Waste Minimization Techniques for SQGsinfohouse.p2ric.org/ref/28/27963.pdfIndustrial Organic Phenol...

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L 7 9 G S /?If- - ICF INCORPORATED International Square, 1850 K Street, Northwest, Washington, D C 20006 (202) 862-1 100

October 9 , 1986

MEMORANDUM

TO : Bob Axelrad, Debbie Rutherford

FROM : Deborah Shaver

SUBJECT: Waste Minimization Techniques for SQGs

This memorandum presents a status report on the work done to date on waste minimization techniques applicable to small quantity generators of hazardous waste in various industries. Attached are summaries of these waste minimization techniques, presented separately for each industry. Additional work has been done on the preliminary summaries sent to EPA in July. Based on the research done thus far, we recommend that fact sheets on waste minimization measures first be prepared for certain industries. In other industries, our work suggests that writing fact sheets may be a lower priority effort. follow for some industries.

We would like to receive EPA's guidance on the course of action to

Research has been conducted on waste minimization options for the following industries:

e

e

e

e

e

e

e

e

e

a

Vehicle Maintenance

Drycleaning

Textile Manufacturing

Equipment Repair

Furniture/Wood Manufacturing and Refinishing

Pesticide End-Users/Application Services

Chemical Manufacturers/Formulators (including cosmetics manufacturing and various formulating industries -- pesticides, paints and fertilizers) Construct ion

Printing Ink Formulators and Printers

Photoprocessing/Photofinishing

Bob Axelrad, Debbie Rutherford October 9, 1986 Page Two

Laboratories

Metal Manufacturing

Paper Industry

Leather Products Manufacturing

Wood Preserving

Information in the attached summaries has typically been presented according to the industrial process and waste generated. In industries which contain several different sectors, waste reduction measures are organized by sector, process, and waste. Research was not conducted on motor freight terminals/railroad transportation and educational and vocational shops. The processes used and the wastes generated by these industries are very similar to those of other industries studied (e.g., vehicle maintenance, metal manufacturing). Should EPA wish to develop fact sheets on these industries, information already gathered could readily be tailored to these industrial applications.

Information about waste minimization techniques was obtained from a variety of sources. ICF maintains an extensive collection of literature on waste reduction which was reviewed to identify measures applicable to particular industries. In addition, extensive telephone contacts were made with trade associations, state waste reduction and technical assistance programs, equipment manufacturers, and individual firms in the various industries. These contacts were made to determine whether particular techniques were applicable to the smaller firms in an industry, and also to identify additional measures. In some industries (e.g., construction), most information came from telephone contacts because there was a paucity of relevant literature. Elajor literature sources used and important telephone contacts have been cited in footnotes in the industry summaries. Finally, some waste minimization measures were observed in site visits conducted by ICF last year as part of research on the impact of EPA regulatory initiatives on small quantity generators.

Based on the research conducted, we recommend that fact sheets be written on the following industries: vehicle maintenance; dry cleaning; furniture/wood manufacturing and refinishing; chemical manufacturers/formulators; construction; printing ink formulators and printers; and metal manufacturing. techniques and technologies appropriate for small quantity generators in all of these industries. It will be a challenge to develop fact sheet formats for

There are a variety of waste minimization

Bob Axelrad, Debbie Rutherford October 9, 1986 Page Three

some of these industries, particularly ones that include several distinct segments, such as chemical manufacturing/formulating.

Other industries may be assigned a lower priority in terms of further effort. These industries include textile manufacturing, pesticide end-users/ application services, photoprocessing/photofinishing, laboratories, leather products manufacturing, and wood preserving. In the textile, leather products manufacturing, and wood preserving industries, attention is focused on wastewater reduction rather than direct hazardous waste minimization; most techniques identified in literature and through telephone contacts pertain to wastewater reduction. In the textile industry, for example, (see attached memo), it was very difficult to obtain information about solvent uses in industrial processes. In the photoprocessing/photofinishing industry, many waste minimization techniques pertain to silver recovery, a practice already being conducted by most firms in the industry. Furthermore, the photoprocessing/photofinishing industry's position regarding their inclusion as SQGs under RCRA may make this industry less receptive to a fact sheet on hazardous waste minimization. Limited information was found on the pesticide end-users/application services industry, and some of the techniques identified (e.g., use of rinsate in subsequent formulations) are applicable to many industries and could be covered in a fact sheet providing general waste minimization techniques. This type of fact sheet could be distributed to industries for which specific fact sheets are not being prepared. In the case of laboratories, a booklet published by the American Chemical Society (Less is Better: Laboratory Chemical Management for Waste Reduction, included in this deliverable) describes most of the basic waste reduction measures appropriate for laboratories. It may be useful, however, to prepare a fact sheet that summarizes the suggestions in the booklet, and contains additional information on some subjects (e.g., less toxic chemical substitutes and specific methods for controlling inventory).

Research was also conducted on two industries that are not included in the summaries in this deliverable, equipment repair, and the paper industry. In the paper industry, it was determined that most waste minimization techniques are highly capital intensive. Furthermore, most firms in the industry are very large, and may be small quantity generators of hazardous waste because they have already implemented pollution control measures. Most waste minimization suggestions for the equipment repair industry pertain to painting and degreasing operations similar to those conducted in vehicle maintenance. It may be helpful to write a general fact sheet on waste reduction measures pertaining to painting and degreasing operations, since these processes are used in many industries. Information on these operations will be included in the fact sheets tailored to specific industries, and also can be presented as a separate fact sheet to be sent to industries such as equipment repair and motor freight terminals/railroad transportation.

Bob Axelrad, Debbie Rutherford October 9 , 1986 Page Four

We would l i k e t o d i scuss t h e s e recommendations wi th you i n t h e next few weeks, i f p o s s i b l e , t o make a de te rmina t ion about which i n d u s t r i e s t o concent ra te f u r t h e r e f f o r t on. I t would be very h e l p f u l t o have t h e a t tached summaries reviewed by s e l e c t e d ind iv idua l s i n t r a d e a s soc ia t ions and s t a t e programs. We hope t o send out ma te r i a l s f o r review dur ing October.

Another p r i o r i t y e f f o r t i s t o e s t a b l i s h a format f o r p re sen t ing information i n t h e f a c t s h e e t s . Discrepancies i n t h e s t y l e and p resen ta t ion of information i n t h e a t t ached summaries w i l l be reso lved i n t h e p rocess .o f w r i t i n g t h e f a c t s h e e t s . Examples of f a c t shee t s prepared by s t a t e t e c h n i c a l a s s i s t a n c e programs a r e included i n t h i s d e l i v e r a b l e . In add i t ion t o t h e f a c t s h e e t s s p e c i f i c t o p a r t i c u l a r i n d u s t r i e s , it may be use fu l t o prepare f a c t shee t s d i scussed e a r l i e r on (1) genera l waste minimization techniques ( inc lud ing good housekeeping" measures), and ( 2 ) opera t ions such a s p a i n t i n g and degreas ing , common t o many i n d u s t r i e s . We look forward t o d i scuss ing t h e s e i s sues with you i n t h e near f u t u r e .

1 1

DS/mdb Attachments

CHEMICAL MANUFACTURING/FORMULATlNG

I n d u s t r i a l S e c t o r I n d u s t r i a I Process Wastes Waste Minimization/Management Opt ions a/

I n d u s t r i a l Organ ic Storage o f v o l a t i l e Organic chemical vapor o I n s t a l l a t i o n o f i n t e r n a l f l o a t i n g r o o f s on Chemica I s I i q u i d o r g a n i c s to rage t a n k s can reduce vapor f o r m a t i o n b y 90%.

chemical vapors. Vapors which a r e formed can be vented f rom t h e tank .

chemical i n l a r g e Roofs r i s e and f a l l a s t h e l e v e l o f t h e l i q u i d t a n k changes. t h u s m i n i m i z i n g t h e f o r m a t i o n o f

Res in and adhesive ma nuf a c t u r e

Phenol wastes f rom r e s i n opera t i o n s

Pheno I f rom de I i ve ry hose

o By u s i n g a two r i n s e method, t h e d i s c h a r g e o f o r g a n i c wastes can be reduced. A sma 1 I f i r s t r i n s e (5-10% o f s i z e o f second r i n s e ) removes most r e s i d u a l m a t e r i a l and produces a r i n s e w a t e r w i t h a v e r y h i g h phenol c o n c e n t r a t i o n . T h i s r i n s e w a t e r can be recovered and used as raw m a t e r i a l i n a l a t e r ba tch . A second. f u l l volume r i n s e i s s t i l l needed, b u t t h i s r i n s e now has a g r e a t l y reduced phenol c o n c e n t r a t ion.

o F l u s h hose w i t h a few g a l l o n s o f w a t e r t o un load t h e l a s t b i t o f phenol i n t o t h e s t o r a g e tank. D i l u t e d phenol can be used w i t h s t o c k phenol a s raw m a t e r i a l . ( N o t a l l raw m a t e r i a l s c o u l d r e a d i l y t o l e r a t e t h i s t e c h n i q u e because t h e q u a l i t y o f t h e f i n a l p r o d u c t would s u f f e r . However, t h e i n t r o d u c t i o n o f w a t e r h a s no e f f e c t on r e s i n p r o d u c t i o n which i s an aqueous process. )

a/ The f o l l o w i n g sources were h e a v i l y r e l i e d on t o p r o v i d e waste minimization/management o p t i o n s f o r t h e chemical

1 ) Dav id J. S a r o k i n e t a l . Cut t inq Chemical Wastes: What 29 Orqanic Chemical P l a n t s Are Doinq t o Reduce Hazardous Wastes

2 ) V e r s a r Inc. and Jacobs Eng ineer ing Group. D r a f t F i n a l Repor t : Waste M i n i m i z a t i o n Issues and O p t i o n s (February,

manuFactur ing and formu I a t i n g i n d u s t r i e s :

(New York: I n f o r m Inc., 1985) .

1 9 8 6 ) .

3 ) Environment Canada. Techn ica l Manual - Waste Abatement. Reuse. Recyc le and Reduct ion O p p o r t u n i t i e s i n I n d u s t r y .

4 ) Gary Hunt and Roger Schecter . "Accompl ishments a t N o r t h Caro l ina I n d u s t r i e s , Case Summaries." ( P o l l u t i o n P r e v e n t i o n Pays Program, N o r t h Caro l ina Department o f N a t u r a l Resources and Community Development, January, 1 9 8 6 ) .

CHEMICAL MANUFACTURING/FORMULATING ( c o n t i n u e d )

I n d u s t r i a l Sec to r I n d u s t r i a I Process Wastes Waste Minimization/Management Opt ions

I n d u s t r i a l Organ ic Phenol manufacture Cumene vapor emiss ions o A d d i t i o n o f r e s i n a d s o r p t i o n systems (wh ich soak Chem i ca I s up o r g a n i c vapors f o r subsequent reuse) can ( c o n t i n u e d ) reduce cumene vapor emiss ions by 80%.

Pigments Dye manufacture Wastewater f rom r i n s i n g o Wastewater g e n e r a t i o n can be min imized by equipment repea ted ly p roduc ing back t o back batches o f t h e

same o r v e r y s imi l a r dyes ( t h u s e l i m i n a t i n g t h e need to r i n s e equipment i n between ha tches ) .

f

Manufacture o f an th ro - Mercu r i c wastes d e r i v e d o The use o f mercury as a c a t a l y s t can be e l i m i - qu inone dyes, commonly f rom u s i n g mercury a s a na ted by u s i n g a new chemical pathway t h a t c i r - used f o r d y i n g c o t t o n c a t a l y s t cumvents the s u l f o n a t i o n s t e p wh ich r e q u i r e s t h e

mercury c a t a l y s t .

P roduc t i on o f t i t a n i u m F e r r i c c h l o r i d e d i o x i d e p igments

P r i n t i n g i n k s

o The use o f h i g h p u r i t y o r e f o r a soitrce o f t i t a n i u m d i o x i d e w i I I g r e a t l y reduce the amount o f i m p u r i t i e s e n t e r i n g t h e process and hence g r e a t l y reduce t h e waste p r o d u c t i o n ra tes , espec ia l l y t h e p r o d u c t i o n o f f e r r i c c h l o r i d e . R u t i l e o r e c o n t a i n s o v e r 90% t i t a n i u m d i o x i d e and o n l y smal l q u a n t i t i e s o f i r o n . I t i s t h e p u r e s t source o f t i t a n i u m d i o x i d e . I l m e n i t e o r e c o n t a i n s 40-70x t i t a n i u m d i o x i d e and l a r g e q u a n t i t i e s o f i r o n . Dur ing t h e c h l o r i n a t i o n r e a c t i o n t h i s i r o n i s conve r ted t o i r o n c h l o r i d e s wh ich can e i t h e r be s o l d a s a s i d e p roduc t o r d i sposed.

I sop ropy l a c e t a t e waste o So lven t can be used t w i c e f o r equipment c lean-up generated d u r i n g equ ip- b e f o r e be ing recovered o n - s i t e b y u s i n g a b a t c h ment c lean-up d i s t i l l a t i o n u n i t . D i s t i l l a t i o n bot toms can be

sen t o f f - s i t e f o r d i s p o s a l .

i d e n t i c a l o r d a r k e r c o l o r e d ba tches o f ink . o D i r t y c l e a n i n g s o l v e n t can be used i n make up f o r

CHEMICAL MANUFACTURING/FORMULATING ( c o n t i n u e d )

~~


I n d u s t r i a l Organ ic T r a n s f e r o f a r a w Chemicals m a t e r i a l f rom a tank ( c o n t i n u e d ) c a r t o a s to rage

tank, and subsequent- l y f rom t h e s to rage tank i n t o r e a c t o r vesse I s

Ch I o r i na t e d organ i c chemica I p r o d u c t i o n

Chemical p r o d u c t i o n

Po lys ty rene manufac- t u r e

P roduc t i on o f pent - a e r y t h r i t o l f rom formaldehyde and aceta I dehyde

Raw m a t e r i a l was l o s t when i t became mixed w i t h n i t rogen gas used t o p r e s s u r i z e t h e tanks t o push t h e r a w m a t e r i a l from the tank c a r i n t o t h e s to rage tank and from t h e s to rage tank i n t o the react.or

C h l o r i n a t e d o r g a n i c chemica I s

A l l chemical wastewater d i scha rges

A i r emiss ion o f s t y rene and o t h e r process chemica I s

Ethy lbenzene

P e n t a e r y t h r i t o1 dus t

Replace gas p r e s s u r i z i n g techn ique w i t h a pumping mechanism the reby e l i m i n a t i n g t h e tank p r e s s u r i z - ing s tep and i t s a s s o c i a t e d r a w m a t e r i a l losses.

C e r t a i n wastes can be burned i n i n d u s t r i a l b o i l e r s .

M o n i t o r i n g program - es tab l i shmen t o f a s e r i e s o f wastewater sampl i ng s t a t i o n s p e r m i t s the mon i to r - i ng o f o r g a n i c chemical c o n c e n t r a t i o n s i n wastewater . As a r e s u l t , p l a n t o p e r a t o r s can q u i c k l y be made aware o f unusua I changes i n chemica I c o n c e n t r a t i o n s i n t h e wastewater, t r a c e them back t o t h e i r source, and remedy t h e problem.

Changeover f rom a b a t c h process t o a con t inuous c losed system process o f s t y r e n e p roduc t i o n can reduce emiss ions by 99.7%.

Ethy lbenzene can e a s i l y be cap tu red as a by- p roduc t o f p o l y s t y r e n e manufacture and r e i n t r o - duced d i r e c t l y i n t o t h e manu fac tu r ing process.

The equ ipp ing o f c e r t a i n emiss ion sources w i t h baghouse f i l t e r s wh ich c a p t u r e p e n t a e r y t h r i t o l dus t f o r reuse ( t h u s p r e v e n t i n g i t s d i scha rge as waste) can recover 99 pe rcen t o f p e n t a e r y t h r i t o l d u s t f rom these sources.

CHEMICAL MANUFAGTUR I NG/FORMULAT I NG ( con t i nued )

I n d u s t r i a l Sec to r I n d u s t r i a I Process Wastes Waste Minimization/Management Op t ions

S y n t h e t i c F i b e r s

S y n t h e t i c woven p o l y - B leach range e f f l u e n t 0 e s t e r / c e l l u l o s e goods f rom wash boxes p roduc t i o n

Product i o n o f synthe- t i c c o t t o n / p o l y e s t e r b lend c o n t a i n i n g approx i mate 1 y 8.5% p o l y v i n y l a l c o h o l s t a r c h

P o l y e s t e r doub le k n i t and p o l y e s t e r / a c r y l i c b I end process i ng

F i be rg I ass c o a t i ng and b i n d i n g - p ro - d u c t i o n o f synthe- t i c g l a s s f i b e r s

Waste generated by 0 v a r i o u s wet p rocess ing ope r a t i ons , i nc I ud i ng hea t s e t t i n g , des i z ing , b leach ing and merce r i z - i ng

Scour i ng bow I s waste- 0 wa te r

Wastewater c o n t a i n i n g 0 b i n d e r sol i d s (phenol i c r e s i n s ) and g l a s s f i b e r

Va r ious open-width range m o d i f i c a t i o n s can be made t o t h e u n i t i n c l u d i n g :

-- au tomat i c c o n t r o l o f s i I i c a t e and pe rox ide

-- c o u n t e r f low ing o f wash boxes

-- r e d u c t i o n i n tempera tures t o be low 71°C

-- e l i m i n a t i o n o f one o r more wash boxes can be

i n f l o w

cons ide red a f t e r wash box Iiqiior and f a b r i c a n a l y s i s o f r e s i d u a l chemica ls .

These changes r e s u l t i n reduced wa te r volume and energy use and can be a p p l i e d t o o t h e r b l e a c h i n g opera t i ons .

Process mod i f i c a t ions may i nc I tide:

-- ad jus tment o f f l o w s i n c e r t a i n washers t o concen t ra te wash I i q u o r s

-- counte rf I ow i rig o f wash bores .

A process m o d i f i c a t i o n u s i n g a new Duobond cont inuous s o l v e n t scou r range rep laced t h r e e b a t c h machines. The aqueous scour e f f l u e n t s were thus e l iminated.

Ma jor r e d u c t i o n s i n n e t cos ts , suspended and d i s s o l v e d so l ids, g l a s s f i b e r and po lymer ized b i n d e r s o l i d s , and phenol use can be ob ta ined by r e p l a c i n g a c a u s t i c c l e a n i n g process w i t h a h i g h p ressu re w a t e r spray process. F i l t r a t i o n and reuse o f t h e w a t e r used f o r c l e a n i n g i n t h e b i n d e r s o l u t i o n p r e p a r a t i o n w i I I c o n t r i b u t e t o sav ings. b/

b/ Savings r e a l i z e d b y one company a f t e r s w i t c h i n g r e c y c l i n g inc lude: g l a s s f i b e r and po lymer ized b i n d e r reduc t ion ; phenol use r e d u c t i o n b y 79% f rom .53 t o .I1 b i n d e r usage.

f rom c a u s t i c c l e a n i n g t o h i g h p ressu re wa te r spray c l e a n i n g w i t h wa te r so l i d reduc t ion : 82% suspended s o l i d reduc t i on ; 49% d i s s o l v e d s o l i d kg/day; n e t c o s t sav ings average $2,700 p e r month due t o r e d u c t i o n i n

CHEMICAL MANUFACTURING/FORMULATlNG ( c o n t i n u e d )

I ndus t r i a I Sec t o r I n d u s t r i a l Process Wastes Waste Minimization/Management Opt ions

P a i n t and Coat ings Pa i n t formu I a t i o n Of f -spec p a i n t ba tches 0 F o r m u l a t i o n s

A d d i t i o n o f p igments I n o r g a n i c p igments t o p a i n t s l e f t o v e r i n p igment

bags arid packages

Pigment d u s t

0

T r y t o rework o f f - s p e c ba tches o f p a i n t and i n c o r p o r a t e them i n t o good batches: c /

-- Mix a b a t c h o f p a i n t w i t h t o o h i g h o r t o o low v i s c o s i t y i n t o a new b a t c h t o lower o r r a i s e v i scos i t y i ts i n g add i t iona I o r reduced q u a n t i t i e s o f s o l v e n t o r w a t e r .

-- E x t r a c t u s a b l e p o r t i o n o f p a i n t f rom "sk inned over " batches. S o l i d p o r t i o n car1 a l s o be reused ( s e e be low) o r i s d isposed.

-- Sludge can sometimes be used a s f i l l e r i n low grade p r o d u c t s where c o l o r i s n o t i m p o r t a n t e . g . , pr imer , d a r k p a i n t s .

The use o f w a t e r s o l u b l e bags Tor hazardous p igments and compounds used i n water-based p a i n t s car1 e l i m i n a t e t h e r e s i d u a l p igment waste. When empty, t h e bags can be d i s s o l v e d o r mixed t h e p a i n t . Mercury compounds and o t h e r pa f u n g i c i d e s a r e o f t e n hand led t h i s w". T h method cannot be used when making h i g h qua smooth f i n i s h p a i n t because t h e paper w i l l t h e p a i n t s f i l m f o r m i n g c a p a b i l i t i e s .

The use o f r i n s e a b l e / r e c y c l a b l e c o n t a i n e r s p l a s t i c I i n e r s can a l s o e l i m i n a t e r e s i d u a l p i gment waste.

Always segregate hazardous packaging f r o m non-haza rdous.

n t o n t

i t y a f f e c t

w i t h

S

The use o f p igments i n p a s t e r a t h e r t h a n d r y powder fo rm w i I I reduce o r e l i m i n a t e t h e r e l e a s e o f p igment d u s t when packaging i s opened.

- c/ Telephone c o n v e r s a t i o n w i t h J.J. L e n z o t t i , D i r e c t o r o f Envi ronmenta l Serv ices, Sherwin W i I I iams Co.


I n d u s t r i a l Sec to r I n d u s t r i a l Process Wastes Waste Minimization/Management Opt ions

P a i n t and Coat ings Fo rmu la t i ons ( c o n t i nued ) p o l l u i i o n

P a i n t c lean-up

S o l i d waste c o l l e c t e d o Baghouse empty ing can be scheduled t o segregate i n baahouse b y a i r and redrice t h e amount o f hazardous waste

equ i pment generated. Hazardoils p igments make up o n l y a smal l p o r t i o n of' t h e waste t rapped i n t h e baghoiise and a r e o n l y p r e s e n t when c o l o r e d p a i n t s a r e produced. S ince many f a c i I i t i e s produce c o l o r e d p a i n t s i n ba tches ( i . e . once a week o r once a month), c l e a n i n g schedi i les o f t h e equipment can be made t o c o i n c i d e w i t h c o l o r e d p a i n t p r o d u c t i o n t h u s p e r m i t t i n g the seg rega t ion o f waste wh ich c o n t a i n s hazardous p igments f rom t h a t wh ich does n o t .

Waste minera I s p i r i t s o Waste m ine ra l s p i r i t s , used t o c lean-up process eqi i ipment a f t e r mix ing , a r c c o l I c c t e d . When a new b a t c h o f p a i n t i s mixed, t h e waste c lean-up s o l v e n t s f rom t h e p r e v i o u s b a t c h can be used i n i t s f o r m u l a t i o n . T h i s reduces the q u a n t i t y o f waste genera ted and t h e q u a n t i t y o f r a w m a t e r i a l s used. The same s e g r e g a t i o n and rerise o f wa te r a I so reduces t h e qi iant i t y o f wastewater genera ted d u r i n g the m i x i n g o f l a t e x p a i n t s .

Caust t i o n s

c c c l e

ean n i n

ng s o l u - o I t i s b o t h more economic and s a f e r t o use a h i g h so I ven t s p ressure h o t a l k a l i c l e a n i n g system t o c l e a n o u t

p a i n t f o r m u l a t i n g and m i x i n g equipment than i t i s t o use s o l v e n t s . To m in im ize con tamina t ion o f t h e washing s o l u t i o n , as much wet p a i n t as p o s s i b l e shou ld be removed b e f o r e c l e a n i n g t h e tanks. Wet p a i n t c l i n g i n g t o c o n t a i n e r w a l l s can be removed u s i n g a squeegee. Caus t i c c l e a n i n g s o l u t i o n i s s t o r e d and heated i n a separa te tank and then pumped under p ressu re t o t h e t a n k t o be c leaned, Hot c a u s t i c s o l u t i o n i s t hen sprayed a g a i n s t t h e w a l Is, top, and bo t tom o f t h e tank . When t h e c l e a n i n g o p e r a t i o n i s complete, t h e d i r t y c a u s t i c s o l u t i o n i s f i l t e r e d and r e t u r n e d t o t h e s to rage tank f o r reuse. The p a i n t m i x i n g tank i s then r i n s e d w i t h h o t wa te r . d/

d/ Monica E. Campbell and W i l l i a m M. Glenn. Rec?/cl inq (Toronto : P o l l u t i o n Probe Foundation,

P r o f i t f rom P o l l u t i o n Prevent ion : A Guide t o I n d u s t r i a l Waste Reduct ion and 1982) , 131.


I n d u s t r i a I S e c t o r I n d u s t r i a I Process Wastes Waste Minimization/Management Opt ions

P a i n t and C o a t i n g s F o r m u l a t i o n s ( c o n t i n u e d )

A g r i c u l t u r a l Chemi ca I s

F i b e r g I ass c o a t i ng app l i c a t i o n s

P a i n t s p i l l s 0

Waste acetone f rom equipment c lean-up

P e s t i c i d e manufacture/ Dust f rom p e s t i c i d e s formu I a t i o n

C lean ing equipment Used kerosene f rom r i n s i n g equipment

0

0

0

0

T r a n s f e r o f raw mate- Loss o f raw m a t e r i a l 0 r i a l s and p r o d u c t s and p r o d u c t f rom t r a n s - f r o m one conta i n e r t o f e r pumps a no the r

In t h e case o f p a i n t s p i l l s , d r y c lean-up methods such a s sawdust o r mopping can be used i n s t e a d o f h o s i n g down an area . I f f l o o r d r a i n s a r e c losed, a l a r g e decrease i n wastewater g e n e r a t i o n w i l I r e s u l t becuase r o u t i n e f l u s h i n g w i t l t w a t e r w i l l n o t be p o s s i b l e .

Waste acetone genera ted d u r i n g process equipment c lean-up can be d i s t i l l e d o n - s i t e o r sen t t o an o f f - s i t e d i s t i I l a t i o n f a c i I i t y f o r recovery. The d i s L i l l a t i o n f a c i l i t y i s a b l e t o recover about 7074 o f t h e o r i g i n a l volume. The rec la imed acetone can t h e n be bought back f o r use i n eqit ipment c lean-rip.

Process mod i f i c a t i o n s can reduce t h e q u a n t i t y o f waste c lean-up s o l v e n t generated. By making l i g h t and t h e n d a r k c o a t i n g s o r p a i n t s , t h e waste c lean-up needed between t h e two ba tches i s reduced.

A s imp le change i n waste management t e c h n i q u e can s i g n i f i c a n t l y reduced waste d u s t . R a t h e r t h a n c o l l e c t a l I d u s t genera ted f r o m v a r i o u s p e s t i c i d e f o r m u l a t i o n s i n a s i n g l e baghouse and t h e n d ispose o f i t as waste, a i r b o r n e d u s t can be c o l l e c t e d i n independent baghouses f r o m each p r o d u c t l i n e . The d u s t f r o m each baghouse can then be reused a s f i I l e r i n t h e p r o d u c t I i n e f r o m w h i c h i t was generated.

Reuse o f s o l v e n t s e v e r a l t i m e s b e f o r e d i s c a r d i n g i t reduces kerosene waste, m a t e r i a l cos ts , and t h e expense o f waste d i s p o s a l .

Pump s e a l s k e e p . l i q u i d i n t h e pump i s o l a t e d f r o m t h e pump mechanism i t s e l f . Use o f "mechanical seats" ( r o t a t i n g e lements ) can v i r t u a l l y e l i m i - n a t e leaks. These s e a l s a r e p r e f e r a b l e t o "packed s e a l s " (which c o n t a i n d e n s e l y packed m a t e r i a l such as g r a p h i t e and s y n t h e t i c f i b e r s , and a r e prone t o l e a k i n g ) .


__

I n d u s t r i a l Sec to r I n d u s t r i a I Process Wastes Waste Minimization/Management Opt ions .~

A g r i c u l t u r a l Pest i c i de t r a n s p o r t Contaminated so i I f rom 0 Chemi ca I s p e s t i c i d e s p i l l s ( c o n t i n u e d )

F e r t i I i z e r f o r m u l a t i o n Var ious e f f l u e n t s p l a n t o p e r a t i o n s (ammon ia -n i t r i c ac e f f I uent; ammon i um n i t r a t e e f f l u e n t )

Trace e lement fo rmula- Reuse o f waste f rom t i o n s f o r f e r t i I i z e r o t h e r companies

rom 0

d

0

Cosmetic Manufac- Manufacture o f a l c o h o l - Damaged o r ou tda ted 0 t u r i n g based p roduc ts a lcoho l -based cosmet ics

Na i I PO I i sh packag i ng Ethyl a c e t a t e 0

Rather than e i t h e r l a n d f i I I ing o r i n c i n e r a t i n g t h e contaminated s o i l , i t can be spread on f i e l d s and used as a p e s t i c i d e . A l though a e r i a l sp ray ing m a y be d i f f i c u l t , manure spreaders can be used f o r land app l i c a t i o n . e / In-house e f f l u e n t r e d u c t i o n and t rea tmen t o f composi te p l a n t e f f l u e n t b y i o n exchange (one system s e l e c t i v e f o r NO3 and o t h e r ions; and t h e o t h e r f o r ammonium and o t h e r c a t i o n s ) . Regene- r a n t s a r e ammonia and ammonium n i t r a t e f rom a moving-bed, con t inuous f low, c o u n t e r c u r r e n t i o n exchange process. A recove ry o f 20% s o l u t i o n o f ammonium n i t r a t e f o r rep rocess ing i s o b t a i n a b l e .

Waste m a t e r i a l s c o n t a i n i n g me ta l s such as copper can be used i n t h e f o r m u l a t i o n o f t r a c e e lement m i x t u r e s f o r t h e f e r t i I i z e r i n d u s t r y . Waste f rom o t h e r companies can be s u b s t i t u t e d f o r v i r g i n raw m a t e r i a l .

M o d i f i c a t i o n s made t o a p l a n t ' s o i l - f i x e d b o i l e r p e r m i t i g n i t a b l e a lcoho l -based waste t o be used as a supplemental f u e l source. A s p e c i a l c o l l e c t i o n appara tus and feed system on t h e b o i l e r can a l low a m i x t u r e o f 20% waste and 80% f u e l o i l t o be used as f u e l f o r t h e b o i l e r . Cost sav ings a r e r e a l i z e d i n saved f u e l and as a r e s u l t o f n o t hav ing t o send t h e waste o f f - s i t e f o r d i sposa I.

E t h y l a c e t a t e used t o c l e a n o u t n a i l p o l i s h packaging l i n e s can be r e c y c l e d e i t h e r o n - s i t e o r o f f - s i t e .

- e/ Telephone c o n v e r s a t i o n w i t h Dennis Reddington, Envi ronmenta l Manager, Monsanto C o .


Tank c l e a n i n g C I ean i ng s o l v e n t

I n d u s t r i a I Sec to r I n d u s t r i a I Process Wastes Waste Minimization/Management Opt ions

Cosmetic Manufac- C lean ing o f l i n e s and Ethyl a l c o h o l o To min imize t h e amount o f waste e t h y l a l coho l t u r i ng ( c o n t i nued ) t anks generated d u r i n g t a n k and l i n e clean-up, a

sp ray ing techn ique can be used t o rep lace t h e o r i g i n a l techn ique o f p o u r i n g a l c o h o l i n t o a t a n k and s l o s h i n g i t around.

-

o T o min imize t h e use o f c l e a n i n g so l ven t : f/

-- A t t he end o f a p r o d i r c t i o n process, use a i r t o b low p roduc t t h rough l i n e s ; save t h i s m a t e r i a l as s a l e a b l e p roduc t .

-- A t t h e end o f a p r o d u c t i o n batch. use a foam p l a s t i c b u l l e t ( p i g (sic,),) t o pi ish p roduc t o u t th rough p ipes . The p i g " pushes o u t p roduc t l e f t c l i n g i n g t o t h e walls o f the p i p e and t t i i i s i nc reases y i e l d and reduces t h e subsequent degree o f p i p e c l e a n i n g reqir i red. Tor t h i s p rocess t o work, p i p e s must have. l a r g e r a d i u s t u r n s . A l though t h i s i s easy and inexpens ive t o d e s i g n i n a new p l a n t , i n an o l d e r f a c i I i t y these types o f renova t ions a re expensive. T h i s techn ique can a l s o be used i n p a i n t manufacture.

compa t ib le w i t h each o t h e r than w i t h o t h e r s . When f o u r o r f i v e d i f f e r e n t types o f p roduc ts a r e be ing produced u s i n g t h e same equipment, p r o d u c t i o n can be o rgan ized so t h a t those p roduc ts wh ich a r e more compa t ib le w i t h each o t h e r a r e produced conseci i t i v e l y and those p roduc ts wh ich a r e l e s s compa t ib le a r e separated. T h i s w i l l reduce t h e amount o f equipment c l e a n i n g wh ich i s necessary. I f t h e amount o f t a n k c l e a n i n g wh ich i s necessary i s reduced, t h e p roduc t i o n o f waste c l e a n i n g s o l v e n t w i l l a l s o be reduced.

-- Used c l e a n i n g s o l v e n t can be s e t a s i d e and saved t o be used as raw m a t e r i a l t h e n e x t t ime t h e s p e c i f i c p r o d u c t i t was used t o c lean-up a f t e r i s made.

-- Some chemica ls and m i x t u r e s a r e more

- f/ Telephone conversa t i on w i t h Gary Johnson, Engineer, P r o c t o r and Gamble.

GENERAL GOOD HOUSEKEEPING TECHNIQUES FOR CHEMICAL MANUFACTURING AND FORMULATING INDUSTRIES

I n d u s t r i a I Process Wastes Waste Minimization/Management O p t i o n s

Tank, L i n e o r Drum Con t a m i na t e d wa s t e - 0 C I ean i ng w a t e r o r s o l v e n t s

0

S o l v e n t Storage and Use

Undes i red so I v e n t emiss ions

0

0

Genera I S o l v e n t Contaminated s o l v e n t 0 Use

Waste Produc t i o n Hazardous and non- 0 hazardous wastes

0

Water o r s o l v e n t used t o c l e a n tanks. l i n e s o r drums can be saved and s t o r e d u n t i I a n o t h e r b a t c h o f i d e n t i c a l p r o d i i c t i s manufactured. S t o r e d s o l v e n t o r wastewater can then be r e i n t r o d u c e d i n t o t h e new b a t c h a s a raw m a t e r i a l . T h i s method reduces raw m a t e r i a l and d i s p o s a l c o s t s . The "waste" s o l v e n t has become raw m a t e r i a l and t h e r e f o r e t h e s t o r a g e drums a r e n o t r e g u l a t e d under RCRA.

A two r i n s e method can s i g n i f i c a n t l y reduce t h e d i s c h a r g e o f wastes. A smal l f i r s t r i n s e (5 -10% t h e s i z e o f second r i n s e ) removes most r e s i d u a l m a t e r i a l . T h i s r i n s e can be s t o r e d f o r f u t u r e use i n a new b a t c h o f i d e n t i c a l m a t e r i a l . A second f u l l volume r i n s e can f o l l o w , b u t t h i s r i n s e c o n t a i n s a g r e a t l y reduced wa s t e concen t ra t i on.

I d e n t i f y and p r e v e n t unnecessary s o l v e n t emiss ions . The v o l a t i l e n a t u r e o f s o l v e n t s c o n t r i b u t e s s i g n i f i c a n t l y t o b o t h a i r p o l l u t i o n and economic losses. S o l v e n t i n p u t s and waste s o l v e n t o u t p i i t s shou ld be compared r o u t i n e l y t o e s t i m a t e t h e q u a n t i t y o f s o l v e n t s unaccounted f o r , and hence u n n o t i c e d leakage.

Keep l i d s on v o l a t i l e chemicals . Use f l o a t i n g r o o f s on l a r g e c o n t a i n e r s o f v o l a t i l e chemicals .

O n - s i t e r e c y c l i n g i n smal l and medium bus inesses i s p o s s i b l e w i t h smal l commerc ia l l y a v a i l a b l e u n i t s . O n - s i t e r e c y c l i n g i s o f t e n more economical t h a n sending used s o l v e n t o f f - s i t e f o r r e c y c l ing.

Keep hazardous wastes and non-hazardous waste streams separa te .

Segregated wastes a r e more e a s i l y r e c y c l e d and reused than wastes contaminated w i t h a m i x t u r e o f o t h e r chemicals . D isposa l and raw m a t e r i a l c o s t s a r e t h u s reduced.

LABORATORY WASTE MINIMIZATION/MANAGEMENT OPTIONS a/

Genera I Labora to ry Manaqement Techniques

o Purchase s m a l l e r q u a n t i t i e s o f chemicals . When l a r g e c o n t a i n e r s o f chemica ls a r e purchased, t h e y f r e q u e n t l y remain unused and must be d isposed o f . O f t e n chemis ts w i l l n o t use opened b o t t l e s o f chemicals because o f concern about t h e p u r i t y o f t h e m a t e r i a l . When d i s p o s a l c o s t s o f unused m a t e r i a l s a r e added t o the purchase p r i c e o f t h e chemical , i t i s o f t e n uneconomical t o buy l a r g e con ta ine rs .

o M a i n t a i n i n g an i n v e n t o r y o f a l l l a b o r a t o r y chemica ls purchased, and then keeping t r a c k o f t h e s t a t u s o f t h e chemica ls w i t h i n a lab. Depending on t h e s i z e and resources o f t he l abo ra to ry , t h i s system can be computer ized o r s i m p l y kep t i n a c a r d f i l e . Having an i n v e n t o r y o f chemica ls i s a p r e r e q u i s i t e f o r t h e exchange/reuse o f chemica ls w i t h i n a p a r t i c u l a r i n s t i t u t i o n , o r f o r p a r t i c i p a t i o n i n a r e g i o n a l waste exchange. D u p l i c a t e purchases o f chemica ls can be reduced by d i s t r i b u t i n g the l i s t o f chemica ls w i t h i n a n i n s t i t u t i o n .

o Some i n s t i t u t i o n s m a i n t a i n c e n t r a l i z e d s to rage areas f o r unused chemicals . These s to rage areas shou ld be we1 I v e n t i l a t e d and a l s o mon i to red t o ensure t h a t l a b e l i n g o f m a t e r i a l s i s adequate and t h a t d e t e r i o r a t e d chemica ls do n o t remain i n s to rage.

o L a b o r a t o r i e s can l i s t unused chemica ls w i t h l o c a l / r e g i o n a l waste exchanges, and thereby g a i n access t o a w i d e r range o f p o t e n t i a I users .

Chemical S u b s t i t u t i o n

o L a b o r a t o r i e s shou ld e v a l u a t e t h e f e a s i b i I i t y o f u s i n g l e s s hazardous m a t e r i a l s i n l a b o r a t o r y procedures. The f o l low ing a r e examples o f t h i s t ype o f s u b s t i t u t i o n :

-- Replacements can be found f o r some c l e a n i n g agents. For example, l a b o r a t o r y d e t e r g e n t s can sometimes be used i n p l a c e o f

-- S u b s t i t u t e s can o f t e n be found f o r benzene and carbon t e t r a c h l o r i d e . For example, i t has been suggested t h a t i n t h e

-- Acetamide can be replaced, under s p e c i f i e d c o n d i t i o n s , by s t e a r i c a c i d i n l a b o r a t o r y p rocedures such as phase changes and

m a t e r i a l s such as chromic a c i d s o l u t i o n and a l c o h o l i c potass ium s o l u t i o n .

s tandard q u a l i t a t i v e t e s t f o r h a l i d e ions, cyclohexane can be used ins tead o f carbon t e t r a c h l o r i d e . Q/

f r e e z i n g p o i n t depress ions. c/

a/ The fo rmat o f t h i s summary i s d i f f e r e n t f rom those o f t h e o t h e r i n d u s t r i e s ; many techn iques a r e g e n e r a l l y a p p l i c a b l e i n l a b o r a t o r i e s , r a t h e r than be ing s p e c i f i c t o p a r t i c u l a r processes. A p a r t i c u l a r l y u s e f u l source o f i n f o r m a t i o n f o r t h i s summary was Less I s B e t t e r : Labora to ry Chemical Manaqement f o r Waste Reduction, pub1 ished by the American Chemical S o c i e t y . Most o f t h e techn iques mentioned i n t h i s m a t r i x were desc r ibed i n Less i s B e t t e r ; o t h e r sources i n c e r t a i n ins tances p r o v i d e d more d e t a i l e d in fo rmat ion . Another ma jo r source o f i n f o r m a t i o n was Prudent P r a c t i c e s f o r D isposa l o f Chemicals f rom L a b o r a t o r i e s ( N a t i o n a l Academy Press, 1983).

- b/ These s u b s t i t u t i o n s were suggested i n Less i s B e t t e r : Labora to ry Chemica I Manaqement f o r Waste Reduct ion .

c/ T h i s s u b s t i t u t i o n was suggested by Rena Benedic t , a chemis t r y teacher a t Fo res t Lake H igh School i n Fo res t Lake, Minnesota. Ms. Bened ic t i s conduct ing a s tudy e n t i t l e d "New Chemicals f o r O ld -- Prese rv ing t h e Student Lab Experiment," commissioned b y t h e Minnesota Department o f Educat ion. The s tudy eva lua tes t h e use o f a l t e r n a t i v e procedures and chemica ls t h a t r e s u l t i n l e s s use and d i sposa l problems i n l a b o r a t o r i e s . Ms. Bened ic t emphasized t h a t t h e s tudy s p e c i f i e s t h e p a r t i c u l a r a p p l i c a t i o n s and procedures t o be used when making s u b s t i t u t i o n s -- i t would be m is lead ing t o s i m p l y s t a t e t h a t c e r t a i n chemica ls can be rep laced b y o t h e r s i n a lab.

LABORATORY WASTE MINIMIZATION/MANAGEMENT OPTIONS ( c o n t i n u e d )

So lven t Waste Manaqement and Recovery/Reuse

o So lven t wastes should be segregated. I t has been suggested t h a t wastes be segregated i n t o a t l e a s t t h e f o l l o w i n g c a t e g o r i e s : d/ -- Ch l o r i na t e d so l v e n t s ( e. g . , methyl ene c h I o r i de )

-- A I i p h a t i c hydrocarbon and oxygenated hydrocarbon s o l v e n t s (e.g. , minera I s p i r i t s , hexane)

-- Aromat ic hydrocarbons (e.g., benzene)

I f s u b s t a n t i a l q u a n t i t i e s o f any p a r t i c u l a r s o l v e n t a r e generated, they should be kep t separa te l y .

o The use o f s o l v e n t s i n c l e a n i n g g l a s s can be reduced b y f i r s t c l e a n i n g equipment w i t h " d i r t y " so l ven t , f o l l o w e d by f r e s h so l ven t . T h i s p rocedure decreases t h e amount o f c l e a n s o l v e n t requ i red .

o C e r t a i n t ypes o f s o l v e n t wastes can be d i s t i l l e d in-house. So lvent s t i I I s a r e a v a i l a b l e i n a v a r i e t y o f s izes , i n c l u d i n g smal l 5 g a l l o n u n i t s . So lven ts can be d i s t i l l e d f o r reuse w i t h i n a p a r t i c u l a r l a b o r a t o r y o r by o t h e r d i v i s i o n s i n an o r g a n i z a t i o n . For example, recyc led s o l v e n t s f rom academic depar tments can be used by teach ing l a b o r a t o r i e s f o r c lassroom demonstrat ions, which can o f t e n make use o f s o l v e n t s o f lower p u r i t y . D i s t i l l e d s o l v e n t s can a l s o be used a s t h i n n e r s and degreasers b y maintenance d i v i s i o n s , f o r example, i n an i n s t i t u t i o n .

Use o f Chemicals f o r Fuel

o C e r t a i n flammable o r g a n i c s o l v e n t s can be used as f u e l i n e x i s t i n g b o i l e r s . These o r g a n i c s o l v e n t s i n c l u d e acetone, b u t y l a l c o h o l , heptane, and hexane. e / I t shou ld be noted, however, t h a t t he bu rn ing o f waste chemica ls i n b o i l e r s m a y be r e s t r i c t e d b y l o c a l r e g u l a t i o n s o r t h e p e r m i t s o f p a r t i c u l a r b o i l e r s .

Recovery o f Meta I s

o Small amounts o f m e t a l l i c mercury can be recovered b y f i l t r a t i o n , c a r r i e d o u t i n a hood. The f i l t e r paper, however, must be d isposed o f as a hazardous waste.

o E l e c t r o l y t i c recove ry techn

o M e t a l s such as p la t inum, pa s p e c i f i c t o p a r t i c u l a r meta

Mic rosca l e Exper iments

o Conduct inu exoer iments on a

ques can be used t o recover s i l v e r f rom photograph ic s o l u t i o n s .

lad ium and rhodium, con ta ined in spent c a t a l y s t s , can be recovered u s i n g chem c a l procedures s. f/

s m a l l e r scale, u s i n g spec ia l g lassware and o t h e r equipment, i s an o p t i o n wh ich can reduce b o t h t h e q u a n t i t i e s o f ' reagents used and a l s o t h e amount o f waste generated.

d / These c a t e g o r i e s were suggested i n Techn ica l Manual f o r t h e Manaqement o f Chemical Wastes i n Labora to r ies , p repared b y

e/ A l i s t o f f lammable o r g a n i c s o l v e n t s t h a t can be reused f o r f u e l i s g i v e n i n Hazardous Chemical Waste Manaqement: A

f/ These recovery techn iques were no ted i n Prudent P r a c t i c e s f o r Disposa I o f Chemica I s f rom L a b o r a t o r i e s (Na t iona I Academy

On tay io Research Foundat ion under c o n t r a c t t o t h e Envi ronmenta I P r o t e c t i o n Serv ice, Envi ronment Canada.

Guidebook f o r Lab Personnel (Department o f Envi ronmenta l H e a l t h and Safety, U n i v e r s i t y o f Minnesota, 1984).

Press, 1983).

CONSTRUCTION

I n d u s t r i a l Process Wastes Waste Minimization/Management Op t ions

P I umb i ng Organ i c so I ven ts / s t rong o Where poss ib le , long f l e x i b l e cables, "snakes," o r d isassembly shou ld f i r s t a c i d s be t r i e d i n removing c l o g s . Other methods such a s u s i n g a i r p ressu re o r

wa te r p ressu re can be used t o d i s l o d g e c l o g s w i t h o u t t h e use o f chemica ls o r ac ids .

Waste o i l s and scrap o O ld p i p e s and metal shav ings can be s o l d a s sc rap r a t h e r than be ing d isposed meta I o f as waste.

o O i l used i n th read c u t t i n g o p e r a t i o n s can be screened and c o l l e c t e d i n a c a t c h pan f o r reuse u n t i I consumed.

Hea t ing and A i r Spent s o l v e n t s C o n d i t i o n i n g

Pa i n t i ng Spent p a i n t waste and so I ven ts

o Ch lo ro f l uo roca rbons and o t h e r gases can be conserved b y f i x i n g leaks and

o Pressure gauges i n s t a I l ed on c o n t a i n e r s w i I I p r e v e n t w a s t i n g unused gases.

o More p r e c i s e assessment o f t h e amount o f p a i n t needed can reduce t h e amount o f l e f t o v e r p a i n t r e q u i r i n g d i s p o s a l . A genera l r u l e o f thumb i s t o a l l o w one g a l Ion o f p a i n t f o r eve ry 400 square f e e t . b/

app l i c a t i o n s .

from l e f t o v e r p a i n t wastes o r f rom c l e a n i n g s o l u t i o n s .

i n s i i r i n g t i g h t f i t t i n g s be fo re d i s c h a r g i n g gases i n t o a u n i t . a/

o Water-based p a i n t s can be s u b s t i t u t e d f o r so lvent -based p a i n t s i n some

o So lvent s t i l l s can be purchased i n smal l 5 g a l l o n s i z e s t o recover s o l v e n t s

a/ Russ A l e s s i o f t h e N a t i o n a l A s s o c i a t i o n o f Plumbing, Heat ing, and A i r C o n d i t i o n i n g no ted t h a t i t i s n o t a lways economical

- b/ T h i s es t ima te was made by Richard Bohl o f Bohl P a i n t e r s i n Columbus, Ohio.

t o f T x leaks. The c o s t t o f i n d and f i x a teak and t h e l i f e expectancy o f t h e u n i t shou ld be cons idered.

CONSTRUCTION ( c o n t i n u e d )


Pa i n t i ng ( c o n t i n u e d )

Manufactured Home Formaldehyde i n scrap C o n s t r u c t i o n p a r t i c I eboa r d

Roo f ing Spent deg rea s i ng s o l v e n t s

Brush k i t s c o n t a i n i n g t h i n n e r and o i l s o l u t i o n save on s o l v e n t s . Brushes a r e s t o r e d i n the k i t s and kep t c l e a n and s o f t . The s o l u t i o n i s c o n s t a n t l y reused w i t h occas iona l removal o f s e t t l e d sol i d p a r t i c l e s and p igments. These s o l i d s can be added t o ready p a i n t a f t e r remain ing solution i s d i s t i l l e d o f f . Some rep len ishment o f s o l u t i o n i s r e q u i r e d due t o l o s s f rom evapora t i on and s p i I Is. c/ Good p a i n t i n g techniques can p reven t waste o f p a i n t due t o d r i p p i n g and poor app l i c a t i o n .

L e f t o v e r p a r t i c l e b o a r d can be used i n c o n s t r u c t i n g k i t c h e n o r speaker c a b i n e t s . e/ Purchase o f s tandard ized, precut. p a r t i c l e b o a r d would e l i m i n a t e t h e g e n e r a t i o n o f sc rap p a r t i c l e b o a r d wh ich would have t o be d isposed.

I f t hey a r e kep t c!ean o f d i r t , c o t t o n / f i b e r g l a s s mops used f o r spread ing t a r can be reheated and reused r a t h e r than be ing c leaned w i t h s o l v e n t s a t t h e end o f t h e day.

C lean ing s o l v e n t s can be reduced by u s i n g a l t e r n a t e r o o f i n g m a t e r i a l s such as heated p l a s t i c s (PVC) o r a rubber the rmos ta t o f e l a s t o m c r i c / p l a s t o m e r i c m a t e r i a l (EPDM). e/ Milch l ess o v e r a l I waste volume i s genera ted i n these f l a t su r face r o o f c o n s t r u c t i o n s .

- c / R icha rd Bohl o f Bohl P a i n t e r s i n Columbus, Ohio f e e l s t h a t t h e i r b rush k i t s a r e a lmost s e l f - s u s t a i n i n g .

d / Anthony Karwoski o f t h e Manufactured Housing I n s t i t u t e i n A r l i n g t o n , V i r g i n i a , a l s o suggested t h a t p a r t i c l e b o a r d c o u l d be

- e/ I n f o r m a t i o n concern ing EPDM was ob ta ined f rom Donald Backenstow o f C a r l i s l e C o r p o r a t i o n i n Car l i s l e , Pennsylvania.

burned as f u e l , b u t he d i d n o t recommend t h i s use.

LEATHER PRODUCTS MANUFACTURING

I n d u s t r i a I Sec to r I n d u s t r i a l Process Wastes Waste M i n in1 i za t i on/Management Opt ions a/

Beamhouse/Ta nhouse C lean ing h i d e s Ha i r, sa It, wastewater, 0 f a t , s ludge

0

Usage o f spray r i n s i n g wh ich washes o f f process s o l u t i o n f i l m by use o f impact and d i f f u s i o n fo rces . T h i s techn ique can reduce wa te r use b y 75%, b u t i t i s n o t e f f i c i e n t f o r s t i r faces t h a t a r e d i f f i c u l t t o reach.

Keeping h i d e s i n t h e same tank and changing so l c i t i ons a l l o w s f o r easy seg rega t ion o f waste streams. no l osses due t o d r i p p i r i g o r d rag ou t , and more e f f i c i e n t recove ry o f waste f o r recyc I i ng . I f s a l t i s used t o p rese rve t h e h i d e s then t h e i n i t i a l soak ing s o l u t i o n can bc screened o f h a i r and f i b r o u s m a t e r i a l and reused a s t h e b r i n e s o l u t i o n needed i n t h e p i c k l i n g o f t h e h ides .

Ac id and a l k a l i n e waste s o l u t i o n s can be c l a r i f i e d and reused seve ra l t imes.

- a/ The f o l l o w i n g i n d i v i d u a l s were con tac ted t o o b t a i n i n f o r m a t i o n about t h i s i n d u s t r y :

I ) Dave Ber icks , S.B. Foot Leather , Red Wing, Minnesota 2 ) Dave Guthe, S.B. Foot Leather , Dumas, Texas 3 ) Bob Laslamme, Prime Tanning Company, Berwich, Maine 4 ) Roger Lang la is , B lues ide Company, SF. Joseph, M issour i 5 ) D r . Rober t L u I I a r , N a t i o n a l Tanners Counc i l o f America.

In a d d i t i o n , t h e f o l rowing sources p rov ided many o f t h e techn iques d iscussed i n t h i s summary:

I ) Monica E. Campbel I and W i I I i a m M. Glenn. P r o f i t f rom P o l l u t i o n Prevent ion : A Guide t o I n d u s t r i a l Waste Reduct ion

2 ) Development Document f o r E f f l u e n t L i m i t a t i o n s Guide1 ines and Standards f o r t h e Les the r Tanninq and F i n i s h i n q P o i n t

and Recycl i n q (Toronto : P o l l u t i o n Probe Foundation, 1982).

Source Cateqory (EPA, November, 1982).

LEATHER PRODUCTS MANUFACTURING ( con t i nued )

~~ ~-


Beamhouse/Tanhouse Ha i r b u r n ( c o n t i nued )

Tanning

P ick1 i ng

Flesh, ha i r, su i f u r , o Spent h a i r b u r n s o l u t i o n can be sen t t o an f a t , I ime, wastewater e q u a l i z a t i o n tank w i t h a f l o t a t i o n chamber f o r

grease removal. A sed imen ta t i on u n i t can be used t o remove p r o t e i n s , k e r a t i n , and suspended s o l i d s . The s o l u t i o n i s a 1 lowed t o ove r f l ow , a g i t a t e d , heated t o p rocess temperatures, rep len i shed w i t h I ime and s u l f u r , and reused.

o Limed s p l i t s can be s o l d and made i n t o e d i b l e sausage cas ings and pack ing m a t e r i a l s f o r f o o d s t u r f s and g e l a t i n food i tems. They can a l s o be used i n p o u l t r y and animal feeds tock o r used t o genera te commercia I p roduc ts such a s beauty creams. rhe l a t t e r uses r e q u i r e a c i d ( H C I ) f o r n e u t r a l i z a t i o n and steam Tor s e p a r a t i o n o f grease f rom p r o t e i n .

Chromium sa I t s , waste- wa te r

o Chrome a c l a r I i quo r f o l low reduce about

Spent p i c k l i n g ac ids , r i n s e waters contam i - nated w i t h a c i d s

s o l u t i o n e f f l u e n t can be r e c y c l e d b y u s i n g f i e r and then f i l t e r i n g t h e exhaust chrome f o r use as a p i c k 1 ing f l o a t f o r t h e ng b a t c h o f h ides , These procedures can t h e chrome c o n t e n t i n t h e e f f l u e n t b y 0%.

o Chrome rur iof f

can be recovered f rom e f f l u e n t streams o r f rom w r i n g e r s by p r e c i p i t a t i o n o f chromium

hyd rox ide a f t e r t h e a d d i t i o n o f l ime. The chrome i s then separated by s e t t l i n g , f i l t e r i n g , and r e d i s s o l v i n g w i t h s u l f u r i c a c i d . EDDA o r NTA must be added t o t h e chrome l i q u o r t o complex a n y t r a c e amounts o f i r o n wh ich would p reven t t h e recovery o f t h e chrome.

o Waste p i c k l i n g a c i d s can be s o l d as a f eeds tock f o r f e r t i l i z e r manufacture o r a s a s ludge genera to r ( f o r n e u t r a l i z a t i o n / p r e c i p i t a t i o n ) t o a wastewater t rea tmen t f a c i I i t y .

LEATHER PRODUCTS MANUFACTURING ( c o n t i n u e d )

I n d u s t r i a l Sec to r I n d u s t r i a l Process Wastes Waste Minimization/Management Opt ions

F i n i sh ing/Trimming S p l i t t i n g and shaving Sc raps, h i de shav i ngs, 0

f a t s , and s p l i t s

0

0

F i n i sh i ng Spent f i n i s h i n g so l - vents, sc raps o f l ea the r , s t i I I bottoms

0

Chrome shav ings can be processed i n t o m a t e r i a l s such as l ea the rboard o r i n s u l a t i o n .

Shavings can be ground and used a s an absorbent f o r soak ing up a number o f o r g a n i c l i q u i d s .

Alum, z i rcon ium, o r t r e e b a r k e x t r a c t can be s i t bs t i t i l t e d f o r chrome. Shavings f rom these o t h e r sources can be used as f u e l i n energy recovery; however, t h e y m a y be sit i t a b I e s u b s t i t u t e s f o r chrome o n l y i n some p roduc ts (e .g . , b e l t s ) because t h e i r use r e s u l t s i n a ha rde r q u a l i t y o f l e a t h e r .

B lue t r i m shav ings ( l e a t h e r sc raps c o n t a i n i n g chrome) can be used i n manu fac tu r ing f e r t i I i z e r and g lues .

Smal I l e a t h e r i tems such as key c h a i n s can be made o u t o f l e a t h e r scraps.

E l im ina te obv ious r e j e c t a b l e ma te r ia I b e f o r e a p p l y i n g f i n i s h e r .

S u b s t i t u t e s lower e v a p o r a t i n g s o l v e n t s such as g l y c o l e t h e r s o r d iace tone a l c o h o l f o r c h l o r i n a t e d s o l v e n t s . Rad ia l f requency d r i e r s wh ich use microwaves t o d r y t h e l ea the r , o r o t h e r d r y i n g methods (e.g., dehumid i fy ing , vacuum d r y i n g ) make up f o r t h e s lower evapora t i on and produce more y i e l d i n t h e l e a t h e r .

Segregate waste streams t o c o l l e c t l e f t o v e r f i n i s h e r f o r d i r e c t reuse i n making a new b a t c h o f f i n i s h e r .

LEATHER PRODUCTS MANUFACTURING ( con t i nued )

I n d u s t r i a I Sec to r I n d u s t r i a l Process Wastes Waste Min im i za t ion/Management Opt ions

F in i sh ing /T r imming ( c o n t i nued )

o S m a l l voliime s t i l l s a l l o w f o r r e c l a i m i n g o f s o l v e n t wh ich can be used i n c l e a n i n g opera t i ons . H e a v i l y con taminated s o l v e n t s can be b lended w i t h f u e l s and used i n b o i l e r s t o genera te steam o r h o t wa te r .

o C h i l l e r s , o r condensing c o i l s , can be i n s t a l l e d ove r t h e vapor zone o f spray booths t o inc rease recovery and lower VOC emiss ions .

o C lean ing spray booths w i t h a squeegee t o remove most o f t h e f i n i s h i n g s o l v e n t p reven ts b u i l d - u p wh ich m a y lead t o c o n t a m i n a t i o n o f r e c y c l e d so l ven ts . A l so c l e a n i n g o f spray nozz les and o t h e r p r e v e n t a t i v e maintenance decreases wasted f i n i s h i n g s o l v e n t s .

o E l e c t r i c eyes ( e l e c t r i c a l dev i ces wh ich d e t e c t t h e presence o f a h i d e i n t h e spray boo th ) can be i n s t a l l ed on spray nozz les t o p reven t waste o f f i n i shers.

TEXTILE MANUFACTURING

I n d u s t r i a l Process Wastes Waste Minimization/Management Opt ions

F i n i sh i ng Wastewater o A number of r e l a t i v e l y low-cost measitres can be implemented by t e x t i l e f i n i s h i n g m i l l s t o reduce t h e amount o f wastewater generated. Many o f these measures i n v o l v e the reuse o r r e c y c l i n g o f wa te r f rom a p r o d u c t i o n process i n e i t h e r t h e same process o r another one. These wastewater r e d u c t i o h techn iq i ies a/ i nc lude :

-- Coun te rcu r ren t washing. I n t h i s procedure, c l e a n wa te r e n t e r s t h e f i n a l r i n s e box and f l ows th rough t h e wash boxes i n t h e o p p o s i t e d i r e c t i o n a s t h e f a b r i c ; f a b r i c i s f i r s t r i n s e d in t h e most contaminated wash box, and l a s t i n t h e wash box f i l l e d w i t h c l e a n water . Coun te rcu r ren t washinq r e s u l t s i n b o t h wa te r and energy savings.

p roduc t i o n processes:

- The f i n a l r i n s e i n b a t c h dye inq o p e r a t i o n s i s u s u a l l y r e l a t i v e l y c l e a n

- I n t h e c a r p e t manufac tur ing segment o f t he i ndus t r y , wa te r i s

-- The f o l l o w i n g a r e examples o f t he reuse o f wa te r i n the same o r o t h e r

and can be d i r e c t l y used a s makeup f o r t h e n e x t dyebath

mechan ica l l y e x t r a c t e d f rom c a r p e t s a f t e r t h e y a r e dyed and r i nsed . T h i s e x t r a c t e d wa te r can be used e i t h e r i n r i n s i n g o r dyebath makeup.

t h a t have lower wa te r q u a l i t y requi rements. For example, wa te r used i n m e r c e r i z i n g and b leach ing o p e r a t i o n s can be reused i n d e s i z i n g processes.

- Washwater used i n one type o f process can be used i n o t h e r processes

New E q i i i pment

o When f i r m s make c a p i t a l investments i n new machinery, t h e y can purchase more e f f i c i e n t equipment t h a t reduces t h e amount o f energy and dye used, i n a d d i t i o n t o decreas ing t h e amount o f wastewater generated. These t ypes o f equipment i nc I ude:

-- J e t dye ing machines c u r r e n t l y a v a i l a b l e have v e r y l o w l i q u o r r a t i o s ( r a t i o o f t h e we igh t o f wa te r used t o t h e we igh t o f t h e c l o t h dyed) . The c o s t s o f j e t dye ing machines range f rom $100,000 t o $225,000. b/

?/ " D i r e c t Recycle/Reuse and Water Reduct ion Measures," Wastewater Recyc le and Reuse P o t e n t i a l f o r l n d i r e c t D ischarqe T e x t i l e F i n i s h i n q M i l Is , U.S. Env i ronmenta l P r o t e c t i o n Agency, March, 1984. The techn iques c i t e d a r e i I l u s t r a t i v e o f wa te r c o n s e r v a t i o n measures, b u t do n o t p r o v i d e a comprehensive v iew o f a l I app l i c a b l e measirres.

Caro r ina . Desp i te t h e h i g h cos t , smal l bus inesses a r e making investments i n these machines. b/ Conversa t ion w i t h Jack F i e l d , Manager o f Marke t i ng and Serv ices, Gaston County Dyeing Machine Company, S tan ley , N o r t h

TEXT I LE MANUFACTUR 1 NG ( c o n t i nued )

~~~


F i n i sh i ng ( c o n t i nued )

D r y C lean ing d/ F i l t e r

S t i l l bottoms

-- Computerized " c o l o r match ing systems" enab le dye rs t o : ( I ) determine t h e exhaus t ion o r s a t u r a t i o n p o i n t o f p a r t i c u l a r dyes; a s a r e s u l t , t h e amount o f dye t h a t must be p u t on f a b r i c s i s min imized, and l e s s dye i s d ischarged t o wastewater, ( 2 ) match c o l o r s and c o r r e c t dye ba tches a c c u r a t e l y , and ( 3 ) de termine t h e c o s t s and c o l o r q u a l i t y t h a t w i l l r e s u l t f rom u s i n g d i f f e r e n t dye combinat ions. For a smal l d y e house, t h e c o s t o f t h i s equipment would range from $ZO,OOO-$~O,OOO. Equipment vendors i n d i c a t e d t h a t sma I I-to-medium s i zed companies have purchased these t ypes o f systems, wh ich r e s u l t i n s i g n i f i c a n t sav ings i n bo th t h e t ime spent on match ing c o l o r s and i n t h e amount o f dye used. c /

C a r t r i d g e s t r i p p e r s a r e more e f f i c i e n t a t removing s o l v e n t f rom c a r t r i d g e s t h a n d r a i n i n g o r d r y i n g c a r t r i d g e s i n the d r y e r . Steam s t r i p p i n g , in p a r t i c u l a r , removes add i t i ona 1 so I ven t f rom ca rhon cores .

Rep lac ing f i l t e r powder w i t h f i l t e r c a r t r i d g e s s i g n i f i c a n t l y reduces t h e amount o f s o l i d waste s ince c a r t r i d g e s a r e r e c y c l a b l e : carbon co res can bc regenerated o r burned, t h e f i l t e r paper i s i nc ine rab le , and t h e metal i s r e c y c l a b l e . f i l t e r powder r e t a i n s 50 ppm s o l v e n t even a f t e r t rea tmen t a t r e c y c l e c e n t e r s and i s d i f f i c u l t t o burn.

Ceramic f i I t e r s a r e "permanent" f i I t e r s t h a t would never need t o be rep laced. However, t he c a p i t a l investment f o r a ceramic f i l t e r capab le o f t i and l i ng t y p i c a l s o l v e n t th roughputs i s ex t reme ly h i g h ($40,000-60,000; a d r y - t o - d r y u n i t Costs $ 3 0 , 0 0 0 ) .

Adding wa te r t o s t i l l bot toms f o l l o w i n g f i n a l b o i l down recovers a d d i t i o n a l so l ven t , reduc ing s o l v e n t c o n t e n t i n t h e bot toms f rom more t h a n 50% t o 1-2%.

S t i I I bottoms can be mixed w i t h a p p r o p r i a t e m a t e r i a l s f o r a u t o undercoa t ing use. (One problem would be f i n d i n g a gas s t a t i o n o r garage t h a t would be w i l l i n g t o accept t h e smal l amounts o f s t i l l bot toms genera ted ) .

- c / Conversa t ion w i t h Ivan Garet, App l i ed C o l o r Systems, Pr ince ton , New Jersey .

- d/ I C F con tac ted t h e f o l l o w i n g i n d i v i d u a l s t o o b t a i n i n f o r m a t i o n about t h i s i n d u s t r y :

1 ) Jon Me i je r , I n t e r n a t i o n a l Fabr i ca re I n s t i t u t e 2 ) John Lucks, S a f e t y Kleen Corp. 3 ) Steven Michaels, Nor ton Company

TEXTILE MANUFACTURING ( c o n t i n u e d )

I ndus t r i a I Process Wastes Waste Minimization/Management Op t ions

D r y C lean ing So lvent vapors ( c o n t i n u e d )

So I ven t wa Stes

Machine C lean ing So I ven t wastes

Using d r y - t o - d r y unli,ts, o r r e f r i g e r a t i o n / c o n d e n s a t i o n c l e a n i n g machines e l i m i - na tes t h e need f o r s n i f f e r s " and v e n t i n g d u c t s which m igh t leak, t he reby reduc ing vapor losses. Also, r e t r o f i t t i n g r e c l a i m i n g d r y e r s w i t h carbon a d s o r p t i o n o r r e f r i g e r a t i o n / c o n d e n s a t i o n u n i t s m in im izes losses t o the a i r .

Good hoiisekeeping; r e p l a c i n g o r r e p a i r i n g f a u l t y hose connect ions , va lves , gaskets , sea ls , and sea t ings reduces s o l v e n t losses.

Use a l ess hazardous s o l v e n t (e .g . , l , l , l - t r i c h l o r o e t h a n e ) . D r y c l e a n i n g equipment i s des igned f o r use w i t h a s p e c i f i c so l ven t , however. For example, because l , l , l - t r i c h l o r o e t h a n e (TCE) i s more c o r r o s i v e than pe rch lo roe thy lene , some s t a i n l e s s s t e e l must be used i n the c o n s t r u c t i o n o f TCE u n i t s . C a p i t a l investment f o r new equipment i s o n l y a l i t t l e h i g h e r due t o c o r r o s i o n r e s i s t a n t m a t e r i a l s . (Adeqiiate de te rgen t and a d d i t i v e f o r m u l a t i o n s a r e s t i l I i n t h e developmenta I stage, however. )

D e d i c a t i o n o f dye ing equipment t o one c o l o r e l im ina tes t h e need f o r equipment c l e a n i n g between c o l o r changes. Th is waste r e d u c t i o n o p t i o n may be f e a s i b l e f o r t e x t i l e p l a n t s t h a t s p e c i a l i z e i n dye ing p a r t i c u l a r c o l o r s , o r dye a l a r g e percentage o f f a b r i c s one c o l o r .

T e x t i l e p l a n t s t h a t mu schedule dye ing f rom 1 equipment c lean ing , t h n o t come o u t c o r r e c t l y

S tud ies o f t he t e x t i l e screen p r i n t i n g o p e r a t expend i t u r e s a r e made, p r i n t i ng .

t use t h e same equipment t o dye many f a b r i c c o l o r s shou ld g h t c o l o r s t o d a r k e r ones. In a d d i t i o n t o m i n i m i z i n g s procedure a l l o w s f a b r i c s t o be redyed i f t h e c o l o r does

i n d u s t r y e / suggest t h a t l e s s c l e a n i n g i s r e q u i r e d i n ons than i n r o l l e r p r i n t i n g o p e r a t i o n s . When new c a p i t a l companies may want t o i n v e s t i g a t e a l t e r n a t i v e methods o f

l i g h t e r f a b r i c s can be dyed a d a r k e r c o l o r .

For degreasing, m a t e r i a l s o t h e r than c h l o r i n a t e d s o l v e n t s may be used. For example, a non-hazardous water-based a l k a l i c l e a n i n g compound i s be ing marketed as a n i n d u s t r i a l degreaser . I n a d d i t i o n , c a u s t i c s o l u t i o n s m a y be used a s degreasers. These a l t e r n a t i v e c l e a n i n g s o l u t i o n s may be more e f f e c t i v e l y used i n c e r t a i n a p p l i c a t i o n s than o the rs .

- e/ Wastewater Recyc le and Reuse P o t e n t i a l f o r I n d i r e c t Discharqe T e x t i l e F i n i s h i n s M i l I s .

FURNITURE/WOOD MANUFACTURING AND R E F I N I S H I N G

I n d u s t r i a I Process Wastes

Spray ing and F i n i sh i ng ma te r ia F i n i s h i n g i g n i t a b l e wastes,

so lvents , i g n i t a b p a i n t wastes

Waste Minimization/Management Op t ions a/

s, o Use o f p roper spray techn iques - I ) 50% o v e r l a p o f t h e spray p a t t e r n , spent 2 ) d i s t a n c e o f gun t o workpiece o f 6-8 inches, 3 ) gun speed o f 250 f t / m i n , e 4 ) h o l d gun p e r p e n d i c u l a r t o sur face , 5 ) t r i g g e r gun a t beg inn ing and end

o f each p a s s .

o Formal t r a i n i n g o f new spray o p e r a t o r s r e s u l t s m a t e r i a l usage, a h i g h e r q u a l i t y f i n i s h , r e d u c t atmosphere, and l e s s overspray ( l e s s c lean -up ) . accomplished by u s i n g the t r a i n i n g a i d s o f f e r e d i i se

o Use

o f t r a i n i n g v ideo tapes.

o f t h e c o r r e c t spray gun f o r p a r t i c u l a r app

n: r e d u c t i o n o f f i n i s h i n g on o f emiss ions i n t o t h e

b y equipment srippl i e rs , o r T h i s t r a i n i n g can be

i ca t i on:

--

Convent ional A i r Spray Gun f o r t h i n f i l m b u i l d requ numerous c o a t s a r e t o be a p p l i e d .

A i r l e s s Spray Giin f o r an inc rease i n . t r a n s f e r e f f i c f i l m i s requ i red .

A i r - a s s i s t e d A i r l e s s S p r a y Gun f o r reduced m a t e r i a l

rements when

ericy when a heavy

--

consumption and reduced compressed a i r . consumption when a w ide range o f f I u i d o u t p u t (2-100 ounces p e r m inu te ) i s needed.

A i r l e s s and A i r - a s s i s t e d A i r l e s s u n i t s can c o s t $2,800-6,300.

o Use o f e l e c t r o s t a t i c f i n i s h i n g by c h a i r manufac turers t o inc rease t r a n s f e r e f f i c i e n c y o f f i n i s h i n g m a t e r i a l s . T h i s can inc rease t r a n s f e r e f f i c i e n c y from 20% t o 60%. T h i s w i l l reduce m a t e r i a l consumpt ion and w i l l a l s o reduce spent s o l v e n t g e n e r a t i o n f rom booth c lean-up by reduc ing t h e f requency o f c lean-ups needed. Wa l l s o f t h e booth can a l s o be grounded t o a t t r a c t t h e overspray ,and keep t h e r e s t o f t h e work area c lean . Hand-held u n i t s a r e n o t e f f i c i e n t i n low r e l a t i v e h u m i d i t y (be low 50%). Hand-held u n i t s can c o s t $2,700-$4,000.

o Use water-based i n k s i n g ravu re p r i n t i n g o f wood g r a i n on to plywood o r

o Use o n l y c l e a n and d r y a i r supply. Water, o i l , and d i r t w i l l ru in t h e

pa r t i c l e boa rd .

f i n i s h j o b .

a/ The waste m i n i m i z a t i o n o p t i o n s i n t h i s summary were p r i m a r i l y ob ta and k e c y c l i n q So lven ts i n t h e F u r n i t u r e I n d u s t r y ( N o r t h C a r o l i n a S t a t e Un Jerome Kohl, was con tac ted by ICF .

ned f rom an e x t e n s i v e s tudy on v e r s i t y , M a y ‘ 1 9 8 6 ) . The p r i n c

t h e i ndus t r y , Manaqinq p a l a u t h o r o f t h e study,

FURNITURE/WOOD MANUFACTURING AND R E F I N I S H I N G ( con t i niied )

I n d u s t r i a I Process Wastes Waste Minimization/Management Op t ions

Spray ing and F i n i s h i ng ( c o n t i nued )

Spray Booth, Spray Guns, and Brush C 1 ean i ng

Spent so lvents , i g n i t - a b l e p a i n t wastes, i g n i t a b l e wastes, s t i I I bot toms

o Good housekeeping

-- Never bi iy t oo much f i n i s h i n g m a t e r i a l a t one t i m e because the m a t e r i a l s have r e l a t i v e l y s h o r t s h e l f l i v e s , and d i s c o n t i n u a t i o n o f a s u i t e can r e s u l t i n excess m a t e r i a l .

o When c l e a n i n g spray guns, submerge o n l y t h e f r o n t end o r f l u i d s e c t i o n s o f t h e gun i n so l ven ts . lhe s o l v e n t s c a n d i s s o l v e t h e o i l s i n t h e l e a t h e r pack ings and cause t h e gun t o leak .

o Good housekeeping

- Clean-up s o l v e n t s can be reused w i t h t h e same r e s i n system. S o l i d s a r e c l l owed t o s e t t l e t o t h e bo t tom o f t h e spent s o l v e n t c o n t a i n e r and t h e

- V i r g i n s o l v e n t can be used f i r s t t o f l u s h o u t t h e pump and a p p l i c a t i o n equipment l i n e s and then used a s a t h i n n e r f o r t h e f i n i s h i n g m a t e r i a l .

- Keep s o l v e n t waste streams segregated and f r e e f rom con tamina t ion by water .

c leaner " spent s o l v e n t on t o p i s used f o r c lean-up.

o So lvent recovery u n i t s can be used t o r e c y c l e spent s o l v e n t s genera ted i n f l u s h i n g opera t i ons . The u n i t s a r e a v a i l a b l e i n 5 g a l l o n c a p a c i t y s izes ; t h e c o s t o f t h e smal l u n i t s i s app rox ima te l y $2,000-$4,000.

- Since t h e compos i t i on o f t h e s o l v e n t may change w i t h d i s t i l l a t i o n , t h e rec la imed s o l v e n t may n o t be reusab le i n t h e f l u s h i n g opera t i ons . However, a component such a s acetone m a y be added t o t h e rec la imed s o l v e n t and used as a t h i n n e r i n t h e spray c o a t i n g s o p e r a t i o n . T h i s reduces t h e amount o f v i r g i n s o l v e n t purchased f o r t h e spray mix.

- N i t r o c e l I u l o s e can become e x p l o s i v e when heated, so s t i I I s must have spec ia l des ign f e a t u r e s i f recove r ing spent s o l v e n t s c o n t a i n i n g n i t roce I I u lose.

o Because of t h e h i g h BTU va lue and low halogen c o n t e n t o f t h e waste so l ven ts , spent s o l v e n t s can be burned f o r hea t recove ry in-house o r s o l d as f u e l .

- A scrubber i s needed i f t h e i n c i n e r a t o r exhausts a r e n o t w i t h i n emiss ion

- Waste s o l v e n t s can be burned i n cement o r aggregate k i l n s s i n c e t h e r e i s

s tandards f o r in-house hea t recovery .

no ash.

WOOD PRESERVI NG

I n d u s t r i a l Process Wastes Waste Minimization/Management Op t ions g/

Raw M a t e r i a l s P r e s e r v a t i v e s l e f t i n 0 Hand I i ng c o n t a i n e r s

0

Wood C o n d i t i o n i n g Steam condensate and T r e a t i n g conta i n i ng prese rva-

t i v e , wood, f i b e r , s a l t , sugars, ac id , and o i I

0

0

0

0

0

The purchase o f r e l a t i v e l y smal l q u a n t i t i e s (e.g., 50 pound bags - n o t cons idered a b u l k purchase ] o f p r e s e r v a t i v e shou ld be avoided, i f p o s s i b l e . I f smal l amounts o f p r e s e r v a t i v e a r e l e f t i n c o n t a i n e r s , t h e e n t i r e conta i n e r m a y be cons idered haza rdoirs.

I n s t a l l a t i o n o f c losed systems f o r hand1 i n g powdered p r e s e r v a t i v e s reduces worker exposure and m a t e r i a l s sp i I I s . These systems a r e es t ima ted t o c o s t $ l O , O O O p e r f a c i I i t y and w i I I be r e q u i r e d f o r un load ing and m i x i n g p r i l l ed o r f l a k e d PCP a f t e r September I, 1987.

Segregate hazardous ma te r ia I s f rom non-hazardous ones.

Wood can be c o n d i t i o n e d by a i r o r k i l n d r y i n g i n a d d i t i o n t o steaming; t h e use o f d r y i n g methods e l i m i n a t e s a ma jo r source o f wastewater . h u t has l i m i t e d a p p l i c a t i o n s . A i r d r y i n g can o n l y be conducted i n some l o c a t i o n s , and k i l n d r y i n g can be used o n l y f o r c e r t a i n woods (e.g. , SouLhern p i n e ) .

I n c losed steaming opera t i ons , t he wa te r used f o r c o n d i t i o n i n g i s recyc led . Sw i t ch ing f rom open t o c l o s e d steaming i s t y p i c a l l y n o t d i f f i c u l t t o implement, and invo lves i n s t a l I ing a s to rage tank f o r r e c y c l e d condensate.

Proper s t a c k i n g o f wood i n t h e r e t o r t used f o r s t e a m i n g / t r e a t i n g a l l o w s b e t t e r d ra inage o f p r e s e r v a t i v e .

Condensate f rom c o n d i t i o n i n g and t r e a t i n g wood i s sen t t o an o i l / w a t e r separa to r t o recover p r e s e r v a t i v e . A i r - f l o t a t i o n u n i t s can be i n s t a l l ed t o inc rease recove ry o f t h e p r e s e r v a t i v e .

Steam c o n d i t i o n i n g can be separated f rom t h e t rea tmen t p rocess by u s i n g separa te c y l i n d e r s f o r each process; as a r e s u l t , t h e waste s t ream f rom c o n d i t i o n i n g w i l l n o t c o n t a i n p r e s e r v a t i v e . I t shou ld be no ted t h a t e x t r a equipment i s r e q u i r e d t o implement t h i s technique, and a d d i t i o n a l o p e r a t i n g t ime i s r e q u i r e d t o t r a n s f e r wood.

The replacement o f ba romet r i c condensers w i t h su r face condensers e l im ina tes c o n t a c t between coo l ing wa te r and process vapors; c o o l ing w a t e r the reby remains uncontaminated, and an a d d i t i o n a l waste s t ream is n o t c rea ted .

A f i n a l vacuum c y c l e i n wood t r e a t i n g can sometimes be used t o inc rease recovery o f unabsorbed p rese rva t i ve .

a/ The waste m i n i m i z a t i o n techn iques no ted i n t h i s summary were p r i m a r i l y ob ta ined f rom t h e D r a f t F i n a l Repor t . Waste M i n i o i z a t i o n Issues and Options, p repared b y Versar Inc . and Jacobs Eng ineer ing Group (February, 1986).

WOOD PRESERV I NG ( con t i nued )

I n d u s t r i a l Process Wastes Waste M i n i m i za t i on/Management Opt i ons

Wood C o n d i t i o n i n g and T r e a t i n g ( c o n t i n u e d )

P rese rva t i ves

O i I / w a t e r emuls ions

S t o r i n g o f Trea ted D r i p p i n g c o n t a i n i n g Wood p rese rva t i ve , waste-

wa te r

o Wood shou ld be tho rough ly c leaned b e f o r e i t i s c o n d i t i o n e d / t r e a t e d i n r e t o r t .

o Unseasoned wood should n o t be t rea ted , and p r e s e r v a t i v e milst be comp le te l y mixed.

o I n processes i n wh ich c o n d i t i o n i n g and p r e s e r v i n g must be conducted t o g e t h e r ( i . e . , B o u l t o n i z i n g ) , f o rced evapora tors a r e l e s s c o s t l y t o use than c o n s t r u c t i n g s i t r face impoundments t h a t comply w i t h t h e RCRA I lazardous and S o l i d Waste Amendments.

o O i l ob ta ined f rom the o i l / w a t e r separa to r can be r e c y c l e d by add ing t h e o i l t o subsequent o i I /water emu I s i ons ( i nc rea s i ng t h e d i spe rsed ptia se w i I I he I p break emu I s i o n s ) .

i n c o r r e c t s u r f a c t a n t can make t h e emuls ion more s t a b l e .

t r a c k s and pads should be i n s t a l l e d t o c o l l e c t these d r i p p i n g s .

r a i n w a t e r t h a t then must be t r e a t e d . T h i s o p t i o n may be expensive.

o D e m u l s i f i e r s can be used; i t shou ld be noted, however, t h a t t h e use o f an

o P r e s e r v a t i v e d r i p p i n g s f rom t r e a t e d wood a r e a ma jo r source o f waste. D r i p

o Cover ing the t r e a t e d wood s to rage area reduces t h e amount o f contaminated

METAL MANUFACTURING

I n d u s t r i a I Process Wastes Waste Minimization/Management Op t ions a/

Meta l C u t t i n g / Waste c u t t i n g 0 Mach i n i ng o i l s , sc rap

me t a I 0

0

0

0

Use o f a i r o r f i n e o i l m i s t as t h e c o o l a n t d u r i n g c u t t i n g o p e r a t i o n s reduces t h e use o f f r e s h o i I and, t h e r e f o r e , t he g e n e r a t i o n o f used o i I.

In many metal cu t t i ng /mach in ing opera t i ons , o i I s can be r e c y c l e d w i t h o u t any t rea tmen t . I n these cases, o i l s can be recyc led u n t i l consumed. I f o i l s r e q u i r e t rea tmen ts such as f i l t r a t i o n and rec lamat ion b e f o r e reuse, waste o i l s shou ld be segregated t o make o n - s i t e o r o f f - s i t e rec lamat ion e a s i e r because complete p u r i f i c a t i o n and r e - a d d i t i o n o f a d d i t i v e s can be avoided.

I t i s g e n e r a l l y b e n e f i c i a l t o s tandard i ze o i l s t o m in im ize t h e t ypes o f o i l s used f o r l u b r i c a t i o n , c u t t i n g , and coo l i ng , so t he o i l s can rep lace each o t h e r i n a v a r i e t y o f uses. In cases where d i f f e r e n t o i l s a r e r e q u i r e d f o r d i f f e r e n t me ta l s (e .g . , i n screw machin ing) , improved schedul ing would reduce t h e number o f equipment c l e a n - o u t s and, t h e r e f o r e , t h e q u a n t i t y o f waste o i l . The use o f ded ica ted l i n e s f o r each meta l i s one o p t i o n .

In c o l d fo rming processes i n which o i l serves a s a l u b r i c a n t r a t h e r than a c u t t i n g o i l o r c o o l a n t (e.g., f a s t e n e r p r o d u c t i o n ) , l ime ( h o t l ime b a t h ) o r Borax soap can bc used t o rep lace o i l as t h e drawing agent. Use o f these s u b s t i t u t e s e l i m i n a t e s t h e o i l waste and t h e need f o r degreasing.

Severa l meta lwork ing o p e r a t i o n s use l a r g e q u a n t i t i e s o f o i I and genera te l a r y e q u a n t i t i e s o f scrap m e t a l / o i l waste (e.g. , screw machine p roduc ts manufac ture) . T h i s o i I / s c r a p m i x t u r e can be c e n t r i f u g e d t o recover the b u l k o f t h e o i l f o r r e c y c l e . Th is s ludge e x t r a c t o r sp ins t h e wet s ludge a t h i g h speed wh ich compacts t h e s ludge and d r i v e s t h e o i l towards t h e c e n t e r o f t h e u n i t where i t i s f i l t e r e d and recovered f o r reuse. b/

a/ The

1 )

r e d u c t i o n i n f o r m a t i o n i n t h i s summary i s l a r g e l y based on s i t e v i s i t s conducted by ICF, and p r e v i o u s I C F s t u d i e s on waste n t h i s i n d u s t r y . In a d d i t i o n , t h e f o l l o w i n g sources p rov ided many u s e f u l suggest ions:

Monica E. Campbell, and W i l l i a m M. Glenn. P r o f i t f rom P o l l i ~ t i o n Prevent ion : A Guide t o I n d u s t r i a l Waste Reduct ion and Recycl i n q (Toronto : Pol f u t i o n Probe Foundation, 1982).

P o l l u t i o n P reven t ion T i p s on Water Conserva t ion f o r E l e c t r o p l a t e r s , pub1 ished by t h e P o l l u t i o n P reven t ion Pays Program, N o r t h Caro l i n a Department o f Na tu ra l Resources and Community Development.

b/ The c o s t o f t h e c e n t r i f u g e d iscussed above ranges f rom $11,000 - $23,000. Es t imate g i v e n b y R icha rd Gash, a s a l e s r e p r e s e n t a t i v e f o r Leon J. B a r r e t t , t h e manufac turer o f t h e c e n t r i f u g e . Gash no ted t h a t smal I bus inesses have purchased t h i s equipment.

METAL MANUFACTURING ( c o n t i ncied )

I n d u s t r i a I ? r o c e s s Wastes Waste Minimization/Managemcnt O p t i o n s

Meta I C u t t i n g / Mach i n i ng ( c o n t i nued )

0

Deg rea s i ng Waste so lvents , o s o l v e n t s t i l l bot toms

0

0

The s e g r e g a t i o n o f meta l sc rap by meta l t y p e does n o t reduce waste q u a n t i t y , h i l t does inc rease income. For example, s t a i n l e s s s t e e l sc rap s e l l s f o r a h i g h e r p r i c e than carbon s t e e l scrap.

Spent degreasing s o l v e n t s can be r e c y c l e d o n - s i t e u s i n g b a t c h s t i l l s . I f the c o s t o f b a t c h s t i I I s i s p r o h i b i t i v e due t o e x t r e m e l y smal I waste volumes, a c o n t r a c t u a l agreement can be e n t e r e d i n t o w i t h companies, l i k e Safety-Kleen, t h a t s u p p l y f r e s h s o l v e n t s and remove spent s o l v e n t s t o r e c o v e r t h e reusab le f r a c t i o n .

The hazards and t o x i c i t y o f degreas ing s o l v e n t s and wastes can be reduced by r i s i ng l e s s hazardous s o l v e n t degreasers (e.g., pe t ro leum s o l v e n t s such a s Stoddard s o l v e n t i n s t e a d o f c h l o r i n a t e d s o l v e n t s ) o r by u s i n g a l k a l i washes (e.g., h o t c a u s t i c washes, u l t r a s o n i c soap c l e a n i n g ) . However, t h e r e a r e I i m i t a t i o n s t o t h e app l i c a b i I i t y o f a l t e r n a t i v e s o l v e n t s and c l e a n e r s wh ich must be e v a l u a t e d on a s i t e - b y - s i t e b a s i s .

Coopera t ive arrangements (e.g., m i I k r u n s ) can be developed w i t h o t h e r smal I g e n e r a t o r s rom many genera t o r s ; whereby s o l v e n t wastes a r e co t l e c t e d by a c e n t r a l o r g a n i z a t i o n

wastes a r e then r e c y c l e d and r e t u r n e d t o t h e genera tors .

The l o s s o f s o l v e n t t o t h e atmosphere f r o m vapor degreas ing equ

-- I n c r e a s i n g t h e h e i g h t o f f reeboard above t h e vapor l e v e l t o

-- Cover i ng t h e deg reas i ng un i t . w i d t h .

pment can be reduced by:

75 p e r c e n t o f t h e t a n k

-- I n s t a l I i ng r e f r i g e r a t o r c o i I s ( o r a d d i t i o n a l c o i i s ) above t h e v a p o r zone.

Tumble w i t h saw d u s t o r o t h e r absorbent o r c o l d c l e a n w i t h m i n e r a l s p i r i t s t o remove t h e bu lk o f t h e o i l b e f o r e f i n a l vapor degreasing. Pre-c lean ing w i l l ex tend t h e l i f e o f t h e vapor degreasing s o l v e n t .

METAL MANUFACTURING ( c o n t i n u e d )

I n d u s t r i a l Process Wastes Waste Minimization/Management Opt ions

Pick1 ing Spent p i c k l i ng 0 a c i d s ( I iquo rs ) , r i nsewa t e r s contaminated w i t h a c i d 0

0

0

0

E l e c t rop l a t i ng Wastewaters 0 contam i na t e d w i t h me ta l s

0

Waste p i c k l i n g a c i d s can be s o l d as a feeds tock f o r f e r t i I i z e r manufac ture o r a s a s ludge genera to r ( f o r n e u t r a l i z a t i o n / p r e c i p i t a t i o n ) t o a wastewater t r e a t m e n t f a c i I i t y . Other o p t i o n s m a y be ava i t a b l e f o r waste exchange.

The g e n e r a t i o n r a t e o f spent r i n s e wa te r can be reduced b y u s i n g c o u n t e r - c u r r e n t r i n s i n g by which p a r t s a r e f i r s t r i n s e d i n t h e most h i g h l y contaminated b a t h and l a s t i n t h e l e a s t contaminated ba th . The g r e a t e r t h e number o f r i nses , t h e l e s s wastewater i s generated.

The q u a n t i t y o f wastewater can a l s o be reduced by m i n i m i z i n g con tamina t ion o f t h e r i n s e ba ths . ba th . There a r e severa l approaches t o reduc inq d ragou t as p resented f o r E l e c t r o p l a t i n g " below.

Ac ids i n t h e r i nsewa te rs m a y be recoverab le by e v a p o r a t i o n techn iques . Economic f e a s i b i I i t y depends on the i n i t i a l a c i d c o n c e n t r a t i o n i n t h e wastewater .

Ac id c l e a n i n g can be rep laced w i t h r o t a t i n g brushes o f pumice wh ich would genera te a non-hazardous s ludge waste.

To reduce b o t h t h e q u a n t i t y and the t o x i c i t y o f t h e wastewaters, me ta l s can be recovered u s i ng evapo r a t ion, i o n exchange, reverse osmos i s , e I e c t r o I y s i s , and e I e c t rod i a I y s i s . The economic f e a s i b i l i t y o f metal recovery depends on t h e c o s t o f v i r g i n meta ls , t h e c o s t t o recover t h e meta ls , and t h e c o s t t o d ispose o f t h e wastewater t rea tmen t s ludge. Me ta l s recovery by evapora t i on (e .g . , u s i n g c l i m b i n g - f i I m vacuum e v a p o r a t i o n ) appears t o be t h e most c o s t e f f e c t i v e o p t i o n f o r genera to rs o f smal l volumes o f waste. I n a d d i t i o n , e l e c t r o l y t i c recovery u n i t s may a l s o be an economica l l y f e a s i b l e techno logy f o r SQGs. c/ Wastewaters c o n t a i n i n g recoverab le me ta l s shou ld be segregated f rom o t h e r wastewater streams.

For some p l a t i n g a p p l i c a t i o n s , l ess t o x i c me ta l s have been a b l e t o rep lace more t o x i c me ta l s (e.g., z i n c can rep lace cadmium f o r a l k a l i / s a l i ne env i ronments ) .

Rinse ba ths become contaminated q u i c k l y hecause o f d ragou t f rom t h e p i c k l ing

c/ Wh i le t h e r e i s a s i g n i f i c a n t c o s t range f o r evapora to rs and e l e c t r o l y t i c recovery u n i t s , t h e lower p r i c e range beg ins a t $4,0~0-$5,000. T h i s e s t i m a t e p rov ided by Gary Hunt, Nor th Caro l ina Pol l u t i o n P reven t ion Pays Program.


I n d u s t r i a l Process Wastes Waste Minim i za t i on/Management Opt i ons

E l e c t r o p I a t i ng f c o n t i n u e d l

o There a r e a v a r i e t y o f water conse rva t i on techn iques i n e l e c t r o p l a t i n g o p e r a t i o n s t h a t reduce the amount o f wastewater qenerated and t h e q u a n t i t i e s o f s ludge produced. Conserva t ion techn iques inc lude:

D r a o u t Reduct ion. ( A p p l i c a b l e t o c l e a n red:cing " ~ ~ ~ , " t h e q u a n t i t y o f chem l e s s r i nsewa te r w i l l be needed t o c l e a n

Slower and smoother removal o f p a r t s o f process chemica ls . B a r r e l - t y p e p remova I .

Use o f s u r f a c t a n t s and o t h e r w e t t i n g

Maximize d r i p t ime.

ng, e t c h i n g , and p l a t i n g b a t h s . ) By c a l s c a r r i e d o v e r t h e edge o f p rocess tanks, he p l a t e d p a r t s . Techniques inc l r ide :

f rom process tanks, a l l o w i n g b e t t e r d ra inage a t i n g equipment shou ld be r o t a t e d d u r i n g

agents t o reduce s u r f a c e t e n s i o n

Use o f d ra inage boards t o c a p t u r e d r i p p i n g s o l u t i o n s and d i r e c t them back t o process tanks . I n s t a l l a t i o n o f d ragout recovery tanks, p laced between process tanks and r i n s e tanks .

Use o f techniques such as a i r dev i ces ( a i r k n i v e s ) t o b low s o l u t i o n o f f p a r t s , f o g r i n s i n g ove r process b a t h t o a l l o w run back i n t o bath, and squeegees t o w ipe chemica ls o f f p l a t e d p a r t s back i n t o process tank.

Process b a t h v i s c o s i t y and su r face t e n s i o n can be reduced by i n c r e a s i n g b a t h temperature o r decreas ing b a t h s o l u t i o n c o n c e n t r a t i o n . Fog r i n s e ove r heated b a t h can be used t o overcome d r y i n g p a t t e r n s on t h e p a r t s . Heated ba ths cause more evapora t i on o f process chemica Is than do non-heated ba ths .

R i n s i n q E f f i c i e n c y . Techniques t o ach ieve g r e a t e r e f f i c i e n c y inc lude:

-- Usage o f coun te r -cu r ren t m u l t i p l e tank r i n s i n g ( r i n s e f i r s t i n most contaminated r i n s e b a t h and l a s t i n t h e c l e a n e s t b a t h ) . Water f l o w s f rom c l e a n e s t b a t h t o most contaminated b a t h ( i .e., coun te r -cu r ren t t o p a r t s f l o w ) . The g r e a t e r t h e number o f r inses , t he l e s s t o t a l wastewater generated; however, t h e r e i s a c a p i t a l c o s t t r a d e o f f based on t h e added number o f p rocess tanks. M u l t i p l e tank r i n s i n g w i t h o u t c o u n t e r - c u r r e n t f l o w i s n o t as e f f e c t i v e i n reduc ing wastewater .


I ndus t r i a I Process Wastes Waste Minimization/Management Op t ions

E I e c t rop l a t i ng ( c o n t i nued )

Heat T r e a t i n g Waste quench 0 o i Is, spent cyan ide o r bar ium s a l t baths, a I ka I i 0 washes

0

-- Use o f spray r i n s i n g which washes o f f p rocess s o l u t i o n f i l m b y cise o f impact and d i f f u s i o n forces. l h i s technique can reduce w a t e r use by 75%, b u t i t i s n o t e f f i c i e n t f o r ha rd t o g e t t o sur faces .

-- Use o f a i r a g i t a t i o n wh ich improves r i n s i n g by p r o v i d i n g a g i t a t i o n o f t h e r i n s e - wa te r w i t h a i r . Concen t ra t i on o f contaminant can become h i g h e r b e f o r e d i s p o s a l when us i ng th i s techn i que.

Use o f non-cyanide p l a t i n g ba ths wh ich a r e a l s o a l k a l i n e and non-dhe la t i ng .

Use o f fume hoods and scrubbers t o cap tu re fumes wh ich evapora te t o m in im ize a i r p o l l u t i o n .

P l a t i n g ba ths can be r e c o n s t i t u t e d when t h e s t r e n g t h i s decreased t o ex tend t h e b a t h l i f e i n d e f i n i t e l y . The p l a t i n g b a t h i s never spent.

Recyc le used r i nsewa te rs i n t o t h e makeup s o l u t i o n s o f t h e i r r e s p e c t i v e t r e a t i n g ba ths .

Vacuum m e t a l l i z i n g ( v i r t u a l l y p o l l u t i o n f r e e ) i s a p o s s i b l e s u b s t i t u t e techno logy f o r e l e c t r o p l a t i n g . Whi le the c o s t s o f implementing t h i s techno logy a r e h igh , i t m a y be a p p r o p r i a t e f o r c o n s i d e r a t i o n by smal I bus inesses t h a t a r e i n v e s t i n g i n new c a p i l i a l equipment and a r e i n t e r e s t e d i n e n t e r i n g new markets.

-- I n vacuum m e t a l l i z i n g , t h e p a r t t o be coated i s p laced i n a vacuum chamber w i t h a s o l i d metal S O L I ~ ~ ~ f rom wh ich metal atoms o r ions a r e removed, i s t r a n s p o r t e d f rom t h e metal source t o t h e p a r t w i t h an e l e c t r o s t a t i c p o t e n t i a l o r a s l i g h t f l o w o f i n e r t gas, and adheres t o t h e p a r t . Vacuum m e t a l l i z i n g i n v o l v e s e i t h e r a hea t source t o vapor i ze t h e metal p a r t i c l e s (evapora t i on /vapor d e p o s i t i o n ) o r an e l e c t r o n beam t o e j e c t metal p a r t i c l e s by f o r c e o f impact ( s p u t t e r i n g ) .

Conver t f rom cyan ide o r bar ium s a l t b a t h hea t t r e a t i n g t o fu rnace hea t t r e a t i n g . Cyanide s a l t s a r e a c u t e l y t o x i c , bar ium s a l t s a r e somewhat l e s s t o x i c . There i s a s i g n i f i c a n t c a p i t a l c o s t assoc ia ted w i t h t h i s convers ion .

Recyc le o i l quench ba ths b y f i l t e r i n g o u t t h e me ta l s o n - s i t e .

A l k a l i wash l i f e can be extended by skimming o f f t h e o i l l a y e r . The w a t e r removed w i t h t h e o i l l a y e r i s separated out, and t h e o i l i s rec la imed b y f i l t r a t i o n and r e - a d d i t i o n o f a d d i t i v e s ( o n - s i t e o r o f f - s i t e ) .

METAL MANUFACTURING ( c o n t in i ied)

I n d u s t r i a I Process Wastes Waste Minimization/Management Opt ions

F a c i l i t y O i I contaminated C I ean-Up absorbent,,oi I

contaminated rags

Meta l F i n i s h i n g Spent so lvents , -- P a i n t i n g p a i n t wastes conta i n i ng heavy meta I s , i gn i t a b I e p a i n t wastes

I n i t i a t i o n o f improved hoi isekeeping p r a c t i c e s w so l ven ts , and c l e a n i n g s o l u t i o n which r e q u i r e c

I n s t a l l a t i o n o f c o l l e c t i o n / d r i p pans under mach o p e r a t i o n s w i 1 I al low f o r t h e recovery o f these absorbents o r rags.

I I reduce the q u a n t i t y o f s p i I l ed o i I, ean-up.

n e r y and r a w m a t e r i a l s l u b r i c a t i o n o i l s i ns tead o f t h e i r d i s p o s a l w i t h

Absorbents a r c genera I l y d i sca rded b e f o r e they have even come c l o s e t o reach i r ig t h e i r c a p a c i t y . Genera t ion o f contaminated absorbent and rags c o u l d be reduced by u s i n g t h e absorbent and rags u n t i I they have reached t h e i r o i I h o l d i n g c a p a c i t y .

There a r e severa l a l t e r n a t i v e c o a t i n g s wh ich can he used t o rep lace so lvent -based p a i n t s i n v a r i o u s a p p l i c a t i o n s . These a l t e r n a t i v e c o a t i n g s reduce t h e use o f o r g a n i c s o l v e n t s the reby reduc ing VOC emiss ions. A l t e r n a t i v e c o a t i n g s i nc lude :

Use o f h i g h s o l i d s c o a t i n g s wh ich c o n t a i n up t o 62% s o l i d s . New equipment f o r a p p l y i n g these c o a t i n g s i s requ i red because i n - I i ne h e a t e r s a r e requ i red t o reduce v i s c o s i t y . There a r e a l s o I i m i t a t i o n s on t h e a l l o w a b l e t e x t u r e s and th i cknesses wh ich can be ob ta ined w i t h these coa t ings . VOC emiss ions can be reduced b y 50%.

Use of water-based c o a t i n g s . Water-based c o a t i n g s s t i I I c o n t a i n about 18% so lven t , b u t t hey serve t o reduce VOC emiss ions by 80%.

Use o f powder c o a t i n g s wh ich a r e 100% s o l i d s . Powders can be a p p l i e d u s i n g e l e c t r o s t a t i c spray dev i ces o r a f l u i d i z e d bed process ( i . e . , p a r t i s d ipped i n t o bed o f a i r f l u i d i z e d p a r t i c l e s ) . Unused s o l i d s can be recyc led (99% of t he c o a t i n g by we igh t i s u t i l i z e d ) , and t h e r e a r e no VOC emiss ions. However, use o f powder c o a t i n g s r e q u i r e s a l a rge c a p i t a l investment, c o l o r changes a r e d i f f i c u l t , and t h i n c o a t i n g s a r e n o t p o s s i b l e .

METAL MANUFACTURING ( c o n t i nued )

I n d u s t r i a I Process Wastes Waste Minim i za t ion/Maiiagernent Opt ions

Meta l F i n i s h i n g -- P a i n t i n g ( c o n t i n u e d )

Meta I Spent so lvents , F i n i s h i n g - - i g n i t a b l e p a i n t P a i n t Equipment wastes, heavy C I ean i ng metal p a i n t

wastes

o There a r e a l s o severa l a l t e r n a t i v e a p p l i c a t i o n techn iques wh ich can be used t o rep lace spray a p p l i c a t i o n (25% t r a n s f e r e f f i c i e n c y ) . These a l t e r n a t i v e app l i c a t i o n techn iques inc rease t r a n s f e r e f f i c i e n c y o f t he c o a t i n g t o the s u r f a c e be ing coated, thereby reduc ing c o a t i n g consumption, c o a t i n g waste, and VOC emiss ions. These a l t e r n a t i v e appl i c a t i o n techniques are :

- - Use o f d i p c o a t i n g and f l o w c o a t i n g which have 90% t r a n s f e r e f f i c i e n c y .

-- Use o f e l e c t r o s t a t i c sp ray ing which has 60-80% t r a n s f e r e f f i c i e n c y . In e l e c t r o s t a t i c

-- Use o f e l e c t r o d e p o s i t i o n (EDP) which has 95% t r a n s f e r e f f i c i e n c y . In EDP,

spray ing, charged p a i n t p a r t i c l e s a r e sprayed toward t h e grounded s v b s t r a t c .

e l e c t r o s t a t i c s a re used t o a s s i s t d i p c o a t i n g . EDP.cannot be used f o r o r g a n i c so lvent-based c o a t i n g s because t h e y a r e n o t conduc t i ve . EDP produces a t h i c k c o a t i n g

o Use o f s o l v e n t recovery o r i n c i n e r a t i o n can reduce VOC emiss ions f rom c u r e ovens.

o So lvent recovery u n i t s can be used t o r e c y c l e spent s o l v e n t s genera ted i n f l u s h i n g

o Methods t o reduce t h e amount o f f r e s h s o l v e n t s used d u r i n g equipment c l e a n i n g i nc lude :

opera t ions.

-- Par t s t o be p a i n t e d should be scheduled f rom l i g h t c o l o r s t o d a r k e r ones, i f p o s s i b l e . T h i s t ype o f schedu l ing reduces t h e amount o f equipment c l e a n i n g r e q u i r e d between c o l o r changes.

f o l l o w e d by f r e s h s o l v e n t . T h i s procedure can reduce t h e amount o f c l e a n s o l v e n t used i n f l u s h i n g by about 50%.

can be used t o c l e a n equipment.

-- I n c l e a n i n g opera t i ons , a d i r t y s o l v e n t shou ld be used f i r s t t o c l e a n equipment,

-- The use o f "hose c leaners " c o n t a i n i n g p r e s s u r i z e d a i r mixed w i t h a m i s t o f so l ven t ,

o Groups o f meta lwork ing shops may c o l l e c t i v e l y a r range t o have p r i v a t e companies r e c y c l e and/or d ispose t h e i r wastes, i n c l u d i n g p a i n t and s o l v e n t wastes, t h u s reduc ing t h e c o s t s o f hand l i ng wastes f o r each genera tor .

METAL MANUFACTURING ( c o n t i nued )

I n d u s t r i a I Process Wastes Waste Minimization/Management Op t ions

Me t a I Unused o r spent F i n i s h i n g - - inks, so l ven ts , P r i n t i n g wastewater,

p l a t e s , s o i l e d wipers, empty c o n t a i n e r s

Meta I Spent so lvents , F i n i s h i n g - - wastewater, P r i n t i n g s o i l e d wipers, Clean-up empty conta iners ,

unused o r waste ink

0

0

0

0

0

0

0

0

0

0

Use i n k s c o n t a i n i n g l ess t o x i c so l ven ts (e .g . , a l coho l , naphthalene, 1 . 1 , l - t r i c h I oroethane, e t c . ) . Complete ly use a c o n t a i n e r o f i n k b e f o r e opening a new one: save unused p o r t i o n f o r f u t u r e runs.

Use o f i n k recovery systems t o reduce t h e amount o f i n k generated.

Use o f o n - s i t e d i s t i l l a t i o n u n i t s f o r s o l v e n t recovery w i l l reduce ov q u a n t i t y and c o s t o f new s o l v e n t s f o r c l e a n i n g . Spent s o l v e n t s may a t h e f o r m u l a t o r f o r use i n f u t u r e batches.

Send unused ink, recovered ink, o r o f f - s p e c batches back t o t h e formu Formula tors can reuse t h i s waste i n k i n f u t u r e batches o r r e c l a i m i t .

Use d o c t o r b lades o r squeegees t o w ipe as much i n k o f f t h e p l a t e s , r o p o s s i b l e p r i o r t o c l e a n i n g .

r a l l waste s o l v e n t so be sen t back t o

a t o r f o r c r e d i t .

l e r s , e t c . a s

P a r t s t o be p r i n t e d shou ld be scheduled f rom l i g h t c o l o r s t o d a r k e r ones, i f p o s s i b l e . Th i s t ype o f schedu I i ng reduces t h e amount o f equipment c I ean i ng requ i red between co I o r changes. Dedicated presses f o r v a r i o u s i n k s w i I I also min im ize c lean-up.

Use p ress wipes a s long a s p o s s i b l e b e f o r e th row ing o u t o r sending t o laundry . Use o f d i r t y w ipe rs f o r g ross c l e a n i n g and c l e a n wipes f o r f i n a l c l e a n i n g w i l l reduce t h e q u a n t i t y o f spent wipes generated. When poss ib le , n o n - t o x i c s o l v e n t s shou ld be used on p ress wipes f o r c lean-up opera t i ons .

Empty c o n t a i n e r s can be s o l d o r g i v e n t o fo rmu la to rs , o r t o c o n t a i n e r r e c y c l e r s o r r e c o n d i t i o n e r s . I f c o n t a i n e r s a r e t o be disposed, c r u s h them f i r s t .

O ld p l a t e s can be rec la imed ins tead o f d isposed.

VEHICLE MAINTENANCE INDUSTRY

I n d u s t r i a I S e c t o r I n d u s t r i a l Process Wastes Waste Minimization/Management O p t i o n s a/

Body Shops Pa i n t i ng

Spray Booth, Spray Guns, and Brush C I ean i ng

I g n i t a b l e p a i n t wastes, o The use o f p a r t i c u l a r s p r a y p a i n t i n g techn iques spent s o l v e n t s , p a i n t can reduce t h e amount of p a i n t req i i i red f o r a j o b wastes w i t h heavy and a l s o reduce p a i n t wastes. These techn iques meta ls , i g n i t a b l e wastes i n c l u d e s e t t i n g c o r r e c t a i r p r e s s l i r e f o r t h e

spray grin, and t h e use o f c e r t a i n movement and s t r o k i n g techn iques w h i l e p a i n t i n g . b/

Spent so lvents , i g n i - t a b l e p a i n t wastes, heavy meta I pa i n t wastes

o Of ten , t,he amount o f p a i n t r e q u i r e d f o r a p a r t i c u l a r j o b i s overes t imated, l e a d i n g t o s u r p l u s mixed p a i n t s w h i c h a r e d isposed o f . More p r e c i s e assessment o f t h e amount o f p a i n t needed w i I I redrice t h e volume o f pa i n L s t o be d isposed. One o p t i o n f o r d i s p o s i n g o f s u r p l u s mixed p a i n t s i s t o remix c o m p a t i b l e p a i n t s t o form "house c o l o r s . " Auto body shops can o f f e r t o p a i n t c a r s a t a d i s c o u n t when "house c o l o r s " a r p used.

o S o l v e n t recovery u n i t s can be i ised t o r e c y c l e s o l v e n t s genera ted i n f l u s h i n g o p e r a t i o n s . These u n i t s a r e a v a i l a b l e i n 5 g a l l o n c a p a c i t y s izes ; t h e c o s t o f t h e smal l u n i t s i s a p p r o x i m a t e l y $2,0U0-$4.000. S t i I I botLoms g c n c r a t e d can be mixed w i t h a s p e c i a l l y p repared m a t e r i a l and t h e n used f o r undercoat ing . c/ (One drawback o f i n v e s t i n g i n such u n i t s i s t h a t t h e y may genera te more recovered c l e a n i n g s o l v e n t t h a n a t y p i c a l body shop can use; recovered s o l v e n t i s n o t t y p i c a l l y used t o m i x f r e s h p a i n t s . )

a/ In o r d e r t o o b t a i n i n f o r m a t i o n about t h i s indus t ry , I C F c o n t a c t e d i n d i v i d u a l s i n s t a t e env i ronmenta l agenc ies who a r e o r g a n i z i n g a u t o body shop p r o j e c t s . These c o n t a c t s a re :

I ) Michael S . Brown, Management.

2 ) H a r o l d Snow, Chem C o r p o r a t i o n (EFC)

P r o j e c t Manager, SmaI I Q u a n t i t y Generator

c a l Engineer, I n d u s t r i a l M a t e r i a l s Recycl

Program, Massachuset ts Department of Env i ronmenta I

ng A c t Program, New York S t a t e Envi ronmenta l Fac i I i t i e s

b/ Jack Adams o f B i n k s Manufac tur ing Company i n F r a n k l i n Park, I l l i n o i s , a vendor o f spray gun equipment, d iscussed t h e s e

c / Gary G. Scheppke, E x e c u t i v e V i c e P r e s i d e n t o f t h e Auto Truck Dea lers A s s o c i a t i o n o f G r e a t e r Milwaukee, expressed t h e v i e w

techn iques . M r . Adams l e c t u r e s on t h e use o f p r o p e r methods f o r o p e r a t i n g and m a i n t a i n i n g s p r a y p a i n t i n g equipment.

t h a t - u s i n g s ludge a s an undercoat ing was n o t a p r a c t i c a l a l t e r n a t i v e . He f e l t t h a t a g r e a t d e a l o f e f f o r t was r e q u i r e d t o g e t t h e s ludge i n t o a p r o p e r c o n s i s t e n c y f o r undercoat ing .

VEH I CLE MA 1 NTENANCE I NDUSTRY ( con t i nued )

I n d u s t r i a l Sec to r I n d u s t r i a I Process Wastes , Waste Minimization/Management Opt ions

Body Shops o Methods t o reduce t h e amount o f f r e s h s o l v e n t s ( c o n t i n u e d ) used d u r i n g eqit i pment c I ean i ng i nc I tide:

Cars t o be p a i n t e d shou ld be scheduled f rom l i g h t c o l o r s t o d a r k e r ones, i f p o s s i b l e . Th i s t ype o f schedu l i ng reduces t h e amount o f equ i pment c I ean i ng reqir i red be tween co 1 o r changes. (Some body shops m a y be r e l u c t a n t t o i ise t h i s techn ique because of ' p o s s i b l e e f f e c t s on p a i n t c o l o r . I n a d d i t i o n , i t m a y r iot be p r a c t i c a l t o use t h i s techn ique i f o n l y a s m a l l amount o f p a i n t i n g i s be ing done -- a s opposed t o an e n t i r e c a r -- and the p a i n t c o l o r must be p r e c i s e l y matched.)

I n c l e a n i n g opera t i ons , a d i r t y s o l v e n t shou ld be used f i r s t t o c l e a n equipment, f o l l o w e d by f r e s h s o l v e n t . r h i s p rocedure can reduce t h e amount of c l e a n s o l v e n t used i n f I i i sh ing by about 50%. d /

The use o f "hose c leaners ' ' c o n t a i n i n g p r e s s u r i z e d a i r mixed w i t h a m i s t o f so l ven t , can be used t o c l e a n equipment. T h i s method decreases t h e amount o f s o l v e n t used i n c l e a n i n g . e / A dev i ce known as a p a i n t gun washer and r e c y c l e r i s c u r r e n t l y be ing marketed. T h i s equipment c o s t s app rox ima te l y $600, and reduces t h e amount o f s o l v e n t used t o c l e a n guns i n a d d i t i o n t o decreas ing t h e t i m e spent c l e a n i n g spray guns. f /

d/ The methods desc r ibed above f o r reduc ing t h e amount o f s o l v e n t s used d u r i n g f l u s h i n g were s p e c i f i e d b y Haro ld Snow o f t h e New v o r k EFC, and a r e suggested t o New York au to body shops as waste r e d u c t i o n measures. The techn ique i n v o l v i n g schedu l ing o f c a r s was d iscussed w i t h o t h e r i n d i v i d u a l s con tac ted f o r t h e p r o j e c t , and seems t o be a c o n t r o v e r s i a l one.

- e/ Suggested b y Jack Adams o f B inks Manufac tur ing Company.

f/ T h i s equipment was endorsed by t h e Auto Truck Dea lers A s s o c i a t i o n o f Grea te r Milwaukee, and i s manufactured b y Herku les Equipment Corp., Wal led Lake, M I .

VEHICLE MAINTENANCE INDUSTRY ( c o n t i n u e d )

I n d u s t r i a l S e c t o r I n d u s t r i a I Process Wastes Waste Minimization/Management O p t i o n s

Body Shops ( c o n t i n u e d )

Garages

0

Deg rea s i ng Opera t i o n s I g n i t a b l e wastes, spent 0 so lvents , c o m b u s t i b l e so lvents , waste a c i d / a l k a l i n e s o l u t i o n s

Change o f o i l i n veh i c I es

Used o i I

0

0

0

0

Groups o f a u t o body shops may c o l l e c t i v e l y a r range t o have p r i v a t e companies r e c y c l e and/or d i s p o s e o f t h e i r wastes, i n c l u d i n g p a i n t and s o l v e n t wastes. I n some areas, t r a d e a s s o c i a t i o n s o r g a n i z e these e f f o r t s , wh ich reduces t h e c o s t s o f h a n d l i n g wastes f o r each gene ra t o r.

C o n t r a c t u a l ar rangements can be e n t e r e d i n t o w i t h compa n i e s t ha t supp I y "pa r t s wa she rlr so I u t ions / s o l v e n t mix tu res ; such f i r m s supply f r e s h washing s o l u t i o n s and remove spent ones.

Coopera t ive arrangements (e .g. , m i I k r u n s ) can be developed w i t h o t h e r sma I 1 g e n e r a t o r s whereby s o l v e n t wastes a r e c o l l e c t e d b y a c e n t r a l o r g a n i z a t i o n f rom many g e n e r a t o r s ; wastes a r e t h e n r e c y c l e d and r e t u r n e d t o g e n e r a t o r s .

S o l v e n t r e c o v e r y u n i t s d e s c r i b e d above may be used t o r e c y c l e spent " p a r t s washer" s o l u t i o n s .

M a t e r i a l s o t h e r t h a n c h l o r i n a t e d s o l v e n t s may be used t o c l e a n p a r t s . For example, a non-hazardous water-based a l k a l i c l e a n i n g compound i s b e i n g marketed a s an i n d u s t r i a l degreaser . In a d d i t i o n , c a u s t i c s o l u t i o n s may be used as degreasers. These a l t e r n a t i v e c l e a n i n g s o l u t i o n s may be more e f f e c t i v e l y used i n c e r t a i n a p p l i c a t i o n s (e.g., eng ine c l e a n i n g ) t h a n o t h e r s .

As i n t h e case o f p a i n t was tes and spent degreas ing s o l v e n t s , garages can c o l l e c t i v e l y a r range t o have used o i l p i c k e d up by commercial waste o i I d e a l e r s . The d r o p i n t h e p r i c e o f o i l and t h e p r o s p e c t t h a t used o i l may become a hazardous waste, has meant t h a t many garages have t o pay d e a l e r s t o have t h e used o i I c o l l e c t e d . As a r e s u l t , garages w i I I p r o b a b l y be L e l u c t a n t t o accept used o i l f r o m o t h e r s (e.g., do i t you r s e I f e r s " ) .

PRINTING I N K FORMULATORS AND PRINTERS

I n d u s t r i a l I n d u s t r i a I Sec to r Process Wastes Waste Minimization/Management Op t ions a/

Formu I a t i ng Formu I a t i o n Unused/off-spec o pigments, kerosene and empty c o n t a i n e r s o

0

0

0

0

0

Formulate water-based o r o i I-based inks . Decrease i n d u s t r y re1 iance on so I vent-ha sed i nk.

Use l e s s t o r i c s o l v e n t s ( i . e . , a l c o h o l , naphthalene, 1 , l . l - t r i c h l o r o e t h a n e , e t c . ), i f p o s s i b l e .

S i i h s t i t u t e hazardous p igments ( such as lead chromate) w i t h o t h e r non-hazardous pigments, i f p o s s i h l e .

Use ded ica ted equipment f o r m ix ing i n k s c o n t a i n i n g hazardous p igments o r so l ven ts , reduc ing t h e need f o r c l e a n i n g .

Formulate d a y ' s batches moving from I i g h t c o l o r s t o d a r k c o l o r s .

Reuse empty c o n t a i n e r s i f poss ih le , s e l I / g i v e t o recyc I ers / recond i t ioners, o r c rush p r i o r t o d i sposa I.

Good Housekeeping

- - comp le te l y empty c o n t a i n e r s t o use as much o f t h e i n g r e d i e n t s as p o s s i b l e .

-- save o f f - s p e c o r excess batches f o r use as make-up i n s i m i l a r o r d a r k e r batches.

-- Be c a r e f u l and reduce s p i l l s and waste.

a/ Most waste m i n i m i z a t i o n o p t i o n s d iscussed i n t h i s summary were observed i n s i t e v i s i t s conducted b y ICF . A few measures were-obta ined f rom t h e D r a f t F i n a l Repor t : Waste M i n i m i z a t i o n Issues and Options, p repared by Versar Inc. , and Jacobs Eng ineer ing Group (February, 1986).

P R I N T I N G I N K FORMULATORS AND PRINTERS ( c o n t i n u e d )

I ndus t r i a I I n d u s t r i a l Sec to r Process Wastes Waste Minimization/Management Opt ions

Formu I a t i ng C I ean i ng Spent so I vents, ( c o n t i nued ) wastewater, and

pigments, s o i l e d w ipers .

P r i n t i ng Nega t i ves and p l a t e p rocess ing

Spent caus t ics, wa stewa t e r. heavy me ta l s and photoprocess i ng chemica ls

0

0

0

0

0

0

0

0

0

Use squeegee o r d o c t o r b lade t o remove a s much o f t h e i n k as p o s s i b l e p r i o r t o c l e a n i n g .

Use d i r t y w i p e r f o r rough c l e a n i n g o r mop-ups. Then use c l e a n wipes f o r f i n a l c l e a n i n g .

Save d i r t y so lvents , wa te r o r o i l genera ted f rom c l e a n i n g o p e r a t i o n s and use as feed s tocks f o r new batch .

Use o l d i n v e n t o r y o f i n g r e d i e n t s o r o f f - spec /excess ba tches f o r new batches o r house c o l o r s .

Reuse w ipe rs a s long a s p o s s i b l e .

I f water-based inks a r e used, r i n s e rags i n washing machine w i t h no soap and ttse r i n s a t e as make-up f o r batches o f b l a c k i nk .

I f so lvent-based i n k o r o i l - b a s e d i n k s a r e used, send rags t o l aundry se rv i ce .

Regenerate spent photoprocess ing chemica ls and c a u s t i c s .

Reuse r i nsewa te r as long as p o s s i b l e .

Use c o u n t e r c u r r e n t r i n s i n g t o reduce c r o s s con tamina t ion o f batches.

Use squeegees t o w ipe chemica ls f rom f i l m o r p l a t e s ( i f hand p r o c e s s i n g ) .

On-s i te n e u t r a l i z a t i o n o f c a u s t i c s and d i scha rge t o POTW.

Use s i I ve r rec I ama t i o n ca r t r i dges/e l e c t r o I y t i c recove ry systems.

Move from "wet" ( chemica l ) p rocess ing t o "d ry" p rocess ing o r wa te r p rocess ing . New p l a t e s and f i l m may be processed d r y o r w i t h water, reduc ing o r e l i m i n a t i n g use o f chemica ls . ( H y d r o l i t h p l a t e s b y 3M).

Use carbon b l a c k paper systems reduc ing t h e need f o r s i l v e r (Napp Systems). These systems a r e expens ive and may be a p p r o p r i a t e f o r c o n s i d e r a t i o n by smal I q u a n t i t y genera to rs when ma jo r c a p i t a l renova t ions a r e be i ng conducted.

Recla im p l a t e s .


I n d u s t r i a I I ndus t r i a I Sec to r - Process Wastes Waste Minimization/Management Op t ions

P r i n t i n g ( c o n t i n u e d )

P r i n t i ng Unused o r spent inks, so l ven ts , was tewa t e r, p l a t e s , s o i l e d w ipe rs and empty c o n t a i n e r s

o Send spent c a u s t i c s t o o t h e r s who can iise them as feeds tocks o r p rocess

o Use l a s e r o p t i c s t o bu rn image o n t o p l a t e s (expens ive ) .

o See "photnp rocess i ng . I'

o Decrease i ise o f so lvent-based inks . For most app l i c a t i o n s , water-based

chemica ls .

i nks a r e equal o r b e t t e r than so lvent -based inks :

-- cheaper, more r e a d i l y a v a i l a b l e ; equal t o so lvent -based i n k s i n p r i n t qua I i ty, g l o s s and adhesion;

-- s I owe r d r y i n g than so I vent-bpsed.

water - based i nks. o Use UV c u r a b l e p igments o r a i r d r y i n g systems t o speed l ip d r y i n g o f

o Use l e s s t o x i c s o l v e n t s ( i .e . , a l coho l , naphthalene,

o Complete ly i ise c o n t a i n e r o r i n k b e f o r e opening a new one.

l , l , l - t r i c h l o r o e t h a n e , e t c . ) , i f p o s s i b l e .

o Save a I I unused p o r t

o Use d o c t o r b lades o r p l a t e s o r r o l l e r s p r

o Use i n k recovery sys

ons f o r house c o l o r s o r f u t u r e p r o d i i c t i o n runs.

squeegees t o w ipe as much i n k as p o s s i b l e o f f o r t o c l e a n i n g .

ems t o reduce amount o f waste i n k generated.

o Send unused ink, recovered i n k o r o f f - s p e c ba tches back t o f o r m u l a t o r

o P r i n t u s i n g l i g h t c o l o r s f i r s t and move t o d a r k e r c o l o r s .

o Use p ress wipes as long as p o s s i b l e b e f o r e th row ing o u t . Use d i r t y ones

o Use non- tox i c s o l v e n t s on p ress wipes.

o Sei I / g i v e empty c o n t a i n e r s t o fo rmu la to rs , c o n t a i n e r r e c y c l e r s o r

f o r c r e d i t .

f o r f i r s t pass then c l e a n ones f o r f i n a l pass.

recond i t i one rs , o r c r u s h p r i o r t o d i s p o s a l .


I n d u s t r i a I I n d u s t r i a I S e c t o r Process Wastes Waste Minimization/Management Op t ions

P r i n t i ng ( c o n t i n u e d )

C I ean i ng

0

0

0

Spent so lvents , o wa s tewa t e r, s o i l e d wipers, o spent c o n t a i n e r s

0

0

0

Recla im o l d p l a t e s .

Use ded ica ted presses f o r i n k s w i t h hazardous p igments /so lvents .

Use d i s t i I l a t i o n u n i t s t o pe r fo rm in-house recove ry o f s o l v e n t s and s o l v e n t vapors.

Use d i r t y o r o l d s o l v e n t s a s make up t o d a r k e r i n k s o r house c o l o r s .

Send spent s o l v e n t s t o f o r m u l a t o r s .

D o n ' t draw t o o much s o l v e n t f rom a drum. Use o n l y as much s o l v e n t as requ i red when c I ean i ng . Use w i p e r s a s long as p o s s i b l e . Use d i r t y w i p e r s f o r g ross c l e a n i n g and c l e a n ones f o r f i n a l c lean ing .

Send w ipe rs t o laundry.

DRY CLEANING

I n d u s t r i a l Process Wastes Waste Minimization/Management Opt ions a/

F i l t r a t i o n F i l t e r 0

0

0

D i s t i I l a t i o n

Evapo ra t i ve Loss Min imiza- t i o n

C I ean i ng

S t i l l bot toms 0

0

So lven t vapors 0

0

So lven t wastes 0

C a r t r i d g e s t r i p p e r s a r e more e f f i c i e n t a t removing s o l v e n t f rom c a r t r i d g e s than d r a i n i n g , o r d r y i n g c a r t r i d g e s i n t h e d r y e r . Steam s t r i p p i n g , i n p a r t i c u l a r , removes a d d i t i o n a l s o l v e n t f rom carbon cores .

Rep lac ing f i l t e r powder w i t h f i l t e r c a r t r i d g e s s i g n i f i c a n t l y reduces t h e amount o f s o l i d waste s i n c e c a r t r i d g e s a r e recyc lab le ; carbon co res can be regenera ted o r burned, t h e f i l t e r paper i s i n c i n e r a b l e , and the metal i s r e c y c l a b l e . F i l t e r powder r e t a i n s 50 ppm s o l v e n t even a f t e r t rea tment a t r e c y c l e c e n t e r s and i s d i f f i c u l t t o burn .

Ceramic f i l t e r s a r e "permanent" f i l t e r s t h a t would never need t o be rep laced. However, t h e c a p i t a l investment f o r a ceramic f i l t e r capable o f h a n d l i n g t y p i c a l s o l v e n t th roughputs i s ex t reme ly h i g h ($~+0 ,000-60 .000 ; a d r y - t o - d r y u n i t c o s t s $30.000).

Adding wa te r t o s t i l l bot toms f o l l o w i n g f i n a l b o i l down recove rs a d d i t i o n a l so l ven t , reduc ing s o l v e n t c o n t e n t i n t h e bot toms f rom more than 50% t o 1-2%.

S t i l l bot toms can be mixed w i t h a p p r o p r i a t e m a t e r i a l s f o r a u t o undercoa t ing use. (One problem would be f i n d i n g a gas s t a t i o n o r garage t h a t would be w i l l i n g t o accept t h e smal l amounts o f s t i I I bottoms genera ted) .

Us ing d r y - t o - d r y un i t s , o r r e f r i gera t ion/condensa t i o n c l e a n i n g mach i nes e l i m i n a t e s t h e need f o r " s n i f f e r s " and v e n t i n g duc ts wh ich m igh t leak, t he reby reduc ing vapor losses. Also, r e t r o f i t t i n g r e c l a i m i n g d r y e r s w i t h carbon a d s o r p t i o n o r re f r igera t ion /condensat ion u n i t s min imizes losses t o t h e a i r .

Good housekeeping; r e p l a c i n g o r r e p a i r i n g f a u l t y hose connect ions , va lves , gaskets , seals, and sea t ings reduces s o l v e n t losses.

Use a l e s s t o x i c s o l v e n t (e .g . , l , l , l - t r i c h l o r o e t h a n e ) . D r y c l e a n i n g equipment i s des igned f o r use w i t h a s p e c i f i c so l ven t , however. Fo r example, because l , l , 1 - t r i c h l o r o e t h a n e (TCE) i s more c o r r o s i v e than pe rch lo roe thy lene , some s t a i n l e s s s t e e l must be used i n t h e c o n s t r u c t i o n o f TCE u n i t s . C a p i t a l investment f o r new equipment i s a I i t t l e h i g h e r due t o c o r r o s i o n r e s i s t a n t m a t e r i a l s . (Adequate d e t e r g e n t and a d d i t i v e f o r m u l a t i o n s a r e s t i I I i n t h e developmental stage, however.)

- a/ In o r d e r t o o b t a i n i n f o r m a t i o n about t h i s i ndus t r y , I C F contac ted :

1 ) Jon Me i j e r , l n t e r n a t iona I Fabr ica r e I n s t i t u t e 2 ) John Lucks, S a f e t y Kleen Corp. 3 ) Steven Michaels , Nor ton Company

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PHOTOPROCESSING/PHOTOFlNl.SHING

I n d u s t r i a l Process Wastes Waste Mlnimization/Management Op t ions a/

B I each i ng

Deve lop ing / P r i n t i n g

F i x ing , R i n s i n g

Fer rocyan ide s ludge

S i I v e r - b e a r i n g

Wa s tewa t e r

o Codes f o r d i scha rge of f e r rocyan ide b leaches a r e v e r y s t r i c t . Sw i t ch ing t o iron-EDTA, a s t l i t a b l e i f somewhat s lower a c t i n g bleach, e l i m i n a t e s t h e need f o r and c o s t o f t rea tment , and i n c i n e r a t i o n o r d i s p o s a l .

e f f i c i e n c y w h i l e m in im iz ing s i l v c r b reak through. A lso , u s i n g a chemical recovery c a r t r i d g e t o po l i s h e l e c t r o l y t i c u n i t e f f l u e n t s i g n i f i c a n t l y reduces s i l v e r d i scha rge l e v e l s .

o A d j u s t i n g s u l f i t e c o n c e n t r a t i o n o f s i I v e r - b e a r i n g wastes t o 10-25 g/L, and pfl t o 7.8 markedly improves e l e c t r o l y t i c recove ry e f f i c i e n c y whi l e reduc ing s u l f i d i n g ; e l e c t r o l y t i c s i l v e r e f f l u e n t c o n c e n t r a t i o n s o f l e s s than 40 ppm a r e e a s i l y o b t a i n a b l e . Th is i s g e n e r a l l y accompl ished w i t . h a ho ld -up tank upstream from t h e e l e c t r o l y t i c [ I n i t .

o When u s i n g an e l e c t r o l y t i c u n i t t o recover s i l v e r , u s i n g low c u r r e n t f o r t h e f i r s t p l a t i n g min imizes s i l v e r f i n f o r m a t i o n ( " f i n n i n g " ) , wh ich I i m i t s t h e amount o f s i l v e r recoverab le f rom a b a t c h o f s i I v e r - b e a r i n g waste. A l s o , e l e c t r o l y t i c e f f i c i e n c y i s g r e a t e r when d i s s o l v e d s i l v e r and i r o n c o n c e n t r a t i o n s a re low. Using a h i g h e r than normal f i x e r rep len ishment r a t e i n f i l m p rocess ing p rov ides op t ima l d i l u t i o n o f s i l v e r and i r o n b leach f rom b o t h f i l m and paper p rocess ing . F i l m f i x i s cheaper than paper f i x a s w e l l .

o Forecas t changes i n pho tog raph ic equipment may e l i m i n a t e much o f t h e need f o r s i l ve red f i I m ( i .e., e l e c t r o n i c imaging on v i d e o t a p e ) . However, photograph ic p r i n t s would s t i I I r e q u i r e s i I v e r - b e a r i n g paper.

systems r e q u i r e a s i z a b l e investment ($45,000). A s a r e s u l t , t h e y may be a p p r o p r i a t e f o r c o n s i d e r a t i o n b y S Q G s t h a t a r e u n d e r t a k i n g ma jo r equipment renova t i ons. b/

accomplished w i t h newly developed evapora t i ve -pho to l ys i s -condensa t ion u n i t s ( f i x e d c o s t $3000).

o Using two chemical recovery c a r t r i d g e s i n s e r i e s maximizes recovery

o Using "washless" p rocess ing systems reduces wastewater b y 97%. These

o On-s i te n e u t r a l i z a t i o n o f spent chemicals, p r i o r t o d ischarge, can be

- a/ I C F con tac ted t h e f o l l o w i n g i n d i v i d u a l s t o o b t a i n i n f o r m a t i o n about t h i s i n d u s t r y :

I ) Tammy Nelson, Konica, U.S.A. 2 ) L o r e t t a T. Reardon, C o l o r f a x Labora to r ies , Inc . 3 ) Gary Barr , C o l o r f a x Labora to r ies , Inc.

- b/ T h i s c o s t e s t i m a t e was p rov ided i n Konica brochures on t h e "Nice P r i n t M in i -Lab System."

I

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