Page
1
of
1
Memorandum
From:
Carey
A.
Johnston,
P.
E.
USEPA/
OW/
OST
ph:
(
202)
566
1014
johnston.
carey@
epa.
gov
To:
Public
Record
for
the
2006
Effluent
Guidelines
Program
Plan
EPA
Docket
Number
OW­
2004­
0032
(
www.
epa.
gov/
edockets/)

Date:
August
1,
2005
Re:
The
Impacts
of
Industrial
Water
Re­
Use
and
Reduction
Technologies
on
End­
Of­
Pipe
Pollutant
Concentrations
and
Loadings
The
following
memorandum
from
the
record
supporting
the
final
rule,
"
Streamlining
the
General
Pretreatment
Regulations
for
Existing
and
New
Sources
of
Pollution,"
EPA
Docket
Number:
OW­
2002­
0007,
is
incorporated
into
the
public
record
for
the
"
2006
Effluent
Guidelines
Program
Plan,"
EPA
Docket
Number:
OW­
2004­
0032.
This
memorandum
evaluates
the
impacts
of
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices
on
end­
of­
pipe
pollutant
concentrations
(
e.
g.,
mg/
L)
and
the
mass
of
wastewater
pollution
(
e.
g.,
pounds/
day)
in
discharged
industrial
wastewater.
This
memorandum
also
presents
case
studies
documenting
the
use
of
these
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices.
Page
1
of
49
Memorandum
From:
Carey
A.
Johnston,
P.
E.
USEPA/
OW/
OST
ph:
(
202)
566
1014
johnston.
carey@
epa.
gov
To:
Public
Record
for
the
Final
Rule:
Streamlining
the
General
Pretreatment
Regulations
for
Existing
and
New
Sources
of
Pollution
EPA
Docket
Number
OW­
2002­
0007
(
www.
epa.
gov/
edockets/)

Date:
June
3,
2005
Re:
The
Impacts
of
Industrial
Water
Re­
Use
and
Reduction
Technologies
on
End­
Of­
Pipe
Pollutant
Concentrations
and
Loadings
This
memorandum
evaluates
the
impacts
of
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices
on
end­
of­
pipe
pollutant
concentrations
(
e.
g.,
mg/
L)
and
the
mass
of
wastewater
pollution
(
e.
g.,
pounds/
day)
in
discharged
industrial
wastewater.
This
memorandum
also
presents
case
studies
documenting
the
use
of
these
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices.
The
memorandum
is
divided
into
three
sections:


Overview
of
Water
Conservation
and
Wastewater
Management;


Examples
of
Industrial
Pollution
Prevention
and
Water
Reduction
Technologies;
and

Case
Studies
of
Industrial
Pollution
Prevention
and
Water
Reduction
Technologies.

I.
Overview
of
Water
Conservation
and
Wastewater
Management
As
demonstrated
by
the
technology
descriptions
and
case
studies
presented
in
this
memorandum,
implementing
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices
can
reduce
the
amount
of
wastewater
pollution
discharged
by
industrial
facilities,
especially
for
those
facilities
that
have
on­
site
wastewater
treatment
systems.
Many
of
these
technologies
and
pollution
prevention
practices
can
also
reduce
the
amount
of
wastewater
pollution
discharged
by
industrial
facilities
that
do
not
have
on­
site
wastewater
treatment
systems.
In
general,
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices
fall
into
one
of
two
general
classes:


Technologies
and
pollution
prevention
practices
that
only
reduce
the
wastewater
volume
discharged
from
an
industrial
operation
(
i.
e.,
no
decrease
in
the
mass
of
wastewater
pollutants
resulting
from
an
industrial
operation);
and

Technologies
and
pollution
prevention
practices
that
reduce
the
amount
of
wastewater
volume
and
mass
of
wastewater
pollutants
resulting
from
an
industrial
operation.
1Eckenfelder,
W.
Wesley,
1989.
Industrial
Water
Pollution
Control,
McGraw­
Hill,
Inc.,
New
York,
New
York,
Page
60.

2Ibid.
Page
53.

Page
2
of
49
Technologies
and
pollution
prevention
practices
that
only
reduce
the
wastewater
volume
discharged
from
an
industrial
operation
There
are
a
number
of
technologies
and
pollution
prevention
practices
that
only
reduce
the
amount
of
wastewater
volume
discharged
from
industrial
operations.
Flow
reduction
can
offer
the
following
example
benefits:
(
1)
increased
pollutant
concentrations
to
on­
site
wastewater
treatment
systems
which
increase
the
efficiency
of
the
wastewater
treatment
system;
(
2)
decreased
wastewater
treatment
system
equipment
sizes,
resulting
in
reduced
treatment
system
capital
and
operating
and
maintenance
costs;
and
(
3)
decreased
water
and
energy
usage.
In
general,
there
is
an
economic
incentive
for
facilities
to
use
as
little
water
as
possible
in
their
industrial
operations.

Water
volume
reduction
technologies
and
practices
usually
increase
the
pollutant
concentrations
in
the
wastewater
resulting
from
the
industrial
operations
prior
to
wastewater
treatment
and
management.
For
facilities
with
on­
site
wastewater
treatment
systems,
the
combination
of
water
reduction
technologies
and
practices
and
well­
operated
wastewater
treatment
will
reduce
the
volume
and
mass
of
discharged
wastewater
pollution
(
i.
e.,
after
treatment).
This
is
due
to
the
fact
that
wastewater
treatment
technologies
operating
within
their
design
specifications
are
limited
solely
by
physical/
chemical
properties
of
the
pollutants
in
the
wastewater,
and
not
necessarily
by
influent
concentrations.
Increasing
influent
pollutant
concentrations
to
a
properly
designed
and
operated
wastewater
treatment
system
generally
leads
to
increased
wastewater
treatment
efficiency.
1
Consequently,
a
properly
managed
wastewater
treatment
system
operating
within
its
design
specifications
can
produce
a
consistent
effluent
despite
fluctuations
or
increases
in
influent
concentration.
For
example,
a
facility
might
discharge
100,000
liters
of
wastewater
per
day
to
a
treatment
system
that
treats
pollutant
X
to
10
milligrams/
liter.
The
post­
treatment
pollutant
loading
is
1,000
grams
per
day.
If
the
facility
reduces
flow
to
50,000
liters
per
day,
the
system
will
still
treat
pollutant
X
to
10
milligrams/
liter,
resulting
in
a
new
loading
of
500
grams
per
day.

The
assertion
that
decreasing
the
volume
of
wastewater
generated
from
industrial
operations
(
and
the
resulting
increase
in
influent
pollutant
concentrations)
leads
to
greater
efficiency
in
the
wastewater
treatment
system
is
well
documented
in
literature
and
supported
by
various
examples.
For
example,
the
performance
of
a
settling
tank
is
directly
related
to
its
overflow
rate
and
detention
time
which
in
turn
are
directly
related
to
the
size
of
the
settling
tank
and
the
rate
of
the
flow
through
the
settling
tank.
2
Lowering
the
flow
through
an
existing
settling
tank
will
increase
the
performance
of
the
settling
tank
(
i.
e.,
better
pollutant
removals).
Moreover,
wastewater
sampling
data
collected
for
many
EPA
effluent
guidelines
also
demonstrate
that
reducing
wastewater
flow
to
a
treatment
system
will
allow
the
system
to
more
successfully
treat
the
increased
pollutant
concentrations.
For
example,
information
supporting
the
Organic
Chemicals,
Plastics
and
Synthetic
Fibers
(
OCPSF)
point
source
category
effluent
guidelines
states:
3U.
S.
EPA,
1983.
Development
Document
for
Effluent
Limitations
and
Guidelines
and
Standards
for
the
Organic
Chemicals
and
Plastics
and
Synthetic
Fibers
Point
Source
Category,
EPA­
440­
1­
83­
009­
b,
Page
IX­
3,
February
1983.

4For
example,
the
January
2004
edition
(
Vol.
111,
No.
1)
of
Chemical
Engineering
highlighted
a
Dow
OCPSF
facility
in
Freeport,
Texas,
that
successfully
applied
water­
reuse
concepts
to
reduce
water
usage
and
wastewater
generation
(
Page
30­
41).

5For
example,
the
Shipley
Company
in
Marlborough,
MA
(
FRS
ID
No.
110000309522)
is
regulated
by
the
metal
finishing
effluent
guidelines
(
Part
433)
and
is
part
of
EPA's
Performance
Track
program.
This
facility
was
able
to
reduced
water
consumption
in
its
printed
wiring
board
and
other
metal
finishing
operations
via
water
conservation
from
8,870,000
to
3,610,000
gallons
(
in
one
year
2001
to
2002).

6For
example,
between
1997
and
2001,
Artistic
Plating
Company
in
Anaheim,
CA,
reduced
its
sludge
volume
by
40%
by
installing
flow
restrictors
and
conductivity
sensors.
Source:
U.
S.
EPA,
2004.
"
Sector
Strategies
Performance
Report,"
EPA
100­
R­
04­
002,
June
2004.

7See:
http://
www.
p2pays.
org/
water/
success.
htm.

8U.
S.
EPA
2000.
Final
Development
Document
For
Effluent
Limitations
Guidelines
and
Standards
for
the
Transportation
Equipment
Cleaning
Category,
EPA­
821­
R­
00­
012,
Page
7­
8,
June
2000.

Page
3
of
49
For
example,
a
good
activated
sludge
plant
will
usually
discharge
20
to
40
mg/
L
of
BOD
whether
the
influent
BOD
concentration
is
100
mg/
L
or
500
mg/
L,
if
the
plant
is
well
designed
and
the
design
loadings
are
not
exceeded.
Similarly,
activated
carbon
effluent
concentration
over
a
wide
range
of
influent
concentrations
as
long
as
the
contact
time
is
adequate
and
the
carbon
capacity
has
not
been
exhausted.
3
Reducing
water
use
will
also
reduce
costs
associated
with
water
use.
Numerous
examples
exist
in
the
literature
of
facilities
maintaining
or
increasing
their
production
and
their
efficiency
(
through
lower
production
costs)
through
use
of
water
conservation.
4
EPA's
Performance
Track
voluntary
initiative
program
also
documents
numerous
examples
of
facilities
demonstrating
compliance
with
concentration­
based
ELGs
and
significant
reductions
in
water
use.
5
Another
EPA
voluntary
program,
the
Strategic
Goals
Program,
also
highlight
successes
with
water
conservation,
compliance
with
concentration­
based
standards,
and
the
reduction
of
wastewater
pollution.
6
State
environmental
programs
are
also
documenting
water
conservation
success
in
voluntary
partnerships
with
industrial
facilities.
7
EPA's
effluent
guidelines
rulemakings
also
document
numerous
example
of
facilities
employing
water
conservation.
For
example,
data
gathered
for
the
Transportation
Equipment
Cleaning
point
source
category
effluent
guidelines
(
40
CFR
442)
show
that
approximately
45%
of
transportation
equipment
cleaning
facilities
practiced
flow
reduction/
water
conservation.
Flow
reduction
technologies
applicable
to
the
transportation
equipment
cleaning
industry
serve
to
reduce
the
amount
of
fresh
water
required
for
tank
cleaning
through
cleaning
process
modifications
and/
or
recycling
and
reusing
process
wastewaters
in
transportation
equipment
cleaning
or
other
operations.
8
9Eckenfelder,
1989.
Page
21.

10Cartwright,
Peter,
2005.
"
Process
Water
Supply
 
The
Big
Picture,"
Chemical
Engineering,
May
2005.

Page
4
of
49
EPA
can
directly
correlate
water
conservation
and
production
in
some
industrial
sectors.
In
such
cases
it
is
possible
to
directly
incorporate
water
conservation
into
the
calculation
of
production­
based
effluent
guidelines.
Specifically,
EPA
uses
a
production
normalized
flow
(
volume
of
wastewater/
unit
of
production)
and
the
concentration
of
the
regulated
pollutant
in
the
discharged
wastewater
that
corresponds
to
the
performance
of
BAT
or
BADT
technology
to
calculate
the
applicable
production
normalized
mass­
based
effluent
guidelines:

Production
normalized
mass­
based
ELGs
=
(
mass­
pollutant)/
production
unit)
BAT
or
BADT
pollutant
concentration
X
(
mass­
pollutant)/
vol.
discharged)
Production
normalized
flow
(
vol.
discharged/
production
unit)

Mass­
based
permit
limits
based
on
production
normalized
mass­
based
effluent
guidelines
are
different
from
mass­
based
permit
limits
based
on
concentration­
based
effluent
guidelines
in
that
the
permit
writer
must
identify
a
reasonable
measure
of
the
facility's
regulated
actual
long­
term
production,
and
not
facility
flow,
in
order
to
convert
production
normalized
mass­
based
effluent
guidelines
to
mass­
based
permit
limits.

Technologies
and
pollution
prevention
practices
that
reduce
the
amount
of
wastewater
volume
and
mass
of
wastewater
pollutants
resulting
from
an
industrial
operation
Many
of
the
water
re­
use
and
reduction
technologies
and
pollution
prevention
practices
allow
for
chemical
recovery
and
reuse,
thereby
reducing
both
the
flow
and
the
pollutant
concentrations
and
loadings.
In
some
cases,
these
technologies
eliminate
the
generation
of
wastewater
altogether.
These
technologies
will
reduce
the
amount
of
discharged
wastewater
pollution
regardless
of
whether
or
not
a
facility
has
a
wastewater
treatment
system
on
site.
There
are
many
industrial
applications
of
this
type
of
water
re­
use
and
reduction
technologies.
9
Industry
Trends
in
Water
Conservation
The
main
incentives
for
industry
to
reduce
or
eliminate
water
use
and
the
related
wastewater
generation
include
water
source
restrictions
(
e.
g.,
drought
or
other
limitations
on
the
water
supply)
and
economics
(
e.
g.,
lower
water
consumption
leads
to
lower
costs
as
a
result
of
less
water
usage
and
potential
less
sludge
generation
and
disposal
costs).
For
most
of
the
industrial
era,
water
has
been
viewed
as
a
free
or
very
low­
cost
commodity
and
until
recently
industries
have
tended
to
be
very
poor
stewards
of
water
conservation.
10
This
perception
of
a
plentiful
resource
is
rapidly
changing,
however,
as
communities
across
the
country
begin
to
face
water
supply
limitations.
Awareness
of
this
issue
is
heightened
as
a
result
of
recent
developments
such
as:
(
1)
widespread
drought;
(
2)
increasingly
strict
standards
for
both
withdrawal
and
discharge
of
water;
(
3)
more
rigorously
enforced
water
rights
limitations;
and
(
4)
increasing
water
11U.
S.
DOE,
2003.
"
Water
Use
in
Industries
of
the
Future,"
http://
www.
oit.
doe.
gov/
pdfs/
100903_
news.
pdf,
July
2003.

12National
Science
and
Technology
Council,
2004.
"
Science
and
Technology
To
Support
Fresh
Water
Availability
In
the
United
States,
http://
www.
ostp.
gov/
nstc/
html/
swaqreport_
2­
1­
05.
pdf,
November
2004.

13Hinrichsen,
Don,
2004.
Water
Pressure,
National
Wildlife,
http://
www.
nwf.
org/
nationalwildlife/
article.
cfm?
articleId=
928&
issueId=
69,
Vol.
42,
No.
5,
Aug/
Sep
2004.

14GAO,
2004.
"
Freashwater
Supply:
States'
Views
of
How
Federal
Agencies
Could
Help
Them
Meet
the
Challenges
of
Expected
Shortages,"
GAO­
03­
514,
July
2003.

15See
http://
www.
worldwatercouncil.
org/.

16Seidel,
Andrew,
2002.
"
Turbulent
Waters,"
Environmental
Protection,
Vol.
13,
No.
1,
Page
26,
January
2002.

Page
5
of
49
demands
of
urban
populations.
11
Water
supply
shortfalls
have
become
increasingly
severe
during
drought
periods
 
raising
the
costs
of
water
access
and
threatening
the
integrity
of
aquatic
systems.
As
demand
for
limited
water
supplies
increase,
the
need
for
economic
efficiency
in
water
storage,
delivery,
treatment,
and
use
becomes
more
critical.
12
The
need
to
measure,
control,
and
record
water
usage,
neglected
in
the
past,
is
starting
to
be
addressed.
Industry,
a
significant
user
of
water,
is
becoming
aware
of
the
importance
of
measuring
and
managing
water
use.
Energy­
intensive
industries,
especially,
are
finding
water
scarcity
to
be
a
limit
to
growth.
The
U.
S.
Geological
Survey
(
USGS)
reported
in
2004
that
the
nation
withdrew
408
billion
gallons
of
freshwater
every
day
from
surface
and
groundwater,
about
a
2
percent
decrease
from
1990
and
a
10
percent
drop
compared
to
1980.
Nationwide,
per
capita
water
use
has
dropped
25
percent
from
its
peak
in
the
1970s.
As
might
be
expected,
water
conservation
drives
this
trend
as
"
the
downward
trend
in
water
withdrawals
is
a
function
of
widespread
water
conservation
measures,
especially
in
industry
and
municipalities
and
to
a
lesser
extent
in
agriculture."
13
Additionally,
a
recent
GAO
survey
of
state
water
managers
indicated
that,
even
under
normal
or
non­
drought
water
conditions,
36
states
anticipate
water
shortages
in
localities,
regions
or
statewide
within
the
next
10
years.
Under
drought
conditions
46
states
expect
shortages
over
the
next
decade.
14
Finally,
the
World
Water
Council15
predicts
that
between
1995
and
2025,
U.
S.
residential
water
consumption
will
increase
100
percent,
while
industrial
water
use
will
increase
by
33
percent.
As
water
costs
increase
and
supplies
dwindle,
more
and
more
industries
are
turning
to
high­
tech
water
treatment
systems
that
recycle
and
reuse
water
within
plant
production
processes.
16
II.
Examples
of
Industrial
Pollution
Prevention
and
Water
Reduction
Technologies
Many
industrial
pollution
prevention
and
water
reduction
technologies
are
currently
in
use
across
the
United
States.
This
section
focuses
on
common
technologies
found
in
the
Metal
Finishing
(
MF)
and
Metal
Products
and
Machinery
(
MP&
M)
industries,
and
describes
how
these
technologies
reduce
water
usage
and
pollutant
discharge
concentrations.
This
section
discusses
some
examples
of
these
technologies
by
the
two
classifications
listed
in
Section
I
of
this
memorandum.
Page
6
of
49
Technologies
and
pollution
prevention
practices
that
only
reduce
the
amount
of
wastewater
volume
generated
by
the
industrial
operation
MF
facilities
apply
flow
reduction
practices
to
process
baths
or
rinses
to
reduce
the
volume
of
wastewater
discharged.
Flow
reduction
practices
consist
of
optimizing
rinse
tank
design
and
configuration,
and
installing
flow
reduction
technologies
such
as
flow
restrictors
or
timers.
These
technologies
tend
to
reduce
wastewater
flow
and
increase
pollutant
concentrations;
however,
after
consideration
of
end­
of­
pipe
wastewater
treatment
these
technologies
will
also
reduce
the
amount
of
discharged
wastewater
pollution.
The
following
subsections
discuss
these
flow
reduction
practices
in
greater
detail.

Rinse
Tank
Design
and
Innovative
Configurations
Rinsing
follows
many
MF
operations
to
remove
dirt,
oil,
or
chemicals
remaining
on
parts
or
racks
from
a
previous
unit
operation.
In
general,
rinses
generate
the
most
wastewater
flow
at
MF
facilities.
Rinsing
improves
the
quality
of
the
surface
finishing
process
and
prevents
the
contamination
of
subsequent
process
baths.
Rinse
tank
design
and
rinsing
configuration
greatly
influence
water
usage.
The
key
objectives
of
optimal
rinse
tank
design
are
to
quickly
remove
drag­
out
solution
from
the
part
and
to
disperse
the
drag­
out
throughout
the
rinse
tank.

MF
facilities
uses
various
rinsing
configurations.
The
most
common
are
countercurrent
cascade
rinsing,
drag­
out
rinsing,
and
spray
rinsing.

Cascade
Rinsing.
Cascade
rinsing
is
a
method
of
reusing
water
from
one
rinsing
operation
to
another,
less
critical
rinsing
operation
before
being
discharged
to
treatment.
Some
rinse
waters
acquire
chemical
properties,
such
as
low
pH,
that
make
them
desirable
for
reuse
in
other
rinse
systems.
For
example,
water
from
an
acid
treatment
rinse
may
be
reused
in
an
alkaline
treatment
rinse.
In
this
case,
the
rinse
water
both
removes
drag­
out
from
the
work
piece
and
neutralizes
the
drag­
out.

Countercurrent
Cascade
Rinsing.
Countercurrent
cascade
rinsing
refers
to
a
series
of
consecutive
rinse
tanks
that
are
plumbed
to
cause
water
to
flow
from
one
tank
to
another
in
the
direction
opposite
of
the
work
flow.
Fresh
water
flows
into
the
rinse
tank
located
farthest
from
the
process
tank
and
overflows
(
i.
e.,
cascades)
into
the
rinse
tank
that
is
closest
to
the
process
tank.
Over
time,
the
first
rinse
becomes
contaminated
with
drag­
out
solutions
and
reaches
a
stable
concentration
of
process
bath
constituents
that
is
lower
than
the
concentration
in
the
process
bath.
The
second
rinse
stabilizes
at
a
lower
concentration,
which
enables
less
rinse
water
to
be
used
than
if
only
one
rinse
tank
were
in
place.
The
more
countercurrent
cascade
rinse
tanks
(
three­
stage,
four­
stage,
etc.),
the
less
rinse
water
is
needed
to
adequately
remove
the
process
solution.
This
differs
from
a
single,
overflow
rinse
tank
where
the
rinse
water
is
composed
of
fresh
water
that
is
discharged
without
any
recycle
or
reuse.
Under
complete
mixing
conditions,
each
additional
rinse
stage
can
reduce
rinse
water
use
by
90
percent.
Page
7
of
49
Flow
Reduction
Technologies
Facilities
can
reduce
water
use
by
coordinating
and
closely
monitoring
rinse
water
requirements
(
e.
g.,
rinse
water
use
is
optimized
based
on
drag­
out
rates
so
that
the
rinse
quality
is
consistent).
Matching
water
use
to
rinse
water
requirements
optimizes
the
quantity
of
rinse
water
used
for
a
given
work
load
and
tank
arrangement.

Many
MF
facilities
use
some
form
of
rinse
water
control.
Three
common
methods
are
flow
restrictors
(
these
can
be
used
with
other
methods
to
regulate
the
rate
at
which
water
is
dispensed),
conductivity
controls,
and
timer
rinse
controls.
These
are
discussed
below.

Flow
Restrictors.
A
flow
restrictor
prevents
the
flow
in
a
pipe
from
exceeding
a
predetermined
flow
rate.
Flow
restrictors
are
commonly
installed
on
a
rinse
tank's
water
inlet.
These
devices
contain
an
elastomer
washer
that
flexes
under
pressure
to
maintain
a
constant
water
flow
regardless
of
pressure.

Conductivity
Controllers.
Conductivity
controllers
use
conductivity
probes
to
measure
the
conductivity
(
total
dissolved
solids
(
TDS))
of
water
in
a
rinse
tank
to
regulate
the
flow
of
fresh
rinse
water
into
the
rinse
system.
Conductivity
controllers
consist
of
a
controller,
a
meter
with
adjustable
set
points,
a
probe
that
is
placed
in
the
rinse
tank,
and
a
solenoid
valve.
As
parts
are
rinsed,
dissolved
solids
enter
the
water
in
the
rinse
tank,
raising
the
conductivity
of
the
water.
When
conductivity
reaches
a
set
point
where
the
water
can
no
longer
provide
effective
rinsing,
the
solenoid
valve
opens
to
allow
fresh
water
to
enter
the
tank.
When
the
conductivity
falls
below
the
set
point,
the
valve
closes
to
discontinue
the
fresh
water
flow.

Rinse
Timers.
Rinse
timers
are
electronic
devices
that
control
a
solenoid
valve.
The
timer
usually
consists
of
a
button
that,
when
pressed,
opens
the
valve
for
a
predetermined
time
period,
usually
from
1
to
99
minutes.
After
the
time
period
has
expired,
the
valve
automatically
closes.
The
timer
may
be
activated
either
manually
by
the
operator
or
automatically
by
the
action
of
racks
or
hoists.
Rinse
timers
installed
in
conjunction
with
flow
restrictors
can
provide
precise
control
when
the
incoming
water
pressure
may
rise
and
fall.

By
using
a
combination
of
optimized
rinse
tank
designs
and
flow
reduction
technologies,
the
MF
industry
is
able
to
reduce
the
volume
of
rinse
water
required.
Options
such
as
using
dragout
tanks
in
conjunction
with
counter­
current
cascade
rinsing
also
help
to
reduce
the
concentration
of
pollutants
that
are
discharged
from
the
rinse.

Technologies
and
pollution
prevention
practices
that
reduce
the
amount
of
wastewater
volume
and
wastewater
pollution
generated
by
an
industrial
operation
Facilities
also
can
implement
several
technologies
or
practices
that
will
either
reduce
or
prevent
pollution
from
processes
or
recover
pollutants
for
re­
use.
These
technologies
will
reduce
both
wastewater
discharge
rates
and
pollutant
concentrations
and
loadings
at
the
process
level.
Page
8
of
49
Modify
Process
Bath
Operating
Parameters
Facilities
can
modify
process
bath
operating
parameters
to
reduce
drag­
out.
Examples
of
these
practices
are
increasing
bath
temperature,
operating
at
lower
batch
concentration,
and
using
wetting
agents,
as
discussed
below:


Temperature
and
viscosity
are
inversely
related;
therefore,
operating
a
bath
at
the
highest
possible
temperature
will
lower
process
bath
viscosity
and
reduce
drag­
out.


Operating
at
the
lowest
possible
concentration
reduces
the
mass
of
chemicals
in
a
given
volume
of
drag­
out.
Also,
viscosity
and
concentration
are
directly
related;
therefore,
lower
process
bath
concentration
will
result
in
lower
process
bath
viscosity
and
less
drag­
out
volume.


Adding
wetting
agents
or
surfactants
to
some
process
baths
reduces
viscosity
and
surface
tension,
thereby
significantly
reducing
drag­
out.

Drag­
out
Recover
Rinsing
A
drag­
out
rinse
is
a
stagnant
rinse,
initially
filled
with
fresh
water,
positioned
immediately
after
the
process
tank.
Work
pieces
are
rinsed
in
drag­
out
tanks
directly
after
exiting
the
process
bath.
The
drag­
out
rinse
collects
most
of
the
drag­
out
from
the
process
tank,
thus
preventing
it
from
entering
the
subsequent
flowing
rinses
and
reducing
the
amount
of
wastewater
pollution
in
those
rinses.
Gradually,
the
concentration
of
process
chemicals
in
the
drag­
out
tank
rises.
In
the
most
efficient
configuration,
a
drag­
out
tank
follows
a
heated
process
tank
that
has
a
moderate
to
high
evaporation
rate.
A
portion
of
the
fluid
in
the
drag­
out
tank
returns
to
the
process
tank
to
replace
the
evaporative
loss.
The
level
of
fluid
in
the
drag­
out
tank
is
maintained
by
adding
fresh
water.
Electrolytic
recovery,
discussed
below,
is
commonly
used
to
remove
dissolved
metals
from
drag­
out
tanks.

In­
Process
Pollution
Prevention
Technologies
This
section
describes
several
in­
process
pollution
prevention
technologies
used
to
reduce
the
amount
of
wastewater
pollution
to
the
wastewater
treatment
system.
Process
baths
become
contaminated
with
impurities
that
affect
their
performance.
If
not
properly
maintained,
process
baths
become
prematurely
unusable
and
require
disposal.
Regeneration
and
maintenance
techniques
help
keep
baths
in
good
operating
condition,
thereby
extending
the
useful
lives
of
process
solutions.
Using
these
technologies
reduces
the
frequency
of
process
bath
discharges,
and
therefore
reduces
the
amount
of
wastewater
pollution
to
the
wastewater
treatment
system.
This,
in
turn,
reduces
wastewater
treatment
requirements
and
sludge
disposal
costs.

This
section
describes
the
following
technologies
used
to
treat
and
reuse
process
solutions:


Centrifugation
and
pasteurization
of
machining
coolants;


Centrifugation
and
recycling
of
painting
water
curtains;
Page
9
of
49

Electrodialysis;


Electrolytic
recovery;


Evaporation;


Ion
exchange;
and

Reverse
osmosis.

Centrifugation
and
Pasteurization
of
Machining
Coolants.
Most
machining
coolants
contain
water­
soluble
oil
in
water.
The
water­
soluble
coolant
typically
is
pumped
from
a
sump,
over
the
machining
tool
and
work
piece
during
machining,
and
back
to
the
sump.
Using
a
centrifugal
separator
and
pasteurization
unit
can
extend
the
useful
life
of
machining
coolants.
The
separator
is
a
rotating
chamber
that
uses
centrifugal
force
to
push
the
coolant
through
a
mesh
chamber,
leaving
behind
solid
contaminants
of
sludge.
Sludge
is
scraped
from
the
centrifuge
and
collected
in
a
sludge
hopper.
Some
high­
speed
centrifuges
also
can
perform
liquid­
liquid
separation
to
remove
tramp
oils.
The
coolant
undergoes
pasteurization
after
separation
to
kill
the
microorganisms
that
cause
bacterial
growth.
Adding
a
biocide
can
also
control
bacterial
growth.

Centrifugation
and
pasteurization
can
be
used
in
conjunction
with
oil
skimming
and
biocide
addition
to
reduce
coolant
discharge
and
pollutant
generation
at
the
source.
Oil
skimming
using
a
vertical
belt
system
(
described
below)
removes
large
amounts
of
tramp
hydraulic
oils
floating
on
the
surface
of
the
machine
coolant.
Oil
skimming
and
biocide
addition
can
further
extend
the
life
of
water­
soluble
coolant,
thereby
reducing
the
amount
of
coolant
and
wastewater
requiring
treatment
and
disposal,
and
minimizing
fresh
coolant
requirements.

Centrifugation
and
Recycling
of
Painting
Water
Curtains.
Water
curtains
are
a
continuous
flow
of
water
behind
the
work
piece
being
spray
painted
in
a
paint
booth.
The
water
traps
paint
overspray
and
is
continuously
recirculated
in
the
paint
curtain
until
the
solids
content
in
the
wastewater
necessitates
either
in­
process
treatment
and
recycling
or
discharge.

Wastewater
from
painting
water
curtains
commonly
contains
organic
pollutants
as
well
as
certain
metals.
Eliminating
the
discharge
of
wastewater
from
painting
water
curtains
may
eliminate
the
need
for
an
end­
of­
pipe
treatment
step
for
organic
pollutants
at
certain
facilities.
Moreover,
if
a
facility
uses
only
painting
water
curtains
and
continuously
recycles
the
water,
the
facility
would
not
need
end­
of­
pipe
wastewater
treatment.

Centrifugal
separators
remove
the
solids
and
recycle
the
water
curtain,
eliminating
the
need
for
discharge.
This
system
can
recycle,
the
paint
curtain
water
continuously.
The
system
pumps
the
water
curtain
from
the
paint
curtain
sump
to
a
holding
tank,
then
through
the
centrifugal
separator,
which
separates
the
solids
from
the
wastewater.
Solids
from
the
centrifuge
are
hauled
for
off­
site
disposal,
while
the
treated
wastewater
is
returned
to
the
paint
booth.
Centrifugation
of
the
paint
curtain
proceeds
until
all
wastewater
is
treated
and
only
sludge
remains
in
the
paint
curtain
sump.
Make­
up
water
is
added
to
the
system
to
compensate
for
evaporation.

Electrodialysis.
Electrodialysis
is
a
process
in
which
dissolved
colloidal
species
are
exchanged
between
two
liquids
through
selective
semipermeable
membranes.
The
technology
applies
a
direct
current
across
a
series
of
alternating
anion
and
cation
exchange
membranes
to
remove
dissolved
metal
salts
and
other
ionic
constituents
from
solutions.
Facilities
typically
use
Page
10
of
49
electrodialysis
to
remove
metal
ions
from
electroplating
wastewater.
By
using
the
electrodialysis
cell,
facilities
remove
impurities
from
the
process
bath,
extending
its
life.
Facilities
can
treat
the
removed
concentrate
stream
on­
site,
or
haul
it
off­
site
for
disposal,
treatment,
or
metals
reclamation.

Electrolytic
Recovery.
Electrolytic
recovery
is
an
electrochemical
process
used
to
recover
metal
contaminants
from
many
types
of
process
solutions
and
rinses,
such
as
electroplating
rinse
waters
and
baths.
Electrolytic
recovery
removes
metal
ions
from
a
waste
stream
by
processing
the
stream
in
an
electrolytic
cell,
which
consists
of
a
closely
spaced
anode
and
cathode.
Facilities
typically
apply
electrolytic
recovery
to
solutions
containing
either
nickel,
copper,
precious
metals,
or
cadmium.
Drag­
out
rinses
and
ion­
exchange
regenerant
are
solutions
that
commonly
are
processed
using
electrolytic
recovery.
Some
solutions
require
pH
adjustment
prior
to
electrolytic
recovery.
The
recovered
metals
may
then
be
used
to
"
feed"
the
plating
baths
or
may
be
recovered
for
profit.

Evaporation.
Evaporation
is
a
volume
reduction
and
water
recovery
technology
applicable
when
raw
water
costs
are
high
or
discharge
to
either
a
receiving
stream
or
the
local
sewerage
district
is
not
permitted.
Evaporators
have
the
potential
to
recover
95
percent
of
the
water
in
a
waste
stream
for
reuse
in
the
process.
MF
facilities
use
two
basic
types
of
evaporators:
atmospheric
and
vacuum.
Atmospheric
evaporators
are
more
prevalent
and
are
relatively
inexpensive
to
purchase
and
easy
to
operate.
Vacuum
evaporators
are
mechanically
more
sophisticated
and
are
more
energy­
efficient.
Facilities
typically
use
vacuum
evaporators
when
evaporation
rates
greater
than
50
to
70
gallons
per
hour
are
required.
MF
facilities
use
evaporators
to
recover
metals
from
ion
exchange
regenerates,
to
reduce
the
volume
of
oily
wastes
that
require
off­
site
transfer,
and
to
recover
and
reuse
rinse
water
from
plating
operations.
Residue
from
evaporators
can
be
recycled
if
sufficiently
pure,
disposed
of
off­
site,
or
used
for
energy
recovery
if
the
material
has
a
sufficient
BTU
content.

Ion
Exchange.
Ion
exchange
is
a
commonly
used
technology
within
MF
facilities.
In
addition
to
water
recycling
and
chemical
recovery
applications,
ion
exchange
is
used
to
soften
or
deionize
raw
water
for
process
solutions.
Ion
exchange
is
a
reversible
chemical
reaction
that
exchanges
ions
in
a
feed
stream
for
ions
of
like
charge
on
the
surface
of
an
ion­
exchange
resin.

MF
facilities
use
ion
exchange
for
water
recycling
and
metal
recovery.
Many
process
wastewaters
are
excellent
candidates
for
ion
exchange,
including
the
rinse
water
from
plating
processes
of
chromium,
copper,
cadmium,
gold,
lead,
nickel,
tin,
tin­
lead,
and
zinc.
Ion
exchange
resins
usually
are
regenerated
using
inexpensive
chemicals
such
as
sulfuric
acid
and
sodium
hydroxide.
Cyanide
rinse
waters
are
amenable
to
ion
exchange;
cation
resins
can
break
the
metalcyanide
complex
and
the
cyanide
is
removed
in
the
anion
column.
The
metals
in
the
cation
regenerant
can
be
recovered
electrolytically
and
the
cyanide
present
in
the
anion
regenerant
can
be
returned
to
the
process
or
discharged
to
treatment.

Reverse
Osmosis.
Reverse
osmosis
is
a
membrane
separation
technology
used
by
MF
facilities
for
chemical
recovery
and
water
recycling.
The
system
pumps
dilute
rinse
water
to
the
surface
of
the
reverse
osmosis
membrane
at
pressures
of
400
to
1,000
pounds
per
square
inch
gauge
(
psig).
The
membrane
separates
the
feed
stream
into
a
reject
stream
and
a
permeate.
The
17U.
S.
EPA,
2004,
"
Sector
Strategies
Performance
Report,"
EPA
100­
R­
04­
002,
http://
www.
epa.
gov/
sectors/
pdf/
performancebw.
pdf,
June
2004.

Page
11
of
49
reject
stream,
containing
most
of
the
dissolved
solids
in
the
feed
stream,
is
retained
by
the
membrane
while
the
permeate
passes
through.
The
permeate
stream
usually
is
of
sufficient
quality
to
be
recycled
as
rinse
water,
despite
the
small
percentage
of
monovalent
ions
(
commonly
potassium,
sodium
and
chloride)
that
pass
through
the
membrane.

A
sufficiently
concentrated
reject
stream
can
be
returned
directly
to
the
process
bath.
Recycling
the
stream
through
the
unit
more
than
once
or
increasing
the
feed
pressure
can
increase
the
reject
stream
concentration.
In
multiple­
stage
units
containing
more
than
one
membrane
chamber,
the
reject
stream
from
the
first
chamber
is
routed
to
the
second,
and
so
on.
The
combined
reject
streams
from
multistage
units
may,
in
some
cases,
have
high
enough
concentrations
to
go
directly
back
to
the
bath.
Reverse
osmosis
is
most
applicable
to
electroplating
rinse
waters,
including
electroplating
of
Watts
nickel,
bright
nickel,
brass
cyanide,
copper
cyanide,
and
zinc
cyanide.

III.
Case
Studies
of
Industrial
Pollution
Prevention
and
Water
Reduction
Technologies
The
following
section
highlights
several
case
studies
and
studies
of
industrial
applications
of
the
technologies
identified
above.
These
case
studies
cover
the
following
industries:
MF
and
MP&
M;
Chemicals
Manufacturing;
Pesticides
Manufacturing;
Pharmaceuticals
Manufacturing;
and
Petroleum
Refining.
Each
of
these
facilities
are
regulated
by
concentration­
based
effluent
guidelines
or
are
required
to
convert
concentration­
based
standards
to
mass­
based
standards
by
the
facility's
flow.
This
memorandum
also
includes
case
studies
from
facilities
located
outside
of
the
United
States.
Note
that
the
case
studies
vary
in
length
and
detail
based
on
the
information
provided
by
each
of
the
referenced
data
sources.

Case
Studies
of
the
MF
and
MP&
M
Industries
Numerous
examples
exist
of
metal
finishing
facilities
complying
with
their
concentrationbased
effluent
guidelines
standards,
reducing
water
consumption,
and
generating
less
wastewater
volumes
and
pollution
amounts
(
e.
g.,
pounds
per
day).
EPA's
voluntary
initiative
program,
the
Strategic
Goals
Program,
tracked
some
of
these
success
in
this
industrial
sector.
Between
1998
and
2002,
more
than
500
metal
finishers,
20
states,
and
80
local
regulatory
agencies
(
primarily
publicly
owned
treatment
works)
participated
with
EPA
in
the
Strategic
Goals
Program.
Participating
metal
finishers
pursued
facility­
specific
environmental
targets
for
resource
inputs
and
waste
outputs,
including:
(
1)
25%
reduction
in
energy
use;
(
2)
50%
reduction
in
water
use;
(
3)
50%
reduction
in
land
disposal
of
hazardous
sludge;
(
4)
50%
reduction
in
emissions
of
metals
to
water;
and
(
6)
90%
reduction
in
organic
chemical
releases
reported
to
EPA's
Toxics
Release
Inventory
(
TRI).
17
An
independent
third­
party,
the
National
Center
for
Manufacturing
Sciences,
tracked
the
progress
of
150
participating
metal
finishers
that
consistently
reported
their
environmental
progress.
Through
2001,
cumulative
improvements
for
these
facilities
included:
(
1)
7%
reduction
in
energy
use;
(
2)
38%
reduction
in
water
use;
(
3)
23%
reduction
in
land
disposal
of
hazardous
18Ibid,
Page
32.

19Ibid,
Page
34.

Page
12
of
49
sludge;
(
4)
62%
reduction
in
emissions
of
metals
to
water;
and
(
5)
62%
reduction
in
organic
chemical
releases
reported
to
TRI.
18
In
many
cases,
metal
finishers
implemented
more
effective
and
efficient
rinsing
techniques,
such
as
concurrent
flow
rinsing,
which
reduce
the
need
to
treat
and
dispose
of
plating
baths.
These
techniques
result
in
less
water
use,
less
chemical
use,
and
less
sludge
generation.
The
findings
from
this
voluntary
industry
program
fully
document
that,
"
Water
use
and
sludge
generation
go
hand­
in­
hand
for
the
metal
finishing
industry.
Reducing
water
use
at
metal
finishing
facilities
can
reduce
sludge
generation
and
allow
wastewater
treatment
systems
to
more
successfully
treat
the
wastewater."
19
Harley­
Davidson
Motor
Company
(
York,
PA)
http://
www.
dep.
state.
pa.
us/
dep/
deputate/
polycomm/
update/
09­
20­
96/
09209605.
htm
Pollution
prevention
is
an
organized,
comprehensive,
continual
effort
to
reduce
or
eliminate
pollution
and
wastes
at
their
source.
Using
this
philosophy
and
a
zero­
discharge
goal,
Harley­
Davidson
installed
a
new
nickel/
chrome
plating
machine
in
1995.
Full
production
began
last
November.
Since
November,
re­
use
of
water
in
the
plating
operation
has
resulted
in
a
75
percent
decrease
in
the
amount
of
city
water
used.
Control
of
rinse
water
flows
and
re­
use
of
rinses
has
resulted
in
a
60
percent
drop
in
average
daily
flow
to
the
on­
site
industrial
wastewater
treatment
system.
Hazardous
wastes
shipped
off­
site
for
treatment
and
disposal
have
been
reduced
by
80
percent
­
a
45,000
gallon
reduction.
Many
of
these
wastes
are
generated
during
wastewater
treatment;
therefore,
a
reduction
in
waste
generation
indicates
a
reduction
in
pollutant
loading
from
the
facility.
Installation
of
a
three­
scrubber
system
to
control
air
emissions
translates
into
reduced
discharges
into
the
atmosphere
and,
therefore,
cleaner
air.

Hyde
Manufacturing
Corporation
(
Southbridge,
MA)
http://
www.
state.
ma.
us/
ota/
cases/
hyde.
htm
Quench
Oil
Recycling
at
Hyde
Manufacturing
Corporation
Summary
Hyde
Tools,
a
division
of
Hyde
Manufacturing
Corp.,
installed
a
filtration
system
to
recycle
the
quench
oils
used
in
its
heat
treating
process.
This
system
reduced
the
firm's
water
consumption,
cut
back
on
testing
and
permitting
costs,
and
eliminated
the
need
for
out­
of­
house
reclamation
of
quench
oils.
The
project
cost
$
25,805
to
implement,
and
it
yielded
a
favorable
net
present
value
in
excess
of
$
15,000
over
its
ten­
year
economic
lifetime.
Page
13
of
49
Background
Hyde
Tools
of
Southbridge,
Massachusetts
is
a
300­
employee
firm
with
two
lines
of
products:
an
industrial
tool
line
featuring
machine
blades,
saw
blanks
and
hand
knives;
and
a
trade
line
of
knives,
scrapers
and
other
surface
preparation
tools
designed
for
do­
it­
yourself
home
improvement
projects.

Hyde's
knife
and
scraper
blades
are
stamped
out
of
high­
carbon
steel,
sent
through
a
vibratory
degreaser,
loaded
into
racks,
then
propelled
via
robotics
through
a
heat
treatment
process.
In
the
heat
treatment
process,
the
blades
are
submerged
in
a
molten
salt
tank
at
temperatures
ranging
from
1600
to
1800
degrees,
then
plunged
into
a
500­
gallon
tank
of
quench
oil.
The
quench
oil
is
removed
from
the
parts
in
a
wash
tank
and
two
rinse
tanks.
The
blades
are
then
ground
and
polished,
and
the
tools
are
assembled,
packaged
and
shipped.

Prior
to
the
implementation
of
in­
house
quench
oil
recycling,
the
heat
treatment
process
generated
approximately
12
drums
of
oily
water
every
six
weeks.
These
were
sent
out
for
reclamation
and
water
removal.

In
1988,
the
firm
instituted
a
systematic
plan
to
attain
zero
discharge
of
water
pollution
within
three
to
five
years.
At
that
time,
company
management
realized
that
eliminating
the
use
of
toxic
chemicals
in
Hyde's
processes
would
not
only
be
cost­
effective,
but
would
also
help
ensure
the
health
and
safety
of
workers
and
the
public,
while
guaranteeing
that
the
firm
would
exceed
compliance
requirements.

With
the
help
of
plant
engineers,
Hyde
Environmental
Manager
Douglas
DeVries
drafted
a
plan
for
attainment
of
the
zero
discharge
goal.
DeVries
decided
to
deal
first
with
discharge
from
the
heat
treatment
process.
After
considerable
analysis,
he
determined
that
in­
process
recycling
was
the
answer.

After
collecting
and
reviewing
proposals
from
various
vendors
of
filtration
and
wastewater
recycling
systems,
DeVries
chose
a
filtration
model
capable
of
recycling
the
wash
and
rinse
water
as
well
as
the
quench
oil.
The
new
system
is
composed
of
a
transfer
pump,
a
bag
filter
for
capturing
excess
dirt,
and
two
heated
cone­
bottom
reclamation
tanks
in
which
suspended
solids
and
water
can
be
separated
from
the
quench
oil.
This
new
system
eliminates
the
need
to
pump
oil
into
drums
and
send
them
out
for
reclamation,
reduces
the
total
cost
of
reclaiming
quench
oils,
and
conserves
wash
and
rinse
waters
by
filtering
and
recirculating
them.

The
purchase
cost
of
Hyde's
oil
recycling
system
was
$
20,055.
The
vendor
trained
Hyde
employees
to
use
and
monitor
the
system
at
no
additional
cost.
In­
house
installation
costs
amounted
to
approximately
$
5,000.

Results
Reductions
Achieved:
Hyde
was
able
to
reduce
the
amount
of
oil
sent
off
site
for
reclamation
by
1,730
gallons
per
year.
The
project
also
reduced
water
usage
in
the
wash
process
by
19,200
gallons
per
year.
Page
14
of
49
Economics:
Purchase
and
installation
costs
for
Hyde's
new
filtration
and
recycling
system
totaled
$
25,055.
Hyde
also
installed
an
alarm
system
that
automatically
shuts
off
the
unit's
pump
when
the
oil/
water
combination
in
the
sump
nears
capacity.
The
purchase
and
installation
cost
of
this
safety
system
was
$
750,
bringing
the
total
up­
front
cost
to
$
25,805.

The
new
system
has
reduced
Hyde's
purchases
of
quench
oil
by
$
4,844
every
year.
In
addition,
Hyde
saves
$
8,760
in
water
bills,
$
4,200
in
NPDES
permits
and
$
300
in
laboratory
testing
costs
each
year.
The
only
new
expenditures
associated
with
the
system
are
the
filtercake
purchase
and
disposal
costs,
which
total
$
2,800
per
year.
Thus,
the
payback
period
for
the
investment
is
about
2.5
years.
This
does
not
take
into
account
the
potential
$
2,500
per
day
fines
or
the
potential
liability
associated
with
discharging
into
the
sewer.

Poly­
Plating,
Inc.
(
Chicopee,
MA)
http://
www.
state.
ma.
us/
ota/
cases/
polyplating.
htm
Chemical
Wastes
and
Water
Use
Reduced
More
Than
90%
at
Poly­
Plating,
Inc.,
Summary
Poly­
Plating
designed
and
installed
integral
repurification
equipment
which
filters,
recycles
and
concentrates
wastes
for
reclamation.
This
equipment
reduced
acid
purchases
to
1%
of
1989
levels.
Reclaiming
and
recycling
has
cut
disposal
costs
by
98%.
Additionally,
water
use
has
been
reduced
to
880
gallons
per
day,
down
from
78,000
gallons
per
day.

Background
Poly­
Plating
Incorporated,
of
Chicopee,
Massachusetts,
employs
16
people
in
the
production
of
nickel­
plated
parts.
A
variety
of
hazardous
and
toxic
chemicals,
in
addition
to
water,
are
used
in
baths
to
prepare
and
plate
nickel
onto
metal
substrates.

The
nickel
plating
process
consists
of
up
to
eight
steps.
Surface
preparation
prior
to
plating
includes
degreasing,
baking
(
depending
on
substrate
hardness),
masking
(
if
necessary),
chemical
cleaning,
rinsing,
and
descaling.
The
part
is
then
chemically
activated
and
immersed
in
a
nickel
solution.
Finally,
the
part
is
hot­
rinsed,
dried
and
sometimes
baked.

In
1983,
the
City
of
Chicopee
announced
a
program
of
significant
future
annual
increases
in
water
rates,
plus
the
addition
of
sewer
use
charges.
Material
purchase
prices
for
acids
and
nickel
were
increasing
at
7­
10%
yearly.
Motivated
by
a
desire
to
cut
operational
costs
and
to
benefit
the
environment,
Ed
Ondrick,
president
of
Poly­
Plating,
instituted
a
research
and
development
program
on
waste
reduction
for
his
plating
lines.

Attempts
to
use
turn­
key
equipment
proved
unsuccessful.
The
acids
and
other
chemicals
involved
in
nickel
plating
were
too
aggressive
on
the
equipment
components.
Ondrick
then
began
to
modify
and
develop
the
technology
for
new
applications,
some
of
which
have
been
patented.
All
plating
employees
participated
in
the
monitoring
of
the
new
equipment,
and
offered
suggestions
as
to
how
the
process
might
run
more
efficiently.
The
six­
year
project
led
to
the
Page
15
of
49
establishing
of
a
second
company.
This
firm,
Zero
Discharge
Technologies,
manufactures
and
sells
repurification
and
acid
reclamation
equipment
for
the
plating
industry.

All
equipment
design
and
construction
or
modification
was
performed
in­
house.
Two
workers
were
trained
to
operate,
monitor
and
maintain
all
key
pieces
of
equipment.
These
workers
follow
specific
maintenance
schedules
and
regularly
meet
with
Ondrick
to
discuss
equipment
status.
The
plating
production
lines
have
12
integral
repurification
units
that
remove
contaminants
and
retrieve
metals
and
acids
for
re­
use.
Additionally,
plating
water
is
recycled
through
a
closed­
loop
system.

Results
Reductions
Achieved:
Acid
purchases
have
been
reduced
96%
while
production
has
increased
20%
during
the
same
period.
Disposal
costs
are
91%
less
as
a
result
of
the
reclaiming
and
recycling
of
acids
and
other
chemicals.
Water
use
and
sewage
fees
have
been
reduced
by
98%.

Economics:
Savings
from
reduced
water
use
and
sewage
fees
total
more
than
$
74,000
annually.
Reduced
purchase
of
new
acid
saves
$
15,000.
The
closed­
loop
design
of
the
system
has
saved
$
14,630
in
disposal
costs.
The
elimination
of
water
discharges
from
the
plating
process
saves
$
4050
in
water
testing
costs.
Overall,
the
project
saves
Poly­
Plating
more
than
$
107,000
annually.
While
total
costs
for
R&
D
on
the
project
were
$
755,000,
the
replacement
cost
of
the
system
currently
in
use
at
Poly­
Plating
is
$
225,000.
The
payback
period
is
25
months.
The
Robbins
Company
(
Attleboro,
MA)
http://
www.
state.
ma.
us/
ota/
cases/
robbins.
htm
Elimination
of
TURA
Chemical
Reporting
at
The
Robbins
Company,
Summary
By
refining
its
manufacturing
operations
over
a
number
of
years,
the
Robbins
Company
eliminated
or
significantly
reduced
all
chemicals
previously
reported
for
the
Massachusetts
TURA
Form
S
and
the
EPA's
Form
R.
Robbins'
ongoing
commitment
to
continuous
improvement
has
helped
to
foster
an
environment
open
to
progressive
ideas
and
new
technologies.
In
1987,
the
company
replaced
its
traditional
wastewater
treatment
system
with
a
state­
of­
the­
art
closed­
loop
ion
exchange
system.
In
1994,
Robbins
updated
and
refined
this
process
by
replacing
the
ion
exchange
equipment
with
a
reverse
osmosis
system
that
uses
minimal
quantities
of
maintenance
chemicals
and
produces
less
waste.
To
eliminate
the
use
of
chlorinated
solvents,
Robbins
switched
in
1993
to
a
closed­
loop
aqueous
cleaning
system.
The
new
system
uses
ultrafiltration
to
recycle
and
extend
the
life
of
cleaning
baths
by
300%,
reducing
costs
associated
with
the
purchase
and
disposal
of
the
cleaner.
Further,
to
eliminate
the
use
of
dissociated
ammonia
in
annealing
ovens,
the
company
converted
to
a
system
that
blends
hydrogen
and
nitrogen
gases.
The
ovens'
noncontact
cooling
water
which
was
once
discharged
to
the
sewer
is
now
chilled
and
recirculated
back
to
the
process.
Since
1986,
through
these
changes
and
other
toxics
use
reduction
strategies,
Robbins
has
reduced
chemical
use
in
wastewater
treatment
by
99%,
reduced
hazardous
waste
generation
by
99%
and
cut
water
use
by
98.5%.
All
told,
these
reductions
have
created
an
annual
savings
of
more
than
$
100,000,
and
the
company
no
longer
has
to
report
chemical
usage
under
TURA
or
chemical
releases
under
EPCRA.
Page
16
of
49
Background
The
Robbins
Company
is
a
350­
employee
manufacturing
company
located
in
Attleboro,
Massachusetts.
The
major
processes
performed
at
the
facility
include
casting,
stamping,
grinding,
polishing,
annealing,
plating,
coloring
and
coating.
Before
the
company
began
to
investigate
ways
to
conserve
water,
reduce
its
use
of
chemicals
and
cut
back
on
its
generation
of
hazardous
wastes,
Robbins
had
a
conventional
wastewater
treatment
system.
The
company's
plating
line
was
without
countercurrent
rinses
or
flow
restrictors,
and
water
poured
into
rinse
tanks
at
a
rate
of
1.8
gallons
per
minute.
With
this
arrangement
Robbins
used
100,000
gallons
of
water
per
day,
multiple
chemicals,
including
trichloroethylene
(
TCE)
and
Freon,
and
was
a
large
quantity
generator
of
hazardous
waste.
Robbins
was
also
using
dissociated
ammonia
in
the
annealing
ovens
to
remove
oxides
and
brighten
the
surface
of
jewelry
manufactured
at
the
facility.

In
the
mid­
1980s,
the
Office
of
Technical
Assistance's
predecessor
agency
­
known
as
the
Office
of
Safe
Waste
Management
(
OSWM)
­
offered
workshops
to
jewelry
manufacturers
in
the
Attleboro
area
on
in­
process
metals
management
and
water
conservation.
Robbins
participated
in
these
workshops
and
subsequently
in
the
OSWM­
sponsored
Southeast
Jewelry
Platers
Project
(
SJPP).
On­
site
environmental
audits
by
OSWM
staff
aided
the
Robbins
Company
in
identifying:


Chemical
use
and
waste
generation
at
the
facility;


Additional
water
conservation
strategies;


Alternatives
to
chlorinated
solvent
use
in
parts
drying
and
cleaning;
and

Metal
recovery
technologies.

After
receiving
detailed
reports
from
the
audits,
Robbins
used
a
variety
of
source
reduction
techniques
to
reduce
the
metal
content
of
its
rinse
water.
The
company
installed
counter­
current
rinsing,
and
drag­
out
(
i.
e.,
dead
rinse)
tanks
after
plating
tanks;
used
ion
exchange
to
recapture
metals
from
the
cyanide
process,
returning
clean
water
to
the
plating
process
tanks;
changed
the
way
that
parts
were
racked
to
ensure
more
efficient
drainage;
and
increased
part
drainage
times.

In
1994,
OTA
again
visited
the
Robbins
Company
and
identified
alternatives
to
the
ammonia
used
in
the
annealing
step.
Robbins
then
took
the
initiative
to
reengineer
their
annealing
process
and
to
eliminate
the
use
of
ammonia,
the
only
TURA
reportable
chemical
still
used.
Additionally,
noncontact
cooling
water
from
the
annealing
furnaces
is
now
recirculated
through
a
chiller
and
returned
to
the
process.

Elimination
of
Cleaning
Solvents:
Robbins
made
it
a
priority
to
eliminate
ozone
depleting
substances
and
trichloroethylene
(
TCE),
a
hazardous
air
pollutant,
from
its
manufacturing
processes.
The
company
has
three
critical
points
in
its
manufacturing
process
where
parts
require
cleaning:
after
coloring/
plating,
after
stamping,
and
after
the
polishing
step.
In
the
coloring/
plating
department,
Robbins
once
used
Freon
to
dry
parts
to
a
mirror
finish,
to
ready
them
for
packaging
and
shipping.
TCE
was
used
to
remove
oils
from
the
stamping
operation
and
to
remove
the
polishing
compound
remaining
from
the
buffing
operation.
At
each
of
these
cleaning
steps,
Robbins
evaluated
and
successfully
installed
an
aqueous
alternative.
Page
17
of
49

Coloring/
Plating:
Deionized
water
and
a
hot
air
drying
step
have
replaced
the
Freon
once
used
following
these
operations.
Robbins
focused
particularly
on
eliminating
Freon
because
of
the
requirement
from
the
1987
Montreal
Protocol
that
requires
parts
processed
with
ozone
depleting
substances
to
be
labeled
after
1994.
Freon
was
eliminated
in
1991,
three
years
before
the
labeling
requirement
took
effect.


Stamping:
A
three­
step
aqueous
cleaning
station,
consisting
of
an
aqueous
wash,
deionized
still
water
rinse
and
a
hot
air
dry,
has
replaced
the
TCE
degreaser
at
this
process
step.
After
the
new
parts
washing
equipment
was
installed,
Robbins
switched
to
lighter
stamping
oils
to
increase
the
effectiveness
of
this
cleaning
operation.


Polishing:
An
aqueous,
ultrasonic
wash
followed
by
several
heated
deionized
water
rinse
tanks
has
replaced
the
TCE
once
used
to
remove
polishing
compound
from
the
parts.
After
reviewing
the
polishing
process,
unnecessary
cleaning
between
polishing
steps
was
eliminated
and
parts
are
now
only
cleaned
after
the
final
polish.
Robbins
has
installed
an
ultrafiltration
unit
that
has
tripled
the
life
of
the
cleaning
solutions
used
in
this
process.


Elimination
of
Ammonia
in
Annealing
Ovens:
In
Robbins'
annealing
ovens,
metal
jewelry
parts
are
heated
and
treated
to
remove
metal
oxides
and
shine
the
surface
of
the
part.
Ammonia
is
dissociated
into
elemental
hydrogen
and
nitrogen
to
create
a
reducing
atmosphere
to
prevent
the
formation
of
oxides.
By
1992,
ammonia
was
the
single
chemical
for
which
Robbins
was
required
to
file
reports
to
both
the
EPA's
TRI
program
and
the
Massachusetts
TURA
program.
In
1994,
with
the
aid
of
a
detailed
report
developed
through
on­
site
technical
assistance
by
OTA,
the
Robbins
company
devised
a
plan
to
eliminate
its
ammonia
usage
entirely.

The
ammonia
dissociation
process
generally
results
in
an
oven
atmosphere
of
75%
hydrogen
and
25%
nitrogen
gas.
Through
trial
and
error,
the
company
determined
that
its
annealing
process
requires
significantly
less
hydrogen
to
produce
the
same
desired
brightened
finish.
The
company
decided
to
take
the
existing
ammonia
dissociator
out
of
service
and
install
a
new
system
where
pure
hydrogen
and
nitrogen
gases
are
blended
to
produce
the
desired
oven
atmosphere.
Robbins
eliminated
the
use
of
approximately
14,000
lbs.
of
ammonia,
and
no
longer
reports
any
chemicals
to
the
EPA
TRI
program
or
the
Massachusetts
TURA
program.
Page
18
of
49
Closed­
Loop
Water
Recycling
and
Reuse
System
Once
the
company
had
reduced
water
usage
and
metal
bearing
rinse
water,
the
flow
rates
were
low
enough
to
make
a
closed­
loop
water
treatment
system
economical.
In
1987,
Robbins
replaced
the
traditional
metal
hydroxide
precipitation
system
with
a
closed­
loop
system
incorporating
ion
exchange
to
remove
metals
and
salts
from
the
rinse
water.

This
system
worked
well,
decreasing
water
usage,
chemical
use
and
hazardous
waste
generation.
It
produced
water
that
was
40
times
cleaner
than
city
water,
contributing
to
greater
plating
quality.
Yet
Robbins
found
that
ion
exchange
still
required
a
fair
amount
of
supervision
and
that
acids
and
bases
were
needed
to
regenerate
the
resin
columns.
The
ion
exchange
closedloop
system
still
generated
significant
amounts
of
liquid
waste
for
evaporation.

In
1994,
the
company
replaced
the
ion
exchange
treatment
system
with
a
state­
of­
the­
art
reverse
osmosis
system.
Robbins
recognized
some
significant
benefits
in
switching
to
reverse
osmosis,
including:


Less
operator
involvement
(
the
system
requires
little
maintenance
or
monitoring);


Minimal
amounts
of
acid
required
to
clean
the
reverse
osmosis
filters;


Lowered
worker
exposure
risks;


Reductions
in
quantities
of
water
requiring
evaporation;


Improved
water
quality;
and

Less
hazardous
waste
generated.

Robbins
realized
significant
reductions
in
the
use
of
sodium
hydroxide
and
muriatic
acid
as
a
result
of
this
change.
The
company's
usage
of
sodium
hydroxide
was
reduced
from
500
gallons
in
1993
to
20
gallons
in
1994.
Chemical
use
in
the
new
system
is
limited
to
filter
cleaning/
maintenance
only.

Results
Summary
of
Reductions
Achieved:
Through
toxics
use
reduction
strategies,
Robbins
eliminated
annual
use
of
6,000
lbs.
of
Freon,
21,000
lbs.
of
trichloroethylene,
14,000
lbs.
of
ammonia
and
3,000
lbs.
of
sodium
hydroxide
and
2,500
lbs.
of
sulfuric
acid
used
in
wastewater
treatment.
Sludge
generation
was
cut
by
99.8%,
from
4,000
gallons
to
7
gallons
per
year,
reducing
the
company's
status
from
a
large
quantity
generator
(
LQG)
of
hazardous
waste
to
small
quantity
generator
(
SQG).
In
addition,
by
using
in­
process
water
conservation
techniques,
Robbins
reduced
its
daily
water
consumption
from
100,000
gallons
in
1984
to
5,000
gallons
in
1986,
to
just
156
gallons
in
1994.
City
water
is
needed
by
the
closed­
loop
system
only
to
compensate
for
evaporation.
These
reductions
continue
to
save
the
company
more
than
$
100,000
annually.
These
savings
are
derived
only
from
lowered
chemical
purchase
costs
and
lowered
hazardous
waste
disposal
costs.
Page
19
of
49
V.
H.
Blackington
&
Co.,
Inc.
(
North
Attleboro,
MA)
http://
www.
state.
ma.
us/
ota/
cases/
blackinton.
htm
Freon
Elimination,
VOC
and
Metals
Reduction
at
V.
H.
Blackinton
&
Co.,
Inc.

In
order
to
eliminate
both
the
health
concerns
and
increasing
environmental
compliance
costs
associated
with
the
toxic
chemicals
used
to
manufacture
its
metal
insignia,
novelties
and
jewelry
­­
and
because
the
Clean
Air
Act
will
end
production
of
some
of
those
chemicals
­­
V.
H.
Blackinton
began
a
program
to
find
ways
to
replace
and
reduce
the
use
of
those
materials.
Working
on
their
own
and
with
the
help
of
the
Office
of
Technical
Assistance,
V.
H.
Blackinton
installed
a
deionized
water
rinse
and
hot
air
dryer
to
replace
Freon
parts
drying.
The
company
has
decreased
use
of
trichloroethylene
(
TCE)
by
substituting
an
aqueous
cleaner
for
most
degreasing
as
well
as
by
ending
some
parts
cleaning
and
bright
dipping
steps.
A
50
percent
reduction
in
zinc
and
copper
in
wastewater
have
been
achieved
through
improved
process
management
of
bright
dip
chemicals;
this
has
also
resulted
in
reduced
use
of
chemicals
for
wastewater
treatment.
The
hot
air
drying
system
and
aqueous
cleaning
process
cost
approximately
$
23,000
to
install.
To
purchase
in
1994
the
quantity
of
Freon
that
was
used
in
1989
could
cost
upwards
of
$
60,000.
There
have
also
been
significant
annual
savings
realized
from
reduced
chemical
purchases,
water
and
sewer
charges
and
energy
usage.
Product
quality
and
productivity
are
unchanged
or
improved.

Background
V.
H.
Blackinton
&
Co.,
Inc.,
North
Attleboro,
Mass.,
is
the
largest
manufacturer
in
the
United
States
of
metal
uniform
insignia
 
badges,
medals,
service
pins.
The
company
also
makes
jewelry
and
other
metal
plated
novelties.
V.
H.
Blackinton's
staff
of
190
people
manufacture
products
from
start
to
finish
 
artwork
and
raw
materials
to
packaged
products
ready
to
be
shipped.
The
manufacturing
operation
includes
blanking,
stamping,
punching
and
machining
raw
stock
prior
to
enameling,
brazing,
polishing
and
plating.
Five
thousand
gallons
of
water
is
used
daily
for
noncontact
cooling
of
brazing
furnaces
in
addition
to
that
used
for
rinsing.
Copper
and
zinc
contaminate
the
rinse
water
required
to
wash
off
the
acids
used
to
etch
the
badges.

In
1989,
V.
H.
Blackinton
began
to
research
and
make
plans
to
reduce
or
eliminate:


Freon
used
for
parts
drying;


TCE
degreasing;


Sulfuric
acid
used
in
brite
dipping;


Waste
from
a
60
gallon
cyanide
activation
tank,
and

The
25,000
gallons
of
water
used
each
day
 
including
the
5,000
gallons
of
noncontact
cooling
water,
which
the
North
Attleboro
wastewater
treatment
plant
no
longer
allows
to
be
discharged
directly
into
the
sewer
system.
Page
20
of
49
V.
H.
Blackinton
moved
to
its
present
location
in
1982
and
as
the
company
streamlined
its
processes
to
meet
increased
demand
they
also
tested
and
implemented
source
reduction
and
conservation
techniques.
TCE
and
Freon
emissions
were
reduced
and
the
company
was
able
to
reduce
water
usage
from
five
million
to
one
million
gallons
a
year.
V.
H.
Blackinton
participated
in
the
Department
of
Environmental
Management
Southeast
Jewelry
Platers
Project
(
SJPP),
which
provided
technical
assistance
from
1986
to
1989
to
metal
finishers
and
platers
in
southeastern
Massachusetts.
V.
H.
Blackinton's
Emilio
Abatecola
attended
SJPP
workshops
and
seminars
and
had
on­
site
consultations
from
OTA
and
its
predecessor,
the
Office
of
Safe
Waste
Management
(
OSWM).
A
number
of
toxics
use
reduction
and
resource
conservation
opportunities
were
identified
in
a
1989
OSWM
audit.

Emilio,
who
took
over
as
finishing
manager
in
1990,
saw
that
concerns
over
the
environmental
impact
of
toxic
chemicals
would
lead
to
increased
fees,
costs
and
regulations.
He
sought
input
and
assistance
from
the
company's
workers,
and
began
implementing
a
program
to
use
less
chemicals
and
reduce
water
consumption.
Emilio
first
focused
on
substitutes
for
Freon
and
TCE
and
then
introduced
additional
water
conservation
and
pollution
prevention
techniques.
He
also
carefully
assessed
the
need
for
each
cleaning,
degreasing
and
brite
dipping
step.

In
1990,
Blackinton
replaced
the
Freon
dryer
used
to
dry
finished
work
pieces
with
a
deionized
water
rinse
and
a
hot
air
dryer.
The
new
dryer,
heated
with
inplant
steam,
requires
five
to
eight
minutes
instead
of
45
seconds
with
Freon,
but
because
production
is
done
in
batches
the
increased
drying
time
has
had
no
significant
effect
on
quality
or
productivity.

All
but
one
of
the
TCE
degreasing
procedures
have
been
replaced
by
a
basic
aqueous
cleaning
system
with
four
countercurrent
rinse
tanks.
At
the
brite
dipping
station,
Emilio
added
a
conductivity
probe
to
the
fourth
and
final
countercurrent
rinse
tank
so
that
fresh
water
is
no
longer
added
continuously,
but
only
when
needed.
Careful
monitoring
of
the
chemistry
in
the
aqueous
bath
has
reduced
the
amount
of
cleaner
used
by
half.
Removing
solids
from
the
cleaning
system
by
decanting
from
the
bottom
doubles
the
time
between
bath
replacements
and
countercurrent
flow
in
the
rinse
tanks
substantially
reduces
water
use.
Addition
of
a
small
intank
filter,
an
oil
skimmer,
and
conversion
to
compatible
aqueous
based
pressing
and
stamping
oils
also
facilitated
the
changeover
and
made
the
new
cleaning
system
more
efficient.
V.
H.
Blackinton's
priority
goal
is
to
eliminate
all
use
of
TCE
within
a
year;
at
present
one
small
tank
of
TCE
with
increased
freeboard
and
a
cover
to
prevent
evaporation
is
still
used
to
remove
buffing
compound.

Decreased
concentration
of
the
cyanide
bath
and
reducing
the
size
of
the
tank
from
60
gallons
to
10
gallons
resulted
in
an
80
percent
decrease
in
the
chemicals
needed
for
those
operations.

The
badge
clasps,
which
used
to
be
loosened
in
a
separate
brite
dipping
step
are
now
freed
during
the
aqueous
cleaning.
The
unnecessary
brite
dipping
added
copper
and
zinc
metals
to
the
waste
water
treatment
system,
generating
large
quantities
of
waste
sulfuric
acid
which
then
required
the
addition
of
sodium
hydroxide
to
neutralize
the
spent
acid.
Page
21
of
49
Results
Reductions
Achieved:
In
1989,
the
dryer
used
6,900
pounds
of
Freon,
which
escaped
into
the
atmosphere.
With
the
installation
in
1990
of
the
hot
air
dryer,
Freon
emissions
have
been
completely
eliminated.
The
workers
had
routinely
degreased
everything,
sometimes
treating
the
same
piece
several
times
during
its
production;
reducing
cleaning
operations
to
the
minimum
continues
to
reduce
the
amount
of
TCE
used.
In
1989,
V.
H.
Blackinton
used
over
30,000
pounds
of
TCE;
in
1993,
6,000
pounds
of
TCE
were
used.
Unnecessary
brite
dipping
steps,
like
that
used
for
loosening
clasps,
have
also
been
eliminated.
The
reduced
brite
dipping
has
cut
H2SO4
and
sodium
hydroxide
(
used
to
neutralize
the
H2SO4
before
discharge)
respectively
from
20,000
pounds
per
year
to
8,500
pounds
and
16,000
pounds
per
year
to
8,000
pounds.

Through
careful
monitoring
of
chemistry
and
redesign
of
the
cyanide
activation
tank
and
the
cleaning
bath
in
the
plating
line,
the
cyanide
and
sodium
hypochlorite
used
in
these
two
operations
have
been
reduced
by
80
percent.

In
1989,
V.
H.
Blackinton
used
over
20,000
gallons
of
water
a
day
in
its
plating
operations.
Aggressive
conservation
efforts
including
installation
of
flow
restricters,
downsizing
tanks
and
implementing
counter
current
rinses,
had
cut
use
to
5,000
gallons
per
day
in
1993.
Additional
implemented
conservation
efforts
include
shutting
off
rinse
tanks
during
lunch,
the
careful
monitoring
of
chemistry,
modernization
and
regular
preventative
maintenance
of
valves
and
piping.

Economics:
The
cost
to
purchase
and
install
the
hot
air
dryer
was
$
11,400,
and
the
deionized
water
rinse
cost
$
1,500.
The
aqueous
cleaning
system
and
four
rinse
tanks
cost
a
net
of
$
9,384
 
a
small
profit
was
realized
from
disposal
of
the
old
unit.
The
savings
realized
from
the
reduced
and
alternative
chemical
purchases
for
these
two
processes
over
the
amount
the
original
materials
would
cost
today
comes
to
at
least
$
70,000
per
year.
Initial
payback
on
the
capital
costs
for
new
equipment,
based
on
the
savings
in
chemicals
and
waste
management,
was
achieved
in
less
than
a
year.

Watkins­
Johnson
Company
(
Palo
Alto,
CA)
http://
www.
city.
palo­
alto.
ca.
us/
cleanbay/
pdf/
wj1.
pdf
Pollution
Prevention
and
Wastewater
Recycling
at
Watkins­
Johnson
Company
Building
1
Watkins­
Johnson
Company
eliminated
its
process
discharge
to
the
sewer
from
its
Building
1
metal
finishing
operations
in
May
1993.
Watkins­
Johnson
now
treats
and
reuses
the
wastewater
generated
from
its
plating
operations.
Installation
of
a
wastewater
treatment
system
to
reduce
cyanide
and
metals
discharge
to
the
sanitary
sewer,
was
required
by
a
compliance
agreement
with
the
Palo
Alto
Regional
Water
Quality
Control
Plant
(
RWQCP)
in
February
1992.
Watkins­
Johnson
went
beyond
the
requirements
of
the
compliance
agreement
by
implementing
pollution
prevention
measures
including
consolidating
plating
operations,
improving
rinsing,
waste
handling,
and
treatment
techniques;
and
recycling
treated
wastewater
for
use
in
its
metal
finishing
process.
Page
22
of
49
Watkins­
Johnson's
metal
finishing
operations
are
conducted
by
three
employees.
The
shop
manager
is
also
responsible
for
maintenance
of
the
wastewater
treatment
and
recycling
system.
In
the
Building
1
metal
finishing
operation,
parts
are
plated
with
metals
such
as
copper,
nickel,
and
gold.
These
specialized
parts
are
then
used
in
semiconductor
applications.

Waste­
Generating
Activities
The
metal­
containing
wastewater
generated
at
the
site
is
from
the
process
rinses.
When
parts
are
removed
from
process
baths
to
rinses,
they
carry
metals
out
of
the
concentrated
baths
into
the
rinse
water.

Spent
process
baths
are
also
a
source
of
waste.
As
contaminants
build
up
in
the
baths
they
become
less
effective
and
must
be
replaced.
Watkins­
Johnson
treats
most
of
its
spent
baths
with
the
distillation
treatment
system.
Concentrated
cyanide
solutions
and
the
gold
plating
bath
are
both
sent
offsite
for
treatment.

Rinse
Water
Use
Reduction
Prior
to
installing
the
wastewater
recycling
system,
Watkins­
Johnson
reduced
its
process
water
use
through
a
series
of
rinse
water
reduction
measures.
Reducing
wastewater
generation
allowed
installation
of
a
significantly
smaller
wastewater
treatment
and
recycling
system,
significantly
reducing
the
treatment
and
recycling
system
installation
and
operational
costs.

During
the
plating
process,
parts
are
dipped
into
tanks
that
contain
various
solutions.
Postplating
rinse
procedures
now
follow
the
minimal
water
use
steps
described
below.
After
the
part
is
plated
it
is
rinsed
with
a
spray
rinse
over
the
heated
plating
solution.
This
keeps
the
metals
in
the
plating
solution
and
reduces
drag
out.
The
part
is
then
suspended
in
a
tank
where
the
rinse
water
is
activated
by
an
operator
controlled
knee
switch.
Water
only
flows
when
a
part
is
present.
Parts
that
need
further
rinsing,
due
to
their
shape,
can
then
be
submerged
in
the
rinse
tank
and
a
timer
can
be
activated
allowing
the
rinse
water
to
flow
for
a
given
period
of
time.

Each
rinse
is
discharged
entirely
only
twice
daily,
thus
reducing
the
overall
volume
of
discharge
rinse
water
and
concentrating
the
metals.
Implementing
these
special
rinse
procedures
reduced
the
rinse
water
used
in
the
plating
shop
from
5,000
gallons
to
1,000
gallons
per
day.

Wastewater
Treatment
and
Recycling
Watkins­
Johnson
installed
an
advanced
wastewater
treatment
system
to
purify
process
wastewater
prior
to
re­
use
of
that
water
in
its
plating
process.
The
plating
line
rinse
waters
are
treated
on
site
to
remove
metals
and
cyanide.
Cyanide
is
first
destroyed
in
a
two
stage
alkaline
chlorination
treatment
process
and
then
combined
with
the
heavy
metal
waste
streams
from
the
non­
cyanide
rinses.
Under
vacuum,
the
combined
wastestreams
are
vaporized
at
21­
27
degrees
Celsius.
The
water
vapor
is
then
condensed,
deionized,
and
returned
to
the
plating
shop
to
be
reused
in
the
rinse
tanks.
The
vacuum
distillation
unit
is
also
used
for
on­
site
treatment
of
spent
Page
23
of
49
baths.
The
concentrated
metal
slurry
waste
resulting
from
this
process
is
hauled
offsite
for
disposal.
The
treatment
system
has
the
capacity
to
treat
1,500
gallons
per
day.
The
cost
to
treat
one
gallon
of
water
is
approximately
$
0.05.

Cost
Analysis
These
projects
involved
the
installation
of
equipment
and
changes
in
operating
procedures.
These
changes
reduced
materials
and
water
use,
thereby
reducing
company's
operating
costs.
The
treatment
system
cost
approximately
$
500,000.
Watkins­
Johnson
believes
the
installation
cost
was
recovered
within
28
months.

Wastewater
Metals
Discharge
These
projects
eliminated
process­
related
sewer
discharges
from
Watkins­
Johnson
Building
1.
The
table
below
shows
a
comparison
of
Watkins­
Johnson's
discharge
and
disposal
data
before
and
after
completion
of
its
pollution
prevention
projects.
The
rinse
water
use
reduction
projects
together
reduced
process
wastewater
generation
from
5,000
gpd
to
1,000
gpd.
These
same
process
changes
dramatically
reduced
wastewater
nickel
loads,
which
fell
80%
from
10
grams/
day
before
the
changes
to
2
grams/
day
upon
completion
of
the
rinse
water
use
reduction
projects.
Installation
of
the
wastewater
recycling
system
eliminated
the
remaining
1,000
gpd
of
wastewater
discharge,
and
eliminated
nickel
discharges
to
the
sewer
from
Building
1
plating
process.

Discharge/
Disposal
Data
Item
Before
Projects
1991
After
Projects
1993
%
Reduction
Nickel
10
grams/
day
0
grams/
day
100%

Flow
5,000
gpd
0
gpd
100%

Total
Facility
Waste
Disposal
500,000
250,000
50%

Tin
Originals
Inc.
(
Gastonia,
NC)
http://
www.
p2pays.
org/
ref/
07/
06139.
pdf
Tin
Originals
Incorporated
is
a
small
manufacturer
and
wholesale
distributor
of
gift
and
home
decorating
items,
specializing
in
tin
ware
with
a
decorative
finish.
Most
material
is
completely
manufactured
in­
house,
and
processing
involves
cutting,
folding,
assembly,
finishing
and
shipping.
The
finishing
process
consists
of
baths
of
phosphates,
acids,
baking
soda,
and
sealer.
Each
bath
is
followed
by
a
rinse.
In
1995,
the
facility
was
having
difficulty
meeting
its
permitted
discharge
limits
for
zinc.
While
investigating
treatment
alternatives,
a
solution
was
discovered
that
not
only
ensured
compliance,
but
also
eliminated
the
need
for
their
discharge
permit
altogether
and
significantly
reduced
water
consumption.
Page
24
of
49
Two
in­
line
filters,
a
25
micron
bag
filter
followed
by
a
five
micron
cartridge
filter,
were
installed
to
remove
solids
so
that
free­
flowing
rinsing
stations
could
be
replaced
with
re­
circulating
rinse
baths.
Re­
circulating
rinse
water
significantly
reduced
the
volume
of
wastewater
generated
and
also
worked
to
greatly
increase
the
concentration
of
zinc
in
the
rinse.
The
company
then
began
looking
at
systems
to
reduce
the
concentrations
of
zinc
in
the
rinse
baths
so
that
it
would
not
build
to
concentrations
that
could
adversely
affect
the
finish
quality.
Traditional
chemical
precipitation
processes
were
determined
to
be
too
expensive
and
labor­
intensive,
and
required
space
that
was
not
available
at
the
small
facility.
The
facility
sought
a
simple,
low­
cost,
compact
method
of
treating
waste
in
small,
discrete
batches.

The
company
installed
an
ion
exchange
unit
containing
1
cubic
foot
of
loose,
chemical
specific
ion
exchange
media,
both
after
and
in
line
with
the
two
previous
filters.
The
original
purpose
of
the
ion
exchange
unit
was
to
treat
the
rinse
water
prior
to
discharge.
However,
the
company
discovered
that
after
treatment
through
the
unit,
the
rinse
water
could
be
re­
circulated
back
into
use.
Since
the
installation
of
the
ion
exchange
unit
there
has
been
no
discharge
of
process
wastewater.
Additionally,
the
ion
exchange
media
only
needs
replacement
once
every
three
to
four
months.
The
maintenance
of
the
system
has
proven
quite
simple.
Once
each
week,
the
in­
line
bag
filters
are
allowed
to
dry
and
the
solids
are
shaken
off
into
the
regular
waste
receptacles.
Cartridge
filters
are
allowed
to
dry
and
the
solids
are
discarded
in
the
same
way.
The
ion
exchange
media
is
emptied
into
a
container
and
allowed
to
dry
before
it
is
disposed
of
as
solid
waste
also.
Occasionally
a
biocide
is
added
to
the
rinse
baths
to
reduce
biological
activity.

During
1995,
Tin
Original
consumed
approximately
100,000
gallons
of
process
water
each
month.
In
1996,
the
total
consumption
decreased
to
13,000
gallons
each
month,
a
reduction
of
87%.
Additionally,
because
Tin
Originals
no
longer
discharges
process
water
to
the
sewer,
they
no
longer
have
the
liabilities
associated
with
an
Indirect
Discharger
Permit.
Zinc
emissions
in
wastewater
have
decreased
by
100%.

During
the
first
year
of
operation,
the
entire
installation
and
maintenance
cost
was
approximately
$
1100
with
installation
costs
of
approximately
$
1000
(
including
all
additional
plumbing
and
filter
purchases)
and
the
replacement
cost
of
the
ion
exchange
cartridge
media
and
filters.
However,
with
the
drastic
decrease
in
water
consumption
came
a
corresponding
decrease
in
utility
bills.
In
1995,
the
average
monthly
sewer
bill
was
$
455.65;
in
1996,
after
the
installation
of
the
recycling
system,
the
average
monthly
bill
was
$
61.98,
an
annual
savings
of
over
$
4,500.
The
payback
time
on
the
project
was
less
than
3
months.

East
Side
Plating
(
Portland,
OR)
http://
www.
epa.
gov/
sectors/
pdf/
performancebw.
pdf
By
installing
two
cooling
towers
and
adding
sludge
dryers,
East
Side
Plating
in
Portland,
OR,
was
abl
to:
(
1)
reduced
water
use
by
64%
(
between
1997
and
1999);
(
2)
reduced
sludge
discharge
by
67%
(
between
1997
and
1999);
and
(
3)
reduced
permitted
copper,
nickel,
chrome,
and
zinc
discharges
by
almost
50%
(
between
1997
and
2002).
Page
25
of
49
SWD,
Inc.,
(
Addison,
IL)
http://
www.
epa.
gov/
sectors/
pdf/
performancebw.
pdf
SWD,
Inc.,
in
Addison,
IL,
adopted
an
EMS
in
1997
and
became
the
first
metal
finisher
in
the
U.
S.
to
certify
its
EMS
to
the
ISO
14001
standard
in
1998.
Through
its
EMS,
SWD,
Inc.
was
able
to
identify
the
environmental
impacts
of
molybdenum
and
barium
as
areas
for
improvement
and
took
steps
to
eliminate
both
substances
from
all
incoming
raw
materials.
Through
implementation
of
pollution
prevention
practices
this
facility
was
able
to:
(
1)
reduced
sludge
by
50%
between
1996
and
1998
by
changing
its
chemical
process;
and
(
2)
reduced
water
discharge
by
28%
between
1996
and
2000
by
reusing
water
in
non­
critical
rinses.

Case
Studies
of
the
Chemicals
Manufacturing
Industry
OxyChem
(
Corpus
Christi,
TX)
http://
www.
utep.
edu/
success/
story.
cfm?
ID=
148
Wastewater
at
this
facility
is
treated
in
a
biodegradation
unit.
After
determining
that
the
treated
effluent
was
of
higher
quality
than
the
cooling
tower
make
up
water,
OxyChem
decided
to
reroute
the
effluent
to
the
cooling
tower
system.
The
wastewater
effluent
was
previously
discharged
at
a
rate
of
184
gallons
per
minute.
Rerouting
the
effluent
stream
resulted
in
reduced
blowdown
rate
and
lower
water
usage
requirements.
The
water
demand
on
the
City
of
Corpus
Christi
has
been
reduced
by
over
200
gallons
per
minute.

The
return
on
investment
for
this
process
change
was
less
than
30
days
due
to
reduced
annual
water
costs.

DuPont
http://
www.
dupont.
com/
corp/
news/
publications/
aboutdup/
02Excbro.
pdf
Engineering
Polymer's
Savli
compounding
operation
in
India
is
located
in
an
arid
region
where
water
consumption
and
water
effluent
are
critical
aspects
of
the
right
to
operate.
To
meet
the
strict
water
requirements,
a
team
consisting
of
Savli
personnel,
EP
Japan
compounding
technical
experts,
and
an
Indian
environmental
consultant
redesigned
the
entire
vacuum
extraction
system
for
the
DuPont
 
Zytel
®
GRZ
process
to
essentially
eliminate
water
consumption
and
ensure
that
the
small
amount
of
water
effluent
met
requirements
for
site
general
purpose
use.
Overall
water
consumption
was
reduced
by
>
99.5%
that
drove
savings
of
$
5,000
per
year
in
potable
water
purchases.
Without
this
innovation,
it
is
likely
that
the
business
would
not
have
been
able
to
produce
in
India,
and
alternative
sourcing
of
polymer
would
have
seriously
jeopardized
the
health
of
the
business.
Engineering
Polymers
has
70
similar
processes
worldwide
that
could
benefit
from
this
new
design.

ChemTex
Laboratories,
Inc.
http://
www.
p2pays.
org/
ref/
26/
25001.
pdf
Chem­
Tex
Laboratories,
a
producer
of
specialty
chemicals
in
Concord,
N.
C.,
requested
the
assistance
of
the
N.
C.
Division
of
Pollution
Prevention
and
Environmental
Assistance
Page
26
of
49
(
DPPEA)
to
assess
various
alternatives
for
reducing
its
water
usages
following
the
institution
of
mandatory
water
use
restrictions
by
the
City
of
Concord.
The
plant
uses
about
26,000
gallons
per
day
of
city
water,
a
major
portion
of
which
is
used
as
noncontact
cooling
water.
The
plant
operates
10­
12
hours
per
day,
five
days
per
week.
The
plant
has
eight
water­
jacketed
reactors
varying
from
about
165
gallon
to
about
5,500
gallon
capacities.
A
couple
of
the
reactors
are
equipped
with
solenoid
valves
in
the
cooling
water
lines
but
most
of
the
cooling
has
been
done
with
the
lines
wide­
open.
The
plant
is
also
equipped
with
a
10­
ton
chiller
which
cools
two
storage
tanks.
Based
on
a
four­
month
average,
the
plant
uses
about
26,500
gpd
for
process
purposes.
The
company
estimates
about
4,000
gpd
end
up
in
the
products
and
about
3,000
gpd
are
used
to
"
boil
out"
the
reactors.
The
effluent
meter
shows
about
16,800
gpd
go
to
the
sewer,
with
about
2,600
gpd
remaining
used
in
the
150
HP
boiler
and
for
miscellaneous
purposes
around
the
plant.

The
cost
of
the
incoming
water
at
this
average
rate
would
be
about
$
23,400
per
year,
and
the
sewer
charge
would
be
about
$
25,900
per
year,
for
a
total
water/
sewer
bill
of
about
$
49,300
per
year.

Water
Reduction
Activities
Chem­
Tex
is
installing
two
new
tanks,
pumps,
and
a
small
cooling
tower
to
cool
and
reuse
the
water
formerly
sewered
after
cooling
the
reactions.
The
plant
also
plans
to
recycle
the
water
used
to
clean­
out
the
reactors.
Other
alternatives
considered
included
installing
additional
control
valves
on
the
reactors,
geothermal
cooling
of
the
water,
and
drilling
water
wells
on
the
plant
property.
Their
management
decided
water
conservation
was
the
best
long
term
approach.
It
took
a
surprisingly
small
cooling
tower
and
tank
system
costing
less
than
$
15,000
to
produce
these
savings,
and
thus
will
also
produce
a
good
financial
return
on
the
invested
capital.

Water
Conserved
Chem­
Tex's
water
conservation
program
will
reduce
the
use
of
water
by
about
60
percent
(
by
about
20,000
gpd),
and
also
reduce
the
plant's
waste
water
effluent
to
the
Concord
Waste
Water
Treatment
Plant
by
about
85
percent.
The
savings
should
be
between
$
35,000
and
$
40,000
per
year.

Advantis
Technologies,
Inc.
http://
www.
state.
ga.
us/
dnr/
p2ad/
advantis.
html
Located
in
Alpharetta,
Georgia,
Advantis,
was
the
recipient
of
the
2001
GW&
PCA
Industrial
Award
for
Pollution
Prevention.
This
facility
is
focusing
on
wastewater
generation
and
water
conservation.

Wastewater
Generation
As
with
many
chemical
companies,
water
was
used
to
rinse
out
chemical
tanks
after
the
manufacturing
process
was
complete.
Advantis
established
a
program
to
re­
use
all
rinse
water
generated
when
cleaning
a
mix
tank.
After
rinsing
for
a
particular
chemical,
the
rinse
water
is
stored
and
then
re­
used
as
make­
up
water
the
next
time
that
chemical
is
prepared.
As
a
result,
Page
27
of
49
Advantis
no
longer
discharges
any
industrial
wastewater
to
the
city
sewer
system.
The
end
result
was
a
reduction
in
wastewater
generation
of
approximately
70,000
gallons
per
year
since
1998.

Water
Conservation
Advantis
also
made
a
concerted
effort
to
conserve
the
amount
of
water
used
at
the
facility
and
in
the
manufacturing
process.
Some
examples
of
their
water
conservation
efforts
are:


Establishing
a
manufacturing
plan
to
run
similar
chemicals
back­
to­
back
in
order
to
reduce
the
number
of
cleanups
and
thus
reduce
the
amount
of
water
needed
for
rinsing.


Modifying
several
formulations
to
make
them
fall
into
existing
chemical
groups
to
avoid
special
runs
with
unique
waste
streams.


Installing
a
programmable
irrigation
timer
with
multiple
time
and
zone
settings.

Case
Studies
of
the
Pesticides
Manufacturing
Industry
DuPont
http://
www.
dupont.
com/
corp/
news/
publications/
aboutdup/
02Excbro.
pdf
Eliminating
By­
Products
Generated
in
Process
Creates
Business
Value
A
Crop
Protection
team
on
the
Griffin
site
in
Brazil
discovered
that
the
by­
product
generation
of
2,3
dicholoronitrobenzene,
dichloronitrobenzene,
and
chloronitrophenols
during
the
production
of
the
DuPont
 
Diuron
®
and
DuPont
 
Propanil
®
herbicides
could
be
significantly
reduced
or
eliminated
by
making
process
modifications.
Using
teamwork
and
Six
Sigma
methodology,
the
process
changes
were
introduced
into
the
plant.
The
total
economic
benefit
of
the
program
exceeds
$
1
million
per
year
while
also
significantly
reducing
storage,
people
exposure,
and
environmental
containment
issues.

This
team
demonstrated
that
their
vision
to
drastically
reduce
residual
by­
product
production
generated
significant
value
for
shareholders
and
the
local
community.
The
use
of
Six
Sigma
methodologies
also
demonstrates
the
value
of
integration
of
sustainable
growth
and
productivity
improvements.
The
team's
commitment
to
the
goal
is
zero
is
obvious
through
their
focus
on
continuous
process,
practices,
and
products
improvements.

Du
Pont
La
Porte
Plant
(
La
Porte,
TX)
http://
p2.
utep.
edu/
success/
story.
cfm?
ID=
64
In
an
effort
to
comply
with
new
regulatory
requirements
on
herbicides,
a
Heinkel
centrifuge
unit
was
installed
at
this
facility
to
decrease
uracil
herbicide
releases
to
wastewater.
This
technology
will
not
only
recover
herbicides
from
wastewater,
but
will
also
recycle
a
large
portion
of
the
water
discharged
from
the
process,
reducing
the
need
for
fresh
make
up
water.
The
centrifuge
process
reduces
releases
of
one
herbicide
by
8,900
lb/
yr,
and
is
expected
to
reduce
Page
28
of
49
releases
of
another
uracil
herbicide
by
119,000
lb/
yr.
In
addition,
TOC
loadings
to
the
wastewater
treatment
plant
will
be
reduced
by
41
percent,
and
hydraulic
loadings
will
be
reduced
by
51
percent.

This
technology
improves
herbicide
yield
and
reduces
wastewater
treatment
costs,
resulting
in
an
estimated
savings
of
$
40,000
per
year.

Organika
Azot
(
Poland)
Reference:
Environmental
Management
Centre.
Waste
Minimization
at
a
Pesticide
Manufacturing
Plant.
Mumbai,
India,
1992.
http://
www.
emcentre.
com/
unepweb/
tec_
case/
chemical_
24/
process/
p23.
htm.

The
Organika
Azot
plant
in
Poland
produces
insecticides,
herbicides,
and
fungicides.
In
1992,
as
part
of
the
Industrial
Waste
Minimization
Program
in
Poland,
cleaner
production
measures
were
evaluated.
Three
of
these
measures
resulted
in
the
reduction
of
wastewater
discharge
and
are
detailed
below.

Recycle
of
Process
Wastewater
The
site
previously
purchased
50,000
cubic
meters
of
water
per
year
for
its
production
processes.
The
site
treated
its
wastewater
through
primary
and
biological
treatment
systems.
As
part
of
the
cleaner
production
measures,
the
reuse
of
treated
effluent
was
evaluated.
The
results
found
that
approximately
150,000
cubic
meters
of
effluent
per
year
could
be
reused
at
specific
operations
rather
than
discharged.

The
implementation
of
the
project
saved
money
for
the
site
by
decreasing
the
amount
of
water
purchased,
amount
of
wastewater
discharged,
and
amount
of
environmental
fees.


Investment:
1,050
US$


Savings:
1,600
US$/
year

Payback
Period:
<
3
weeks
Reuse
of
Washing
Water
As
part
of
the
production
of
Brilane
(
an
insecticide),
a
benzene
organic
phase
containing
the
intermediate
chemical
dichloroacetophenone
(
DCAP)
undergoes
a
three­
step
washing
process.
The
washing
processes
generate
wastewater
containing
aluminum
salts.
The
site
previously
sold
a
portion
of
the
spent
wash
water
as
a
25
percent
solution
of
aluminum
chloride;
however,
the
majority
of
the
spent
wash
water
was
discharged
to
the
treatment
plant.

Experiments
performed
during
the
clean
production
measures
evaluation
showed
that
the
spent
wash
water
from
the
second
and
third
washings
could
be
reused
in
the
hydrolysis
process
(
eliminating
the
need
to
purchase
fresh
water).

The
implementation
of
the
project
saved
money
for
the
site
by
decreasing
the
amount
of
raw
material
purchased,
amount
of
wastewater
discharged,
and
amount
of
environmental
fees.
Page
29
of
49

Investment:
1,100
US$


Savings:
13,000
US$/
year

Payback
Period:
1
month
The
clean
production
measures
evaluation
included
a
review
of
the
site's
hot
and
fresh
water
distribution
and
usage.
The
evaluation
showed
that
the
use
of
proper
monitoring
equipment
would
significantly
decrease
the
consumption
of
hot
water
and
industrial
water
at
the
site.
The
monitoring
also
helps
to
identify
leaks
throughout
the
pipelines.

The
implementation
of
the
project
saved
money
for
the
site
by
decreasing
the
amount
of
hot
water,
fresh
water,
and
industrial
water
required
for
the
site.


Investment:
5,965
US$


Savings:
11,900
US$/
year

Payback
Period:
<
4
months
Case
Study
of
a
Pesticide
Manufacturing
Facility
Reference:
Matthew
J.
Barcaskey.
An
Analysis
of
Pollution
Prevention
Opportunities
and
Impediments
in
the
Chemical
and
Allied
Products
Sector
in
Georgia.
Georgia
Department
of
Natural
Resources,
http://
www.
ganet.
org/
dnr/
p2ad/
pblcations/
chemical/
pest_
ch.
htm.

The
case
study
site
formulates
pesticide
products
using
a
batch
process.
The
site
pipes
raw
materials
from
storage
tanks
into
its
mixing
kettles.
The
resulting
pesticide
formulations
are
then
sent
to
a
container
filler
line
for
packaging
and
distribution.

The
site
generates
most
of
its
wastewater
from
equipment
cleaning
between
batches.
The
cleaning
process
involves
spraying
water
or
solvent
into
the
kettle,
circulating
the
rinsate
through
the
pipes
and
filters,
and
pumping
the
rinsate
to
a
holding
tank.
The
site
then
sends
the
rinsate
through
the
filler
lines
and
out
of
the
process.
The
kettle,
pipes,
and
filters
are
then
blown
dry.

Source
reduction
practices
implemented
by
the
site
include
the
following:


Air
blowing
of
lines
before
and
after
system
cleaning
to
reduce
the
amount
of
rinsate
generated.


Reuse
of
rinsate
for
future
batches
(
when
possible).
Reuse
of
water
rinsate
for
next
water­
based
product
and
reuse
of
solvent
rinsate
for
next
solvent­
based
product.


Use
of
absorbent
pads
rather
than
clay
for
spills.
Pads
are
then
wrung
out
and
reused,
resulting
in
reduction
of
hazardous
waste
to
be
disposed.
Page
30
of
49
DuPont
http://
www.
dupont.
com/
corp/
news/
publications/
aboutdup/
02Excbro.
pdf
Eliminating
By­
Products
Generated
in
Process
Creates
Business
Value
A
Crop
Protection
team
on
the
Griffin
site
in
Brazil
discovered
that
the
by­
product
generation
of
2,3
dicholoronitrobenzene,
dichloronitrobenzene,
and
chloronitrophenols
during
the
production
of
the
DuPont
 
Diuron
®
and
DuPont
 
Propanil
®
herbicides
could
be
significantly
reduced
or
eliminated
by
making
process
modifications.
Using
teamwork
and
Six
Sigma
methodology,
the
process
changes
were
introduced
into
the
plant.
The
total
economic
benefit
of
the
program
exceeds
$
1
million
per
year
while
also
significantly
reducing
storage,
people
exposure,
and
environmental
containment
issues.

This
team
demonstrated
that
their
vision
to
drastically
reduce
residual
by­
product
production
generated
significant
value
for
shareholders
and
the
local
community.
The
use
of
Six
Sigma
methodologies
also
demonstrates
the
value
of
integration
of
sustainable
growth
and
productivity
improvements.
The
team's
commitment
to
the
goal
is
zero
is
obvious
through
their
focus
on
continuous
process,
practices,
and
products
improvements.

Case
Studies
of
the
Pharmaceuticals
Manufacturing
Industry
An
award­
winning
P2
success
in
the
pharmaceutical
industry
http://
www.
nywea.
org/
clearwaters/
301050.
html
Seeking
to
overcome
its
notoriety
as
one
of
New
York's
largest
industrial
sources
of
chemical
releases,
a
major
pharmaceutical
manufacturer
undertook
a
massive
pollution
prevention
program.
This
strategic
effort
included
contributions
from
the
facility's
chemical
development,
manufacturing,
and
environmental
divisions
and
was
focused
on
solvent
substitution
and
process
modifications.

Facility
researchers
succeeded
in
developing
a
penicillin
V
isolation
procedure
that
combined
whole
broth
filtration
with
solvent
substitution
after
they
assessed
potential
pollution
prevention
opportunities
and
pilot­
tested
alternative
methods
and
materials.
Their
efforts
have
reduced
reportable
releases
from
the
facility
by
more
than
1
million
lb/
yr.

The
pharmaceutical
complex
consists
of
manufacturing,
quality
control
and
research
laboratories,
pilot
plants,
and
administrative
offices.
Manufacturing
activities
include
production
of
several
pharmaceutical
intermediates
including
6­
aminopenicillanic
acid
(
6­
APA)
which
is
used
worldwide
in
the
production
of
anti­
infectives
such
as
amoxycillin
and
ampicillin.

The
manufacturing
process
for
6­
APA
begins
with
the
fermentation
of
penicillin
V
in
a
nutrient­
rich
aqueous
broth.
Next,
the
penicillin
V
is
extracted
in
a
solvent­
based
isolation
process.
After
isolation,
the
penicillin
V
extract
is
enzymatically
hydrolized
to
produce
6­
APA.

Long­
known
to
be
a
significant
source
of
fugitive
and
point­
source
air
emissions,
the
6­
APA
manufacturing
process
was
a
ready
pollution
prevention
target.
Several
obstacles,
however,
Page
31
of
49
had
to
be
overcome.
For
instance,
in
the
highly­
regulated
pharmaceutical
industry,
even
the
simplest
process
modifications
often
require
extensive
pilot
testing
and
lengthy
regulatory
approvals
to
confirm
that
the
effectiveness
and
safety
of
the
drug
produced
is
not
compromised.

Process
Description
The
manufacture
of
6­
APA
was
a
complicated
multi­
step
process
involving
fermentation,
extraction,
concentration,
crystallization,
filtration,
washing,
and
drying.
The
former
isolation
process
used:

1.
Methyl
isobutyl
ketone
(
MIBK)
to
perform
whole
broth
extraction
of
the
penicillin
V
from
the
fermentation
process;

2.
Concentration
of
the
penicillin
V
extract
with
six
Merco
centrifuges
(
manufactured
circa
1970);

3.
Crystallization
of
penicillin
V
slurry
by
a
series
of
filtrations
and
washes
using
acetone;
and
4.
Drying
of
the
crystallized
penicillin
V
product
to
ready
it
for
further
processing
(
for
example,
6­
APA
production).

Fueled
by
safety
and
environmental
concerns
associated
with
these
processes,
the
facility
organized
a
pollution
prevention
task
force
consisting
of
engineers
and
scientists
from
the
facility's
chemical
development
and
manufacturing
divisions.
Their
goal
was
to
develop
a
process
that
would
eliminate
or
materially
reduce
the
use
of
toxic
solvents
used
in
the
production
of
penicillin
V.

Following
a
series
of
evaluations
and
pilot
studies,
the
team
identified
three
significant
opportunities
for
pollution
prevention:


Replacement
of
the
whole
broth
extraction
step
with
an
ultrafiltration
system;


Substitution
of
n­
butyl
acetate
for
MIBK
as
the
extraction
solvent
and
completion
of
the
extraction
following
filtration;
and

Replacement
of
the
outdated
centrifuges
with
more
technologically
advanced
centrifuges.

The
ultrafiltration
system
separates
the
penicillin
V
from
the
fermented
broth
by
passing
the
broth
tangentially
over
a
membrane
at
high
velocity
and
pressure.
Membrane
surfaces
are
kept
clean
by
the
high
velocity
profile,
and
the
pressure
differential
forces
a
clear
liquid
solution
of
the
product
through
the
membrane.
This
effectively
filters
the
biomass
and
other
insoluble
impurities
in
the
broth.
The
permeate
is
sent
to
a
surge
tank
for
further
processing;
the
retentate,
containing
primarily
mycelium,
may
be
safely
discharged
to
the
process
sewer
system.
Page
32
of
49
Risks
of
MIBK
and
n­
butyl
Acetate
Hazardous
Characteristic
MIBK
 
butyl
Acetate
OSHA
8­
hr
limits
Exposure
limits
(
ppm)
Biological
limits
(
mg/
L)
50
2
150
not
identified
Toxicity
(
ACGIH)
Time­
weighted
average
(
ppm)
20
75
150
200
Biodegradability
(
BOD)
2.72
2.21
Flash
point
(
deg
F)
62.6
72
TRI­
listed
chemical?
yes
no
Another
innovation
in
the
new
isolation
process
was
substitution
of
n­
butyl
acetate
as
the
extraction
solvent
rather
than
MIBK.
MIBK
is
defined
as
a
hazardous
air
pollution
under
the
Clean
Air
Act
and
is
a
toxic
chemical
subject
to
reporting
under
community
right­
to­
know
laws
such
as
SARA
Title
III.
N­
butyl
acetate
is
nearly
three
times
less
toxic
than
MIBK
and
is
not
a
SARA­
reportable
chemical.

Since
the
extraction
now
occurs
after
filtration,
less
solvent
is
involved.
The
efficiency
of
the
extraction
is
also
enhanced
by
the
whole­
broth
filtration
process
because
the
number
of
centrifuges
required
for
concentration
is
reduced.
Furthermore,
since
the
solvent
extraction
procedure
is
now
physically
isolated
from
the
filtration
system,
the
extraction
process
has
been
equipped
with
a
separate
collection
system.
Wastewater
discharges
from
the
new
centrifuges
are
directed
to
an
existing
stripper
system.
Since
this
wastewater
discharge
no
longer
contains
broth
solids,
the
stripper
is
able
to
treat
the
effluent
more
efficiently,
improving
the
effectiveness
of
solvent
recovery
operations.

Centrifuge
operations
were
previously
conducted
in
six
Merco
centrifuges
­
encased
metal
bowls
suspended
on
a
high­
speed
drive
shaft
and
operated
under
atmospheric
conditions.
They
were
known
to
be
a
significant
source
of
fugitive
emissions
of
MIBK.
These
centrifuges
were
replaced
with
two
enclosed
units
which
reduce
fugitive
losses
of
MIBK
and
lower
worker
exposure.
The
new
centrifuges
also
allow
nitrogen­
blanketing
of
the
equipment.
The
only
emissions
from
this
equipment
now
are
from
conservation
vents
that
are
directed
to
an
existing
carbon
adsorption
VOC
recovery
system.

Cost/
Benefit
Analysis
Costs
to
Implement
Changes
Capital
item
Cost
Civil
work
$
100,000
Building
740,000
Equipment
4,820,000
Mechanical
work
720,000
Page
33
of
49
Electrical
work
1,200,000
Automation
and
instrumentation
660,000
Engineering
820,000
Subtotal
$
9,060,000
Contingency
(
10%)
910,000
Total
$
9,970,000
The
estimated
capital
costs
to
implement
these
changes
were
$
10
million.
New
process
equipment
and
advanced
electrical
controls
made
up
60%
of
this
total.
The
$
10
million
of
capital
costs
are
offset
by
a
10%
increase
in
production
capacity.
This
increase
is
largely
attributable
to
removal
of
the
bottleneck
that
was
the
extraction
process.
This
increased
efficiency
helped
the
facility
realize
additional
cash
flow
of
$
4.9
million/
yr
resulting
in
an
undiscounted
payback
period
of
2.7
yr
for
this
project.

Environmental
Benefits
Releases:
1994
and
1997
(
lb/
yr)

Environmental
Media
1994
MIBK
1994
n­
butyl
Acetate
1997
MIBK
1997
n­
butyl
Acetate
Net
Reduction
Air
(
point
and
fugitive)
1,000,000
0
0
250,000
75.0%

Wastewater
230,000
0
0
35,000
84.8%

Hazardous
waste
20,000
0
0
5,000
75.0%

Total
facility
TRI
releases
1,900,000
860,000
54.7%

Environmental
benefits
of
the
new
isolation
process
include
across­
the­
board
reductions
in
chemical
releases
to
the
air,
water,
and
land.
Despite
the
10%
increase
in
production
that
accompanied
this
pollution
prevention
project,
the
facility
has
reduced
actual
solvent
air
emissions
from
this
process
by
75%.
Furthermore,
since
n­
butyl
acetate
is
not
a
SARA­
reportable
chemical,
the
facility
has
reduced
reportable
releases
by
more
than
1
million
lb/
yr.

Wastewater
discharges
of
solvents
have
also
been
drastically
reduced.
Since
extraction
is
now
performed
after
filtration
and
the
discharge
from
the
new
centrifuges
has
a
dedicated
collection
system,
the
recovery
efficiency
of
the
stripper
system
is
no
longer
inhibited
by
the
presence
of
broth
solids
in
the
effluent.
Furthermore,
since
less
solvent
is
required
to
effect
the
extraction,
there
is
a
corresponding
reduction
in
wastewater
loadings.

Hazardous
waste
generated
from
the
process
has
been
reduced
by
75%.
The
efficiency
of
the
new
isolation
system
is
such
that
it
has
allowed
the
facility
to
remove
the
polish
filtration
step
at
the
end
of
the
process.
Reduced
usage
of
cartridge
filters,
filter
paper,
and
other
solid
wastes
have
led
to
a
15,000
lb/
yr
reduction
in
off­
site
hazardous
waste
disposal.
Page
34
of
49
Other
Benefits
The
company
has
garnered
social
rewards
and
improved
safety
conditions
from
this
P2
initiative.
The
facility
has
benefitted
from
improved
public
perception
and
better
community
relations.
Indeed,
having
been
awarded
the
1996
New
York
State
Governor's
Award
for
Pollution
Prevention,
the
facility
has
gained
a
great
deal
of
positive
press
both
in
New
York
and
nationally.

Abbott
Laboratories
(
Coyoacan,
Mexico)
http://
abbott.
com/
citizenship/
ehs/
highlights.
shtml
Water
Conservation:
Coyoacan,
Mexico
Our
Coyoacan
water
recycling
team
implemented
a
conservation
project
that
included
the
recirculation
of
cooling
water
for
the
sterilization
process
at
our
nutritionals
plant.
The
team
installed
a
cooling
tower,
heat
exchangers
and
filters,
which
enable
the
recycling
of
cooling
water
up
to
30
times.
This
resulted
in
an
overall
reduction
in
water
use
of
46
percent,
or
30.5
million
liters
annually,
saving
approximately
$
110,000
per
year.
The
new
process
also
markedly
increased
the
productivity
of
the
sterilization
cycle,
with
one
sterilization
process
increasing
production
capacity
by
54
percent
(
from
29,250
to
45,000
bottles
per
shift).

Abbott
Laboratories
(
Granada,
Spain)
http://
abbott.
com/
citizenship/
ehs/
highlights.
shtml
Waste
Reduction:
Granada,
Spain
Our
Granada
facility
has
made
significant
progress
on
its
aggressive
nonhazardous
waste
reduction
goals,
while
cutting
costs,
reducing
liability
and
decreasing
our
regulatory
burden.
Since
1999,
the
facility
has
reduced
the
volume
of
nonrecycled
waste
by
73
percent;
reduced
disposal
costs
by
70
percent;
and
is
now
generating
income
from
the
sale
of
recyclable
waste
to
third
parties.

Waste
Minimisation
in
a
Bulk
Drug
Manufacturing
Unit
­
A
Case
Study
http://
www.
cleantechindia.
com/
eicnew/
successstories/
bulk.
html
Introduction
The
pharmaceutical
industry,
which
manufactures
a
large
variety
of
products
uses
a
huge
amount
of
resources
in
terms
of
energy,
water
and
various
utilities,
besides
utilizing
in
large
quantities
a
whole
range
of
chemicals.
Both
domestic
and
multinational
companies
are
engaged
in
manufacturing
bulk
drugs
in
India.
They
employ
advanced
technologies
in
the
production
processes,
yet
scope
exists
in
minimizing
wastes
being
generated
in
these
industries.

The
case
presented
here
describes
waste
minimisation
potential
explored
in
one
such
bulk
drug
manufacturing
industry.
The
study
was
aimed
at
reducing
aqueous
load
to
the
incinerator
of
Page
35
of
49
the
unit.
The
aqueous
wastes
being
generated
during
the
manufacture
of
an
anti­
helminthic
drug
called
Albendazole
is
the
focus
of
the
study.

Production
Process:
Anti­
Helminthic
Drug
(
Albendazole)

Albendazole
©
H
N
O
S)
with
the
chemical
name:
methyl
5
­
(
propyl
thio)­
2
­
benzimidazole
carbamate
is
an
anti­
helminthic
drug
prescribed
for
humans.

The
base
chemical
used
in
the
manufacture
of
the
drug
Albendazole
is
(
ortho)
­
Nitro
Aniline
which
is
converted
to
ABZ
Thiocyano
in
an
independent
process,
or
purchased
by
the
plant.
Through
a
sequence
of
chemical
reactions
under
specified
process
conditions,
ABZ
Thiocyano
(
molecular
wt.
195
gms.)
is
converted
to
the
final
product
Albendazole
(
molecular
wt.
265
gms.).

The
reactions
in
the
production
process
are
carried
out
in
reactor
vessels
(
or
kettles)
made
of
stainless
steel
(
in
some
cases
they
are
glass
lined)
with
necessary
infrastructure
apparatus
for
monitoring
and
controlling
process
conditions
and
using
the
various
utilities.
The
various
steps
in
the
manufacturing
process
(
depicted
for
reaction
process
at
each
stage)
are
numbered
as
per
sequence
of
operations
observed.
A
brief
description
is
given
below.

In
Stage­
1
conversion
of
ABZ
Thiocyano
to
ABZ
PT
occurs
through
steps
1
­
5.
Intermittent
tests
using
Thin
Layer
Chromatography'
technique
for
samples
extracted
from
the
reactor
is
carried
out
to
check
status
of
the
reaction
and
its
completion,
other
quality
assurance
tests
are
also
carried
out.
Upon
completion
of
reaction
n­
propanol
solvent
is
recovered
by
distillation
(
step
6).
The
product
mass
is
washed
by
water
and
brine
solution
to
remove
impurities
(
steps
7
and
10).
The
product
is
extracted
by
toluene
(
step
8)
and
the
toluene
containing
product
is
separated
from
other
aqueous
mass
in
the
reactor
by
simple
decantation/
separation
of
the
immiscible
layers
owing
to
density
difference
(
steps
9
and
11).
Toluene
is
also
used
to
recover
washed
out
product
from
aqueous/
mother
liquor
(
step
14).
Thereafter
toluene
is
separated
from
the
product
by
distilling
it
out
by
raising
temperature
to
105C­
130
C
(
step
17).
The
recovered
product
ABZ­
PT
is
next
charged
to
reactor
in
stage
2.
Similarly
in
stage
2,
ABZ­
DA
is
produced
from
ABZ­
PT
in
a
suitable
reaction
mass
charged
in
a
reactor
under
suitable
process
conditions.
In
stage
3
pure
ABZ­
DA
is
distilled
out
by
high
vacuum
distillation
(
vacuum
maintained
between
0.1
­
0.5
torr)
at
180­
250
degree
C.
Stage
4
involves
preparation
of
Sodium
Ester
(
in
situ)
and
allowing
it
to
react
with
ABZ­
DA
under
suitable
reaction
conditions
in
the
reaction
mass.
The
final
product
mass
is
obtained
after
refluxing
out
acetone
solvent.
The
product
is
then
recovered
through
centrifuge
where
from
the
separated
mother
liquor
(
aqueous
wastewater)
is
despatched
to
the
incinerator.
The
product
undergoes
several
washings
at
the
centrifuge
before
being
sent
for
drying,
quality
testing,
micronising
and
packing.
Page
36
of
49
Reactant
Addition
in
Excess
of
Stoichiometric
Requirements
Stage
Chemical/
Reactant
%
Excess
Stage
1
NaOH
99%

CHBr
25%

Stage
2
NaHS
97%

Stage
4
Cyanamide
135%

Sodium
Ester
(
produced
in
situ)
107%

CH(
3)
COOCI
(
MCF)
120%

NaOH
107%

Waste
Assessment
and
Process
Audit
A
detailed
study
of
the
process
chemistry
under
each
stage
of
the
manufacturing
process
(
Albendazole
Manufacture)
and
analysis
of
mother
liquors/
aqueous
waste
waters
led
to
the
following
observations:

Observations
(
A)
Several
active
ingredients
were
added
in
excess
in
the
various
reaction
stages
in
comparison
to
stoichiometric
requirements
as
depicted
in
the
table
above.
The
unit
attributed
the
addition
of
excess
chemical
inputs
in
the
process
as
a
requirement
to
ensure
optimum
product
yield.

(
B)
The
aqueous
waste
water
generated
contained
large
quantities
of
salt
and
impurities
besides
residual
solvents
like
n­
propanol,
methanol
etc.
The
aqueous
generated
in
Stage
1
averaged
450
ltrs.
per
batch
of
ABZ­
Propyl
Thio
(
ABZ­
PT)
manufactured,
and
in
Stage
2
averaged
650
ltrs.
per
batch
of
ABZ­
Diamine
(
ABZ­
DA)
manufactured.
Thus
in
order
to
manufacture
3
batches
of
final
product
(
Albendazole),
where
two
batches
of
ABZ­
PT
and
one
batch
of
ABZ­
DA
are
required,
a
total
of
1550
ltrs.
of
aqueous
waste
water
(
Mother
Liquor)
is
generated
which
is
sent
for
incineration.
The
burden
on
the
incinerator
thus
was
found
to
be
immense
where
Liquid
Diesel
Oil
(
LDO)
was
consumed
at
the
rate
of
15
ltrs/
hr
to
incinerate
the
above
mother
liquor
and
other
aqueous
streams
fed
to
the
incinerator.
The
various
aqueous
streams
were
found
to
be
fed
to
the
incinerator
at
the
rate
of
37
ltrs/
hr
in
addition
to
15
ltrs/
hr
of
organic
effluent
(
organic
effluent
received
from
antibiotics
producing
unit).
The
cost
of
operating
the
incinerator
(
furnace
temperature
maintained
above
950
C
requiring
the
above
feed
rate
of
LDO)
and
the
associated
air
pollution
control
system
was
considered
to
be
a
huge
drain
on
the
resources
of
the
organization.

(
C)
The
quality
of
aqueous
when
analyzed
revealed
that
they
were
strong
effluents
with
a
BOD/
COD
ratio
of
less
than
0.3.
These
malodorous
waste
waters
are
highly
alkaline
(
pH
>
12)
and
contain
solvents
such
as
n­
propanol,
methanol
etc.,
between
3.5%
to
11%
respectively.
Page
37
of
49
Moreover
the
inorganic
salts
contained
were
very
high
such
that
the
aqueous
from
ABZ­
PT
and
ABZ­
DA
manufacture
had
TDS
in
the
range
of
217000
mg/
l
to
362000
mg/
l
respectively.

(
D)
Approximately
35­
40
kg
of
solid
organic
residue
(
solid
waste)
was
generated
during
Stage
3
(
purification
process
by
High
Vacuum
Distillation)
which
was
indicative
of
heavy
product
loss
per
batch.

Load
Reduction
at
the
Incinerator
 
Waste
Minimisation
Option(
s)

The
waste
assessment
study
led
to
the
exploration
of
waste
minimisation
options
for
reducing
aqueous
load
at
the
incinerator.

(
A)
In
Stage
1
Step
10
Hot
Water
+
NaCI
is
used
to
wash
organic
layer
(
toluene
solvent
+
product)
to
remove
impurities.
Subsequently
aqueous
layer
separated
at
Step
9
and
aqueous
salt
water
wash
separated
in
Step
11
are
recharged
into
the
reactor
tank
for
recovery
of
washed
out
product
from
the
aqueous
layers
by
extraction
of
organic
product
using
toluene
solvent
in
Step
14.
It
was
determined
that
the
product
concentration
in
aqueous
salt
water
wash
was
negligible.
Moreover,
this
waste
water
was
suitable
to
be
discharged
to
solar
evaporation
pond
(
SEP).
The
unit
was
therefore
advised/
recommended
that
Step
11
aqueous
need
not
be
recharged
to
the
reactor,
and
instead
this
aqueous
(
approx.
130
ltrs.)
be
sent
to
the
SEP,
and
thus
be
eliminated
from
further
steps
so
that
it
is
not
mixed
with
the
wastewater
stream
(
mother
liquor)
that
is
currently
sent
for
incineration.
Similar
to
Stage
1,
in
Stage
2
the
aqueous
salt
water
wash
of
Step
8
(
approx.
265
ltrs.)
was
analyzed
and
found
suitable
to
be
discharged
to
SEP
without
having
to
be
recharged
to
the
reactor
in
Step
10.
The
above
measures
therefore
would
ensure
that
for
every
three
batches
of
Albendazole
produced,
a
total
of
525
ltrs
of
aqueous
salt
water
wash
stream
(
2*
130
ltrs
of
Stage
1
+
1*
265
ltrs
of
Stage
2)
could
be
sent
to
SEP
and
not
burnt
at
the
incinerator.

(
B)
The
remaining
aqueous
wastewater
(
mother
liquors)
generated
during
production
of
156
kg
of
Albendazole
(
3
batches
of
Albendazole),
through
2*
Stage
1
and
1
*
Stage
2
(
i.
e.
640
ltrs
of
Stage
1
+
385
ltrs
of
Stage
2
of
mother
liquor(
s))
could
be
sent
for
solvent
recovery.
It
was
assessed
that
the
recovery
of
n­
propanol
and
methanol
from
these
mother
liquors
as
analyzed
through
the
laboratory
tests
amounted
to
approx.
80%
of
the
concentration
of
these
solvents
in
the
discharged
mother
liquors.
Therefore
it
was
estimated
that
at
the
Solvent
Recovery
Unit
(
SRU)
at
least
50%
of
these
solvents
in
the
mother
liquor
could
be
recovered
in
about
25%
of
the
distillate.
The
recovered
distillate
at
the
SRU
could
then
be
subject
to
incineration
(
having
thus
an
enhanced
calorific
value).
Balance
75%
volume
of
aqueous
wastewater
(
mother
Liquor)
would
thus
be
suitable
for
discharge
to
SEP
or
taken
to
ETP
for
further
treatment.
Thus
the
load
to
the
incinerator
would
further
be
reduced
by
765
1trs.

Results
The
above
measures
focused
on
reducing
aqueous
load
to
the
incinerator
resulted
in
260
ltrs
of
aqueous
waste
water
being
sent
for
incineration
instead
of
1550
ltrs
(
a
reduction
of
83%
in
volumetric
load
to
the
incinerator)
from
the
Albendazole
manufacturing
process.
This
was
estimated
to
result
in
reduction
of
LDO
consumption
at
the
incinerator
by
30%.
The
overall
Page
38
of
49
benefits
taking
into
account
fuel
savings,
savings
in
treatment
cost
at
ETP
(
due
to
diversion
of
some
effluent
streams
to
SEP)
and
savings
in
terms
of
reduced
manufacturing
time
in
Stages
1
and
2
(
thus
leading
to
increased
production
capacity
per
annum)
was
estimated
to
be
approx.
Rs.
10
lakhs
per
annum.

Conclusion
The
Waste
Assessment
study
strengthened
the
resolve
of
the
management
to
undertake
resource
conservation
measures
especially
focused
on
reducing
inputs
of
reactive
ingredients
to
optimal
levels.
Further
the
unit
initiated
exploration
of
potential
improvements
in
high
vacuum
distillation
process
(
Stage
3).

The
unit
initiated
feasibility
studies
for
waste
heat
recovery
from
the
flue
gases
discharged
from
the
incinerator.
The
waste
minimisation
study
led
to
a
new
initiative
in
the
industry
to
explore
resource
conservation
measures
in
its
bulk
drug
and
other
units
through
focused
R&
D
efforts.

Source
:
National
Productivity
Council
(
NPC)

Genentech
(
Vacaville,
CA)
http://
ateam.
lbl.
gov/
cleanroom/
doc/
Genentech_
Final.
doc
Genentech:
New
Energy
Efficient
Pharmaceutical
Manufacturing
Cleanroom
Facility,

Project
Benefits
Summary
Estimated
Annual
Energy
Cost
Savings
$
552,800/
y
Actual
Incremental
Project
Cost
$
1,783,360
Utility
Incentive
$
842,400
Project
Payback
(
after
incentive)
1.7
years
Facility
Description
The
Genentech
Vacaville
facility
is
made
up
of
six
buildings
in
Vacaville
California.
This
is
the
second
site
for
Genentech,
the
first
site
is
located
in
South
San
Francisco,
CA.
Genentech
is
a
leading
biotechnology
company
that
discovers,
develops,
manufactures
and
markets
human
pharmaceuticals
for
significant
unmet
medical
needs.

The
site's
six
buildings
include:

1.
180,000­
ft2
Bulk
Manufacturing
Building
with
class
10K
and
100K
cleanroom
areas
and
10
air
handling
units
(
approx.
400,000
cfm);
Page
39
of
49
2.
18,000­
ft2
Central
Utility
Plant
with
3,400
tons
of
chilled
water,
3,000
scfm
of
compressed
air,
14,000
gpm
of
tower
water
(
process
and
HVAC),
and
70,000
lb/
hr
of
high
pressure
steam;

3.
40,000­
ft2
Lab/
Administration
Building;

4.
30,000­
ft2
Warehouse;

5.
20,000­
ft2
Facilities
Service
Building;
and
6.
A
"
spine"
connecting
all
of
the
buildings
together.

The
energy
saving
measures
for
the
site
were
aimed
at
the
entire
facility.
However,
this
study
focuses
only
on
measures
that
affect
the
cleanroom
areas.
In
addition
to
internal
production
requirements,
these
areas
are
required
to
comply
with
Food
and
Drug
Administration
(
FDA)
regulations
for
cleanliness
because
the
facility
is
intended
for
the
production
of
pharmaceuticals.

Project
Description
A
total
of
twenty­
two
separate
energy
efficiency
measures
were
performed
at
the
Vacaville
site.
These
measures
are
summarized
below
with
a
mention
of
estimated
energy
savings.
The
estimated
savings
were
calculated
by
Genentech's
energy
consultant,
Southern
Exposure
Engineering
based
upon
baseline
and
enhanced
energy
consumption
models.
No
measured
data
is
currently
available
for
these
measures.

Key
Aspects
of
the
Energy
Efficiency
Project
Discharge
Air
Temperature
Reset
(
Makeup
Air
Handlers)

Control
logic
was
implemented
to
reset
the
discharge
air
temperature
up
from
55
°
F
to
60
°
F
when
the
demand
for
cooling
decreases.
This
leads
to
a
reduction
in
energy
use
because
the
makeup
air
is
not
cooled
all
the
way
down
to
55
°
F.
All
of
the
cleanrooms
are
regulated
by
the
FDA,
which
requires
that
they
be
supplied
with
a
constant
volume
of
makeup
air.
This
temperature
reduction
prevents
overcooling
and
subsequent
unnecessary
reheating
of
the
supply
air
to
the
space,
thereby
saving
chilled
water
and
steam
plant
energy.
This
measure
is
expected
to
have
annual
energy
cost
savings
of
about
$
155,000/
y
and
a
reduction
in
peak
electrical
load
of
about
19
kW.

Variable
Speed
Drives
for
the
Variable
Volume
Air
Handlers
Instead
of
inlet
vanes
for
the
supply
and
return
fans,
variable
speed
drives
(
VSDs)
were
installed
on
the
six
variable
volume
air
handlers
throughout
the
building
including
one
serving
the
cleanroom.
The
VSDs
reduce
the
horsepower
of
the
fans
to
reduce
flow,
whereas
inlet
vanes
reduce
the
flow
by
increasing
pressure
drop
while
the
fans
are
still
running
full
speed.
VSD
operation
reduces
fan
motor
energy
use
more
than
vanes
do
at
low
flow
conditions.
The
annual
Page
40
of
49
energy
cost
savings
are
expected
to
be
about
$
23,000/
y
with
a
reduction
in
peak
load
of
about
40
kW.

High
Efficiency
Boilers
and
Boiler
Economizers
High
efficiency
boilers
were
installed
as
well
as
boiler
economizers.
The
boiler
stack
economizers
recover
waste
heat
out
of
the
flue
gas,
allowing
more
steam
generation
using
the
same
amount
of
fuel.
Together
these
measures
are
expected
to
have
annual
energy
cost
savings
of
about
$
48,700/
y.

Tower
Water
for
Process
Cooling
Water
from
the
cooling
towers
is
being
used
for
high
temperature
processes
that
do
not
need
the
low
temperatures
provided
by
the
comparatively
less
efficient
chillers,
which
operate
at
0.5
kW/
ton
efficiency,
at
best.
The
cooling
towers
are
able
to
provide
cooling
at
about
0.04
kW/
ton
(
an
order
of
magnitude
improvement
in
efficiency).
The
cooling
towers
provide
75
°
F
water
for
processes
that
do
not
require
40
°
F
chilled
water
such
as
pasteurizing
and
cooling
for
the
water
for
injection
(
WFI).
This
measure
is
expected
to
save
about
$
62,700
annually
and
reduce
peak
load
by
about
455
kW.

Process
Chiller
with
a
Surge
Tank
A
dedicated
process
chiller
was
installed
in
manufacturing
building
to
provide
the
low
temperature
processes
with
40
°
F
water
instead
of
using
the
chilled
water
from
the
central
utility
plant.
A
surge
tank
was
also
installed
for
chilled
water
storage
to
reduce
the
peak
electric
demand.
The
surge
tank
holds
15,000
gallons
and
provides
approximately
600
ton­
hours
of
thermal
storage.
Large
energy
savings
also
come
from
this
separation
of
low
temperature
loads
from
the
higher
temperature
loads.
This
allows
the
central
plant
to
operate
at
44
°
F,
instead
of
40
°
F,
resulting
in
a
significant
improvement
in
its
efficiency.
The
low
temperature
chiller
and
surge
tank
are
expected
to
save
about
152,000
kWh
annually
and
reduce
peak
loads
by
about
560
kW,
results
in
cost
savings
of
about
$
36,000/
y.

High
Efficiency
Equipment
and
Unequal
Chiller
Sizing
A
high
efficiency
process
chiller
and
high
efficiency
central
plant
chillers,
vacuum
pumps,
and
motors
were
installed.
In
an
effort
to
operate
the
chillers
as
close
to
full
load
as
possible,
where
they
are
most
efficient,
a
600
ton
chiller
and
two
1,400
ton
chillers
were
selected
instead
of
three
1,134
ton
chillers.
This
unequal
sizing
method
saves
energy
by
allowing
the
chillers
to
stage
up
in
smaller
steps
and
operate
much
closer
to
full
load.
The
two
large
chillers
are
run
at
full
load
while
the
smaller
one
can
be
run
to
supply
any
additional
cooling
that
is
needed.
By
selecting
high
efficiency
equipment
and
unequal
sized
chillers,
about
$
113,250
will
be
saved
annually
with
a
reduction
in
peak
load
of
296
kW.
Page
41
of
49
Low
Approach
Cooling
Towers
Large
cooling
towers
were
installed
to
reduce
the
approach
from
14
°
F
to
8
°
F
above
the
design
wet
bulb
temperature
of
71
°
F.
In
addition,
the
spray
nozzles
were
reconfigured
to
spread
the
condenser
water
more
evenly
over
the
fill
while
allowing
the
flow
to
better
match
the
required
flow
for
the
chillers.
This
modification
of
the
nozzles
allowed
the
approach
to
drop
even
further
down
to
4
°
F.
There
was
an
increase
in
cooling
tower
fan
power
from
102
kW
to
167
kW,
however,
much
more
energy
was
saved
by
providing
the
chillers
with
cooler
condenser
water,
which
improves
the
ability
of
the
chiller
to
reject
heat.
This
reduction
in
condenser
water
temperature
in
expected
to
improved
the
efficiency
of
the
large
chillers
from
0.62
kW/
ton
to
0.49
kW/
ton
(
0.013
kW/
ton
per
°
F
decrease
in
condenser
water
supply
temperature).
This
measure
is
expected
to
save
about
$
24,000
annually
with
a
decrease
in
peak
load
of
70
kW.

Pump
Variable
Speed
Drives
VSDs
were
installed
on
the
condenser
water
pumps,
primary
chilled
water
pumps,
secondary
chilled
water
pumps,
tertiary
chilled
water
pumps,
and
heating
water
pumps.
The
VSDs
save
energy
by
precisely
matching
the
flow
and
the
pressure
requirements
of
the
system
to
minimize
pump
energy.
These
drives
will
save
approximately
$
36,900
annually
and
will
reduce
the
peak
demand
by
140
kW.

Applicability
to
the
Cleanroom
Industry
These
efficiency
measures
have
not
inhibited
Genentech
from
complying
with
strict
FDA
regulations
for
pharmaceutical
plants.
The
plant
it
is
expected
to
operate
and
more
reliably
with
these
modifications
and,
because
the
project
had
an
excellent
payback
of
1.7
years,
after
the
utility
incentive,
it
will
be
more
profitable
to
operate
in
the
long
run.
One
example
of
improved
reliability
is
the
surge
tanks,
which
guarantee
that
process
chilled
water
will
be
available
when
needed
in
case
of
a
shutdown.

Part
of
the
reason
that
this
project
was
so
successful
was
that
the
measures
could
be
implemented
in
the
development
phases
of
the
plant
before
any
equipment
was
purchased
or
installed.
Energy
efficiency
measures
implemented
in
a
new
building
can
achieve
greater
and
more
cost­
effective
savings
than
retrofit
measures
implemented
in
existing
buildings.

Project
Challenges
Genentech
encountered
a
number
of
challenges
while
trying
to
implement
energy
saving
measures
for
this
project.
In
a
concerted
effort
to
maintain
the
goal
of
efficient
operation,
Genentech
worked
through
solutions
to
most
problems
they
encountered.
Some
of
these
problems
are
common
in
the
cleanroom
industry
and
their
solutions
should
be
instructive
for
other
facility
operators
and
planners.
The
first
problem
was
that
no
review
period
was
scheduled
for
analysis
of
the
energy
saving
alternatives.
These
reviews
were
to
be
included
in
the
overall
design
review
period,
where
they
would
probably
fall
through
the
cracks.
To
solve
this
problem,
the
energy
consultant
was
integrated
with
the
design
team
to
provide
quick
feedback
on
ideas
and
recommendations
to
improve
energy
use
during
the
design
process.
Secondly,
no
defined
budget
Page
42
of
49
was
allocated
for
development
of
energy
saving
ideas
at
the
beginning
of
the
project.
However,
money
for
actual
projects
was
included
in
the
overall
project
budget.
The
solution
was
to
obtain
utility
funding
for
idea
development
and
analysis
and
with
utility
incentives
for
ideas
that
resulted
in
a
payback
of
greater
than
two
years.
A
third
challenge
to
successfully
capturing
the
savings
from
energy
efficiency
measures
lies
with
the
building
operations
staff.
This
is
being
addressed
through
education,
training
and
awareness
of
the
original
design
intent.

Merck
&
Company
Inc.
­
Cherokee
Plant
(
Northumberland
County,
PA)
http://
www.
dep.
state.
pa.
us/
dep/
deputate/
pollprev/
pdf/
fact_
sheets/
fs1580.
pdf
Background
Merck
&
Company
Inc.
established
a
pharmaceutical
manufacturing
facility
in
Riverside,
Northumberland
County,
in
1950.
Since
1984,
this
facility
has
used
methylene
chloride,
a
volatile
organic
solvent,
to
synthesize
imipenem,
a
component
of
the
broad
spectrum
antibiotic
drug
PRIMAXIN.
Methylene
chloride
is
an
animal
carcinogen
and
is
listed
as
a
priority
pollutant
by
the
federal
Environmental
Protection
Agency
(
EPA).
Changes
in
the
use
of
these
chemicals
can
reduce
environmental
emissions
of
suspected
carcinogens.

In
April
1989,
Merck
voluntarily
established
environmental
policy
goals
to
reduce
air
emissions
of
carcinogens
or
suspect
carcinogens
by
the
end
of
1991,
then
to
eliminate
or
reduce
air
emissions
by
the
end
of
1993.
Another
goal
was
to
reduce
all
environmental
releases
of
toxic
(
SARA)
chemicals,
including
transfers
of
materials
offsite
for
treatment
or
disposal,
by
the
end
of
1995.
Although
manufacturing
operations
have
grown,
Merck
met
its
1991
goal.

The
federal
Clean
Air
Act
Amendments
of
1990
address
methylene
chloride
emissions
in
the
pharmaceutical
industry
through
the
Hazardous
Organic
National
Emission
Standards
for
Hazardous
Air
Pollutants
(
HON)
regulations,
which
were
proposed
on
Dec.!
31,
1992.
More
regulations
are
due
from
EPA
in
November
1997.

Process
Change
Methylene
chloride
was
the
major
solvent
used
in
the
synthesis
of
imipenem.
In
order
to
meet
its
air
emissions
goals,
Merck
chemists
and
engineers
developed
a
new
manufacturing
chemistry
process
that
eliminated
the
use
of
methylene
chloride
in
the
synthesis
of
imipenem
at
a
cost
of
$
34
million.
As
part
of
this
change,
Merck
substituted
smaller
amounts
of
solvents
which
are
viewed
to
have
fewer
environmental
effects
than
methylene
chloride.
This
new
process
was
implemented
at
Merck
¹
s
Cherokee
plant
in
1992.

Some
of
the
other
chemistry
process
modifications
include:

1.
Computer
controlled
ultrafiltration
technique
to
filter
extremely
small
particles.
This
method
increases
product
yield
and
improved
quality
of
imipenem;
and
2.
Solvent
recovery
to
reuse
solvent,
which
reduces
solvent
consumption
and
disposal.
Page
43
of
49
Equipment
Change
When
the
new
process
was
installed,
the
factory
area
was
upgraded
with
a
computerized
distributed
control
system
(
DCS)
and
equipment
modularity.
The
number
of
imipenem
processing
operations
was
reduced
by
almost
50percent
with
the
DCS
automated
and
sequenced
chemical
reaction
steps.
Key
measurements
are
continuously
monitored
by
a
computer
that
operates
valves,
pumps
and
motors
on
the
equipment
to
provide
control
of
the
chemical
process.
The
DCS
reduces
the
potential
for
human
error.

Environmental
Results
Reduced
VOC
Management
With
the
new
process,
Merck
eliminated
not
only
the
purchase
of
significant
quantities
of
methylene
chloride,
but
also
the
storage
and
disposal
of
hazardous
waste.
According
to
Merck,
the
new
chemistry
process
has
also
resulted
in
a
75percent
reduction
of
biological
oxygen
demand
(
BOD)
load
to
the
onsite
waste
water
treatment
plant.
BOD
is
the
amount
of
oxygen
used
by
microrganisms
in
the
breakdown
process
of
pollutants
in
polluted
water
and
waste
water.

Also,
best
available
technology
end­
of­
pipe
controls
were
added
with
the
installation
of
a
fume
incinerator.
Toxic
(
SARA)
air
emissions
were
decreased
more
than
300,000
pounds
a
year
in
the
antibiotic
production
area
by
this
incinerator.

Bonuses
from
the
new
process
were
decreased
risk
of
accidental
spills
of
hazardous
materials,
increased
employee
protection,
and
ease
of
achieving
compliance
with
more
stringent
environmental
regulations.
Additionally,
Merck
reduced
its
environmental
liability
by
implementing
pollution
prevention
into
its
manufacturing
process.

Cost
Savings
The
improved
process
lowered
production
costs
of
imipenem.
At
an
estimated
savings
of
more
than
$
14
million
per
year,
Merck
&
Company
expects
a
short
term
payback
of
their
$
34
million
investment
for
the
new
process.

Pollution
Prevention
Goal
The
goal
of
pollution
prevention
is
to
reduce
the
quantity
or
toxicity
of
waste
generated
within
the
production
process.
To
achieve
this
goal
and
protect
the
environment,
Merck
¹
s
Cherokee
Plant
personnel
developed
an
innovative
manufacturing
process
that
eliminated
the
use
of
methylene
chloride,
increased
product
yield
and
added
manufacturing
flexibility
for
future
process
changes.

These
efforts
were
recognized
when
Merck
won
the
Governor's
Waste
Minimization
Award
in
1990
and
1992.
20CO2
emission
reduction
could
also
be
achieved
by
switching
to
alternative
fuels
or
purchasing
steam,
without
reducing
energy
consumption.

Page
44
of
49
This
case
study
illustrates
how
industry
can
use
innovation
to
protect
the
environment
by
preventing
pollution
before
it
is
created,
contain
costs
and
boost
productivity.

Novartis
(
Rovereto,
Italy
)
http://
www.
novartis.
com/
downloads_
new/
news/
AR03_
HSE.
pdf
Health,
Safety
and
Environment
This
section
summarizes
the
Group's
Health,
Safety
and
Environmental
(
HSE)
performance
in
2003.
Our
HSE
targets
focused
once
again
on
reducing
the
number
of
accidents,
lowering
energy
use/
CO2
emission,
safely
disposing
of
the
hazardous
waste
we
produce,
and
successfully
integrating
recently
acquired
partners
and
newly
founded
organizations.
This
report
describes
the
most
important
measures
undertaken
to
fulfill
our
ambitious
targets,
and
discusses
our
achievements
as
well
as
areas
in
which
we
intend
to
improve.
The
full
Novartis
HSE
report
is
available
on
our
website
at
www.
novartis.
com/
hse.
There
you
will
also
find
additional
information
on
all
the
issues
mentioned
in
this
report.

Strong
Commitment
Protection
of
the
environment
has
a
high
priority
in
all
our
activities.
We
strive
to
make
efficient
use
of
natural
resources
and
minimize
the
environmental
impact
of
our
activities
and
products.

Between
2001
and
2003,
we
set
ourselves
the
target
of
reducing
our
direct
CO2
emission
by
3%
(
based
on
2000
emission
levels).
As
can
be
seen
in
our
report
on
Air
Emission
(
see
page
66)
we
achieved
a
reduction
of
2.8%,
in
spite
of
a
4.8%
growth
in
production.
The
reduction
was
facilitated
by
a
move
to
more
energy­
efficient
facilities,
and
has
resulted
in
a
CO2
emission
level,
relative
to
sales,
that
is
well
below
the
industry
average.

In
light
of
these
achievements
and
with
the
goal
of
further
improvement,
we
have
proposed
individual
energy
efficiency
targets
for
the
Pharmaceuticals
and
the
Consumer
Health
Divisions
for
2004­
2006.
We
will
continue
to
report
our
absolute
CO2
emission
and
will
also
include
indirect
emission
(
e.
g.
from
electricity
and
purchased
energy).

Our
focus
on
energy
efficiency
as
opposed
to
absolute
CO2
emission
better
reflects
our
commitment
to
the
sustainable
use
of
natural
resources20.
Energy­
efficiency
improvement
targets
for
each
Business
Unit
will
be
2%
per
year,
based
on
their
most
representative
denominator
(
e.
g.
sales,
production,
employees).
Moreover,
each
Business
Unit
must
report
energy­
saving
projects
that
amount
to
a
total
reduction
of
1%
of
the
previous
year's
energy
consumption.
21ISO
issued
the
international
standard
ISO
14001
for
environmental
management
systems
in
1996.

Page
45
of
49
Enough
Water
for
a
Small
City
When
Sandoz,
our
generic
pharmaceuticals
Business
Unit,
originally
acquired
the
Roferm
S.
p.
A.
plant
at
Rovereto
in
Italy
in
1995,
there
was
considerable
room
for
improvement
both
economically
and
environmentally.
Following
the
acquisition,
the
product
portfolio
was
adapted
to
the
needs
of
Sandoz
and
focused
on
the
production
of
antibiotics.
Investments
worth
approximately
USD
170
million
were
also
made
in
new
technologies
and
equipment,
together
with
logistical
and
environmental
improvements.

In
2002,
Rovereto
achieved
a
reduction
of
more
than
50%
in
halogenated
VOC
emission
by
cryocondensation,
a
major
first
step
towards
an
HSE
performance
that
is
inline
with
the
highest
environmental
standards.
During
2003,
further
progress
was
made
through
energy
conservation
and
groundwater
saving
initiatives.

To
reduce
energy
consumption,
two
new
air
compressors
were
fitted
with
heat
recovery
exchangers.
The
compression
heat
generated
(
2x360
kW)
is
now
recovered
and
used
to
preheat
the
feed
water
for
the
plant's
steam
generators.
This
process
has
increased
efficiency,
reduced
CO2
emission
by
approximately
800
tonnes
per
year,
and
provided
a
cost
saving
of
around
USD
90
000
per
year.

Rovereto's
reduction
of
approximately
40%
in
its
groundwater
consumption
during
2003
is
an
equally
important
achievement.
Cooling
water
at
the
plant
was
previously
used
only
once,
before
being
discharged
into
the
River
Adige.
Thanks
to
the
investment
in
new
technology,
a
recycling
system
has
been
installed
that
allows
the
water
to
be
reused
for
cooling
condensers
and
solvent
recovery
processes.
The
new
system
has
resulted
in
an
overall
saving
in
groundwater
consumption
of
around
510
m3/
h,
equal
to
the
hourly
water
consumption
of
an
Italian
city
of
50,
000
inhabitants.

Now
Rovereto
is
looking
to
go
further
and
formalize
its
commitment
to
environmental
management
by
applying
for
ISO
14001
and
OHSAS
18001
certification
in
200421.
Kurt
Gstrein,
Head
of
HSE,
Sandoz
is
delighted
with
what
has
been
achieved
at
the
plant:
"
Rovereto's
success
shows
how
HSE
management
can
combine
with
top­
level
engineering
at
acquired
sites
to
bring
about
exceptional
improvements
in
HSE
performance.
It
is
an
excellent
model
for
the
integration
of
new
partners
in
the
future".

Case
Studies
of
the
Petroleum
Refining
Industry
Refinery
Expansion
Reference:
Giesbrecht,
Gary.
Water
Use
in
Industries
of
the
Future:
Petroleum
Industry.
CH2M
Hill.
Prepared
for
the
U.
S.
Department
of
Energy's
Office
of
Energy
Efficiency
and
Renewable
Energy
(
under
contract
to
the
Center
for
Waste
Reduction
Technologies).
July
2003.

A
petroleum
refinery,
originally
built
in
the
1950s,
expanded
overall
capacity
and
modified
its
operations
to
accept
a
higher
American
Petroleum
Institute
(
API)
gravity
feedstock
and
reduce
Page
46
of
49
the
sulfur
in
gasoline
and
diesel
fuel
products.
The
planned
expansion
would
result
in
an
increase
in
the
steam
rate
and
cooling
load,
therefore
the
refinery
modifications
included
a
new
water
management
plan
with
the
following
objectives:


Maintain
pre­
expansion
water
withdrawal
volumes
(
i.
e.,
no
additional
make­
up
water);


Do
not
increase
capacity
of
existing
subsurface
injection
well;
and

Be
able
to
obtain
wastewater
discharge
permit.

To
minimize
the
use
of
river
water
and
the
amount
of
deepwell
disposal,
the
refinery
modified
water
management
operations
as
follows:


Demineralize
all
boiler
feedwater,
via
a
reverse
osmosis
(
RO)
system;


Re­
use
the
RO
reject
stream
from
boiler
feedwater
treatment
as
cooling
tower
makeup;


Use
deepwell
disposal
for
high
TDS
(
total
dissolved
solids)
wastewater
only;


Upgrade
the
refinery
wastewater
treatment
system;
and

Reuse
refinery
effluent
as
cooling
tower
makeup
water.

The
wastewater
discharges
prior
to
the
expansion
included
163
gallons
per
minute
(
gpm)
boiler
blowdown
and
568
gpm
treated
effluent.
Both
streams
were
discharged
to
surface
water.
Following
the
expansion,
259
gpm
of
treated
effluent
is
discharged
to
surface
water,
and
776
gpm
of
treated
effluent
is
recycled
back
to
the
cooling
system.

The
refinery
is
located
near
a
major
river
and
a
city
with
a
population
of
approximately
1
million.

Golden
Bear
Refinery
(
Oildale,
CA)
Reference:
USFilter.
Case
History,
Refinery
Wastewater
Reuse:
The
Golden
Bear
Refinery
Experience.
Rothschild,
WI.
2001.

In
1999,
USFilter's
Zimpro
Products
(
Rothschild,
WI)
installed
a
wastewater
treatment
system
at
the
Golden
Bear
Refinery
(
Oildale,
CA),
enabling
the
refinery
to
reuse
treated
effluent
water
in
its
boiler
and
cooling
tower
systems.
The
refinery
generates
about
130
gallons
of
wastewater
per
minute
and
reuses
approximately
70
percent.

The
treatment
system
includes
a
reverse
osmosis
(
RO)
pretreatment
system,
powdered
activated
carbon
(
PACT
®
)
biological
system,
sand
filter
(
Hydro­
Clear
®
)
,
and
two­
stage
RO
system.
USFilter
chose
the
PACT
biological
system
based
on
economics,
system's
ability
to
Page
47
of
49
handle
variable
organic
loads,
treatment
stability,
minimization
of
volatile
organic
compounds
(
VOC)/
odor
stripping,
and
minimal
solids
generation.

The
Golden
Bear
Refinery
produces
high­
quality
lubricants
and
paving
asphalt.

USFilter
Wastewater
Treatment
Plant
at
the
Sunoco
Refinery
(
Toledo,
OH)
Reference:
USFilter.
Case
Study:
Sunoco,
Lower
Costs,
Stronger
Balance
Sheet
Drive
Refinery
Agreement.

In
1998,
USFilter
purchased
the
wastewater
treatment
plant
located
at
the
Sunoco
refinery
in
Toledo,
OH.
USFilter
operates
the
system
and
treats
the
wastewater
from
the
refinery.

USFilter
improved
operation
of
the
wastewater
treatment
plant
by
using
a
computerized
preventive
maintenance
program
and
process
control.
These
systems
control
maintenance
schedule,
detect
issues,
and
handle
influent
variations
at
the
treatment
system.
One
million
dollars
worth
of
capital
improvements
and
maintenance
were
installed.
The
system
recycles
3.25
million
gallons
per
day
of
treated
effluent
back
to
the
refinery's
cooling
system
and
discharges
2.0
million
gallons
per
day
to
a
POTW.

All
the
raw
wastewater
is
treated
by
screens,
API
separators,
dissolved
nitrogen
flotation,
aeration,
and
clarification.
Effluent
for
use
at
the
cooling
towers
is
treated
further
by
sand
filters
to
reduce
pollutants
further.

The
Toledo
refinery
can
process
140,000
barrels
per
day
of
crude
oil,
forming
products
such
as
gasoline,
diesel
fuel,
kerosene,
solvents,
propane,
and
residual
fuels.

Rompetrol
Refinery
Complex
Petromidia
(
Navodari,
Romania)
Reference:
Rompetrol
Refinery
Complex
Petromidia.
Improving
Water
Management
at
a
Refinery
Complex
in
Romania.
Navodari,
Romania.
April
2001
­
January
2002.
http://
www.
rec.
org/
ecolinks/
bestpractices/
PDF/
romania_
rompetrol.
pdf
The
Petromidia
Refinery
Complex,
located
in
Romania,
was
built
in
1975.
The
Complex
refinery
has
a
capacity
to
process
4.8
million
tons
of
crude
oil
per
year
into
leaded
and
unleaded
gasoline,
diesel
fuel,
jet
fuel,
fuel
oil,
coke,
various
aromatics,
propane,
butane,
and
sulfur.
Currently,
the
plant
processes
between
3
and
3.5
million
tons
of
crude
oil
per
year.

The
Complex
pumps
process
water
from
the
Danube­
Black
Sea
Cana
(
Carasu)
approximately
20
kilometers
away.
The
water
supply
pumps
are
oversized,
pumping
at
a
rate
of
approximately
1,700
cubic
meters
per
hour,
exceeding
site
requirements
by
up
to
800
cubic
meters
per
hour.
Firewater
is
pumped
from
Lake
Tasaul
and
used
without
treatment
(
sometimes
for
certain
process
applications
as
well).

With
the
support
of
an
EcoLinks
Challenge
Grant,
the
Complex
evaluated
current
water
management
at
the
refinery
and
developed
an
improved
water
management
plan
(
the
Implementation
Plan)
to:


Reduce
environmental
compliance
costs;


Optimize
energy
consumption
and
equipment
efficiency;
and
Page
48
of
49

Reduce
wastewater
discharges.

The
project
team
evaluated
the
following
items:
water
supply,
wastewater
collection,
wastewater
treatment,
cooling
towers,
boilers,
petrochemical
process
water,
refinery
process
wastewater,
ground
water,
and
stormwater.
This
evaluation
occurred
from
April
2001
to
January
2002
and
cost
a
total
of
$
72,078.

The
components
of
the
Implementation
Plan
are
highlighted
in
the
table
below
(
reproduced
from
the
reference).
The
report,
Improving
Water
Management
at
a
Refinery
Complex
in
Romania,
provides
a
summary
of
all
options
considered.

Petromidia
Refinery
Complex
Implementation
Plan
Alternatives
Saved
Energy
KWh/
month
Investment
US
$
Savings
Simple
Payback
Years
Install
smaller
pumps
in
separators,
storm
water
and
ground
water
pump
stations
32,800
56,000
16,900
US
$/
year
2.53
Install
flow
meters
NA
270,000
75,000
US
$/
year
3.6
Install
level
indicators
in
grease
separators
NA
205,000
Wastewater
quality
improvement
Not
available
yet
Repair
oil
skimmers
in
separators
NA
1,800
Reduced
petroleum
discharge
into
WWTP
Not
available
yet
Install
smaller
raw
water
pumps
230,
580
141,000
to
181,000
14,490
to
16,537
US
$/
month
9.75
to
11
months
Rehabilitation
of
cooling
towers
NA
3,865,904
Not
available
yet
Not
available
yet
Replace
existing
cooling
towers
with
smaller
units
Not
assessed
yet
4,850,000
1,200,000
US
$/
year
4
Re­
use
of
Marox
caustic
waste
for
sulfides
and
mercaptans
More
power
need
for
pumps
(
increased
from
22
to
25
kW
/
motor)
2,750
857.6
US
$/
month
3.21
months
Boiler
blowdown
used
for
process
purposes
1,552,778
Not
assessed
yet
28,060
US
$/
month
Not
assessed
yet
Wastewater
used
as
fire
water
64,800
22,180
13,450
US
$/
month
1.65
months
The
Implementation
Plan
focuses
on
using
less
energy
and
raw
water,
and
generating
less
wastewater.
Using
the
Implementation
Plan,
the
Complex
can
lower
energy
use
by
approximately
1.8
million
kWh
per
month
and
a
total
annual
savings
of
$
1.9
million
using
all
the
alternatives
developed.
Page
49
of
49
Wastewater
discharge
was
reduced
from
1,000­
1,100
cubic
meters
per
hour
to
600­
750
cubic
meters
per
hour.
The
reduction
in
wastewater
discharge
results
in
a
savings
of
$
258,000
per
year.
