d .

The e x h a u s t g a s e s pass t h r o u g h a se r ies o f c y c l o n e separators t o remove a n y p a r t i c l e s and t h e n i n t o a smoke s t a c k . A t t h i s p o i n t a h e a t e x c h a n g e r t r a n s f e r s h e a t f rom t h e e x h a u s t and r e i n j e c t s i t u n d e r t h e g r a t e i n t h e combus t ion chamber. S i n c e t h e M i l l h a s ample c a p a c i t y i n t h e i r d y e h o u s e h e a t e x c h a n g e r , t h e y a r e u s i n g t h e p r e h e a t e d water a s t h e i r bo i le r makeup water. T h i s resul ts i n g r e a t e r e n e r g y e f f i c i e n c y f o r t h e system.

105

The new boiler system has eliminated the need for 300,000 gallons/yr of fuel oil. The sawdust fuel costs approximately $12.00/ton; the Company reports a 66% savings on fuel costs. They estimate a payback period of only 4 years for the new system. The new boiler is also a much cleaner system since it is equipped with state of the art pollution control devices. Cyclone separators scrub the vapors and prevent the particulate "fallout" that was present with the oil-fired steam generator.

PROCESS DIMENSIONS:

WASTES GENERATEID Reduced waste effluent temperature Reduced particulate air pollutants



DOWN TIME No change

FAC I L I T I ES No change

EQUIPMENT $100,000 (heat exchanger) One-time cost $800,000 (wood-fired boiler One- t ime cost


WATER No change

ENERGY $225,00O/yr savinqs

WASTE DISPOSAL NO change



NET BENEFITS Annual cost savings, reduced I

air and thermal pollution, relief from requlatory concerns

106

CASE STUDY 19

TYPE OF INDUSTRY: Textile Dye and Finishing Plant NAME OF FIRM: West Point Pepperell

LOCATION: Lumberton, North Carolina SIC: 266

(Ken McDowell 919/739-2811)

MODIFICATION

ESTABLISHMENT OF A TOXIC CHEMICALS REVIEW COMMITTEE

ABSTRACT: West Point Pepperell is a textile dye and finishing plant. In 1975 the Company established a Toxic Chemicals Committee in 1975 to review products in use or under consideration and evaluate them according to a wide range of health and environmental impact criteria. The Committee has proven to be an effective management initiative which has minimized hazardous waste production and the accompanying costs and environmental impacts.

107

ANNUAL COST SAVINGS: N/A

PAYBACK PERIOD: N/A

TIME TO IMPLEMENT: One year

TRANSFERABILITY: This management program is a preven- tive measure, transferable to any firm making significant use of a number of different chemicals. Time and money are invested in preventing pollution rather than cleaning it up.


Reduced risk to the environment; Improved health and safety conditions for plant personnel.

108

PROJECT DESCRIPTION: Westpoint Pepperell is the third largest publicly held textile manufacturer in the nation. There are 22,000 employees with 40 manufacturing facilities located in Georgia, Alabama, North and South Carolina, Florida, Maine, Texas, and Virginia. The establishment of a Toxic Chemicals Committee for evaluation and screening of chemicals used in their operations was first proposed by the Director of the Medical Department. It was suggested that an interdisciplinary team be appointed to ensure that chemical safety be a priority in the f inn.

In 1975, a committee was assembled which included a medical doctor, an industrial hygienist, three research chemists, a professional engineer, a corporate attorney, a corporate safety officer, a representative from chemical production, and a corporate information specialist. In 1976, the committee began its evaluations. It reviewed both chemicals in use and new products considered for use.

Several criteria were used for evaluation in addition to the original considerations of personnel safety and fire hazard potential. These include:

hazardous waste characteristics (ignitability, toxicity, corrosivity, reactivity) "priority pollutant" status availability of safer alternatives biodegradability heavy metal content potential for accumulation in the facility potential for release to the environment hazard potential when mixed with other chemicals proposed manner of use ultimate fate of the chemical hazard potential to the consumer

Products under use such as hydrazine and hydrofluoric acid were eliminated due to limited ventilation.

Some of the new products considered by the Committee and rejected include dichlorobenzidine dyes because of the benzidine base, and a chloride catalyst for resins because of its association with bis-(chloromethyl) ether. Another committee recommendation involved the substitution of SAF-T-Kleen, a water- based cleaner, for organic solvent cleaners.

When it was first organized, the Committee scheduled regular quarterly meetings. Part of its function was to establish a set of workable procedures for each plant to follow prior to any chemical purchases. Once these were in place, much of the Committee's work could be handled in-plant. Currently, all new chemical purchase requests must be approved by the Corporate Research Center Chemist, who follows quidelines set forth by the Committee . - -

109

WestPoint Pepperell is very satisfied with its chemical safety review program. They attribute their extremely low levels of hazardous waste production to the work of the Toxic Chemicals Comm it tee. They believe their costs are kept lower by controlling chemicals at the point of use and avoiding waste management costs. They currently generate only a small amount of spent solvent from a dry cleaning operation. The solvent is reclaimed out-of-house by a refining company.

PROCESS DIMENSIONS: .

WASTES GENERATED Minimized use of toxic hazardous chem ica Is

PRODUCTIVITY No change,,


DOWN TIME No change

FAC I L I T I ES No ,ch?,nge

EQUIPMENT No change,

RAW MATERIALS Safer,, eas,ier to handle

WATER No chgnge

ENERGY No chan.ge

WASTE DISPOSAL Minimized

POLLUTION CONTROL Minimized

PERSONNEL/MAINTENANCE Reduced exposure to hazards

NET BENEFITS Reduced hazardous waste generation, enhanced workplace ,safety

110

CASE STUDY 20

TYPE OF INDUSTRY: Electric Power Company NAME OF FIRM: Carolina Power and Light Company

LOCATION: Shearon Harris Energy & Environmental (Grover Dobbins 9 19/8 36-608 3 )

Center Route 1, Box 321 New Hill, North Carolina 27562

SIC: 4911

MODIFICATION

SALE OF FLYASH AND BOTTOM ASH FOR REUSE

ABSTRACT: Carolina Power and Light Company (CP&L) has been selling waste 3 -- ash and bottom ash for reuse since 1973. The Company does not sell ash directly to USE ?rs but has contracted with another firm, Monier Resoirces, Inc., to oversee the marketing of the ash. Prior to this arrangement, all of the ash produced was sluiced to on-site ash ponds. The company has now reduced its disposal costs and prevented the burial of useable material.

111

ANNUAL COST SAVINGS: Variable

PAYBACK PERIOD: Unknown


TRANSFERABILITY: The success of Ely ash and bottom ash sale depends on several factors, including the composition of the ash, the local market options, and the current costs of ash disposal. Composition can be affected by the type of coal burned, boiler design, operating conditions, and the methods used to handle and collect the wastes. The Utility Companies have a large resource base available to assist in evaluating and developing marketing programs. Any firm producing significant quantities of waste ash could pursue opportunities for sale or donation of the ash to reduce storage and disposal costs and risks. The Electric Power Research Institute has prepared a by-product utilization manual which contains a step-by-step methodology to assist power companies in estimating the feasibility of marketing ash. (See resource listing) Other industry groups may be able to make use of this information as well, or they may need to investigate material composition, alternate uses, and available markets on their own or with the assistance of their respective trade associations.

Conservation of land and material resources, and energy used to produce materials for which fly ash can substitute; reduced opportunity for accidents related to fly ash ponds; reduced threat of surface and groundwater contamination from ash pond effluent.


112

PROJECT DESCRIPTION: Operation of Carolina Power L Light Company’s coal-fired power plants currently produces 800,000 to 900,000 tons of fly ash and 300,000 to 350,000 cubic yards of bottom ash annually. This ash is typically sluiced to on-site ash ponds. Since 1972, CP&L has been selling limited qunatities of ash. They are currently working with Monier Resources, Inc. (MRI) to expand ash utilization activities. CPLL does not sell ash directly to users but works through MRI, which purchases the ash from CP&L and manages the resale to users.

Initially, fly ash and bottom ash sales were from the Roxboro Steam Electric Plant. Subsequently, bottom ash has been sold from the Sutton Steam Electric Plant (from 1979 to 1982) and fly ash sales from the Mayo Electric Generating Plant began when Unit No. 1 started commercial operation in 1983. Bottom ash sales from the Mayo Plant began in 1984.

Fly ash sales capability requires dry handling of the fly ash. Fly ash collected by electrostatic precipitators is transferred to a storage silo from which it is loaded into haul vehicles (trucks or rail cars) for delivery to users. Bottom ash sales capability typically involves wet transfer of the ash to a reclamation area to allow drainage before it is loaded for transport.

The amount of ash sold is variable from year to year, depending on market conditions. Whatever volume is sold reduces the land requirements for disposal, conserves raw materials and the energy required to produce them, and reduces the potential for pollution from ash ponds. A summary of recent ash production and sales volumes follows:

Production Sa le (units in thousands) (units in thousands)

Roxboro Fly Ash 400-500 tons 30-40 tons (5-10%) Plant Bottom Ash 150-200 cu yds 35-45 cu yds (20-30%)

Sutton Bottom Ash 30-35 cu yds 4 cu yds (10-15% Plant

Mayo Fly Ash 150-175 tons 50-60 tons (30-358 Plant Bottom Ash 55-65 cu yds no data available

The primary equipment investment is reported to be highly site specific. The investment is more quickly recouped when installed as the sole ash handling process, rather than duplicating the dry process alongside the wet process. A rough estimate offered by the CP L L representative for construction is $1-2/ton of ash based on designed load: $3-4/ton of ash/year for equipment operation and maintenance.

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PROCESS DIMENSIONS:

WASTES GENERATED

PRODUCTIVITY

Reduced up to 30%

No Change


DOWN TIME No Change



RAW MATERIALS NO Change

WATER Information n o t provided


WASTE DISPOSAL Information not provided

POLLUTION CONTROL Information n o t provided


NET BENEFITS Reduced waste management costs and risks

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. ,

CASE STUDY 21

TYPE OF INDUSTRY: Electric Power Company NAME OF FIRM: Duke Power Company

LOCATION: Charlotte, North Carolina SIC: 4911

(David Roche 704/373-8775) (Russell Propst 704/373-2377)

~

I

I

MODIFICATIONS

1) SALE OF FLY ASH AND BOTTOM ASH 2) INCINERATION OF POLYCHLORINATED BIPHENYLS (PCBs) . 3) SEGREGATION OF WASTE STREAMS TO REDUCE

HA Z AR DOUS WASTE VOLUME

AND EQUIPMENT

TREATMENT EFFICIENCY

ESTABLISH AN ON-GOING WASTE MINIMIZATION PROGRAM

: 4) DECONTAMINATION AND REUSE OF RADIOACTIVE TOOLS

5) REVISED EQUIPMENT OPERATION TO IMPROVE WASTE

6 ) INTRODUCTION OF A MANAGEMENT INITIATIVE TO

ABSTRACT: Duke Power Company has reduced waste production in three major areas of operation. % -- ash and bottom ash wastes from coal-fired plants are now offered for reuse as a concrete constituent, plastics component or roadway construction material. Mineral oil insulating fluid contaminated with the organic chemical polychlorinated biphenyl (PCB) is burned as a supplemental fuel for - heat recovery at a steam electric generating station. A comprehensive prOgram to achieve volume reduction of - low level radioactive wastes (LLRW) has also been instituted. The p r o g r a m m o w p i n g improvements, the purchase of equipment to allow cleaning rather than disposal of contaminated tools and equipment, conversion from an evaporator- based non-recyclable waste processing system to one based on ion- exchange equipment, redesign of existing evaporator equipment for use in recyclable waste processing, and review and revision of filtration equipment operation to improve performance and minimize replacement and disposal costs. The Company attributes the success of these modifications to the team approach __ encouraged by management initiative.

__ ~

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PAYBACK PERIOD:

TIME TO IMPLEMENT:

TRANSFERABILITY:


$6,184,000

Less than 1 year

Radwaste program -- 3 years Complete information not provided on the impl0mentation times of other modifications

All of the programs and modifications described would obviously be applicable to other companies engaged in coal and nuclear based energy production. HOwever, any firm producing significant quantities of waste ash cnuld pursue opportunities for sale or donation of the ash to reduce storage and disposal cQsts and risks. TKe use of incineration for PCB destruction is an excellent method of disposal, but may not be cost effective for firms producing small quantities of PCB-contaminated material . An out-of-house or crropsrat ive arrangement might be f easibls. The mmaqement policies used by Duke Power t6 handle low level radio- aotive wastes can be adopted by any firm wishing to institutionalize the pollution prevention philosophy. Regardless o f what waste products are generated, providing employees with encouragement and the time to review existing processes and propose improvements will result in opportunities for waste reduction. Certainly the housekeeping improvements involving separation of hazardous and non-hazardous waste streams, review of cleaning procedures, and a policy of vigilance ant] cooperation can be adapted to any industrial work setting.

Reduced risk of PCB and low-level radioactive waste contamination .-

of soil, surface and groundwater; reduced risk of PCB bioaccumulation; reduced risk of hazardous waste

tion of land and material resources. transportat ion accidents : conserva- -~

116

PROJECT DESCRIPTION: Duke Power Company is one of the major electric power generating firms in the State of North Carolina. They have implemented several major pollution prevention activities which have resulted in annual cost savings and which serve as an example to other industries in the State. They have reduced waste production in three major areas of their operation: fly ash and bottom ash wastes from their coal-fired power plants, low-level radioactive wastes from their nuclear power plants, and PCB wastes from their electrical distribution equipment.

-Y-- Ash and Bottom Ash Wastes F1

Since the late 1960's, Duke Power has sold some of the fly ash from one or more of their coal-fired power plants to be used as a component in portland cement for concrete production or as a filler in asphalt. The ash is removed from stack gases by electrostatic precipitators and conveyed to a storage silo where it can be loaded onto trucks. The amounts of fly ash sold for concrete products at Duke's several facilities were:

Marshall Steam Station, 1979 116,700 tons Cliffside Steam Station, 1983 79,400 tons Belews Creek Steam Station, 1983 42,700 tons

The sale of fly ash generates revenue and avoids the costs of sluicing and ponding the fly ash for disposal. In some instances, ponded fly ash (cenospheres) has been removed from ash ponds and sold in small quantities to a plastic manufacturer for use as a filler.

Because fly ash constitutes 80% or more of the ash produced by burning coal, Duke Power is seeking to expand fly ash reuse into markets that do not have the quality control restrictions of concrete production. The pozzolanic property, light unit weight, and compressive strength of fly ash make it desirable in use as structural backfill and to stabilize roadbase. Duke Power contractors have constructed a one-mile road at the Marshall Steam Station this year using 1200 tons of fly ash to demonstrate stabilization techniques that the North Carolina Department of Transportation may be able to adopt in their roadbuilding and repair projects. If uses for large volumes of fly ash can be developed in road construction, disposal costs for ponding or landfilling of this material can be greatly reduced or totally eliminated . Bottom ash has been sold at the Belews Creek Station since 1979 for use as lightweight aggregate in concrete production. In 1981, 65,400 tons were sold. Since 1983, bottom ash from the Marshall Steam Station has been provided without cost to the North Carolina Department of Transportation to be used in place of crushed stone as an aggregate base course applied to unpaved secondary roads. Approximately 30,000 tons of bottom ash have been used in this way by the State as of October 1984. Bottom ash is sluiced from the bottom of the steam boiler to holding ponds for dewatering and reuse. The periodic excavation of ash

117

from the disposal ponds saves storage space and minimizes the need for making other disposal arrangements.

- PCB Disposal

Duke Power's efforts to, reduce the amount of PCB wastes requiring hazardous waste disposal are part of a comprehensive program across its service area to phase out PCB contamination from their electrical distribution system.

When electrical equipment needs repair on the Duke system, the unit's fluid is tested for PCB concentration. If the fluid is non-PCB, it is reprocessed at a company facility and used again, at an annual savings of $400,000 compared to the cost of new mineral oil. If the fluid is contaminated with PCB at the regulated levels, it is designated to be burned as a supplemental fuel (the heat value is identical to that of fuel oil) in a high efficiency boiler (Riverbend Steam Station). This incineration is approved by the Environmental Protection Agency and has been proven to totally destroy PCB, as shown by Duke's own stack emission tests. The contaminated oil is, therefore, used for heat recovery at a steam electric generating station, and does not place additional demand on the limited capability of commercial hazardous waste disposal facilities. The mineral oil storage and feed system at Riverbend required approximately $75,000 in capital, but use of the system since July 1981 has saved Duke Power $168,000 in disposal costs. The system, and the whole PCB management program, are expected to continue to realize substantial economic benefits while removing PCB from the electrical distribution network.

Radioactive Waste Volume Reduction

Because all processed low level radioactive wastes must be packaged, shipped, and disposed of on a restricted volume basis in a hazardous waste facility or released to the environment in controlled, dilute quantities, it was imperative that Duke Power minimize the volume of wastes produced at their new McGuire Nuclear Station. A team of staff members from the Company's Design Engineering and Nuclear Production Departments was assembled to aggressively pursue waste reduction strategies.

Solid low-level radioactive waste studied included: a) Contaminated compactible materials: paper, plastic,

and other materials used at the station for both ~

office work and radiation protection in areas traditionally viewed as parts of the "radiation area" in the plant. The projected volume was 30,000 cu ft/year. ~

b) Contaminated tools and equipment: maintenance tools used on radioactive-contaminated components, and of components removed for replacement. The projected volume was 19,000 cu ft/year.

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c) Evaporator concentrate: The concentrated byproduct of liquid low-level radioactive waste purification. The projected volume was 11,000 cu ft/year.

Contaminated compactible materials were segregated by area within the plant into "potentially contaminated" and "not contaminated". A designated area and equipment were set up to survey all materials from non-contaminated collection points in order to give final assurance of radioactive cleanliness. This removed large quantities of material from the volume normally generated in similar plants in the nuclear industry while complying with regulations and industry "Good Practices" standards. For the contaminated wastes, improved compactor equipment was purchased, installed, and placed in operation. This equipment further reduced the volume of wastes requiring disposal.

Contaminated tools and equipment volumes were determined to be higher than could be achieved if the best technology for effective decontamination were used (removal of activity from the surfaces such that the component is no longer a source of radioactivity). The station issued contracts to a variety of service companies to process these components using a variety of decontamination techniques. The program allowed the clean-up of components such that disposal was no longer necessary and allowed the collection of data on the effectiveness of each technique. The data were used to choose the most efficient equipment for purchase and permanent installation during 1984. Capital costs totalled $200,000, and the modifications have saved Duke approximately S1,000,000/year.

The production of evaporator concentrates was reviewed by the station and questioned as to its necessity when compared to the newer approach of processing non-recyclable liquid wastes using ion exchange technology. Laboratory testing and review of early data in the nuclear industry were conducted. A program was implemented to allow modification of existing systems to convert processing of non-recyclable wastes from evaporator-based to ion exchange-based. The objective was to eliminate production of evaporator concentrate while generating less ion exchange resin byproduc t . The ion exchange modifications included the capability to supplement permanent equipment with portable equipment. This provides the capability to adapt processing equipment to changing waste properties such that effluents released to the environment remained consistently low.

The use of ion exchange for non-recyclable liquid waste processing represents the application of a technology infrequently used until recently. The success of this technology at McGuire placed the station and Duke Power Company among the early leaders in a trend toward more widespread use of this process in the nuclear industry.

Liquid low-level radioactive waste included: a) Evaporative processing: use of evaporators €or treat-

119

ment of non-recyclable equipment drainage and cleaning wastes had proven to be difficult with the type of evaporator provided by the supplier of plant equipment. Evaporator operation had demonstrated lower-than-design process capacity, and had produced large volumes (11,000 to 20,000 cu ft/year.) of concentrate as a byproduct. Reduced process capacity forced processing of recyclable liquids by other systems, resulting in increased release of dilute quantities of boron and tritium to the environment. The systems, as originally installed, lacked the capability of adaptation to change in waste stream chemistry and radionuclide concentrations.

b) Filtration equipment: during preoperational tests, the size and capacity of filtration equipment were discovered to be inadequate for routine processing. A throughput rate of less than 4,000 gallons per cartridge changeout was experienced. The spent cartridge replacement cost was greater than $200,000 per year.

Existing evaporator equipment was determined to be better suited for processing recyclable liquid wastes. The evaporator performance problems at other plants indicated that unless improvements or replacement were accomplished, recyclable waste backlogs would require drainage of this waste to the non- recyclable waste process streams. A test program was conducted, and the evaporators extensively modified. The evaporator originally designed for non-recyclable waste processing was converted to recycle processing so as to minimize boron and tritum release to the environment, and to minimize process costs. (This conversion was allowable due to the modifications for ion exchange processing of non-recyclable wastes.) Evaporator performance was improved from 60% of design process rate to 110% of design process rate. The combined ion exchange and evaporator modifications cost $1,030,000 and have yielded an annual payback of $2,000,000/year. The conversion of evaporators for recyclable waste processing occurred at a time when many utilities were abandoning their use, and it placed Duke Power among industry leaders in the evaluation and utilization of unit processes based on waste stream and equipment compatibility analyses.

Filtration equipment was reviewed, tested, and modified to improve filter performance and to minimize replacement and disposal costs. The modifications required a $60,000 investment, but they have resulted in $200,00O/year savings. Operating data show radioactive cobalt removal rates were doubled, and - throughput to exhaustion improved by a factor of 25.

1982. Both McGuire reactor units either operated or were tested ___ under conditions which produced radioactive byproducts during 1983. The results of the program through September 3 0 , 1983, showed low-level radioactive waste volumes from McGuire to be less than 15% of the industry average, despite outages for major

The programs and modifications were in place by the end of

120

. ,

component modifications (high waste volume generation) during this period. Evaporator concentrates were eliminated as a waste byproduct. Resin from ion exchange processing produced less than 5% of the projected 11,000 cubic feet of concentrates. Boron releases were reduced by 5 4 % , and tritium reduced by 60% due to waste recycle processing. Filtration cost was reduced by a factor of 24. Liquid release radioactive concentrations were greater than a factor of 100 below the levels permitted under the station license and federal regulations.

Duke Power Company has encouraged improved waste management by creating and expanding organizational waste management groups at each of its stations. At McGuire Nuclear Station, a special "Radioactive Waste Processing Introduction" is identified in the "McGuire Chemical Manual" which stresses the impact of: a) "participation of all plant personnel in notifying the

radwaste organization of unusual occurrences such as leakage of coolant or oil: segregating waste streams where feasible: and minimizing extraneous waste such as cleaning chemicals and trash from sumps and floor drains." b) "coordination and cooperation in reduction of waste

production: efficient scheduling and performance of system maintenance: timely waste sampling, analysis, and receipt of results and recommendations: and system operation to the highest professional standards." The policy statement concludes, "The most fundamental concept of MNS radwaste philosophy is waste release minimization through operational optimization. This concept should be distinctly segregated from the notion of releasing radioactive waste at a rate which merely satisfies a pre-determined legal limit."

A cost benefit analysis of the improvements to low-level radioactive waste programs and equipment yielded net savings within one year of operation following implementation.

Duke has also identified several other benefits of the program : 1) Waste disposal site use has been minimized through more efficient and effective solid and liquid waste contol and processing. 2 ) The number of low-level radioactive waste shipments has been reduced. 3 ) Reclamation and reuse of recyclable liquid waste reduced release of boron and tritium to the environment. 4 ) Liquid releases from the station are maintained at a small fraction of permissable levels.

121

PROCESS DIMENSIONS:

WASTES GENERATED Waste fly ash reduced approx. 250,000 tons/yr Waste bottom ash reduced approx. 9 5,000 tons/year PCB waste volume reduced Solid LLRW volume reduced Projected evaporator LLRW concentrates volume reduced 9 5% Tritium and boron release reduced 60%


PRODUCT QUALITY No chanqe

DOWN TIME No change


EQUIPMENT $1,290,000 One-time cost (LLRW) $75,000 One-time cost (PCB incinerat ion)

RAW MATERIALS $400,00O/yr savings (insulating



WASTE DISPOSAL Approx. $2,500,000/yr savings ( f lyash) $84,00O/yr savings (PCB) $3,200,000/yr savings (Solid LLRW)


PERSONNEL/MAINTEN&NCE Information not provided

NET BENEFITS Annual cost savings, extended landfill life, reduced environmental and health risks -

122

CASE STUDY 22

TYPE OF INDUSTRY: Municipal Wastewater Treatment NAME OF FIRM: Hickory/Newton/Conover Complex

LOCATION: Fairgrove Wastewater Treatment Plant

SIC: 4952

(Burmeister, Wright E, Assocs.,consultants, John E.R. Burmeister 704/525-605$)

Catawba County, North Carolina

MODIFICATION

MUNICIPAL SEWAGE SLUDGE COMPOSTING (PROPOSED)

ABSTRACT: A

facility is in the final design phase, and it is scheduled for construction in 1986. When operational, the system will be the first mechanical enclosed composting system in North Carolina. The reuse of waste sludge as composting material is expected to save the County as much as $827,000 annually in disposal costs.

for the Complex in Catawba County. The

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ANNUAL COST SAVINGS: N/A

PAYBACK PERIOD: N/A

TIME TO IMPLEMENT: 1-1/2 years design and construction

TRANSFERABILITY:


Since municipal solid waste can no longer be automatically landfilled, many cities are looking to land disposal, composting, and incineration as possible alternatives. Because incineration is capital intensive, it is often not a feasible aption. It also precludes any reuse value of the sludge biomass. There are several types of composting operations. The mechanical system to be used by Catawba County is more expensive than some of the other methods, 'but it is less labor intensive. A static pile system is cheaper to set up, (see City of Morganton), but requires more labor and involves more worker exposure.

Conservation of land and material resources, improved physical properties of soil receieing compost.

There is a risk that unprotected piles might become a play area for children or pets. Because of variation in the metal content of composted sludge, it is not approved for use in vegetable gardens or in areas where direct-line food crops are to be grown.

124

. .

PROJECT DESCRIPTION: The Hickory/Newton/Conover Complex in Catawba County was seeking an alternative to their current landfill disposal of municipal wastewater sludge. In 1981 they performed a preliminary investigation to evaluate incineration, composting, and land application. Based on this study, composting was selected as the most efficient and cost effective method .

The firm of Burmeister, Wright and Associates was retained to design a composting operation for the region. Several composting designs were evaluated with respect to capital cost, operation and maintenance costs, revenue from composted material, and environmental impacts. Based on their evaluation, the firm recommended an enclosed composting system. When the facility is completed it will be the first mechanical enclosed system in North Carolina.

Five commercial mechanical systems were evaluated by the consultants. The most important criteria for evaluation were the mechanical complexity of each system and energy costs required for operation. The "mechanical enclosed system" will include reactors in which the actual composting process will take place; a carbonaceous storage tank; air blowers and scrubbers: conveyor and solids handling system: and associated buildings and structures. Sludges from several treatment plants and septage systems in the county will be transported to a regional facility for dewatering. Sludge will be delivered to the regional plant in tankers. Four tankers will suffice initially, although it is anticipated they will have to be replaced within 1 0 years and an additional tanker purchased. Septage will be hauled by individual pumpers.

The proposed composting facility will be designed to meet the needs of the participating communities over the next 20 years and will have an ultimate capacity to process 20 tons per day of dry sludge. At start-up, it will process approximately half this amount.

Capital costs for the entire system are estimated to be $6,135,000. This amount will be offset by federal grants totaling up to 75% of the eligible costs. Local savings will be proportionate to the grant amount that can be obtained and the actual amount and price of the compost sold.

An example of a savings calculation would be to assume that 75% funding is received for the capital costs and that on the average 7 5 % of the compost is sold at $20 per ton over the life of the facility. The net annual cost of the compost system would be $250,000 per year vs. $1,077,000 using the present disposal practices, or a net average savings of $827,000 per year.

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The project has been placed on the federal funding list and is scheduled for construction at the start of the federal fiscal year 1986, which commences in October 1985. Commitment to reimburse the local governments for the funds for preparation of the plans and specifications has been received from the North Carolina Department of Natural Resources and Community Development. The process of plan preparation has begun and the plans will be submitted to the Department in July or August of 1985.

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PROCESS DIMENSIONSt

WASTES GENERATED lO/tons/day dry waste sludge

PRODUCTIVITY Information not provided

PRODUCT QUALITY Information not provided


FACILITIES $6,135,000 est.

EQUIPMENT One-time cost including

RAW MATERIALS Bulking materials will be

WATER No chanqe anticipated


WASTE DISPOSAL Est. $800,00O/yr savings

POLLUTION CONTROL No change anticipated


NET BENEFITS Conservation of land and

e 1 imina ted

equipment

required

material resources, minimization of waste disposal costs

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CASE STUDY 2 3

TYPE OF INDUSTRY: M u n i c i p a l Waste NAME OF FIRM: C i t y of Morganton

LOCATION: P. 0. Drawer 4 3 0

SIC: 4 9 5 2

( C a r l D. Hennessee 7 0 4 / 4 3 7 - 8 8 6 3 )

Morganton, N o r t h C a r o l i n a 28655

MODIFICATION

COMPOSTING M U N I C I P A L SEWAGE SLUDGE

ABSTRACT: The Catawba R i v e r P o l l u t i o n C o n t r o l F a c i l i t y i n Morganton , N o r t h C a r o l i n a h a s implemented t h e f i r s t f u l l scale composting o p e r a t i o n i n t h e State. A m i x t u r e of m u n i c i p a l waste s l u d g e and b a r k are composted u s i n g a s t a t i c p i l e s y s t e m d e s i g n e d by C i t y p e r s o n n e l . They h a v e e l i m i n a t e d t h e need f o r l a n d f i l l i n g t h e waste s ludge and have c r e a t e d a s y s t e m t o r e u s e a n o t h e r w i s e u n d e s i r a b l e p r o d u c t . The compost is m a r k e t e d t o t h e p u b l i c , and t h e C i t y is u n a b l e t o k e e p up w i t h c o n s u m e r demand. A l t h o u g h t h e y do no t make money on t h e opera t ion , t h e i r s l u d g e management costs are below t h o s e e s t i m a t e d fo r o t h e r s y s t e m s i n v e s t i g a t e d , i n c l u d i n g l a n d a p p l i c a t i o n and i n c i n e r a t i o n . I n response t o t h e s u c c e s s of t h e Morganton p r o j e c t , t h e S t a t e is d e v e l o p i n g a permit s y s t e m f o r compos t ing o p e r a t i o n s t o e n s u r e s a f e l e v e l s of heavy metals a n d t h e a b s e n c e o f p a t h o g e n s .

128


PAYBACK PERIOD:

TIME TO IMPLEMENT:

TRANSFERABILITY:


5 years, including extensive preliminary study

Morganton was the first municipality in North Carolina to develop sewage sludge composting. As such, they have done a lot of experimentation that other municipalities can now build on. Their decision to try a composting operation came only after careful evaluation and cost comparisons with land application systems. Thus, depending on geographic, climatic, transportation and land availability conditions, both of these options might be feasible alternatives for consideration. Although the City designed its own system, there are several commercial systems on the market as well. The Morganton composting operation uses a static pile system. There are also enclosed mechanical systems which are more expensive but less labor intensive.

Conservation of land and material resources, improved physical properties of soil receiving compost. In heavy textured clay soils, the added organic matter increases the soil's permeability to water and air and minimizes surface water runoff. Addition of sludge compost to clay soils has also been shown to reduce compaction (i. e., lower the bulk density) and to increase root development of plants. Composted sludge may become a nuisance if mismanaged. There is a risk that unprotected piles ' might become a play area for children or pets. Due to variations in the metal content of composted sludge, it is not approved for use in vegetable gardens or in areas where direct-line - food crops are to be grown.

129

PROJECT DESCRIPTION: Morganton's Catawba River Pollution Control Plant began operation in January 1975. The facility is an 8.0 MGD pure oxygen activated sludge plant which genegates approximately 1700 tons of dry sludge per year. Solids handling is accomplished by two 80 foot Eimco clarifiers, aerobic digestion, and dewatering with two Sharples P 5000 centrifuges. As was the case with many of the facilities constructed about this time, plans for management of the sludge consisted of burying it in a sanitary landfill.

Fear of groundwater pollution and the aesthetic impact of diposing of this semi-solid material prompted the North Carolina Division of Health Services and Burke County to refuse to accept sludge for disposal in the County operated landfill. These decisions were. made during construction of the Catawba River Plant. Therefore, upon completion of the plant, the City was forced to construct temporary lagoons until a solution could be developed.

In February 1976, with the help of Mr. Bob Carlisle and Mr. Leslie Miller of the North Carolina Agricultural Extension Service, direct land application to two state approved tracts was begun. Sludge was applied at various rates to silage cornland bel,onging to Broughton Hospital and grazing land owned by a local farmer. A three year program for each tract was developed along with data concerning yields from various application rates and analyses of the sludge and soil. The cornland experiment is still being performed, however, the grassland experiment was terminated after two years because of the distance from the plant.

During the experiments with direct land application department personnel were also experimenting with a pilot composting operation. Early experiments consisted of hand-mixing sawdust, bark, soil and leaves with sludge followed by a final mixing with a coal stoker. A conveyor system with a mixing screw was later used to proportion sludge and sawdust. By this time, information was also becoming available about pilot EPA composting projects in Bangor and at the United States Department of Agricultural Research Center in Beltsville, Maryland.

In 1978, the City authorized a sludge management study to review the existing facilities and determine the most feasible method of sludge disposal. The principal alternatives were land application, composting, and incineration. It was the conclusion of that study that the handling costs per dry ton of sludge would be $49.00, $59.00, and $141.00 for land application, composting, and incineration respectively.

130

During the next several months the City staff investigated the land application solution. A large number of sites of sufficient size were identified; however, topography, excessive hauling distances, close proximity to streams, and opposition by property owners quickly eliminated all but three of the sites. These problems, along with increasing fuel costs, the lack of final guidelines on sludge disposal by EPA, and the unavailability of farmland prompted a closer look at the composting process. City personnel then visited composting project at the United States Department of Agricultural Research Station in Beltsville, Maryland. This facility was set up in 1972 as a co-operative experiment between the Research Center, Maryland Environmental Services and the Environmental Protection Agency.

After a careful review of their data, it soon became evident that while land application theoretically appeared to have a slight cost advantage, the composting process offered a more dependable solution and resulted in a more marketable and manageable final product. After review with the Morganton City Council, it was decided to implement the composting operation and also maintain land application as a back-up solution, The capital cost was lower for composting (estimated at $104,000) compared to capital costs for land application ($442,000). The composting operation could also be implemented much sooner, thereby eliminating the need for construction of additional lagoons.

After an in-plant study to plan the logistics and space requirements of a somposting operation, a site of slightly less than one acre was chosen at the rear of the existing wastewater treatment plant. Site preparation which consisted of blacktopping and installation of a tun off drain system, was begun in February 1980.

The Morganton composting process consists of mixing a centrifuged sludge cake (14-158 solids) with a bark bulking agent. The latter provides free air space and ensures a continuous supply of oxygen throughout the pile. Perforated steel pipes are laid on the asphalt pad and covered with a layer of bark. The mixture is piled on this layer seven to eight feet high and covered with a blanket of finished compost for insulation and odor control. Each pile represents two to three days of sludge accumulation. The mix is presently a ratio of nine yards of bark to four of sludge. The bark used is a mixture of new and previously composted bark. A Sweco separator with 1- inch and one half inch mesh screen is used to recycle wood chips and bark from a local de-barking operation.

Air is drawn through perforated pipe by blowers and exhausted through a pile of finished compost for deodorization. The operator measures temperature and oxygen level in the compost pile with probes and adjusts the blowers to maintain a 5% oxygen content and minimum temperature of 140 degrees Farenheit for four days. Temperatures normally increase to 160 degrees after four

-

~

~

131

. .

days and remain constant for the remainder of the 21 day composting period. Some drying also results from the passage of air through the pile. Blowers are normally operated 4 minutes out of each 20 minute cycle. At the end of the composting period, the pile is taken down and cured for an additional 28 days. Prior to screening, a thin layer of compost is spread on asphalt for additional drying. The material is screened through either a one half or one inch screen. The coarse bark is re-used for composting and the final material is available as finished compost. The system processes about 4 1/2 dry tons of compost per day.

Numerous studies have shown that in a properly controlled composting process, practically all the common pathogenic organisms normally associated with sewage sludge are destroyed or reduced to insignificant levels. Salmonellae, the common food poisoning organism, can regrow to a limited extent. Although many of the salmonellae group possess the biological ability to repopulate compost after the thermal sterilization phase, the organism does not compete well with other microorganisms present. According to studies conducted by the Environmental Protection Agency and the United States Department of Agriculture, "no significant hazard should be associated with their presence in compost so long as the compost does not come in contact with food . 'I

The City has prepared specific guidelines for employees working with the composting system to prevent any adverse health effects. These guidelines state:

1. A medical history shall be compiled for all prospective employees. 2 . Persons hypersensitive to allergens, such as dust, fungus, animal hair, etc., or persons with respiratory conditions such as asthma, emphysema or tuberculosis shall not be permitted to work on the site. 3. Protective clothing will be provided all on-site employees and shall be changed before leaving the site. 4 . Respirators shall be provided and their use encouraged during dry weather periods. Front-end loaders must be equipped with air conditioned cabs.

Each consumer also receives a brochure describing how to use the compost.

The compost presently produced at Morganton contains 1.67% nitrogen, 0.38% phosphorous and 0.018% potassium. Although this is not equivalent to commercial fertilizer, the material serves as a good soil conditioner, mulch and potting medium. The finished product is environmentally safe, does not have an unpleasant odor, and is an excellent soil amendment. The City believes that by using good marketing tools and maintaining effective quality control, a sufficient demand will be created to establish and maintain a competitive price for the product. They anticipate it will become a significant revenue source capable of offsetting a large portion of the costs of operation.

132

The City is presently selling their composted sludge, called Morganite, to the general public for $ 4 . 5 0 per cubic yard. This price is equivalent to approximately $20.00 per ton compared to a production cost of $ 5 3 . 7 5 per ton based on annual operating and maintenance costs alone. The selling cost was purposely kept low in order to acquaint the public with the product and to try to eliminate the stigma attached to anything regarding sewage sludge. As a result of media coverage, the number of repeat customers from homeowners to commercial farmers is growing. Acceptance of the product has been extremely favorable.

Sludge compost can be utilized advantageously in potting mixes, on lawns, and as a mulch. It can also be used as a topsoil substitute for land reclamation and public works projects, for turfgrass production, for nursery production of trees and ornamental plants, on golf courses and cemetaries, for revegetation of disturbed lands (e. g. from surface mining), and for landscaping of parks and around public buildings.

The application of sludge compost at fertilizer rates (i. e., the nitrogen requirement of the crop) to marginal soils can produce significantly higher yields than commercial fertilizers applied alone at the same nitrogen level. Higher yields are attributed to an improvement in the physical properties of the soil. Several commercial container nuserymen are now purchasing screened compost as a potting ni'edium. This was promoted by a horticulture experiment by Mr. Dick Eir and Mr. Vinnery Eoniminio of the Agricultural Extension Service. At a site on the grounds of the plant, azalea, japanese holly, juniper, rhododendron and other varieties of one year landscape specimens were planted in a medium consisting of 100% screened compost. A temporary irrigation system was installed, and the plants are checked periodically to determine growth. To date, growth and general health of the plants has been comparable to the results produced by commercial potting mixes, and at only a fraction of the cost.

Additional experiments either under way or being considered in conjunction with the composting program include bagging of the product, methods to decrease the drying time required for screening, capture of the hot air from the process blowers as a form of heat energy and the use of the compost as a combustible fuel.

The State has no official permitting system for compost, but the North Carolina Department of Natural Resources is working with the City of Morganton to develop a facility permit to certify the sludge. The permit application will require extensive analyses for heavy metals and pathogens.

133

PROCESS DIMENSIONS:

WASTES GENERATED Eliminated Approx. 1700 dry tons sludge per year

PRODUCTIVITY No Change


DOWN TIME No Change

FACILITIES $47,615 One-time cost


RAW MATERIALS $58,65O/year cost

WATER Information not Provided

ENERGY $75.00/year cost

WASTE DISPOSAL $55,434/year savings

POLLUTION CONTROL N/A

PERSONNEL/MAINTENANCE $63,41l/year cost

NET BENEFITS Minimization of cost for environmentally sound management of sewage sludge

A Detailed budget for the composting operation for 1984-85 is follows:

1. Labor (including fringe benefits) $ 45,724.00

as

2. Vehicles: a. Fuel b. Maintenance

3. Screen and Blowers a. Electricity b. Maintenance C. Plastic pipe and couplings

and 50% return)

lab analysis)

4. Bark (assumes 2.2:l bark to sludge ratio

5 . Miscellaneous (advertising, brochure

Total operations and maintenance costs

8,431.00 5,330.00

75.00 1,840.00 936.00

58,650.00

1,150.00

$ 122,136.00

134

ATTACHMENTS

Plan Views of Composting System

Flow Diagram of Composting System

Sample Compost Bed Data Sheet

City of Morganton: Typical Temperatures and Oxygen Levels Recorded During the Composting Operation

a) Comparative Study of Morganton Sludge Composition with

b) Determination of Fertilizer Composition with Literature Literature Citations, April 1983

Citations, April 1983

Recommeded Maximum Cumulative Metal Loadings for Compost Application to Burke County Soils

Regulations Concerning the Production and Sale of Composted Sludge for the City of Morganton, North Carolina

Proposed State Requirements for Granting Tentative Approval for the Commercial Production of Sewage Compost

Selected References on Destruction of Pathogens in Sewage Sludge Compost

1.

2 .

3 .

4 .

5.

6.

7.

8 .

9.

135

Plan V i e w of Composting System

COVER MATERIAL

DRAINAGE DITCH DEODERIZING P I L E

Plow Diagram of Composting System - A DEWATERED SLUDGE B BARK STORAGE C M I X I N G G SCREENING H SCREENED COMPOST

8

136

- COMPOST BED DATA SHEET

DAY COMPOSTING 1 2 3

BLOblER (ON-OFF)

TEMP OF

02 (%I

AMBIENT AIR TEMP (Fo)

RAINFALL (INCHES)

PAD NUMBER

DATE ON

SLUDGE MOISTURE ( % I

- a ? - i o 1 1 1 2 13. 14 15 16 17 18 ' 1 9 20

---__ .- .- I - - -

i I

SLUDGE pH

BARK MOISTURE i%)

BARK-SLUDGE RATIO

COMPOST MOISTURE (%)

DATE OFF

FECAL COLIFORM

COMMENTS:

c. W U

% -13h31 N3SAXO

138

1. COMPARATIVE STUDY OF COMPOSTED S L U D G E , C I T Y OF MORGANTON ~

APRIL 2 9 , 1 9 8 3 , C a r l D . H e n n e s s e e ~

E l e m e n t Maximum* R a n g e

C d l p p m 2 5

Z n l p p m 2500

C d I Z n (Z) 1 . 0

f i i l p p m 2 0 0 0

P b l p p m 1000

M o r g a n t on S o m m e r W N o r t h e a s t ** A n a l y s i s

0 . 5 1 6 13

8 5 0 1 7 4 0 1430

.059 1 . 0 1 . 0

1 3 8 2 42

3 5 5 0 0 500

* D i g e s t e d - S l u d g e , _- C h a n e y a n d G i o r d a c c . , 1 9 7 7

** S o m m e r s , L . E . , 1 9 7 7 , C h e m i c a l composi tLo_qn o f S e w a g e S l u d g e s And -- A n a l y s i s of t h e i r P o t e n t i a l U s e a s F e r t i l i z e r s , J . E n v i r o n Quai- 6 ( 2 ) : 2 2 5 - 2 3 7

*** 4 3 T r e a t x f i ? t P l a n t s ( d i g e s t e d s l u d g e ) C h a n e y , R . L . , H.B. Hori ; i . ck , a n d P . W . - S i m o n , 1 9 7 7 R e a v y e t a l R e l a t i o n s h i F : ; D u r i n g L a n d U t i l i - z a t i c n o f S e w a g e - S l u d g e i n t h e N c , r t h e a s t . P : 2 8 3 - 3 1 4 , L a n d a s a - Waste M a n a g e m e n t - A L c f r n a t i v e . Ann A r b o r S c i e t i c e P u b l i c a t i o n s -- Inc., Ann A r b o r , M i

2 . DETbRNIMATION OF T H E FERTILIZER VALUES OF COMPOSTED SLUDGE C I T Y OF M O R G A N T O N , N O R T H C A R O L I N A 'APRIL 2 9 , 1 9 8 3

E l e m e n t

N i t r o g e n . P1:o s p h o r u s Po t o s s i u n Sulfur C a l c i u t . ! M a g n e s i u m Sod i c n Ammonia ( N ) % S c ; . i d s PH

P e r c e n t ( X I

2 . 0 9 0 . 5 8 0 . 1 4 0 . 4 7 i.20 0 . 1 8 . 0 3 3 0 . 6 4 4 0 . 1 6 6 . 5

139

CUMULATIVE COMPOST LOADINGS (METALS) FOR BURKE COUNTY SOILS

~~

~

The following Table shows the recommended maximum cumulative sludge metal loadings for Bulike County soils. For the purpose of this study two types of soils were censidered. Soils with C E C range of 5-15 which included sandy loams, loams, silt loams; and soils with CEC: above 15 which includes (silty clay loams and clayr. Higher metal loadings kould be considered reasozably allowable on heaviei textured soils. Cadmibai icadings on land should not exceed 2 kg/ha/yr for values added by compost and ;~bould' not exceed the total cumulative loadings shcvr in the following table. When compost is applied, the soil should be limed t c pH 6.5 and maintained at 6.2 or higher. In general, sludge compost used on 1and.used t o grow leafy vegetablos.should b e low in cadmicc and cd/zn ratio to minimize any effects on humans.

Cn publicly controlled lht!d, a maximum of up to five times the amount of compost-borne metals listed in thar table seems to re- preser.t a reasonable limit i f thc sludge in incorporated into the soil to- a depth of 15 cm. With deeper incorporation, total metal applications may be proportionally higher. These metal loitdings are permissible only when the pH is maintained above 6.5; The use of crops such as corn and various erains which yraturally exclude cadmium minimizes the impact of this practice.

METAL soil cation exchangc capacity

5-15 15+

Zn

cli

M i

Cd

Pb

500

250

100

1 0 0 0 RECOMMENDED MPXIMUM

500 INGS FROM C O M P O S T

200

C U M U L A T I V E METAL LOAD-

APP1,ICATION

10 2 0

1000 2000

MAX I X U H MET &I.. ADD I T I ON ( kg / ha

C E C should be determined prior to sludge a~plication using IN neutrzl ammonia acetate and is expressed here as a weighted average for depth of 5C cn,.

Carl D. Hennessee April 29, 1983

140

R e g u l a t i o n s Governing the P r o d u c t i o n and S a l e of Composted S ludge f o r t h e C i t y of Morganton, No1 t h C a r o l i n a .

A , P r o d u c t i o n Process_

1. T h e methods and o p e r a t i o n s of composting employed by t h e C i t y c f Morganton f a c i l i t y s h a l l comply w i t h all a p p l i c a b l e f e d e r a l l a w s , r e g u l a t i o n s O K agreements and w i t h a p p l i c a b l e s t a t e r e g u l a t i o n s upon p r o m u l g a t i o n .

2 . Sludge composting s h a l l be done by t h e B e l t s v i l l e a e r a t e d p i l e ~

method as d e f i n e d i n USDA's Manual Composting Sewage S ludge by The B e l t s v i l l e Aerated __ P i l e Method, EPA - 60018-80-22 May, 1980. Any m o d i f i c a t i o n t o t h i s method w i l l r e a u i r e . e x c e p t i n t h e g a t h e r i n g of - - e x p e r i m e n t a l d a t a , a p p r o v a l o f gove rn ing laws and r e g u l a t i o n s p r i o r t o imp lemen ta t ion .

3 . p r o c e s s h a s been shown t o e f f e c t i v e l y e l i m i n a t e human pa thogens and c o n t r o l o d o r s when p r o p e r l y managed (see r e f e r e n c e s a t t a c h e d ) .

4 . P r o p e r management r e q u i r e s t h a t t h e a e r a t e d p i l e s be mon i to red on a c o n t i n u i n g b a s i s . p r o c e s s m o n i t o r i n g p l a n .

The C i t y o f Morganton r e c o g n i z e s t h a t t h e B e l t s v i l l e Aera t ed P i l e

The s i t e o p e r a t o r s h a l l comply w i t h t h e f o l l o w i n g

a . Temperature . Aera t ed p i l e t e m p e r a t u r e s must be measured u s i n g a probe-type t h e r m i s t o r o r thermocouple . be m a i n t a i n e d and be made r e a s o n a b l y a v a i l a b l e t o t h e p u b l i c upon r e q u e s t t h rough t h e C i t y o f Morganton, Department of Water Resources ( s e e a t t a c h e d compost bed d a t a s h e e t ) . Each s e c t i o n o r " c e l l " i n a n ex tended p i l e must be mon i to red f o r t e m p e r a t u r e a t t h r e e l o c a t i o n s o n b o t h ends of t h e p i l e .

(1) The f i r s t l o c a t i o n w i l l be d e f i n e d a s 2 .0 f e e t above ground l e v e l and 2 .5 f e e t h o r i z o n t a l l y i n t o t h e p i l e . T h i s l o c a t i o n w i l l be r e f e r r e d t o a s the. " toe" of t h e p i l e .

(2) l e v e l and f o u r f e e t h o r i z o n t a l l y i n t o t h e p i l e . T h i s l o c a t i o n shou ld g i v e a n i n d i c a t i o n of t h e c o n d i t i o n s i n t h e p i l e i n t e r i o r .

A t e m p e r a t u r e &og w i l l

The second l o c a t i o n w i l l be d e f i n e d as f o u r f e e t above 'g round

( 3 ) T h e t h i r d l o c a t i o n w i l l be a t t h e i n t e r f a c e between t h e s ludge - c h i p m i x t u r e and t h e p i l e b l a n k e t material a t a h e i g h t of abou t f o u r feet. Earh D i l e s e c t i o n m u s t be monitored d a i l v u n t i l i t h a s main-

~ - ~ _ . ~ - __ - __-. -~ tained-tcnlperature of a t l e a s t 5STC f o r a t least t h ree c o n s e c u t l v e d a y s a t a l l m o n i t o r i n g l o c a t i o n s . Bi-weekly t e m p e r a t u r e m o n i t o r i n g i s r e a u i r e d once a p i l e h; as m e t t h e s e t e m p e r a t u r e r e q u i r e m e n t s . Each pile s e c t i o n n u s t s t a n d f o r a t l e a s t 2 1 days b e f o r e i t may be removed f o r c u r i n g . I f a p i l e s e c t i o n does n o t beg in t o deve lop these t e m p e r a t u r e s w i t h i n s e v e n d a y s , i t m u s t be t o r n down, remixed and r e b u i l t u n t i l a n d e q u a t e t e m p e r a t u r e p r o f i l e i s ach ieved .

141

b . M o i s t u r e Con ten t . Moi s tu re c o n t e n t of t h e s l u d g e / b u l k i n g a g e n t m i x t u r e must be between 50% arid 65% a t t h e t ime of p i l e c o n s t r u c t i o n . Sufficis!r . t b u l k i n g a g e n t w i l l b e added t o ;&vide t h i s r a n g e o f i n i t i a l m o i s t u r e c o n t e n t . m o i s t u r t c o n t e n t s h a l l be done weekly, w i t h a l o g k e p t t h a t w i l l b e made r e a s o n a b l y a v a i l a b l e t o t h e p u b l i c t h rough the C i t y o f Morganton, Department of Water Resources .

c . Oxygen s h a l l be measured d a i l y f o r t h e f i r s t week o f a e r a t i o n , and weekly t h e r e a f t e r a t t h e same i n t e r i o r p i l e l o c a t i o n t h a t t e m p e r a t u r e measurement i s t a k e n as d e s c r i b e d i n

Q u a n t i t a t i v e sam2l ing f o r i n i t i a l mix

Oxygen Con ten t .

p a r a g r a p h 3 ( a ) . A l o g of oxygen mon i to r ing -da ta w i l l be m a i n t a i n e d and b e made r e a s o n a b l y a v a i l a b l e t o t h e p u b l i c upon r e q u e s t t h r o u g h t h e C i t y of Morganton, Department of Water Resources . A t no t i m e sho,uld t h e oxvgen c o n c e n t r a t i o n b e a l lowed t o f a l l below 5%. A e r a t i o n rates s h a l l be a d j u s t e d t o e n s u r e t h a t t h e oxygen concen- t r a t i o n r ema ins near t h e 5% l e v e l .

d . The pli of t h e incoming s l u d g e s h a l l be mon i to red d a i l y - a n d a&, k e p t and made r e a s o n a b l y a v a i l a b l e t o t h e p u b l i c upon r e q u e s t t h r o u g h t h e C i t y of Morganton, Department of Water Resources .

B. The C i t y r e c o g n i z e s t h a t c e r t a i n d a i l y o p e r a t i o n a l p rocedures are r e q u i r e d t o e n s u r e t h a t s u r r o u n d i n g community impac t s a r e minimized. T h e r e f o r e , t h e f o l l o w i n g p r o c e d u r e s are r e q u i r e d of t h e s i t e o p e r a t o r :

1. Dust C o n t r o l . A s p r a y e r t r u c k and water hoses w i l l be q i n t a i n e d on- s i t e and u t i l i z e d a t l e a s t d a i l y i f needed t o w e t down pad and roadway a r e a s ( a s w e a t h e r p e r m i t s ) . i n such a way as t o keep d u s t g e n e r a t i o n t o a minimum.

E f f o r t s s h o u l d be t a k e n t o pe r fo rm s c r e e n i n g o p e r a t i o n s

2 . Odor C o n t r o l . (1) A e r a t i o n p i p e s and b lower c o n n e c t i o n s s h a l l be checked d a i l y f o r a i r l e a k a g e ; ( 2 ) Scrubbe r p i l e s s h a l l be u t i l i z e d i f

(3) Ponding of waters on t h e pad s u r f a c e must be p r e v e n t e d . n e c e s s a r y ; --

3 . s h a l l be p r e s e n t o n - s i t e a f ter o p e r a t i o n a l h o u r s .

4 . f u m i g a t u s , t o t a l fungus and t o t a l suspended p a r t i c u l a t e s . i n c l u d e t i m e of sampl ing , wind d i r e c t i o n , wind v e l o c i t y , ambient a i r t e m p e r a t u r e , and ambient re la t ive h u m i d i t y .

5 . Storm water run-off c o l l e c t e d from t h e compost and woodchip s to ' r age a r e a s s h a l l be r e t u r n e d t o t h e p l a n t i n f l u e n t o r b e used as s p r a y i r r i g a t i o n . L o a d i n g ' r a t e s w i l l be de t e rmined by t h e n i t r o g e n c o n t e n t of t h e waters and the n i t r o g e n r e q u i r e m e n t s of t h e c r o p unde r i r r i g a t i o n .

The -. s i t e s h a l l be f u l l y s e c u r e d when n o t i n o p e r a t i o n and C i t y p e r s o n n e l

P e r i o d i c a i r m o n i t o r i n g _ s h a l l be conducted t o de t e rmine a s p e r g i l l u s , Data s h a l l

142

6 . A compleLe and a c c u r a t e l o g of t h e a c t i v i t i e s of t h e f a c i l i t y s h a l l be m a i n t a i n e d and r e a s o n a b l y a v a i l a b l e f o r p u b l i c review. Such l o g s h a l l c o v e r s i g n i f i c a n t o p e r a t i o n a l e v e n t s of t h e f a c i l i t y .

7. D a i l y weekday i n s p e c t i o n s s h a l l be conduc ted by t h e s i t e o p e r a t o r t o a s s u r e t h a t t h e f a c i l i t y i s m a i n t a i n e d i n a c l e a n , s a n i t a r y and o r d e r l y manner. N1 equipment used on t h e s i t e , p a r t i c u l a r l y t h e f ron t - end l o a d e r s s h a l l be washed r e g u l a r l y and b e m a i n t a i n e d i n a clean manner.

8. A c i t i z e n compla in t l o g s h a l l be i n i t i a t e d and m a i n t a i n e d by t h e , C i t y of Morganton which i n c l u d e s t h e d a t e and time of c o m p l a i n t , name and a d d r e s s o f p e r s o n s s u b m i t t i n g c o m p l a i n t , and s u b s e q u e n t a c t i o n t a k e n on t h e p a r t of t h e o p e r a t o r .

9. A copy o f t h e s e r e g u l a t i o n s s h a l l be p o s t e d a t t h e Morganton f a c i l i t y . All employees of t h e f a c i l i t y s h a l l b e r e q u i r e d t o b e knowledgeab le of t h e s e r e g u l a t i o n s .

10. I n t h e e v e n t of a v i o l a t i o n of any F e d e r a l , S t a t e or l o c a l l a w or r e g u l a t i o n gove rn ing t h e o p e r a t i o n o f t h e compost f a c i l i t y , t h e s i te o p e r a t o r w i l l immedia t e ly t a k e s t e p s t o c o r r e c t the o f f e n d i n g d e f i c i e n c y .

C. Compost Q u a l i t y

The C i t y of Morganton d e s i r e s t o e n s u r e t h a t the compost produced a t t h e Catawba R i v e r f a c i l i t y is o f s u c h a q u a l i t y tha t i t may b e d i s t r f b u t e d and u t i l i z e d w i t h o u t r e s t r i c t i o n s and w i t h complete s a f e t y . The d i s t r i b u t i o n and u s e of compost from t h e Morganton f a c i l i t y must comply w i t h a l l a p p l i c a b l e approved F e d e r a l r e g u l a t i o n s . I n a d d i t i o n , t h e f o l l o w i n g r e q u i r e m e n t s must be met f o r compost t o b e p u b l i c l y d i s t r i b u t e d by t h e C i t y .

1. The ma in tenance of a t e m p e r a t u r e p r o f i l e s u f f i c i e n t t o e l i m i n a t e human pa thogens i s e s s e n t i a l . P i l e t e m p e r a t u r e a t a l l m o n i t o r i n g l o c a t i o n s must m a i n t a i n a minimum t e m p e r a t u r e of 55O C f o r a t l e a s t t h r e e c o n s e c u t i v e days.

2 . Before p u b l i c d i s t r i b u t i o n , compost must undergo a 30 day c u r i n g p e r i o d . As a check o f t h e comple t eness o f pathogen e l i m i n a t i o n , a sampl ing pro- c e d u r e s h a l l b e e s t a b l i s h e d whereby t h e 21-day o l d a e r a t e d p i l e s , s c r e e n e d compost s t o r a g e p i l e s , and unsc recned compost s t o r a g e p i l e s are sampled a t a p o i n t one f o o t below t h e p i l e s u r f a c e and t h e samples are immediately a n a l y z e d q u a l i t a t i v e l y f o r S a l m o n e l l a . A copy of t h e comple t e l o g of t h e m o n i t o r i n g r e s u l t s m u s t b e ma in ta ined by t h e C i t y and made a v a i l a b l e for p u b l i c review.

3 . F i k s h e d compost which w i l l b e made a v a i l a b l e f o r u n r e s t r i c t e d d i s t r i - b u t i o n s h a l l be sampled and a n a l y z e d q u a r t e r l y and must meet t h e f o l l o w i n g l i m i t s o n heavy metal c o n c e n t r a t i o n :

__

143

C3 -- 1:!.5 ppm ( d r y we igh t b a s i s ) Pb -- 500.0 ppm ( d r y we igh t b a s i s ) Zn -- 1,250.0 ppm (d ry w e i g h t bas i s ) Cu -- 500 ppm (d ry we igh t b a s i s ) N i -- 290 ppm (d ry we igh t b a s i s ) Hg -- 5 ppm (d ry w e i g h t b a s i s )

4 . t o meet the f o l l o w i n g l i m i t s on o r g a n i c compounds:

Compost a v a i l a b l e f o r p u b l i c u s e s h a l l b e sampled and a n a l y z e d a n n u a l l y

PCB -- 2 . 0 ppm (d ry weight b a s i s ) Endr in -- 0.10 ppm (dry w e i g h t ' b a s i s ) Lindane -- 0.10 ppm (dry we igh t b a s i s ) Methoxychlor -- 0 . 2 5 ppm (d ry w e i g h t b a s i s ) Toxaphene -- 1.0 ppm (d ry we igh t b a s i s ) 2 , 4 - D -- 0.10 ppm (dry we igh t b a s i s ) 2 , 4 , 5-T S i l v e x -- 0/10 ppm (d ry w e i g h t b a s i s )

5 . To a d e q u a t e l y assess t h e f e r t i l i z e r and s o i l c o q d i t i o n i n g va lue of t h e f i n i s h e d compost., t h e f o l l o w i n g p a r a m e t e r s s h o u l d b e a n a l y z e d q u a r t e r l y :

a. N i t r o g e n -- % t o t a l n i t r o g e n , % NH4-N, NO3-N (ppm) b. Phosphorus -- % t o t a l phosphorus c . S p e c i f i c c o n d u c t i v i t y of a 1 : 2 ext rac t d . P o t a s s i u m

6 . Any compost produced t h a t f a i l s t o meet t h e r e s t r i c t i o n s s p e c i f i e d in p a r a g r a p h s C l , C2, C?, and C4 above , s h a l l be used o n l y on w b l i c l y - o w n e d l a n d s . Any compost t h a t exceeds 4% i r o n (Fe) on a d r y we igh t b a s i s m u s t n o t be used t o t o p d r e s s p a s t u r e l a n d s t h a t w i l l be used f o r g r a z i n g .

7. Recommended a p p l i c a t i o n r a t e s s h a l l be l i m i t e d t o t h o s e s p e c i f i e d i n USI)A's p u b l i c a t i o n e n t i t l e d "Use o f Sewage S ludge Conipost f o r S o i l %rove- ment a a d P l a n t Growth," r e g d a t i o n s .

(AIMZNE-6) o r any a p p l i c a b l e S t a t e o r Federal-

D. Compost _. D i s t r i b u t i o n

1. Bulk u s e r s o f t h e compost p r o d u c t m u s t be p r o v i d e d w i t h a copy o f t h e USDA p u b l i c a t i o n e n t i t l . . e d Use of Sewage S ludge Compost f o r Soil Improvement _.~.~_____ and P l a n t Growth. A p p l i c a t i o n ra tes s h o u l d n o t exceed t h o s e s p e c i f i e d i n t h e USDA p u b l i . c a t i o n o r a p p l i c a b l e F e d e r a l o r S t a t e r e g u l a t i o n s .

2 . In C l i e e v e n t t h a t the. compost p r o d u c t i s marketed i n a bagged fo rm, a l a b e l must he affixed o r i n c l u d e d i n t h e bag which c l e a r l y i d e n t i f i e s t h e p r o d u c r ; s t a t e s any c r o p u s e r e s t r i c t i o n s t h a t may be imposed by t h e S t a t e ; and g i v e s a n a n a l y s i s of t h e p r o d u c t and recommended a p p l i c a t i o n rates.

(AFiM-NEI6) o r o t h e r C i t y approved i n f o r m a t i o n a l material;

144

3 . c o s t ,s[iproved by the Morganton C i t y Counc i l and i n cor, ipliance w i t h The Sched ;!!e of Fees aad Charges of t h e C i t y o f Morganton.

4 . w i l l be i s s u e d a r e c e i p t f o r c h a r g e s i n accordan.ce w i t h C i t y of Morganton r e g u l a t i o n s .

5. A l l f u n d s c o l l e c t e d shall be t o r n e d i n a t C i t y H a l l on a d a i l y b a s i s .

CJmpost s h a l l be a v a i l a b l e f o r sale a t t h e Catawba River P l a n t a t a

, .

Charges s h a l l '>e c o l l e c t e d on s i t e by t h e o p e r a t o r . Each customer

E . Purchase of Bark

1. Bark s h a l l b e purchased b u l k from l o c a l b i d d e r s . Bid p r i c e s h a l l i n c l u d e d e l i v e r y and u n l o a d i n g a t the b a r k s t o r a g e s i t e .

2 . The si.te o p e r a t o r i s r e s p o n s i b l e for a s s u r i n g t h a t h o n e s t measure i s r e c e i v e d by measu r ing t h e t r u c k bed.

3 . d e l i v e r y .

4 . Reques t s f o r a change i n b a r k p r i c e s s h a l l be made by l e t t e r a t l e a s t t h i r t y (30) d a y s p r i o r t o the e f f e c t i v e d a t e .

5. o p i n i o n , ' i s u n a c c e p t a b l e t o t h e compost ing p r o c e s s .

A t r i p t i c k e t showing t h e c u b i c y a r d s d e l i v e r e d i s r e q u i r e d of each

T h e , s i t e o p e r a t o r c a n r e f u s e t o a c c e p t any b a r k d e l i v e r y wh ich , i n h i s

e F. Eniployee H e a l t h

1.

2 . P e r s o n s h y p e r s e n s i t i v e t o a l l e r g e n s , such as d u s t , f u n g u s , an ima l h a i r , e t c . , o r p e r s o n s w i t h r e s p i r a t o r y c o n d i t i o n s s u c h as a s thma , emphysema or t u b e r c u l o s i s s h a l l n o t be p e r m t i t e d t o work on t h e s i t e .

3 . changed b e f o r e l e a v i n g t h e s i te .

4 . w e a t h e r p e r i o d s . Front-end l o a d e r s must be equ ipped w i t h a i r c o n d i t i o n e d c a b s .

A m e d i c a l h i s t o r y s h a l l b e compiled f o r a l l p r o s p e c t i v e employees.

P r o t e c t i v e c l o t h i n g w i l l be p rov ided a l l o n - s i t e employees and s h a l l be

R e s p i r a t o r s s h a l l be prov ided and t h e i r u s e encouraged d u r i n g d r y

145

1.

2.

3.

4 .

5 .

REQUIREHENTS FOR GRANTING TENTATIVE' APPROVAL FOR THE COMMERCIAL PRODUCTION OF SEWAGE COMPOST: . -

ComDlete Ana lys i s rrf. I n f l u e n t Waste and P r o c e s s e a S ludge I n c l l - d i n g (ppm):

Cadmium Chromium N i c k e l Lead A r s e n i c Mercury

Selenium Cyanide Molybdenum Boron Zinc Copper -

-_

Complete De te rmina t ion & N u t r i e n t s P rocessed S l u d g e I n c l u d i n g ( X ) :

N i t r o g e n Phosphorus P o t a s s ium Sulfur

Calcium Magnesium '

Sodium Ammonia Ni t rogen .

D e t e r m i n a t i o n Hazardous Waste by RCRA (EP t o x i c i t y ) :

R e a c t i v i t y - Methoxychlor (ppm) 1 g d . t a b i l i t y - Toxaphene (ppm) Lindane (ppm) 2, 4-D ( p e d Endr in (ppm) S i l v e x (ppm)

PH - Complete Review g Proposed C o n s t r u c t i o n Plans I n c l u d i n g :

S ludge and Composting h a n d l i n g equipment S l u d g e S i t e Approval Equipment and a b i l i t y n e c e s s a r y f o r q u a l i t y c o n t r o l Run-off c o n t r o l Odor c o n t r o l D u s t c o n t r o l Arrangements f o r p e r i o d i c a i r mon i to r ing s e c u r i t y P r o t e c t i v e c l o t h i n g and equipment f o r p e r s o n n e l Logs and mon i to r ing d a t a forms Source and type of b u l k i n g material

Temporary approva l s h o u l d be i s s u e d f o r s i x months d u r i n g which t i m e f i n i s h e d compost i s ana lyzed f o r c r i t i c a l d a t a i n c l u d i n g :

Sa lmone l l a A s p e r g i l l u s fumigatus T o t a l Suspended P a r t i c u l a t e s . Heavy Metals 1. N u t r i e n t s CadmiumIZinc R a t i o

146

6.

7 . F i n a l s creened compost should not v i o l a t e the f o l l o w i n g parameters:

No commercial sales of compost should be author ized during the test period. .

Cd 25 ppm

CdIZn Rat io 1.0% N i 2000 ppm

1000 ppm Pb

Zn 2500"

.. 3. A l l sales shou ld be accompanied by an approved brochure e x p l a i n i n g land

l o a d i n g rates , f e r t i l i z e r v a l u e and sa feguards .

147

Selected References on Destruction of Pathogens in Sewage Sludge Compost

1. Destruction of Pathogens in Sewage Sludge by Composting, 1 9 7 8 . Burge, W.D., Cramer, W.N., Epstein, E., Transactions of the ASAE V o l . 2 1 # 3 pp 510-514

2. Criteria for Control of Pathogens During Sewage Sludge Composting, 1978. Burge, W.D., Colaciacco, D., Cramer, W., Epstein, E. pp 124-129, Proceedings of the National Conference on Design of Municipal Sludge Composting Facilities, Chicago, Illinois. Information Transfer, Inc., Rockville, Maryland.

3 . Effect of Heat on Pathogenic Organisms Found in Wastewater Sludge, 1977. Ward, R.L. & Brandon, J.R., in Composting of Municipal Residues and Sludges, 1978. Information Transfer Inc., Rockville, Maryland.

4. Occurence of Pathogens and Microbial Allergens in the Sewage Sludge Composting Environment, 1 9 7 7 . Burge, W.D., March, P.B.. Millner, P.D., -in Composting of Municipal Residues and Sludges, 1 9 7 8 . Information Transfer, Inc., Rockville, Maryland.

5. Procedures €or analysis of soil, sludge, or sludge compost for total and Fecal Coliforms, Fecal Streptococci, and Salmonellae. Burge, W.D., Biological Waste Management and Organic Resources Laboratory paper, 1983.

148

CASE STUDY 24

TYPE OF INDUSTRY: S o l i d Waste L a n d f i l l NAME OF FIRM: N a t u r a l Power ( B i l l P o w e l l 919/876-6722) LOCATION : R a l e i g h , N o r t h Caro l ina

MODIFICATION

INSTALLATION OF A BIO-GAS RECOVERY SYSTEM AT A LANDFILL

ABSTRACT: Na tu ra l Power, o p e r a t i n g f rom t h e Gresham L a k e L a n d f i l l i n R a l e i g h , N o r t h C a r o l i n a , h a s implemented a methane recovery s y s t e m f o r convers ion o f “ b i o g a s “ t o e l ec t r i c power, which is t h e n s o l d to t h e l o c a l u t i l i t y . N a t u r a l Power recovers c o m b u s t i b l e g a s g e n e r a t e d from t h e a n a e r o b i c d e c o m p o s i t i o n o f m u n i c i p a l wastes b u r i e d a t t h e l a n d f i l l . The g a s is c o l l e c t e d u n d e r vacuum f rom a number o f wells s u n k i n t o t h e l a n d f i l l . A f t e r E i l t r a t i o n t o remove p a r t i c u l a t e s , i t is f e d d i r e c t l y i n t o t w o d i e s e l g e n e r a t o r s m o d i f i e d t o u s e a me thane f u e l source. E lec t r i ca l e n e r g y g e n e r a t e d a t t h i s source is m e t e r e d and f e d i n t o t h e l o c a l power u t i l i t y ’ s t r ansmiss ion l i n e s .

149


PAYBACK PERIOD:

TIME TO IMPLEMENT:

TRANSFERABILITY:

ENVIRONMENTAU AND HEALTH BENEFITS:

$25,700

variable, dependent on rate of methane recovery and price/KWH paid by utility

6 months to 3 years estimated

Applicable at any landfill which has received organic solid waste and is found to be generating gaseous by- products of anaerobic decomposition. Variables which would affect the economics of such a facility include cost/KWH sale value to local utility, time which has elapsed since landfill was closed, size of landfill, production rate of gas, and percent methane composition of gas. Additional energy use variations of this methane include sale of it directly to an industrial user and/or refinement of it to pipeline grade, high BTU methane and conducting it to the natural gas pipeline. Depending on economic and other variables, production of natural gas may yield a greater financial return on investments than conversion of it to electrical energy.

Reduced risk of explosion and odor nuisance caused by the migration and emission of flammable landfill gas. Enhanced recovery of biosphere above the landfill, and the conservation of energy resources.

150

PROJECT DESCRIPTION: Natura l Power o f R a l e i g h , N o r t h Carol ina is c o n t r o l l i n g and e x t r a c t i n g t h e g a s e o u s p r o d u c t o f a n a e r o b i c d e c o m p o s i t i o n from organic wastes b u r i e d i n t h e Gresham L a k e l a n d f i l l . The gas is removed f rom t h e g round a t a p p r o x i m a t e l y 130'F. T h e raw g a s h a s a methane c o n t e n t which v a r i e s f rom 32- 6 2 % , a v e r a g i n g a p p r o x i m a t e l y 42% methane . The v a r i a t i o n is due t o t h e o r g a n i c source of t h e g a s by-product and t h e d u r a t i o n o f g a s e x t r a c t i o n f rom a g i v e n wel l . I t h a s been found t h a t gas f rom c e r t a i n we l l s m a i n t a i n s a c o n s i s t e n t l y h i g h e r methane c o n t e n t t h a n t h e g a s f rom o t h e r wel l s . T h i s is a t t r i b u t e d t o t h e t y p e o f o r g a n i c r e f u s e b u r i e d i n t h a t v i c i n i t y , and i n some c a s e s , d e e p e r w e l l d e p t h . Wells which h a v e n o t been pumped f o r a p e r i o d of t i m e p r o v i d e a h i g h e r p e r c e n t methane gas t h a n t h o s e which have been pumped r e c e n t l y .

A 3 HP vacuum pump is u s e d to co l l ec t t h e gas from 1 0 wells s u n k i n t e r m i t t e n t l y i n t o t h e l a n d f i l l . The w e l l s a r e c o n s t r u c t e d o f 2 i n c h , s c h e d u l e 40 PVC p i p e . The p i p e is m o d i f i e d w i t h 15-25/1000 i n c h p e r f o r a t i o n s l o t s which r u n t h e l e n g t h o f t h e p i p e from t h e l a n d f i l l bo t tom to w i t h i n 1 5 f e e t o f t h e l a n d f i l l s u r f a c e . The w e l l p i p e is s u n k "naked" i n t o d r i l l h o l e s , and b u f f e r e d f rom t h e l a n d f i l l c o n t e n t s by a s a n d and g r a v e l f i l l . The w e l l s a r e capped w i t h a 5- to-1 e x p a n d i n g c l a y and a concrete seal .

The 1 5 f e e t o f l a n d f i l l c o n t e n t s n o t a c t i v e l y mined f o r g a s s e r v e s a s a b u f f e r t o c o n t a i n t h e b i o g a s i n t h e l a n d f i l l and t o p r e v e n t t h e i n v a s i o n o f oxygen i n t o t h e a n a e r o b i c e n v i r o n m e n t . A 3-5 f o o t compacted c l a y s u r f a c e c a p s t h e l a n d f i l l . The e d g e s o f t h e l a n d f i l l are e s p e c i a l l y w e l l s e a l e d and i n s p e c t e d r e g u l a r l y f o r c r acks or s i g n s o f s u b s i d e n c e .

The l a n d f i l l a r e a c u r r e n t l y mined is 4 a c r e s w i t h a n a v e r a g e d e p t h o f 30 f e e t ( 6 , 3 0 0 , 0 0 0 c u f t ) . The c o l l e c t e d gas is t a p p e d f rom a 4" d i a m e t e r p i p e which is a n g l e d down and away from t h e g e n e r a tor b u i l d i n g . T h i s d e s i g n p e r m i t s e a s y removal o f c o n d e n s a t e which is c o l l e c t e d a t t h e f a r end o f t h e 4 " p i p e and is p e r i o d i c a l l y d r a i n e d when t h e f a c i l i t y is not i n o p e r a t i o n .

The raw g a s is o f s u f f i c i e n t q u a l i t y and q u a n t i t y t o power two model 3306 C a t e r p i l l e r d i e s e l e n g i n e s 1 5 h o u r s a d a y , 5 d a y s a week . I t is c a l c u l a t e d t h a t t h e g a s is consumed a t a rate o f 2684 c u f t p e r h o u r . Because o f t h e weekly v a r i a t i o n i n g a s q u a l i t y , t h e Monday t o F r i d a y c u r v e f o r KW/H g e n e r a t e d r u n s from a h i g h o f 182 KW o n Monday t o 140 KW o n F r i d a y s . Because t h e q u a l i t y o f g a s d o e s v a r y , t h e g e n e r a t o r s m u s t be c o n s t a n t l y m o n i t o r e d t o o p t i m i z e t h e i r f u n c t i o n i n g . The AC c u r r e n t g e n e r a t e d a t t h e s i t e is c h a r a c t e r i z e d a s 3 p h a s e , 60 c y c l e a t 480 v o l t s .

The c a p i t a l costs t o i n s t a l l t h e co l l ec t ion s y s t e m , e l e c t r i c a l s y s t e m , and generators w a s $125,000. The o p e r a t o r c l a i m s , however , t h a t t h i s cost c o u l d b e r educed t o $100 ,00O,based o n t h e knowledge g a i n e d by i n s t a l l i n g t h e

151

Gresham's Lake system. The plant currently operates at slightly less than 50% of maximum capacity, but i s designed for expansion into additional landfill acreage (18 acres).

~ Electrical energy generated by the engines is metered and fed directly into the Carolina Power and Light Company (CP&L) transmission lines. Operation times are determined to maximize energy generation during peak demand hours when a higher rate is received per KWH. Rates are generally either "fixed", with a higher price/KWH yield, or "variable". For CP&L there is a 15 year contract for fixed rates. The variable rate dropped from 3 . 1 cents/KWH in late 1984 to 2.8 cents/KWH. This rate decrease has reduced the profitability of the operation and extended its payback period. Maintenance on the system is minimal. Maintenance and other down-time are planned for off-peak hours.

152

PROCESS DIMENSIONS: ( $ 1984)

WASTES GENERATED Reduced venting of methane

PRODUCTIVITY Additional revenue from landfill

PRODUCT QUALITY N/A


FACILITIES $125,000 one time cost

EQUIPMENT Included in facilities cost

RAW MATERIALS No cost

WATER None

ENERGY $25,716/yr revenue (1985 $ )

WASTE DISPOSAL None

POLLUTION CONTROL None

PERSONNEL/MAINTENANCE Apx. $6000/yr costs

NET BENEFIT Low co,st renewable energy generation and reduced risk of landfill explosions from methane accumulation

153

CASE STUDY 25

TYPE OF INDUSTRY: M u n i c i p a l i t y NAME OF FIRM: N e w Hanover Coun ty , N o r t h C a r o l i n a

LOCATION : Wilmington , N o r t h C a r o l i n a S I C : 4952

( C . Ed H i l t o n , Jr . 919/341-7139)

MODIFICATION

VOLUME REDUCTION OF M U N I C I P A L WASTES BY I N C I N E R A T I O N STEAM GENERATION AND ENERGY RECOVERY

ABSTRACT: N e w Hanover County h a s r e c e n t l y i n s t a l l e d a r e f u s e - f i r e d steam g e n e r a t i n g f a c i l i t y t o r e d u c e t h e volume o f m u n i c i p a l s o l i d wste r e q u i r i n g b u r i a l . The s a l e of steam and e l e c t r i c i t y g e n e r a t e d by t h e waste i n c i n e r a t i o n is u s e d t o o f f s e t t h e c a p i t a l and o p e r a t i n g costs o f t h e s y s t e m . The C o u n t y e x p e c t s t o r e a l i z e l o n g t e r m cost s a v i n g s a s f u e l p r i c e s rise, and a f o u r - f o l d increase i n t h e l i f e o f i ts c u r r e n t l a n d f i l l o p e r a t i o n .

154


PAYBACK PERIOD:

TIME TO IMPLEMENT:

TRANSFERABILITY:


N/A

Unknown

3 1/2 years

The feasibility of incineration will depend on a cost-benefit analysis which includes the capital investment, auxiliary fuel charges, tipping fees for disposal of the solid waste, markets and lodal price for steam or electricity, land availability, and cost and volume of wastes available to burn. There is a wide variability in the cost data reported nationally for such systems, ahd each system must be evaluated oh a case-by-case basis. I f the sale of steam or electricity can be used to offset the operating costs, incineration can economically reduce the land capacity required for solid waste.

Conservation of land and fuel resources. Because the heat of the incinerator degrades many harmful materials in the waste stream, there is reduced threat of leakage of these compounds into groundwater near the landfill. The incinerator does not destroy metals, however, and the volume reduction accomplished by the incinerator serves to concentrate the metals which can be recycled.

Incineration introduces the opportunity for air pollution. Suffi- cient pollution control and monitoring are required. One of the drawbacks to incineration is that it does little to discourage a "throw away" ethic. In order to maintain the design operating conditions, waste volumes must be generated at their current and projected rates.

155

PROJECT DESCRIPTION: New Hanover County operated a conventional landfill for burial of municipal solid wastes. Due to the particular hydrologic and geologic conditions in the county and the demographics of the Wilmington area, landfilling of solid wastes was becoming increasingly expensive and an environmental liability.

A cost-benefit analysis evaluating some alternative waste management plans indicated that incineration of solid wastes with cogeneration of energy would be less expensive than continued reliance on the local landfill, with its attendant special design requirements and environmental risks.

The facility was designed through the collaboration of Charles R. Velzy Associates, consultants, and Clark-Kenith, Inc. builders/contractors. These firms had designed a similar: system in Virginia and adapted the plans for New Hanover County. The New Hanover facility consists of a pair of "package boiler" units, factory fabricated and shipped in two sections. The units are manufactured by Keeler Dorr-Oliver, and they are each designed to incinerate 100 tons of refuse/day. The facility can store up to 660 tons (3000 cu.yards) of refuse/day. Two Harnischfeger cranes, each with 5.5 ton capacity and a 3 cu.yard grapple, are used to feed fuel to the boilers. No separation of non-burnable or recyclable material is performed. The system uses reciprocating grate stokers made by Detroit Stoker Company. Electrostatic precipitators have been installed to maintain air quality . The new system took 3 1/2 years to implement. Test burns began

in June 1984, and commercial operations commenced on August 1984. Solid waste is accepted from 8 am - 5 pm weekdays and from 8 am - 12 noon on Saturday. The facility incinerates approximately 190 tons/day and is in continuous operation, 24 hrs/day, 7 days/week.

Down-time requirements for the new sydtem have not yet been established, but the County has estimated a 7 5 % availability factor for budget analyses. This will not affect the schedule for receipt of wastes, since ample stotage capacity has been provided.

Water consumption averages about 80 gallons/minute, but it varies with the amount of condensate returned to the plant. Plans are to install and operate a condensate recovery operation to conserve water at a future date. No supplemental fuel is required; the unprocessed municipal wastes burn at approximately 5000 BTUs/pound. Electrical power requirements are estimated to be about 3.1 million KW/year.

The facility is an energy co-generator. The boilers are rated at 26,144 lbs/hr per unit at 6500F., 450 psig. The steam produced by the incinerator boilers is used to generate electricity which is sold to the local utility, and is available for sale to local industry. A back pressure turbine and a condensing turbine, both manufactured by Turbodyne Division of

156

McGraw Edison Company, produce approximately 7 8 Kilowatts and 4000 Kilowatts respectively of electricity. Carolina Power and Light Company has contracted to purchase between 2 and 4 megawatts of electricity for $O.O41/KWH during peak hours, and $0.027/KWH during off peak hours. The County will also receive a cogeneration capacity credit for electricity generated during peak hours, which will provide an additional $0.026/KWH in the summer months and S0.022/KWH during the winter.

The system can deliver up to 40,000 pounds/hour of steam to local industries. Approximately 18,000 lbs/hr. at 425*F and 250 psig is currently purchased by a local firm. The formula used for determining the price of 1,000 pounds of steam (1 million BTUs) is 110% of the cost of purchasing 1 million BTCJs of the cheapest fuel available to the buyer each month.

The incinerators are targeted to reduce the volume of the County's municipal solid waste by at least 85%. The remainder of the waste will contain glass, metal, and other non-combustible refuse as well as the ash from the incinerators. The County estimates they have extended the life of their current landfill capacity by a factor of four.

The capital cost of the facility was $ 1 3 . 1 million. A $12 million bond referendum provided the funding, and the County has an Equipment Lease Purchase agreement with First Union National Bank. The first year operation, maintenance, and debt service costs will total approximately $ 3 . 8 million, and revenue from electricity and steam sale and tipping fees will be about $2.6 million. Anticipated increases in fuel prices are expected to improve the payback for the system. The County projects the facility will operate in the black within 5 years.

157

PROCESS DIMENSIONS:

WASTES GENERATED Volume of municipal waste

PRODUCTIVITY $1.6 million/yr cogeneration

PRODUCT QUALITY N/A

DOWN TIME Incinerator 25%, waste

reduced by 85-90%

collection operation-no change

FACILITIES $13 million, One-time Cost

EQUIPMENT Included with facility costs

RAW MATERIALS N/A

WATER 80 gal/min, to be reduced when planned modifications completed

ENERGY 3.1 million KW/yr

WASTE DISPOSAL Reduced long-term costs likely

POLLUTION CONTROL Included with facility costs

PERSONNEL/MAINTENANCE $ 3 . 8 million/year (including debt service)

NET BENEFITS Increased landfill life, energy conservation, and decreased risk of ground-water contamination

158

Diagrammatic view of a Refuse-Fired Steam Generating Facility

U

STACK-

~~~~~~ ~ ~ ~~

--BRIDGE CRANE ELECTROSTATIC I

I r P R E C I P I T A T O R STEAM I N I

FORCED] RESIDUE CONVEYORS DRAFT FAN

INDUCEC DRAFT F

8

A

159

Chapter 4. ABSTRACTS CROSS REFERENCING CASE STUDIES MATERIAL

The abstracts of the case studies are arranged in this chapter to highlight the waste reduction and resource conservation of classes of material. The purpose of this arrangement is to facilitate the examination of pollution prevention strategies which are appropriate for a material of interest to the reader.

The categories of: material identified with respect to the case studies included in this compendium at present are:

AGRICULTURAL/FOOD PROCESSING WASTES FLY ASH & BOTTOM ASH LOW LEVEL RADIOACTIVE WASTES METALS AND OTHER INORGANIC CHEMICALS MUNICIPAL WASTES PROCESS WATER SOLVENTS AND OTHER ORGANIC CHEMICALS

160

AGRICULTURAL/FOOD PROCESSING WASTES

CASE STUDY 1 ABSTRACT: The C h o p l i n Fami ly Farm r a i s e s swine and v a r i o u s f i e l d ~

c r o p s . I n 1982 t h e C h o p l i n f a rm s a v e d $8 ,000 i n f e r t i l i z e r costs by s p r a y i n g s w i n e wastes o n c r o p s w i t h a s t a n d a r d i r r i g a t i o n gun . They a l s o r educed o r g a n i c m a t e r i a l losses by 1,670%, t o t a l n i t r o g e n losses by 4 9 0 % , and t o t a l p h o s p h o r u s losses by 525%

t e r r a c i n g , g r a s s e d waterways and c o v e r c r o p s . The reuse o f t h e s e a g r i c u l t u r a l wastes and t h e management i n i t i a t i v e t o i n c o r p o r a t e c o n s e r v a t i o n p r a c t i c e s i n t h e fa rm o p e r a t i o n r e s u l t e d i n corn crop y i e l d s t h a t were 300% above t h e c o u n t y a v e r a g e .

~

t h r o u g h t h e i n t e g r a t e d u s e of c o n s e r v a t i o n t i l l a g e , p a r a l l e l -~

CASE STUDY 2 ABSTRACT: Dunbar Foods p r o c e s s e s canned p e p p e r s a n d sweet p o t a t o e s . They have d e v e l o p e d a s p r a y i r r i g a t i o n land a p p l i c a t i o n s y s t e m f o r t h e i r food p r o c e s s i n g wastes. Process w a t e r c o n t a i n i n g v e g e t a b l e w a s t e s is r e u s e d t o i r r i g a t e and f e r t i l i z e g r a s s l a n d which is owned by t h e Company.

CASE STUDY 3 ABSTRACT: Food p r o c e s s i n g wastes g e n e r a t e d d u r i n g b e e r brewing o p e r a t i o n s a t Miller Brewing Company are t r e a t e d and made a v a i l a b l e f o r l a n d a p p l i c a t i o n . The by-p roduc t is used f o r l i m i n g and a s a n i t r o g e n s u p p l e m e n t . T h e reuse o f t h i s p r e v i o u s l y l a n d f i l l e d m a t e r i a l h a s e l i m i n a t e d d i s p o s a l costs €or Miller, p r o v i d e d a v i r t u a l l y c o s t - f r e e s u b s t i t u t e f o r s t a n d a r d a g r i c u l t u r a l l i m i n g m a t e r i a l , and p r e s e r v e d v a l u a b l e l a n d f i l l c a p a c i t y .

161

FLY ASH AND BOTTOM ASH

C A S E STUDY 2 0 ABSTRACT: C a r o l i n a Power and L i g h t Company (CP&L) h a s been s e l l i n g w a s t e fly a s h and bo t tom ash f o r reuse s ince 1 9 7 3 . The Company d o e s n o t s e l l a s h d i r e c t l y t o u s e r s b u t h a s c o n t r a c t e d w i t h a n o t h e r f i r m , Monier R e s o u r c e s , I n c . , t o oversee t h e m a r k e t i n g o f t h e a s h . Prior t o t h i s a r r a n g e m e n t , a l l of t h e a s h p roduced was s l u i c e d t o on - s i t e a s h ponds . The company h a s now r e d u c e d i t s d i s p o s a l cos t s and p r e v e n t e d t h e b u r i a l of u s e a b l e ma te r i a l .

-- -

C A S E STUDY 2 1 ABSTRACT: Duke Power Company h a s been m a r k e t i n g waste & a s h and bottom - a s h from t h e i r c o a l - f i r e d power p l a n t s s i n c e t h e l a t e 1960's. The a s h h a s been used f o r c o n c r e t e p r o d u c t i o n , a s p h a l t f i l l e r , and p l a s t i c s f i l l e r . The Company is e x p l o r i n g o t h e r u s e s f o r t h e a s h a s w e l l , p a r t i c u l a r l y t h e p o s s i b i l i t y o f u s i n g i t a s s t r u c t u r a l b a c k f i l l o r t o s t a b i l i z e r o a d b a s e .

_c

162

LOW LEVEL RADIOACTIVE WASTES

C A S E S T U D Y 2 1 ABSTRACT: Duke Power Company h a s i n s t i t u t e d a c o m p r e h e n s i v e program to a c h i e v e volume r e d u c t i o n o f - low l e v e l r a d i o a c t i v e ~

was tes . The program i n c l u d e s housekeepi f lq improvements , t h e p u r c h a s e o f e q u i p m e n t t o a l l o w c l e a n i n g r a t h e r t h a n d i s p o s a l o f c o n t a m i n a t e d too ls and equ ip inen t , c o n v e r s i o n f rom a n e v a p o r a t o r - based n o n - r e c y c l a b l e w a s t e p r o c e s s i n g s y s t e m to one b a s e d on ion- exchange e q u i p m e n t , r e d e s i g n o f e x i s t i n g e v a p o r a t o r equ ipmen t f o r u s e i n r e c y c l e waste p r o c e s s i n g , and r e v i e w and r e v i s i o n of f i l t r a t i o n equ ipmen t o p e r a t i o n t o improve p e r f o r m a n c e and min imize r e p l a c e m e n t and d i s p o s a l costs .

~

~~

163

METALS AND OTHER INORGANIC CHEMICALS

CASE STUDY 9 ABSTRACT: Data G e n e r a l C o r p o r a t i o n g e n e r a t e s s e v e r a l h a z a r d o u s w a s t e streams d u r i n g t h e m a n u f a c t u r e o f p r i n t e d c i r c u i t b o a r d s . Most o f t h e s e wastes are c h a r a c t e r i z e d by h i g h heavy meta l c o n c e n t r a t i o n s . I n 1981 t h e Company l a u n c h e d a v i g o r o u s p rogram to r e d u c e t h e i r r e l i a n c e on h a z a r d o u s w a s t e l a n d f i l l s . A management i n i t i a t i v e t o d e v e l o p m a r k e t s f o r t h e i r wastes r e s u l t e d i n $9000 /yea r i n d i s p o s a l cost s a v i n g s and r e v e n u e from s a l e o f u n t r e a t e d wastes. T r e a t m e n t o f o t h e r wastes u s i n g n e w p r o c e s s c h e m i s t r y , i n c l u d i n g c h a n g e s i n e q u i p m e n t d e s i g n o r operat ion , r e n d e r e d a d d i t i o n a l m a t e r i a l s u i t a b l e f o r sa le for metal r e c o v e r y . T h e i r program t o p r o d u c e s a l e a b l e w a s t e s and m a r k e t t h o s e wastes h a s r e d u c e d t h e h a z a r d o u s m a t e r i a l t h e y l a n d f i l l by o v e r 4 0 0 t o n s / y e a r and y i e l d e d a cost s a v i n g s o f $180,00O/year .

CASE STUDY 11 ABSTRACT: F l o r i d a S t e e l C o r p o r a t i o n se l l s metal d u s t c o l l e c t e d from f u r n a c e fumes to a z i n c smelter. T h i s p r a c t i c e h a s r e d u c e d t h e i r d i s p o s a l costs by a l m o s t h a l f and a l lows reuse of t h e metal r a t h e r t h a n d i s p o s a l .

CASE S T U D Y 6 ~

ABSTRACT: I A C u s e s m a t e r i a l s s u b s t i t u t i o n t o r e d u c e t h e i r raw mater ia l cos ts i n t h e m a n u f a c t u r e o f t r a c e e l e m e n t compounds. S u i t a b l e i n o r g a n i c c h e m i c a l wastes a r e r e c e i v e d from f i r m s t h a t would o t h e r w i s e pay t o l a n d f i l l t h e m a t e r i a l s . T h r e e examples a re c i t e d d e s c r i b i n g t h e u t i l i t y of t h i s a r r a n g e m e n t t o b o t h - 1 A C and t h e waste ma te r i a l d o n o r .

CASE STUDY 1 4 ABSTRACT: PCA I n t e r n a t i o n a l g e n e r a t e s s e v e r a l h a z a r d o u s N a s t e s t r e a m s d u r i n g t h e i r color p o r t r a i t p r o c e s s i n g o p e r a t i o n s . E l e c t r o l y t i c r e c o v e r y is u s e d t o remove s i l v e r f rom f i x i n g and b l e a c h - f i x s o l u t i o n s . The r e c o v e r e d s i l v e r is 9 6 % p u r e and t h e f i x e r c a n be r e p l e n i s h e d and r e u s e d . - Ion e x c h a n g e co lumns are u s e d t o remove t h e i no rgan ic c h e m i c a l , b romide , from color d e v e l o p e r s o l u t i o n , and t h i s s y s t e m h a s a l l o w e d 99% r e u s e o f color d e v e l o p e r .

164

METALS AND OTHER INORGANIC C H E M I C A L S , CONTINUED

CASE STUDY 1 3 ABSTRACT: The S t a n a d y n e Company u n d e r t o o k a comprehens ive and s y s t e m a t i c r e v i e w o f t h e i r e l e c t r o p l a t i n g p r o c e s s e s i n o r d e r t o r e d u c e or e l i m i n a t e waste g e n e r a t i o n . The r e s u l t of t h e i r e f f o r t s h a s b e e n a b r o a d s p e c t r u m o f a c t i v i t i e s which h a s s a v e d t h e f i r m money and min imized p o l l u t i o n . A s u l p h u r i c / p e r o x i d e mater ia ls s u b s t i t u t i o n f o r c h r o m i c a c i d r educed s l u d g e D r o d u c t i o n f rom t h e i r Darts c l e a n i n a oDeration. The comDanv a l s o - - i o u n d t h e y c o u l d o p e r a t e t h e i r c y a n i d e ' c o p p e r and chrome p l a t i n g b a t h equipment . a t a lower c y a n i d e c o n c e n t r a t i o n , s a v i n g b o t h raw mater ia l and s l u d g e h a n d l i n g costs . O t h e r equ ipmen t d e s i g n and o p e r a t i o n c h a n g e s which r educed d r a g o u t volumes and rack r e c o a t i n g costs a l s o improved p l a t i n g e f f i c i e n c y . Tanks were i n s t a l l e d b e f o r e t h e r i n s i n g o p e r a t i o n t o r e c y c l e v a l u a b l e metals back to t h e p l a t i n g b a t h s . A change i n p l a t i n g b a t h f i l t r a t i o n e q u i p m e n t o p e r a t i o n d r a s t i c a l l y reduced s o l u t i o n losses and r e s u l t e d i n a 9 3 % cos t r e d u c t i o n i n f i l t e r media. A f i l t e r press o p e r a t i o n f o r s l u d g e d e w a t e r i n g minimized t h e cost o f s i u d g e t r a n s p o r t and d i s p o s a l . A new w a s t e w a t e r f i l t r a t i o n s y s t e m h a s improved t h e treated p r o c e s s water q u a l i t y . Housekeep ing improvements l e d t o l e a k e l i m i n a t i o n and a p r e i n s p e c t i o n program which p r e v e n t s p l a t i n g o f d e f e c t i v e p a r t s .

165

MUNICIPAL WASTES

CASE STUDY 2 2 ABSTRACT: A municipal waste sludge composting system is planned for the Hickory/Newton/Conover Complex in Catawba County. The facility is in the final design phase, and it is scheduled €or construction in 1986. When operational, the system will be the first mechanical enclosed composting system in North Carolina. The reuse of waste sludge as composting material is expected to save the County as much as $ 8 2 7 , 0 0 0 annually in disposal costs.

CASE STUDY 2 3 ABSTRACT: The Catawba River Pollution Control Facility in Morganton, North Carolina has implemented the first full scale composting operation in the State. A mixture of municipal waste sludqe and bark is composted using a static pile system designed by City personnel. They have eliminated the need for landfilling the waste sludge and have created a system to reuse an otherwise undesirable product. The compost is marketed to the public and the City is unable to keep up with consumer demand. Although they do not make money on the operation, their sludge disposal costs are below those estimated €or other systems investigated, including land application and incineration. In response to the success of the Morganton project, the State is developing a permit system for composting operations to insure safe levels of heavy metals and the absence of pathogens.

CASE STUDY 2 4 ABSTRACT: Natural Power is a small generator of electricity operating from the Gresham Lake Landfill in Raleigh, N.C. They have implemented a landfill gas recovery system €or conversion of "biogas" to electric power, which is then sold to the local utility. Natural Power recovers combustible gas generated from the anaerobic decomposition of municiple waste and other organic material buried at the landfill. The gas is collected, filtered and fed directly into two diesel generators modified to use a methane fuel source. Electrical energy generated at this source is metered and fed into the local power utility's transmission 1 ines.

CASE STUDY 2 5 ABSTRACT: New Hanover County has recently installed a re€use- fired steam generating facility to reduce the volume of municipal solid waste requiring burial. The sale of steam and electricity generated by the waste incineration is used to offset the capital and operating costs of the system. The County expects to realize long term cost savings as Euel prices rise, and a four-fold increase in the life of its current landfill operation.

166

PROCESS WATER

CASE STUDY 9 ABSTRACT: Data G e n e r a l C o r p o r a t i o n m a n u f a c t u r e s p r i n t e d c i r c u i t b o a r d s f o r compute r s . P r o c e s s water c o n t a i n i n g h i g h c o n c e n t r a t i o n s o f heavy m e t a l s is p a s s e d t h r o u g h a f i l t e r - b a s e d water p u r i f i c a t i o n s s y s t e m and t h e n d i s p o s e d of by l a n d a p p l i c a t i o n on f o r e s t l a n d owned by t h e Company. T h i s s i t e was t h e f i r s t l a n d a p p l i c a t i o n s i te €or p r e t r e a t e d metal p l a t i n g waste i n N o r t h C a r o l i n a .

CASE STUDY 8 ABSTRACT: Two major h a z a r d o u s waste s t r e a m s g e n e r a t e d d u r i n g U n i t e d GlobeOs f u r n i t u r e m a n u f a c t u r e are i n c i n e r a t e d t o p r o d u c e steam and h e a t . S o l i d s f rom t h e ragwash and s p r a y b o o t h process water wastes are t h i c k e n e d u s i n g d i s s o l v e d a i r f l o t a t i o n . The r e s u l t i n g s l u d g e i s mixed w i t h woodch ips , d r i e d , and f e d t o t h e p r i m a r y c o m b u s t i o n chamber o f a two-s t age i n c i n e r a t i o n s y s t e m . S e m i - s o l i d and l i q u i d f i n i s h i n g wastes, i n c l u d i n g h i g h BTU s o l v e n t s , are f e d t o t h e s e c o n d a r y combus t ion chamber. The steam p r o d u c e d is u s e d f o r s p a c e h e a t i n g , r a g w a s h i n g / d r y i n g o p e r a t i o n s , and t h e s l u d g e d r y e r . Use o€ t h e i n c i n e r a t o r h a s r e d u c e d B u r l i n g t o n ' s waste volume by 95%, and t h e a s h p roduced i s n o t h a z a r d o u s . D i s c h a r g e l o a d i n g t o t h e m u n i c i p a l sewer s y s t e m h a s d e c r e a s e d d r a m a t i c a l l y , a s have h a z a r d o u s waste t r a n s p o r t and d i s p o s a l costs .

167

SOLVENTS AND OTHER ORGANIC CHEMICALS

CASE STUDY 17 ABSTRACT American Enka is a nylon yarn production and research facility. They have found it is economically profitable and environmentally sound to recycle their waste isopropyl alcohol solvent in-house rather than having it recycled by an outside firm. They purchased a bsed distillation unit and, with appropriate modifications, American Enka is now saving $90,00O/yr. They have also been able to reuse the still bottom residues as an asphalt emulsifier in another product line.

CASE STUDY 4 ABSTRACT: The Coty Division of Pfizer, Inc. has developed a method of - heat recovery from waste hydro-alcoholic products. The ignitable organic wastes are mixed with fuel oil and burned to produce steam and hot water. The company saves over 1000 gallons of fuel oil a year, and the costs of hazardous waste disposal have been eliminated.

CASE STUDY 5 ABSTRACT: Daly-Herring Company altered their dust collection equipment operation so that waste streams containing organic chemicals from various production areas are now collected separately rather than mixed in a single bag house. The collected materials are no longer contaminated by alternate waste streams, and each is recycled back to the process where it was generated. The firm has eliminated over $9,000 in annual disposal costs and estimates the recovered material is worth more than $2000/year.

CASE STUDY 21 ABSTRACT: Duke Power Company has an on-going program to phase out polycholrinated biphenyl (PCB) from their electrical distribution system. Insulating organic chemical fluid contaminated with PCBs is burned as a supplemental fuel for heat recovery at one of their steam electric generating stations. The PCBs are totally destroyed, and the Company has saved about $84,00O/year in hazardous waste disposal costs over the past few years.

168

SOLVENTS AND OTHER ORGANIC CHEMICALS, CONTINUED

CASE STUDY 10 ABSTRACT: Emerson Electric Company has made a series of modifications which have significantly decreased operating costs; increased productivity: reduced solvent, paint solids and plating chemical costs; conserved energy; improved product quality; provided a safer working environment: and conserved raw materials. Several of the improvements involved the purchase of new equipment which allowed automation of their electroplating process and energy management system. Conversion from an organic solvent-based paint system to a waterborne system reduced paint solvent and paint sludge losses by 4 0 % .

CASE STUDY 7 ABSTRACT IC1 Americas, Tnc. operates an agricultural chemical research and development lab in Coldsboro, N.C. As a research facility, it does not produce a large amount of waste. An

. Environmental Compliance Committee reviews study protocals with emphasis first on early planning to minimize waste production, second on attempting to recycle or treat the waste whenever possible so that there is zero discharge. Measures recommended by the committee and implemented include: housekeeping improvements and the initiatibh of waste solvent recovery by distillation.

CASE STUDY 16 ABSTRACT: The Rexham Corporation facility in Greensboro, North Carolina is involved in the manufacture and printing of specialized product labels. They have made several modifications in their printing operations at various North Carolina facilities to reduce hazardous waste production. A water-borne ink material substitution for some of their alcohol/acetate ink applications reduced the volume of spent solvent requiring disposal and lowered air emission levels. The Company also installed a distillation unit to reclaim n-propyl alcohol from their waste inks. The unit reduced their hazardous waste disposal costs by 1 4 % and decreased their raw material costs by 16%.

169


CASE STUDY 15 ABSTRACT: The Rexham Corporation facility in Matthews North Carolina laminates and coats specialized paper, film, and foil substrates for the photography industry. A management initiative to develop a comprehesive waste management plan for the firm has resulted in several pollution prevention modifications. The initiation of new housekeeping practices which require the segregation of spent solvent by ink color and type has resulted in almost 100% reuse of liquid toluene. Toluene-laden vapors are collected in a carbon adsorption-based air pollution control system and sold for use in the coatings industry. Off-site distillation of spent solvent mixtures has allowed reuse of methyl ethyl ketone solvent for washup operations. Methyl ethyl ketone vapors are removed from the air and incinerated for heat recovery.

CASE STUDY 12 ABSTRACT: Scovill, Inc. uses 1-1-1 trichloroethane solvent to degrease metal stampings produced in their manufacturing process. Solvent wastes are collected in 55 gallon drums and housed in a storage building designed to contain spills if they should occur. The drums are picked up by a company that distills 1-1-1 trichloroethane from the wastes and returns it to Scovill for reuse. The recycled solvent costs about half as much as the virgin material. The company has also experimented with material substitution of water soluble synthetic cleaners, and they have consequently reduced their use of organic solvents by 30%. A management initiative to reward other ideas from employees for waste reduction and cost savings projects is also a Dart of _ _ _ - Scovillos program for pollution prevention.

CASE STUDY 13 ABSTRACT: The Stanadyne Company undertook a comprehensive and systematic review of their electroplating processes in order to reduce or eliminate waste generation. They also incorporated pollution prevention goals in their recent plant expansion, which resulted in the selection of a new degreaser which has significantly lowered solvent costs. The unit selected has several features which help to lower solvent requirements and prevent solvent losses.

170


CASE STUDY 8 ABSTRACT: Two major hazardous waste streams generated during United GlobeOs furniture manufacture are incinerated to produce steam and heat. Solids from the ragwash and spraybooth process water wastes are thickened using dissolved air flotation. The resulting sludge is mixed with woodchips, dried, and fed to the primary combustion chamber of a two-stage incineration system. Semi-solid and liquid finishing wastes, including high BTU solvents, are fed to the secondary combustion chamber. The steam produced is used for space heating, ragwashing/dryin operations, and United GlobeOs waste volume by 95%, and the ash produced is not hazardous. Discharge loading to the municipal sewer system has decreased dramatically, as have hazardous waste transport and disposal costs.

the sludge dryer. Use of the incinerator has re 3 uced

171.

Chaper 5. ABSTRACTS CROSS REFERENCING CASE STUDIES PROCESSES

The a b s t r a c t s of t h e case s t u d i e s are a r r a n g e d i n t h i s c h a p t e r t o h i g h l i g h t t he p a r t i c u l a r t e c h n o l o g y a p p l i e d i n t h e r e s p e c t i v e case s t u d i e s t o c o n s e r v e resources o r r e d u c e waste g e n e r a t e d . The p u r p o s e f o r t h i s a r rangement is t o i l l u s t r a t e app l i ca t ions o f ~

t h e s e t e c h n o l o g i e s which may be o f assis tance t o t h e r e a d e r i n d e v e l o p i n g a p o l l u t i o n p r e v e n t i o n program.

The categories o f p r o c e s s t e c h n o l o g y and p o l l u t i o n p reven t ion s t r a t e g y i d e n t i f i e d w i t h r e s p e c t t o t h e case s t u d i e s i n c l u d e d i n t h i s compendium a t p r e s e n t are:

ADSORPTION DISTILLATION ELECTROLYTIC REACTIONS EQUIPMENT OPERATION FILTRATION HOUSEKEEPING

ION EXCHANGE LAND APPLICATION MANAGEMENT INITIATIVES MATERIAL SUBSTITUTION RECYCLE, REUSE & RECOVERY

INCINERATION/HEAT RECOVERY

172

ADSORPTION

CASE STUDY 15

p h o t o g r a p h y i n d u s t r y a t t h e i r Mat thews , N o r t h C a r o l i n a f a c i l i t y . They have i n s t a l l e d a c a r b o n a d s o r p t i o n - b a s e d a i r p o l l u t i o n c o n t r o l s y s t e m which c a p t u r e s v a p o r s f rom o i l - b a s e d s o l v e n t s . The reclaimed s o l v e n t is t h e n s o l d f o r u s e i n t h e c o a t i n g s

s i g n i f i c a n t l y and h a s a l l o w e d t h e Company t o expand w i t h o u t e x c e e d i n g a i r p o l l u t i o n l i m i t s .

Rexham C o r p o r a t i o n d o e s h i g h - t e c h p r i n t i n g and c o a t i n g f o r t h e ~~

i n d u s t r y . The r e c o v e r y s y s t e m h a s r e d u c e d e m i s s i o n s ~~

173

DISTILLATION

CASE STUDY 17 American Enka is a nylon yarn production and research facility. They have found it is economically profitable and environmentally sound to recycle their waste isopropyl alcohol solvent in-house rather than having it recycled by an outside firm. They purchased a used distillation unit and, with appropriate modifications, American Enka is now saving $90,00O/yr. They have also been able to reuse the still bottom residues as an asphalt emulsifier in another product line.

CASE STUDY 7 IC1 Americas, Inc. operates an agricultural chemical research and development lab in Goldsboro, N.C. As a research facility, it does not produce a large amount of waste. A management initiative was undertaken in 1981 to form an Environmental Compliance Committee to review issues and activities at IC1 that impact on the environment. Emphasis is first on early planning to minimize waste production, second on attempting to recycle or treat the waste whenever possible so that there is zero discharge. Measures recommended by the committee and implemented include: housekeeping improvements and the initiation of waste solvent recovery by distillation. The Committee's recommendations saved the Company an estimated $37,000 in waste disposal costs in 1984.

CASE STUDY 16 Rexham Corporation manufactures and prints product labels at their Greensboro, North Carolina plant. They have installed a distillation unit to receive a solvent blend of normal propyl alcohol and normal propyl acetate. Total cost of the distillation unit and the structural modifications was approximately $16,000. The unit recovers 85% of the solvent in the waste stream, resulting in annual savings of $15,000 in virgin solvent costs and $22.800 in hazardous waste disposal costs. The reclaimed alcohol/acetate mixture is reblended with virgin materials to provide the required composition for new batches and for cleanup use. Rexham plans to add a further distillation unit in order to recover the remaining 15% of the solvents in the sludge wastes.

CASE STUDY 12 Scovill uses 1-1-1 trichloroethane solvent to degrease metal stampings produced in their manufacturing process. Waste solvent is collected in 55 gallon drums and housed in a storage building designed to contain spills if they occur. The drums are picked up by a company that distills the solvent from the waste and returns it to Scovill for reuse. The recycled solvent costs about half as much as virgin solvent.

174

ELECTROLYTIC REACTIONS

CASE STUDY 14

electrolytic silver recovery system is used to recover silver from color negative film fixing solutions and the p9per bleach- fix solutions. The silver recovery system allows reuse of the film fixer, and the silver chip obtained is about 96% pure.

PCA International is a color portrait processing company. An ~

~

175

EQUIPMENT OPERATION

CASE STUDY 5 Daly-Herring Company manufactures pesticides and insecticides. They altered their dust collection equipment so that waste streams coming from various production areas are now collected separately rather than mixed in a single bag house. The collected materials are no longer contaminated by alternate waste streams, and each is recycled back to the process where it was generated. The firm has eliminated over $9,000 in annual disposal costs and estimates the recovered material is worth more than $2000/year.

CASE STUDY 9 Data General Corporation generates several hazardous waste streams during the manufacture of printed circuit boards. Their hazardous waste management modifications have focused on the sale of their wastes for reuse or recovery. Several equipment modifications have resulted in making some of their wastes more marketable. Modification of their existing water purification filters allowed quicker, easier cleaning. When coupled with a process chemistry change, the resulting sludge could be successfully processed for copper recovery. An air blow-down line was added to their existing filter press to increase the sludge solids content, and reusable polishing filters were developed for the water treatment effluent.

CASE STUDY 21 Duke Power Company is one of the major electric power generating firms in the State of North Carolina. The Company assembled a team of staff members to pursue low level radioactive waste reduction strategies. Improved compactor equipment was installed to reduce the volume of wastes requiring disposal. Decontamination equipment was purchased to allow clean-up and reuse rather than disposal of contaminated tools and equipment. Existing evaporator equipment, originally designed for non- recyclable waste processing, was extensively modified to process recyclable liquid wastes. The conversion improved evaporator performance and minimized boron and tritium release to the environment. Filtration equipment was modified to improve filter performance and minimize replacement and disposal costs. The filter modifications required a $60,000 investment, but they have resulted in $200,00O/year savings.

176

EQUIPMENT OPERATION, CONTINUED

CASE STUDY 10 Emerson Electric Company manufactures stationary power tools, ~

which requires both metal finishing and painting operations. ~

They installed an automated metal elctroplating system to replace their manual operation, and increased annual productivity $200,000. The substitution of a water-based anodic electrostatic

system improved annual productivity by $1,000,000. The water based system allows 99.5% recovery and reuse of paint. Hazardous waste disposal costs have been reduced from $10,00O/year to only $300/year. Equipment modifications in a die cast sump and pumping facility allowed the recovery of 65 gallons/week of waste oil. A steam cleaner was purchased for $5,000, and degreasing is , accomplished by using an alkaline detergent and steam rather than chlorinated organic solvents. The addition of chlorinators for the plantos cooling towers eliminated the influx of zinc chromate algicide into the storm drains. Finally, a computerized energy management system was installed in the plant which saves the Company approximately S147,000/year.

immersion paint system €or the existing organic solvent paint ~~

CASE STUDY 18 Hampshire Hosiery manufactures womenos pantyhose. They replaced an existing oil-fired boiler system for steam generation with a wood-fired system capable of using sawdust from nearby lumbermills as fuel. The new boiler operation saves the firm $200 , 000/year.

CASE STUDY 13 Stanadyne, Inc. manufactures plumbing products which require cleaning and electroplating operations that generate hazardous wastes. As part of a comprehensive review of their processes to reduce or eliminate waste production, several equipment design and operation modifications were made. They found they could operate their cyanide copper and chrome electroplating bath equipment at a lower cyanide concentration, saving both raw material and sludge handling costs. Other changes reduced dragout volumes and rack recoating costs while improving plating efficiency. Tanks were installed before the rinsing operation to recycle valuable metals back to the plating baths. A change in plating bath filtration equipment operation drastically reduced solution losses and resulted in a 93% cost reduction in filter media. A filter press operation for sludge dewatering has ~

minimized the cost of sludge transport and disposal. A new wastewater filtration system has improved the treated process water quality.

~

177

FILTRATION

CASE STUDY 9 Data General Corporation generates several hazardous waste streams during the manufacture of printed circuit boards. Process water from the circuit board fabrication, assembly, and testing is treated using a cross-flow filtration water purification system. The filtration effluent is disposed of by land application on forest land owned by the Company.

CASE STUDY 10 Emerson Electric Company manufactures stationary power tools, which requires both metal finishing and painting operations. The addition of a $65,000 oil skimmer and ultrafiltration system to their existing wastewater treatment system has allowed recovery of oil and cleaning solution. The unit has cut water treatment costs by $10,00O/year.

HOUSEKEEPING

CASE STUDY 21 Duke Power Company is one of the major electric power generating firms in the State of North Carolina. A team of staff members was assembled to develop comprehensive low level radioactive waste reduction strategies. One of the elements of the resulting program was an effort to improve housekeeping acitivities. Compactible materials suspected of radioactive contamination were segregated by area within the plant into "potentially contaminated" and "not contaminated". Since a significant portion of the material was free of radioactivity, this procedure significantly reduced the amount of hazardous waste requiring disposal.

CASE STUDY 10 Emerson Electric Company manufactures stationary power tools, which requires both metal finishing and painting operations. Several new housekeeping procedures were instituted to reduce waste generation. They included cessation of unauthorized dumping of waste chemicals in the on-site wastewater treatment system and improved drum storage and handling procedures of wastes stored on-site. These changes eliminated the risk of environmental damage from high metal concentrations in the treated effluent and from improperly protected wastes stored on- site.

CASE STUDY 7 IC1 Americas, Inc. operates an agricultural chemical research and development lab in Goldsboro, N.C. Emphasis is first on early planning to minimize waste production, second on attempting to recycle or treat the waste whenever possible so that there is zero discharge. Housekeeping measures and improvements are important because IC1 does not generate large quantities of wastes, and cannot justify large capital expenditures for their management. Housekeeping innovations and solvent recovery by distillation saved the Company an estimated $37,000 in waste disposal costs in 1984.

CASE STUDY 15 Rexham Corporation does high-tech printing and coating for the photographic industry at their facility in Matthews, North

solvent is seyregated by color and type of ink contaminant has allowed almost 100% reuse of the solvent.

Carolina. A new housekeeping procedure in which cleaning -

179

HOUSEKEEPING, CONTINUED

CASE STUDY 13 Stanadyne, Inc. is a manufacturer of plumbing products which require electroplating and cleaning operations that generate hazardous waste. When the Company undertook a comprehensive review of their processes to eliminate unnecessary waste, one of the outcomes of their analysis was improved housekeeping. Preinspection of parts to eliminate obvious rejects before plating and a leak elimination program were instituted to reduce plating solution and dragout wastes.

180

INCINERATION/BEAT RECOVERY

CASE STUDY 4 The Co ty D i v i s i o n o f P f i z e r , I n c . h a s d e v e l o p e d a method o f r e c o v e r i n g h e a t from waste h y d r o - a l c o h o l i c p r o d u c t s . The i g n i t a b l e wastes are mixed w i t h f u e l o i l and bu rned to p r o d u c e steam a n h o t water. The company s a v e s o v e r 1000 g a l l o n s o f f u e l o i l a y e a r , and t h e costs o f h a z a r d o u s waste d i s p o s a l have been e 1 i m i na t e d . CASE STUDY 2 1 Duke Power Company is one o f t h e m a j o r e lectr ic power g e n e r a t i n g f i r m s i n t h e S t a t e o f N o r t h C a r o l i n a . T h e i r e f f o r t s to r e d u c e t h e amount o f p o l y c h l o r i n a t e d bypheny l (PCB) wastes r e q u i r i n g h a z a r d o u s w a s t e d i s p o s a l are p a r t o f a n o v e r a l l p rogram t o p h a s e o u t PCB c o n t a m i n a t i o n f rom t h e i r e l e c t r i c a l d i s t r i b u t i o n sys t em. I n s u l a t i n g f l u i d c o n t a m i n a t e d w i t h PCB's is burned a s a s u m l e m e n t f u e l f o r h e a t r e c o v e r y a t a steam e l c t r i c a e n e r a t i o n

.&

s t a t i o n . s a v e d a b o u t $84,00O/year i n h a z a r d o u s waste d i s p o s a t h e p a s t few y e a r s .

The PCB's are t o t a l l y i e s t r o y e d , and t h e

CASE STUDY 18

CoGpany h a s costs o v e r

The have Hampshi re H o s i e r y m a n u f a c t u r e s women's p a n t y h o s e i n s t a l l e d a h e a t e x c h a n g e r t o c a p t u r e h e a t from s p e n t d y e s o l u t i o n s and p r e h e a t s u b s e q u e n t dye operations. I n a d d i t i o n t o e n e r g y s a v i n g s , t h e e x c h a n g e r s y s t e m lowers t h e t e m p e r a t u r e o f e f f l u e n t e n t e r i n g t h e m u n i c i p a l sewer s y s t e m f rom 130 d e g r e e s F t o 70 d e g r e e s F , which a l l o w s improved t r e a t m e n t pe r fo rmance .

CASE STUDY 25 N e w Hanover County h a s r e c e n t l y i n s t a l l e d a r e f u s e - f i r e d steam g e n e r a t i n g f a c i l i t y t o r e d u c e t h e volume o f m u n i c i p a l s o l i d waste r e q u i r i n g b u r i a l . The sa le o f s t e a m and e l e c t r i c i t y g e n e r a t e d by w a s t e i n c i n e r a t i o n is u s e d t o o f f s e t t h e c a p i t a l and o p e r a t i n g cos ts o f t h e s y s t e m . The County expects to r ea l i ze long term cost s a v i n g s a s f u e l p r i c e s r ise, and a f o u r - f o l d increase i n t h e l i f e o f i ts c u r r e n t l a n d f i l l operation.

CASE STUDY 1 5 The Rexham C o r p o r a t i o n f a c i l i t y i n Mathews N o r t h Carolina

f o r t h e p h o t o g r a p h y i n d u s t r y . A management i n i t i a t i v e t o d e v e l o p a c o m p r e h e s i v e waste management p l a n f o r t h e f i r m h a s r e s u l t e d i n s e v e r a l p o l l u t i o n p r e v e n t i o n m o d i f i c a t i o n s . Of f - s i t e d i s t i l l a t i o n of s p e n t s o l v e n t m i x t u r e s h a s a l l o w e d reuse o f m e t h y l e t h y l k e t o n e s o l v e n t f o r washup o p e r a t i o n s . Methyl e t h y l k e t o n e v a p o r s are removed f rom t h e a i r and i n c i n e r a t e d f o r h e a t r e c o v e r y .

l a m i n a t e s and coats spec ia l ized p a p e r , f i l m , and f o i l s u b s t r a t e s ~-

_____

181

INCINERATION/HEAT RECOVERY, CONTINUED

CASE STUDY a United Globe generates two major waste streams during their furniture manufacturing operations. They purchased an incinerator and use their treated waste streams as fuel for producing steam and heat. Solids from the ragwash and spraybooth process water are thickened using dissolved air flotation, mixed

and liquid finishing wastes, including high BTU solvents, are fed to the incinerator as well. Use of the incinerator has reduced United Globe's waste volume by 95%, and the ash produced is not hazardous. Discharge loading to the municipal sewer system has decreased dramatically, as have hazardous waste transport and disposal costs.

~

with woodchips, dried, and fed to the incinerator. Semi-solid ~~

182

ION EXCHANGE

CASE STUDY 14 PCA I n t e r n a t i o n a l i s a color p o r t r a i t p r o c e s s i n g company. They i n s t a l l e d an i o n exchange system to remove bromide from color d e v e l o p e r s o l u t i o n and a l l o w r e g e n e r a t i o n and r e u s e of t h e d e v e l o p e r . The system has a l lowed 99% r e u s e of the color d e v e l o p e r s o l u t i o n .

183

LAND APPLICATION

CASE STUDY 9 Data General Corporation manufactures printed circuit boards for computers. Process water containing high concentrations of heavy metals is passed through a filter-based water purification system and then disposed of by land application on forest land owned by the Company. This site was the first land application site for pretreated metal plating waste in North Carolina.

CASE STUDY 2 Dunbar Foods processes canned peppers and sweet potatoes. They developed the first industrial wastewater land application system in North Carolina. Process water containing vegetable wastes is applied by spray irrigation to grassland owned by the Company.

CASE STUDY 3 Miller Brewing Company is a beer manufacturer in Eden, North Carolina. Food processing wastes generated during the brewing operation are treated and made available for land application. It has value for liming and use as a nitrogen supplement. The reuse of this previously landfilled material has eliminated disposal costs for Miller, provided a virtually cost-free substitute for standard agricultural liming material and fertilizer, and preserved valuable landfill capacity.

184

MANAGEMENT INITIATIVES

CASE STUDY 1 The Choplin Family Farm raises swine and various field crops. In 1982 the Choplin farm saved $8,000 in fertilizer costs; they reduced organic material losses by 1,670%, total nitrogen losses by 490%, and total phosphorus losses by 525%. The management initiative to incorporate conservation practices in the farm operation resulted in corn crop yields that were 300% above the county average.

CASE STUDY 9 Data General Corporation manufactures printed circuit boards for computers. In 1981, the Company initiated a management policy that landfill disposal of wastes should be used only as a last resort. In order to reduce reliance on landfilling, primary emphasis was placed on the sale of spent chemicals and sludges, not on reducing or eliminating the production of these wastes. Their program to reduce wastes has included marketing activities to find buyers for their wastes and operational revisions and development of new process chemistry to make their wastes more saleable.

CASE STUDY 21 Duke Power Company is one of the major electric power generating firms in the State o f North Carolina. A team of staff members has been assembled at each of Duke's power stations to oversee waste management activities. At the McGuire Nuclear Station a special section in the Company handbook for employees stresses the importance of reducing wastes through a variety of activities. The management policy emphasizes that wastes should be reduced as much as operationally possible and not just to the point of satisfying pre-determined legal limits.

CASE STUDY 10 Emerson Electric Company manufactures stationary power tools, which requires both metal finishing and painting operations. A broad-based waste management program was developed and led by the President and Vice President of Operations. Daily log sheets are maintained to insure stated procedures are followed. The Company also maintains an incentive awards progzam to encourage employee suggestions for cost savings and waste reduction. __

MANAGEMENT INITIATIVES, CONTINUED

CASE STUDY 12 Scovill Corporation manufactures small appliances and generates hazardous wastes from cleaning and degreasing operations. They have instituted an incentive awards program to encourage ideas for cost savings and waste reduction. Monetary awards are made each year to the team of employees making the greatest contributions in these areas.

CASE STUDY 13 Stanadyne, Inc. manufactures plumbing parts, and their operation requires cleaning and electroplating processes that generate hazardous wastes. The management at Stanadyne has a comprehensive program for reducing waste production, and they believe the key to the success of the program is employee education and participation. Representatives from Stanadyne have also participated in numerous state and local programs to educate other industries and the general public about hazardous wastes and pollution prevention.

CASE STUDY 19 WestPoint Pepperell is one of the major textile manufacturers in the nation. They established a Toxic Chemicals Committee in 1975 to review products in use or under consideration and evaluate them according to a wide range of health and environmental impact criteria. The Company believes the Committee has helped them to minimize hazardous waste production and the accompanying costs and environmental impacts.

186

MATERIAL SUBSTITUTION

CASE STUDY 6 IAC manufactures trace element compounds for fertilizer formulations. They use materials substitution to reduce their raw material costs. Suitable inorganic chemical wastes are received from firms that would otherwise pay to landfill the materials.

CASE STUDY 16 Rexham Corporation manufactures and prints product labels at their Greensboro, North Carolina plant. They found that replacement of alcohol/acetate-borne inks with water-borne inks significantly reduced spent solvent volumes and air emissions.

CASE STUDY 12 Scovil1,Inc. manufactures small appliances and uses 1-1-1 trichloroethane solvent for cleaning. They found that they could substitute a water-soluble synthetic cleaner for some of their degreasing applications and reduce the volume of spent organic solvent generated. The substitution has saved the Company approximately $12,00O/year.

CASE STUDY 13 Stanadyne, Inc. manufactures plumbing products which require cleaning and electroplating operations that generate hazardous wastes. The substitution of a sulphuric/peroxide brite dipping solution for a chromic acid-based brite dip reduced the amount of hazardous sludge produced from this process.

187

RECYCLE/REUSE & RECOVERY

CASE STUDY 17 American Enka is a nylon yarn production and research facility. They have found it is economically profitable and environmentally sound to recycle their waste isopropyl alcohol solvent in-house rather than having it recycled by an outside firm. They purchased a used distillation unit and, with appropriate modifications, American Enka is now saving $90,00O/yr. They have ~

also been able to reuse the still bottom residues as an asphalt emulsifier in another product line.

CASE STUDY 20 Carolina Power and Light Company is a major electric power generating facility in North Carolina. They have been selling waste fly ash and bottom ash from their coal-fired plants since 1973. The Company uses another firm, Monier Resources, Inc., to oversee the marketing of the ash. Prior to this arrangement, all of the ash was sluiced to on-site ash ponds for permanent disposal. The Company has now reduced its disposal costs and prevented the burial of useable material.

CASE STUDY 1 The Choplin Family Farm raises swine and various field crops. In 1982 the Choplin farm saved $8,000 in fertilizer costs by spraying swine wastes on crops with a standard irrigation gun. The reuse of these agricultural wastes and the incorportation of conservation practices in the farm operation resulted in corn crop yields that were 300% above the county average.

CASE STUDY 5 Daly-Herring Company manufactures organic pesticides and insecticides. By segregating waste dust streams, they have been able to recycle each dust-type back to the process where it was generated. The firm has eliminated over $9,000 in annual disposal costs and estimates the recovered material is worth more than $2000/year.

CASE STUDY 21 Duke Power Company is one of the major electric power generating firms in the State of North Carolina. Since the late 1960%, they have been marketing waste fly ash and bottom ash from their ~ _ _ coal-fired power plants. The ash has been used for concrete ~

production, asphalt filler, and plastics filler. The Company is ~xploring other uses €or the ash as well, particularly the possibility of using it as structural backfill or to stabilize roadbases.

~

~

I88

RECYCLE/REUSE & RECOVERY, CONTINUED

CASE STUDY 2 Dunbar Foods, Inc. processes canned peppers and sweet potatoes. The development of a spray irrigation land application system for their waste process water has allowed them to reuse the water for irrigation and fertilization and eliminate disposal in the municipal sewer system.

CASE STUDY 11 Florida Steel Corporation produces steel in two electric arc furnaces. Metal dust collected from the furnace fumes is sold to a zinc smelter for metal recovery. This practice has reduced their disposal costs by almost 50% and prevents burial of a valuable, recoverable resource.

CASE STUDY 22 A municipal waste sludge composting system is planned for the Hickory/Newton/Conover Complex in Catawba County, North Carolina. The facility is in the final design phase, and it is scheduled for construction in 1986. The reuse of waste sludge as composting material is expected to save the County as much as $827,000 annually in disposal costs.

CASE STUDY 6 IAC manufactures trace element compounds for use in fertilizer. By substituting suitable waste inorganic chemicals received from other firms for some of their virgin raw materials, they have been able to reduce their production costs and prevent the landfilling of useable material.

CASE STUDY 7 IC1 Americas, Inc. operates an agricultural chemical research and development lab in Goldsboro, N.C. A management initiative was undertaken in 1981 to form an Environmental Compliance Committee to review issues and activities at IC1 that impact on the environment . Emphasis is first on early planning to minimize waste production, second on attempting to recycle or treat the waste whenever possible so that there is zero discharge. The Committee's recommendations saved the Company an estimated $37,000 in waste disposal costs in 1984.

CASE STUDY 3 Miller Brewing Company generates waste activated sludge as a by- product O E their beer brewing operation. The treated sludge is made available for land application as a liming agent and nitrogen supplement. The reuse of this previously landfilled material has eliminated disposal costs for Miller and preserved valuable landfill capacity.

~

189

RECYCLE/REUSE & RECOVERY, CONTINUED

CASE STUDY 23 The municipal wastewater treatment facility in Morganton, North Carolina implemented the first full-scale sludge composting operation in the State. They purchase bark as a bulking material and compost the sludge using the static pile method. The compost is sold to the public, and the response has been so favorable the City has been uable to keep up with the demand. They have eliminated the need to landfill the waste sludge and have created ~

a system to reuse an otherwise undesirable material.

CASE STUDY 24 Natural Power is a small generator of electricity operating from the Gresham Lake Landfill in Raleigh, N.C. They have implemented a landfill gas recovery system for conversion of "biogas" to electric power, which is then sold to the local utility. The gas is collected, filtered and fed directly into two diesel generators modified to use a methane fuel source. Electrical energy generated at this source is metered and fed into the local power utility's transmission lines.

CASE STUDY 14 PCA International is a color portrait processing company. They have installed several new equipment systems which have allowed them to reuse large volumes of process water and process chemicals. A reverse osmosis water purification system allows 90% recycle of process water, and ion exchange columns used to remove excess bromide from color developer solution allows 99% reuse of the solution.

CASE STUDY 15 Rexham Corporation does high-tech printing and coating for photography industry at their Matthews, North Carolina facility. The segregation of waste toluene used for print and roller cleanup by color and type of ink contaminant has allowed almost 100% reuse of the solvent.

CASE STUDY 13 Stanadyne, Inc. is a manufacturer of plumbing products which require electroplating and cleaning operations that generate hazardous waste. The Company altered their nickel electroplating

rinsing step is begun. The dragout is returned to the plating tanks, which saves valuable chemicals and the treatment and disposal costs oE removing high metal concentrations from the rinse water. The recovered nickel saves Stanadyne $4200/year and

process so that dragout is captured in still tanks before the -_

~

reduces the nickel sludge volume generated by 9500 lbs/year. ~

190

Appendix

The Questionnaire Used I n Gathering Data For The Conpendium.

Proven P r o f i t - from Pol lut ion Prevention.

191

- Dear Respondent:

s i m i l a r types o f i n fo rma t ion f rom o ther i n d u s t r i a l f i rms, w i l l be used t o develop a conpendium o f case s tud ies t h a t w i l l i l l u s t r a t e t h e b e n e f i t s t o i n d u s t r i e s and t h e environment f rom t h e u t i l i z a t i o n o f p o l l u t i o n prevent ion approaches.

I n f i l l i n g out t h i s form, p lease add attachments i f more space i s needed and, where appl icable, p lease i n c l u d e tab les, photographs o r f l o w diagrams. I f t h e r e i s s e n s i t i v e i n fo rma t ion you would p r e f e r no t t o d ivu lge, we w i l l honor whatever l i m i t s o f c o n f i d e n t i a l i t y o r anonymity you des i re . I f you have any quest ions about any th ing r e l a t i n g t o t h i s p r o j e c t or t h i s quest ionnai re, p lease contact one o f us.

The in fo rma t ion requested i n t h i s quest ionnaire, a long w i t h

Dr . Don Huisingh (919)-737-2470 MS. Helene H i l g e r (704)-597-4175 Mr. Sven Thesen (919)-737-2479

1. Name o f Firm:

2. Contact Person:

4. Address: (p lease i n c l u d e county)

5. Telephone:

6. Type o f I ndus t r y :

7. Standard I n d u s t r i a l C l a s s i f i c a t i o n :

8. Length o f t ime t h e f i r m has been a t

9. Approximate number o f enployees:

3. T i t l e :

t s cu r ren t

10. Type o f P o l l u t i o n Prevent ion M o d i f i c a t i o n :

ocat ion: ,

11. I n a n a r r a t i v e and/or d i g r a m t i c form, con t ras t t h e p o l l u t i o n p reven t ion process w i t h t h e p rev ious l y used method.

192

12. Please complete the following table i n order t o compare the previous process t o the pol lut ion prevention process.

I METHOD PREVIOUSLY USED I POLLUTION PREVENTION METHOD

Raw Material I I

Water: Costs and Volumes

--

-------------------- Wastes Generated :

Hazardous and

Non-Hazardous

I Personne 11 Maintenance

193

12. P lease complete the f o l l o w i n g t a b l e in order t o compare the previous process t o t h e p o l l u t i o n prevent ion p r o c e s s . ( c o n t . )

------------------____________l___l___

I METHOD PREVIOUSLY USED I POLLUTION PREVENTION METHOD ---------------I -- -------

Qual i ty of I I

194

13. What were the capital costs of implementing the pollution prevention process?

a. Facilities:

b. Equipment:

14. What are the annual net cost savings and the payback period due to the new process?

15. What time was required to plan and implement the modification?

16. How have the following factors encouraged, inhibited, or otherwise influenced the implementation of the pollution prevention process?

a. Federal programslregulations: (including influences from KCKA, NPDES, OSHA, the Air Quality Act, etc.)

b. State environmental programslregulations:

C. Economic Factors:

d. Other Factors:

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17. Please list the cosultants and equipment suppliers needed to install the pollution prevention process.

18. Please provide any overall comments or recommendations about this particular modification that might be useful to others in this industry or related industries.

19. Does your firm have an incentive awards program that encourages employees to eubmit suggestions of additional pollution prevention approaches? If so, please describe your incentive awards program.

20. Are there any problem areas associated with your pollution prevention process that need to be addressed at the State or Federal level?

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21. Narrative Summary: Please summarize the general process(es), the description of the modification(s), and the rewards in terms of residues (wastes) not produced, raw materials not used, decreased environmental and human health risks, energy and money saved.

Please return this completed form to:

Dr. Don Huisingh Division of University Studies P.O. Box 7107 North Carolina State University Kaleigh N.C. 27695-7107 (919)-73 7-2470

Thank you for your valuable contribution to the POLLUTION PKEVENTION COMPENDIUM

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