POLLUTION PREVENTION TECHNICAL ASSISTANCE
FOR SELECTED INDUSTRIES
RESEARCH AND TECHNOLOGY TRANSFER
U.S. EPA Pollution Prevention Incentives for States Grant
FINAL REPORT
Georgia Tech Research Institute
Carol C. Foley, Project Director
James L. Walsh, Jr., P.E.
H. Allen Davis
John
Bennett
Maria Cecilia Metzger
James A. Russell, Jr.
Melvin C. Halstead
Georgia Tech Research Institute
Environmental Science and Technology Laboratory
Environmental Engineering Branch
September 30,1991

ACKNOWLEDGEMENTS
We wish also to acknowledge the industrial participants who openly shared their experiences with pollution prevention and provided us with challenging problems to research. Thanks also to Nancy
Davis, Rae Adams, Stephanie Babbitt, and Carrie Stikeleather of GTRI’s Communications Branch for their expertise in editing and designing the publications developed under this contract. Finally, we would l i e to express our gratitude to the Georgia Tech Alumni Association for their assistance in locating retired engineers for the Pollution Prevention Mentor Program. The loyalty of Georgia Tech
Alumni was vital to the success of this project.
DISCLAIMER
The contents of this report are offered as guidance. The report has been prepared as accurately an( completely as possible; however, the Georgia Institute of Technology and the Georgia Tech Researcl
Institute (GTRI) do not make any warranty or representation, expressed or implied, that the use of an! information, apparatus, method, or process disclosed in this report may not infringe on privately ownec rights or assume my liabilities to the use of, or for damage resulting from the use of any information apparatus, method, or process disclosed in this report.
Thereportdoesnotreflect theofficialviewsorpolicy of the abovenientionedinstitutions. Mentionof trad names or commercial products does not constitute endorsement or recommendation for use.
The Georgia Tech Research Institute is a division of the Georgia Institute of Technology which is a unit c theuniversity Systemof thestateof Georgia. As astateorganization,GTRIcannot endorse aprivateedt but can only provide the guidance of its employees on a particular project.
INQUIRIES
Inquiries to Georgia Tech concerning this report should be addressed to:
Director, Pollution Prevention Program
Georgia Tech Research Institute
Environmental Science and Technology Laboratory
O’Keefe Room 143
Georgia Institute of Technology
Atlanta, Georgia 30332

Pollution Prevention Assessments
3.0
4.0
Table: Waste Management Hierarchy
Pollution Prevention Seminars
Table: 1991 Pollution Prevention Seminars
Industrial Process Study
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3- 1
Table 1.
Table 2.
Table 3.
Table 4.
Table
Table
5.
6.
Listing of the 17 Target Chemicals and Number of Reports
Number of Chemicals Reported by Each Facility
Listing of Indusmes Releasing the 17 Targeted Chemicals
Summary of Processes Producing the 33/50 Program
Listed Chemicals
Comparison of Amount of Chemical Released and
Number of Report
Summary of Pollution Prevention Activities Reducing the
Release of the 33/50 Program Listed Chemicals
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4-3
4-7
4-8
4-16
4-28
Figure 1.
Figure 2.
Figure 3.
Figure 4.
Total Reports for 17 Targeted Chemicals in the State of Georgia
Process and/or Unit Operation Generating Release
Process and/or Unit Operation Generating Xylene Release
Process and/or Unit Operation Generating
1 ,1 ,1-Trichloroethane Release
Process and/or Unit Operation Generating Toluene Release Figure 5 .
Figure 6.
Figure 7.
Process and/or Unit Operation Generating Dichloromethane Release
Process and/or Unit Operation Generating
Methyl Ethyl Ketone Release
Figure 8. Summary of Methods of Reduction in Releases for the 17 Targeted
Chemicals in the State of Georgia
Figure 9.
Figure 10
Methods of Reduction in Releases of Xylene
Methods of Reduction in Releases of 1,1,1-Trichloroethane
Figure 1 1. Methods of Reduction in Releases of Toluene
Figure 12, Methods of Reduction in Releases of Dichloromethane
Figure 13 Methods of Reduction in Releases of Methyl Ethyl Ketone
4-9
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4-11
4-11
4-12
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4-13
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4-25 iii

1.0 Introduction
Letter to Retirees
2.0 Pollution Prevention Assessments
Phase I Reports
Phase I1 Reports
3.0 Pollution Prevention Seminars
Seminar Information
Map of Locations
Sample Brochure
Sample Press Release
Presentation Materials
Overheads
Barriers to Pollution Prevention
Guidelines to the Site Inspection
Pollution Prevention Guides
The Georgia Pollution Prevention Guide
Guides to Waste Reduction Options
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Printing
-
Cleaning and Degreasing
Electroplating
- Painting
- Drycleaning
5.0 Technology Transfer
Publications
Letter to Hazardous Waste Generators
Fact Sheets
Environmental Spectrum ii

1.0
-Introduction
1.1
1.2
Project Scope and Goal
Pollution Prevention Mentor Program
2.0
Pollution Prevention Assessments
2.1
2.2
2.3
3.0
3.1
3.2
4.0
5.0
5.1
5.2
5.3
5.4
4.1
4.2
4.3
4.4
4.5
Participants
Philosophical Approach
Technical Assistance Design
Pollution Prevention Seminars
Location and Marketing of Seminars
Seminar Materials
Industrial Process Study
Introduction
TRI Assessment
Process Identification
Pollution Prevention Activities
Demonstration Projects
Technology Transfer
Fact Sheets
Pollution Prevention Column
Distribution of Technology Transfer Materials
ConferenceiRegion IV Roundtable
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1-1
1-1
2-1
2- 1
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2-3
3-1
3- 1
4- 1
4- 1
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4-14
4-25
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5-1
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5-2
1

1.0
1.1
Introduction
Project Scope and Goals
The Georgia Environmental Protection Division (EPD) received a $300,000 Pollution
Prevention Incentives for States (PPIs) Grant from the U.S. Environmental Protection
Agency (EPA) which allowed EPD to direct resources towards achieving the State's multimedia toxic reduction goals. The EPD contracted with the Georgia Tech Research
Institute (GTRI) to: o Perform pollution prevention assessments at twenty facilities identified by EPD, including eleven which were initiated under a previous contract with EPD;
0
0
0
0
Develop and conduct pollution prevention workshops at GTRI's regional Economic
Development Laboratory (EDL) field offices;
Conduct a study of the industries, their products and processes, responsible for releasing priority toxic substances;
Identify two candidates for technology demonstration projects; and
Promote technology transfer through the development of fact sheets, articles for
J5nvironmental Spectrum, and co-sponsorship of a regional conference on pollution prevention.
The pollution prevention project initiated under this contract has created an atmosphere where voluntary toxics reductions and mandatory facility planning will achieve real reductions in the amount of toxic chemicals generated and released into the environment.
1.2 Pollution Prevention Mentor Program
The Pollution Prevention Mentor (PPM) Program combines the talents of retired engineers with graduate students at Georgia Tech. While other states have successfully used retirees to provide waste reduction technical assistance to industry, none have augmented this assistance with the excellent case study and literature researching capabilities of students at an engineering college. A retiree/student mentor program is attractive in that it effectively uses the talent and experience of retired engineers and students, provides real world experience to students, and results in excellent technical assistance to industry.
1-1

The strength of the PPM Program is derived from the loyalty of Georgia Tech alumni. The
Georgia Tech
Association supported the PPM Program by providing a mailing list of alumni sorted according to discipline, year of graduation, and residence in the State of
Georgia. For our purposes, we selected mechanical, chemical, and civil engineers, living in
Georgia, who had graduated prior to 1955.
We sent letters directly to 75 alumni inviting them to participate in the program. The letter explained the purpose of the Pollution Prevention Project, the nature of the work to be performed in the PPM Program, and the benefits. A copy of the letter is included at the end of this chapter. The compensation package included: one week of training at the Waste
Reduction and Technology Transfer (wRA?T) program offered by the University of
Tennessee Center for Industrial Services; $10.00 per hour worked during the site visit and report prepwation; and travel expenses reimbursed at $21.00 per day for meals and $60.00 per day for lodging.
The selection criteria fell into two categories, the expertise required to address the significant needs of the target industries and the motivation of the retirees to participate in the project. With few exceptions, the retirees met the motivational Criteria. We wanted people who were interested in doing something for Georgia Tech and participating in the education of its students. Technically, we needed people knowledgible about solvents used in coatings and cleaning and degreasing. These topic areas were identified during the review of industries and processes responsible for releasing the 17 toxic substances in EPA's
33/50 program. Two retirees met these criteria. The retirees were hired using a subcontract arrangement.
The retirees and students attended the " program in December 1990. This offered them the opportunity to get acquainted and establish patterns for working together in the
Iture. The graduate students in the PPM Program held undergraduate degrees in chemical, nuclear, and civil engineering. Two were graduate students in the environmental engineering program and one was a graduate student in industrial and systems engineering/statistics. One tremendous benefit to using environmental engineering students, the "end-of-pipe" people, was the opportunity to use them to infuse pollution prevention concepts into the environmental engineering program.
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October 9, 1990
To:
From:
Subject:
Georgia Tech Alumni
Carol Foley
Georgia Tech Research Institute
Environmental Science and Technology Laboratory
Phone: (404) 894-3806
FAX: (404) 894-8281
Positions Available in Mentor Program
We are pleased to announce the availability of two part-time consulting positions for retired engineers in the Pollution Prevention project at the Georgia Tech Research Institute.
Please read the attached announcement for more details on the positions. As Georgia Tech alumni, you will have the opportunity to be involved in an important project for the State of Georgia as well as contribute to the education of two Tech graduate students.
Two engineers will be selected to perform a total of ten on-site waste reduction opportunity assessments at companies located in Georgia. Training for performing these assessments will be provided by GTRI. The commitment for each of the engineers is approximately 10 weeks of work between December 1990 and September 1991 (five company assessments for each engineer which take approximately two weeks per assessment including the on-site facility tour, research, and writing). All travel expenses will be reimbursed.
Please note the followinv No environmental experience is necessary.
Date of training program = December 2-7, 1990.
Must be able to travel.
Hourly rate of $10.00
1,1990.
Send a resume today. We hope to see you on the Tech campus soon!

Quallficatlons
Compensation
Deadline
Pollution Prevention Mentor Program
T$e Environmental Sciences and Technology Laboratory of the Georgia Tech Research Institute (GTRI) is looking for two retired engineers to work in a pollution prevention program for Georgia industry. The program is designed to assist industries in Georgia which have significant releases of toxic substances to the environment and/or generate large amounts of hazardous wastes. The companies will be selected by the Georgia
Environmental Protection Division and will work with GTRI on a voluntary basis. Emerience in environmental geulations is not neces saru?
The Pol provides a unique opportunity for experienced engineers to contribute to tbe education of future Tech engineers and promote environmentally sound manufacturing proasses In Georgia. The retired engineers will work on a contract basis for GTRI. The students will be employed as research assistants by GTRl and will use the program to fulfill part of their degree requirements.
The Project Retired engineers and students employed by GTRI will perform a "pollution prevention opportunity assessment" for each company. The pollution prevention assessment will include a review of the company data obtained from the environmental records at the
Georgia Environmental Protection Division and an on-site inspection; a Literature review to identify source reduction and waste minimization options; and a selection of options for further consideration by the company. An assessment report of selected options for the company will be written. In addition, they will follow-up the initial assessment six months later by telephone.
Training We're looking for engineers with degrees in mechanical, chemical, civil, or industrial engineering who have experience in industrial manufacturing processes.
Training for performing pollution prevention opportunity assessments will be provided by GTRI. Candidates miist be able to attend a training seminar to be held at
Montgomery Bell State Park in Tennessee on December 2-7,1990. All erpenses and an hourly fee (40 hoiirs) will be paid by GTRI.
We want people who are interested in working with students, have an interest in the environment, and want to help industries improve their processes. You must be retired from industry and have the training described above. Candidates must have their own car. n2e commitment is for one year.
GTRI will pay an hourly rate of $10.00 and reimburse travel expenses for site visits to industry. Approximately 10 pollution prevention opportunity assessments will be performed (one week per assessment) and will be divided between the two retired engineers. Scheduling of site visits will be flexible.
Please send a copy of your resume by November 1, 1990 to:
More Information:
Carol Foley
Georgia Tech Research Institute
GTRIIESTL
Room 143 O'Keefe Building
Atlanta, GA 30332
Call Carol Foley or Jim Walsh at (404) 894-3806.
~

2.0 Pollution Prevention Assessments
2.1 Participants
The companies were sent a formal letter of invitation from the Assistant Director of the
Georgia Environmental Protection Division to participate in the program on a voluntary basis. In order to help the companies decide whether or not to come on board, meetings were held with each company which included the compliance officers from each branch and the EPD Pollution Prevention Coordinator. The company names and contacts were then sent to GTRI to set up the technical assistance site visit.
2.1.1 Industries Assisted Under Previous Contract
GTRI completed 11 on-site technical assists under a previous contract with EPD. The assessments, reports and information packages were completed between May 1 and
December 31, 1990 and sent directly to the company representatives. A summary of the technical assistance projects can be found at the end of this chapter (Phase I). The project participants under the previous contract were:
Atlantic Steel
Delta Airlines, Inc.
Forstmann & Company
Kemira, Inc.
Merck & Company
Union Camp Corporation
Lockheed Aeronautical Systems Company
Monroe Auto Equipment Company
DSM Chemicals North America, Inc.
Dow Chemical
Chemical Products Corporation
2.12 Industries Assisted Under PPIs Contract
The industries participating in the PPIs project were assisted by student/retiree pairs from the Pollution Prevention Mentor Program. The on-site assessments and reports were completed between May 15 and September 30, 1991. The summaries for these assists can be found at the end of this chapter (Phase 11). The participants in the PPIs project were:
General Motors CPC-Doraville
Douglas &
Southwire
Lomason
Federal Paperboard
Robins Air Force Base
Rheem-Ruud Manufacturing, Inc.
Davidson Exterior Trim-Textron
PPG Industries
Engineered Fabrics
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2.2 Philosophical Approach
2.2.1 Waste Management Hierarchy
Congress established a waste management hierarchy in the Hazardous and Solid Waste
Amendments (HSWA) of 1986. This hierarchy can be applied to multimedia pollution prevention as well. GTIU adopted this hierarchy as a guiding principle for its technical assistance programs for hazardous waste and worker health and safety. Over the years, the scope of GTRI's activities has expanded to include multimedia toxics reduction.
2.2.2 Georgia Hazardous Waste Management Act
~
The Georgia Hazardous Waste Management Act, as amended in 1990, requires that large quantity generators of hazardous waste and users of Georgia's hazardous waste treatment, storage, and disposal facilities develop and submit to the Georgia Environmental Protection
Division (EPD) hazardous waste reduction plans no later than March 1, 1992. The forms for submitting the plans will be mailed by EPD with the 1992 Hazardous Waste Biennial
Report.
The definition of waste reduction in the Georgia Hazardous Waste Management Act reinforces the waste management hierarchy of HSWA. Waste reduction is any activity that reduces or eliminates the generation of waste at its source, before it becomes a pollutant or "lost" resource. This includes changes in production technology, materials, processes, operations or procedures, or use of in-process, in-line, or closed-loop recycling. Waste reduction does not include dewatering, dilution, or evaporation; waste burning in industrial furnaces, boilers, or cement kilns; transfer of an environmental waste from one
2-2
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environmental medium to another (waste shifting); conversion of a potential waste into another form for use in a production process or operation without serving any substantial productive function; off-site waste recycling; or any other method of end-of-pipe management of wastes.
23 Technical Assistance Design
23.1 Project Definition
The first step in defining the technical assistance project for each company involved a review of data available at the Environmental Protection Division. The data included 1987 and
1989 Biennial Report Data; Toxic Chemical Release Inventory Data (1987 1988); and relevant information from the company’s air, water, or land compliance files.
During the facility tour the GTRI project director, retired engineer, graduate student and the company representative reviewed process diagrams to get a feel for the facility layout; discussed Biennial Report and SARA Title III data in the context of the process layout; reviewed what had already been accomplished to reduce environmental releases or had been attempted; and identified process personnel to discuss problem areas.
The companies are all large complex facilities with multiple processes. Obviously, GTRI could not assume to be an expert in every process at every facility. For the most part, the companies selected the project for consideration and the on-site consultation focused on the problem area.
The retiree/student pair then performed the site assessment together. Five days on-site were alloted per company. Following the on-site work, the retiree would provide initial recommendations to direct the student’s case study/literature research. The pair would draft a report on their recommendations to the company for review by the Program Director and the company representatives. The final draft of the report is included in this Eollution
Prevention Incentives for the States Grant report.
23.2 Resources/Case Study Research
We used case studies and papers available through the Waste Reduction Resource Center for the Southeast located in North Carolina, the publications of technical assistance programs in Tennessee and California, and the technical journals located in the Georgia
Tech library, and consultations with vendors, Georgia Tech engineering faculty, and industrial experts to develop the recommendations for each company. The experiences of the retirees proved invaluble in the coatings related projects.
233 Report Format
The report includes a technical contact for the facility, a summary of the products or
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services, and a description of the processes involved. The wastes generated at the facility
well as any efforts to reduce them are summarized. The recommendations include a discussion of the technology, concept or management practice and a listing of references for further consideration. The full references were sent to the company with the report. The summary in the Appendix of this report does not include copies of the references.
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GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Atlantic Steel Company
1714
Atlanta, Georgia 30301
C.A. (Neil) Harmon
Environmental Engineer
Steel, wire
Process Description:
Atlantic Steel Company is a steel manufacturing firm which uses scrap and recycled steel as its primary resource. The manufacturing process involves three major areas of production: steel making, rolling and wire drawing. As a recycling company, Atlantic has from its origin sought to find a use for its residual materials from the steel production processes. The steel process generates a metal-containing dust called electric arc furnace
(EAF) dust. Small parts are washed in mineral spirits during routing maintenance.
Waste Generated
1. The two hazardous wastes generated by Atlantic Steel's operations are electric arc furnace dust (K061) from the steel making process and mineral spirits (D001) from various parts washing sinks located throughout the facility. In 1989, Atlantic Steel generated 6,675 tons of electric arc furnace dust and sent it offsite to be incorporated into fertilizer (zinc content) or for recovery of zinc by the Zinc Corporation of
America. Metals in the
dust were reported as off-site transfers under SARA
Title
Section 313. The off-site transfers were to the fertilizer and zinc recovery plants and not to disposal facilities.
2.
3.
The mineral spirits are provided and recycled by the Safety Kleen Corporation. In
1989 Atlantic Steel generated 53,238 pounds of spent mineral spirits.
Atlantic Steel also has a solid waste management concern. Empty drums which contained greases and lubricants are stored on-site until a drum reconditioning service picks them up, cleans them and then returns unusable drums to Atlantic Steel as scrap. The drum storage area gets disorganized and residual grease in the drums leaks out onto the storage pad. The pad must be cleaned periodically, thus costing
Atlantic Steel time and labor. Occasionally the lids are not replaced and trash,
A- 1

Atlantic Steel Company
Atlanta, Georgia residual grease, and rainwater fill the drums. Atlantic Steel generates approximately two empty drums per day at the Atlanta plant and one drum per day at the
Cartersville plant.
Efforts to Reduce Waste:
1. Steel is no longer manufactured at the Atlanta plant. At the Cartersville plant,
Atlantic Steel intends to install a closed-loop on-site treatment system for the EAF dust using plasma technology. The system is considered the state-of-the-art for treating
dust and is the treatment method preferred by the Environmental
Protection Agency.
2.
3.
The solvent recycling service provided by Safety Kleen is an acceptable method to reduce the amount of solvent disposed of as hazardous waste. Some employees have complained about
rashes and would prefer an alternative cleaner. Large parts are cleaned with steam and detergent rather than solvent.
Atlantic Steel has reduced the number of waste drums by purchasing hydraulic fluids in ~Oo-gallon returnable tote bins. Some transmission oils are purchased in returnable drums.
Recommendations: s Washino
Source ReductlQp. Atlantic Steel cleans small parts by soaking them
a tank of petroleum distillates provided by Safety Kleen. One way to reduce the amount of waste solvent at the source is to convert to aqueous solvents. We recommend that you review all areas at both plants where the Safety Kleen parts washers are located and identify which applications are amenable to aqueous cleaners. There are several questions that should be answered before selecting a solvent:
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Will the solvent clean the part adequately?
Is the solvent compatible with the part’s material of construction?
Will the solvent interfere with or contaminate subsequent processing operations?
What is the solvent’s cost and replacement frequency?
Is the solvent volatile, flammable or toxic?
Is the solvent photochemically reactive?
What are the rules and regulations regarding the solvent’s use and disposal?
A-2

Atlantic Steel Company
Atlanta, Georgia
The of substituting aqueous cleaners for solvent include:
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Minimizing worker’s exposure to solvent vapors;
Reduced liability and disposal problems associated with solvent use; and
- cost
The d i s a d v a n t w of aqueous cleaners are:
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Possible inability of aqueous cleaners to provide the degree of cleaning required;
Incompatibility between the part’s material of construction and the cleaning solution;
Need to modify or replace existing equipment; and
Presence of moisture on parts leaving the cleaning operation (to obtain dry parts, an air blown or heated drying unit is required)
Some of the parts cleaned by Atlantic Steel must be protected from corrosion, for example ball bearings. Unless a corrosion inhibitor or a dryer is used, aqueous cleaners may not be suitable for such applications. However, for many cleaning applications at Atlantic Steel a cleaner which contains butyl cellosolvem may work. One product that is widely available is Simple Greenm. We’ve enclosed the product literature supplied to us for you to review.
Reqclixg,
may not be able to eliminate all of the petroleum distillates from the parts washers. The California Department of Health Services’ hazardous waste reduction checklist for automotive repair shops has a number of recommendations for reducing losses from parts washers. A copy is included with this report. Some general guidelines are:
1. Use a solvent sink that drains directly into a waste storage drum rather that a dunk bucket or dip
2.
3.
4.
off the solvent when the
is not in use.
Place a plug in the drain of the solvent sink or cover the sink when not in use to prevent evaporation.
Don’t use parts cleaning solvent on floors or use them to clean your hands.
6.
Place the parts cleaning equipment near the work areas to reduce drips and spills.
If you must use the solvent sink continuously, place an inexpensive steel tray or pan next to the sink. Drain the parts in the tray for a few minutes after cleaning them and empty solvent remaining in the tray back into the sink.
A-3

Atlantic Steel Company
Atlanta, Georgia
Remove parts from solvent baths slowly to prevent splashes and evaporation.
Reference:
Haza r dous W aste Reduction Checklist: Auto oti e R epa ir Shops
, California
Department of Health Services, Toxic Substances Control Division, Alternative Technology
Section, Sacramento, CA, October 1988. v
Drum
-.
. . .
Drum reconditioning is a viable alternative to drum disposal and is used when possible by Atlantic Steel. Reconditioning is a process whereby used drums are cleaned, straightened, retoped (if necessary), and repainted. The reconditioned drum is then available for reuse. For Atlantic Steel a closed loop drum recovery program eliminates the need for direct disposal of used drums. The program includes the following steps:
The vendor ships the full drums to Atlantic Steel for use;
1)
Atlantic Steel empties the drums;
2)
3)
The empty drums are stored on site until they can be collected and recycled by the reconditioner;
4)
The reconditioned drum is then shipped back to vendor for reuse, thereby completing the loop.
Three companies in Atlanta specialize in drum reconditioning. They are as follows:
McConnell Drum Services h c .
47451
DoraviUe, GA 30340
(404) 451-1100
Bemath Barrels and Drum Co. Inc.
1835 Dickerson Drive
Mableton, GA 30059
(404)
Atlanta Drum Services
1090
Riverdale, GA 30274
523-3278
These companies can provide the necessary service to Atlantic Steel and to the vendor of the drums. Details regarding storage and shipping of empty drums are addressed in the drum management section of this report.
_ _
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Atlantic Steel Company
Atlanta, Georgia
Polvethvlene Liners. Another alternative to disposal of drums is the use of liner materials.
A polyethylene liner placed inside each container eliminates the need for reconditioning or disposal of the drums after use. The liner is essentially a flexible tank which, when full, conforms to the sides of the drum. Depending on the durability of the polyethylene material, it is possible that the liner could be reused several times before removal and replacement became necessary. When the liner does become unusable it can be removed and replaced with a new liner. This process would again require a closed loop recycling program between the vendor and Atlantic Steel. It is also possible that such a liner would allow greater efficiency in removal of the contents in the drum thereby recovering what would normally be disposed of as a waste product.
References:
Moore, John, "Polyethylene liner for steel container may ease costly problem of disposal." The 0 issue for users of containers. Problems arise from how and where to store the empty drums, how to guard against leakage of residual materials, and how to dispose or recycle the drums in an environmentally sound manner. In view of these and other problems, the Association of Container Reconditioners (NABADA) has established a program on "Responsible
Container Management." Elements of this program include: use of drums; disposition of drums; drum certification; user's audit; and reconditioning plan review. A synopsis of these elements is presented in the following paragraphs.
USE
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A "full to empty" control program will help to minimize problems regarding drum usage. Drums should always by labeled with information regarding the contents of the drum as well as safety procedures on how to handle the drum and its contents.
once empty, drums should not be refilled with products which differ from the original contents.
DISPOSITION
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Disposition includes storage and shipment of the empty containers.
NABADA recommends that empty drums be resealed to prevent other materials (Le. rainwater) from entering the drum. Such materials would then be considered contaminated and would require treatment. Also, information labels on the drums should be kept intact and up to date. This will eliminate any questions regarding the contents of the drums.
CERTIFICATION
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NABADA provides an "Empty Drum Certification" document which enables the user to track the disposition of the empty drum. Documentation of this type helps to insure that all regulations regarding the disposition of the drum are followed.
It also provides a record of such events.
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Atlantic Steel Company
Atlanta, Georgia
USER'S AUDIT
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NABADA has prepared an audit which enables drum makers to identify applicable regulatory requirements involving drum management. The audit also provides a review of drum handling procedures which may expose companies to liability including ways to rectify such procedures.
FACILITY
-
also recommends that all drum users visit a reconditioning facility so that they may better understand the processes involved. The reconditioner visited should have all required regulatory permits for reconditioning and if necessary be identified as a hazardous waste transporter.
In summary, problems related to drum use, storage, and shipping.
References:
Barlower, Paul M., "Responsible Drum Handling: An Environmental Necessity."
Modem Q&g, February 1989, p.30-32.
"Container Management Program"
NABADA
Association of Container Reconditioners
1030 15th St
20005
(202) 296-8028
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A-6

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE
TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Chemical Products Corporation
P.O. Box 4494
Cartersville, GA 30120
Timothy E. McCown
Environmental Manager
Primary Products:
Barium carbonate, Barium chloride, Strontium carbonate, Strontium nitrate, Barium sulfide,
Sodium sulfide, Sodium sulfhydrate solution, Ammonium sulfide solution, Elemental sulfur,
Sodium silicate solutions, Sodium metasilicate.
Process Description:
Ore and petroleum coke are fed into a rotary kiln. The resultant barium or strontium sulfides are fed via screw conveyors to aqueous leach tanks. The liquids containing dissolved barium or strontium sulfides are decanted into heated, agitated tanks. Carbon dioxide gas is bubbled through the liquid, forming barium carbonate or strontium carbonate.
The solid carbonates are fed to slurry tanks, then settled. The solid carbonate products are either dewatered using a rotary vacuum filter press or calcined and spray-dried.
The carbonation towers generate hydrogen sulfide gas which is recovered and converted into sodium sulfhydrate solution, sodium sulfide, and ammonium sulfide.
The strontium nitrate is produced by reacting strontium carbonate with nitric acid. Barium chloride is generated by reacting barium sulfide with hydrochloric acid.
Waste Genera&&
The unreacted barium in solution is regulated as a hazardous waste. Chemical Products has a hazardous waste treatment permit to convert the barium to an unleachable form.
Approximately 90% of the barium in the ore is consumed in the process. The wastewater containing unreacted barium and unleachable solids is sent to an air oxidation pond. After clarification, settling, and vacuum filtration, the solids are treated with gypsum in a cement truck. The resultant sludge is tested and then sent to a landfill located on the barite mining company’s property.
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Chemical Products Corporation
Cartersville,
Waste:
1. Flue gases
the rotary kilns and spill residues are returned to the process.
2. The sulfide products are the result of Chemical Product Corporation’s decision to capture and use the hydrogen sulfide byproduct rather than bum it,
Waste Generated:
Chemical Products Corporation uses a considerable amount of process and cooling water each day. In an effort to conserve water Chemical Products Corporation has taken several substantial steps in assessing their process water usage and methods for cooling applications.
After implementing several water conservation programs they have reduced their waste water discharge from 1.4 million gallons/day to 1.0 million gallons/day in the last three years.
Efforts to Conserve Water:
1. Installed water meters on three plant wells for improved measurements of water intake and usage.
2.
Periodic surveys are conducted throughout the facility to insure water usage is kept to a minimum.
An operator education program was conducted awareness and create to establish water conservation a forum for conservation recommendations.
4.
5.
6.
Strontium process waste water was recycled back into the strontium process instead of sending it directly to the wastewater treatment facility.
Well water, instead of city water, is used when possible.
A large water recycle tank was purchased and put into service for storage and overflow
of recycled cooling water.
-
Future recommendations include the reuse of barium process waste water by recycling it back into the barium process, similar to the strontium process.
__

Chemical Products Corporation
Cartersville, Georgia
Source evaporation. Water
A large volume of water is lost during the cooling process due to is both sprayed and gravity discharged onto large process tanks. The water is then diverted back to the recycle water tanks via ground drains and reused.
Depending on the level of tank cooling required, water jackets or cooling coils can be used in and around the vessels. If minor heat transfer is required, water jackets welded partially around the vessels can serve as the only means of cooling. If a more extensive amount of cooling is needed cooling coils can be immersed into the vessels for more direct heat transfer. Jacketed type cooling is a slightly more expensive option, however the maintenance investment is insignificant. The application of these jackets around each tank would substantially reduce the evaporative water loss as well as provide a better control of the cooling water into the ground drains. By initially using a larger volume of water in the cooling process, coupled with the use of water jackets, this water can be recycled many more times and still provide adequate cooling of the process vessels. This will then reduce the amount of cooling water needed daily.
Cooling water which is lower than a certain threshold temperature should be devoted to the cooling water system. When the temperature of the cooling water rises above the threshold level it can be diverted to the process water system for storage and eventual use.
can reduce unnecessary heating costs associated with heating process water amount of well and public water initially required. as well as the
References:
Alexander, W., "Heat Transfer in Agitated Tank Jackets With Liquid Media", Ger,
Chem.
September 1986, pp. 362-371.
Brain,
"Heat Transfer in Stirred Tank Bioreactors", C h e w
. .
Energy Cost",
January 1987, pp. 82-85.
B-3

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Delta
Lines, Inc.
TOC 1
-
Department 594
Hartsfield Atlanta International Airport
Atlanta, Georgia 30320
Mr. David R. Hesterlee
Manager, Occupational/Environental Safety and Compliance
Maintenance and repair of aircraft and ground support equipment
Process Description:
The Delta Airlines facility at Hartsfield Atlanta International Airport is responsible for the major maintenance and repair of all aircraft owned by the company. Operations include mechanical and electrical system repair and overhaul, aircraft stripping and painting operations, electroplating of aircraft components, and jet engine maintenance and rebuilding. The facility has the equipment and systems to re-manufacture almost all components of the aircraft operated by the company.
1. Every five years the paint coating on a jet is stripped and replaced. The stripping operation uses methylene chloride-based stripper and generates stripper waste and wastewater containing residual stripper. All of the stripper wastes are sent off-site for disposal as hazardous waste.
Delta drycleans seat covers in-house using perchloroethylene drycleaning equipment. 2.
3. A modern plating operation is used to plate airplane parts with a variety of metals.
Degreasing solvent and plating wastewater treatment sludge are generated and disposed of as hazardous waste.
Waste Generated:
The hazardous wastes generated at the facility are described on the Waste Profile Sheets included in Attachment 1. A summary of these wastes is presented in Table 1. The table was generated by imputing the data from the Waste Profile Sheets into a Lotus 1-2-3 spreadsheet and using the automatic computational features of the spreadsheet to compute the total cost of handling each waste. c-
1

Delta Air Lines
Atlanta, Georgia
The total cost of waste handling for each waste stream was determined by multiplying the sum of the unit costs for disposal and handling by the number of units generated and then adding the annual laboratory costs. The total cost for facility hazardous waste disposal was determined by adding the costs for each of the 26 waste streams. The total cost for the entire facility was $1,191,924.
to Reduce Wastes:
Delta
undertaken a number of initiatives to reduce wastes.
1)
Delta evaluated the use of bead blasting (plastic and dry ice) to strip the planes.
Plastic beads were rejected because they caused unacceptable pitting of the plane’s surface. Dry ice has been rejected because it does not strip the plane well enough.
2)
3)
Delta’s employees have designed a system for collecting the paint/stripper sludge as it is removed from the plane. This system has resulted in a higher quality sludge which may be reclaimed. The stripper supplier has indicated that he may be able to recycle the paint/stripper sludge and retum the reclaimed stripper to Delta. The supplier also is identifying caustic strippers.
The drycleaning operation has carbon absorption and recovery units for the drycleaning solvents, perchloroethylene and freon. The shop will be investing in new equipment in the next year.
The plating shop design includes a number of waste reduction technologies, including counter-current rinsing systems and conductivity probes to reduce water usage (and subsequent treatment), drip racks to promote complete drainage of process solutions from the parts back into the process baths, agitation in the rinse tanks for efficient rinsing, and elevated bath temperatures to aid in rinsing. The treatment system includes evaporative units which generate plating bath salts which can be reused in the process.
~
Recommendations:
Prioritization of Pol lution PreventiQgS Ooportum sz
.
One of the steps required to implement a pollution prevention program is to prioritize the opportunities. An evaluation of Table 1 indicated that there were a number of wastes with a disposal cost that was significantly higher than other wastes. It was concluded that prioritization based on total cost was an acceptable method of targeting opportunities. The
_ _ c - 2

Delta Air Lines
Atlanta, Georgia data sort features of Lotus 1-2-3 were used to sort the waste streams based on total disposal cost starting with the most expensive waste and progressing to the least expensive. The results of this data sort are presented in Table 2.
An analysis of the table indicates that the solid stripper and stripper residues from the aircraft stripping and painting operations account for more than 50% of the total waste generated by the facility. Adding the waste from the plating operations to these first wastes accounts for almost 70% of the total waste from the facility. This analysis indicates that these three waste streams should be the first targets for Delta’s Pollution Prevention program.
Once the first priorities have been addressed, the targeting of additional waste streams can become more difficult. In this situation the glass bead, contaminated liquids, and stripper sludge account for 5.7% and 5.6% of the total waste generated at the facility. The decision as to which waste stream to target may require some subjective factors that are used to adjust the actual disposal cost.
An example of these subjective factors is illustrated in Table 3. The waste streams are evaluated on handling problems, paperwork problems, worker exposure problems, and complaint problems. If the problem is major, it is given a rating of 10. If the problem is not major, it is rated at a lesser factor (9-0). An explanation of the ratings in Table 3 might be as follows: w
Rationale
Glass Bead Handling
Paperwork
Exposure
Complaints
8
8
9
9 not too difficult not too difficult some problems with hitting o p e r a t o r s , r e q u i r e s protection floor slipping problem
Contaminated Fluids Handling
Paperwork
Exposure
Complaints
10
10
9
7 comes from many sources paperwork from many s o u r c e s m u s t b e consolidated not a big problem very few
The rating are converted to a decimal by dividing by 10, multiplied by each other, and then the actual cost is multiplied by the product of the rating factors.
shown in Table 3, the c-3

Delta
Atlanta, Georgia contaminated fluids has a higher adjusted disposal cost due to the problems discussed above and should be the first target of opportunity. This is only an example of how the process could work. The actual factors used must be determined by Delta.
1. There have b e e n m viable alternatives to perchloroethylene and CFC-113 identified at
two time. The rapidly increasing cost of CFC-113 (from $22 to $78/gal years) makes this solvent m e s i in the last
2. Perchloroethylene is a suspect carcinogen and OSHA is lowering the exposure limit to half of its previous value (new limit = 25 ppm). This action has prompted the development of more efficient equipment. Fisher stated that IFI is recommending that perc operations use "Dry-to-dry No-vent'' refrigerated machines. Apparently these machines use refrigerated condensation during the dry cycle and therefore do not require a final purging. Total solvent consumption with these new machines drops over 50%. The perc emissions compare as follows:
Mach ins
4 lbs emissions /lo0 lbs laundry
Drv-to-drv. No-vent
0.1-0.2 lbs emissions/100 lbs laundry
Contact the local office of IFI, the Southeastern Fabricare Association, for information on vendors of this equipment. Mr. Bobby Landers of the Southeastern
Fabricare Association (763-4741) will be of assistance in selecting the equipment.
References:
"Chlorinated Solvents: Market Interactions and Regulation." Journal of Hazardous
M a t e r i b Vol. 15, 1987, pp. 137-161.
Directory, International Fabricare Institute, 12251 Tech Road, Silver Spring,
"Update on Key Legislation and Regulations." IFI Alert: Lggd ative Updak , Silver
Spring, MD: International Fabricare Institute, December 12, 1983.
"Waste Reduction
...
Waste
. . . tion." Dowper a nd the
-
C-4

Delta Air Lines
Atlanta, Georgia
MI: Dow Chemical U.S.A., Chemicals & Metals Department, Form No. 100-6367-88-PM&L.
"Drycleaning Equipment." D o m e r and the Environment, Midland, MI: Dow
Chemical U.S.A., Chemicals & Metals Department, Form No. 100-6368-88-PM&L.
"Recovery, Reuse, and Disposal of Chlorinated Solvents." Dowper a nd the
Environmer& Midland, MI: Dow Chemical U.S.A., Chemicals & Metals Department, Form
NO. 100-6370-88-PM&L.
"Solvent Recovery in the Dry Cleaning Industry SIC-7216.'' Washington State
Department of Ecology, Office of Waste Reduction and Recycling, Mail Stop PV-11,
Olympia, WA 98504-8711, March 29, 1985.
"Waste Reduction Assistance Program (WRAP) On-Site Consultation Audit Report:
Cleaner, Anchorage, AK: Alaska Health Project, 1987.
"Reducing Vapor Exposure: OSHA Compliance." IFI Focus o n Drvcleaning, Vol. 13,
No. 5, November 1989.
"A Study of the Frimair Mach 12 Drycleaning Machine."
Research Fellowship,
NO. F-37, March 1981.
"Recovering Perchloroethylene from Used Filter Cartridges with the Puritan 4000
SRSm Solvent Recovery System, JFI Resea rch Fellowship, No. F-40, May 1987.
"Filters, Filter Pressure, and Flow Rate,"
Fab ricare News Technical Oue rating
TOI-608, p. 13, February 1989. c-5

GEORGIA TECH RESEARCH INSTITUTE
SCIENCE AND TECHNOLOGY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Dow Chemical U.S.A.
1468 Prosser Drive,
Dalton, Georgia 30720
Joe Seyer
Waste Reduction Manager
Styrofoamm and styrenelbutadiene latex
Process Description:
Polystyrene pellets are heated, mixed with an HCFC blowing agent, and molded into insulation boards of varying sizes using a proprietary production process. The boards are cured, cut, imprinted, and wrapped for storage.
In styrene/butadiene latex production, monomers, modifiers, and emulsifier catalyst are mixed together in a steel, glass-lined reaction vessel. The reactor is equipped with an agitator, external jacket, and internal coils for exchange fluids to effect temperature control.
The latex is further processed to remove residual unpolymerized monomers and stabilized through the addition of antioxidant.
Waste Generated:
1. The latex process generates 80,000 pounds per month of "recycle oil" which is shipped by a hazardous waste carrier to another Dow facility for incineration. The recycle oil consists of the following:
Constituent
Styrene
1,l Dichloroethylene
Ethylbenzene
1,3 Butadiene
4 Vinylcyclohexane
Isopropylbenzene
Butenes
N-Propylbenzene
Webht %
65.0
6.0
6.0
3.0
10.0
3.8
4.6
1.5
D-1

USA.
Ceorgia
2. The "white water" from the styrene/butadiene latex operation is sent to an on-site wastewater treatment facility. The skimmings from the dissolved air flotation (DAF) tank consist of 15% solids by weight. Dow produces an average of 92,000 pounds per month of solids on a dry basis.
to Reduce Waste:
1. Raw material conversion rates in the latex production process have been improved to reduce the process vent stream volume (recycle oil) to treatment systems. Reuse options for the recycle oil is under investigation at other Dow facilities.
2. A process water reuse project has been implemented which: reduces the organic load on the treatment system and secondary emissions; reduces effluent volume to the outfall by 3.6 million gallons/year; and decreases the need to consume fresh city water by the same volume.
3. Containment in the raw material storage area and latex raw material and product rail
loading areas has reduced the impact of spills on the soil and groundwater.
4.
5.
Open trenches have been eliminated, thus preventing the mixing of storm water and process waste water. The process wastewater is transferred via closed pipe.
A number of white water reduction projects have been initiated, including: reuse of heals in returning railcars; modification of final product filters to allow rinsing of solid waste prior to disposal; replacement of hose stations with hard piped headers; conversion of all latex handling pumps to double mechanical seals; modification of methods used to prepare equipment for maintenance activities; and improvements in computer process controls which result in greater yields of prime product allowing complete reuse of white water back in the product.
Recommendations:
Recvcle 0
The recycle oil is a complex mixture which would be impossible to separate. This, as Dow is well aware, limits its value for reuse. We hope that Dow will be able to reuse the material at another Dow facility. Another option, already initiated by Dow, is to market the material through a waste exchange. We have enclosed catalogs from two waste exchanges for your use.
-
_ _
D-2

DorrCh&U.S.A.
Daltoo, Georgia
References:
Resource Exc hanee & News: Exchang 'ne Waste. Informatio n & TechnolQgy
Waste Systems Institute of Michigan, Inc., Vol. 6, No. 3, May/June 1990.
The Southern Waste Information Exchange C learinghouse, Tallahassee,
Florida, Vol. 9, No. 3, October 1990. mite Water DAF Skimmings
Mr. M.E. Sikorski of the School of Textile Engineering at Georgia Tech has supplied the following description of his research. He may be reached at (404) 894-2541.
In order to reuse rubber from carpet backing, which was applied as styrene-butadiene latex, dissolution in selected gases is proposed.
Solubilities of polymers in gases appear to be sufficiently large so that gaseous solutions can be used for transport and fabrication (reuse) of polymers. The polymers are soluble at temperatures close to or above the softening or melting temperatures. For example, styrene can be dissolved in carbon dioxide and ethane at temperatures above
155°C and higher.
Usually, extrusion of polymers is carried out at temperatures substantially above softening or melting points of polymers in order to lower viscosities into workable ranges. The gaseous solutions of polymers are attractive as transport and fabrication media since they can be manipulated at substantially lower temperatures (as much as 1OOOC). Gaseous solutions could be used for applications involving spraying or coating, for example.
Excessive amounts of water present in carpet backing may be deleterious to the process since gases such as carbon dioxide dissolve in water.
Precipitation of styrene rather than its gaseous dissolution might take place, thus negating the expected result.
Initial investigations directed toward the reuse of carpet backing material can be conducted in a batch process. However, eventually a continuous process can be devised leading to direct application of the recovered material.
D-3

GEORGIA TECH RESEARCH INSTITUTE
TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
DSM Chemicals North America, Inc.
1 Columbia Nitrogen Road
2451
Augusta, GA 30903
B.M. Beal
Manager, Environmental, Safety & Security
Caprolactam, the Nylon-6 monomer
Process Description: Cyclohexane is oxidized to form a mixture of cyclohexanone and cyclohexanol. The cyclohexanone is reacted with hydroxylamine sulfate to form a cyclohexanone oxime and ammonium sulfate as a byproduct. The ammonium sulfate is extracted from the reaction mixture with water, crystallized and sold as a fertilizer.
Hydroxylamine sulfate is formed by reacting ammonium nitrate and sulfur dioxide. The cyclohexanone oxime is converted to caprolactam by the Beckmann rearrangement in sulfuric acid. Caprolactam is extracted from the reaction mixture using benzene.
Waste Generated:
Organic wastes generated in the production of caprolactam are collected throughout the production facility and sent to a liquid/liquid separator. The water immiscible organics which includes cyclohexane, cyclohexanol, and toluene are separated from the water miscible organics. The water immiscibles pumped to are pumped to a waste tank which the miscibles are an activated sludge biological treatment plant. The bottoms from the benzene still and the overheads from the distillation column are pumped directly to the waste storage tank. The organics in the waste storage tank are pumped to one of the boilers for heat recovery. In 1989 3,600,000 pounds of organic wastes were sent to the boilers for heat recovery.
Raney Nickel is a catalyst used in the production of caprolactam. The catalyst must be replaced from time to time due to its loss of activity. As a new catalyst, the material is pyrophoric; as a spent catalyst the material has lost all or most of its hazardous characteristic.
has chosen to treat the spent catalyst as a hazardous waste. In 1989,
39,180 pounds of spent catalyst were sent for recovery of nickel.
The boiler water is demineralized using ion exchange resins. The regenerates contain sodium hydroxide and sulfuric acid and are neutralized prior to discharge.

Chemicals Augusta, Inc.
Augusta, Georgia
to Reduce Waste:
1. The volatile organic chemicals in the aqueous waste stream are removed by a steam stripper. The reduction in chemicals previously lost through volatilization from the wastewater has resulted in an increase in organics sent to the boiler for heat recovery.
2. Spent catalyst generation has been reduced by extending the run time on each charge of catalyst. The run time extension is balanced with loss of catalyst activity. Catalyst activity is related to final product quality.
Recommendations:
The organic waste currently used for energy recovery in boilers appears to be composed of chemical isomers, byproducts of the reactions, or impurities in the raw materials. We looked at two approaches to managing this waste: source segregation to recover valuable and reusable solvents and reuse to produce synthetic lubricants. The complex nature of the waste makes segregation and recovery a less attractive alternative. We have included a brief discussion of the approach for you to consider. The potential for recovering caprolactam waste and using it to make lubricants appears to be worth further investigation.
Source Seere-. Simple distillation of the mixture may not be a viable alternative since a sufficient boiling point difference does not exist to selectively separate the components.
Only waste streams
less components can be successfully distilled, and an effective way of obtaining these purer waste streams is by source segregation.
The basic strategy that must be followed for source segregation to be successful is to accumulate waste materials in the form or state of their highest value and not allow any dissimilar material to become mixed with it. Pursuing this strategy will permit the highest possible revenue to be generated from a given amount of waste. Segregation of solvent wastes containing common Characteristics will greatly facilitate their recovery.
Segregation is
important part of the recycling effort. Single component waste streams are generally good candidates for recycling, and therefore should be separated from the other waste streams generated. Normally it is not possible to recycle solvent mixtures, they must be brought back for reuse as a single type of solvent. If segregation can be practiced, then only simple distillation or possibly filtration is needed to produce a recyclable solvent.
If two or more types of solvent get mixed together it becomes necessary to perform the more expensive and difficult process of fractional distillation to purify and separate the various component types of solvent. The segregation scheme utilized by a specific facility will depend wholly upon the types of waste streams that are generated. A strategy for
~
-
__
E-2

Chemicals Augusta, Inc.
Augusta, Georgia managing organic solvents is outlined in Figure 1.
We recommend that you evaluate the purity of raw materials to minimize the number of constituents in the solvent waste. In addition, a review of the caprolactam process may reveal opportunities to segregate, recover and reuse a wastestream of higher purity.
Blaney, Benjamin L., "Alternative techniques for managing solvent wastes." Journal d the
Assoa
Reuse to Produce We discovered two articles which propose using caprolactam wastes to produce synthetic lubricants. The journals are not available in the
Georgia Tech library, but we have ordered copies from the editors. We will forward them when we receive them. The abstracts are as follows:
Mehta, K. J., "Caprolactam waste streams a source of raw material for synthetic lubricants." Chem 24, March 1989, pp. 63-65.
A mixture of aliphatic mono-carboxylic acids (mainly butyric, valeric, and caproic) and dicarboxylic acids (succinic, glutaric and adipic) are generated as by-products during air oxidation of cyclohexane to cyclohexanol, a reaction step in the manufacture of caprolactam. Separation of mono carboxylic acid and dicarboxylic acids and the esterification of the former with pentaerythritol produces synthetic lubricant base stock.
Krachun,
Soviet Joumal of
Friction and Wear, Volume 9, 1988, pp.67-7.
We present the results of investigations devoted to studying the formation and structure and evaluating the antiwear and antifriction properties of solid lubricant as a function of load, temperature, and nature of the gaseous medium.
E-3

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Forstmann & Company, Inc.
272
Louisville, Georgia 31521
Mr. Mike Anderson
Finishing Manager/Environmental Control Manager
Wool textiles Primary Products:
Process Description:
The Forstmann Louisville plant finishes wool fabric produced at other Forstmann textile mills. Cloth is either piece-dyed or stock-dyed before it is sent for finishing at the Louisville plant. The fabric is scoured with biodegradable detergents and then routed through the fulling process which creates a flannel effect. After fulling, the fabric is dried. Piece-dyed fabric is then dyed or bleached. Some of the dry, dyed fabric is treated with silicon, zepel, or hand-building treatments for special applications. After treatment, the fabric is sent to the dry f i s h area where it is sheared and pressed. Shrinkage is stabilized by passing the fabric through spongers and a steam finishing process.
Wool fabric has vegetable matter woven into it. The vegetable matter comes from grasses and corn present in the sheep’s coat. The woven fabric is carbonized with a weak sulfuric acid solution (3-5%) and heated (carbonized) to destroy the vegetable matter, but not the wool fiber.
Waste Stream IdentiKcation:
The textile finishing processes used at the Forstmann Louisville Plant does not generate hazardous wastes.
The largest volume of toxic chemical used at the plant is dilute sulfuric acid in the carbonizing process.
Forstmann does generate some potentially usable solid wastes. Approximately one ton per week of flock (textile fibers from the shearing process which are collected in a cyclone).
Waste fabric ends and clippings are also generated. The textile wastes are compacted and sent to the sanitary landfill. The disposal costs for this waste are approximately
$1,50O/month including rental for the compactor.
F-1

Forstmann & Company
Louisville, Georgia
to Reduce Wastes:
Forstmanu has focused much of its waste reduction efforts on the toxic chemicals on the
S A R A Toxic Chemical List.
1. In 1988, the Louisville plant emitted over 350,000 its cleaning operations. Since 1989 the plant has replaced the solvent with a citrus- based aqueous cleaner. This results in a reduction of more than 350,000 pounds of volatile organic chemicals per year.
2. Trichlorobenzene is a dye carrier which was used in Forstmann’s dye process. They have identified a new dye carrier, monochlorotoluene, which is not a SARA toxic chemical. This results in a reduction of over 40,000 pounds of a
toxic chemical.
A dilute solution of sulfuric acid is used in the carbonizing process. The acid is neutralized with sodium hydroxide prior to discharge.
4. Solid waste has been minimized by purchasing chemicals in fiberpack drums or in returnable bulk containers. Paper is recycled, but identification of stable paper recycling
has been difficult.
Recommendations:
In a paper presented to a conference sponsored by the Wool Bureau in April, 1990, Dr.
Trevor Shaw of the Intemational Wool Secretariat identified the four high priority areas where wool manufacturing would face environmental difficulties:
-
The presence of residues of pesticides (used for control of ectoparasites in sheep) in raw wool. and the downstream consequences of their presence;
-
-
Mothproofing agents in effluents from carpet manufacturing;
(absorbable organic halogen compound) in the effluent from shrink-resist processes; and
-
Chromium in dyehouse effluent.
-
_ _
F-2

& & f
Forstmann & Company
Louisville, Georgia
The Louisville plant does not use chromium-based dyes. The presence of pesticides and
AOX was not determined during the site visit, but should be considered in the company’s long-term waste reduction program.
Another paper from the same conference, presented by Peter A. Duffield of the
International Wool Secretariat, addresses the environmental impacts of wool bleaching, for which phosphate stabilizers predominate in oxidative bleaching processes. Duffield discusses several methods possible for bleaching wool with minimum or zero phosphate levels. hate D i s c h a r s The rapid hydrogen peroxide bleaching method uses phosphate stabilizers. One way to reduce the phosphate discharge by 75% is to reuse the bleaching liquors. The bleach liquor is titrated with potassium permanganate to determine the amount of hydrogen peroxide needed to restored the original concentration. In addition to reducing the phosphate discharged, reuse also results in savings on hydrogen peroxide and phosphate stabilizer. hate-Free Bleaching, Two phosphate-free bleaching processes include reductive bleaching with thiourea dioxide and oxidative bleaching under mildly acid conditions.
Reductive methods often do not produce the degree of whiteness required, but significant improvements in whiteness have been achieved with the addition of sodium lauryl sulfate to the thiourea dioxide process.
Reference:
P r o c e u Woo 1 in the N ineties Tec hnical Seminar, The Wool Bureau, Inc., Plymouth,
MA, April 25-26, 1990.
:
.
I
Source Red-
.
In conventional carbonizing processes, the residual acid content in the carbonizing cloth is high, and therefore subsequent washing requires a high water consumption along with a high level of acid discharge, both of which are economically and ecologically unsatisfactory. The carbonizing of wool fabrics by means of the new Sperotto
Rimar combined solvent/water process overcomes the disadvantages of traditional carbonizing, while at the same time offering several qualitative economic and ecological advantages. These are achieved by the combination of solvent scouring with perchloroethylene and aqueous acidizing carried out in a suitably designed machine: the
CARBOSOL range. Although acid discharges will be reduced with the Sperotto Rimar process, the use of perchloroethylene may be undesirable.
F-3

Forstmann & Company
Louisville, Georgia
RePerences:
Mr. Alan Elgort
REPUBLIC TEXTILE EQUIPMENT CO.,INC.
P.0.Box 625
York, S.C. 29745
Tek(803)684-2321
For further information on
Technical Seminar" enclosed. the carbonizing issue refer to the "Wool in the Nineties
Flock and CliDDi-
Spurce R e d u d . Product quality requires that the product be sheared. The shearing process will inevitably generate flock and waste ends.
These by-products could be used to make other items rather than placed in a landfill. A list of companies which may be interested in flock and clippings follows.
The companies have been arranged in four categories: those that produce wiping cloths, those that manufacture toys, those that concentrate on textile fibers and waste recycling, and those that produce furniture and upholstery.
F-4

Company:
Contact:
GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE
TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Primary Products:
KEMIRA, Inc.
P.O. Box 368
Savannah, GA 31402
William E. Trees
Manager, Environmental Control
Titanium Dioxide
Process Description:
There are two processes for manufacturing titanium dioxide, the sulfate process and the chloride process. KEMIRA uses both processes.
Sulfate Process, The feedstock in the sulfate process is ilmenite (4560% Ti02) or titanium-rich slag (70% TiO,) obtained by electric smelting of ilmenite. The slag or ore is digested with sulfuric acid. The solid cake of titanium and iron sulfates is then dissolved in water. The solution is clarified by an organic flocculant or by precipitated antimony sulfide. Some of the ferrous sulfate is crystallized from the solution by vacuum distillation. The concentrated liquor is nucleated, diluted with water, and boiled until about 96% of the titanium has been precipitated in the form of flocculated titanium dioxide (anatase) hydrate. The precipitate is filtered from the acid liquor and then leached under reducing conditions to remove most of the residual iron. Various conditioning agents are added, and the hydrate is then dried and calcined in a large rotary kiln having an exit temperature of about 900°C.
Chloride Process. The chloride process requires a feedstock high in titanium and low in iron. Mineral rutile (95% TiO,) is preferred. The ore, mixed with coke, is chlorinated in a fluidized bed at about 900°C. The main product is titanium tetrachloride, but iron and other impurities are also chlorinated and must be removed by selective condensation and distillation. Selective reduction prior to the
distillation removes VOCI,. The purified TiCI, is reacted with oxygen at temperatures above loooOC in the presence of AlCI?, which promotes the formation of rutile rather than anatase. Although the oxidation is exothermic, it is not self- sustaining and must be assisted by extra heat. This heat is supplied to either or both reactants through heat exchangers, by electrical dischargers, by the simultaneous combustion of CO, or by the use of a fluidized bed. Chlorine is regenerated in the oxidation step, and after cooling and separating it from the product it is recycled to the chlorinator. The raw titanium dioxide product is typically neutralized by washing

Kemira, Inc.
Savannah, Georgia in aqueous acid or alkali.
The individual pigment particles are coated with a uniform layer of hydrous oxides in order to reduce their photocatalytic activity and to improve dispersibility. The raw chloride or sulfate product is usually milled before coating.
This can be done wet in ball or sand mills. The milled, slurried product is coated by the successive addition of salt solutions. After coating, the pigments are filtered off, washed, dried, and fluid-energy-milled.
Reference: Considine,
M.,
and Process Techno
New York, Ny: McGraw-Hill
Company,
1102-1104.
Waste Generated:
1. Waste acid
the sulfate process is treated in a neutralization plant. In
of acid were neutralized. The treatment uses a lime slurry. Gypsum is recovered, filtered, dried, and sold as a product.
Chloride and sulfate process wastes containing unreacted ore, coke, iron and other
hydroxides are pumped to sedimentation ponds on the property. In
sulfate process generated
tons of sludge and the chloride process generated
tons of wastes.
~
~~
Effoorts to Reduce Waste:
1. Hydrochloric acid treatment.
recovered
a waste stream that goes to waste
dioxide, a byproduct of the reaction between sulfuric acid and hestone, is captured, liquefied, and sold under a contract with the Cardox
Division of Liquid
Gypsum, a product of the sulfuric acid neutralization process, is sold as a product.
Dramatically reduced acid waste by segregating waste streams and prevention of run-on.
-
G-2

Kemira, Inc.
Savannah, Georgia
Recommendations:
Source produced the following information.
. .
Waste W a m
It is possible that Kemira could find a market for the iron containing waste stream in the plating industry. Waste waters produced in the chrome plating industry have chromate
(dichromate) ions present in solution. The treatment process for this waste water involves reducing the Cr(VI) to Cr(lII) which is then hydrolyzed to form the precipitate chromium
hydroxide. Reagent methods of water treatment show that sulfur compounds or Fe(II) compounds
be used to reduce Cr(VI) to Cr(III). The use of Fe(II) compounds allow reduction of
to take place over a wide range of acidity while using only a small excess of reducing agent and high rate of the process. Investigation of this process shows that it is feasible to replace green vitriol which is currently being used to treat chromium- containing waste with the Fe(II) sulfate produced in ilmenite processing.
References:
Burtnenko, LM., et
. . to
From Hvdrows A&
Since Kemira has titanium remaining in the process waste stream, it is feasible that the removal of titanium phosphate would reduce the volume of the waste stream before it becomes a sludge and at the same time retrieving a valuable commodity for Kemira.
Titanium phosphate has properties which enable it to take the place of titanium dioxide in several different applications. These include being used as a catalyst or ion exchanger; and
pigments and fillers in the production of enamels, plastics, rubbers, and paper. The technology of producing titauium phosphates from hydrolysis acid waste basically consists of precipitating titanium phosphate by introducing phosphoric acid into the hydrolysis acid waste.
process recovers titanium phosphate which has valuable catalytic and pigment properties.
References:
et al, "Industrial Tests of a Method of Producing Titanium Phosphate"
18,
c-3

Kemira, Inc.
Savannah, Georgia
. .
As an alternative to disposal, it may be possible to use Kemira's waste hydrolysis acid in the treatment of municipal waste waters. Due to the scarcity and expense of aluminum sulfate, research has been performed in area of feedstock base options for coagulant production.
Results of
research have shown that it is possible to use hydrolysis sulfuric acid, which
a waste from
dioxide processing, and iron oxide, which is a waste from the production treatment of sulfuric acid, to produce an effective coagulant which is suitable for the of municipal waste waters.
ZvyaSintsev, . .
Wastes"
.
Vol. 8, No. 5, p. 91, 1986.
-
The processing of bauxite minerals generates mud". an alkaline residue commonly called "red
residue
considered a waste product and must be disposed of in some fashion.
The
of this residue
been examined and it has been determined that the addition of hydrochloric acid and neutralization by the addition of gypsum and a strong acidic effluent from titanium dioxide processing will generate a neutral or near neutral mixture. The advantages of such a mixture would be that it w i l l have improved properties regarding storage and alternative uses. Since Kemira generates both gypsum and acidic effluents from the processing of titanium, it is possible that a market for "co-disposal" of both titanium and bauxite wastes could be created. A potential problem exists in the fact that the majority of bauxite processing occurs in
and therefore would require
of the waste products to the treatment location.
Gleinister, DJ.,
M.R., "AlkaWty of Red Mud and Its Application for the
Management of Acid Wastes" ma
There are two basic categories of centrifuges used for sludge dewatering: imperforate basket and scroll type decanter. A discussion of the operation process for each included.
64

Kemira,
Savannah, Georgia
1. Imperforate Basket
The cycle begins with the acceleration of the centrifuge. After a specific time interval, a feed pump is started. This device pumps sludge into the unit through a stationary feed pipe located at the top of the unit. The amount of sludge pumped into the unit is controlled by either a preset timer or a centrate monitor that shuts off the feed pump when the operating volume has been delivered to the unit. As the unit operates, the fluid (centrate) being pumped off is monitored. When the centrate flow decreases to a predetermined level and separation can no longer take place, the sludge pump turns off. At this time the centrifuge begins to decelerate to a predetermined rpm. Once that rpm is encountered, a plow mechanism is activated and starts to travel horizontally into the bowl where solids have accumulated. The plow breaks up the dewatered solids and facilitates removal and discharge. Once the solids have been discharged the cycle is complete.
1)
2)
3)
4)
5)
6)
7)
Machine can be used for dewatering and thickening;
It may not require chemical conditioning;
Centrifuges have a clean appearance and fast start-up and shut-down capabilities;
Basket centrifuge is very flexible in meeting process requirements;
It is not affected by grit;
It has low total operational and maintenance costs;
Does not require continuous operator attention.
1)
2)
3)
4)
5 )
The unit is not a continuous feed or discharge;
Requires a specific structural support system;
limited
capacity;
For easily dewatered sludges, it has the highest capitol costs versus capacity ratio;
For most sludges, it gives the lowest cake solids concentration; and
the exception of the vacuum filter, consumes more direct horsepower per unit of product processed.
G-5

Kemira, Inc.
Savannah, Georgia
2. Solid Bowl Decanter
The principles of operation of the solid bowl decanter involves the entrance of a sludge stream, via a feed pipe, into the end of a horizontally placed rotating bowl.
The sludge particles are exposed to a gravitational field generated by the rotating bowl. The exposed particles begin to settle out on the inner surface of the rotating bowl. The liquid (centrate) pools above the sludge layer and flows toward the outlet of the device. The dewatered sludge is removed by a rotating conveyor which transports the sludge to the other end of the device. In this type of decanter, the sludge is conveyed up an incline to facilitate the dewatering process. Solid bowl decanter centrifuges are available in different configurations. Countercurrent (as described above) or concurrent flow design and either "high speed or "low speed design. Available operating capacities range from 6 gpm to 400 gpm.
~
1) Yields high throughput is a small area;
2 )
It is easy to install;
3) It is quiet;
4)
low capitol cost for installation;
5 )
6)
It is a clean looking installation;
ability to constantly achieve four to six percent solids in the dewatered sludge.
-s
1)
2)
V of this sy,&m incl-
It is a high maintenance item;
Conveyor system is potentially a high maintenance item.
In vacuum filtration, a vacuum is applied downstream of the filter media therefore using upstream atmospheric pressure as the driving force. There are two basic types of vacuum filtration processes: rotary
vacuum filters and belt type rotary vacuum filters.
The rotary drum vacuum filter consists mainly of a horizontal cylindrical drum that rotates while partially submerged in a vat of conditioned sludge. The surface of the drum is divided into several different sections around its circumference. Each individual section is sealed off from the other sections and is enclosed at the ends.
the drum rotates it passes through zones of dewatering. These zones are defined as cake forming, cake drying, and cake discharging.
G-6

Kemira, I n c
Savannah, Georgia
Approximately 10 to 40 percent of the surface of the drum is submerged in the sludge.
submerged section is the cake forming zone. A vacuum applied causes the filtrate to pass through the media and a cake to be formed on the media.
rotation continues each individual section is carried through the cake forming zone then to the cake drying and then to the cake discharging zone. In this final cake discharging zone, cake is removed from the media.
Belt-type rotary vacuum filters differ from the drum or scraper-type units because the drum covering or media-belt leaves the drum.
1)
2)
3)
Does not require skilled personnel;
low maintenance requirements for continuous operating equipment;
Provides a filtrate with a low suspended solids concentration.
of th is svste m include;
1)
Consumes the largest amount of energy per unit of sludge dewatered in most applications;
2) Requires continuous operator attention;
3)
Auxiliary equipment (vacuum pumps) are very loud.
Belt Filter Press
Belt filter presses use a moving belt system to continuously dewater sludges.
process involves three basic stages: conditioning of the sludge slurry, gravity drainage for bulk dewatering, and compaction of the remaining sludge.
The type of conditioning required depends on the type of sludge being dewatered. Good chemical conditioning though is the key to successful operation of a filter press.
After conditioning, the readily drainable water is removed from the slurry in the gravity drainage section of the belt filter press. This section typically reduces the volume sludge
50% and concentrates the solids to 6
-
10% of original concentration. of the
The last stage of the belt press begins as soon as the increased pressure is applied to the sludge. This can be achieved by either compression of the sludge between the carrying belt and cover belt or the application of a vacuum on the carrying belt. This stage completes the belt press process and produces a sludge cake ready for disposal.
G-7

Kemira, Inc.
Savannah, Georgia
1)
2)
High pressure machines are capable of producing very dry cake;
low power requirements.
Very sensitive to incoming feed characteristics;
Machines hydraulically limited in throughput;
Short media life as compared with other devices using cloth media.
1)
2 )
3)
Kemira already uses a belt vacuum filter press to dewater gypsum. If such a system can handle the capacity of the sludges and energy costs are not prohibitively high, then it may be worth further investigation. In regard to this,
Company of Ft. Lauderdale FL., ph. (305) 974-6610
provide technical assistance regarding the selection and installation of the appropriate belt filter press system.
Reference:
-
625-1-79-011.Sludee Treat- and Disposal Process
The waste material generated in the titanium dioxide process has several valuable constituents remaining after the processing is completed. The recovery or separation of these constituents would be beneficial to Kemira as a raw material and
a pollution prevention measure. There are several different methods that
be used to separate such materials, These include gravity concentration, magnetic separation, electrostatic separation, flotation, and leaching. The above mentioned processes that are relevant to Kemira’s waste sludges are discussed in the following paragraphs.
This process
the differences in density to separate valuable components of a material.
There are several techniques used which include jipping, tabling, spirals, and sink/float separation. All of these have a limited range of particle sizes that can be effectively separated.
-

Kemira, Inc.
Savannah, Georgia
1. Jigs
There are many different jig designs that are used in the gravity separation process.
Generally, ore ranging in size from 0.5" (0.02 in) to 25" (1.0 in.) is fed as slurry mix to a chamber where mixing is provided by a pulsation plunger or other such mechanism. The feed separates by gravity into layers of equal density inside the jig, with the water overflow and the dense material being drawn off the bottom.
In many cases, more than one jig is used in series to achieve both acceptable recovery and higher concentration.
2. Tables
Shaking tables are an effective means of achieving gravity separation of particles ranging in size from 0.08mm 2.5" in.) in diameter. Basically, these units work by having the ore flow over the tables while suspended in water.
The tables have ridges or riffles which are perpendicular to the water flow and can trap heavy particles which settle out while the lighter ones, which are suspended, flow over the obstacles with the water stream. The heavy particles move along the ridges to the edge of the table where they are collected. Tables may be used to separate materials of minor density differences, and for optimum operation, uniformity of the feed must be maintained.
3. spirals
Humphreys spiral separators can efficiently separate large volumes of material ranging in size from 0 1
2" (0.08 in.) in diameter.
application has been widely used in the processing of heavy sands for ilmenite (FeO.
TiO,) and monazite. This unit consists of a helical conduit of about five turns around a vertical axis. The slurry material flows down the spiral under gravity. The denser materials converge along the inside edge of the spiral where they are withdrawn through a series of ports while the lighter materials flow on through and out.
type of single spiral system can be used to process between 0.5 and 2.4 metric tons of ore per hour. It is also possible to use several such systems in parallel.
USEPA Document
EPA 440/1-82/057. Cod
63

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL. SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Lockheed Aeronautical Systems Company
Department 49-52; Zone 329
Marietta, Georgia 30063
Della A. Ridley, CM, CSP
Safety Engineer Coordinator
Aircrafts
Process Description:
Lockheed paints airplane parts using solvent-based paints in a various colors. Paints may contain chromium, cadmium, or lead pigments. The primary solvent is methyl ethyl ketone.
Painting occurs in controlled and uncontrolled paint booths. Solvent vapors from the controlled booths are collected in charcoal beds and recovered by steam distillation. Paint residues are poured into 55-gallon drums along with paint thinner used to clean paint guns.
1986, Lockheed purchased a Finish Engineering Model 380B Solvent Recovery Still. The still is capable of reclaiming both halogenated and non-halogenated solvents with boiling points ranging from 100 to 320 degrees Fahrenheit. Up to 250 gallons of material can be distilled per shift. The still trichloroethane. In has been dedicated to distillation of relatively clean
1989 Lockheed generated approximately 110 gallons of
1,lJ- l,l,l- trichloroethane (Fool) per week.
Waste Generated:
The painting operation generated 20,960 gallons of waste paint and thinner in 1989. The waste is recycled off-site.
to Reduce Waste:
Lockheed has taken a number of steps to reduce the amount of paint-related wastes.
1. Paint is distributed in small amounts from a controlled storage area. The painter signs a log sheet indicating the amount of paint disbursed.
2. Solvent usage is reduced by high volume, low pressure paint spray guns.
H-1

Lockheed Aeronautical Systems Company
Marietta, Georgia
3.
4.
Solvent losses through evaporation have been reduced by installing funnels with threaded stems and sealing lids onto waste solvent/paint collection drums.
The VOC recovery system reduces evaporative losses of paint solvent.
Recommendations:
The costs and environmental impact of solvent use can be reduced relatively easily by implementing some good housekeeping practices. Other options which require a capital investment, for example on-site distillation units, can be cost effective. Lockheed has demonstrated a commitment to reducing its dependence on organic solvent cleaners, solvent- based coatings, and coatings which contain heavy metal pigments. The recommendations made in this report expand on a number of initiatives in progress at Lockheed. g&&B&@j Waste
B u r c e Reducflpq. The most effective method for reducing solvent waste from painting operations is to convert to water-based coatings. Lockheed is currently using some water- based coatings in their uncontrolled booths. In addition, Lockheed has identified acceptable substitutes for lead-containing paints and coatings. When permissible, lead free paint will be purchased and used.
Another option for paint solvent waste reduction is to convert all spraying units to high volume, low pressure spray guns. Lockheed has already identified and purchased four high- volume, low pressure spray guns
- e m o r e ) . for evaluation. Twenty-four more guns are on order
We recommend that the new spraying units be used for all painting operations.
Good housekeeping practices can reduce material losses through spillage, during material transfer, and through evaporation. Lockheed has implemented a number good housekeeping practices, including supplying threaded funnels with lids for paint transfers; locating paint storage areas
close
possible to all painting process areas; and outfitting paint waste
with tight-fitting lids with sealing gaskets. When cleaning spraying equipment, we recommend that the operators purge the guns with reclaimed solvent (see below). The purged solvent should be directed into an enclosed container, much like the parts washing stations provided by services such
Safety Kleen, and recovered. One reference contains case studies on good housekeeping practices (Automotive Paint Shops).

Lockheed Aeronautical Systems Company
Marietta, Georgia
References:
Jntemal Memorandum; Pollution Prevention Goals for 1991, from J.K. Giles to F.H.
Reed, Lockheed Aeronautical Systems Company, 1 June 1990. s, California Department of Health
Services, January 1987.
Reqcli-. The Finish Engineering Model 380B Solvent Recovery Still is not being utilized to its full capacity. The still is capable of reclaiming up to 250 gallons per shift (roughly
195,000 gallons per year) of either halogenated or nonhalogenated solvents with boiling points ranging from 100 to 320 degrees Fahrenheit. Lockheed produces approximately
21,000 gallons of paint solvent waste per year and 6,000 gallons of l,l,l-trichloroethane waste per year. The still currently is dedicated to recovery of the l,l,l-trichloroethane waste. We recommend that the still be recalibrated to distill the 21,000 gallons/year of paint solvent and thinner waste. The reclaimed solvent could be used as paint thinner or to clean spraying equipment. Recalibrating a distillation unit for this purpose is simple and a u l d easily be performed in-house.
The still operators could be trained to calibrate the still for both solvent wastes. Since the amount of degreasing solvent (l,l,l-trichloroethane) generated is much smaller than paint/solvent waste, the degreasing solvent could be collected and stored in Lockheed's permitted storage area. The still would be used for paint solvent recovery on a daily basis and then recalibrated once a month or quarterly for batch distillation of the degreasing solvent.
For small batches of non-routine solvents which would require recalibration of the still, an inexpensive option is to gravity separate the paint and solvents. This system of removal is relatively easy: the thinner/sludge mixture is allowed to separate under quiescent conditions. The supernatant can be decanted using a drum pump and a float valve to retrieve the surface thinner. Although the reclaimed thinner may not meet military specifications for thinning coatings, it can be used to clean paint equipment.
References:
Carney, Michael, "Solvent Distillation: In-House or Contract?" Industrial Finishing,
March 1990, pp. E-30 to E-31.
"On-Site Solvent Reclamation." Minnesota Technical
Minneapolis, MN: August 1989.
H-3

Lockheed Aeronautical Systems Company
Marietta, Georgia
Y m t e Audit Study : Automot ive Paint Shops, California Department of Health
Services,
1987, p. 33,
~ h l o m e u n e Waste
One option to reduce the l,l,l-trichioroethane waste from degreasing operations is to use alternative degreasing solvents which do not generate a hazardous waste. Lockheed is currently evaluating a list of ten emulsion cleaners and will test the top one or two alternatives in a pilot program ( I n t e c h m Q ) .
Another option is to use alternative cleaning systems, for example a high pressure power washer which uses a detergent containing a rust inhibitor which protects the cleaned parts from corrosion. Another alternative is an ultrasonic cleaner with an aqueous detergent.
The cleanliness achieved with these options were evaluated cleaning with l,l,l-trichloroethane. as equal to or better than
Good housekeeping practices and general maintenance can save a substantial amount of waste. Sealing leaking joints, gaskets, and valves; routine inspection of all containers; and inventory updates each month can reduce environmental releases.
Fteferences:
-am
"1,1,1 Trichioroethane Reduction Alternatives." Minn
(MnTAP1, Minneapolis, MN: 1987.
"Solvent Waste Reduction Alternatives: Things
Can Do Now." Waste Reduct ion
Besource Center For The S e October 1989.
stated in the =ed
section, the degreasing solvent could be distilled in campaigns using the existing distillation unit. Otherwise, a smaller still with a
7,000 gallon/year capacity could be purchased to recover the 6,000 gallons/year of l,l,l- trichloroethane waste. The still can be calibrated to l,l,l-trichloroethane specifications and remain dedicated to its recovery. The estimated installation cost is approximately $11,000; and operating costs would be approximately $300/month.
Efficient use of the current Model 380B still and/or purchase of a new distillation system
save on the purchase of new paint solvent, paint thinners, and cleaning solvents. Also transportation and processing costs for shipment and recycling of the approximately 21,000 gallons of paint solvent waste each year could be reduced dramatically.
-
H-4

Lockheed Aeronautical Systems Company
Marietta, Georgia
The references include a list of vendors and a fact sheet outlining important considerations when purchasing a still. Both references were developed by the Minnesota Technical
Assistance Program.
References:
"Considerations For Selecting a Still for On-Site Recycling." Minnesota Technical
Program (MnTAP), Minneapolis, MN: March 1988.
"On-Site Solvent Recovery,"
. .
1987, p.75. l May
Schmutzer, Michael J., 'The Case For Solvent Recovery." Platine and Surface
December 1986, pp. 10.

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Merck Chemical Manufacturing Division
Merck & Co., Inc.
3517 Radium Springs Road
Albany, Georgia 31708-8301
Mr. Michael D. Slaymaker
Environmental Control Manager
Pharmaceuticals and intermediates
Process Description:
The pharmaceuticals and intermediates manufactured at Merck’s Flint River Plant are produced in “campaigns.” In other words, the manufacturing processes depend on the product. Most of the unit operations required for the campaigns are modular and can be configured for the required reaction sequences. The variability of the processes makes pollution prevention a difficult task if done “after the fact.”
Efforts to Reduce Wastes: a proactive approach to pollution prevention. The company’s Waste
Mmmhation Committee is composed of senior level staff members and other plant personnel who have responsibility and authority for plant departments which produce wastes
Waste
. . . waste minimization projects. The
Committee is charged with managing and coordinating the plant’s overall waste reduction plan. Merck has documented a sincere and successful effort to reduce the company’s wastes. Although Merck‘s initial efforts are directed towards reducing
S A R A
the company’s long range goals extend to all waste streams.
Waste Streams Identifiedfijeet Definition:
Waste streams from manufacturing processes for current and future products. Merck would like to incorporate pollution prevention into new product development and existing manufacturing operations through the use of a computer system designed to estimate the waste generated per unit product.

Merck Chemical Manufacturing Division
Albany, Georgia
Recommendations:
Because the volume and characteristics of wastes generated by Merck are dependant on the product and the unit operations involved in the process, the integration of computer software which simulates Merck's processes
assist in the minimization of wastes generated through modifications of production schemes.
An interactive "user friendly" PC or mainframe-based computer system can be assembled according to Merck's process requirements and can simulate the separate chemical processes related to a specific production campaign. The processs-specific software can then be used to characterize the wastes generated based on reactant characteristics and volume of production. A benefit analysis program scheme is best. can then be used to determine which production
analysis is based on the volume and characteristics of wastes generated and the waste management requirements, with the wastes produced in one particular process scheme compared to another.
~
~
Two options for the development of this type computer software system are:
1. Purchase a complete prefabricated software system which has incorporated modifications to suit Merck's production needs. This option can provide Merck a complete analysis system in a relatively short time. The only drawback is that the system may not suit Merck's exact needs considering the complexity of Merck's modular production systems.
example of this type of pre-fabricated software system is provided by Virginia
Cunningham, Ph.D. of Smith, Kline KK French laboratories. Ms. Cunningham's program source. is based on the approach of prevention or elimination of the pollution
This is accomplished through early identification of the potential wastes produced by chemical processes as well
an evaluation of those waste streams potentially generated.
The first step in Cunningham's process is to plan the individual process steps and estimate a material balance associated with products of the respective processes.
Individual waste streams are then characterized based on the previously set process parameters.
wastes and associated "difficulty factors" are then determined.
These dficulty factors are based on the degree of difficulty related to the treating, recycling, and disposing of the resulting wastes.
The chemical/process engineers can then redesign the individual processes, perform the same material balance functions to attain a minimized waste stream and difficulty
__

Merck Chemical Manufacturing Division
Albany, Georgia factor per unit product. A more detailed description of Ms. Cunningham's software is provided. A similar software program has been developed by George Beetle
Company (Beetle). A copy of the description of this software is enclosed
(cunni-).
2. Purchase a vendor-developed software program for base chemical process simulation and modify the program to simulate Merck's unique process modules. Then develop subprograms which will account for all waste streams (including characteristics) and eventual waste volumes. Additional subprograms can perform benefit analysis on the types of wastes produced compared to the product developed. This system will provide you with better support for your specific needs. However the cost and time spent developing and modifying such a system can be extensive.
example of this base system software is provided by E. I. Du Pont de Nemours
& Co.. It is an interactive process simulation program running in a widely distributed computing environment with a truly "user friendly" interface with the process engineer,
Pont has made extensive use of their proprietary process simulator, the
Chemical Process Evaluation System (CPES). With the use of a VAX type computer
(or with vendor supplied support software used with mini- or micro-computers), there is
limit to the size of a process that can be modelled. These systems provide a very wide spectrum of simulation capabilities for varying process streams linked together in ordered sequence. This newly developed system includes a number of new features which provides a user friendly interface between the process engineer and the computer. Features associated include menus, on-line help for direct user assistance, and access to a physical property data base system.
type of base system integrated with waste characterization, waste summation, and benefit analysis software can provide Merck with a full support system. More detailed descriptions of two base process simulation software systems are provided
(Beut ler. et a 1: Evans. et a 1.).
Dr. Cunningham is working with the environmental staff at Merck's Corporate Headquarters through the Pharmaceutical Manufacturers' Association on a study on environmental assessments for the Food and Drug Administration. She is interested in a possible joint venture with Merck to update the ECAS system. Dr. Cunningham stated that Mr.
Slaymaker of Merck could consult with Merck's corporate environmental manager and then contact her directly at (215) 270-7337.
1-3

Merck Chemical Manufacturing Division
Albany, Georgia
References:
Beetle, George R., “Compiled Project Economic Assessment Software,” letter to Bert
Langley, GA DNR, June 18, 1990.
Beutler,
F.W. Comegys, and P.V.LN. Sarma, “Interactive Process Simulation in a Widely Distributed Computing Environment,“ E.I. DuPont de Nemours & Company,
Inc., AICm Spring National Meeting, New Orleans,
April 6-10,
Cunningham, Virginia L, “Integration of Waste Minimization into New Product
Development,” Smith Kline & French Laboratories, King of Prussia, PA, 1988.
Evans, S.F., M. Fidgett, and IJ. Smith, ‘The Development and Benefits of Plant
Simulators for Waste and Spent Fuel Management,”
Section, Warrington, United Kingdom.

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Monroe Auto Equipment
200 McIntyre Drive
Hartwell, Georgia 30643-4743
Daniel B. Moorhead
Plant Environmental Engineer
Shock absorbers
Process Description:
Monroe Auto plates parts with chromium in an electroplating operation. The process design includes a number of traditional waste reduction technologies: racks designed to drain bath solutions efficiently from the parts; automation to reduce drag-out losses; triple and quintuple counter-current rinse systems with agitation; and evaporators for contaminated rinse water from the final rinsing stage.
are cleaned electrically---unwanted metals plated on the parts are removed with the electric currents run in reverse polarity. Rinse water is collected in a sump and discharged to the chrome wastewater treatment plant. Cleaned parts are etched in sulfuric acid, then rinsed again. The parts are plated in a hexavalent chrome/sulfuric acid plating solution.
After plating, the parts are rinsed in triple counter-current rinse baths equipped with agitators. Rinse water from the first rinsing bath is shunted to an evaporator. Concentrated salts from the evaporator are returned to the plating bath. All other rinse water is discharged to the chrome wastewater treatment plant.
Waste Generated:
The rinse water from this process is treated in a dedicated wastewater treatment plant. The treatment process consists
a wastewater collection system; an equalization system; a chrome reduction system using sodium bisulfite; a neutralization system using sodium hydroxide which generates insoluble chromium hydroxide; a clarification system designed to concentrate
into a sludge, leaving a clear water overflow; and a solids handling system consisting of a sludge holding tank and a filter press, for removing excess water from the sludge.
In 1988 Monroe Auto generated over 397 tons of dewatered electroplating sludge characterized
a
F006 waste.
J- 1

Monroe Auto Equipment
Harhwll, Georgia
to Reduce Waste:
1. In 1982 and 1988 evaporative recovery systems were installed on the chrome plating lines. Approximately 1500 pounds/year of chromium trioxide are recovered with these systems.
1989, anticipated that segregation would result in a reduction of approximately 100 tons per year of electroplating sludge. Problems associated with the evaporators and the capacity of the chrome wastewater treatment system have reduced the effectiveness of this project.
3, The materials group of the corporate office of Monroe Auto is looking for a substitute for chromium plating. This would eliminate all electroplating sludge
(F006).
4.
old plating line will be replaced. This affords an opportunity to incorporate additional waste reduction technologies.
Recommendations:
There are many waste reduction opportunities in traditional chrome electroplating processes.
We have summarized some of the options available and provided references for each concept. Ideally, a new plating line would incorporate most of these options. Some of the recommendations may be incorporated into the existing plating lines. aectroless Nickel
The expense of managing chrome waste is causing chromium platers to consider electroless nickel
an alternative. Electroless nickel is being used more frequently in place of hard chromium for wear resistance. The introduction of high hardness electroless nickel has narrowed the performance difference between electroless nickel and hard chromium plating.
Electroless nickel plating requires a non-cyanide nickel salt solution such as nickel chloride or nickel sulfate. A reducing agent, such as sodium hypophosphate, is required to plate out the nickel, and chelating agents, for example triethanolamine, allow metals to remain in solution beyond normal solubility limits.
Nickel must be removed from the wastewater prior to discharge to the wastewater treatment works or direct discharge to a receiving stream. Calcium chloride is used to break down the
-
_ _
5-2

Monroe Auto Equipment
Hartwell, Georgia metal chelates in the plating solution and increases the amount of wastewater treatment sludge. Typically, caustic is used to produce the insoluble metal hydroxides which result in a wastewater treatment sludge. The wastewater treatment sludges from electroless nickel plating are not regulated as hazardous wastes. The value of the nickel which could be recovered from the sludges makes recycling an attractive alternative to disposal.
The Dow Chemical company recently published a pamphlet on the use of magnesium hydroxide for precipitation, with a special application for the selective removal of nickel from wastewater. Magnesium hydroxide removes everything but nickel, so the more expensive nickel can be precipitated and removed separately. The high concentration of nickel in the sludge makes nickel recovery more efficient.
References:
Bleeks,Tom and ShawhWGary. “New Electroless Nickel Technology as an
Alternative to Hard Chromium Plating,” Metal Finishing, Volume 87, October 1989, pp.21-
27.
Cushnie, George C. Electrodatinv Wastewater Pollution Control Technology, Park
Ridge, New Jersey: Noyes Publications, 1985, pp.227-232.
Sa€ranek,W. H. “Waste Not Want Not,” Plating and Surface Fini s hin g , Volume 74,
November 1987, p.18.
Water
The use of deionized water in place of tap or softened water has potentially the greatest impact and the widest application for the reduction of waste. Deionized water can be used to replace tap water for process bath makeup and rinsing operations. The natural contaminants, such as carbonates and phosphates found in tap water can reduce rinse water efficiency, “ i z e the potential for drag-out recovery, and increase the frequency of process bath dumping. Hard water ions also contribute to sludge volume when removed from wastewater during treatment. Systems are available to generate sufficient volumes of deionized water for rinsing, but rinse water volumes should be reduced due to the high costs associated with the use of deionized water.
References:
Foecke, Terry. “Source Reduction Opportunities in the Plating Industry,”$muos ium
‘ n w Metal Waste Management Atema tives, Toxic Substances Control Division,
5-3

Monroe Auto Equipment
HartweJl, Georgia
California Department of Health Services, Pasadena, CA., 1989, pp.45-55.
Toxic Substances
Control Division, California Department of Health Services, San Francisco, CA., May 1988. p. 21.
-
Cmductiv&h€i Meters
A conductivity or pH meter can be used to control water flow through a rinse system. A conductivity/pH cell is used to measure the level of dissolved solids in rinse water. When
level reaches a preset minimum, the meter activates a valve that shuts off the flow of water into the rinse system. When the concentration builds to the preset maximum level, the probe again activates a valve which then opens to continue the flow of water. Water flows only when needed and only to a set value of contamination, thus reducing the volume of water requiring management or treatment.
References:
"Flow Controls," I l Fi
* hin In y
Toxic Substances
Control Division, California Department of Health Services. San Francisco, CA., May 1988, pp. 35-36.
Lowerins the Conce ntration of Process Bath Co nstituentg
A decrease in the concentration of metal salts and other components of the plating solution directly reduces the amount of hazardous substances dragged out of the bath. The greater the concentration of chemicals in a solution, the greater the viscosity, and the film that adheres to the workpiece is thicker and will not drain back to the process bath as quickly.
In order to determine the lowest process bath concentration that will adequately provide product quality, one may mix a new process bath at a slightly lower concentration than usual and determine if the product is adequately coated. The chemical concentration can continue to be reduced until the quality begins to be affected. Many concentration reductions have been successfully implemented.
References:
"Reduction of Rinsewater Toxicity and Volume," Technical Report :Reducing
, a Califorma s Metal -Bearhe Waste St reams, Toxic Substances Control Division, California
Department of Health Services, Pasadena, CA.,August 1989, 7-11.
__
J-4

Monroe Auto Equipment
Hartwell, Georgia
25% Efficient Solution
A 25% efficient solution appears to have the potential to extend the bath life of the chromium plating solution. A mixed-catalyst bath with supplemental fluoride-free catalysts in addition to sulfate, results in a current efficiency of about 25%, twice that of conventional baths and equal to the efficiency of the older mixed-catalyzed fluoride solutions. With its constant chemistry and operational stability, the 25% efficient solution requires less clean-up and, if properly maintained, the potential for indefinite bath life.
References:
Jones,Allen R. “New in Hard Chromium Plating,” Products Finishing, Volume 53,
NO.7, April 1989, pp.62-69.
“Developments in Chromium Plating,”platine and Surface F inishing, Volume 74, July
1987, pp.29-32.
Chromium
Plating with trivalent chrome rather than hexavalent has been very effective in decorative chrome plathg. Lower metal concentrations, no reduction step, more parts can be placed on a rack, and lower current density are only a few of the advantages offered by trivalent chromium systems. Trivalent Chromium systems are new, but have already shown tremendous potential for the future. As waste management costs continue to rise, the savings that trivalent systems offer will increase markedly. Trivalent chromium processes are receiving substantial amounts of research and attention and in the future
probably be suitable for hard chromium plating as well.
References:
“Plating With Trivalent Chrome,”
Assistance Program, 1988.
MnTAP Fact S heel, Minnesota Technical
Snyder, Donald L “Case for Trivalent Chromium,” Products Finishing, Volume
53,No.ll, August 1989, pp.61-69.
. . .
‘Turn to Trivalent,” Volume 53, No.1, October 1988, pp.72-79.
J-5

Auto Equipment
Hartwell, Georgia
New Chromiu m Reco verv Technolow
ion exchange chromium system processes several chromium rinse streams to remove both trivalent and hexavalent chromium while producing product water suitable for recycling and reuse. The cation and anion regeneration solutions are further processed by an electrodialitic recovery system that concentrates the chromium into reusable fotm. a nonhazardous,
References:
"Chromium Recovery Technology," Metal F inish inz, Volume 88, January 1990, p.27.
~
~
5-6

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company: Union Camp Corporation
Chemical Products Division
P.O. Box 2668
Savannah, Georgia 31402
Contact: Mr. Thomas J. Dillon
Associate General Counsel
Primary Products:
Fatty acids, dimer acids, esters, rosin and rosin derivatives, and high performance polyamide resins and resinates. Terpene products, aroma chemicals, and flavor and fragrance ingredients. Solvents used in gravure inks.
Process Description:
Union Camp sells solvent and tackifiers to ink manufacturers which add pigments. As a service to the gravure ink users, Union Camp accepts solvent recovered from the printing process. The solvent is returned in tank cars to the Savannah facility. If the solvent meets quality requirements, it is reincorporated into subsequent batches of ink solvent.
At one time reaction vessels in the Chemical Products Division pilot plant were cleaned with a toluene and isopropyl alcohol mixture. The vessels now are cleaned in two steps: first with tall oil heads; and then with an aqueous solution.
Waste Generated
1. Until 1989, Union Camp did not receive the recovered ink solvent. The solvent was managed as a hazardous waste by the individual printing companies. Since Union
Camp initiated the recycling process approximately 15 million pounds of ink solvent have been recycled. Occasionally the recovered solvent does not meet quality specifications and cannot be reclaimed with equipment on-site in the Chemical
Products Division. The unusable solvent is blended into a fuel offsite. This new
'baste" is a
fraction of the solvent Union Camp is recovering and will appear as a new hazardous waste stream on the biennial report.
2. The quality control lab and pilot plant generated 92,000 Ibs of a solvent mixture containing xylene, acetone, butanol, methanol, toluene, and pyridine. This solvent waste also is blended into a fuel offsite and burned in a lime kiln.

Union Camp Corporation
Chemical Products Division
Savannah, Georgia
to Reduce Waste:
1.
Camp is providing an essential service to the printing companies. What was once a ”lost” resource is now a valuable product. The small fraction of unusable solvent is beneficially reused as fuel and may be recovered with different distillation equipment.
Camp has investigated the use of off-site solvent recyclers. The practice was rejected due to uncertainties of the recyclers’ feedstocks, recyclers’ QA/QC procedures, and lack of control over the recycled solvents sent back to Union Camp.
Other options will be considered including solvent recovery services.
2.
Camp’s policy is to reduce batch sizes to minimize solvent use. Smaller amounts of chemicals are stored onsite thus reducing losses from spoilage. Toxicity reduction is achieved by substitution of less toxic chemicals whenever possible.
feedstock material used to wash reaction vessels in the pilot plant has been replaced with a two-phase cleaning process. The vessels are cleaned first with tall oil heads. The solvent wash is then returned as feed stock to the tall oil process.
The second phase is an aqueous wash. The wastewater is sent to the on-site wastewater treatment system where it is treated biologically. This change will result in a reduction of 15 tons of solvent waste per year.
Public Relations:
In response to public concern about the environmental impact of Chatham County’s industries, industry representatives, in conjunction with the Chamber of Commerce and the
Chatham County Commission, have formed an Environmental Forum. The Environmental
will be composed of an equal number of representatives from industry, the public, and environmental professionals. The mission is to attain a consensus on issues of concern in the community. Industries will contribute to a trust fund to support third party research into select issues. A facilitator has been selected to assist in group meetings and selection of issues for consideration.
Camp will be an active participant in the Environmental
Forum. -
K-2

Union Camp Corporation
Chemical Products Division
Savannah, Georgia
Recommendations:
Spent
Sol vent
Source Reductio% One way to reduce the solvent waste at the source is to use water-base inks instead of solvent-base inks. Water-base inks can now be used in place of solvent-base inks in the gravure printing industry. We recognize that a change from solvent-base inks to water-base
is not a practical solution for Union Camp since the solvent is Union
Camp’s product. However, Union Camp customers which are having difficulties managing solvents should be encouraged to change to water-base inks. Detailed information regarding water-base inks can be obtained from:
1) Flint
19693
Station N
Atlanta, GA 30325.
2)
California Dept. of Health Services.
Printing
.
California, 1988.
Waste Audit Studv
-
Commercial
Reqcling, The Union Camp Savannah Plant recycled approximately 15 million pounds of printing ink solvent in 1989. Some of the solvent could not be recycled using available on-site equipment. Since the volume of unrecycled solvent is significant and incineration of it is not a preferred management practice, a literature review of available portable and stationary recycling units for special case recycling was performed and is summarized in the following paragraphs.
On-site Sol vent Recoverv Services
The literature review produced two companies which offer on-site solvent recovery services.
These services can recycle 100 gallons of solvent per hour, and in some cases up to 200 gallons per hour. The advantages of such a service are:
Recovery of reusable solvent;
*
Reduction of final waste products; and
Reduced liability as a result of waste transportation.
K-3

Camp Corporation
Chemical Products Division
Savannah, Georgia
Hypothetically, if Union Camp produces 4000 gallons of ”waste” solvent per month, a portable distilling unit would take approximately 40 hours per month to recycle the solvent, assuming 100
5 working days per month or 40 hours of straight processing time per month.
Considerations must be made regarding the liability and logistics of such a process.
Detailed information regarding on-site solvent recovery services can be Qbtained from:
References:
Tabor Environmental Services, Inc.
4455 South pine Street
Spartanburg, South Carolina 29302
~
~-
Solvent Processors and Reclaimers Cop.
3195 Profit Dr.
P.O. Box 9118
Fairfield, OH 45014
(513) 860-1126
March
Carney, Michael, ”Solvent Distillation: In-House or Contract?” In
se Solvent R&I”I
Another option is to install a permanent on-site recovery system which can be adjusted to distill solvents of varying composition and properties. The advantages of the in-house solvent recovery system are the same as stated for portable solvent recovery and also include the internal quality assurance of recovered product. The disadvantages of such a system are the capital investment for the equipment and the allocation of space for the system.
References:
“On-site Solvent Recovery,”+Am encan Machinist and Automated Ma n u
75.
-
August
62.
__
K-4

1)
2)
3)
Union Camp Corporation
Chemical Products Division
Savannah, Georgia
Public Concern a nd Inout
Industry organizations which promote exchange of information between the public and industry can be useful in promoting waste reduction. The Chemical Manufacturer's
Association (CMA) has developed a successful program called "Responsible Care: A Public
Commitment." This program appears to have been a model for the Chatham County
Environmental Forum. CMA is currently developing a management practice code for waste and release reduction and management. This code could be adopted by the Environmental
Forum.
References: ents from the C M
Brochure outlining the guiding principles for Responsible Care.
Summary description of Responsible Care program elements, April 1990.
4)
5 )
Questions and answers about Responsible Care, April 1990.
"CAER Community Awareness & Emergency Response
Protecting the Community."
. . .
Informing and
"Community Awareness and Emergency Response: Title additional CMA publications and audio-visual materials.
order form for
We have also included a bibliography of articles on risk communication. If you would like complete copies of any of these articles, please contact us at any time.
article, "Making the Difference: Using the Right-to-Know in the Fight Against Toxics," should provide insight into how environmental activists are using right-to-know data.
K-5

Company:
GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Davidson Exterior Trim
-
Textron
Route 6, P.O. Box 10
Americus, GA 31709
Contact: Mr. David R. Green
Director, Environmental Affairs
Fascia, trim, and grills for automobiles Primary Products:
Project Scope
The scope of this project includes the following two areas identified by Davidson Exterior
personnel as pollution prevention opportunities:
1. Reduction of the volume of solid waste generated and disposed of in the county landfill. Off-spec plastic fascia, flash, and trimmings as well as cardboard makeup a large percentage of Davidson’s solid waste stream. The plastic components consist of approximately 40% of Davidson’s solid waste stream, while cardboard is approximately 25% of solid waste generated.
2. Reduction of Methyl Ethyl Ketone (MEK) usage in Davidson’s painting operations. MEK is used as a flush and cleanup solvent in each paint booth.
Efforts to Reduce Waste
Davidson Exterior Trim utilizes robotic paint booths and booths with high speed electrostatic bells which add to the efficiency of their painting operations and reduction in the amount of paint waste. They also use a dump valve system that recovers a portion of the purge solvent between color changes.
Repair of all off-spec fascia is attempted in a dedicated repair department. Fascia which has been repaired is returned to the process whereas non-repairable fascia is discarded for land disposal.
Davidson contracts a mobile distillation company to distill used MEK onsite. Davidson then reuses the reclaimed
A Solid Waste Committee has been formed to generate ideas on landfill alternatives to
Davidson’s solid waste. A program is being initiated to send all corrugated cardboard to offsite recycling in lieu of land disposal.
L- I

Davidson Exterior Trim
-
Textron
Americus, Georgia h e s s Description
Davidson manufactures flexible automotive fascia utilizing a Reaction Injection Molding
pIastic molding process based primarily on polyurethane technology. The fascia are shipped to OEM manufacturers throughout the country and much of the scheduling conforms to "Just in Time" inventory requirements characteristic of the automotive industry.
coatings used are solvent base one component, thermoset types, including elastomeric polyurethanes. Conductive primer is used to enhance electrostatic application of succeeding base coats and clears. Applied VOC's are at approximately 5.6 lbs/gallon for primers and
4.5 lbs/gallon for base coat/clears.
Much of the coatings technology is driven by the requirements of OEM manufacturers who specify what is wanted and what is compatible with finished OEM production. The impetus for future low solvent technology improvements will probably originate from the same source. It appears that future use of water borne coats could be feasible but this brings about a change in appearance that would have to be compatible with the finished original equipment. The change would also be of some magnitude for revision of application equipment, etc. Powder coating does not seem to be feasible because of substrate temperature constraints.
Davidson uses 60-80 base coat colors. Of these, 20 colors are in separate lines from mix room to the booths. Approximately eight of these lines are changed daily for color. There can be 150-200 automatic color changes, back and forth amongst the line colors, at each base coat booth per day. There are a lesser number of material changes for primers and clears.
Because of time constraints most of the GTRI survey addressed application of base coat/ clears with primary emphasis on the manual spray booth for base coats. Minimal time was spent at prime booths and the older, manual finishing line.
On the automated line, base coat is applied in three booths as follows:
Booth 1
Overhead reciprocating high speed electrostatic bells
Side mounted high speed electrostatic bells
Side bells are used for fewer applications because of part configuration
Booth 2
Two robotic electrostatic REA guns
L-2

Davidson Exterior Trim
-
Textron
Americus, Georgia
Booth 3
Four conventional Binks model #62 air spray guns
Color change sequence programs quite effectively cycle liquids through manifolds at the automatic booths for optimum use of coating materials and rinse solvents.
Approximately 90 gallons of MEK are required to flush a line for a complete line color change. All but 3 gallons of this is recovered. For automatic booth color changes there are dump valves for recovery of MEK from each line flush at the electrostatic bell and robotic gun stations. There is some non-recoverable loss from solvent flushing the portion of the line from dump valves through each bell or robotic gun.
In the #1 Base Coat Booth approximately 182 lbs/day of MEK and paint solvent are non- recoverable or exhausted from the stack. In the #2 Base Coat Booth approximately 117 lbs/day are non-recoverable. For all of the prime/base coat/clear automated booths and total line flushes the non-recoverable loss is approximately 616 lbs/day of wash solvent.
T h i s data had been calculated by Davidson for a day with 155 base coat color changes. The material cost of coating waste and non-recoverable wash solvent in this example was calculated ai $3,023. Figures were not available for the four guns in the manual booth and this can vary since individual spray operators clean the guns.
Collection of final clean-up solvent through the robotic guns has been attempted but has not been successful to date because the last purge through the nozzle is made up of the new color which dries and eventually clogs the collection funnel.
The average daily use of MEK is 7,000 lbs. The recovered MEK wash solvent is reclaimed on site by an outside contractor. About 70% of all recovered MEK wash solvent is reclaimed to 95% purity and blended with new MEK for reuse.
The #3 Manual Base Coat Booth is designed to supply a lesser part of the total film thickness and its purpose is to finish off the desired pattern or appearance. It is reported that electrostatic or
guns cannot be used here because they give undesirable texture or pattern control of metallics. There are as many color changes here, 150-200/day, as there are in the #1 Booth. Colors lines are changed at the manual booth with the use of snap on gun fittings which minimize paint waste. A procedure for collecting MEK wash from these guns is reportedly established but it did not seem to be in practice during our visit.
The spray operators were cleaning these guns by spraying MEK into the water curtain.
G3

Davidson Exterior Trim
-
Textron
Georgia
RECOMMENDATIONS
Usage
Color C h a n w
It
apparent that numerous, frequent color changes represent increased paint waste and increased solvent usage for cleaning application equipment. This has both a cost and environmental impact. Separate production runs of the same colors were observed which
have had to do with the busy pace of 1992 model change overs. Those in a position to optimize the length of these color rum are aware of this double impact, and should continue efforts to minimize color changes.
J a l u u d J
- _ - in the manual booth should be recovered and reclaimed as planned. With a ready method of turning off the atomizing air, spray operators shsuld be able to divert this solvent to a collection system.
If a combined purge of air/solvent is needed, something like a DeVilbiss/Ransburg hose/gun cleaner could be used. These are available in 2-15 gallon sizes.
The following equipment offers a very positive method of thorough spray gun cleaning:
Graco Pro Gun Washer
Herkules GWNR Washer
Safety-Kleen Corporation
These washers are completely enclosed systems with air driven pumps for recirculating solvent through the guns in a cycle of 30-60 seconds. Solvent is recycled back to a self-contained fluid chamber, Small parts can be cleaned in this unit. The exterior of the gun would also be sprayed with solvent.
sc-vent collection containers should be kept closed when not in use.
The solvent cleaning containers in the manual booth should be kept closed when not in use.
This could be addressed with small cleaning tanks which have hinged, fuze link lids. x
It obotic Gun Cleaning is recommended that efforts be renewed to collect the final solvent purge through the robotic guns, whether that be by the use of larger funnels, cleaning and/or redesigned funnels, adjustment of robotic programs, etc. Recovery of this type is reported to be in practice in the automotive industry.
-
-
G 4

Davidson Exterior Trim
-
Textron
Americus, Georgia
A 3' trough could be constructed and placed near the robotic arm. As a color change occurs, paint can be discharged just before the trough. Following the old paint discharge,
could then be discharged along the trough, spanning its length. Then just after the gun reaches the end of the trough the new paint could be discharged. The bottom of the trough can be constructed on an incline so the solvent can easily be shunted to a collection sump. The collection system should be designed to minimize solvent exposure to the open
The robots would be reprogrammed to discharge the old paint, MEK, and the new paint in sequence as the gun spans the trough (see Figure 1 on page 6).
Another option is to consider a solvent wash collection system similar to that developed by
Haden-Schweitzer Corporation. This type of system is routinely used in the automotive industry. Contact: Haden-Schweitzer Corporation
Andrew Slater
32200 North Avis Drive
Madison Heights, MI 48071
(313) 583-1900 fiture Tech nology
The automotive industry has extensive ongoing efforts to utilize alternative, low solvent coatings; it is recommended that lower solvent coatings technology continue to be pursued, including water base, higher solids etc., as it might become mutually applicable and compatible with OEM production.
Solid Waste Disposal Options
Davidson Exterior Trim generates approximately 1,285 tons of solid waste which goes to the county landfill. Approximately 40% of this solid waste is plastic waste consisting of off-spec, non-reusable fascia and flash generated from the molding process. The next largest waste constituent is cardboard boxes (25% of solid waste generated) used to transport different components.
Solid Waste S
A program to segregate solid waste at the production level will assist in decreasing the amount of solid waste which is sent to the landfill. This can be achieved by placing dedicated containers for cardboard and possibly plastic wastes in locations where these waste are generated. A site survey can be conducted to determine where the wastes are generated and where the most accessible location would be to position recycle containers for convenient disposal. The containers can be retrieved routinely for offsite disposition. A formal training program could be initiated to encourage segregation of the waste stream.
It has been GTRI's experience that the more the employees know about programs such as this, the more enthused thus more successful these programs become.

Davidson Exterior Trim
-
Textron
Americus, Georgia
Old
Paint
Pigure L-

Davidson Exterior Trim
-
Textron
Americus, Georgia
Corrueated Ca rdboard Waste
Since Davidson currently plans to recyc.- corrugated, GTRI did not perform a study on this waste stream. However, additional recycling centers in the Americus area, which accept corrugated waste, are provided.
and Off-spec F a s h
Due
the high BTU-value (12,000 to 14,000 BTU/Ib as determined by Dow Chemical
Company, Freeport,
of the fascia, flash and other plastic waste generated at
Davidson, cogeneration is a attractive alternative to land disposal. There exist companies/brokers who are dedicated to purchasing industries' high energy content solid waste and in-turn selling it to companies that have cogeneration facilities. A company called
ECON Corporation has been contacted for this purpose and is in receipt of a sample of
Davidson's facia waste. If
Corporation is interested in this waste, Davidson could benefit by segregating the off-spec, non-reusable facia, flash, and other plastic waste for shipment to an arranged location. See ECON Corporation contact in the appendix.

Davidson Exterior Trim
-
Textron
Americus, Georgia
Project Appendix
The following are two suppliers of paint sprayer solvent wash systems. Information on some of these systems is inclosed.
Herkules Equipment Corporation
8230 Goldie St.
Walled Lake, MI 48088-1298
(313) 363-8882
Safety-Kleen Corporation
1750-T Birchwood Ave.
Des Plains, IL 60018-3066
(708) 299-4060
Gram Pro Gun Washer
P.O. Box 1441
Minneapolis, MN 55440
(800) 367-4023
Recycling Centers in close proximity to Americus.
Albany
Consolidated Recycling
1178 East Board Avenue
Albany, GA 31705
(912) 888-3446
Macon
Macon Iron & Paper Stock Co.
344 Oak Street
Macon, GA 31201
(912) 745-9817
Columbus
Columbus Recycling, Inc
756 Lindsey
Columbus, GA 30906
(404) 323-6306
Solid Waste Broker
ECON Corporation
1 Willowpoint Road
Alexander City, AL 35010
(205) 234-4721
Contact: Jerry Scott
L8

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE
TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company: Douglas & Lomason
540 Alabama Street
Carrollton, GA 30117
Contact:
Reid
Employee Involvement Facilitator and Director of
Environmental Activities
Products: Interior and Exterior Decorative Trim parts mainly for the
Automotive Industry
Wastes Generated
1. Waste water treatment sludge
2. Waste oil
3. Solvents/paint sludge from the stripping operation
Anodizing process waste such as rinse overflow and batch dumps 4.
5. Dry filter paper from paint spraying booths
6. Dirty cleaner/rust inhibitor solution used to clean steel parts
The total amount of waste has decreased due to a decrease in production. The plant no looger manufactures aluminum bumpers except for a few replacement parts. The production of these bumpers was a significant source of oil waste. The use of solvents has also decreased since most of the painting operations have been eliminated and waterbased or alternative coatings have been introduced over the last three years.
An average of 20 cubic yards of non-hazardous waste water treatment sludge is sent to the landfill weekly. Approximately 250 gallons/week of treated used oil are sent off-site for reuse by an outside company. The use of solvents for stripping decreased from nearly 300 35 gallons per month. The on site waste water treatment facility treats 200,000 gallons/day of waste water from the anodizing and buffing processes. An 800 gallon tank of cleaner/rust inhibitor is emptied every day.
In 1988, Douglas & Lomason received an award for outstanding operation of an individual water pollution control facility which was awarded by the Georgia Water
& Pollution Control Association. M-l

Douglas & Lomason
Carrollton, Georgia
~~
Process Description
Douglas & Lomason manufactures a wide variety of products depending on customer needs. These products have diverse specifications and require different production steps. The main steps observed were:
Stamping
Welding
Assembling
Buffing
Anodizing
Painting
Application of Rust Inhibitor
Parts are fabricated from steel, aluminum, and brass. They are individually stamped by mechanically powered presses. On certain parts depending on the shape of the draw, a polypropylene film is used instead of using oil to lubricate the part to protect against marring. One of Douglas & Lomason’s products is a steel seat pan which requires a minimum corrosion protection. This is accomplished by washing with a cleaning solution that removes oil and applies a rust inhibitor.
Those parts that require welding to complete a subassembly are sent to the welding area where component parts are welded together. Weld-nuts and springs are applied to the seat pan to complete the subassembly at another location. Parts that require buffig receive this operation first, otherwise they are sent to the anodizing line directly. Parts being anodized go through a variety of tanks: alkaline cleaning, acid cleaning, bright dip, anodizing, preseal, seal, and various rinses. The time required in each tank depends on the nature of the bath and the type of part being anodized.
Once anodizing is complete and parts pass quality control tests, parts are either shipped directly, assembled and/or painted. The painting is accomplished by using manual spray guns and, in some cases, an automatic sprayer. They are then inspected and placed in reusable containers or cardboard boxes for shipment to the customer.
Those that do not pass the quality control tests have to be reworked. Defective paint requires stripping the paint completely with methyl ethyl ketone and/or toluene.
This paint stripping is done by hand in an isolated area in the plant. The parts that require reanodizing are stripped and reanodized through the original process.
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M-2

FACILITY L A Y O U T
I r l
1
I BUFFING
-
W A S E
TREATMENT
1 I I I I
I
WASTE WATER TREATMENT
M-3
I

_ _
I
ANODIZING PROCESS
,
RINSE
-
I
CAUSTIC SODA ZINC PURIFIER
1
M 4

CHROMIC SEAL
I
PHOSPHATE
CITY WATER
RINSE
10% NITRIC ACID
CAUSTIC SODA
ZINC PURIFIER
CITY WATER
RINSE
1
I
~~
POTASSIUM
HYDROXIDE
CITY WATER
RINSE
CITY WATER
RINSE
I
4 LK 411 N E WATER
CITY WATER
RINSE
PICKLE TANK
I
,

Douglas & Lomason
Carrollton, Georgia
Occasionally some parts are phosphated. The phosphate line is also used for cleaning aluminum extrusions. These extruded parts are sent out for coating.
Efforts to Reduce Waste
Disposal of excessive waste oil became a problem. One possible solution would be to send it off-site for incineration at a significant charge to the plant. However, the plant has discovered and implemented a process to separate this waste oil from the waste water and rendered it desirable for waste exchange at no cost to the plant except the cost of treatment.
2.
4.
Phosphoric acid solution recovered from the anodizing process is sent to another division that utilizes it to produce Trisodium Phosphate (TSP) cleaner.
One of the products, the steel seat pan, did not need paint except for rust prevention.
The painting process and its associated wastes and hazards were eliminated by simply applying a water-soluble rust inhibitor.
A hot wax system was implemented for mask preparation. Masks are used to allow painting of certain specified areas on parts and to shield the paint from the surrounding area of the part. After extended use, these masks become coated with a buildup of paint and require cleaning. The hot wax is applied to a mask before it is used so that the excessive paint buildup can easily be removed by mechanical stripping. This method eliminates the excessive use of solvents such as methyl ethyl ketone and toluene.
5. The minimal amount of solvent used in the mask cleaning area is solvent that has been previously used in the paint stripping operation.
6.
8.
9.
Counter-current rinsing is used wherever possible in the anodizing process.
Nickel is recovered from the black anodizing process and is reused.
Efforts are being made with plant customers to replace cardboard boxes for shipping with reusable containers.
Efforts are being made to use returnable drums.
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M-6

Douglas & Lomason
Carrollton, Georgia
Detailed Information on Oil Treatment
The waste oil is generated from the buffing operation. The solution used in this operation is approximately 99% H 2 0 and 1% Oil. This solution, once it has been used, is collected in a skimming tank. The oil is skimmed and sent to a cooking tank. The mixture in this cooking tank is 50%
and 50% Oil when the treatment begins.
The first step is to add dry sodium hydroxide solution which reacts with the metallic aluminum, converting it to aluminum hydroxide that goes into the water phase. Thus the oil is free of any metallic particles.
The second step is to decrease the pH of the mixture to the 3.0-3.5 range by adding spent sulfuric acid. After the addition, the mixture is cooked for 24 hours at 19OOF.
The mixture then sets for a minimum of 24 hours. The water is drained out from the bottom of the tank and is sent to the waste water treatment system. The oil is shipped off-site where it is further treated and blended for use as fuel. See Appendix for waste oil experiment performed at the Georgia Tech Research Institute.
Recommendations
Source Reduction
Conductivity/pH Meters
A conductivity or pH meter can be used to control water flow through a rinse system depending upon the nature of the bath involved. A conductivity cell is used to measure the level of dissolved solids in rinse water. pH may be an indication of the contamination level as well. When the concentration builds to the preset maximum level, the probe activates a valve which introduces fresh water into the rinse system. When this level reaches a preset minimum, the meter activates a valve that shuts off the flow of water into the rinse system. Clean water is used only when needed and only to a set value of contamination, thus reducing the volume of water requiring management or treatment.
M-7

Douglas & Lomason
Carrollton, Georgia
~~
Lowering the Concentration of Process Bath Constituents
A decrease in the concentration of metal salts and other components of the plating solution directly reduces the amount of hazardous substances dragged out of the bath. In order to determine the lowest process bath concentration that will adequately provide product quality, experiments should be
with baths at slightly lower concentrations than usual and it should be determined if the product is adequately coated. The chemical concentration can continue to be reduced until just before the quality begins to be affected. Many concentration reductions have been successfully implemented.
Decals in Place of Paint
The customer may be contacted to determine the feasibility of using decals rather than paint for some of the parts. The use of decals would eliminate the need to use toxic substances such as methyl ethyl ketone and toluene for painting and subsequent cleaning of masks and application equipment.
In Process Quality Control
The electrical conductivity of all racks should be tested to avoid incomplete anodizing and eliminate the wastes associated with reanodizing. Clamps should be checked periodically to determine their capability for reuse.
Change 5n Paint Stripping Procedures or Equipment
It is recommended that two solvent tanks be made available: the one in use presently and a smaller one for smaller parts. In this manner less solvent surface area is exposed. This would decease the amount of solvent necessary.
The use of an air driven rotating brush just inside the container should be considered to eliminate the necessity of extensive brushing by hand. This would decrease employee exposures as well as VOC emissions.
Recycling/Reuse
Reuse of Waste Oil
The recovered oil should be checked against specifications of the original oil.
If these specifications are met and care is taken not to drag out part of the
-
M-8

Douglas & Lomason
Carrollton, Georgia water phase, efforts could be made to reuse the oil in-house. If further precautions are necessary to avoid any other foreign particles, filtration may also be conducted.
Treatment
Sludge Dewatering
A filter press can typically increase solids content 35 percent. Sludge can be further dewatered by using sludge dryers. Typically, a sludge dryer can increase the solids content of the sludge to 85 or 95 percent. Enclosed is information on different types of dryers available.
Several types of sludge dewatering units are available. A unit designed to handle approximately 20 gallons of sludge per load that uses an electrical heating unit would cost approximately $10,000. These types of units are energy intensive and can cost approximately $6.00 per load to operate. Other units are available that use steam as the heat source. A dryer of this type designed to handle approximately
However, a
15 gallons of sludge would cost steam source would also be required. A
$9,000. steam generator designed for this application would cost approximately $4,000. These units are less energy intensive, however. The electrical costs to operate the dryer are approximately $0.50 per load not including the cost of the steam.
Evaluations by consulting engineers are recommended before proceeding with purchase of drying systems.
Two samples of filter cake were analyzed for solids content. The results indicate the one marked Non-BOD had an average of 70% solids. The ones marked BOD averaged 72%.
If the filter cake remains at the 70-72% range the sludge dryer might not be economically justifiable to install. If the filter cake solid content varies significantly from the 70% range due to press malfunctions, it is suggested that more and proper attention be given to the maintenance of the machine.
Proper scheduling of maintenance might be appropriate. This should be discussed with your filter press supplier. If maintenance is excessive to the point that it hinders consistent sludge dewatering, a stand-by filter press could be considered.
an alternative to a stand-by filter press, a small dryer for occasional problems while the filter press is undergoing maintenance might be worthwhile.
M-9

Douglas & Lomason
Canollton, Georgia
Bibliography
"Reduction of Rinsewater Toxicity and Volume". Technical Report: Reduc ing
California's Metal-Bearing Waste Streams. Toxic Substances Control Division,
-
California Department of Health Services. Pasadena, CA. August 1989,7-11.
"Flow Controls". Waste Audit Studv:Metal Finishing Industry. Toxic
Substances Control Division. California Department of Health Services. San
Francisco, CA. May 1988. pp. 35-36.
"Wood Fuel Drying". Wood Fuels Supulv and Processing Methods. Atlanta,
GA Geornia Institute of Technology Engineering Experiment Station.
December 1981. pp. 1-37.
~
M-10

Douglas & Lomason
Carrollton, Georgia
Project Appendix-Waste Oil Treatment Experiment
Introduction
A sample of the waste oil/water mixture from the Douglas & Lomason waste water treatment facility was taken to the Georgia Tech Research Institute laboratory for study.
The sample had been prepared as if it were to be cooked at the plant.
Procedure
Samples were prepared by pouring 200ml of the oil/water mixture into four 200ml beakers.
(a height of 2 314 in.).
Sample 1:
Sample 2:
Beaker at a room temperature of 73°F
Sample 3:
Beaker in oven at 150°F for 24 hours
Beaker in oven at 190°F for 24 hours
Sample 4: Beaker in oven at 210'F for 24 hours
All samples were observed every hour for the first six hours of cooking, after 24 hours of cooking, and 24 hours cooling.
Measurements were taken by determining the amount of oil that separated from the oil/water mixture (in inches). All observations are on a comparative basis rather than an absolute.
Observations a
Hours
After 24 Hours
After 48 Hours
After 72 Hours
Amount ( in inches)
0
1/16
118 nothing
Comments slight oil separation slight oil separation
M-11

Douglas & Lomason
Carrollton, Georgia
Sample 2
1
- in oven
Hours
2
- in oven
3
- in oven
4
- in oven
5
- in oven
6
- in oven
After 24 hours
After 48 hours
After 72 hours
Sample 3
1
-
2
- in oven
- in oven
Hours
3
4
- in oven
- in oven
5
- in oven
6
- in oven
After 24 hours
After 48 hours
After 72 hours
0
I
1/32
Amount ( in inches)
I
1/8
I
1/8
I
114
5/16
11 /32
11/32
Comments
No oil
- slight bubbles
I oil layer appears
I sharp split oil layer sharp split oil layer sharp split oil layer sharp split oil layer sharp split oil layer sharp split oil laver no change from 48 hrs
Amount (in inches)
1/16
13/32
118
3/16
114
5/16
1518
314
314
Comments sham s d i t sharp split sharp split sharp split sharp split sharp split cooling increases seDara. no change from 48 hrs
M-€2
It
II

& Lomason
Carrollton, Georgia
Sample 4
After 1 no change from 48 hrs.
Conclusions
Based on the laboratory tests at room temperature, 150°F, 190°F and 21OoF, of separation and the amount of separation both increase as temperature increases. This is based on 200ml samples and results should be verified with larger batches before attempting to run the 500 gallon batch. If verification is obtained, cooking the mixture at 210°F Gust below the boiling point of water) could increase the separation by approximately 15-20 percent.
It was also noted that maximum separation occurred after the sample had been cooled to room temperature.
The oil separation appeared complete with no visible trace of water in the oil phase except at the immediate interface of the oil and water. An attempt to check the pH of the oil was made but since there was no water present, this could not be done.
The following charts show how the rate and amount of separation vary with time.
M-13

8 Lomason
Ceorgia
-
0
@ 4
0 3
0 2
0 1
0 t
I f I
SAMPLES TESTED
AFTER 24
--
D
C
D
0 3
0 2
0 1
0
SAMPLES TESTED
M-14

0 w a w
>
0
U w a d
0
1 .
O S
0 8
0 7
0 6
0 5
0 4
HOURS
D
C
B
SAMPLES TESTED
Tested Samples r
A
Description
(73OF)
I
2OOml
210°F

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company: Engineered Fabrics
669 Goodyear Street
Rockmart, GA 30153
Contact:
Primary Products:
Bill Ritter
Industrial Hygiene Safety and Environmental Engineer
Aircraft Fuel Tanks
Wastes Generated
1. Solvent based polymeric materials (adhesives)
2. Waste solvent from degreasing operation
3. Paint spray booth filters
4.
5.
Fabric trimmings and polyethylene carrier
Used plaster and cardboard forms
The above wastes are generated from the construction of fabric fuel tanks. This accounts for 80 percent of the total waste generated by Engineered Fabrics. The remaining 20 percent are from other manufacturing processes which do not generate a significant amount of hazardous waste.
Process Description
Engineered Fabrics manufactures a wide variety of fabric fuel tanks for use mainly in the aircraft industry. The main reasons for using fabric in the construction of these tanks are durability and shape requirements imposed by aircraft design.
The construction process involves first obtaining the fuel tank dimensions and shape and feeding that information to a cutting device which then cuts the cardboard into the appropriate sizes. These cardboard pieces are then assembled to make the desired tank building form. Plaster forms are also used in construction process.
These are built using fiberglass forms.
The assembled cardboard form is then suspended by a hoist to allow for access to all sides of the cardboard form. The cardboard form is then sprayed with a spray
N- 1

Plaster Forms Cardboard Forms
I
Spray Release
I
Plaster/Cardboard
Stnpped Out
Parts Cleaned.
Reworked, and Finalized
N-2

Engineered Fabrics Corporation
Rockmart, Georgia release so that the cardboard form can be removed from the tank without damaging it once construction is complete.
The fabric tank is then constructed on top of the cardboard/plaster form using pieces of fabric attached together with a solvent based adhesive. The adhesive is applied to the fabric by hand.
The constructed tank is then either air cured or autoclave cured depending on the type of tank being constructed and its intended purpose.
After the curing process is completed, the form is stripped out from the inside of the tank. The tank is then cleaned and reworked and tested to insure integrity. Once integrity of the tank is confirmed the tank is ready to be shipped.
Efforts to Reduce Waste
Reduced the usage of methyl ethyl ketone, toluene, and xylene barrier formulations by going to alcohol/water base where possible.
A distillation unit was installed to reclaim and reuse wash solvent.
"Empty" drums are sent to a reclaimer.
Removed all underground tanks and all above ground tanks are in spill containment dikes.
Water is recirculated and therefore only 50 percent is discharged.
For some products, the plant is switching to reverse build to eliminate the need for and wastes generated by plaster or cardboard forms.
A state-of-the art Gerber cutter was installed and reduced waste from trimming.
The company has been looking at water-based materials, but have not found a workable product that meets specifications required by the U.S. Department of
Defense.
Electrostatic spraying was investigated but is products manufactured. not appropriate for the types of
Statistical Process Control has been implemented which minimizes quality control problems as well as waste.
N-3

Engineered Fabrics Corporation
Rockmart, Georgia
A monitoring program regarding the quality of the trichloroethane in their vapor degreaser has been implemented and has increased the useful life of the solvent by a factor of 2.
The company has investigated the use of a computerized spraying/coating operation, but it was not practical due to production scheduling.
A continuing effort is being made to reduce emissions from the various types of containers used in the glue application process.
Recommendations
Source Reduction
Reduce Solvent Emissions &om Vapor Degreaser
Degreasers with 45% freeboard will have about 40% more solvent emissions than ones with 75% Freeboard when both are idling and open. Degreasers with 75% freeboard will have about 15% more solvent emissions than one's with 100% freeboard.
% Freeboard = fTou of the cooline coils to the lip distance) X
Width (short dimension) of the degreaser mouth lOQ
The freeboard-to-width ratio should be at least 1.0.
For the degreaser at Engineered Fabrics the freeboard-to-width ratio is:
% Freeboard = 12"*(100)/36" = 33.3%
The freeboard-to-width ratio is 0.33
This value is well below the recommended value of 1.
The freeboard extension required to achieve a ratio of 1 is:
(12"
+
24")/36" = 1 An extension of 24" would meet optimum freeboard.
The follqwing companies specialize in increasing freeboard:
Delong Equipment Co. Ultronix
Dept. 2-A
1216 Zonolite Rd.
Atlanta, GA 30306
1423 Mayer Rd.
Ultra-Kool
Box 458
Telford, PA 18969 500 County Line Rd.
(800) 553-7881 Gilbertsville, PA 19525
(800) 548-8233 (215) 367-2019
N-4
~ _ _
~

Engineered Fabrics Corporation
Rockmart, Georgia
Freeboard cooling coils are a second set of cooling coils placed in the freeboard zone below the lip of the unit. They will decrease the diffusion rate since they will keep the solvent vapors cold and heavy for a longer time.
Freeboard chillers also create a cold, dense air blanket above the vapor zone which is less susceptible to the effect of drafts. A disadvantage is the fact that freeboard chillers dehumidify the air blanket. T h i s additional water can overwhelm standard water separators, which can lead to acidification of the solvent, which in turn can lead to equipment damage and high waste disposal costs. Make sure your separator is adequate to the task.
One of the most serious causes of excess loss is draft. Any air movement in the degreaser vicinity creates vapor turbulence. Look for open windows and doors ventilation fans and space heaters, air conditioners,, even drafts caused by paint spray booths of roof exhaust. Over ventilation through the slot exhaust of the degreaser is a common problem. Reducing this ventilation to proper rates can decrease vapor loss.
"Wet looking" parts withdrawn from a degreaser can result in 150% more solvent emissions than withdrawing dry parts. Leave parts in the vapor zone
(below cooling coils) at least until there are no drops visible. Dripping wet parts indicate that the temperature of the parts is considerably below the vapor temperature. Thus the rinshg effect of the vapor degreaser may not be fully utilized.
N-5

Engineered Fabrics Corporation
Rockmart, Georgia
Withdrawing parts from the degreaser unit directly from a hold in the vapor zone can result in 60% more emissions than if the parts are held in the freeboard zone just above the cooling coils, for a short time. Leave parts in the vapor zone (below cooling coils) at least until all dripping from parts stops until all parts are completely dry. If time allows, lengthen the hold in the vapor zone.
Position parts so draining is promoted and liquid hold up is minimized.
Minimize the surface area, weight and heat capacity of the fixture or basket to reduce drag-out caused by the parts holder.
1,1,1
-
Trichloroethane Reduction Alternatives
An alternative to the solvent based cleaning system is the non-hazardous aqueous based system. This type of system utilizes proprietary detergents in an agitation cleaning system which can clean a wide range of items.
According to the manufactures of such cleaning systems, the dirt removal is equal to that of the solvent based units. Aqueous based system suppliers will in most cases demonstrate their system on your dirty items.
The following table contains a list of the different types of parts cleaning equipment available and an approximate price.
~ _ _
~
N-6 cleaned separately.
It would work well for parts with man)

Engineered Fabrics Corporation
Rockmart, Georgia
Ultra-sonic
Cleaner
$200- Ultrasonic
3,500 vibration
$7,300 Lift oscillating mechanism
$10,300- Jet stream agitation 440-750 lbs s 13,995 and lift oscillating mechanism up to 50 lbs Excellent Works very well for smaller parts but it is difficult tc use on large parts.
1000 Ibs 4verage
3ood
Air operated lift.
Long cleaning cycles are required
Large capacity.
Tested only small demo-model. A larger system would probably perform even better.
$2,200-
10,100
Jet stream agitation 125-700 lbs and lift oscillating mechanism
$2,595- Lift oscillating
15,675 mechanism
$3,074 Lift oscillating mechanism
50-2000 1bS
150 lbs
3ood
4verage
4verage
Vot rested
Economically a good value. It would work very well on long time cycles.
Electric motor operated lift. Lon, cleaning cycles are required. Large capacity.
Air operated lift.
Long cleaning cycles are required
It would probably do the job but the
Turbo-LiftKleen is a better value.
N-7

Engineered Fabrics Corporation
Rockmart, Georgia cans. Lessens
The following manufactures supply these products:
Graymills Corporation
3705 North Lincoln Ave.
Chicago, IL 60613
(312) 248-6825
Local Sales Rep:
ADF Systems, LTD.
1103 16th Ave. North
P.O.Box 278
Humbolt,
50548
Power Washer
Sydney Roland
Tempest, Turbo-LiftKleen, Turbo-Clean-0-Matic
ManGill Chemical
Magnus Division
23OOO St. Clair Avenue
Cleveland, OH 44117
(800) 627-6422
Miji-Lif, Magna-Lif
Sonicor
1365 Marconi Blvd.
Copiague,
11726
Bowden Industries, Inc.
7540 Memorial Parkway
Huntsville,
35802
(800)
Contact: Michael Hunt
Turbo Parts Washer
Ultrasonic Cleaner
Justrite Manufacturing Company
2454 Dempster Street
Des Plaines, IL 60016
Plunger Can, Dip Tanks
Kleer-flo
15151 Technology Drive
Eden Prarie, MN 55344
Spraymaster, Powermaster
N-8

Engineered Fabrics Corporation
Rockmart, Georgia
High Volume, Low Pressure Finishing Systems
HVLP systems, which are among the most economical commercial finish sprayers available, provide higher transfer efficiency than any other spray system in use today. These sprayers routinely deliver up to 80% of the finishing material to the object being coated; by contrast, typical compressed-
systems do no better than 2535%. HVLP spray finishing uses a high volume of air delivered at low pressure to atomize material into a very soft, low-velocity pattern. Overspray, blow-back and particle bounce are virtually eliminated so transfer efficiencies can be very high. According to the suppliers, these systems can be used for applying urethane spray cement.
Brochures for the following
system suppliers are enclosed.
DeVilbiss Ransburg Brochure
Industrial Coating Equipment
An Illinois Tool Works Company
Maumee, Ohio 43537
Contact: Shaun
(404) 696-4988
Croix Air Products Inc. Brochure
520 Airport Road/Fleming Field
South St. Paul, Minnesota 55075
(612) 455-1213
Contact: Tim Whaylan
Recycling/Reuse
Recycling Plaster
Many states are now ser ing to estdish regulations for facilities whic
1 dispose of construction and demolition (C&D) materials. Plaster may be considered one of these materials. States are trying to encourage markets for
C&D materials. According to the Waste Reduction Resource Center, the only one company in the Eastern U.S. that recycles this type of material is:
Horton Iron & Metal Company
U.S.Highway 421 North P.O.Box 1285
Wilmington, NC 28402
Contact: R.T.Hornton Senior
N-9

Engineered Fabrics Corporation
Rockmart, Georgia
The following is a list of Waste Exchanges that could be contacted to determine if this waste could be used as a filler and to locate companies that may be interested in using it.
Southern Waste Information Exchange (SWIX)
Florida State University/CBTR
Institute of Science and Public Affairs
2035 East Paul Dirac Drive
Suite 226
Morgan Building, Innovation Park
Tallahassee, FL 32313
(904) 644-5516
Contact: Dr. Roy Herndon
Southeast Waste Exchange
UNCC Station
Urban Institute
Charlotte, NC 28223
(704) 547-2307
Contact: Maxie May
Indiana Waste Exchange
Environmental Management & Education Program
2129 Civil Engineering Building
Purdue University
West Lafayette, IN 47907-1284
(317) 494-5038
Contact: Mary Hardaway
_ _
~~
Bibliography
Fact Sheet: Solvent Emissions from Vapor Degreaserz, Minnesota
Technical Assistance Program, July 1989.
Smythe, Alan H., 1.1.1
-
Trichloroethane Reduction Alternatives Minnesota
Technical Assistance Program, 1987 Summer Intern Report.
__
Center for the Southeast, October 1989.
N-10

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Federal Paper Board Company, Inc
Augusta Operations
Highway 56 South
P. 0. Box 1425
Augusta, GA 30913-1699
Mr. Jeremy J. Pearson, P.E.
Senior Environmental Engineer
Heavy Stock Paper Primary Products:
Process Description
The Federal Paper Board Company at Augusta produces a nominal 1500-2000 tons per day was purchased by Federal in 1985 (from Continental Forest Industries) and various plant renovations and additions have been made since that time to improve plant efficiency, reduce environmental impacts, and increase production capacity.
All pulp is produced in three Kamyr continuous digesters, the oldest of which is presently on stand-by status. Bleaching is accomplished with two older 4-stage [(C,) E,, H D] plants and a new 3-stage [(C,) (E,) (D)] plant. One of the older bleach plants has been put on standby and the other will be converted into a [(C,) (E,) D N D] sequence. The elimination of hypochlorite and high C10, substitution should significantly reduce chloroform and dioxin formation during the bleaching process.
Other plant changes planned for completion by 1994 include the addition of a fourth paperboard mill and a new lime kiln which will bring mill capacity to about 2800-3000 TPD.
At that time, employment at the mill is expected to reach over 1000 persons.
The wastewater generated from this process and from the Augusta Newsprint Company goes to three parallel primary wastewater clarifiers. The clarified water is then sent to two fiber traps which are
to a series of six treatment ponds, the first three of which are aerated and the last three are nonaerated. The water is then routed to the Savannah River. Sludge from the three clarifiers is pumped to three parallel screw presses. The dewatered sludge is then landfilled onsite.
0 - 1

Federal Paper Board Company, Inc.
Augusta, Georgia
Project Scope
Federal Paper Board generates approximately 150 dry tons/day of sludge from their water treatment plant clarifier. The sludge is dewatered in three parallel screw presses which increase the solids content to 30%. They are currently disposing the dewatered sludge in an onsite landfill. The Federal Paper Board landfill is now near capacity. Plant personnel have expressed an interest in burning the clarifier sludge in its power boilers for energy recovery. A major factor in burning this sludge for energy as it comes out of the sludge press is its moisture content. The higher the moisture content, the lower the BTU-value of the material.
has examined the kinetics of outdoor sludge moisture loss and evaluated the alternative methods to increase solids content.
Analyses Results and Discussion
A study was performed by Simons-Eastern Consultants, Inc. to investigate the feasibility of burning sludge at moisture levels of 55% or less. Simons has recommended expanding the existing dewatering capabilities to decrease the moisture level to 55% and conveying the dewatered sludge to a metering bin and then to a boiler feed.
Federal Paper Board is planning to perform a trial burn of their sludge at 45% solids with a mix of 20% sludge (80% bark) and 28% sludge (72% bark). The study will be performed using two of their three boilers. A comprehensive plan has been developed to monitor the feed fuel, operating parameters of the boilers, and input sludge parameters (including moisture, BTU-value, carbon, nitrogen, sodium, hydrogen, oxygen, sulfur, and chloride). The resulting ash will also be analyzed for several hazardous and TCLP constituents. The trial bum will prove to be very informative in terms of boiler performance and generation of effluent gases at the two sludge feed rates.
the event that the trial bum proves inefficient at 45% solids content, a study was performed to investigate the drying kinetics of Federal Paper Board's water treatment sludge and to support possible implementation of drying systems. A large sample of sludge was obtained from Federal Paper Board. Transportation by conveyor was simulated by distributing the sludge on a cardboard pad at approximately 2.5 to 3 inches thick. Samples were taken at 0, and after air-drying for 2,4, 6, and 25 hours and were analyzed for BTU- value, moisture content and ash content. BTU-values were also determined on three 100% solids samples. The weather condition at the time was 80 to 85 deg C, 75% humidity and clear skies. See Table 1 for data and Figure 1 for a plot of BTU-value versus Moisture content.
~
-
0 - 2

Federal Paper Board Company, Inc.
Augusta, Georgia
Sample
Number
Sample 1
Sample 2
Sample 3
Sample 4
Sample 5
Dry
Table 0-1
Moisture, Ash, BTU-value Data
Drying
Number of
Analvm
hours
2 hours (am.)
3
2
4 hours (a.m.,p.m.) 2
6 hours (a.m.,p.m.) 2
hours 2 n/a 3
Moisture
67.0
60.0
52.3
32.3
18.2
0
Ash
BTU-value nla
11.1
12.0
10.7 nla nla
2,685
3,817
4,574
6,173
7,057
8,662
Figure 0 - 1
Solids Content vs. BTU-value
Linear Plot
BTU/lb
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
0 10 20 30 40 50 60 70 80 90 100
Solids Content (%Dry
Linear Curve Fit
Rx)
+
2.8779343+2
R squared = 9.8801083-1
0 - 3

Federal Paper Board Company, Inc.
Augusta, Georgia
If the sludge is spread to a depth of 2.5 to 3.0 inches, solids content of 40% can be achieved at approximately four hours, whereas at 6 hours the solids content jumps to approximately
70% solids. Four to six hours of drying time, under ideal outdoor conditions, would result
moisture content and BTU-values which are adequate for burning in Federal Paper
Board's boiler.
Ambient drying times are probably too long for practical application considering the transport time of the sludge from the press to the boiler and less than ideal weather conditions. Therefore support drying systems to aid the drying identified and are presented below. of the sludge have been
Recommendations
following are some system alternatives to drying sludge beyond the 45% dry solids content level.
Sludme Dwe rs
There are several alternatives which will bring moisture content down to less than 45% dry solids. Thermal drying is a process which ;an raise solids content up to 85% to 90%.
D+g can be accomplished using both thermal and mechanical systems. In some drying processes the thermal gases transfer the heat by direct contact to the sludge. Several of these direct dryer systems are listed below:
Belt Dryers
Multiple Hearth Dryers
Drum Dryers
Fluidized Bed Dryers
Flow Dryers
Grinding Dryers
In indirect drying technology, thermal energy is transferred to the sludge using a heating surface and an intermediate heat transfer medium (such as steam, hot water, or thermal oil).
Several indirect dryers are listed below:
Screw Dryers
Disk Dryers
Thin Film Dryers
Kneading Dryers
Thermal drying systems are expensive in terms of capital and operational costs and would probably exceed Federal Paper Board's drying needs. However, if the trial run proves that
0 - 4
~~~
~
_ _

Federal Paper Board Company, Inc.
Augusta, Georgia greater sludge solids content is necessary, thermal dryers or other alternative drying systems would probably be Federal Paper Board’s only alternative.
See the Appendix for companies which supply drying systems.
Solar Panels
In most cases solids content at 85% to 90% is not necessary, however solids content above
45% is necessary for adequate boiler operation efficiency. Solar panels directed at the sludge along the conveyor (from the sludge press to the boiler) would assist in drying the sludge to the 60% to 70% solids content level by providing additional thermal energy to the sludge and increase moisture loss. Solar panels require little operating and maintenance cost and can provide the additional drying required by the boilers.
Alternatively, solar energy can also be used as a power source in conjunction with a thermal heating device to aid in sludge drying.
See the Appendix and Bibliography for companies and facilities which provide and utilize these systems.
Infra-red elements, which are run on local power, can be used along a portion of the conveying system to further dry dewatered sludge. This type of system uses infrared energy directed at the material for drying purposes. The capital costs of such a system would be moderate, however the power, operational, and maintenance costs may be prohibiting.
Although solar energy as a power source can also be used for this system.
See the Appendix for a company which supplies this type of system.
Outdoor Storaee
By storing sludge in the open air for 24 to 48 hours, the sludge can naturally dry to 60% to
70% solids content. An auger could be used to aid in drying the sludge thoroughly.
Following 24 to 48 hours, the sludge can be transferred to the boiler using a front-end loader.
See the bibliography for facilities involved with this type of application.
0 - 5

Federal Paper Board Company, Inc.
Augusta, Georgia
Project Appeadix
The following are companies which supply sludge dryers or potential sludge drying equipment.
Sludge Dryers
MEC Company
P. 0. Box 330
Neodesha, Kansas 66757
Richard Chaney
(316) 325-2678
The Dupps Company
Department M
Germantown, Ohio 45327
(513) 855-6555
Envirex Corporation
Milwuakee, Wisconsin
Jim Methurst
(414) 547-0141
Stord, Inc.
309 Regional Road South
Greensboro, North Carolina 27409
Bruce Low
(919) 668-7727
I*-red Application
Casso-Solar Corporation
US Route 202
Pomona, New York
(914) 354-2500
Solar Applications
Industrial Solar Technology
Denver, Colorado
Randy Gee
(303) 431-8348
Siemens Solar Industries
4650 Adohr Lane
Camarillo, California 93011
(805) 482-6800
0 - 6

Federal Paper Board Company, Inc.
Augusta, Georgia
Bibliography
"A State Demonstration Program in Wood Energy", Georgia Institute of Technology,
Engineering Experiment Station, Volume VI1 Project A-2400.
"Paper Mill Sludge as a Valuable Fuel", TaDDi Journal, December 1989, pp. 139-141.
"Drying of Sewage Sludge
-
An Important Step in Waste Disposal", Water Science and Technolpey, December 1990, pp. 57-63.
"Dewatering of Sludge by Natural Methods", Water Science and Technolggy,
MarchfApril 1990, pp. 239-246.
"Improved Efficiency of Sewage Sludge Incineration by Preceding Sludge Drying",
Water Sc ience and Technolggy, December, 1990, pp. 269-276.
"Solar Energy For Sludge Drying in Alexandria Metropolitan Area: Case Study in
Egypt", Water Science and Technology, December, 1990, pp. 193-204.
0 - 7

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL. SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Chevrolet-Pontiac-Canada Group
Doraville Plant
General Motors Corporation
3900 Motors Industrial Way
Doraville, GA 30360
Don L. Smith
Senior Staff Engineer
Environmental & Energy
Plant Engineering
Automobiles (Cutlass Supreme) Primary Products:
Project Scope
1. ELPO (Electrodeposition) Paint Filters
-
DO08
2. Purge Thinner
-
3. Waste Paint
-
DO01
4. Waste Oil
-
Non-Hazardous
5. Batteries
-
Recycled
6. Waste Water Treatment Sludge
-
Non-Hazardous
Paint & Sealer Sludge
-
Non-Hazardous
Due to the limited amount of time, limited amount of resources, previously implemented pollution prevention technologies, plant size and diversity of plant operations, it was decided that a limited project scope was necessary. In addition, the plant has a full-time employee responsible for complying with state and federal regulations as well as evaluating pollution prevention options. Once the above listed possibilities were reviewed, the "ELPO paint filters" study was chosen as the main subject to be analyzed.
P-1

General Motors
Doraville, Georgia
Two different kinds of filter system hazardous waste were observed: a. ELPO Filter Bag - a long cylindrical filter bag with a plastic ring for positioning in the filter pot. Approximately 100 of these bags are used weekly and must be disposed of as DO08 hazardous waste because of the content of leachable lead. b. Ultrafilter Cartridge
- cartridge composed of numerous capillary-like tubes encased in a plastic cylinder. Approximately 130 are in use and are required to process the proper amount of filtrate to satisfy the system. Occasionally these are replaced and must be disposed of as DO08 hazardous waste.
Lab0 ratorv Test Result for ELPO Filter Bag
Selenium, mg/L *
Silver,
*
<0.01
0.18
7741
7760
* Concentration in TCLP Leachate per EPA method 1311.
E *
Individual method for particular metal as specified in EPA SW846.
1.0
5.0
Analytical tests were performed for other parameters (remaining RCRA TCLP Rule organics, herbicides, and pesticides) and indicated levels were below the regulatory limits.
The only contaminant of concern is lead and its concentration varied from approximately
5Oppm to 175ppm.
P-2
-

General Motors
Doraville, Georgia
Process Description
The following description emphasizes those operations associated with the generation of waste in the paint filtering system.
The assembly plant has four basic assembly departments:
1. Body
2. Paint
3. Trim
4. Chassis
The body shop assembles and welds all component parts together to form the body-in-white.
Once the body-in-white is completely assembled it is then conveyed to the paint department where all painting operations are completed. The first operations are cleaning with organic detergent and the application of a zinc phosphate coating followed by a chromic acid rinse.
The body is then air-dried and enters the cathodic electrodeposition tank where it is coated with the corrosion resistant primer containing lead pigments. All excess undeposited paint is removed by subsequent rinsing. The rinsewater is recirculated and constantly filtered to remove any foreign particles. Magnets are also placed in the tanks as well the filters to remove any ferrous metal particles. as in some of
Filter bags are replaced weekly and two filter pots are changed at the same time since they are fed by a common pump series. This varies slightly from filter pot to filter pot depending on the pump arrangements. Filters are temporarily isolated from the system by a valve arrangement. The top of the filter pot is removed and each bag is individually taken out of the pot and placed in a plastic bag, which is then thrown into a gondola. The maintenance department then transports the gondola to the hazardous waste storage area where the bags as well as an occasional ultrafilter cartridge are loaded into drums where they will be subsequently shipped to a permitted TSD facility.
P-3

r
I
BAG FILTERS
I
I
CATHODIC
llON

General Motors
Doraville, Georgia
following table gives more details on the types of filters used:
Filter Bags
U l t r a f i l t e r s
I
Filter Type
11
Total # of Cartridges
I
# of Cartridges
P-5
128

General Motors
Doraville, Georgia
Efforts to Reduce Waste
Observed efforts related to the paint filter project include:
-
The paint filter bags non-hazardous paint wastes in order to reduce the paint related wastes that must be handled as hazardous waste.
-
New state-of-the-art ultrafilter cartridges were purchased which reduces the amount of waste generated since they do not have to be disposed of as often.
-
An in-house repair program was established. Approximately thirteen ultrafilters had to be disposed of weekly and this number has been reduced to 4 or 5 non-repairable cartridges per year.
Recommendations
These recommendations are not based on a formal economic analysis. An evaluation of cost data is not included as part of the study.
Source Reduction
Elimination of Lead in Primer
Manufacturers of corrosion resistant primers containing lead pigments have been under considerable pressure from both public and private sectors to eliminate these traditional inhibitive systems due to their toxicity.
Formulators are continuously researching and working together with applicators to try to develop new corrosion resistant primers that do not contain lead. The use of lead pigment offers the maximum corrosion protection for the automobile body. No replacement pigments have been found that offer the same corrosion protection for the automotive industry but this should be considered as a long-term goal.
-
P-6

General Motors
Doraville, Georgia
Lower Quantity of Foreign Particles that Reach the Filters
The material buildup on magnets in the tanks as well as in the filters was analyzed. Under the microscope, it was evident that they were metal particles. By increasing the number of magnets in the tanks, cleaning them more often to reduce buildup, or inspecting and removing any foreign particles from the body-in-white before they enter the tank, the number of foreign particles the filter must capture will be minimized, which may increase the life of the filter bags, and consequently, decrease the number of bags that will have to be disposed.
Purchasing More State-of-the-art Ultrafilter Cartridges
Some new state-of-the-art ultrafilters are already being used and as the old ones have to be replaced, it is suggested that they be replaced by the new more efficient ultrafilters which do not have to be disposed of as often even though the more efficient cartridges are 30% more expensive.
Minimize Drag-out
Enough time should be allowed for paint drag-out to drain back into the paint filter system. A method for determining the quantitative effect of reducing drag-out would be to weigh the filter bag in a plastic bag before draining, weigh after draining, and determine the amount of time to significantly reduce drag-out. In this way a minimum amount of drain time could be specified. If a significant reduction is observed, a rack could be devised that would fit over the filter pot and raise the bags above the bottom layer of liquid. This would effectively drain the filter bags with minimal employee exposure and effort. A squeegee consisting of spring-loaded rollers that would have enough tension to remove excess paint from filters could also be used to minimize drag-out. However, appropriate measures should be taken to minimize employee exposure.
Recycling/Reuse
Recycling
The recycling option is not feasible because once the life of the filter bag has expired, it can no longer be efficiently used for filtering.
P-7
~~
~

General Motors
Doraville, Georgia
Fuel Substitution
It has been proposed that the waste could be used for fuel substitution.Fue1 substitution involves using hazardous waste as a fuel in industrial furnaces or in boilers for generation of steam. The hazardous waste may be blended with other non-hazardous wastes and/or fossil fuels. The wastes used for fuel substitution can be handled in a solid, liquid, or gaseous form.
The parameters that affect the selection of fuel substitution are (in the case of solid waste):
1. Halogen content of the waste;
2.
3.
Inorganic solids content (ash content) of the waste, particularly heavy metals;
Heating value of the waste; and
4. Sulfur content.
The heating value of the waste must be high enough (either alone or in combination with other fuels) to maintain combustion temperatures consistent with efficient waste destruction and operation of the furnace. For many applications, only supplemental fuels having minimum heating values of 8,000 to 10,OOO BTU/lb can be considered to be feasible. The ELPO filter bags have a BTU/lb value of approximately 11,000 and fulfills the other prerequisites for fuel blending. This option was more expensive than the current method for treatment and disposal under consideration based on the current purchase order of $293/Drum versus $212/Drum.
Treatment
Wash the Filter Bags
Prior to replacing the filter bags, they could be flushed with water in the filter pot system. The water would then be sent to on-site waste water treatment system where it would be appropriately treated. Further testing is required to determine the amount of leachable lead in the washed filter bags and wastewater treatment sludge, the amount of water necessary to appropriately rinse the bags, and the amount of time required. Research should be conducted to determine the most efficient way to clean the filter bags and to determine whether or not the regulatory limits could be met.
P-8
~
-
-

General Motors
Doraville, Georgia
Vitrification
Glass vitrification is a high-temperature stabilization technology that is applicable for treatment of lead-containing wastes. Glass vitrification is a process wherein the waste is blended at fairly low concentrations into a mixture of lime, soda ash, silica and other ingredients normally used for glassmaking. The blended waste and glass constituent mixture is then fed to a glassmaking furnace. Material is normally introduced near the top of the furnace and descends to the surface of a pool of molten glass maintained at
1100°C to 1200OC. At these temperatures, organic constituents of the water are combusted, and inorganic constituents dissolve into the glass melt. Molten glass is withdrawn from the base of the furnace and cooled into chunks or blocks. The waste inorganic constituents become physically and chemically incorporated into the glass matrix. A more detailed cost analysis of this option is necessary to determine its feasibility.
Bibliography
Barlow, James, et
EPA/S30/SW-89/048A. Environmental Protection Agency, Washington, DC.
June 1989.
Rosengrant, et Al. Final Best Demonstrated Available Technolop (BDAT)
Backeround Docu ment for DO08 and P and U Lead Wastes. Volume 23.
Versar Inc. Springfield, VA.EPA/530/SW-90/059W. May 1990. S8P
Rosengrant, et AI.
PO08 and P and U Lead Wastes. Volume 1-H. EPA/530/SW-90/061J. May
1990.398P
Memorandum, Lasko, T.C., CPC Doraville, to Smith, D., CPC Doraville,
June 20, 1991.
P-9

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
PPG Industries
1377 Oakleigh Drive
East Point, Georgia 30344
Marvin Branch
Waste Reduction Coordinator
House Paints
Heavy Duty Maintenance Paints
Wastes Generated
1. Wash solvent contaminated with pigments containing heavy metals from rinsing stationary tanks, filling equipment, and grinding equipment.
2. Spent filter cartridges
3.
4.
Paint wastes such as off-specification paint and obsolete materials
Bag-house dust
5.
6.
Spent caustic cleaning solution sludge
Empty bags, off-specification containers, and emptied containers from paint which had to be reworked
-
Non-Hazardous
This plant manufactures all of its products in individual batches, and as a result, generates a variety of hazardous and non-hazardous wastes in their operations. Tank and equipment cleaning is the principal source of waste generated in batch formulation. In this particular plant another significant waste stream is bag-house dust. This dust is presently collected and mixed with other paint wastes which are subsequently incinerated off-site.
Approximately 25,000 gal/month of wash solvent composed of a variety of chemicals including toluene, xylene, methyl ethyl ketone, and methyl isobutyl ketone are sent off-site to a local reclaimer.
Q-1

Approximately 200 lbs/week of bag-house dust which may be contaminated with heavy metal pigments are mixed with the paint wastes. This dust may contain lead, barium, chromium, and cadmium and must be considered hazardous.
pigments currently cannot be reincorporated into subsequent paint batches because of contaminants, possibly dirt and gelled resins.
Analysis Results for Bag-house Dust
Sample: Two different drums
Drum 1 Analysis
P
CaSiO,
Wollastonite
SiO, / Quartz
CaO
(Zn, Ca) Al2P2H6OI2
TiO, / Rutile
C4H,05Pb
lead acetate
UCS for Me.S.Cl.K.Cr.Mn.Zr.Fe *
Weight % major minor minor minor minor minor
~ trace c
~
Drum 2 Analysis
J 3 a e
SiO,
Quartz
Zn
TiO, / Rutile
ZnO
CaCO,
Calcite
CaA12Si20,* 4H20
/
Gismondine
Weieht % maior minor minor minor minor minor
I trace
II
II
* Unidentified Crystalline Species

PPG Industries
East Point, Georgia
Process Description
PPG produces batches of oil-based paints and water-based paints. This plant produces approximately six million gallons of paint per year. The processes for both types of paints are generally similar, although the raw materials vary. The major production difference is the carrying agent: oil-based paints are dispersed in a solvent mixture, while water-based paints are dispersed in water with a surfactant as the dispersing agent. The three major steps involved in the paint manufacturing process are (1) mixing and grinding of raw materials, (2) tinting and thinning, and (3) filling operations.
Pigments and additives are purchased in bags and are added manually to the mixing tank. Solvents are pumped into the tank directly from bulk storage containers outside. In most cases grinding and mixing are performed in one production step.
For specialty paints, the material is sent to a grinder which contains fine glass beads which disperse pigment to the proper particle size. Vents from the dispersing units capture dust and the empty bags. Empty bags are removed and collected to be compacted. Dust is collected by using a bag-house. The paint is transferred to a holding tank and analyzed. The composition is adjusted as necessary to meet the required specifications for the type of paint being produced. The paint is then filtered to remove any undispersed pigment and foreign particles and is then transferred to a filling operation and dispensed into labeled cans. The cans are placed on pallets and moved into a storage area.
Portable tanks are cleaned with a portable cleaning machine which utilizes high pressure nozzles. The equipment holds up to 200 gallons of solvent, but typically only 75 gallons are used. One tank per batch of solvent can be used to clean several tanks. The used solvent from this operation is sent to the appropriate waste storage tank. Stationary holding tanks axe cleaned when the subsequent batch to be manufactured is of a different type of material.
Spent solvents used to clean tanks and filling equipment are separated depending on whether they can or cannot be reused in a paint formulation. Solvent which cannot be reused is sent to an off-site reclaimer. Solvent which can be reused is kept in three different tanks, depending on the product into which it will go: (1) reds and browns, ( 2 ) gray, or (3) white. Wash water is kept in a fourth tank, to be reused in the next batch of latex paint. This segregation of reusable solvent allows it to be used in a larger number of products and, therefore, increases the percentage of wash solvent which is reused. It may also reduce problems associated with potential pigment interactions which result in material settling in the bottom of the wash solvent tanks.
Q-3

-
I
-SOLVENT
7
c
i
TANK
1
L J
REDS
&
BROWS
GRAY WlTES
"-REUSABLE
SOLVENT
44
-
w

PPG Industries
East Point, Georgia
Plant Efforts to Reduce Waste
Organizational
The plant has a full-time employee responsible for evaluating pollution prevention options.
Wash Solvents
-
Wash solvent from mixing tanks is incorporated as part of the solvent requirement for the batch of paint being manufactured.
Where possible, the wash solvent from cleaning holding tanks and filling equipment is collected and used in the next compatible batch of paint as part of the formulation.
A portable tank cleaning machine has replaced the daily cleaning with caustic cleaning solution. The use of caustic solution has been reduced to cleaning each tank once a year. This caustic solution is settled, decanted, and reused.
* One more tank was added to the three tanks in the wash recovery system in order to segregate reds and browns from gray. Because of the additional color separation, the wash can be incorporated into a larger number of products, which allows for a larger percentage of the wash to be reused.
Solvents used to clean pull-off tanks are incorporated into the batch.
Paint-related Wastes
Pull-off, overruns, and customer returns are worked back into new batches of paint.
Quality control samples are reused in compatible batches.

PPG Industries
East Point, Georgia
Equipment Modifications
Tanks were modified to completely purge equipment. Flat bottoms were converted to cone-shaped surfaces to remove material more efficiently.
Mechanical pumps were changed to more efficient air pumps.
Wire screen filtering equipment is being installed in order to slowly eliminate the use of filter bags and cartridges. The wire screen filters can be reused almost indefinitely because they are backwashable.
Bag-house Dust
Bag-house dust was used to produce a gray deck enamel but paint proved to be unsatisfactory. The contaminants produced a rough finish.
Water
The latex paint has a closed system for water which results in zero discharge.
All water from the production of latex paints is reused. Therefore, no process water is discharged from this facility.
Recommendations
Source Reduction
Batch Sequencing
Batches should be scheduled in such a way that compatible paints are produced consecutively. This could mean the elimination of an intermediate cleaning step in some cases.
Waste Documentation
Computerized waste documentation can help track the wastes in the process and can be used to manage solvents that have to be segregated or stored for reuse or distillation. Additional Stock Keeping Units (SKUs) in the plant’s current computerized inventory control system could be determined in order to track wastes.
-

PPG Industries
East Point, Georgia
Dedicated Bag-house System for Pigment Loading Area
Since all pigment dusts are mixed, the pigments cannot be recycled to the process that generated them. Due to the system already in place, this option is not economically feasible at present but may be considered as an option in the future if replacement is necessary. Note that, even if this system was implemented, it may not solve the problem of contaminants (dirt and gelled resins) in the dust which restrict the reuse of the dust.
Recycling/Reuse
On-site Distillation of Wash Solvent
On-site reclamation has the following benefits:
The transportation of the wastes and the associated risks are minimized because less waste leaves the facility.
More control over the purity of the reclaimed solvent.
Even though the distillation residues require off-site incineration, the fact that the waste volume is considerably reduced, decreases off-site disposal costs.
The following conditions must be satisfied before the distillation unit is purchased and installed:
The still should meet technical requirements for reclaiming solvents which have a wide variety of boiling points.
The economics of on-site distillation must be proven to be favorable.
This analysis should include technical personnel to operate the still.
The measure should be proven to be an environmentally safer option
(short term and long term) compared to the presently employed off- site recycling.
Q-7

PPG Industries
East Point, Georgia
A more detailed analysis of the types of solvents used should be performed and cost and performance data should be obtained from vendors to determine the technical and economic feasibility of this option. Enclosed is a list of suppliers of distillation equipment and some of their brochures.
Some of the difficulties that might be encountered are:
.
Loss of solvent during distillation process
. Low solvent recovery efficiency
Installation problems
. Maintenance problems
Permitting
If it is not feasible to install and use a solvent recovery unit, it may become feasible to employ the services of an on-site recycling company. Enclosed is information on two companies that provide such services.
Separate Gelled Particles from Bag-house Dust
A Particle Size Analysis (ASTM D422
-
63) should be performed to determine what type of equipment is necessary to achieve this separation.
Particle Size Analysis is a quantitative determination of a material's particle size distribution and is broadly used in engineering classification of materials.
Cyclones can be used to separate solid particles from an air stream and customized cyclones to selectively remove particles of above a certain size can be designed. Even though cyclones are very effective, this customized system may be very expensive.
One separation method that may be of particular interest is a vibro-separator.
vibration motion is based on a principle in which motor rotation imparts vibration to an entire screen assembly in both vertical and horizontal planes.
These separators are very effective in separating solid material accurately up to five different sizes with a single separator.
~~
~

PPG Industries
East Point, Georgia
The following are suppliers of vibrating screens which may be contacted for further information:
1. Macon Wire, Inc.
2907-2913 Joycliff Road
Macon, Georgia 3 121 1
1-800-768-9155
Contact: Steve Dew
(Brochure Enclosed)
2. SWECO, Inc.
7120 New Buffington Road
Florence, KY 41042
(606) 727-5147
Analyze Settled Material in Wash Solvent
If new procedures initiated by the plant do not eliminate settling, the material should be analyzed to determine its composition. If the analysis indicates that it is primarily pigment, companies that produce sealers, deadners and adhesives that may be interested in using the pigment as filler should be contacted. If it is concluded that the material is primarily resin, the source should be determined before appropriate measures could be taken.
Determine if Bag-house Dust Could be Used as a Filler
Waste Exchanges could be contacted to locate companies that may be interested in using the bag-house dust as a raw material even though it is hazardous. Waste could be advertised in a Waste Exchange magazine.
The following are Waste Exchange Addresses:
Southeast Waste Exchange
UNCC Station
Urban Institute
University of North Carolina at Charlotte
Charlotte, NC 28223
(704) 547-2307
Contact: Maxie May

PPG Industries
East Point, Georgia
Southern Waste Information Exchange (SWIX)
Florida State University/CBTR
Institute of Science and Public Affairs
Tallahassee, FL 32313
(904) 644-5516
Contact: Dr. Roy Herndon
Bibliography
"On-Site Solvent Recovery", American Machinist & Automated Manufacturing, May
1987, p.75.
DEWCO Vibro-seDarators Brochure obtained through Macon Wire, Inc., Macon, GA
Guides to Pollution: The Paint Manufacturing Industry. Jacobs Engineering Group,
Inc., Pasadena, California. EPA/625/7-90/005. June 1990.
Guide to So lvent Reduction Alternatives. Toxic Substances Control Division,
California Department of Health Services, Los Angeles, California. October 1986.
"Considerations For Selecting a Still for On-Site Recycling." Minnesota Technical m a n c e Proeram (MnTap), Minneapolis, MN. March 1988.
Stabilization/Sol idification of CERCLA and RCRA Wastes. EPA/625/6-89/022. U.S.
Environmental Protection Agency. Cincinnati, OH. May 1989. p. 4-1.
Waste Minimization in Metals Parts Cleaning. EPA/530-SW-89-049.
Environmental Protection Agency. Washington. DC. August 1989. p.27.
U.S.
Q-10

GEORGIA TECH RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY
POLLUTION PREVENTION PROJECT
Company:
Contact:
Primary Products:
Rheem Manufacturing Company
Air Conditioning Division
Roberson Mill Road
Milledgeville, Georgia 31061
Mike Brooker
Air Conditioners, Furnaces
Efforts To Reduce Waste
Manufacturing Company has made substantial progress in reducing hazardous waste.
The following outlines their efforts to reduce waste.
1. Rheem has a very proactive pollution prevention attitude which is supplemented by a Corporate Policy Statement on "Rheem Milledgeville Plant's Voluntary
Participation in the Georgia EPD Multimedia Pollution Prevention Program".
2. In July, 1990, Rheem converted its air conditioner coating line from the use of a 3.5 lbs/gallon VOC high solids enamel to a powder coating. The switch has reduced their coating VOC emissions by 60%. Cleanup solvent usage has also been reduced because the powder coating system does not require HiSol #10 solvent cleaning, which is required in wet coating systems.
Xylene Emissions: 134,154 lbs
1990
53,877 lbs
3. Rheem has six stamping stations where air conditioning coil assemblies are fabricated. Originally, the fabricating oil used in the process required removal with a trichloroethylene vapor degreaser. The process has been converted to one using
oil incorporated in a mineral spirits solvent which requires no subsequent degreasing. This eliminated the use of trichloroethylene, a potential source of toxicity. The mineral spirits material is a source of VOC and, in cooperation with another Rheem plant, work is now underway to convert to a water based "synthetic" oil. With the completion of this work, approximately 144,400 lbs/year of mineral spirits VOC emissions will be eliminated.
Trichloroethylene
Emissions:
465,700 lbs
R- 1
160,710 lbs 0

Rheem Manufacturing Company
Milledgeville, Georgia
4. Water Treatment Sludge Volume Reduction: The water treatment sludge generated from the wash water treatment plant is piped to a sludge press which reduces the sludge volume approximately 4:l. Rheem is in the process of investigating the purchase of a sludge or filter cake dryer which can further reduce the sludge volume.
5.
6.
The furnace coating line at Rheem will be converted from an electrostatic system
(3.5 lbs/gallon VOC high solids enamel) to the use of prepainted metal which is postformed into heating units. Production trials have shown the concept to be feasible. Prepainted production coils from an outside supplier are now in stock and are being fabricated for certain parts. The plan is to have this prepaint operation fully implemented by March, 1992. This step eliminates the major portion of the remaining coating VOC's. Again, HiSol #10 cleanup solvent usage will be greatly diminished. The conversion will also reduce the zinc phosphate metal pretreatment apportionment that now serves the furnace line. This will also result in a corresponding reduction in metal sludge wastes, water usage, and energy usage.
With the five stage system for cleaning and phosphatizing metal prior to painting, it is suggested that the metal pretreatment chemical supplier be consulted to ascertain that all has been done to minimize water waste through:
1.
2.
3.
Possibilities of separating soils through use of oil skimmers etc.
Possibilities in using process filtration or ultrafiltration.
Possibilities with the partial use of rinse waters for make-up of stage
1 or stage 3 solutions.
If a new seven stage or other type zinc phosphate washer system is planned in the future, design consideration should be given to the above or to any other water saving opportunities, such as possible counterflow rinse stages.
Solid Waste Reduction: Rheem recycles a large percentage of their solid wastes including scrap steel and copper, cardboard, paper, and computer paper. They reuse packing material, pallets, and reconditioned drums. They also return reusable containers to their originating facility.
Solid Waste Survey Results
A survey of the solid waste generated by Rheem Manufacturing was conducted to identify recyclable solid waste streams. Visual inspections of 21 solid waste disposal sites within the facility were conducted. Even though cardboard is segregated and recycled at Rheem, recyclable cardboard was found to still be the largest portion of the solid waste generated and shipped for disposal. The second largest percentage of the solid waste was stretch wrap
-
_ _
R-2

Rheem Manufacturing Company
Milledgeville, Georgia generated from unwrapping packed pallets of components. Another less significant portion of Rheem’s solid waste is plastic strap. Miscellaneous rubbish generally comprises the remaining waste. In removing these waste streams the amount of solid waste needing shipment for land disposal could be reduced by an estimated 40% to 60% based on the waste characteristic survey.
Recyclable cardboard was found in 17 of the 21 disposal sites surveyed. Recyclable cardboard was also found to be the largest portion of waste in the back compactor and disposal area. To further encourage corrugated recycling, several more corrugated recycle sites should be situated in the key areas of 13B, 125,16L, and 135. Segregation should also be conducted at the back dock area, which is the end point of the trash processing before removal from the facility. This could serve as the final retrieval area €or cardboard which passed the previous segregation locations. Recycling should be routinely stressed to all employees, since in the day-to-day operations personnel tend to forget to segregate recyclable wastes. By insuring all corrugated is recycled, Rheem’s landfilled solid waste could be decreased by as much as 20% each year.
Currently the only option for disposal of wax-coated cardboard is incineration/cogeneration.
However, Rheem does not generate enough of the wax-coated cardboard waste for this to be economically feasible. The only other alternative is to contact suppliers that ship merchandise in wax-coated cardboard and persuade them to change to uncoated corrugated.
Through contacts with Georgia Pacific and Union Camp, who are major producers of wax- coated cardboard, it seems that wax-coated containers are soon to be a “thing of the past”.
So it would be ideal for a company to voluntarily change their packaging material to one that is more suitable to the environment’s, as well as Rheem’s, waste disposal needs.
Stretch Wrap
discussed above, waste stretch wrap, which is generated by the receipt and unloading of secured pallets of components, is the second largest solid waste streamat Rheem. A large producer of stretch wrap material and Rheem’s supplier, Mobil Chemical, Plastic Packaging
Division, is initiating a program to recycle used stretch wrap. Mobile Chemical will accept
Rheem’s waste stretch-wrap and recycle it in-process at their Covington, GA facility. Mobil has set forth some provisions as to how the material will be accepted: o
0
0 o
The stretch-wrap must be clean.
It must not contain paper (labels, trash, etc.).
The plastic wrap must be bailed before transport.
The type and brand of stretch wrap received must be identified with either a suppler name or Material Safety Data Sheet (MSDS) of the material. This is to insure that no toxic by-products are released during the recycling process.
R-3

Rheem Manufacturing Company
Milledgeville, Georgia
Initially, companies which ship materials bound by plastic stretch wrap material should be identified. In cooperation with Mobil Chemical, the supplier of the stretch wrap material from each company should then be identified. From this information, MSDS’s of each of the supplier’s stretch wrap material could be obtained and forwarded to Mobil Chemical.
Mobil Chemical will then decide which of the suppliers stretch wrap it can accept for recycling.
It is recommended that a program be developed to segregate, store, and ship (for recycling purposes) all applicable stretch-wrap. All areas in which stretch wrap is removed from loaded pallets should be identified. Clean drums should then be situated in the Vicinity to store the removed stretch wrap. The personnel removing the stretch wrap should be asked
remove (cut out) any labels found on the wrap before storing. The stored wrap can then be routinely picked up, bailed, and stored until enough material is accumulated to ship.
Contact: Tom Brighton Bill Happe
(In
Mobil Chemical Co.
Rochester,
Ph. charge of the program)
(716) 248-1355
(Rheem’s Sales Rep)
Mobil Chemical Co.
Covington, GA
Ph. (404) 786-5372 ext 518
It was discovered that recycle centers will not generally accept stretch wrap due to the possibility of toxic by-product emissions from unknown contaminants during reprocessing.
Plastid Strap
The solid waste survey revealed that a significant amount of green translucent plastic strap waste is generated daily. This plastic strap is used to secure individual boxes, loaded pallets and component parts on pallets. A major producer of green translucent plastic strap which makes up a portion of Rheem’s solid waste is a company called Signode Corporation. They are beginning a recycling program that will receive all waste translucent green polyester strap produced by their company and recycle it at their facility.
It is recommended that the green polyester strap waste, the predominant strap type found at Rheem, be segregated in the same manner as the stretch wrap. Rheem will then be required to purchase a sweed chopper (supplier can be obtained by the Signode contact) which will chop the material into 2 sections for preferred volume handling. The material should be stored long enough to accumulate a truck load quantity to ship. This amount of strapping may be prohibitively high. Signode Corporation will pay 8 cents/lb of the material and the associated shipping cost.
Contact: Don Robinson
Signode Corp.
Florence, KY
Ph. (606) 342-6400
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R-4

GEORGJA RESEARCH
LABORATORY
POLLUTION PREVENTION PROJECF
Company: Robins
Force Base
WR-ALC/EMM
Warner Robins, GA 31098
Contact: Margaret Harris
Pollution Prevention Program Manager
Primary Products
Robins Air Force Base maintains and repairs Air Force aircraft and equipment. C-l40's,
C-l31's, and F-15's are the aircraft most often repaired and maintained at this facility.
Project Scope
The focus of this report is a documentation of Robins AFBs current painting practices.
Efforts to Reduce Waste
Robins AFB has initiated a hazardous waste reduction program. A comprehensive waste minimization study was performed by Lee Wan and Associates, the scope of which was among the best encountered by GTRI. Lee Wan provided a number of very good site specific recommendations on reducing RAFB's hazardous waste streams, many of which will result in sizable waste reductions when implemented. GTRI is very enthusiastic with the current steps taken by RAFl3 to develop a comprehensive pollution prevention plan, and feel that with continued emphasis, RAFB can easily become one of the model facilities in the state of Georgia.
Low VOC coatings are currently under evaluation at Robins AFBs buildings 180, 89, and
Area 137. Some successful production trial runs have been conducted with high solid versions of major aircraft finishes with notable reductions in VOC/gallon as applied. These types of coatings have become available for 'IT-P-2760 Coroflex and MIGC-85285 Epoxy
Primers at 340 grams/liter (2.8 lbs/gallon) VOC and for MIGC-85285 Polyurethane Top
Coat at 420 grams/liter (3.5 lbs/gallon) VOC as applied. s-1

Robins
Force Base
Warner Robins, Georgia
Comparison o f Auproximate VOC Va lues as Amlied*
Coating
High Solids
C-130's & "IT-P-2760 Primer 560 grams/liter 340 grams/liter
C-141's MIL-C-85285 630 grams/liter 420 grams/liter
F-15's MIL-P-23377F
MIL-C-83286
600 grams/liter 340 grams/liter
590 grams/liter 420 grams/liter**
VOC's are expressed in grams/liter or pounds/gallon as applied excluding water.
**Assumes H/S version of MIGC-85285 Top Coat would replace MIGC-83286 for high solids application.
These coatings or versions of these coatings are used at a number of Robins AFB locations.
It
be seen that adoption and continued implementation of high solids applications for these major aircraft finishes offer a significant opportunity for reduction of VOC emissions.
A thermal fume oxidizer has been installed at Building 137 where F-15 aircraft will be refinished in the future; this is being done even though the current permitting does not require it. The equipment is designed to incinerate all VOC's exhausted from the coating operation in this facility. The system is planned to be in operation by October 1991.
Information concerning additional oxidizing systems is provided in the appendix.
Current Status of Robins
Painting Operations:
Buildine 18Q
Number of Booths: 4 (all water-curtain)
Product Painted:
Paints:
Spray Equipment:
Storage Procedures:
Small to Large Aircraft parts, and vehicles
Coroflex and epoxy primers; 2k polyurethanes; miscellaneous lacquers, alkyds, etc.
Conventional 30-35 psi applicators with one quart cups and in some cases pressure pots.
A very large quantity of paint is stored in the building 180 storage area. This paint is received from the main receiving and distribution facility.
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_ _ s-2

Robins Air Force Base
Warner Robins, Georgia
Paint disposal:
The paint is allocated, in gallon containers, by the painters on an as-needed basis. There exists no inventory control; no paint check-out procedures are required. The paint, after use, is stored in a large paint mix booth. The painters assert that the paint, once opened and stored in the mix booth, would be used again. However it was found that there were several gallon containers in the mix booth which were of the same type and had greater than half-a-gallon of paint remaining. The housekeeping in the mix booth was poor. One painter said that the booth was cleaned approximately twice every month and all unused paint was discarded.
The used paint is disposed into 55-gallon drums located in the back of the paint booths. There are several drums located in two of the four booths where the excess paint, paint waste, and cleanup solvent waste are disposed. n
Number of booths:
Product Painted:
Paints:
Spray Equipment:
1 (water-curtain)
Non-aircraft parts
Nitrocellulose lacquers, 2k polyurethanes, etc.
Conventional (30-40 psi) applicators with attached quart cups.
Brushes are also used in some cases. The painters in this facility are not currently using HVLP sprayers. They currently have
HVLP applicators which are not in use. The painters is no urgency to begin using the HVLP applicators. They also mentioned that the cups were smaller than the high pressure units. There has not been a thorough testing of the applicators as well, many of the painters have heard good stories on the effectiveness of the applicators but haven't had the opportunity to use the system. The supervisor feels they will begin using only HVLP applicators by October, however they have had some units for over a year and are still not using them. The supervisor mentioned that airless sprayers will be tested. s-3

Robins Air Force
Warner Robins, Georgia
Buil&&@
Number of Booths
Product Painted
1 (water-curtain)
The products (aircraft parts) coated in this booth first undergo an anodizing process before being coated. The product is then oven cured.
Paints:
Spray Equipment
Storage Procedures:
Waste Disposal:
Structural adhesive primers
Conventional applicators attached to pressure pots using approximately 60 lbs of pressure.
The painters have not been exposed to the HVLP sprayers, and are not planning to change their operation.
The paint is allocated from Building 180 and is stored in cabinets. The paint is pulled on an as-needed basis.
The waste paint and cleanup solvent is transferred to a 55- gallon drum located behind the paint booth.
~
Number of Booths:
Product Painted
Paints:
Spray Equipment:
Alternative Equipment:
Storage Procedures:
1 small booth (dry filter)
GYRO navigational electronic equipment. Sometimes shop equipment is painted as well.
Paladin lacquer
Conventional sprayer with one quart cup.
Have not been introduced to the HVLP type sprayer. This facility uses a relatively small amount of paint.
The paint is allocated on a monthly basis from supply. The paint is then stored in a cabinet and used on an as-needed basis.
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_ _ s-4

Robins Air Force Base
Warner Robins, Georgia
Paint Disposal: The waste paint and cleanup solvent are stored in a container under the booth. The waste is picked up routinely. The amount of paint waste generated at this booth is relatively small considering the amount of paint used. The spray equipment does not need cleaning very often since only one paint is predominantly used in this booth.
V. Buildine 14Q
Number of Booths:
Product Painted:
Paints:
Spray Equipment:
Alternative Equipment:
Storage Procedures:
Paint Disposal:
2 booths (1 large water-curtain, 1 small dry filter)
Props, spooners, slip rings, dome shells
Small amounts of lacquer, 2k polyurethanes, some 'IT-H-489
High solids
In the large booth conventional guns with pressure pots are used 90% of the time. Aerosol applicators are used the other
10%. The small paint booth utilized conventional sprayers with one quart cups.
The sprayers had heard of the HVLP's but have never tried them at this facility.
Paint is allocated from supply routinely, and the paint is stored in cabinets until needed.
The waste paint and solvent waste is stored together in 55- gallon drums.
VI. Buildine 15Q
Number of Booths:
Products Painted:
1 medium (water-curtain) and 2 small (dry filter) stenciling booths.
1 medium booth
2 small booths
- fire (halon) bottles
- stencilling is performed
'IT-P-1757 ZnCrO, Primer and nitrocellulose lacquers
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Robins Air Force Base
Warner Robins, Georgia
Spray Equipment: Conventional sprayers are used for top coatings. HVLP’s are used for spraying the chromate primer.
Storage Procedures:
Disposal Procedures:
Note: Painter does not like the
for painting, says it is too slow and time consuming.
The paint is allocated from supply routinely and is then stored in a cabinet for use on an as-needed basis. There are duplicate partially filled paint cans in this facility.
The paint and solvent waste is stored together in 55-gallon drums.
Buildine 181
Number of Booths:
Products Painted
Spray Equipment:
Alternative Equipment:
Storage Procedures:
Disposal Procedures:
1 large booth (water-curtain)
Ground support equipment less than 10 feet high. The facility is run by a commercial contractor.
‘IT-P-23377E SrCrO, Primer and MIL-C-83286 Polyurethane
Enamels
Conventional sprayers with pressure pots.
They use their own equipment for spraying. They have not been introduced to the H W investigate the option.
The paint is allocated from supply and is stored in a shed located beside the facility. A large amount of paint is stored for use on an as-needed basis.
Observation: This facility seems to do more painting than observed in the other facilities.
Even though this facility’s waste is generated by a commercial contractor, Robins Air Force Base is responsible for its final disposal. The waste paint and cleanup solvent is transferred into a 55-gallon drum located in the paint facility.
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Robins Air Force Base
Warner Robins, Georgia
VIII. Building 67Q
Number of Booths: 1 booth (water-curtain)
Product Painted
Paints:
Spray Equipment:
Radomes, Antennas
Coatings with specialized electrical properties, polyurethanes etc. A recent, successful trial run of MILC-85285 Polyurethane
High Solids was reported at this location.
Conventional sprayers with pressure pots when possible, however it seems that 1-quart cups are used most often. The painters in this booth have tried HVLP's and have them attached to small pressure pots. However they have not been able to get the parts to use them.
Storage Procedures:
Paint Disposal:
Paint and solvent is allocated from supply and stored in a cabinet for use on an as-needed basis.
Paint and cleanup solvent is stored together in 55-gallon drums located in the facility.
J x J ! a u
Number of Booths:
Product Painted:
Paints:
Spray Equipment:
Storage Procedures:
Disposal Procedures:
Not applicable, this is an outdoor sand blasting and painting facility. (Sand blasting for equipment to be painted in building
181 is also performed here.)
Large ground support equipment. This facility like that of building 181, is operated by a contractor.
Same as building 181.
Airless sprayers supplied by Robins AFB.
Same as building 181.
Same as building 181.

Robins Air Force Base
Warner
Georgia
& Building @
Number of Booths: Building 89 is supplied with temperature and humidity controlled make-up air, has balanced airflow through the spray area and has a double filtration system for collection of over- spray.
Product Painted:
Paints:
Spray Equipment:
Storage Procedures:
Disposal Procedures:
Whole aircraft (C-141, C-130, and F-15) are painted.
Approximately 10 aircraft are painted per month.
Coroflex and epoxy primers, 2k polyurethane top coats
Conventional sprayers with pressure pots. Have tried airless sprayers, however most of the painters do not use them claiming they are too slow. The painters claim not to have been exposed to HVLP applicators.
Paint is allocated from supply and stored in the hanger facility for painters to use on an as-needed basis.
Paint and cleanup solvent are disposed together in 55-gallon drums.
XI. Buildine 64Q
Number of Booths:
Products Painted
Paints:
Spray Equipment:
2 booths
However one is out of commission and may not go back on line.
Avionics electrical black boxes, antennas, and other electrical related equipment.
ZnCrO, and epoxy primers, lacquers, polyurethanes
Apparently low usage
Conventional sprayers are used with pressure pots (in most cases) and with in some cases 1-quart cups. Aerosol primers are also used.
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S-8

Robins Air Force Base
Warner Robins, Georgia
Storage Procedures: Paint is allocated from supply and is stored in a cabinet for use on an as-needed basis.
Disposal Procedures: The cleanup solvents and waste paint are separately segregated as much as possible in this facility. The cleanup solvent waste is stored below a hooded wash booth. The small amount of paint waste generated in this facility is stored in a separate container. The two wastes are routinely removed from the facility and transferred to 55-gallon drums in a waste storage area.
Note: A program is being developed to control hazardous material storage and allocation. Bar codes will be used in a computer controlled environment. Recycling of partially used containers of paint and solvents will be an integral part of this program.
.XII. Buildine
Number of Booths:
Products Painted:
2 Booths (2 water-curtain)
Paints:
Spray Equipment:
Storage Procedures:
Electronic Equipment, black boxes, miscellaneous equipment, antennas
Primarily nitrocellulose lacquers, some ZnCrO, primer
Currently use conventional sprayers with 1-quart cup. The painter in this booth has tried an airless sprayer but doesn’t like it for his application. The painter also has an HVLP by
DeVilbiss, but has not used it.
LY-Controlled booth
-
Formerly used conventional sprayers with pressure pots. Now use conventional sprayers with cups due to the painter’s preference.
Paints, thinners and other cleaning solvents are ordered from supply. The paint and solvents are stored in a cabinet next to the booth and allocated on an as-needed basis.
Isopropyl alcohol and PD 680 are used in cleaning booths next to the paint booths (in both locations of Building 645). These cleaning booths are used to clean parts. The solvent is allocated s-9

Robins Air Force Base
Warner Robins, Georgia
Disposal Procedures: by the paint booth operator for those who need to use the cleaning booth.
paints and solvents are collected weekly from the booth and taken to 55-gallon drums in a waste storage area outside the building. The paints and solvents are placed in the same drum.
. .
B u d b g 8 0 S A C
Number of Booths:
Product painted
Paints:
Spray Equipment:
Storage Procedures:
Disposal Procedures:
XIV. Building 304
Number of Booths:
The dry filters at this booth have reached their prescribed pressure head and need to be replaced. There is, however, no procedure for replacing and disposing of filters (according to the booth operators).
Small Parts (SAC)
Government specification primers and polyurethane top coats
Conventional sprayers are currently used. HVLP's have been tried and are available, however the painter felt that the H W sprayers were too slow. Note: The manufacturer didn't train the painters in their proper use, and this paint booth goes through only 0.5 to 1.0 gallons of paint/day.
Paint is allocated from stores, stored in a cabinet, and is used on an as-needed basis.
Paint and solvent is disposed together in a 55 gallon drum.
Product Painted:
Paints:
1 Booth (water-curtain)
This is a renovated booth which planned on re-opening July 31.
The booth is operated by a commercial contractor.
Vehicles
Conventional auto refinish paints, government specification paints, and will also apply CARC coatings
~ s-10

Robins Air Force Base
Robins, Georgia
Spray Equipment: Currently use conventional sprayers, however they claim that they are going to use HVLP sprayers.
Storage Procedures:
Disposal Procedures:
Paint is purchased by a commercial supplier and is stored onsite and is used on an as-needed basis.
It is not known how the paint will initially be disposed of, however, Safety Clean Corp. will be contracted to manage the waste generated in this facility.
XV. Buildine 354
Number of Booths:
Product Painted:
Paints:
Spray Equipment:
Storage Procedures:
Disposal Procedures:
1 Booth (water-curtain)
Guardrails, forklifts, wood equipment, metal equipment, misc. ground support equipment
Various maintenance, commercial refinish and specification finishes
Conventional sprayers with 1-quart cups, in some cases they use brushes and rollers.
As in most cases the paint, thinners and solvents are allocated from supply, stored in a cabinet and is used on an as-needed basis.
All paints, thinners, and cleanup solvents are stored together in a 55-gallon drum for eventual removal.
This facility is also in need of a better cleanup solvent tank with lid.
Building 275 C E Paint Shap
Number of Booths: 1 Booth (formerly dry filter, currently using water-curtain)
As in Building 80 (SAC) the current dry filter system had reached its headloss capacity and was in need of replacement.
The dry filters were removed and stored on-site for s-11

Robins Air Force Base
Warner Robins, Georgia
Product Painted:
Paints:
Spray Equipment:
Storage Procedures:
Disposal Procedures: replacement. Since a replacement time is not foreseen the waterfall booth was tumed back on for the interim.
Building support equipment (furniture, cabinets, vehicles also parking lot stripes bumper guards etc..)
Various maintenance, light industrial and specification finishes
HVLP's by Devilbiss have been in use for 2 years. All painters like the HVLP's above all the other type sprayers. They are quoted as saying "It's the best thing to come along." Never have had any real problems with the sprayers, as long as they are cleaned routinely.
Paints and some thinners are allocated from stores and used on an as-needed basis. Reclaimed solvents are allocated from the distillation building. The reclaimed solvents are shipped in 55- gallon drum containers. At the facility a spigot is attached to the drum to make solvent transfer efficient and clean. The reclaimed solvents are used to clean painting equipment.
Paints and thinners are segregated and disposed of separately.
Waste paint is disposed of in one 55-gallon drum, while waste solvent is stored in a different 55-gallon drum to be sent to the distillation building. This facility uses a washing system to clean sprayers. The system is made by Herkules (model 650228). The system is a closed loop/recycle process that cleans the paint can, sprayer, and sprayer cup at the same time using reclaimed solvent. Approximately 2 to 5-gallons of solvent, which is used and stored in the wash system, can wash a weeks worth of sprayers, cans, and cups.
Building 985 Auto Hobbv Shop
Number of Booths: 1 Booth (dry filter)
Products Painted:
Paint:
Personal vehicles
Apparently any type of commercially available refinish coating.
Personnel using the paint booth evidently supply their own coatings.
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Robins Air Force Base
Warner Robins, Georgia
Paint Equipment: Personnel using the paint booth use their own sprayers.
Storage Procedures:
Disposal Procedures:
Personnel use their own paint and thinners and bring the material with them when they paint.
One attendant at the building said that waste paint and thinner is disposed with used oil, transmission fluid etc. Another attendant said it is the responsibility of the person using the paint booth to dispose of the waste paint and thinner off-site.
Recommendations
Adoption and continued implementation of high solids for major aircraft finishes offer a significant opportunity for reduction of VOC emissions. It is recommended that high solids usage be implemented at all applicable spray stations as soon as approval can be gained.
Reportedly, a high solids epoxy top coat, MIGC-22750 at 420 grams/liter VOC, is also available to the aircraft industry for high-performance use in areas where exterior UV resistance might not be so critical.
It was noted that ground support equipment (apparently steel) was being sand blasted at
Pad 9 for subsequent painting at Pad 9 and Building 181. The removal of considerable rust is necessary in some cases. At both locations, the equipment is primed with MLP-23377
Epoxy Primer and top coated with MIGC-83286 Polyurethane in various colors. The total coating usage at these two stations is approximately 350 gallons/month. It is recommended that the use of a non-chromate primer, such as a non-chromate two component epoxy, be investigated for this application. This would eliminate the presence of toxic chromates in overspray and waste at these stations. It has been noted that the MIGC-83286 Safety
Orange being sprayed at Pad 9 had a warning label indicating the presence of lead. It is recommended that a non-leaded color variation or a non-toxic (organic) yellow pigmentation be considered for this use.
At buildings 640 and 645 low solids nitrocellulose lacquers are used. It is recommended that a water reducible polyurethane be investigated for replacement of these lacquers at applicable paint stations. Water-base polyurethanes, such as that available from Crown
Metro/Dexter, have reportedly been used for coating aircraft interior components.
At building 670 Plastic Shop, coatings with very specialized properties are used, a number of which are polyurethanes. It was reported that a MIGC-85285 Polyurethane High Solids had recently undergone a trial run with success. Final approval for implementation of this
S-13

Robins Air Force Base
Robins, Georgia substitute should be sought. It is recommended that these paints be implemented as soon as
approval is given.
During the
survey, it was difficult to determine the exact scope of non-specification painting being conducted. Some cases of non-specification painting were observed and some non-specification air dry alkyds etc., were in inventory. These more conventional type coatings might be better utilized when the resistance of specification coatings, such as 2- component polyurethanes, are not required. A means of assisting in controlling the use of specification coatings is covered in the inventory control recommendation.
Hkh Volume Low Pressure (HVLP) sprayers have a high transfer efficiencv and could be
I _
- usid for most of the coatingapplication processes idenyified on the base. -The success of any new equipment depends on proper training, ideally by the vendor of the equipment.
We recommend that the painters in all painting areas be trained on HVLP equipment. The t r a i h g session should include coatings and products appropriate to the painters' responsibilities. The painters from Building 275 CE are strong advocates for HVLP systems, have successfully demonstrated their use, and could serve as trainers for other painting areas
the base.
W N C O ntrol
Paint waste and solvent usage rates can be reduced by limiting access to raw materials. An inventory control program requires little, if any, capital investment and uses documented self-monitoring to help painters recognize wasteful practices. Lockheed Aeronautical
Systems Company has successfully used inventory control to reduce wastes from their painting areas. An inventory control program should include: (1) a listing of the appropriate materials to be used for various applications (i.e. non-specification parts, such as cabinets, can be painted with non-toxic or high solids non-specification coatings); (2) a responsible person to monitor materials usage; (3) limited access to raw material storage areas (Le. locked storage areas accessible to the responsible person); and (4) a written record on the type and volume of materials taken from the storage area and by whom. p solvent
Purchase of a similar washing system used in the CE Building 275 for all paint shops is recommended. This type ofsistem is made by Herkules (model 650228j. The ciosed loop/recycle system cleans paint cans, sprayers, and sprayer cups using reclaimed solvent.
At Building 275, approximately 2 to 5-gallons of solvent, used and stored in the wash system, can clean a weeks worth of sprayers, cans, and cups. Since it is a closed loop/recycle system, it minimizes solvent loss to the air and maximizes solvent usage. For large painting operations, this type of system can realize a pay-back period of less than a year.
Information and suppliers of two paint sprayer wash systems are supplied.
S-14
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Robins Air Force Base
Warner Robins, Georgia
Parts Washing
A major source of VOC output in buildings 640 and 645 is from cleaning stations using isopropyl alcohol and PD-680. The cleaning booth utilizes this solvent and a high-pressure sprayer to clean parts. The current system is inefficient in terms of VOC emissions and in solvent generated as waste. It is recommended that an alternative cleaning system such as a power washer which utilizes an aqueous, citrus, or detergent- based cleaning agent may be used where corros ion resistance is not cruc ial. These cleaning systems may be able to clean as well as the existing systems, cost less in terms of cleaning materials, generate a non- hazardous waste, and emit little or no VOC's. An investigation would have to be conducted to determine which type of system/systems would be effective for each facilities' parts. A listing of several parts washing vendors are listed in the project appendix. osal P r o c e d m
A program should be initiated to control the segregation and disposal of paint and solvent waste. In most painting areas, paint and cleanup solvents are combined in the same drum.
This combined waste cannot be recycled efficiently. Separate drums should be used for paint waste and solvent waste and painters should be trained on the importance of segregation.
The current distillation systems at Robins AFB are not used to maximum capacities. One reason is the package in which reclaimed solvent is returned to the painting areas. The reclaimed solvent is put in 55-gallon drums, but the fresh stock is purchased in convenient one-gallon containers. The painters prefer the smaller containers. One way to overcome the inconvenience is to outfit all drums containing reclaimed solvent with spigots and place them on racks or stands. Then reclaimed solvent could be easily transferred to reusable one-gallon containers for use.
Solid Waste Recycling
It was observed that a large amount of solid waste is generated at the uaint sites. A site- wide program to recycle s&d waste should be implemented. Large amounts of cardboard, plastic, and pallets which are sent to a landfill should be recycled. Recycling centers (listed in the project appendix) are within close range and will accept corrugated and plastic waste.
5-15

Robins Air Force Base
Warner Robins, Georgia
Project Appendix
The following are two suppliers of solvent spray equipment wash systems. Information on some of these systems is inclosed.
Herkules Equipment Corporation
8230 Goldie St.
Walled Lake, MI 48088-1298
(313) 363-8882
Safety-Kleen Corporation
1750-T Birchwood Ave.
Des Plains, IL 60018-3066
(708) 299-4060
Tbe following table contains a list of the different types of parts cleaning equipment available and an approximate price.
)€TON COST CLEANING
PROCESS
Pray- laster
'arts
3eaner
$8,940 High pressure
( 4 W 4 spray washer
'ower
Vasher
$5,795 High pressure
(7ooPsi) spray washer
XPACI'IY CLEAN COMMENTS
!OO lbs Good It did an adequate job but it is not very economical.
'empest $2,695 High pressure liquid detergent spray cabinet
Jltra-sonic $2W Ultrasonic
:leaner 3,500 vibration leaner mechanism
100 lbs Excellent Very good cleanink ability on all types of parts including lapped parts.
lbs Not tested Individual parts cleaned separately.
It would work well for parts with man; blind holes. ip to 50 lbs Excellent Works very well for smaller parts but it is difficult to use on large parts.
LOO0 lbs Average Air operated lift.
Long cleaning cycles are required
Large capacity.
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Robins Air Force Base
Wamer Robins, Georgia different containers
Sood Tested only small demo-model. A larger system would probably perform even better.
Sood Economically a good value. It would work very well on long time cvcles.
4verage Electric motor operated lift. Lon€ cleaning cycles are required. Large cauacitv.
4verage Air operated lift.
Long cleaning cycles are required
\Tot rested
Sood
Sood
It would probably do the job but the
Turbo-LiftKleen is a better value.
One pint to one gallon capacity cans. Lessens problems of evaporation and drag-out solvent losses.
One quart to 20 gallon capacity.
Each individual part is cleaned by hand.
S-17

Robins Air Force Base
Warner Robins, Georgia
The following vendors supply these products:
Graymills Corporation
3705 North Lincoln Ave.
Chicago,
60613
(312) 248-6825
Local Sales Rep:
Sydney Roland
Tempest, Turbo-LiftKleen,
Turbo-Clean-o-Matic
ADF Systems, LTD.
1103 16th Ave. North
P.O.Box 278
Humbolt,
50548
Power Washer
(404) 754-6700
ManGill Chemical
Magnus Division
St. Clair Avenue
Cleveland, OH 44117
(800) 627-6422
Miji-Iif, Magna-Lif
Sonicor
1365 Marconi Blvd.
Copiague, NY 11726
(516) 842-3344
Ultrasonic Cleaner
Bowden Industries, Inc.
7540 Memorid Parkway SW
Huntsville, AL. 35802
(800) KLEENER
Michael Hunt
Parts Washer
Kleer-flo
15151 Technology Drive
Eden Prarie, MN 55344
(612) 934-2555
Spraymaster, Powermaster
Justrite Manufacturing Company
2454 Dempster Street
Des Plaines, IL 60016
(708) 298-9250
Plunger Can, Dip Tanks
S-18

Robins Air Force Base
Warner Robins, Georgia
Information and Brochures for the following HVLP system suppliers are enclosed.
DeVilbiss Ransburg Brochure
Air Products Inc. Brochure
Industrial Coating Equipment 520 Airport Road/Fleming Field
An Illinois Tool Works Company South St. Paul, Minnesota 55075
Maumee, Ohio 43537 Contact: Tim Whaylan
Contact: Shaun
(612) 455-1213
(404) 696-4988
Graco Brochure
'awaiting information that has been requested
Spray Tips for the
Volume-Low Pressure Spray Systems
Information for the following VOC treatment systems is provided.
Terr-Aqua Enviro Systems, Inc.
15355 Manila Street
Fontana, CA 92335
(714) 350-9131
ASEA Brown Boveri
Adwest Technologies, Inc.
803 W.
Ave.
Orange, CA 92668
(714) 997-8722
Recycling Centers in close proximity to Warner Robins.
Albany Columbus
Consolidated Recycling Columbus Recycling, Inc.
1178 East Board Avenue 756 Lindsey
Albany, GA 31705
(912) 888-3446
Columbus, GA 30906
(404) 323-6306
Macon
Macon Iron & Paper Stock Co.
344 Oak Street
Macon, GA 31201
(912) 745-9817 s-19

GEORGIA
RESEARCH INSTITUTE
ENVIRONMENTAL SCIENCE
TECHNOLOGY LABORATORY
POLLUTION
Company: Southwire Company
Copper Division
P.O. Box lo00
Carrollton, GA 30119
Contact: Mr. Greg McKibben
Environmental Engineer
Copper Rod Primary Products:
Wastes Generated
Solid Waste
Second-Hand Cardboard
Pallets
Fugitive emissions from low grade lay-down yard
Fugitive emissions of lead in smelter building
The scope of this project includes the following four areas identified by Southwire Copper
Division personnel as pollution prevention opportunities:
1. Reduction of the volume of solid waste generated and disposed of in the county landfill. Wood pallets and cardboard boxes makeup a large percentage of Southwire's solid waste stream.
Reduction of fugitive dust emissions for the low grade lay-down yard. 2.
3.
4.
Reduction of fugitive emissions from furnaces by finding a substitute process to replace the anhydrous ammonia currently used for removing oxygen.
Reduce the volumes of gases generated by furnaces by the use of an electric plasma gun (plasma torch) in furnaces. The use of the plasma torch for treatment of furnace dust will also be investigated.
Process Description
Southwire Company is one of the largest producers of copper rod for the development of copper wire. Southwire acquires large amounts of scrap copper from over 100 suppliers around the U.S.. The scrap is received in second-hand boxes, segregated, and stored for input into the process. A large lay-down yard is used to store loose large piles (approx 30

Southwire Company
Carrollton, Georgia ft high) of low-grade scrap metal. Southwire converts the impure scrap copper into an interim product called the electrolytic copper anode. This anode is transferred and purified into an electrolytic copper cathode via electro-deposition in an acid bath. The copper cathode then undergoes four processes (melting, casting, rolling, pickling and coiling) to convert the raw copper into a copper wire rod. The copper rod is then converted into copper wire at a separate Southwire facility.
to Reduce Wastes
Southwire has made considerable progress over the last several years to reduce wastes and clean up the facility. The waste reduction areas considered in this analysis represent a team effort where personnel from all sectors of the plant provided input to generate the final list.
type of input from the working levels is the key to successful implementation of a pollution prevention program.
Recommendations
A detailed assessment of each of the four pollution prevention opportunities was conducted and the results are presented in Appendices 1 through 4. The analyses did not generate any single recommendation that should be immediately implemented, but resulted in a series of options that should be further investigated by Southwire. With the exception of finding a process to replace anhydrous ammonia for removal of oxygen, one of the options identified in the appendices could possibly be implemented in the foreseeable future. It is recognized that a replacement for ammonia will take some additional research on some of the topics identified in the literature search included in Appendix 3.
Attachments
Appendix 1
-
SOLD
Appendix 2
-
DUST EMISSION REDUCTIONS
Appendix 3
-
AMMONIA REPLACEMENT LlTERATURE SEARCH
Appendix 4
-
ASSESSMENT OF PLASMA TORCH FOR PROCESSING COPPER
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Southwire Company
Carrollton, Georgia
APPENDIX 1
SOLID
A large percentage of Southwire's solid waste is second-hand cardboard, used to contain low-grade scrap copper components. The next largest solid waste source is used pallets.
Cardboard
Uncontaminated corrugated cardboard can be recycled. Southwire's cardboard contains considerable contaminants which can be power-sprayed clean. Cleaned cardboard can then be dried and stored until enough can be collected to be economically feasible to be shipped to a recycle firm. Money earned from recycling corrugated can easily pay for shipping costs, while the cost of landfilling can also be saved. Recycle firms that accept corrugated cardboard and are in the Carrollton area are provided in the appendix.
Wax-coated cardboard currently cannot be recycled. The only alternative to landfilling is incineration/cogeneration. However, Southwire does not generate enough wax coated cardboard for this to be feasible.
Used Pallets
Southwire generates pallet waste which formerly contained boxes of low-grade copper components. There are several landfill alternatives for used pallets. Further information is provided.
Rebuild and Reuse
-
Pallets can be rebuilt and reused for outgoing shipments. Some companies save scrap pallets during fall, winter, and spring, then hire a dedicated summer student to rebuild all pallets for reused throughout the year. Unusable wood from pallets can be denailed and stored for employees' winter fireplace use.
Grind and Sale
-
Non-usable pallets can be ground into a course material. AI1 metal material should then be magnetically removed. The ground pallets can then be sold as a bedding to cattle and poultry farmers. The Gold Kist Poultry plant in Carrollton is a suggested first contact.
Selective Sale from $1.50
-
Pallets which are 48 X 40 4-way can be sold to several companies
-
$3.75 per pallet, depending on the condition. Several companies occasionally purchase different size pallets as well. Pallet companies that purchase pallets are provided in the appendix.
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Southwire Company
Carrollton, Georgia
Bibliography
"Properties of Shredded Wood Pallets", Forest Products Jou mal, June 1989, pp. 50-
54.
"Wooden Pallets: Disposal, Design and Distribution", Maten Handling
, October, 1990, pp. 71-75.
Recycling centers which are in the same proximity as Southwire and accept corrugated cardboard
Austell
Austell Box Board Corp.
3100 Washington Street
AusteqGA 30001
(404) 948-3100
Cartersville
Self Recycling Inc.
168 Cassville Road
Cartersville, GA 30120
(404) 382-2320
Albany
Consolidated Recycling
1178 East Board Avenue
Albany, GA 31705
Dalton
Berry Environmental Technologies
P.O. Box 982
700 North Hamilton Street
Dalton, GA 30722-0982
(404) 278-7677 Atlanta
G d e r &
594 Decatur Street
Atlanta, GA 30312
(404) 525-3183
Peachtree City
National Fiber Supply Co.
14 Eastbrook Bend
Peachtree City, GA 30269
(404) 487-2408 Mindis Recycling
1905 Lower Roswell Road NE
Marietta, GA
(404) 973-2312
Southeast Recycling Corporation
565 Western Avenue
-
Rear
Atlanta, GA 30314
(404) 524-4324
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Southwire Company
Carrollton, Georgia
Companies which purchase 48 X 40 4-way pallets. The price listed is the amount paid per pallet
Douglasville
Hill Top Pallet Inc
5556 Yeager Road
Douglasville, GA
(404) 949-0247
Price: $1.50
Atlanta
John Jones Pallet Company
705 Constitution Rd SE
Atlanta, GA
(404) 622-6304
Price: $2.50
Hapeville
Young C. Bowlden, Jr.
983 North Central Ave
Hapeville, GA
(404) 768-2347
Price: $1.50
-
$3.75
Loganville
C & D Pallet Inc.
Highway 78
Loganville, GA
(404) 466-4589
Price: $1.50

Southwire Company
Carrollton, Georgia
APPENDIX 2
FUGITIVE DUST EMISSION REDUCTIONS
Several alternatives can reduce the fugitive dust emissions from Southwire’s low-grade lay- down yard
Dry Fog
-
Water can be sprayed using a proprietary device which emits a fog of very fine water droplets. When applied, fugitive dust particles become agglomerated and settle onto the pile. This type of spray system will not actually wet the area since the spray is in essence a fog which will settle on the area of concern. The frequency and amount of application will depend on the climate and amount of fugitive emissions. See the appendix for information concerning vendors.
Contact: Sonic Development Corporation
or Chemical Application
-
Another alternative is foam or a solution of chemicals and water which is applied to a pile using a spray device. In most cases these ty-pes of materials can provide the same suppression as water suppression but with much less application frequency. This combination reduces manpower costs, water usage, and accumulated mud. See the appendix for information concerning vendors of foam and chemical additives.
Contact: DeTer Company, Inc., Johnson March Systems, Inc.
Note: These types of chemical and foam additives should be evaluated before implementation. The components may interfere with Southwire’s process and may also be a source of fugitive and stack toxic emissions. Non-toxic additives are the preferred application.
Physical Barrier
-
A physical barrier could be constructed to provide protection from wind. The barrier must be strategically placed to block the prevalent wind, but not obstruct transient traffic. An example is a fence approximately 3/4 the height of the lay-down pile with a porous cover, much like that used around tennis courts. If situated close enough to the pile, this type of protection can block much of the approaching wind thus substantially reduce fugitive emissions. According to a representative of Johnson March Systems, Inc., a protective barrier, if correct for the circumstance, can provide as good, if not better, dust suppression as water-based systems.
type of approach can also save substantial future material costs. __

Southwire Company
Carrollton, Georgia
Bibliography
"Dust Suppression System Doesn't Wet Coal", m, p.104.
"Enclosure, Wet Suppression Will Help Control Dust", Pit & Ouarry, January 1988, pp. 72-74.
"Keeping Down the Dust", Pit & Ouany , November 1988, pp. 27-29.
Vendor Information
Sonic Development Corp
Parsippany, NJ
(201)882-9288
Johnson March Systems, Inc.
220 Railroad Drive
Ivyland, PA 18974
(215) 364-5425
DeTer Company, Inc.
Kentucky 40310
(606) 748-5262

Southwire Company
Carrollton, Georgia
APPENDIX 3
ASSESSMENT OF METHODS OF OXYGEN REMOVAL
FROM MOLTEN COPPER
Pollution h v e n t i o n Objective
Research of the methods for the removing oxygen from molten copper to replace the ammonia currently used for oxygen removal and a major source of emissions.
Current System
The current system of oxygen removal from molten copper utilizes ammonia to react with the oxygen in the copper and remove the oxygen as a gas. The complete reaction of ammonia and oxygen assuming the oxygen is in the form of copper oxide is as follows:
2NH.4
+
2CUO -> 2HzO
+
N, +2CU
Since the copper oxide is a solid, one volume of ammonia gas is producing three volumes of gases consisting of 2 volumes of water vapor and one volume of nitrogen dioxide. The large volume of gases emitted from the reaction tends to carry particulates in the form of metals which increases emissions from the process.
The current process has three major drawbacks.
1. the process generates large quantities of gas which carry heavy metals such as lead and chromium into the environment,
2. ammonia is a reportable chemical on the toxic release inventory although the quantities actually released are minimal, and
3. ammonia is an extremely hazardous substance (EHS) which requires additional reporting requirements under
111 and consideration of exposure limits for worker health and safety under OSHA requirements.
Method of Assessment
The process of removal of oxygen from copper of any molten metal is a complicated process and is not easily analyzed. Many of the current techniques were established years ago, and there is reluctance to modify these methods since the quality of the product produced meets production standards. Any change in the process should be carefully evaluated before implementation since changes in quality could be disastrous. A systematic process of
~
~
__
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Southwire Company
Camllton, Georgia literature research, laboratory evaluation, bench scale evaluation, and pilot scale evaluation should first be conducted. The first step in this evaluation is to review the research currently being conducted on the technology of the removal of oxygen from molten metal and, specifically, molten copper.
The Library of the Georgia Institute of Technology was utilized for literature search a computerized of processes for the problem. This literature review is essential in determining which technologies have been investigated and are currently being studied to prevent investigating a technology that has proven to be ineffective or those that have the potential to solve a problem but need additional research.
After discussions with representatives from several of the database sources, the Library identified the ’key words” that should be used in the search of the databases. Key words have different uses in different data bases. Many data bases use key words in a ”wild card format which means that if the “key word’ appears any place in the citation including the title and abstract even the authors name or publisher) a citation will appear in the database search.
a result, the search will be complete but many citations w l not appear to be relevant to the topic.
A search was conducted of several data bases using copper wire(s), copper wiremaking, copper rod(s), or copper (base) alloys for the copper and the stem words deoxidiz and deoxygenat for the oxygen removal process. The following data bases were accessed as a part of the search process:
METADEX
COMPENDEX
CASEARCH
ASTI
ENGI
INSP
- A metals and metallurgy database
-
A general engineering database
-
Chemical Abstracts Search
-
Applied Science & Technology Index
-
Engineering Index Monthly/Compendex Plus
-
A index of engineering journal articles
-
Trade and Industry Index
The search identified a total of 223 citations using the key words and stem words previously discussed. The output from the search has been reviewed and 14 citations appear to have data or information related to the problem. The following is a summary of the citations found in each of the databases.
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Southwire Company
Carrollton, Georgia
Database
METAJIEX
COMPENDEX
CASEARCH
ASTI
ENGI
TRND
Total CI 'tations
40
13
52
1
12
24
21
223
Amlicable Citatiow
3
1
5
0
5
0
0
14
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Southwire Company
Carrollton, Georgia
The complete computer output has been provided to the Southwire Copper Division under a separate cover. The following is a review of the 15 citations applicable to the problem:
JETADEX
-
Bydalek' reported laboratory studies using carbide as a refining agent.
The study reported good deoxidizing and desulfuring of the castings. The citation indicates the paper is written in Polish, but translations can usually be obtained.
Pimenov and Gofenshefe8 conducted laboratory studies to generate a mathematical model for the melting process. Their research indicated that finer fraction and larger flux layer contribute to a significant decrease in the amount of the dissolved oxygen in the melt. A translation of this paper was found in the ENGI database. The final citation in this database was an article3 that discussed the use of boron for deoxidation.
COMPENDEX
-
The only applicable citation identified in the database was a paper by Dompas and Lockyer4 which describes the development of a probe for monitoring of the oxygen content of molten copper. Since this paper is almost 20 years old, it likely that newer technology is available.
CASEARCH
-
Arakida and Kiyomiyas have a British patent for a production process for low-oxygen copper wire. The data in the citation is limited but it appears that the process involves specific controls of the reducing gas atmosphere to control the oxygen content of the product. Another paper by Bydalek6 appears to discuss some of the same work as reference 1. Unfortunately, the second paper is also in a foreign language. However, it may be worthwhile to contact the author since this appears to be an area of interest. It appears that Mr. Bydalek can be reached through the
Polish Academy of Sciences, 00-901
Poland. Nanda and Geiger7 investigated the kinetics of oxygen removal by carbon monoxide. A patent by Froulard and Galef describes processes for removal of oxygen using hydrogen and nitrogen, and a second patent by Associated Electrical
Industries' uses hydrogen for the same process.
-
Nagai et d .
describe a vacuum system for removal of oxygen from molten copper. The citation indicates that a system has been installed in a fully continuous casting plant. An english translation of Pimenov and Gofenshefer" (Reference
Number 2) was found in this database. Sudavtsova et aZ.12 studied the effect of lithium, boron, magnesium, and yttrium on the activity of liquid copper and concluded that the elements could be used for deoxidation. Correlations were drawn between the deoxidizing features of the elements. Selenium as a deoxidizing agent was investigated by Seetharaman and Staffan~son,'~
Razavi-Zadeh and Miramadi."
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Southwire Company
Carrollton, Georgia
Summary
The research in the United States in methods of removing oxygen from copper seems to ten to twenty years old. However, research in other countries is much more current, probably driven by environmental problems. Several of these technologies might have potential for the elimination of the use of ammonia.
References
1. Bydalek, A, "Interaction of Active Calcium Compounds with Copper and Its Alloys in Liquid Form," loth Repotting Meeting of the Polkh Academy of the Sciences,
Division WMetallurgy Committee, 1981-1 984, Papers, Volume ZZ, Kozubnik, Poland,
(1984).
2. Pimenov, A. M. and Gofenshefer,
"Deoxidizing Capacity of Carbon-Containing
Covering Fluxes During Copper Melting," Liteinoe Proizvod (3), (1989)
3. "A Specially Processed Boron Deoxidized Copper Developed for Electrical
Conductors," Wre wire Prod Vol42 No. 6, p 982 (1967)
4. Dompas, J. M. and Lockyer, P. C., "Oxygen Control in Liquid Copper by the Oxycel,"
Metallurgical Technologies Vol. 3 No. 10,
5. Arakida, Y and Kiyomiya, S.,
Kingdom Patent No. GB 2041411.
United
6. Bydalek, A, "Studies on Copper and Copper Alloy Refining Using Calcium Carbide,"
22, NO. 12, pp. 663-665, (1977).
Nanda, C.R. and Geiger, G. H., "Kinetics of Deoxification of Copper and Copper
Alloys by Carbon Monoxide," Metallurgy Transactiom VoL 2 No. 4, pp. 1101-1106,
(1971).
8. Froulard, J. and Galey, J., "Deoxidization and Degasification of Copper and Its
Alloys," French Patent No. 1552137.
9. Associated Electrical Industries, "Deoxidizing of Copper and Its Alloys," Netherlands
Patent No. 6607251.
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Southwire Company
Carrollton, Georgia
10. Nagai, Y., et
"Mass Spectrometric Observation of Vacuum Treated Oxygen Free
Copper," Proceedings of the 11th International Vacuum Conference and 7th
International Conference on
Surjkces, Cologne, Germany, (1990).
11. Pimenov, A. M. and Gofenshefer, L. I., "Deoxidizing Capacity of Carbon-Containing
Covering Fluxes During Copper Melting," Soviet Castings TechnologV No. 3, (1989)
12. Sudavtsova, V.
et al., 'Effect of Lithium, Boron, Magnesium, and Yttrium on the
Activity of Liquid Copper," Melts VoLI N0.2, pp. 111-114,
13. Seetharaman,
and Staffansson, L., 'Bffect of Selenium on the Activity of Oxygen in Dilute Liquid Copper Alloys," Scandinavian Joumal ofMetallurgv VoL 17No. 3, pp.
14. Razavi-Zadeh, H. and Miramadi, T. S., "Deoxidizing Copper with CaB," Journal of
Metal- VoL 39 No. 2, (1987)
T-13

Southwire Company
Carrollton, Georgia
APPENDIX 4
ASSESSMENT OF PLASMA TORCH FOR PROCESSING COPPER
Pollution Prevention Objective
Research and evaluate methods to reduce gas volumes generated in the processing of copper and increase the efficiency of the current control equipment. The project would include the suitability of an electric plasma gun (plasma torch) for processing copper.
Project Description
Plasma technology is used in numerous situations in the metals fabrication industry. These include blast furnaces, smelting, and other applications. Plasma is a physical state of matter obtained by ionizing a gas. A plasma consists of positively charged ions and negatively charged free electrons, but remains electrically neutral. However, the fact that a plasma is ionized makes the plasma an electrical conductor.'
A plasma transfers electrical energy to another material. A plasma torch works in a transferred and non-transferred arc mode. In the transferred arc mode, one of the electrodes is attached to the torch and the other is attached to the material being heated.
This mode is typically used when the material being heated is a conductor such as copper.
In the non-transferred arc mode both electrodes are attached to the torch. This mode is used when the material being heated is not a conductor such as municipal solid waste. The gas used for the plasma gas can be selected to establish an oxidizing, neutral, or reducing environment.
initial review of the operations at the Copper Division of Southwire (CDS) indicated the possible use of the technology in the blast furnace, Hoboken converter, anode holding furnace, Maertz furnace, the melting of cathodes in the rod mill, and/or the treatment of dust from any of the furnaces. After discussion with CDS personnel, it was decided to analyze the use of plasma technology in the anode holding furnace and the treatment of dust
the anode holding furnace. The analysis of the plasma torch for the anode holding furnace was conducted on a Lotus 123 spreadsheet. The seven tables presented in this analysis are part of the same spreadsheet. Therefore, the analysis can be easily modified to reflect changes in factors that were estimated to conduct the analysis or evaluate alternative factors such as the currently low cost of natural gas. A copy of the spreadsheet will be provided to CDS.
__
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Southwire Company
Carrollton, Georgia ldine Furnace Assessme nt
anode holding furnace assessment will evaluate the replacement of the oxygen blown natural gas burners in the current furnace with plasma torches. The operating parameters
for the holding furnace are presented in Table 1.
The current system has one 7-million Btu per hour, two 2-million Btu per hour, and one 4-million Btu per hour burners in the system.
This analysis combines all four burners into one 15-million Btu per hour system. It is recognized that the actual replacement could involve any of the burners and could be phased to evaluate the impact of a single torch before further investment. The plasma torch for
application would be operated in the transfer arc mode.
The maximum permitted annual operation of was provided by
The energy costs of $1.30 per million Btu for natural gas and $0.035 per kilowatt hour and the cost of oxygen of $0.23 per 100 cubic feet were also provided by
The cost of anhydrous ammonia of $145 per ton was obtained from the Chemical
Marketing Reporter? The air pollution control operating cost of $980,000 per year, the processing rate of 58 tons per hour, and the maximum temperature of 2,180°F were provided by CDS.
P--
Table 1. Operating Parameters for Holding Furnace
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Southwire Company
Carrollton, Georgia
The physical constants used
in the computations are presented in Table 2. The densities
and molecular weights were obtained from Crane? The oxygen composition of air by volume and the anhydrous ammonia specific volume were obtained from Hawley’s4. The water density of water was also obtained from Crane’.
The assumptions for the current operation of the holding furnace are presented
in Table 3.
These were used in the analysis of the current system and the analysis of the current system fired with a plasma torch. The first assumption is the efficiency of the current burners in the transfer of input energy in the form of natural gas into the copper. The factor is not used in the analysis of the current system, but used to size the plasma torch for the modified system.
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Southwire Company
Camllton, Georgia
Table 2. Physical Constants
Air Density
Methane Densitv
Oxygen Density
Carbon Dioxide Density
Water VaDor Densitv
Nitrogen Dioxide Densitv
Ammonia Density
Methane Molecular Weight
Oxygen Molecular Weight
Nitrogen Molecular Weight
Carbon Dioxide Molecular Weight
I
Water Vapor Molecular Weight
Ammonia Molecular Weight
Percent Oxveen in Air bv Volume
Water Density
Anhydrous Ammonia Specific Volume
I
I
I
0.07528 pounds per cubic foot
0.04163 vounds Der cubic foot
I
0.08305
0.11420
I pounds per cubic foot
I I pounds per cubic foot
0.03731
I
Dounds Der cubic foot
I
0.07274
I pounds per cubic foot
0.04420 pounds per cubic foot
16
28
I I
44
I
17
20.95%
8
I pounds per gallon
1
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Southwire Company
Carrollton, Georgia
Table 3. Assumptions For Current Operation of Holding Fumace
Bumer Efficiency
Percent Pure Oxygen to
Burners
Percent of Pollution Control
Cost Attributed to Holding
Fumace Operation
50.0%
30.0%
30.0%
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Southwire Company
Carrollton, Georgia
The 50% estimate is based on discussions with other engineers who are familiar with the operation of oxygen fired natural gas burners and data in Industrial Furnaces? The actual computation of the burner efficiency is complicated and involves the computation of a number of factors. These factors, as outlined in Chapter 5 of Industrial Furnace?, include:
0
0 o o o
0
Heat losses through the wall of the furnace,
leakage through the wall of the furnace,
Heat loss by radiation through openings,
Heat loss by gases escaping around doors,
Sensible heat camed out of the furnace by products of combustion, and
Heat loss by incomplete combustion.
The second factor is the percentage of pure oxygen in the combustion air supplied to the burners. This factor was provided by CDS personnel and is used to compute the annual amount of pure oxygen purchased for economic computations. The annual cost for operation of the total air pollution control system of $988,000 was supplied by CDS.
However, this cost includes the control of emissions from other sources such as the blast furnace and the Hoboken converter. The 30% factor is an estimate of the cost of the total air emissions contributed by the anode holding furnace. The last factor of 1,OOO Btu per cubic foot is a typical value for the energy content of natural gas.
The analysis of the current operation of the holding furnace using the four oxygen enhanced
natural gas burners is presented in Table 4.
The energy input to the burners is computed by multiplying the total energy input to the four burners in Btu per hour by the number of operating hours per year. The energy input to the copper is computed by multiplying the energy input to the burners by the burner efficiency. As previously discussed, this value is used to size
the plasma torch in the analysis presented in Table 6. The natural
gas required in cubic feet is computed by dividing the energy input to burners by the heating value of the natural gas and this value is converted to pounds by multiplying the amount in cubic feet
by the density of natural gas (methane) by the density shown in Table 2.
The next part of the analysis computes the oxygen from air and pure oxygen required for the natural gas burners. The computation is based on the reaction of natural gas (methane) and oxygen at the stoichiometric condition, Le., without excess air or pure oxygen. The following is the reaction and stoichiometric mass balance for the reaction:
CH,
+
202 = COZ
+
2HzO
16 lb
+
2 x 32 lb = 44 lb + 2 x 18 lb
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Southwire Company
Carrollton, Georgia
The reaction of one mole of methane and two moles of oxygen generate one mole of carbon dioxide and two moles of water vapor. On a mass basis, 16 pounds of methane and 64 pounds of oxygen ( 2 moles x 32 lb per mole) generate 44 pounds of carbon dioxide and
36 pounds of water vapor. The multiplication of the amount of the methane (in pounds)
the ratio of the mass of oxygen to mass of methane in the above equation are used to compute the oxygen required.
~~
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thwire Company rollton, Georgia
4. Computation of Current Operation of Holding Furnace
I I
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Southwire Company
Carrollton, Georgia
The combustion oxygen required accounts for the oxygen naturally occurring in air and the pure oxygen supplied to the natural gas burner. The following equation is used to compute the oxygen in the combustion gas: oxygen in combustion gas = percent pure oxygen percent oxygen in air
+
(1
- percent pure oxygen) x
The values computed are on a volumetric basis, since the percent of pure oxygen in the total combustion air is typically volumetric. The percent oxygen in the combustion gas is multiplied by the density of oxygen to determine the density of the oxygen in the combustion
in pounds per cubic foot. The value computed is then multiplied by 1,OOO to convert to pounds per 1,OOO cubic feet (a more readable number).
The oxygen required is divided by the oxygen in the combustion gas to determine the combustion oxygen required. The pure oxygen required is computed by multiplying the combustion oxygen required by the percent of pure oxygen from Table 3, and the value is later use in the economic analysis. The air required is computed by multiplying the combustion oxygen required by the difference between the combustion required and the pure oxygen required and dividing the percent of oxygen naturally occurring in air. The nitrogen produced is calculated by multiplying the air required by the percent of nitrogen in air, i.e., 100% minus the oxygen concentration by volume. The nitrogen in the air is one of the gases contributing to the load on the air pollution control system.
The next part of the analysis determines the other gases produced by the burner system from the combustion of methane. The volume of these gases will later be compared with the volume of the gases produced from the plasma torch and used to compute the savings that are achievable with the plasma torch. The computation is based on the stoichiometric mass of carbon dioxide and water vapor produced from the reaction of methane and oxygen that was previously discussed. The amount of gases in pounds produced is determined using the stoichiometric mass balance where 16 pounds of methane produce 44 pounds of carbon dioxide and 36 pounds of water vapor. The total combustion gases produced is the sum of the carbon dioxide and water vapor from combustion. The amount of carbon dioxide and
water vapor produced is converted to gas volume using the densities in Table 2. The
combustion gases produced in million cubic feet produced is the sum of the volumes of carbon dioxide, water vapor, and nitrogen from the system.
Ammonia is also added to the anode holding furnace to remove oxygen from the copper.
The estimate of 3 gallons per minutes was provided by CDS. The ammonia flow rate was converted to gallons per year by multiplying the gallons per minute by the operating hours
per year and converted to pounds per year using the constants in Table 2.
___
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Southwire Company
Carrollton, Georgia
The reaction products from the addition of ammonia are based on the following reaction and stoichiometric mass balance for the reaction:
4NH3
+
30, = 2N2
+
6H,O
One of the advantages of a plasma torch is that the plasma gas can be selected to create an oxidizing, neutral, or reducing atmosphere. This analysis will assume that methane is selected as the plasm gas to create a reducing atmosphere, and that ammonia will be eliminated from the system. Therefore, the next step in the analysis is to compute the amount of oxygen removed to determine the amount of methane required in the plasma torch analysis. This computation is based on 68 (4 x 17) pounds of ammonia removing 96
(3 x 32) pounds of oxygen from the copper.
The next part of the analysis determined the amount of gases produced from the reaction in a similar manner to the computation to the products and is similar to the computation for the combustion products from the burner. The amounts in pounds are converted to volumes using the conversion factors in Table 2, and the total gas from ammonia is computed. The volume of gases from ammonia is added to the volume of gases from combustion to compute the total of 556 million cubic feet per year.
The economics of the current operation of the anode holding furnace are presented
in Table
5. The cost for
natural gas, pure oxygen, and ammonia are computed by multiplying the
quantities consumed in Table 4
by the unit costs in Table 1. The air pollution operation
costs are computed using the 30% factor for the operation of the total system as previously discussed. The estimated total operating cost for the current system is $580,915.
Table 5. Economics of Current Operation of Holding
Natural
Cost
Pure Oxygen Cost
Ammonia Cost
Pollution Operation Cost
$37,050
11
$88,278
$159.187
$296,400
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Southwire Company
Carrollton, Georgia
The assumptions for the plasma torch operation of the anode holding furnace are presented
in Table 6.
The plasma torch efficiency of 90% is based on estimates presented in ARC' for a plasma torch operated in the transferred arc mode which is typically used for heating
conducting materials such as copper. The assumption to the operational cost of the air pollution control system was previously discussed.
Table 6. Assumptions For Plasma Torch Operation of Holding
Furnace
~~
Plasma Torch Efficiencv
Percent of Pollution Control
I
90.0%
30.0%
The analysis of the plasma torch operation of the anode holding furnace is presented in
Table
7. The energy input to the copper was computed in Table 5
based on an assumed transfer of heat from the natural gas burners to the copper. The energy input to the copper is divided by the torch efficiency to obtain the energy input to the torch. The energy input to the torch is divided by the annual hours of operation to obtain the torch power in million
Btu per hour. This value is divided by 3,413 Btu per hour to obtain the torch power in megawatts (MW). The total torch power for the system would be 2.44 MW. As previously discussed, the system would probably consist of several smaller torches, but the total torch system was used for comparison purposes. The torch power is multiplied by the annual hours of operation to obtain the annual torch energy requirement in megawatt-hours.
The oxygen removed in the existing anode holding furnace using ammonia was computed
in Table 6.
The reaction is the same as for the natural gas burner where 16 pounds of methane react with 64 (2 x 32) pounds of oxygen. The amount of methane in pounds required for
reduction is computed and converted to cubic feet using the constants in Table
2.
The methane consumption is converted to cubic feet per hour by dividing by the annual operation and finally to cubic meters per hour. ARC' indicates plasma gas flows vary from to 15 to 1,500 cubic meters per hour. Since the 277 cubic meters per hour for this system is within this range, it appears to be a reasonable number for a first estimation.
The remainder of the analysis computes the carbon dioxide and water vapor generated from the reaction
methane and oxygen. The computation is first made in pounds and
converted to million cubic feet per hour using the densities in Table 2.
The final
T-24
_ _
-

Southwire Company
Carrollton, Georgia computation if the total gas flow in cubic feet per hour from the anode holding furnace heated with a plasma torch to the air pollution control system. It should be noted that the
65 million cubic feet per year is significantly less than the 556 million cubic feet per year from the current system.
The economic analysis of the plasma torch operation of the anode holding furnace is presented
in Table 8. The natural gas and electricity costs are computed by multiplying the
consumption computed in Table 7 by the
unit
costs in Table 1.
The air pollution operation cost is
computed by multiplying the cost shown in Table 6
by the plasma system to those produced by the current system. The total operating cost of the plasma torch system i s estimated to be $221,405 annual savings over the existing system.
T-25

Southwire Company
Carrollton, Georgia
Table 7. ComDutation of Plasma Torch Operation of Holding Furnace
Energy Input Required to Copper 14,250 million Btu per year
Energy Input to Torch
Torch Power
Torch Power
Torch Energv Reauirement
Oxygen Removed
Plasma Gas Required as Natural Gas
Plasma Gas Reauired as Natural Gas
Plasma
Required as Natural Gas
Plasma Gas Required as Natural Gas
Natural Gas Reauired
Natural Gas Reauired
15,833
8.33
2.44
4.639
3,099,778
I
774,945
I I
I
18.62
I
9,797
277
18.62
I
774,945 million Btu per year
I million Btu per hour
I I
MW
I
MW hours
1 pounds per year
I I pounds per year
I
I cubic feet per hour
I I cubic meters per hour
I million cubic feet Der vear
I uounds per year
Carbon Dioxide Produced
Water Vapor Produced
Combustion Gases Produced
2,131,098
1,743,625 pounds per year
I pounds per year
I
3.874.723
I uounds per year
Carbon Dioxide Produced 18.66 million cubic feet per year
+
Water Vapor Produced
Combustion Gases Produced
46.73
65.39 million cubic feet per year million cubic feet per year
A estimated capital cost for a plasma torch system is $1,000 per kilowatt. The 2.44 MW system
cost an estimated $2,241,441. The system will payback in 6.8 years representing a 14.7% return on investment. The torch(s) could be installed in the existing anode holding furnace with a change in the refractory material. The torch electrodes have a service of 200 to 500 hours depending on the plasma gas used. A cost for replacement of electrodes was not included in the analysis.
T-26

Southwire Company
Csmllton, Georgia
Conclusions
The use of plasma technology for the anode holding fumace will significantly reduce the volume of gases from the furnace. This reduction in gas volume should also significantly reduce the lead emissions from the system. The technology has the potential for use on other furnaces at the facility. However, it is suggested that installation in the anode holding furnace be accomplished first to verify system operation and allow plant personnel to become familiar with plasma technology.
The payback shown for this analysis, while positive, might be considered marginal at this time. However, there a number of other factors that should be considered that could significantly improve the economics of the plasma torch system. These factors include: o o o the cost of disposal of residues from the air pollution control system (if not included in the operating cost already), increased operation efficiency of the furnace due to better temperature control achievable with the plasma torch, and the possibility of more annual hours of operation due to the reduction in emissions from the system.
This preliminary assessment has demonstrated a sufficiently acceptable return on investment to warrant an further, more detailed analysis of plasma technology.
T-27

Southwire Company
Carrollton, Georgia
Table 8. Economics
Plasma Torch Operation of Holding Furnace
Natural Gas Cost
Electricity Cost
Air
Operation Cost
Subtotal
I
I
I
$24.200
I
$162,369
1
$34,836
I
I
$221,405
I
I
$359.509
I
I
Plasma Torch Cost
Total Plasma Torch Cost
Simple' Payback - on Investment
$1,000 per kW
$2,441,645
6.8 years
14.7%
T-28

Southwire Company
Carrollton, Georgia
References;
1. ARC Plasma Processes, UIE ARC Plasma Review 1988, Report written by the UIE
Plasma Process Working Group, International Union for Electroheat (UIE), Tour
Atlantique, Cedex 6, Paris, France, 92080.
2.
3.
Chemical Marketing Reporter. 1991. Schnell Publishing. New York, NY. August 12,
1991.
Flow of Fluids through Valves, Fittings, and Pipe, Technical Paper No. 410, Crane
Company, New York, NY, 1976.
4.
5.
Hawley's Condensed Chemical Dictionary, Eleventh Edition, Van Nostrand Reinhold
Company, New York, NY, 1987.
Industrial Fumaces, 5th Edition, W. Tinks and M. H. Mawinney, John Wiley & Sons,
New York, NY, 1961.
Assessment of the treatment of dust from the blast furnace and converter
The treatment and disposal of dust from the metals processing industry is problem for all sectors of the industry. A process for recovery of metals from this dust was described by
ARC'. The process is based on the PLASMADUST process developed by SKF Plasma
Technologies AB, P.O. Box 44, S-182 11 Danderyd, Sweden. The company has designed, built, and is operating the SCANDUST facility that can process 77,000 tons of dust per year at Landskrona, Sweden. This facility uses three 7-MW plasma torches for processing the dust. The SKF torch operates in the non-transferred arc mode. However, another system could be operated in the transferred arc mode resulting in an increase in efficiency.
The process injects dust, coal powder, and slag formers into a low shaft furnace. Practically all the metal oxides in the feed material are instantaneously reduced when these enter the reaction zone in the shaft furnace. The zinc and lead oxides are also reduced as these enter the reaction zone. The metals are then vaporized, removed from the shaft furnace with the off-gas, and recovered by condensation outside the furnace. Lead is used to cool and dissolve the zinc metal produced. The zinc-containing lead is continuously pumped from the condenser to a cooling launder with immersed cooling coils. When the lead is cooled, a zinc layer is formed and removed in a separate furnace. The zinc produced is considered to be of Prime Western Grade. The waste material from the process is no longer considered hazardous although the results of toxicity characteristic leaching procedure
T-29
~
~~

Southwire Company
Carrollton, Georgia
(TCLP) is not mentioned in the report.' Energy can also be recovered from the export gases and cooling water to improve the efficiency of operation.
The plant is used for processing electric arc furnace (EAF) dust from the production of carbon and stainless steel. Table 9 provides a comparison of the zinc and lead content from the
blast furnace and converter and from the SCANDUST facility. The data on copper dust was provided by CDS and the SKF data from ARC'. The CDS data was from several different dates and the data indicated is the range for these dates.
Table 9. ComDarison of CDS and SKF Dust
I
Zinc Oxide
CDS Blast Furnace CDS Converter SKF EAF Carbon Steel
Dust Analysis Dust Analysis Dust Analysis
I
35.15
-
59.86%
I
26.59
-
52.56%
I
25
-
30%
I I
15.74
-
30.52%
I I I
13.88
-
27.84% I 2 - 6 % Lead Oxide
II
II
The zinc concentrations in the CDS dusts are higher than the SKF EAF dust. This should result in the production of more zinc and improve the economics over the SKF EAF system.
However, the concentration of lead is significantly higher which could reduce zinc recovery or require modifications in the process. Tests will be required with a bench-scale system to determine recoverJt efficiencies.
Table 10 provides a
summary of the energy and feed requirements for the SKF plant from
ARC'. As previously discussed, standard refractories can be used in these systems and the plasma torch electrodes last from 200
-
500 hours depending on the plasma gas.
Table 10. Energy and Feedstock Inputs for SKF Plant for Carbon Steel EAF Dust
Electric Enerev For Plasma Torches
I
1.814 kWh Der ton of dust coal
Coke
Energy Recovery from Export
and
Cooling Water
,
220 pounds per ton of dust
I
240 pounds per ton of dust
1,100
-
1,400 kWh
I
T-30

Southwire Company
Carrollton, Georgia
Conclusim
The data on treatment of dust, particularly from copper operations, is not complete.
However, it appears that the potential exists for the development of a system using plasma technology. Additional research on a bench-scale system is warranted.
T-3 1

. . . . . .. .
3.0
Seminars
_ _
___

3.0 Pollution Prevention Seminars
3.1 Location and Marketing of Seminars
The Georgia Tech Research Institute Economic Development Laboratory has twelve field offices located throughout Georgia. The PPIs Grant funding was used to sponsor the development and printing of the seminar materials, presentation time, marketing, and travel expenses for seminars at ten of these offices. Local co-sponsors were identified, normally community colleges, which provided a seminar room, audio-visual equipment, refreshments, and collected registration forms from the participants. Most co-sponsors charged a small fee, $20.00-30.00, to cover their expenses. If any revenues were generated, they remained with the local community colleges.
The Pollution Prevention Program obtained mailing labels for all hazardous waste generators from the Georgia Environmental Protection Division. The labels were sorted by zip-code into regions corresponding to the ten seminar locations. Brochures were developed and printed for each site and mailed to the appropriate industries. As the date for a seminar approached, notices were placed in local newspapers and telephone calls were made to industries on the mailing list. A sample brochure, newspaper notice, and map are included in the Seminar Information section at the end of this chapter. The table below lists the seminar locations, number of brochures sent out per location, and the number of participants.
1991 Pollution Prevention Seminars
Region
Atlanta
Augusta/Madison
Gainesville
Columbus
Albany
Savannah
Rome
Macon/Dublin
Douglas/Brunswick
Carrollton
Date
2/27/91
3/04/91
3/19/91
3/21/91
3/25/91
4/08/91
4/16/91
4/25/91
5/23/91
5/29/91
Companies
Invited
1788
332
206
136
285
192
327
379
219
212
4076
Attendancg
41
25
8
35
41
20
30
25
15
15
-
255
3-1

3.2 Seminar Materials
32.1 Seminar Agenda
The Georgia Pollution Prevention Guide was used as a textbook for the seminar. The Guide was developed by
EPD. The three-hour seminar
divided into three sessions separated by a break or discussion period.
The first session in the seminar covered the following topics: incentives for pollution prevention activities; Georgia Hazardous Waste Management Act/Waste Reduction
Planning Requirements; integration of pollution prevention into other environmental programs; and definition and examples of pollution prevention activities including source reduction, technology changes, material substitution, recycling and reuse, and product changes.
The second session in the seminar covered: the elements of a hazardous waste reduction/pollution prevention plan, including keys to successful policies and guidelines, soliciting and demonstrating management support, putting together assessment teams, performing an assessment, and identification of options.
The third session in the seminar included practice in drawing flow diagrams and calculating materials balances. This session also included the demonstration of concepts and techniques using case studies for painting, cleaning and degreasing, printing, electroplating, and drycleaning operations.
3.2.2 Seminar Materials and Handouts
Participants received a copy of the Georgia PoNution Prevention Guide, a compressed-format handout of the overheads, Guides to Waste Reduction Options for the case studies (4-5 pages each), and two one-page handouts on barriers to implementing waste reduction options and performing site assessments. Copies of all materials, except the compressed-format of the overheads, are included at the end of this chapter.
3-2

2A-ThoAlbanySundayHerald-Sun., Mar. 24,1991
By HeraldStaff Writer
A workshop on pollution preven- tion, an important issue facing com- panies t h a t g e n e r a t e hazardous waste, will be conducted here Mon- day.
Art Ford. research engineer at the
College. Registration-begins a t 830 a.m. and the fee is 520. which in- cludes instructional materials and refreshments. and Alban State College and the
Albany Tecinical Institute. view of t ments for hazardous waste reduction
~~~~~~
The pro ram will include an over.
~ ~ a
~~~~~~~~~~ e new Georgia require- plans. planning requirements lor implementing a pollution prevention program, and case studiesand pollu- tion prevention information for common orocesses such as naintine. printing, 'dry cleaning, deireasinz; d r u m management a n d solvent usage.
An amendment to the Georgia
Hazardous Waste Management Act in 1990 requires generatgrs of iarge quantities of hazardous wastes to
Workshop speakers include Carol
Foley, director prevention project at the Georgia
Tech Research Institute, and Susan
Hendricks, ollution prevention coordinator
P or of the pollution the Georgia En- vironmental Protection Division.
Sponsors include Georgia Tech, the
InterCampus Unit of Darton College develop ians by hlarch 1, 1992, to reduce trem. By pollution preven- tion, officials said, organizations can remain in compliance and also save money on disposal.
Ms. Foley, who joined the Georgia
Tech staff in 1988, conducts on-site hazardous waste consultations for
Georgia industry. A chemistry grad- uate of University of Wisconsin-
Madison, she has a master's degree
. . from Georgigi'ech.
She has previously worked with the
U.S. E n v i r o n m e n t a l Protection
Agencyand ATdrTBellLabs.
MIS. Hendricks developed the
EPD's Pollution Prevention Pro- ram and has been its coordinator f or two years. She is a graduate of
F l o r i d a S t a t e U n i v e r s i t y a t
Tallahassee and has a master of science degree from Georgia State
University.
In addition to being a resource person for the industry, Mrs. Hen- dricks has been involved in a variety of programs to increase the public's awareness and involvement in all a s p e c t s of h a z a r d o u s w a s t e management. In addition, she is
EPD's expert on household harard- ous waste

Wednesday
May 29,1991
8:30 a.m.
-
11:30a.m.
Douglas County
Chamber of Commerce
Sponsored by the
Georgia Tech Research institute
Environmental Science and
Technology Laboratory
L
Carrollton Regional Office
Georgia Environmental Protection Division
Douglas County Chamber of Commerce
. . -.
DOUGLAS COUNTY
CHAMECR O F C O M M E R C E
Pollution Prevention and You
Pollution Prevention is a winhin opportunity you can take advantage of now. Through
Pollution Prevention your company can remain in environmental compliance by reducing your wastes and accumulate substantial savings. The nature of non- regulatory prevention allows businesses to evaluate the opportunities specific to their operations and implement the most cost- effective changes.
Pollution Prevention and the Georgia
Tech Research Institute
GTRl's environmental professionals have extensive experience in performing assess- ments and supplying information to over
200 industrial firms in Georgia. The seminar leader is Carol Foley, director of GTRl's
Pollution Prevention Program. GTRl provides on-site technical assistance to small to medium-size industries, as well as technology transfer through Tech Guides, newsletters, and other written materials and research.
A New State Law
The State of Georgia is committed to pollution prevention. The General Assem- bly amended the Georgia Hazardous Waste
Management Act in 1990 to require the development of hazardous waste reduction plans by large-quantity generators of hazardous waste.

REGISTRATION FORM
Jollution Prevention
Name:
Organization:
.,..,'
Organization Phone:
Method of Payment:
Make checks payable lo Douglas County
Chamber Commerce
Bill My Company 0 Purchase Order #
Course Fee: Chamber of Commerce
Members $25.00
Non-Members $35.00
Contact Carol Foley at 404-894-3806 for further information.
Position:
Organization Address:
State:
Home Phone:
Mail your registration to:
Zip:
Linda Read
Douglas County Chamber of Commerce
P.0 Box395
Douglasville, Georgia 30134
Telephone: (404) 942-5022

for
Prepare an agenda in advance that covers all points that still require clarification.
Provide staff contacts in the area being assessed with the agenda several days before the inspection.
Schedule the inspection to coinade with the particular operation that is of inter- est (e.g. makeup chemical addition, bath sampling, bath dumping, start-up, shut-down, etc.)
Monitor the operation at different times during the shift and if needed, during all three shifts, especially when waste generation is highly dependent on human involvement (e.g. in painting or parts cleaning operations.)
Interview the operators, shift supervisors, and foremen in the assessed area. Do not hesitate to question more then one person
an answer is not forthcoming.
Assess the operators' and their supervisors' awareness of the waste generation aspects of the operation. Note their familiarity (or lack thereof) with the impacts their operation may have on other operations.
0 Photograph the area of interest, if warranted. Photographs are valuable in the absence of plant layout drawings. Many details can be captured in photographs that otherwise could be forgotten or inaccurately recalled at a later date.
0 Observe the "housekeeping" aspects of the operation. Check for signs of spills or leaks. Visit the maintenance shop and ask about any problems in keeping the equipment leak-free. Assess the overall cleanliness of the site. Pay attention to odors and fumes.
Assess the organizational structure and level of coordination of environmental activities between various departments.
Assess administrative controls, such as cost accounting procedures, materials purchasing procedures, and waste collection procedures.
Source: Waste Minimization Owortunitv Assessment Manual,
mental Protection Agency

~
Production
A new operating procedure will reduce waste but may also be a bottleneck that de- ueaSeS the overall production rate.
Production will be stopped while the new process equipment is installed.
A new piece of equipment has not been demonstrated in a similar service. It may not work here.
Facilities / Maintenance
Adequate space is not available for the installation of new equipment.
Adequate utilities are not available for the new equipment.
Engineering or construction manpower will not be available in time to meet the project schedule.
Extensive maintenance may be required.
Quality Control
More intensive QC may be needed.
More rework may be required.
Client Relations/Marketing
Changes in product characteristics may affect customer acceptance.
Inventory
A program to reduce inventory (to avoid material deterioration and reprocessing) may lead to stockouts during high product demand.
Finance
There is not enough money to fund the project.
Purchasing
Existing stocks (or binding contracts) will delay the replacement of a hazardous mate- rial with a nonhazardous substitute.
~
Environmental
Accepting another plant’s waste as a feedstock may require a lengthy resolution of regulatory issues. m
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Sponsored by:
Produced by:

2
is Waste
Waste reduction is any activity that reduces or eliminates the generation of waste a t its source, before it becomes a pollutant or “lost” resource. This includes changes in production technol- ogy, materials, processes, operations, or procedures, o r use of in-process, in-line, or closed-loop recycling.
N o t
Waste reduction does not include dewatering; dilution; or evapo- ration; waste burning in industrial furnaces, boilers, or cement kilns; transfer of an environmental waste from one environmen- tal medium to another (waste shifting); conversion of a potential waste into another form for use in a production process or operation without serving any substantial productive function; off-site waste recycling; or any other method of end-of-pipe management of environmental wastes.
This guide is advisory only. It is intended to help businesses take the first step toward evaluating waste reduction opportunities and to build awareness of the benefits of waste reduction. Compliance with environmental and o c c u p a ~ tional safety and health laws is the responsibility of each individual business and is not the focus of this guide. Mention of any product, business. service, or process in this guide is for educational purposes only and should not be considered an endorsement.

On the following pages you will find tips on developing a wasta reduction plan for your company.
. . . . . . . . . . . . . .
Contains a summary of the requirements for hazardous waste reduction plans.
Outlines the planning and organizational aspects that provide a necessary foundation for a waste reduction assessment.
. . . . . . . . .
.E!
Describes the assessment phase, including questions t o be answered by the assessment and sources of infor- mation.
. . . . . . . . . . . . . .
.IO
Sets out criteria for prioritizing wastes for further atten- tion. Also describes a method for ranking wastes as well as waste reduction options.
. . . . . . . . . . . . . .
Defines waste reduction and identifies a hierachy of op- tions for consideration.
. . . . . . . . . . . .
Lists agencies that can provide information on performing waste reduction assessments.
3

I
Georgia Department of
INATURAL RESOURCES
I
1
4
A written policy articulating upper management and corporate support for the hazardous waste reduction plan and a commit- ment to implement plan goals.
The scope and objectives of the plan, including the evaluation to ensure unnecessary hazardous waste is not generated and specific goals for hazardous waste reduction, based on what is technically and economically practical.
The plan should contain performance goals, numerical if pos- sible, and an explanation of the rationale for each performance goal. The rationale should address any impediments to hazard ous waste reduction. Reductions can be prioritized by waste stream; that prioritization scheme must be included.
Internal analysis of hazardous waste streams, with periodic hazardous waste reduction assessments, to review individual processes or facilities and other activities where hazardous waste may be generated and to identify opportunities to reduce or eliminate hazardous waste generation. Such assessments shall evaluate data on the types, amount, and hazardous

constituents of hazardous waste generated, v ere and why hazardous waste was generated within the production process or other operations, and potential hazardous waste reduction and recycling techniques applicable to the hazardous wastes. at
Hazardous waste accounting systems that identify hazardous waste management costs and factor in liability, compliance, and oversight costs t o the extent technically and economically practical.
Employees awareness and training programs, to involve em- ployees in hazardous waste reduction planning and implemen- tation to the maximum extent feasible.
Implementation of technically and economically practical hazardous waste reduction options, including a plan for imple- mentation. Institutionalization of the plan to ensure a n ongoing effort.
A biennial hazardous waste reduction progress report must be submitted to the Environmental Protection Division, which analyzes and quantifies progress made in hazardous waste reduction, relative to each performance goal established; sets forth amendments to the hazardous waste reduction plan; and explains the need for the amendments.
5

I
The objectives of a waste reduction program are best conveyed to a company's employees through a formal policy statement or management directive. For example:
[Company XI
"is committed to continue excellence, leadership, and stewardship in protecting the environ- ment. Environmental protection is a primary management responsibility, as well as the responsibility of every employee.
"In keeping with this policy, our objective a s a company is to reduce waste and achieve minimal adverse impact on the air, water, and land through excellence in environmen- tal control."
A company's Environmental Guidelines should include the following points:
Environmental protection is a line responsibility and an important measure of employee performance. In addition, every employee is responsible for environ- mental protection in the same manner he or she is responsible for safety.

Minimizing or eliminating the generation of waste has been and continues to be a prime consideration in research, process design, and plant operations and is viewed by management like safety, yield, and loss prevention.
Reuse and recycling of materials has been and will continue to be given first consideration prior to classification and disposal of waste.
Team work is vital to achieving successful waste reduction.
Workers and managers both have important roles to play in implementing waste reduction programs. For larger facilities, a task force should be set up.
Find a Cause Champion with the following attributes:
Is familiar with the facility, its production processes, and its waste management operations.
I s familiar with the people.
Is familiar with the quality control requirements.
Has good rapport with management.
Is familiar with new production and waste manage- ment technology.
Is familiar with waste reduction principles and tech- niques and environmental regulations.
Has aggressive managerial style.
Involve people from the affected departmental groups who know the facility, processes, and procedures. These include:
Production
Facilities/Maintenance
Process Engineering
Quality Control
Environmental
Research and Development
7

a
It’s easiest to focus on each waste separately. On a separate sheet, describe the process(es) in which the waste is generated.
You should be able to:
List the raw materials used that generate the waste streams of this process.
Specify how much of the raw material: o
Enters the waste stream. o
Can be accounted for through fugitive losses. o
Can be found in the product.
Compute the efficiencies of the process and/or treatment system.
Describe the type of waste: c
Is it a fugitive emission, a sludge, a solid, a liquid? o
Is it mixed with other wastes? o
Is it a hazardous waste? o
Has it been analyzed?
Assess the amount of waste: o How much waste is generated (pounds per year)? o
What is the maximum and average amount generated? o How often is it generated? o What is the average batch size?
Establish which regulations or permits apply to: o o this process. its wastes.

Identify concerns about compliance.
Determine whether there have been problems with employee exposures or injuries, spills, leaks, or contamination.
Information about waste streams can come from a variety of sources: written, visual, and verbal. You can often fill in g a p s in the written records by performing a careful walk-through survey and interview with employees. A walk- through inspection should be performed during various operating hours for all shifts. Results should be discussed with operators, shift supervisors, and foremen. Information can also be obtained from:
9

10
Ideally, all waste streams and plant operations should be assessed. However, ranking the order in which to assess them is necessary when available funds and/or personnel he weste reduction assessment should con- portant waste-problems first and then riority problems as time, personnel, ies of which waste streams o r processes reat deal of care end attention, since mainder of the assessment activity. tting your priorities.
Compliance with current and future regulations
Potential environmental and safety liability
Quantity of waste
Hazardous properties of the waste (including toxicity, flammability, corrosivity, and reactivity)
Other safety hazards to employees
Potential for (or ease of) reduction or minimization
Potential recovery of valuable by-products
Costs of waste management
Potential liability for releases of chemicals into t h e environment
Management/personnel time for recordkeeping
On-site storage and handling
Pretreatment
Containers
Transportation fees/disposal fees
Local, state, and federal taxes
Costs for liability insurance
Costs for lost raw materials based on the purchase price of the material
Available budget for the waste reduction assessment program and projects

One way to rank waste streams based on subjective criteria is to use the Weighted Sum Method. Weights (on a scale of 0 to 10, for example) are determined for each of the criteria in relation t o its importance. For example, if regulatory compliance is very impor- tant, while the potential for recovery of valuable by-products is ol minor importance, then regulatory compliance is given a weight of 10 and the recovery of by-products is given a weight of 1 or 2.
Criteria that are not important are not included or given a weight of 0.
Each waste stream is then rated based on t h e relevance of each criterion to that particular waste stream. Again, a scale of 0 to 10 can be used (0 for low and 10 for high). In the example below, regulatory compliance is important for this waste stream
(rating = 7). There is also a high potential for recovery of a by- product from t h i s waste stream (rating
=
10).
Finally, the rating of each waste stream for a particular criterion is multiplied by the weight of the criterion. A waste stream's overall rating is the sum of the products of rating and weight of the criterion.
Waste streams with t h e highest overall ratings should be evalu- ated for waste reduction options first.
I
Regulatory compliance
I I I
I Potential for recovery of byproducts
I 2 1 1 0 1 2 0 1
I
Overall rating
1
I I
I

12 n# and causes of waste generation are further asessment have
Improved operating practices
Technology changes
Input material changes
Improved housekeeping practices
Public image
Economic advantages
Product changes
Use and reuse
Reclamation
Plant engineers and operators
Trade associations
Published literature
State and local environmental agencies
Equipment vendors
Consultants
To decide which options merit further study, ask yourself the following questions:
What is the main benefit gained by implementing this option (e.g., economics, compliance, liability, workplace safety, etc.)?
Does t h e necesssary technology exist t o develop the option?

.
.
How much does it cost? Is it cost effective?
Can t h e option b e implemented within a reasonable amount of time without disrupting production?
Does the option have a good "track record"? If not, is there convincing evidence that the option will work a s required?
Does the option have a good chance of success?
What other benefits will accrue?
Georgia Tech Research Institute
Environmental Science and Technology Laboratory
Atlanta, Georgia 30332
404/894-3806
Georgia Department of Natural Resources
Environmental Protection Division
Floyd Tower East, Suite 11 54
2 0 5 Butler Street, SE
Atlanta, Georgia 30334
404/656-7802
Waste Reduction Resource Center for the Southeast
P.O. Box 27687
512 North Salisbury Street
Raleigh, North Carolina 2761 1-7687
1/800/476-8686
U.S. Environmental Protection Agency
Pollution Prevention Information Clearinghouse
401 M Street, SW
Washington, DC 20460
202/475-7161
This guide is a condensed version of
Waste Minimization Opportunity Assessment Manual
U. S. Environmental Protection Agency
Hazardous Waste Engineering Research Laboratory
Office of Research and Development
Cincinnati, Ohio 45268
13

GUIDE
TO
WASTE
REDUCTION
OPTIONS
Tech
~
~
~~

The Division was recipient of a "Pollution Prevention Incentives for
States" grant from US. EPA. The preparation of this document was financed under contract to the Georgia Environmental Protection
Division (EPD).
We would like to acknowledge the following sources:
Waste Minimization Opportunity Assessment Manual. US.
Manual on Vapor Degreasing, 3rd Ed. American Society for Testing and
Materials, ASTM Subcommittee D26.02, 1989.
Solvent Reduction Alternatives-Things You Can Do
Reduction Resource Center for the Southeast, October 1989.
Waste Reduction Assessment and Technology Transfer (WRATT) Training
Manual, 2nd Ed. The University of Tennessee Center for Industrial
Services, Waste Reduction Assistance Program, 1989.
~
September 1991

?e objective of pollution prevention is to reduce generation of
Illutants and wastes at the source as much as possible and to recycle ose wastes that cannot be eliminated. Wastes include materials lost rough evaporation, wastewater discharges, and nonhazardous and kzardous solid wastes. dlution prevention options fall into two categories: source reduction
Id recycling.
)urce Reduction: Good Operating Practices sod operating practices are procedural, administrative, or stitutional measures that a company can use to reduce waste. Often sting little and yielding a high return on investment, these practices n be implemented in all areas of a plant, including production, aintenance operations, and raw material and product storage.
0 Train employees and give incentives to encourage
0 employees to strive conscientiously to reduce waste.
Segregate wastes to reduce the volume of hazardous wastes by preventing the mixing of hazardous and nonhazardous wastes.
0 Allocate waste treatment and disposal costs directly to the departments or groups that generate waste, rather than charging these costs to general company overhead accounts.
The departments or groups that generate the waste will become more aware of the effects of their treatment and disposal practices, and will have a financial incentive to reduce their waste.
0 Schedule batch production runs judiciously to reduce the frequency of equipment cleaning and the resulting waste.
0
0
Change the way materials and inventory are handled, to reduce loss of input materials because of mishandling, expired shelf-life of time-sensitive materials, and improper storage conditions.
Reduce wastes by avoiding leaks from equipment and spills. lurce Reduction: Technology Changes e technology to modify processes and equipment to reduce waste, imarily in production. Technology changes include changes in:
0
0
0 the production process, including the addition of automation equipment, layout, or piping process operating conditions such as:
-flow rates
-temperatures
-pressures
-residence times
Tech
RESEARCH INSTITUTE 1

Source Reduction: Input Material Changes
Reduce or eliminate the hazardous materials that enter the production process and avoid generating hazardous wastes within the production processes by purifying or substituting input materials.
Source Reduction: Product Changes
Sometimes the composition or end use of a product can have a negative impact on the environment. If practical, you should identify acceptable substitutes for a hazardous product or scarce or hazardous raw materials needed to produce a product. Another option is to identify conservation measures for a product composed of scare materials. Finally, you may change the composition of the product to eliminate any negative impact altogether.
Recycling:
Reuse, Reclamation
Return a waste material either to the originating process as a substitute for an input material (use) or to another process as an input material
(reuse). Recover a valuable material from a hazardous waste
(reclamation). Reclamation differs from use and reuse in that the recovered material is not used in the facility but instead is sold to another company.

ROCESS DESCRIPTION uts are cleaned and degreased in a wide range of industrial
‘ocesses, including automotive and repair shops; painting operations; eta1 working and plating shops; and printing, electrical, and ectronics industries. Parts typically are cleaned by one of the
Illowing methods: (1) vapor degreasing, (2) dipping and soaking in a dvent, (3) wiping with solvent-soaked rags. The focus of this guide is
1 vapor degreasing. A solvent is a substance capable of dissolving
\other substance. Organic solvents, which are very effective in
,caking up and removing dirt, grime, or grease, are used in industrial
Zaning and degreasing. ipor degreasing is a physical method of removing solvent-soluble or her entrapped dirt, grime, or grease from metal, glass, or other mporous objects. When the soiled articles at room temperature are ought into contact with hot solvent vapor, the vapor condenses into iquid on them. Sufficient liquid solvent is formed to carry the luble and insoluble soils away as the solvent drains by gravity. In its ost basic form, a solvent vapor degreaser is a tank with a heat source heat the solvent and a cool surface onto which to condense the
Ipor. The soiled articles are suspended in the hot vapor zone of the nk. The hot vapor condenses onto the cool articles, dissolving oils
Id greases and providing continuous rinse in clean solvent. As the ndensed solvent drains from the part, it carries off the soils and turns to the heated liquid reservoir. Variations of this basic system clude ultrasonic agitators, liquid immersion chambers, and spray ices. fPlCAL WASTES astes produced by these processes include contaminated liquid lvents that are recovered from the process, and solvent vapors that ve escaped into the open air and into ventilation exhaust ducts.
‘ASTE REDUCTION OPPORTUNITIES
Operating Practices
and Diffusion
.aft is one of the most common causes of excess loss. Any air wement near the degreaser creates vapor turbulence. Look for open indows and doors; ventilation fans and space heaters; air nditioners; and even drafts caused by paint spray booths or roof haust. Overventilation through the slot exhaust of the degreaser is a mmon problem. Reducing this ventilation to proper rates can crease vapor loss. Increase the freeboard-to-width ratio to at least
), install freeboard cooling coils above the primary condenser coils, d reduce primary condenser temperature. This creates more efficient ndensation. Install an automated cover and top with tight-fitting
Tech
RESEARCH INSTITUTE 3

gaskets. The top should be kept closed and the condenser coils should be kept on during idle or down times.
Dragout of Solvent
Rack parts for proper drainage from the item’s blind holes and recesses. Also, keep articles in the vapor long enough to ensure total
~~~ heating of the work. Move part/work unit into and out of the vapor zone at the slowest speed consistent with production needs; vertical speed should not exceed 11 ft/min. Parts should also be totally dry before entering the degreaser.
General Maintenance
Clean and check separators frequently to avoid cross contamination of solvents or water. Check joints, connectors, valves, gasket covers, and seals routinely. Promptly remove sludge collected at the bottom of the tank to increase cleaning efficiency by not allowing contaminants to adsorb solvent and dissolve into the solution.
As solvents are used, their ability to neutralize acid is lessened. While the common practice is adding new solvent to the aged solvent, analyzing the solvent and adding specific components is more efficient. The expense of analysis will be offset by the savings in solvent for tanks of approximately 500 gallons or more.
Control the amount of heat supplied to the vapor degreaser. Keep the heat exchanger surface clean and descaled (both internal and external)
Manual Spraying
Manual spraying of articles must be done well below the vapor level.
Spraying from above the vapors will cause turbulence and will result in excessive fumes in the work area. Avoid all high pressure sprayers.
Solvent Standardization
Standardize the solvent used to allow for better recycling during distillation. (See Distillation.)
~
Process
Aqueous Cleaning Systems
A nonhazardous aqueous-based system is an alternative to the solvent based cleaning system. This type of system utilizes proprietary detergents in an agitation cleaning system that can clean a wide range __ of items. Most of these systems have skimmers that remove considerable amounts of contaminants and allow the aqueous-based detergent to clean longer. According to the manufacturers of such
~ cleaning systems, the soil removal is equal to that of the solvent-based units. In most cases, aqueous-based system suppliers will demonstrate their system on your soiled items.

ist illation
'cause solvents have relatively low boiling points, on-site distillation an ideal method of reclaiming used contaminated solvents. Simple
?sting and condensing systems remove impurities from the solvent aste stream, returning the solvent or solvent blend to the process that merated it. Small solvent recycling units are now commercially railable for businesses generating as low a5 150 gallons/month. r g e r distillation units are also available. Depending on the degree of intamination and contaminants involved, the reclaimed, distilled llvent can be as high as 99 percent pure. ill bottoms that result from the distillation process are still
Insidered hazardous waste and need to be disposed of as such. owever the difference in volume of waste shipped off-site is reduced ibstantially. Because a facility can save purchasing, shipping, and sposal costs, as well as cradle-to-grave liability, the capital vestment of an appropriate distillation system can be quickly covered.
,haust Recovery llvent vapors vented into a plant's exhaust stack can be collected by tivated carbon adsorption, and eventually condensed back into luid solvent. This type of operation can save substantial vapor losses d reduce stack emissions. lntracted TreatmentlRecycling Firm any small quantity generators lack the capital and expertise to lerate a distillation system. Outside firms can be contracted to rform a number of different services in removing solvent waste. her options include having a contracted company come to your
:ility and, using its equipment and expertise, distill and return the
:laimed solvent to your facility.

!
!

GUIDE
TO
WASTE
REDUCTION
OPTIONS
~
~
~
Tech

The Division was recipient of a "Pollution Prevention Incentives for
States" grant from US. The preparation of this document was financed under contract to the Georgia Environmental Protection
Division (EPD).
We would like to acknowledge the following sources:
Waste Minimization Opportunity Assessment Manual.
88/003, 1988.
Waste Audit Study-Automotive Paint Shops. California Department of
Health Services, Sacramento, California, January 1987.
The Efficient Utilization of Material
the Finishing Room. DeVilbiss
Educational Services.
~
September 1991

he objective of pollution prevention is to reduce generation of dlutants and wastes at the source as much as possible and to recycle ose wastes that cannot be eliminated. Wastes include materials lost rough evaporation, wastewater discharges, and nonhazardous and izardous solid wastes.
)llution prevention options fall into two categories: source reduction td recycling. w c e Reduction:
Operating Practices
3od operating practices are procedural, administrative, or stitutional measures that a company can use to reduce waste. Often lsting little and yielding a high return on investment, these practices n be implemented in all areas of a plant, including production, aintenance operations, and raw material and product storage.
0 Train employees and give incentives to encourage employees to strive conscientiously to reduce waste.
0 Segregate wastes to reduce the volume of hazardous wastes by preventing the mixing of hazardous and nonhazardous wastes.
0 Allocate waste treatment and disposal costs directly to the departments or groups that generate waste, rather than charging these costs to general company overhead accounts.
The departments or groups that generate the waste will become more aware of the effects of their treatment and disposal practices, and will have a financial incentive to reduce their waste.
0 Schedule batch production runs judiciously to reduce the frequency of equipment cleaning and the resulting waste.
0 Change the way materials and inventory are handled, to reduce loss of input materials because of mishandling, expired shelf-life of time-sensitive materials, and improper storage conditions.
0 Reduce wastes by avoiding leaks from equipment and spills. w c e Reduction: Technology Changes
,e technology to modify processes and equipment to reduce waste, imarily in production. Technology changes include changes in:
0 the production process, including the addition of automation
0 equipment, layout, or piping
0 process operating conditions such as:
-flow rates
-temperatures
-pressures
-residence times
RESEARCH INSTITLJTE 1

kh
Source Reduction: Input Material Changes
Reduce or eliminate the hazardous materials that enter the production process and avoid generating hazardous wastes within the production processes by purifying or substituting input materials.
Source Reduction: Product Changes
Sometimes the composition or end use of a product can have a negative impact on the environment. If practical, you should identify acceptable substitutes for a hazardous product or scarce or hazardous raw materials needed to produce a product. Another option is to identify conservation measures for a product composed of scare materials. Finally, you may change the composition of the product to eliminate any negative impact altogether.
~
Recycling: Use, Reuse, Reclamation
Return a waste material either to the originating process as a substitute for an input material (use) or to another process as an input material
(reuse). Recover a valuable material from a hazardous waste
(reclamation). Reclamation differs from use and reuse in that the recovered material is not used in the facility but instead is sold to another company.

ROCESS DESCRIPTION
2int application processes are part of many industrial operations and
In generate hazardous waste and air emissions through the use of iemicals in paint thinners and reducers and the paint itself. Coatings e applied by hand, dipping, or with spray application equipment. dvents, aqueous or organic, are used to transfer the pigment and
)sting to the part. Once the paint is applied, the solvent evaporates, id the paint dries and hardens. le factors affecting waste generation in coating operations are:
0
0
0
0 inventory /purchasing policies material handling paint application equipment cleaning
(PICA1 WASTES lint applicators generate a variety of wastes in their operations.
)"on waste types include:
0 obsolete stock
0 off-specification materials
0 spills
0 evaporative losses
0
0
0 overspray paint sludges solvents from rinsing or purging equipment
'ASTE REDUCTION OPPORTUNITIES
Operating Practices ientory Control ough time consuming, rigid inventory control provides a very ective means of source reduction at practically no cost to the erator. The owner can monitor employee operations and make rbal or written comments on material usage and suggested limits. In ger industries where monitoring of employees may not be possible,
2 owner or manager can limit access to storage areas containing raw iterials, encouraging the employee to stretch the use of raw iterials. A written materials log located in the storage area can be
-d to monitor the raw material usage rates by employees. js Prevention sic housekeeping techniques can be very effective for source luction. Methods to control and minimize leaks can be plemented easily at no cost to the operator. Proper drum location,
Geqgia Tech
KFSEARCH INS?lTUTE 3

product transfer methods, leak collection, and drum transport can effectively limit product loss.
Drums can be located most effectively in two ways. First, if inventory control is necessary to minimize product usage, drums should be stored together in an area of limited accessibility, such as indoor/ outdoor sheds, flammable lockers, or locked storage rooms. Second, if- employees take individual responsibility for regulating product use and if inventory control is not a problem, drums can be separated and placed at points of highest use in the facility. This alternative reduces the chance of product leaks and spills during transport from storage to work areas.
Accidental spills and leaks are most likely to occur when product is transferred from bulk drum storage to process equipment. Spigots or pumps should always be used when new materials are dispensed, and funnels should be used when waste materials are transferred to storage containers. Material should never be poured directly from drums to smaller containers.
You can control evaporation in part by using accessory equipment such as tight-fitting lids and spigots. Controlling evaporation loss will conserve materials and reduce solvent purchase costs.
Material Handling
If drum transport or movement is necessary, drums must be moved correctly to preserve the integrity of the containers and to prevent damage or punctures. Drums should be lifted with powered equipment or hand trucks. Under no circumstances should drums be tipped or rolled, even when empty. Negligent transport will damage drums, particularly seams, which could lead to leaks or ruptures during future use.
Appropriate Spray Technique
~
The fundamentals of good spray technique consist of :
0 a 50 percent overlap of the spray pattern
0 a gun speed of approximately 250 feet per minute
0 a gun distance of six to eight inches
0
0 holding the gun perpendicular to the surface triggering the gun at the beginning and end of each stroke
An average operator typically will use more than a 50 percent overlap _ _ of the spray pattern, which is tiring to the operator, slows production, creates dry film, and wastes material.
On average, the operator also will use too high a gun speed, which is
~ usually responsible for the pattern not overlapping 50 percent. When the gun is moved too fast, a number of passes are necessary to build
UF the film. Furthermore, high gun speed accounts for poor aiming and gun control, resulting in loss of material.

dvent and spray losses increase as the distance between the gun and e part increases. Solvent loss can be corrected either by adding more llvent or slower solvent when the material is mixed or when it is anufactured. However, spray that ends up in the spray booth cannot b retrieved. rcing the gun is an undesirable habit developed by many operators, metimes because of difficulty in reaching areas but usually because improper wrist action. Some operators may arc the gun at an angle as much as 45 degrees to the surface. When the gun is used in such
Josition, the spray loss is approximately 65 percent. iggering the spray gun is similar to, and serves the same purpose as, sathering” a paint brush. If the trigger is not released at the end of a
.eke, the material continues to flow; and, when the direction is anged, the momentary stopping of the gun results in a pile up. To oid piling material on the surface, the operator invariably turns the in away from the surface. In doing so, the operator may spray as uch as six inches beyond the area to be coated, which results in nsiderable spray loss. bchnology Changes ipropriate Sprayer Cups indard paint sprayers consist of two main units: a sprayer gun jembly and a paint cup. A paint cup can contain up to a quart of int. Some painting operations, such as touch-ups and repair, should
E!
substantially less paint than jobs that cover large surfaces. Having
.ariety of sizes of paint sprayer cups available enables operators to
2 the equipment best suited to the size of a particular job. Varying int cup sizes can be an effective means of source reduction: first, to lit overmixing of paint to be used on a specific project; and, second, decrease the amount of solvent needed for equipment cleanup spot painting and small jobs. Leftover paint may be given to jtomers to use for touch-up jobs if the paint is not likely to be
2d. mess Changes e amount of coating overspray can be reduced when the efficiency th which the coating is applied is improved. Transfer efficiency can increased when High-Volume Low-Pressure (HVLP) sprayers are
?d. HVLPs use a high volume of air delivered at low pressures to bmize the coating into a pattern of low-speed particles. Instead of ng a conventional high-pressure sprayer, which blasts the coating to the part, low pressure (10 psi) is used to break the coating into all particles. As the material flows into the air stream and to the rt, far less material is lost. Less overspray, bounce, and blow-back ult in increased transfer efficiency. Georgia
RESEARCH INSI‘ITUTE 5

6
Tech
RESEARCH INSTITUTE
Electrostatic, air-assisted airless, and airless technologies also lead to high transfer efficiencies, generating lower waste than conventional sprayers.
Input Material Changes
Paint Substitution
The organic solvents and toxic metal pigments in many paints cause most of the environmental problems in coating operations. When searching for substitutes, look for nonsolvent coatings, such as powde: coatings or water-borne coatings.
Advantages of water-borne coatings include: low, volatile organic- compound (VOC) emissions; smooth film; corrosion resistance; good adhesion; easy application and cleanup; low-cost equipment outlay; nonflammable; fast drying; and low toxicity. Contact the paint supplier for more information on the types of paint available.
Other alternative coatings include high-solids/low-VOC and powder coatings. Many types of high-solids/low-VOC coatings are now available in industry. High solids coatings result in reduced VOCs pel gallon by as much as 45 to 50 percent as applied. This leads to improved air compliance and increased worker safety. Many high-solids/low-VOC coatings have corrosive resistance properties similar to conventional moderate- and high-solvent coatings.
Powder-coating technology uses a powder that is applied to a part electrostatically. Because powder coatings do not contain solvents, their use eliminates the need for solvent cleanup, and oversprayed powder can be collected and reused. However, powder-coating technology requires modifications in painting, include application and oven curing.
Toxic metal pigments, such as chrome or lead, are often used where corrosion resistance is desired. The strict regulations associated with worker exposure to these substances, however, have increased interesi in finding substitutes.
Product Changes
Does your product need to be coated? Corrosion prevention can be achieved through anodization or simply oiling the metal parts. Decals can provide desired aesthetic details. For example, some airlines no
. longer paint their airplanes.
Use and Reuse
Gravity Separation
Gravity separation is an inexpensive form of resource recovery that is relatively easy to implement. Furthermore, it is cost effective because

reduces purchases of thinner. In gravity separation, the thinner/ idge mixture separates under quiescent conditions. The supernatant n be decanted with a drum pump and a float valve to retrieve the rface thinner. Thinner reclaimed using this process can be used as gash thinner" (e.g., thinner used for primer and base coats and for
?aning equipment). Reclaimed thinner can be used to supplement lrchased wash thinner supplies. This process is currently used in rts washers where thinner purity is not critical.
2-Site Dist
ion r larger painting operations, on-site distillation may provide a more st-effective alternative. The distillation of all high-grade thinner istes can virtually eliminate purchases of lower quality thinners for eliminary painting operations and cleanup. From 5 gallons of paint d thinner wastes, the operator can generate approximately 4.5 llons of reclaimed thinner and 0.5 gallons of sludge. However, this io varies, depending on operations. Commercial additives nbined with the 0.5 gallons of paint sludge yield a viscous sludge i t can be used as underseal. iste Exchanges iste exchanges provide another waste management alternative for inting companies. Waste exchanges are organizations that manage arrange the transfer of wastes between industries-one producer's ste material might be another industry's feedstock. Most exchanges st as information clearinghouses that provide information on waste iilability. Opportunities exist for the direct transfer (without xessing) of waste solvents from industries requiring ultra-high- rity solvents (e.g., the electronics industry) to industries that do not
#e such exacting requirements (e.g., the machinery and painting lustries). Several generators have also recently found new portunities to ship residual still bottoms to cement industries for use supplemental fuels. Facilities that currently use on-site recycling iipment, as well as those that generate large volumes of sludge,
Ild find this alternative valuable for removing concentrated paint dge produced through distilling operations.
Ech
RESEARCH INSTITUTE I

GUIDE
TO
WASTE
REDUCTION
OPTIONS
Tech

The Division was recipient of a "Pollution Prevention Incentives for
States" grant from US. EPA. The preparation of this document was financed under contract to the Georgia Environmental Protection
Division (EPD).
We would like to acknowledge the following sources:
Waste Minimization Opportunity Assessment Manual. U.S. EPA/625/7-
88/003, 1988.
Waste Reduction for the Commercial Printing Industry. California Depart- ment of HeaIth Services, Toxic Substances Control Program, August
1989.
~
Waste Audit Study-Commercial Printing Industry. California Depart- ment of Health Services, Toxic Substances Control Division, May 1988.
Guides
Prevention
-
The Commercial Printing Industry. EPA/ of Research and Development, August 1990.
Waste Reduction Assessment and Technology Transfer (WRATT) Training
Munual, 2nd Ed. The University of Tennessee Center for Industrial
Services, Waste Reduction Assistance Program, 1989.
September 1991

le objective of pollution prevention is to reduce generation of pollut-
Its and wastes at the source as much as possible and to recycle those astes that cannot be eliminated. Wastes include materials lost rough evaporation, wastewater discharges, and nonhazardous and izardous solid wastes.
)Hution prevention options fall into two categories: source reduction id recycling. puree Reduction: Good Operating Practices
)od operating practices are procedural, administrative, or institu- mal measures that a company can use to reduce waste. Often costing tle and yielding a high return on investment, these practices can be iplemented in all areas of a plant, including production, maintenance lerations, and raw material and product storage.
0
0
0
Train employees and give incentives to encourage employ- ees to strive conscientiously to reduce waste.
Segregate wastes to reduce the volume of hazardous wastes by preventing the mixing of hazardous and nonhazardous wastes.
Allocate waste treatment and disposal costs directly to the departments or groups that generate waste, rather than charging these costs to general company overhead accounts.
The departments or groups that generate the waste will become more aware of the effects of their treatment and disposal practices, and will have a financial incentive to reduce their waste.
0
0
Schedule batch production runs judiciously to reduce the frequency of equipment cleaning and the resulting waste.
Change the way materials and inventory are handled, to reduce loss of input materials because of mishandling, expired shelf-life of time-sensitive materials, and improper
0 storage conditions.
Reduce wastes by avoiding leaks from equipment and spills. urce Reduction: Technology Changes e technology to modify processes and equipment to reduce waste, marily in production. Technology changes include changes in:
0
0 the production process, including the addition of automa- tion equipment, layout, or piping
0 process operating conditions such as:
-flow rates
-temperatures
-pressures
-residence times Georpia
RESEAR&
INSTITUTE I

2
RESEAR
Tech
Source Reduction: Input Material Changes
Reduce or eliminate the hazardous materials that enter the production process and avoid generating hazardous wastes within the production processes by purifying or substituting input materials.
Source Reduction: Product Changes
Sometimes the composition or end use of a product can have a nega- tive impact on the environment. If practical, you should identify ac- ceptable substitutes for a hazardous product or scarce or hazardous raw materials needed to produce a product. Another option is to identify conservation measures for a product composed of scare mate- rials. Finally, you may change the composition of the product to elimi- nate any negative impact altogether.
~
Recycling: Use, Reuse, Reclamation
Return a waste material either to the originating process as a substitutc for an input material (use) or to another process as an input material
(reuse). Recover a valuable material from a hazardous waste (reclama- tion). Reclamation differs from use and reuse in that the recovered material is not used in the facility but instead is sold to another com- pany.

DESCRIPTIONS AND TYPICAL WASTES
'hile printing processes vary operationally, the production steps- iage processing, plate processing, printing, and finishing-remain e same. The following information profiles the wastes and waste duction opportunities for each process.
Processing
)age 'processing produces wastewaters that contain photoprocessing emicals and silver dissolved from developed film.
) reduce image processing waste:
0 Use silver-free materials, such as vesicular, diazo, and electrostatic films. Photopolymer films, which contain carbon black, are another silver substitute.
0
0
For larger volume generators, purchase a silver recovery unit, and recycle fixer on the premises, If this is not feasible, the recovered silver from fixing baths can be picked up by a contracted firm to be recycled off-site.
Add ammonium thiosulfate to silver-contaminated baths to
0
0 extend the allowable silver buildup.
Manually process film; use an acid stop bath prior to the fixing bath. This reduces the effect of an alkaline developer on the fixing bath pH. Also, add acetic acid to the fixing bath. This keeps the pH low to maximize soluble complexes.
Use personal computers with commercial printing capabilities to allow the user to set up and edit jobs before going to print. Materials, time, and wastes are reduced from draft to final product.
0
0
0
Keep floating lids on bleach and developer containers so that the contents remain fresh.
Install waterless paper and film developing units to reduce the volume of fixer waste.
Implement electronic imaging or laser platemaking. Editing on a video terminal reduces the need for photographing and reshooting. However, this alternative is costly; evaluate the payback period before purchase.
0 Employ countercurrent rather than parallel rinse techniques.
In countercurrent rinsing, water from previous rinsings is used in the initial film washing stage. Fresh water enters the process at the final rinse stage, at which point much of the contamination is already rinsed off the film.
0 Protect process baths that spoil easily by keeping them containerized. Small-scale photodevelopers can containerize process baths and use glass marbles to raise the liquid level to the brim each time the liquid is used.
Georpia Tech
INSTITUTE 3

Plate Processing
Recent advances in plate-processing techniques offer substantial waste-reduction opportunities. These advances are alternatives to metal-plate processing, which typically involves chemical compounds that are deemed hazardous. (Metal processing solutions usually require treatment before discharge to the municipal sewer, or they must be disposed of as hazardous waste.)
Altematives include:
0 Presensitized lithographic plates, which produce some solutions that can be discharged directly to the industrial sewer with written authorization or sanitation district permit. Used plates can be sold to an aluminum recycler.
0 Plastic or photopolymer plates, which generally are processed with water-based solutions and generate little or no hazardous waste.
0 Electrostatic plates, made of paper directly from artwork, which are used on copier/duplicators presses and eliminate several process steps.
0 Hot metal plates, an alternative that can be remelted or sold to a recycler after use.
In addition to implementing a metal-plate processing alternative, use nonhazardous developers and finishers.
Printing and Finishing
The major wastes produced during printing and finishing are scrap paper, waste ink, and cleaning solvents. In many printing establishments, excess ink and solvent are collected into a drip pan underneath the press.
While gravure printing generates equipment cleaning and solid waste streams similar to those of other processes, the wastewaters produced are similar to those of metal-processing operations, which fall under a stricter set of treatment requirements.
Reducing Scrap Paper
Because paper is the largest and sometimes most expensive raw material purchased, paper use and disposal are of critical concern.
To minimize paper waste:
0 Recycle paper through an outside contractor, which usually entails separating wastes by grade (for example, inked pape should be separated from unprinted white paper), then arranging for pickup.
0 Monitor press performances continually to minimize bad runs and waste. Quality control systems are available to inspect virtually every process detail.

0 Find ways to use paper. Make notepads and posters from scrap. Recycle all paper wastes, or donate them to schools and churches. Recycle aluminum plates, negatives, and silver-laden paper.
Options k composition varies widely-some inks contain chemicals that are issified as hazardous, others do not. The company owner‘s sponsibility is to determine which materials used in their operations e hazardous. To identify an ink’s classification, review the label and aterial safety data sheet, or ask an ink distributor. nce metal and solvent-based inks are often classified as hazardous,
I U should investigate using water-based or ultraviolet inks, ernative materials that have experienced tremendous performance vances in recent years. Your customers may be willing to use less zardous products if end-product quality is not compromised. Inform
?m of the benefits of non-hazardous materials, and provide samples indicate potential performance. Providing less hazardous materials iuces wastes and positions your company as an environmentally nscientious supplier. addition to choosing non-hazardous inks, to minimize ink waste:
0 Fill ink fountains only enough for a particular run or shift.
0
0
Return all unemulsified inks to containers.
Install automatic ink levelers to keep ink fountains at the optimum minimum level for good print quality.
0
0
0
Run similar jobs simultaneously to reduce waste generation between clean-up and start-up of the next run.
Save old inks, and market them as ”house colors.”
Donate unemulsified inks to trade schools and colleges. ernative Fountain Solutions intain solutions contain water, volatile isopropyl alcohol (IPA), gum bbic, and phosphoric acid, all of which either end up on paper or are iausted into the air stack. IPA evaporation may create emission
)blems in states or regions with stringent air-quality VOC limits and y result in mandatory installation of pollution control equipment. nsequently, you should seek fountain solutions with little or no P A . proving Cleaning Procedures uipment-cleaning wastes consist of leftover inks (covered in ”Ink tions”), solvents, rags, and spent lubricants. By improving cleanup
)cedures, you can enhance cleaning efficiency while reducing ociated waste by-products. To improve cleaning procedures:
0 Reduce solvent and rags used, and clean fountains only when a different color ink is used or when the ink might dry
Georpia Ech
RESEARCH INSTITUTE 5

6
Tech
RESEAR H out between runs. Aerosol spray materials for ink fountains can prevent overnight drying, eliminating the need to clean at day‘s end.
0 When using solvent and roller blade washup to clean rollers, increase cleaning efficiency by ensuring that rollers and blades are in good condition; that the blade’s angle is adjusted to exert sufficient pressure on the roller; and that
____ press speed is quick enough.
0 Reuse solvent cleaners by dedicating one container of solvent to each color printing unit. The used solvent can be reused in cleaning most of the ink from rollers and blankets, with only a small amount of fresh solvent needed for final cleanup.
0 Choose specially made blanket washes that are less toxic anc less flammable than cleaning solutions containing benzene, carbon tetrachloride, trichloroethylene, and methanol.
Conduct general cleanup with detergent or soap solutions whenever possible, using solvents for cleaning inks and oils only.
0 To handle spent lubricants, collect the oil and send it to a recycler who will either refine the material into new lubricating oil, create fuel grade oil, or use the material for blending asphalt.
Good Operating Practices: Waste Minimization Outside the
Production Process
Good operating practices are company procedures and policies that reduce waste. Material handling and storage are crucial elements of housekeeping: improper storage and handling can result in raw materials spoiling or becoming obsolete.
To minimize waste during material handling and storage:
0 Conduct preinspection of incoming raw materials to ensure their quality and usability.
0 Store raw materials and supplies in their optimum environment. (Some shops waste up to one-fourth of all materials because of improper storage.) For photoprocessing and plate-developing chemicals, consult the package for recommended storage conditions. Paper should be kept at a proper temperature and humidity, because it easily absorbs
_- moisture.
0 Keep inventory on a first-in, first-out method, which will reduce expired shelf life. Consider implementing computer - inventory systems that track raw material amounts and ages
0 Store raw materials, such as inks, solvents, and cleaning materials, near production sites to reduce spillage and breakage.

0
0
Order ink quantities to match usage. This avoids spoiling large amounts of partly used inks because of improper sealing.
Purchase ink in recyclable bulk containers to reduce cleanup labor for leftover containers. eaping the Benefits
Waste Minimization ore often than not, waste minimization is the result of good mekeeping practices, simple recycling, and source reduction. Many mpanies have incorporated the options discussed in this manual, d are now cutting hazardous waste management costs while otecting employees and the environment.
G a
RESEAR%
Tech
INSTITUTE I

GUIDE
TO
WASTE
REDUCTION
OPTIONS
[ ia Tech

The Division was recipient of a "Pollution Prevention Incentives for
States" grant from
financed under contract to the Georgia Environmental Protection
Division (EPD).
We would like to acknowledge the following sources:
Waste Minimization Opportunity Assessment Manual. US. EPA/625/7-
Waste Reduction Assessment and Technology Transfer ( W R A T )
Manual, 2nd Ed. The University of Tennessee Center for Industrial
Services, Waste Reduction Assistance Program, 1989.
Metal Waste Management Alternatives. California Department of Health
Services, Pasadena, Califomia. 1989, pp. 45-55.
~
September 1991

he objective of pollution prevention is to reduce generation of dlutants and wastes at the source as much as possible and to recycle ose wastes that cannot be eliminated. Wastes include materials lost rough evaporation, wastewater discharges, and nonhazardous and izardous solid wastes. dlution prevention options fall into two categories: source reduction td recycling. mrce Reduction: Good Operating Practices
3od operating practices are procedural, administrative, or stitutional measures that a company can use to reduce waste. Often
'sting little and yielding a high return on investment, these practices n be implemented in all areas of a plant, including production, aintenance operations, and raw material and product storage.
0 Train employees and give incentives to encourage employees to strive conscientiously to reduce waste.
0 Segregate wastes to reduce the volume of hazardous wastes by preventing the mixing of hazardous and nonhazardous wastes.
0 Allocate waste treatment and disposal costs directly to the departments or groups that generate waste, rather than charging these costs to general company overhead accounts.
The departments or groups that generate the waste will become more aware of the effects of their treatment and disposal practices, and will have a financial incentive to reduce their waste.
0 Schedule batch production runs judiciously to reduce the frequency of equipment cleaning and the resulting waste.
0 Change the way materials and inventory are handled, to reduce loss of input materials because of mishandling, expired shelf-life of time-sensitive materials, and improper storage conditions.
0 Reduce wastes by avoiding leaks from equipment and spills. lurce Reduction: Technology Changes imarily in production. Technology changes include changes in:
0 the production process, including the addition of automation
0 equipment, layout, or piping
0 process operating conditions such as:
-flow rates
-temperatures
-pressures
-residence times
RESEARCH INSTITUTE 1

Source Reduction: Input Material Changes
Reduce or eliminate the hazardous materials that enter the production process and avoid generating hazardous wastes within the production processes by purifying or substituting input materials.
Source Reduction: Product Changes
Sometimes the composition or end use of a product can have a negative impact on the environment. If practical, you should identify acceptable substitutes for a hazardous product or scarce or hazardous raw materials needed to produce a product. Another option is to identify conservation measures for a product composed of scare materials. Finally, you may change the composition of the product to eliminate any negative impact altogether.
Recycling: Use, Reuse, Reclamation
Return a waste material either to the originating process as a substitutc for an input material (use) or to another process as an input material
(reuse). Recover a valuable material from a hazardous waste
(reclamation). Reclamation differs from use and reuse in that the recovered material is not used in the facility but instead is sold to another company.

{OCESS DESCRIPTIONS le electroplating industry includes facilities that perform any or all of e following operations:
0 electroplating
0 anodizing and coating
0
0 chemical etching and milling printed circuit board manufacturing ectroplating involves coating a metal or plastic object with one or x e metals using electrodeposition. Ferrous and nonferrous objects mmonly are plated with aluminum, brass, bronze, cadmium, romium, copper, iron, lead, nickel, tin, and zinc. The electroplating ths may contain metallic salts, alkalies, and other bath additives. me of these additives may be used to reduce irregularities in the
?tal surface, to increase brightness of the finished surface, or to h c e the texture of the plated layer of metal. electroplating, the object to be coated generally moves through a pies of baths arranged in a carefully designed sequence. Typically,
2 sequence consists of cleaning; rinsing; and a number of alternating sctroplating and rinsing steps. The workpiece can be carried on zks or in barrels. The various electroplating baths can include: silver stannate tin tin-nickel alloy zinc cyanide iron lead-tin nickel-acid fluoride cadmium cyanide copper cyanide acid tin tin-copper alloy acid zinc gold cyanide lead fluoborate nickel brass and bronze cadmium fluoborate copper fluoborate
‘PICA1 WASTES xtroplating process wastes originate from four different processes:
0 work cleaning wastes
0
0
0 spent plating solutions and sludges waste rinsewater treatment wastes
1st electroplating hazardous waste is generated from plating tsewater, sludges from electroplating bath solutions, and sludges bm the treatment of waste rinsewaters. Contaminated rinsewater, iich is used to remove the drag-out from a workpiece, accounts for a ijority of waste produced. Drag-out refers to the excess cleaning or iting solution that adheres to the workpiece surface and is carried t of the bath along with the workpiece.
Geo@a Tech
RESEARCH INSTITUTE
3

Spent cleaning and plating solutions are another waste source.
Cleaning solutions may be acidic or basic and may contain organics.
Although some cleaning solutions contain cyanide, heavy metals usually are not present. Spent plating solutions contain high concentrations of metals. These solutions are not regularly discarded but may need to be purged if impurities build up:
The wastewater produced in the electroplating process may contain a variety of heavy metals and cyanide, which are removed with lime or other precipitation agents. The result is a dilute metal hydroxide sludge, which often is managed as hazardous waste. The type of hazardous waste generated from electroplating depends on the type o electrodeposition.
~
Good operating practices encompass many small changes th processors can implement easily and at little cost. Processors should inspect for spills, leaks, and overflows once a month using a sheet of white paper slipped under process tanks. Processors should scrupulously maintain racks, especially coating and excess plating racks, both of which can increase drag-out by trapping solution. They should check for draining efficiency, since the action of tumbling wori can "peen" the openings closed. Finally, they should protect inventory, especially from moisture. Some of the most expensive wastes to dispose of are unusable raw materials.
Multiple
Tanks
Multiple rinse tanks designed to flow in a counter-current fashion are unanimously supported in the literature. Many arrangements are possible, and water reduction can be remarkable. A three-tank systen for example, can rinse as effectively with 0.1 gpm as a single-tank system can with 10 gpm. When combined with other waste reductior options, multiple rinse tanks do not impair product quality. Howeve! this option may be difficult to implement in existing operations because of space restrictions.
Drain Boards
Although simple and inexpensive, drain boards are rarely found in plating operations. Drain boards catch drips, preventing them from reaching the floor where they must be treated as waste. Drain boards can be constructed out of any compatible material. The boards shoulc be oriented
direct drips to the correct solution (e.g., drips of proces solution back to the process bath, not into the following rinse). A sm: dam at either end is useful in preventing runoff.

Rinses and Air Knives
>ray rinses and air knives operate similarly. When they are mounted
T the lip of a process tank, these devices direct a flow of either water
. air at the work. Appropriate nozzles can reduce the amount of
M i o n carried over into subsequent steps. However, these devices
.e not appropriate with some solutions, and neither system is
3plicable to barrel plating. gitation sed in a rinse system, agitation can improve rinsing efficiencies ramatically, resulting in lower rinse water volumes. The agitation is itroduced at the bottom of the rinse tank through an H-shaped set of ipes (sometimes called a sparger) drilled with enough holes to create irbulence, which enables less water to do more work. Only clean air iould be used. Small diaphragm compressors are often sufficient hen equipped with a ball valve for throttling the flow.
Tis option applies only to rack operations. A part can be adjusted so at it doesn't "cup" solution. However, in many operations and for any parts, plating coverage and trapped gaps are more important nsiderations. In general, you should ensure that parts are racked ith points or corners oriented downwards. ow Restrictors ow restrictors are effective in dealing with the all-too-human ndency to rinse with the cleanest water possible, which is sometimes
It necessary in a well-designed rinse system. Placed directly in the let to a rinse tank, flow restrictors maintain a predetermined, correct
)w of water for the process. However, restrictors are nonadjustable, hich can be a problem in jobshops with variable work flows.
Jnductivity Cells ow controllers that utilize conductivity cells can regulate water flow, ducing the volume of wastewater generated. Rinsing more than one pe of process solution in the same rinse system can complicate the
[librations required for the system. The equipment also requires ligent maintenance, since the probes must be cleaned regularly to
.event their coating over.
'ithdrawal Time le speed at which a part is removed from a process solution can have e greatest impact of any single factor on drag-out volume. Slower ithdrawal rates allow more drag-out to drip back into the process iths. When the process is automated, withdrawal speed is easily ntrolled; manual operations are highly variable.
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RESEARCH INSTITUTE
5

6
Tech
Extended Drain Times
A drain time of at least 10 seconds reduces drag-out by 40 percent ovei immediate rinsing. When processing is automated, drain times are straightforward. For manual operations, provide suitable rests for the workpiece while it drains.
Contact Time
Contact time is the amount of time a workpiece is actually in a rinse tank. Taken together, withdrawal times, extended drain times, and contact times provide a set of rinsing procedures that can reduce drag- out and, consequently, wastewater treatment, by over 50 percent.
Input Material Changes
Deionized Water
Of all the material substitutions possible, deionized water in place of tap or softened water has potentially the greatest impact and widest application in reducing waste generation. Most plating operations usc deionized water only to replace evaporation from plating process solutions, if at all.
Other than pure water or replenishment chemistry, any material addec to a process solution may be a potential contaminant that must be removed later through purifying or disposing of solutions. Therefore, tap water used to replace evaporative loss shortens the life of that solution, increasing waste generation.
Systems are available that generate sufficient volumes of deionized water for rinsing in a plating operation. However, at the volumes required in most plating facilities, these systems may be too expensive
Noncyanide Plating Solutions
Alternatives to cyanide plating solutions completely eliminate hazardous process chemistry components, not only reducing pretreatment but also reducing health and safety hazards. Noncyanidc zinc plating has been developed to the point that there are two competing chemistries. Noncyanide copper plating, especially acid copper plating, is being used for more and more applications.
Noncyanide cadmium processes also are being developed. However, more research in these areas must be done before either of these alternatives is used on a wider scale.
__
Nonchelated Process Chemicals
Nonchelated process chemical baths can reduce hazardous waste generation. Chelators are used in chemical process baths to allow metal ions to remain in solution beyond their normal solubility limit.
Chelators are usually found in baths used for metal etching, cleaning, and selective electroless plating. Once the chelating compounds enter
-

le waste stream, they inhibit the precipitation of metals, and lditional treatment chemicals must be used. These treatment iemicals end up in the sludge and contribute to the volume of izardous waste sludge. Also, many of the spent process baths ntaining chelators cannot be treated on-site and must be jntainerized for off-site disposal, adding to waste disposal costs. variety of chelators are used in different processes found in the eta1 finishing industry. In general, mild chelators such as iosphates, silicates, and ammonia are used for most cleaning and ching processes. Electroless plating baths are typically chelated with ronger chelating compounds such as organic acids. These include tric acid, maleic acid, and oxalic acid. Ethylenediaminetetraacetic id (EDTA) is also used but is less common than the others. onchelated process chemistries can be used for many cleaning ocesses. Metal finishers have found that that they do not need to
'ep metals in solution that have been removed from workpiece rfaces during cleaning and etching. Instead, these metals can be
!owed to precipitate, and the process bath can be filtered to remove lids. Nonchelated chemistries for electroless plating are less feasible cause the chelators play a significant role in the chemical process at allows the plating bath to function. ivalent Chromium Plating and Chromating Solutions ivalent chromium plating and chromating solutions reduce bstantially the health risk associated with hexavalent chromium ocess solutions. Furthermore, they reduce waste treatment costs. ice trivalent chromium processes are much more dilute than xavalent, losses to the rinsing system are greatly reduced, thus k i n g treatment needs. In addition, the reducing step required for etreatment of hexavalent chromium before precipitation can be minated. As many as 500 installations are performing trivalent romium plating nationwide. Trivalent chromating solutions are ich less prevalent because of technical barriers such as production ies and reduced corrosion protection.
;e and Reuse ag-out Recovery xess modification requires not only capital but also floor space. erefore, this option is most easily implemented in new facilities or
)ere substantial reconstruction of process lines is taking place. A nflowing rinse or empty tank captures process solution for eventual urn to the process tank, with or without further separation or icentration. This process has been widely applied to nickel and rome plating and seems to function quite well. Processors must alyze all elements of the process, including cleaning and etching utions, to implement successful drag-out recovery.
Tech
INSTITUTE RESEARCH
7

I

GUIDE
WASTE
REDUCTION
OPTIONS
Tech v

The Division was recipient of a "Pollution Prevention Incentives for
States" grant from U.S. EPA. The preparation of this document was financed under contract to the Georgia Environmental Protection
Division (EPD).
We would like to acknowledge the following sources:
Waste Minimization Opportunity Assessment Manual.
Fact Sheet - Dry Cleaners. Office of Waste Reduction, Washington State
Department of Ecology, November 1988.
Waste Reduction Assistance Program Onsite Consultation Audit Report: Dr!
Cleaner. Alaska Health Project, August 14,1987.
Dry Cleaning - A Basic Handbook. The Dow Chemical Company,
Chemicals and Metals Department.
~
September 1991

?e objective of pollution prevention is to reduce generation of illutants and wastes at the source as much as possible and to recycle ose wastes that cannot be eliminated. Wastes include materials lost rough evaporation, wastewater discharges, and nonhazardous and izardous solid wastes.
)llution prevention options fall into two categories: source reduction id recycling. wrce Reduction: Good Operating Practices
3od operating practices are procedural, administrative, or stitutional measures that a company can use to reduce waste. Often sting little and yielding a high return on investment, these practices n be implemented in all areas of a plant, including production, aintenance operations, and raw material and product storage.
0 Train employees and give incentives to encourage employees to strive conscientiously to reduce waste.
0 Segregate wastes to reduce the volume of hazardous wastes by preventing the mixing of hazardous and nonhazardous wastes.
0 Allocate waste treatment and disposal costs directly to the departments or groups that generate waste, rather than charging these costs to general company overhead accounts.
The departments or groups that generate the waste will become more aware of the effects of their treatment and disposal practices, and will have a financial incentive to reduce their waste.
0 Schedule batch production runs judiciously to reduce the frequency of equipment cleaning and the resulting waste.
0 Change the way materials and inventory are handled, to reduce loss of input materials because of mishandling, expired shelf-life of time-sensitive materials, and improper storage conditions.
0 Reduce wastes by avoiding leaks from equipment and spills. urce Reduction: Technology Changes e technology to modify processes and equipment to reduce waste, marily in production. Technology changes include changes in:
0
0
0 the production process, including the addition of automation equipment, layout, or piping process operating conditions such as:
-flow rates
-temperatures
-pressures
-residence times
Ech
RESEARCH INS’IlTUTE 1

2
Source Reduction: Input Material Changes
Reduce or eliminate the hazardous materials that enter the production process and avoid generating hazardous wastes within the production processes by purifying or substituting input materials.
Source Reduction: Product Changes
Sometimes the composition or end use of a product can have a negative impact on the environment. If practical, you should identify acceptable substitutes for a hazardous product or scarce or hazardous raw materials needed to produce a product. Another option is to identify conservation measures for a product composed of scare materials. Finally, you may change the composition of the product to eliminate any negative impact altogether.
~
Recycling: Use, Reuse, Reclamation
Return a waste material either to the originating process as a substitutc for an input material (use) or to another process as an input material
(reuse). Recover a valuable material from a hazardous waste
(reclamation). Reclamation differs from use and reuse in that the recovered material is not used in the facility but instead is sold to another company.

ROCESS DESCRIPTIONS le primary goal of the dry cleaner is to remove soils and stains from a iriety of fabrics. The difference between dry cleaning and ”wet
2aning” or laundering is the use of a dry cleaning solvent as the
,inciple cleaning ingredient. Typical industries that use dry cleaning e:
0 retail dry cleaners
0 industrial and linen supply plants
0 leather and fur cleaning plants
0 transportation industries, such as bus lines and airline companies. le three major types of dry-cleaning processes are:
1. Perchloroethylene (perc)
2. Petroleum
3. Valclenem rchloroethylene, the most common method of dry c.-aning, invc ‘es
.mersing textiles in perchloroethylene in the washing unit. Two
3es of washing units are employed in this process: (1) a ”dry-to-dry” it, where the textiles are washed and dried in one unit; and (2) a ret-to-dry” unit, where the textiles are washed in one unit and are ysically transferred to another unit to dry. troleum is an older process that uses a cleaning solvent similar to soline. Normally, the cleaning efficacy of the petroleum solvent is or compared with perchloroethylene. xess. This relatively new process uses a different mechanical stem.
‘PICA1 WASTES e volume of wastes generated is process dependent. However, the lstes are very similar. rc process wastes include:
0 still residues from solvent distillation
0 spent filter cartridges, which collect solvent vapors
0 powder residue from cooking drained filter muck
0 still residues from solvent distillation
0 spent filter cartridges
.roleum process wastes include:
0 still residues, unless 140-FM
Tech
RESFAR H INSTITUTE 3

WASTE REDUCTION OPPORTUNITIES
Operating Practices
Routine equipment inspections can substantially reduce wastes.
Because solvents are volatile, solvent leaks from worn equipment and
_ _ _ hoses can easily go unnoticed unless the operator routinely checks for signs of solvent loss. Liquid leaks can be identified by the presence of a brown residue left on the underside of the leak. Check the following areas regularly for leaks:
~
0
0
0
0 hose connections door gasket and seatings filter head gaskets and seatings pumps and storage tanks
0 water separators
filter sludge recovery units
0 cartridge filters
0 distillation units
0 valves
Routine maintenance practices can reduce losses and wastes generated
Periodically replace:
0
0 dryer seals deodorizing and aeration valves
0
0 faulty gaskets non-repairable hoses.
Repair:
0
0 holes in the exhaust ducts hoses and pipes with leaks.
And institute good housekeeping procedures:
0
0
0
Keep containers of solvents closed while not in use.
Clean lint screens regularly to avoid clogging fans and condensers.
Avoid opening all solvent containers.
0 Use spigots and pumps when dispensing materials and funnels when transferring wastes to storage containers, which can reduce the possibilities of spills.
0 Store products in locations that will maintain their shelf life.
_ _ _
0 Accumulate wastes indoors or in a covered area to prevent moisture from seeping in.
0 Never mix different types of wastes together. Mixing waste can make waste disposal more expensive and recycling impossible.

echnology Changes xhnology changes for preventing pollution significantly increase pita1 investments; however, depending on the volume of dry
2aning that your company performs, the payback can be as little as te year because of savings in materials and reductions in operating
IStS. you are currently using a wet-to-dry cleaning unit, consider placing it with the newer, more efficient dry-to-dry system. The dry-
-dry system combines washing and drying in a single unit. These stems require less employee contact with the solvent in addition to asting less solvent during operation. You may also want to consider e Valclenem system, which produces the least amount of waste. se and Reuse rbon Adsorption irbon absorption is another system that can be used to reduce lvent vapor loss out of the system. Many new systems employ rbon adsorption as an integral part of their machines. Existing ichines without this technology can be retrofitted to include carbon sorption. Exhausts from storage vessels, distillation units, muck olers, dryer condensers, and ambient air systems can be rerouted d fed into the carbon adsorption system. The solvent-laden air sorbs onto the carbon filter while air that is free of solvent is vented tside. The solvent then is flushed from the carbon filter with steam. e steam and solvent vapor condense and separate, and the clean
,vent that is recovered can be reused in dry cleaning.
Fuigerution/Condensutio~ refrigeration/condensation unit also can be used to recover solvent- len air. In this system, incoming solvent-laden air is cooled by rigeration below the solvent's dewpoint. The solvent then is ldensed and is stripped from the air. The clean solvent can be ised in dry cleaning, while the solvent-free air is returned to the y-cleaning unit. Since there is no requirement for a costly steam stem, this process is more cost effective than the carbon adsorption stem. jtillation cause solvents have relatively low boiling points, on-site distillation in ideal method for reclaiming used, contaminated solvents. Simple iting and condensing systems remove impurities from the solvent iste stream, returning the solvent or solvent blend to the process that nerated it. Small solvent recycling units now are commercially
Iilable for businesses generating as low as 150 gallons per month. rger distillation units also are available for processing larger antities. Depending on the degree of contamination and itaminants involved, the distilled solvent that is reclaimed can be as
Tech
RESEARCH INSTlTUTE 5

high as 99 percent pure. Still bottoms, which result from the distillation process, are nevertheless considered hazardous waste and need to be disposed of as such. However, the volume of waste needing to be shipped off-site is reduced substantially. Since a facility can save repurchasing costs, shipping and disposal costs, as well as cradle-to-grave liability, a facility's capital investment in an appropriate distillation system can quickly be recovered.
~

__

4.0 Assessment of the Processes Generating and Methods for Reducing Releases of the
17 Priority Chemicals in EPA's 33/50 Project in the State of Georgia
4.1 Introduction
The
Environmental Protection (USEPA) initiated the 33/50 Program (formerly called the Industrial Toxics Project) in an effort to achieve a voluntary reduction in the release of
17 toxic chemicals by industry. The objective of the program, and hence the name, is to reduce the emissions to all media by 33% in 1992 and 50% in 1995. The reductions will be measured using the Toxic Release Inventory (TRI) reports submitted under the requirements of Section 313 of SARA Title I11
-
Community Right-to-Know regulations of
1986.
The Pollution Prevention Incentives Grant awarded to the Georgia Environmental
Protection Division (EPD) includes a report on the industries, their products, processes, and/or unit operations, responsible for the releases of 10 TRI substances. This analysis has been conducted by the Georgia Tech Research Institute (GTRI) on a subcontract. When the 33/50 Project was announced in early 1991, it was decided that a state-level analysis of the 17 chemicals would be consistent with the EPA project.
A project goal was established to analyze the industries, their products, processes, and/or unit operations, responsible for 90% of the releases of the 17 substances identified by EPA in the 33/50 (Industrial Toxics) Project. 'Target chemicals" are those 17 TRl substances identified by EPA for the 33/50 Project. For the purposes of this analysis, the term refers to any of the 17 substances for which a facility contributes to the top 90% released in
Georgia.
4.2 Analysis Methodology
4.2.1 Assessment of TRI Data
The Georgia facilities responsible for 90% of the releases were identified using the
TOXNET
database at the National Library of Medicine and Georgia's own TRI database. The comparison between the TOXNET and Georgia databases revealed several data quality problems which were corrected by referring to the hardcopies of the Form R's on file at EPD. There are 121 industries in Georgia which release 90% of the 17 chemicals.
The next analysis performed was a determination of the distribution of reports for each
4-1

chemical. The listing of the 17 chemicals and the number of reports for each chemical are presented in Table 1. As indicated in the table, a total of 171 reports were received from the 121 industries which accounted for the release of 90% of the targeted chemicals.
The next part of the analysis was to assess the degree of difficulty these industries would have in identifying pollution prevention opportunities for the target chemicals. One way to gauge this was to determine the number of the target chemicals which would have to be assessed at each facility. This data was also useful in determining the scope of the telephone survey that was conducted as a part of this analysis. The initial plan determined that a survey of one to two hundred companies was achievable using a telephone contact methodology to contact each company. A survey of more than two hundred companies that included telephone contact would not be practical.
The results of this analysis are presented in Table 2. As indicated in the table, for over 70% of the facilities, only one targeted chemical and the associated processes would have to be evaluated to meet the goals of the 33/50 Project. The number of chemicals does not tell
4-2

us anything about the degree of difficulty in changing the processes. However, it does indicate the amount of resources that will be required to assess the facility, develop pollution prevention options, and track the progress. The number of chemicals from each plant was also considered to be in the range that could be surveyed using the letter and telephone contact methodology planned for the project.
4.2.2 Telephone Survey
M e r identifying the facilities responsible for these releases, a literature review was conducted to identify their products and likely process equipment. A letter was sent to each of the facilities that described the EPA 33/50 Project, the reason the company was identified, and the purpose of our study. A telephone survey of these companies was conducted in which the following were discussed:
0
0
0 the processes involved in the releases of the targeted chemicals; any changes they have made since 1988; any changes they plan to make in the future.
During the investigation, 116 companies were contacted to discuss their individual uses of the 17 chemicals targeted for reduction. The original data from EPD listed 121 companies.
The 5 companies not included had either closed, moved to another state, or would not provide data. As part of that discussion, the companies were also asked what they had done since 1988 to reduce the amount of emissions released. The following summarizes the anecdotal responses.
The companies have been very cooperative in providing us information. Most seemed to be very interested in the voluntary approach EPA is taking and are anxious to participate.
Many have expressed interest in learning more about the early reduction program in the
4-3

Clean Air
for the TRI.
Amendments and the source reduction/recycling information to be reported
4 3 Processes and Unit Operations Generating
Emissions
The results of the telephone survey to identify the processes and unit operations generating
90% of the TRI
emissions in Georgia are presented in Table 4
and Figures 1
and 2. Table
3 lists the number of companies reporting each of the 17 targeted chemicals and the number of companies using the process and/or unit operation responsible for the releases. The table indicates that a total of 158
reports were made while Tables 1 and 2 indicate 171 reports. The 5 companies who have closed, moved to another state, or would not provide data account for the 13 reports not included in the study.
The amount of the 17 target chemicals released in the State of Georgia is presented in
Table 4.
The table also shows the ranking of the amount of the chemical released on a poundage basis and the ranking of the chemical on the basis of the number of reports that comprise 90% of the release. Some of the chemicals such as trichloroethylene and methyl isobutyl ketone have the same ranking since the same number of reports were received for each chemical. The data indicate that the solvents account for the majority of the amount released and the number of companies that are responsible for the majority of the release.
The short name at the bottom of Table 3 is the abbreviated chemical name used in the
graphical representation of the number of chemicals reported presented in Figure 1.
The figure shows the number of companies reporting each of the 17 target chemicals. The
process and/or unit operation generating the chemical is graphically illustrated in Figure 2.
The figure shows only the 8 most common processes generating the release. All of the other processes reported has less than 5 reports.
indicated in Figure 2, the most common process is coating application. This category represents a solvent used to transfer a coating to a surface and also to clean-up any application equipment. The second most common process generating a release is degreasing.
operation could be for parts degreasing prior to coating, electroplating, or subsequent processing or for simple parts cleaning in a maintenance shop.
Solvents are used in a variety of processes in addition to coatings. The analysis separates the reports into general, cleaning, ink, and glue solvents and paint stripper to provide a better understanding of the uses of these chemicals. As indicated in Figure 2, the sum of these uses would exceed degreasing and be second only to coating solvents. However, targeting possible reductions of these chemicals would be difficult without the further analysis shown in
Figure 2.
Xvlene
-
The processes generating xylene releases are graphically illustrated in Figure 3.
4-4
~
~
_ _

indicated in the figure, the use of xylene as a coating solvent accounts for 78.1% of the xylene release and is the process responsible for the largest release of xylene. The balance of the releases are somewhat equally divided between ink, cleaning and general solvents.
The general solvent category includes such things as varnish solvent, protective coating solvent for use on electric motor windings, and a rubber degradant in the glove manufacturing process. Since xylene was the most frequently reported release of all of the
17 targeted chemicals in Georgia, it can be concluded that coating solvents account for a large percentage of the targeted chemical releases in the state.
1;l.l -Trichloroet hane
-
The processes generating l,l,l-trichloroethane (TCE) are graphically
illustrated in Figure 4.
Most of the releases occurred from degreasing operations. A review of Table 3 indicates that l,l,l-trichloroethane, trichloroethylene, and tetrachloroethylene were the only substances of the 17 listed chemicals used for degreasing. A general solvent was reported as the second most common source of release, and cleaning, ink, glue solvents and foaming agents were of somewhat equal percentage as a source. TCE was not used as a coating solvent according to the survey.
-
The processes generating toluene releases are graphically illustrated in Figure 5.
The use of toluene as a coating solvent is the major use although the percentage is not as high as xylene. The other uses of toluene are somewhat balanced indicating that toluene should be considered a more general solvent with multiple uses. However, it does appear that the toluene is the most commonly used glue solvent of the 17 targeted chemicals.
Methyl Ethyl Ketone
-
The processes generating methyl ethyl ketone (MEK) are graphically illustrated in Figure 6. The largest percentage of MEK (61.9%) is used in coating operations. that
It appears that xylene and MEK are the primary chemicals of the 17 targeted are released by coating operations. The remainder of the uses of MEK are mixed among the various solvent uses including glue and lacquer solvent and a solvent for a protective coating used on metals. However, MEK appears to be the most frequently used
solvent among the 17 target chemicals.
Dichlorometha ne
-
The processes generating dichloromethane (DCM) are graphically
illustrated in Figure 7. The uses are varied, but DCM appears to be primarily used as a
foaming agent. Other uses of DCM include paint stripping, floor cleaning, extraction solvent, glue solvent, tool and dye cleaner, proprietary labeling process solvent, and as an ingredient in an insecticide. DCM, like TCE, is not used as a coating solvent.
Trichloroethylene
-
As shown in Table 3, trichloroethylene had only 5 reports filed which accounted for 90% of its release. All 5 reports indicated the chemical was used in a vapor degreasing operations.
Methvl I s o b l Ketone
-
As shown in Table 3, methyl isobutyl ketone (MIBK) had only 5 reports accounting for 90% of the release. Three reports indicated that the chemical was used as a coating solvent, and one report indicated the chemical was used as an extraction
4-5

solvent for the removal of rosins and turpentine from tree stumps and one report indicated that the chemical was used as a cleaning/flushing solvent for coating equipment.
M l o r o e t h v l e n e
-
All 3 reports for the chemical indicated that the chemical was used for degreasing as
shown in Figure 1.
4-6

3

-
Table 4. Compdrimn of Amount of Chemical Released and Number of Reports
Chemical Amount Released
(Pounds)
Ranlung of Release on
Poundage Basis
Ranking of Release on
Number of Reports
Chloroform
-
The 3
reports of the substance shown in Figure 1 were from byproducts
generated from Kraft bleaching process used in paper manufacturing.
Mercury
-
indicated in Table 3 , 2 of the 3 reports for mercury were from the production of chlorine where mercury is used as an electrode in an electrolytic cell operations and 1 from a fiber optic cable manufacturing process.
~
-
One of the three nickel reports was for electroplating, and second for nickel/cadmium battery manufacturing (press negative process), and third for use as a catalyst in a process to hydrogenate edible oils. (See Table 3.)
-
4-8

a s a 4
2 5
$ 0
5
0
1 0
1 6
CUEMI C A L ABBREYIATI P R O W O E D
i n
T A B L E 4
gure 1. Total Reports for 17 Targeted Chemicals in the State of Georgia
4-9

8 0
5 0
4 0
3 0
2 0
1 0
0
0.11 n g S o l v e n l I G e n e r a l S o l v e n t
I
I n k S o l v e n t
F o a m l n g A g e n t
D e g r e a r l n g C I e a n l n g S o l v e n t G I u e S o l v e n t
P R O C E S S P R O D U C I N G C H E M I C A L
P a l n l
I
S I r I p p e r igure 2. Process andlor Unit Operation Generating Release
4-10

Ink solvent
(6.39)
@re 3. Process and/or Unit Operation Generating Xylene Release gure 4. Process and/or Unit Operation Generating l,l,l-Trichloroethane
Release
4-11

p r e 5. Process and/or Unit Operation Generating Toluene Release
'igure 6. Process and/or Unit Operation Generating Methyl Ethyl Ketone
:elease
4-12

Figure 7.
Release
Process and/or Unit Operation Generating Dichloromethane
Cadmium
-
One cadmium report indicated the chemical was in the ore from which copper is extracted, and the second was a raw material used in nickel/cadmium battery manufacturing (press negative process). (See Table 3.)
Chromium
-
One chromium report indicated the substance was in the ore used to make titanium dioxide, and the second indicated the chemical was released as a constituent of electric arc furnace dust during steel manufacturing. (See Table 3.)
Benzene
-
The only benzene report shown in Table 3 indicated the chemical was used in a proprietary process for the production of caprolactam.
Carbon Tetrachloride
-
The single carbon tetrachloride report shown in Table 3 indicated the substance was used as a transfer agent in the manufacturing of styrene-butadiene latex.
-
The single lead report in Table 3 was a constituent in electric arc furnace dust from steel manufacturing.
4-13

Summary
-
The evaluation of the individual uses of the 17 targeted chemicals reported lead to the following observations regarding the major uses of the chemicals: o
0
The use of xylene and methyl ethyl ketone in coating operations are the largest source of releases in terms of number of processes. Toluene and methyl isobutyl ketone make up a smaller of the release sources; l,l,l-trichloroethane used in degreasing operation is responsible for the largest number of sources. Trichloroethylene and tetrachloroethylene are secondary sources in processes; o The "general use" category of solvents in various operations accounts for the significant portion of the releases of all chemicals.
4.4 Pollution Prevention Activities that Have Reduced Emissions
methods reported by the companies to reduce the release of the 17 targeted chemicals are presented in Table 5
and graphically presented in Figure 8. The responses received
during the survey were categorized into the following groups:
0
0
0
Better Operating Practices
Input Material Change
Technology Change
0
Product Change o Recycling
0
Treatment
0 Plant Change o Technology/Information Limitations
4.4.1 Input Material Change
The most frequently reported method of reduction is a change in input material as shown in
Figure 8.
Table 5 indicates that 52 of the 148 chemical releases reported were reduced by a change in input material. Input material change is considered one of the most desirable methods of pollution prevention. Input material changes include:
~
_ _
4-14

0
0
Material purification
Material substitution
Some of the unique solutions described include the following:
For solvent degreasing operations, several alternatives are currently being used. These include oven degreasing, caustic cleaning with rust inhibiting rinse, citrus based cleaners, aqueous based surfactant cleaners, and hot wax cleaners.
For coating operations, vendors have reformulated their products don't include solvents. Also, so they many companies have switched to high solids paint, water based paints, or powder coatings.
For glue operations, water based adhesives are now being used where possible.
For printing operations, water based inks are being used where possible
(gravure printing).
For rigid foam manufacturing, which typically uses dichloromethane to purge the foam lines and nozzles at the end of each shift, a water/surfactant-based product is being used to purge equipment. Another foam product manufacturer has been successfully using a water/surfactant-based cleaning solution, and is willing to share its experience with the first company.
4-15

' I I
4-16

e o
5 0
Y
0
S O gure 8. Summary of Methods of Reduction in Releases for 17 Targeted Chemicals in the State of Georgia
4-17 i
.

4.4.2 Technology/Information Limitations
The second highest number of reports indicated no reduction was possible due to technology/information limitations. In some cases such as chromium in steel, the chemical cannot be eliminated from the raw material. However, newer treatment technologies such as plasma torches could reduce chromium emissions. The technology/information limitation includes: o
0 o
The chemical exists as a component or impurity in the raw material such as lead in scrap copper
A substitute for the chemical does not exist
A customer will not accept a product manufactured using a substitute chemical o o o
No manufacturing technology currently available which can effectively reduce emissions of the chemicals and still maintain cost/quality effective production of product.
No effort at reduction is being made by the individual company.
In some cases the individual companies have substituted one of the seventeen targeted chemicals in place of another. This is not considered a reduction under the 33/50 program.
For those companies that reported technology/information limitations 70% of them were investigating new technologies or substitutions for the indicated chemicals. For example, several companies reported that it was not economically feasible to change technologies until the present system failed. At that time, a different technology would be implemented.
Another case of technology/information limitations involved the customer requirement of using dichloromethane as a glue solvent because of its solubility in water. Until the customer can be convinced that a substitute solvent can be used, DCM will remain in use.
The remaining 30% of the companies reporting technology/information limitations indicated that no reduction of emissions had occurred. One facility indicated that no efforts at reduction were currently being implemented because they were already operating within
EPA regulations. Three other companies indicated that emission reductions had occurred due to production decreases, which is not considered a reduction under the guidelines of the
33/50 program. It appeared that the remaining companies had not yet begun investigating reduction opportunities.
~
_ _
4-18

4.43 Better Operating Practices
The third most common reduction method reported was better operating practices. These were typically general housekeeping practices such as keeping lids closed on degreasers.
These are normally the most easily implemented methods of reduction. Better operating practices include the following: o Waste Minimization Programs
0
0
Waste Segregation
Personnel Training and Practices
0 Cost Accounting Practices o Material Handling Inventory Practices
0
Production Scheduling o Loss Prevention (Le. eliminate leaks)
0
0
Better System Maintenance
Equipment updates (Le. new storage tanks)
Some o€ the general solutions described included:
0
industries reported implementing material handling inventory practices which include tighter controls on incoming inventory and what is used by employees. This tighter control helped to reduce wastage of the chemical and therefore emissions. o
0
Three companies reported updating recovery equipment such as recovery stills and air strippers to make them more efficient, which reduced emissions.
One manufacturer reduced emissions by training the employees on proper cleaning techniques. This company is also investigating alternative chemicals. o The remaining companies reporting better operating procedures indicated that better system maintenance which includes replacing worn out parts, eliminating leaks, and better lubrication had reduced emissions.
4-19

4.4.4 Recycling and Reuse
The next most common method of reduction was recycling of the chemical. This would require some additional effort such as better operating practices or some technology to capture the chemical and prevent release. Recycling includes:
0 On-site recycling
0 Off-site recycling o Waste exchange
Some of the unique solutions described include the following: o o
For coating operations, in-process recycling has been used to reduce the amount of solvent discharged. Also, in one case an in-process heater had been installed to reduce the amount of solvent required in the operation.
For general solvent use, many companies are installing on-site stills to recover their used solvent. This recovered solvent may either be reused by the company or sold for use elsewhere. Also, some companies are sending their used solvent to off-site recovery facilities.
4.4.5 Technology Changes
A change in technology was the fifth most common method. This is often hard to accomplish due to capital costs involved and the current state of recession in the manufacturing industry. The plant site visits accomplished as a part of this grant also identified worker reluctance as a problem with technology changes. Technology changes include the following: o Changes in the production process o
0
Equipment, layout, or piping changes
Use of automation o Changes in process operating conditions such as flow rates, temperatures, pressures, residence times etc.
Some of the unique solutions described include the following: o For coating operations, anodizing of the individual parts may be possible.
Also, decorative tape can replace coating. Some companies have also
4-20
~
~~

switched to High Volume Low Pressure (HVLP) application systems which effectively reduces the amount of solvent required for the process. o A battery manufacturing company reported a technology change from the press negative process (dry dusting process) to the plastic bonded process (wet slurry process) for battery plate making. This process change eliminated the release of cadmium. o The pulp and paper industries indicated that they were replacing the hypochlorite stage of the
bleaching process with a new technology which does not generate as much chloroform.
0
One company which operated a resin coating process switched from a roller application system for trichloroethane to a wick application system. The roller operation produced a large amount of fugitive emissions because of the large surface area whereas the wick system has a much smaller surface area and therefore much less evaporation.
4.4.6 Reduction in Production Levels
A plant or process shutdown was reported as the cause of a reduction in 6 situations. Many of the companies contacted indicated that reduction of some of the targeted chemicals had occurred due to elimination of the original process/operation that generated the waste.
4.4.7 Treatment
Treatment is considered a waste minimization activity, but not a pollution prevention activity by USEPA and the State of Georgia. However, several facilities reported treatment as the method of reduction. Treatment of these wastes include the installation of incinerators, strippers, afterburners, bag houses, thermal oxidizers, etc.
4.4.8 Product Changes
None of the facilities reported a change in product as the pollution prevention activity that resulted in the reduction of emissions of one the 17 targeted chemicals. Product changes were defined as:
0
Product substitution
0
0
Product conservation
Changes in product composition
4-21

4.49 Summary
The methods of reduction of emissions of xylene, 1,1,l-trichloroethane, toluene, methyl ethyl ketone, and dichloromethane are graphically presented in Figures 9, 10, 11, 12, and 13, respectively. The data indicate that input material change is the major reduction source for all of the reductions except for methyl ethyl ketone where recycling had a significant impact on the reduction in release of the chemical. Better operating practices seemed to be the second most common method of reduction. A review of the data for the other chemicals in Table 5 indicate a similar pattern.
All of the data presented in Table 5 and in Figures 9 through 13, show a large number of facilities indicate that the best available technology is currently being used. Therefore, it appears that there is a large opportunity for further reductions in the 17 targeted chemicals.
~
.~
4-22

4-23

'igure 11. Methods of Reduction in Releases of Toluene
Bee 01, Prmcr. 119.0)1) i p r e 12. Methods of Reduction in Releases of Methyl Ethyl Ketone
4-24

T*Ch/TnLO I.imie.l
(31.5.) i p r e
13. Methods of Reduction in Releases of Dichloromethane
4.5 Demonstration Projects
The data from this analysis indicates that solvents for coatings and degreasing offer the greatest opportunity for reduction of releases of the 17 chemicals. In addition, a large number of facilities reported technology/information limitations, indicating that there is a large potential audience for demonstration of new technology. Therefore, the proposed demonstration projects would be:
4.5.1 Coatings Demonstration Project Description
Paint application processes are part volumes of hazardous of many industrial operations and generate large waste through the use of chemicals such as paint thinners and reducers, and the paint itself. Solvents are used to transfer paint onto surfaces by hand or using pressurized spraying equipment. Once the paint is applied, the thinner evaporates and the paint dries and hardens.
The various operations in the painting process which generate waste are: o inventory/purchasing policies o material haridling o paint application
4-25

0 equipment cleaning
For the proposed demonstration project, the focus will be on the paint type and application portion of the coating process. This demonstration will include providing, to the various industries, access to the different coatings and application technologies. This will allow the individual companies to experiment with the different coatings and techniques such as High
Volume Low Pressure (HVLP) sprayers, high solids paints, aqueous based paints, and powder coatings to see if any of them can be effectively applied to their individual needs.
The demonstration could also be used by an industry for demonstration of the quality of a product using substitute technology to a customer.
4.5.2 Degreasing Demonstration Project Description
Parts cleaning and degreasing operations are important to a wide range of industrial processes. Parts are cleaned and degreased in automotive and repair shops, painting operations, metal working and plating shops, printing industry and electrical and electronics industries. An important component of any cleaning process is the solvent. A solvent is defined as a substance capable of dissolving another substance (for example dirt, grease, and grime) to form a solution. Although water is the most common of solvents, organic solvents such as methylene chloride, perchloroethylene, trichloroethylene (TCA), 1,1,1 trichloroethane (TCE), and trichlorotriflouroethane are used in industrial cleaning and degreasing. Organic solvents are very effective in breaking up and removing dirt, grime, and grease. Parts typically are cleaned using one of the following methods: (1) dipping and soaking, (2) vapor degreasing, (3) or in some cases with the application of solvents to rags and physically wiping the equipment clean.
The degreasing operation is a physical method of removing solvent soluble and entrapped grease, grime, and dirt from metal, glass, and other nonporous objects. By bringing the soiled articles at room temperature into contact with hot solvent vapor, the vapor condenses to a liquid soils away on them. Sufficient liquid solvent is formed to carry the soluble and insoluble as the solvent drains by gravity. A solvent vapor degreaser
in its most basic form, a tank with a heat source to heat the solvent and a cool surface to condense the vapor in the upper section of the tank. The soiled articles are then suspended in the hot vapor zone of the tank. The hot vapor condenses onto the cool articles, dissolves oils and greases providing continuous rinse in clean liquid reservoir. Variations of this basic system include ultrasonic agitation, liquid emersion chamber, and/or a spray lance.
The wastes produced by these processes include contaminated liquid solvents and spent solvents which are recovered from the process and solvent vapors which have escaped into the open air and into ventilation exhaust ducts. For the proposed demonstration project, the focus will be on presenting alternatives to solvent degreasers. Such alternatives include caustic cleaners with rust inhibiting rinses, ultrasonic cleaners, citrus based cleaners, surfactant based cleaners, and possibly hot wax cleaners and oven degreasers.
___
4-26

45.3 Demonstration Project Format
The are several formats that these demonstrations could take:
1. The demonstrations could be conducted in an industrial facility. The list of the industries releasing 90% of the 17 targeted chemicals in the State of
Georgia is presented in Table 6. Many of these companies are viable candidates for the demonstration projects. cooperation with the funding to
In 1981, Georgia Tech in
U. S. Department of Energy (USDOE) provided co- two industrial plants to install wood-fired boilers as a demonstration of biomass technology. In return, the facilities allowed other companies to visit the facility and provide data on the economics of wood fuels. A similar arrangement using USEPA or possibly USDOE funds could be considered. Limitations include finding a facility that could utilize all (or most) of the reduction technologies and allow outside companies to actually test the equipment at their facility.
2. The demonstrations could be conducted at the facilities of the manufacturers of alternative technologies or materials. One limitation with this scenario would be selecting a demonstration site among competitive manufacturers' of the technologies.
3. The demonstrations could be conducted at a state facility such as the
Agricultural Exposition Center in Perry or the Manufacturing Research
Center at Georgia Tech. Donations of equipment from manufacturers could probably be obtained. Companies could bring their own materials to paint or degrease on site.
Additional, reductions in releases of the 17 targeted chemicals appears possible. The demonstration projects outlined could be beneficial in expediting these reductions.
4.6 Conclusions
This analysis has identified the industries and the processes responsible for 90% of the 17 chemicals in
33/50 Project released in Georgia. The methods currently employed to reduce releases have also been evaluated and demonstrations to further decrease releases have been identified. Additional work is needed in the evaluation of the decision-making structure in companies that have successfully implemented pollution prevention options.
The study would include interviews with company personnel involved in the decision-making process in order to delineate the managerial, organizational, and financial characteristics which facilitate the identification, funding, and implementation of voluntary pollution prevention activities. AU of this information is needed to completely implement the goals of the 33/50 program.
4-27
~~
~

Chemical and Facilitv
DSM Chemical8 Auguata, Inc.
Doar Gumical Dalton Site
CHLOROFORM
Georgia Pacific BNnsprick
ITI Rawmier Inc.
Federal Paper Board Company
Gilman Paper Company r
CYANIDE
A m e m n i lnc.
Georgia Tubing Corp.
Sarainsbom Bcetmlatine Inc.
Torrington Co.
LEAD
Atlantic Steel Cn.
Atlantic Steel Co.
Ate1 General Inc.
Total Release in Pounds
22,609
1,852
1.500
750
186,115
138,747
'%MM
246,714
730,640
362.840
~,~ m,m
4-28

Memk & Company
Hickory SpMp Manufacturing
McGun-&Am h c .
Park Coinoration
RohmPoulenc AG Company
P c “ x FYodu*s, Inc.
CraiD Industries
Austin Umthanc. Inc.
Owen8 Illinois Glass Container
Hercules Specialty Chemicals
AT&T Netwrk Syrtems hyiiner Mame Corporation
Glidden Company, The
PPG lndurtries
Pocpl Point, IaF.
MElTNLETHnKETONE
Mom0 Prsor tonl Fabrim
Davidaon -nor Trim
Gc”I MotorrCPC Doravillc
LoeLhccd Aeronautical Svatems rlT
Thompson
-
Rant 3
5n)der Bmthes Co.
Qrcudenbeg-NOK
Gulfst” Aeroapan Cop. k l t e -0-Highland Plant
BloeLvay Standard, Inc.
4T&T Netwrk Svatcma
PPG Industries
D u t b r d Marine Copration
U. S. Can Comosnv
4-29
1,677,700
299,981
255,059
2 5 4 m
254,159
187,318
W,875
130,W
113,071
83,700
71,280
56,862
54 754
53,100
52,062
490,205
336,250
103.062
88,399
70,452
68,441
46,740 u 5 0 0
42.300

Continental Can Company
Boeing oeorgia,
Dougiar & Lamson
VaIspar Corporation, The
Oilruth Industries
Pitrgsrald Railear Services
Permite Corporation, The printpack, Inc.
METHYL ISOBUTYL "
Hemlcs-Brunssvick Plant
Dwidmn Exterior Trim
Gulfstmm Aerohppre Cnrp.
Wellington Leisure Products
Great Dane Trailers, Inc.
NICKEL
Kemira, Inc.
Beatriapunt-Wrrson Savannah
& C d FOStCnCK, InC.
TOLUENE
Ringisr America, lac.
FPG Industries
DSM Chemicals, Augusta. Inc.
Wellington Leisure Products
Rapidtee
Union Camp Corporation
Vantage Prod-, Inc.
Merck & Co.
Blue Bird Body Company
Loekhecd Aeronautical Systems
General MotorsCPC Doraville
Basutt Furniture Company
I
4-30
113,400
10,453
6524
1,934,137
755,wo
675?460
579,766
460,164
326200
261590
24"
237,234
220570
201,250
189,959
24,037
2,1Y,7M)
336,wo
323,648
212581
65512
32,585
29poo
27,907
26,223
26,186
25900
24,850
24,037

General MotOK Corporation
Douglas 81 L 0 " n Company
Linear Dynamics, Inc.
Grut Dane Trailerr, lac.
Bssrett Fum. Ind. of N. C
Amsrican Welding 81 Tank Company
Parka Corwration
ATBIT Nctvmrk Syatems
Metal Coatera of Gear@
I I T l R o m p o n
-
PLAiW 3
Bayliner Marine Corporation
Rhwm Manufacturing Co.
Fontmarin 81 Co., lnc.
Thsrmo King Corporation
General l i m Coiporatton
LnrLin.
1°C.
Div. Genuine Paris Co.
Robenshaw Controls Company
KaydMI Copxatian
Lcckhssd Aeronautical Svstem
TRlCHLOROETHANE
Gulfstrum AerosDaee Core.
Amercod Inc.
Mom0 Prsar
4-31
I
I
381;770
133,000
1W,%9
76.263
362.200
U5,m
167,980
48.m
644.813
SW,001
490,205
163,074
146,000
126,248
113,088
104523
101,142
79,038 n.200
69,000
67,412
62,wO
54,432

Dittler Brothers, Inc.
W d Aeronautical Systems
Fmudemberg-NOK
Union Camp Corporation
EcPcltc Dymo
-
Highland Plant
M p t a Erie Noah America, Inc.
P n t t & Whitney
Harris Califoric
Production Color, lnc.
RockwcII International Cop.
I
Atlantic Stecl Company
Amrep, Inc.
Kpto Spring of Gwrgia, Inc.
Torrington, Co.
AT&T Netwrk Systems
Hickory Springs Manufaaunng
Milliken & Company Avalon
Combustion Teehnolops, Inc.
Douglas & lamason Company w e - M i m y Household
A=ry
Plastican, Inc.
Inland Container Corporation
PMI F d
G a t z c Corporation of America
BuU M a s c Tube Company
Thenno King Corporation
OKI Tele"
PPG Industries
Hercules
-
B N k C k Plant
Ford Motor Company Atlanta
40,000
40,000
39,912
3,m
37,577
37,200
34,000
33,018
31,805
278,811
U9,2W
128.704
123,900 i i 6 , m i
95,090
85,750
82,275
81,755
75,720 a 3 w
6Zr,200
60,392
47,850
47,000
45,108
M,000
~ W J
%2,m
512,200
301,100

Great Dam Tniles Inc.
But Manufacturing Company
Barrett Furniture Company
American Yard Pmdvcts
Rheem Manufacturing Company
G i k t h Industria, Inc.
Ameriesn Yard Products
IWiancc Ekevie Company
Amarfite Architectural
P i c h y Corporation
American Elemic
Roper Cnrpomtion
Bmckway Standard, m
-
Plant 3
Mastemck, Division of Lsggctt
Ringier America, Inc.
Cryltsl Springs Print Works
American & Tank Co.
111725
113J01
104,653
99.377
8 9 W
83,886
79,900
77,856
76,724
54,093
51,190
51,W
46,165
42500
41208
4Q.W
35541

4-34

5.0 Technology Transfer
5.1 Fact Sheets
The survey of Georgia industries and their processes, discussed in the previous chapter of this report, provided insight into the topic areas for the fact sheets. Fact sheets were developed for waste reduction options for painting, cleaning and degreasing, printing, electroplating, and drycleaning. In addition, a one-page fact sheet was developed to inform industry about Georgia’s new hazardous waste reduction planning requirement. Many state programs have developed excellent fact sheets and reports for these processes. We reviewed the fact sheets and reports available from other states, literature available through the technical publications, and discussions with industry representatives to develop the one-page fact sheets required for this contract. We would like to acknowledge the following references that were used to develop the fact sheets for this project:
Dry Cleaning
-
A Basic Handbook The Dow Chemical Company, Chemicals and Metals
Department.
Fact Sheet
-
Dty Cleanem. Office of Waste Reduction, Washington State Department of
Ecology, November 1988.
Guides to Pollution Prevention
-
The Commercial Printing Industy EPA/625/7-90/008.
United States Environmental Protection Agency, Office of Research and Development,
August 1990.
Manual on Vapor Degreasing, 3rd Ed. American Society for Testing and Materials, ASTM
Subcommittee D26.02, 1989.
Metal Waste Management Alternatives. California Department of Health Services, Pasadena,
California. 1989, pp. 45-55.
Solvent Reduction Alternatives
-
Things You Can Do
Waste Reduction Resource Center for the Southeast, October 1989.
The Effcient Utilization of Material in the Finishing Room. DeVilbiss Educational Services.
Waste Reduction Assessment and Technology Transfer (WRATT) Training
The University of Tennessee Center for Industrial Services, Waste Reduction Assistance
Program, 1989.
5-1

Waste Reduction Assistance Program Onsite Consultation Audit Report: Dry Cleaner. Alaska
Health Project, August 14, 1987.
Waste Audit Study
-
Automotive Paint Shops. California Department of Health Services,
Sacramento, California, January 1987.
Waste Audit Study
-
Commercial Printing Industry. California Department of Health Services,
Toxic Substances Control Division, May 1988.
Waste Reduction for the Commercial Printing Industry. California Department of Health
Services, Toxic Substances Control Program, August 1989.
.
~
5.2 Pollution Prevention Column in Environmental Saectrum
A regular Pollution Prevention column was established in GTRI's quarterly newsletter
Environmental Suectru m. The column has been used to announce the new hazardous waste reductiofi planning requirement and the infusion of pollution prevention into national environmental rules. Copies have been distributed to over 3,000 facilities.
53 Distribution of Technology Transfer Materials
All large quantity generators of hazardous waste were sent a copy of Environmental
Spectrum. In addition, they received a copy of the fact sheet announcing the hazardous waste reduction planning requirement, an order form for additional fact sheets on waste reduction options, and an invitation to request a free subscription to
5.4 Conference/Region
Roundtable
The conference was conducted on September 30
-
October 1, 1991. The original plan designated the first day as the traditional Region IV Roundtable meeting of state pollution prevention contacts and the second day as a showcase of industry research/efforts in pollution prevention. The conference was co-sponsored by Georgia Tech, EPD, and EPA
Region
5'4.1 Planning Activities at GTRI o
presented a summary of the pollution prevention project at the Region IV
Pollution Prevention Roundtable in Mississippi on February 20-21, 1991. At this meeting the conference was discussed with the EPA Region IV contact and the representatives from the other states.
_ _
5-2

o The EPA Region IV Pollution Prevention Coordinator recommended that GTRI coordinate the conference with the HazMat South Conference in Atlanta to be held on October 2-4, 1991 at the Georgia World Congress Center. HazMat South featured a pollution prevention session with a panel of Region
representatives. o GTRI compiled a list of hotels and their government rates for the conference participants. The list was forwarded to EPA Region
for inclusion in their notice to the roundtable members. o o
A letter was sent to each of the state roundtable representatives announcing the conference and requesting nominations for industrial presentations.
contacted the state pollution prevention contacts by telephone for their industrial candidates. A list of the state and industry contacts was submitted to EPD and EPA Region IV.
5.42 Conference Outcome
The EPA Region IV Pollution Prevention Coordinator developed the agenda for the meeting. EPA also distributed agendas and Georgia Tech campus maps, provided by GTRI, to the state pollution prevention contacts. The second day of industry presentations was abandoned when it became apparent that many of the nominees would not be able to attend. The list of industry nominees could be used for a future conference on pollution prevention research and implementation.
The conference was held at the Wardlaw Center on the Georgia Tech Campus. GTRI provided the conference materials and refreshments, which were not included as part of this contract. In addition, GTRI coordinated the lunches which were paid for by the attendees.
The conference was attended by 41 people, with representatives from all eight states in EPA
Region
5-3

1991 EPA REGION IV P2 ROUNDTABLE
AGENDA
1045
11m
1200
1:30
200
2 3 0
3:00
3 4 5
4 15
4:30
MONDAY, SEPTEMBER 30
8 3 0
9:00
9
9:45
SPEAKER
Coffee & Refreshments
*Welcome
*Introduction
*Update on Waste Reduction Resource Center
Jim Walsh
Tom Nessmith
Gary Hunt
Bob Carter
*Update on State Activities/State Appropriated Grants
(15 minutes each State)
BREAK
'State updates (continued)
LUNCH
*Evaluating Outreach Efforts
*EPA/Business Outreach
Gagnet
Bernie Dupperray
Bill Green, Enform *Private Sector Business Outreach
BREAK
*33/50 ORD Workshops
*P2 in Enforcement Activities
*General Discussion
ADJOURN
Jon Johnston
10:00
1030
1045
11:15
11:45
1200
1:30
2:00
2:30
3:00
TUESDAY, OCTOBER 1
8:30
Coffee & Refreshments
*EPA Activities
Municipal Water F
Federal Grants (status)
Ben Chen
Angie Fugo
Carol Monell
Lena Hann
Jim Walsh *Targeting Technical Assistance
BREAK
'Update on TVA Activities
*UAH/TVA Solar Evaporator
*ORD/RTP Activities Betsy Shaver
LUNCH
*Industry
-
Great Dane Trailers (Governor's Award) Dick Walpole
*Federal Sector/Consumer Sector Strategies Carol Monell
*R2 P2 Coly Berish
ADJOURN

AlTENTION
Georgia Tech Research Institute of charge several publications of interest to generators of hazardous waste. Environmental Spectrum is a newsletter published by the Environmental Science and Technology Laboratory of GTFU.
Also available is a guide on how to implement a hazardous waste reduction plan as well as guides for waste reduction options in:
-
Dry-cleaning
-
Commercial Printing
-
Electroplating
-
Painting
-
Cleaning & Degreasing
If you or your company would like a subscription to Environmental Spectrum or would like any of the available guides, simply fill out the attached form and mail it to the following address:
Dara @Neil
Georgia Institute of Technology
G TR / E S TL
143 OKeefe Building
Atlanta, GA 30332 useful.
Thank you for your time and consideration. We think you will find these publications

Please check all of the following in which you are interested:
- subscription
-
& Degreasing
Area of General Interest:
Your Address:
Send to: Dara O’Neil
Georgia Institute of Technology
GTRI/ESTL
143 O’Keefe Building
Atlanta, GA 30332

The Georgia Hazardous Waste Management Act as amended in 1990 requires that Large Quantity Generators of hazardous waste and users of Georgia's treatment, storage, and disposal facilities develop hazardous waste reduction plans and submit them to the Georgia Environmental Protection Division
(EPD) no later than March 1,1992.
The forms for submitting this plan will be mailed by EPD with the
When developing y o u hazardous waste reduction plan, the law requires that you do the following:
Management Support Devise a written policy stating goals of upper management and corporate commitment to hazardous waste reduction.
Goals Decide scope and objectives of your plan based on what is technically and economically practical.
Assessments Analyze hazardous waste streams and perform periodic waste reduction assessments on individual processes or facilities to find where your waste is generated. Consider applicable recycling techniques.
Accounting Systems Identify your hazardous waste management costs, factoring in liability, compliance, and oversight expenditures.
Employee Training Implement awareness and training programs to involve your employees in hazardous waste reduction planning.
Implementation Implement technically and economically practical hazardous waste reduction options.
Institutionalize your plan to ensure an ongoing effort.
Progress Reports Submit a hazardous waste reduction report to the Environmental Protection Division every two years. The report should analyze and quantify your company's progress in hazardous waste reduction relative to your established goals.
For more information, contact the Pollution Prevention Coordinator at (404) 894-3806
Environmental Science and Technology Laboratory, Atlanta, Georgia 30332
Printed on recycled paper
@
RF,SFAR?fI INSTITUTE

Georgia Environmental Protection Division
The Division was recipient of a "Pollution Prevention Incentives for the States" grant from
U.S. EPA. The preparation of this document was financed under contract to the Georgia
Environmental Protection Division (EPD).
September 1991
~

The best waste reduction options fall into t w o categories: eliminate wastes, emissions, those or discharges a t t h e source through that changes in operating practices, technologies, input materials, or products; and those that recover and recycle spent materials.
Reduce pollution at the source
Set up good operating procedures.
0 Inspect equipment routinely to detect leaks.
0 Replace seals, valves, gaskets, and hoses periodically.
0 Repair holes and leaks.
Set up good housekeeping procedures.
0 Keep solvent containers closed.
0 Use spigots and pumps to reduce spills.
0 Clean lint screens regularly.
0 Store products in a place that will preserve their shelf life.
Change to more efficient systems.
0 Replace a wet-to-dry cleaning unit with a more efficient dry-to-dry system. Dry-to-dry systems mean less employee contact with the solvent anc less solvent used during operation.
0 Contact your trade association for information o state-of-the-art drycleaning equipment and solvent alternatives.
Recycle waste materials
Use systems and procedures that recycle solvents.
0 Change to carbon-adsorution svstems, which reduce solvent-vapor loss. Existing machines can be retrofitted with these systems.
0 Use a refrigeration/condensation unit to recover solvent.
0 Use on-site distillation to reclaim used contaminated solvents.
Accumulate wastes indoors or in a covered area to prevent moisture from seeping in.
Don't mix wastes together. Mixing wastes can make recycling impossible and waste disposal more expensive.
The state of Georgia has a new Hazardous Waste
Reduction Planning requirement. Please request
Guide #I for more information.
For more information, contact the Pollution Prevention Coordinator at 404/894-3806
Environmental Science and Technology Laboratory, Atlanta, Georgia 30332
'rinted on recycled paper
IC
@ch
RESEAKCH INSTITLITE

Georgia Environmental Protection Division
The Division was recipient of a "Pollution Prevention Incentives for the States" grant from
of this document was financed under contract to the Georgia
Environmental Protection Division (EPD).
September 1991

The best waste reduction options fall into two categories: those that eliminate wastes, emissions, or discharges at the source through changes i n operating practices, technologies, input materials, or products; and those that recover and recycle spent materials.
Reduce image-processing waste.
Reduce pollution at the source
Use alternatives to metal-plate processing.
0 Use silver-free materials whenever possible. allowable silver buildup. prior to fixing.
0 Use personal computers to edit before going to print.
0 Keep floating lids on bleach and developer containers to keep them fresh.
0 Install waterless paper- and film-developing units to reduce the volume of fixer waste.
0 Use electronic imaging or laser platemaking to reduce photographing and reshooting.
0 Use countercurrent rather than parallel rinse techniques to reduce water use. so that they don't spoil.
Recycle image-processing waste. generally use water-based solutions and generate little or no hazardous waste.
0 Use electrostatic plates, which can eliminate several process steps.
Minimize ink waste. ultraviolet inks.
Use only enough ink for a particular run or shift, and run similar jobs simultaneously.
0 Seek fountain solutions with little or no volatile isopropyl alcohol (IPA).
Monitor press performance to minimize bad runs and waste, and improve cleaning procedures.
Store materials and supplies properly to maintain their shelf life,
Recycle waste materials
Save old inks and market them as "house colors." to be recycled off-site.
Use alternatives to metal-plate processing. aluminum recycler.
Remelt Or sell hot metal Plates to a recycler.
Recycle negatives and silver-laden paper.
Purchase inks in recyclable containers to reduce cleanup.
Donate unemulsified inks to trade schools and colleges.
Recycle waste paper through an outside contractor.
Find ways to use paper, such as making note pads and posters from scrap. Donate paper waste to schools and churches.
Reduction Planning requirement. Please request
'or more information, contact the Pollution Prevention Coordinator at 404/894-3806 hvironmental Science and Technology Laboratory, Atlanta, Georgia 30332 rinted on recycled paper
@
RESEARCH I m I

Georgia Environmental Protection Division
The Division was recipient of a "Pollution Prevention Incentives
the States" grant from
this document was financed under contract to the Georgia
Environmental Protection Division (EPD).
September 1991
~

The best waste reduction options fall into t w o categories: those that eliminate wastes, emissions, or discharges at the source through changes in operating practices, technologies, input materials, or products; and those that recover and recycle spent materials.
Use good operating procedures.
0 Check process tanks every month for spills, leaks, and overflows.
0 Maintain racks.
0 Check barrels to make sure they are draining efficiently.
0 Store materials and supplies properly to maintain their shelf life.
0 Use drain boards to catch drips.
0 Use trivalent instead of hexavalent chromium plating and chromating solutions to reduce health risks. Because trivalent chromium processes are more dilute than hexavalent processes, losses to the rinsing system are reduced. reduce hazardous waste generation.
Control dragout, the amount of excess solution that gets carried out of the bath along with the work- piece.
Use other available technologies.
0 If space permits, use multiple rinse tanks, which require less water.
0 Use spray rinses and air knives to keep solu- tions inside process tanks.
0 Use air agitation in rinsing solutions to improt rinsing efficiency and to lower the amount of rinsewater used.
0 Use flow restrictors to avoid wasting water.
Flow controls that use conductivity cells will ensure that water flows only when needed for a process.
0 Use noncyanide plating solutions to reduce pretreatment of solutions and to reduce health and safety hazards.
0 Use automated speeds for withdrawing parts from processing solutions to control dragout.
0 Extend drain times to reduce dragout.
0 Place parts in the solution with points or corners downwards.
Recycle dragout solutions.
0 Use a nonflowing rinse or an empty tank to retain process solutions. These solutions can be returned to the process tank, with or without further separation or concentration.
Switch to deionized water for replacing water cessing solutions. that evaporates from plating process solutions. Tap or softened water is a potential contaminant to pro-
The state of Georgia has a new Hazardous Waste
Reduction Planning requirement. Please request
Guide #I for more information.
For more information, contact the Pollution Prevention Coordinator at 404/894-3806
Environmental Science and Technology Laboratory Atlanta, Georgia 30332
Printed on recycled paper
@
Georgia Tech
RESEARCH INSllTUTE

Georgia Environmental Protection Division
The Division was recipient of a "Pollution Prevention Incentives for the States" grant from
was financed under contract to the Georgia
Environmental Protection Division (EPD).
September 1991
~

The best waste reduction options fall into two categories: those that eliminate wastes, emissions, or discharges at the source through changes in operating practices, technologies, input materials, or products; and those that recover and recycle spent materials.
Reduce pollution at the source
Use good operating practices.
0 Set u p inventory controls, or limit access to storage areas. fl Check drums for leaks.
0 Store drums near areas where they are used to reduce leaks and spills during transport.
0 Avoid leaks and spills. Use spigots or pumps to dispense new materials, and use funnels to transfer waste materials.
0 Install tight-fitting lids and spigots to reduce evaporation.
0 Lift drums with powered equipment or hand trucks to prevent damage or punctures. fl Train employees to use spray guns properly.
Use various sizes of paint sprayer cups to reduce the amount of paint used for repairs and touch-ups and to reduce the amount of solvent needed for cleanup.
Substitute water-based paints for solvent-based paints to reduce organic solvents. Solvent-based paints are sources of hazardous wastes and air pollution.
Eliminate paints that contain toxic metal pigments such as lead, chromium, or cadmium.
Determine if the product must be coated. If not, use decals instead of painting the product.
Recycle waste materials
Use gravity separation: let thinner/sludge mixtures sit quietly until they separate. The thinner can then be used as "wash thinner" for primer and base coats and for cleaning.
Employ waste exchanges, which are organizations
(such as information clearinghouses) that arrange the transfer of wastes between industries: what is one industry's waste may be another industry's feedstock.
Use on-site distillation, which is more cost-effective for large quantities of thinner waste. The sludge also can be used as underseal.
The state of Georgia has a new Hazardous Waste
Reduction Planning requirement. Please request
Guide #1 for more information.
For more information, contact the Pollution Prevention Coordinator at 404/894-3806
Environmental Science and Technology Laboratory Atlanta, Georgia 30332
'rimed on recycled paper
@
Tech
RESEARCH INSIITUTE

Georgia Environmental Protection Division
The Division was recipient of a "Pollution Prevention Incentives for the States" grant from of this document was financed under contract to the Georgia
Environmental Protection Division (EPD).
September 1991

The best waste reduction options fall into t w o categories: those that eliminate wastes, emissions, or discharges at the source through changes in operating practices, technologies, input materials, or products; and those that recover and recycle spent materials.
Reduce pollution at the source
Reduce fugitive emissions caused by drafts.
0 Reduce unnecessary air movements in the vicinity of the degreaser.
0 Reduce slot exhaust ventilation to proper rates. install freeboard cooling coils above the primary condenser coils.
0 Install covers with gaskets.
Reduce dragout of solvent.
0 Rack parts for Proper drainage from the item's blind holes and recesses.
0 Leave articles in the vapor long enough to ensure total heating of the work.
0 Reduce part/work movement in and out of the vapor zone.
0 Make sure parts are totally dry before they enter the degreaser.
Institute general maintenance procedures.
0 Routinely clean and check separators, joints, connectors, valves, gasket covers, and seals.
0 Remove sludge at the bottom of the tank to increase cleaning efficiency.
0 Analyze the solvent, and add specific compo- nents when the solvent needs to be replenished.
0 Control the amount of heat supplied to the vapor degreaser.
0 Keep the exchanger surface clean and descaled.
0 Manually spray articles well below the vapor
0 Standardize the solvent to permit better recy- cling during distillation.
Use alternatives such as aqueous (water-based) cleaning systems instead of organic, solvent-based cleaning systems.
Recycle waste materials
Use on-site distillation to reclaim used contami- nated solvents.
Use activated charcoal to collect solvent vapors vented into a plant's exhaust stack.
Contract with an outside firm to remove solvent waste and transport it to a recycling center or to distill waste on site.
The state of Georgia has a new Hazardous Waste
Reduction Planning requirement. Please request
Guide #1 for more information.
For more information, contact the Pollution Prevention Coordinator at 404/894-3806
Environmental Science and Technology Laboratory, Atlanta, Georgia 30332
Printed on recycled paper
43
K?ch
RESEARCH INSllTUTE

Georgia Environmental Protection Division
The Division was recipient
a "Pollution Prevention Incentives for the States" grant from
of this document was financed under contract to the Georgia
Environmental Protection Division (EPD).
September 1991
~
_ _

I
VOLUME 7, NUMBER 2,1990
Jew
\ worker in a plywood manufacturing plant was pairing a 50 horsepower motor when it dropped onto his est, pinning him to the floor and preventing him from lling for help. Fortunately, he had locked out the line
,fore he began working on it. When a worker on the next ift went to start the line, he was stopped by the lock and g. Not only was a probably fatal injury averted, but the cond worker, looking for the person who had applied the ck, found the injured man and rescued him.
The lockout/tagout standard covers situations where injury or death could be caused by unexpected start-up, energization, or release of stored energy while a machine or equipment is being serviced or maintained. Most people recognize that electricity must be turned off and discon- nected before a machine is serviced or maintained. But they can get into trouble if they fail to consider stored energy from a capacitor or battery. Other sources of energy include:
This is the type of positive result the Occupational Safety
Id Health Administration (OSHA) hopes to assure with its
'w lockout/tagout standard that became effective January 2,
90. The standard, listed as 29 CFR 1910.147 in the Federal
:gister, outhes required control measures for isolating tzardous energy by a process called lockout/tagout.
0 kinetic energy, such as that in a raised object, which can fall, or in the stored momentum of a flywheel;
0 pressure, such as steam in a boiler; a coiled spring; hydraulic systems; compressed air; continued
on page 2
:TL researcher Mike Lowish demonstrates proper way to lockoutltagout a valve. A ffover the valve prevents it turning. The tag irs Lowish's name, so anyone wanting to en the valve knows whom to look for.

Geqy Tech
RESEARCH INSTITUTE
2
-
I
_ - ~
Public and private sector building workers. The amendment requires According to Metzenbaum, this owners comprise an increasing percentage of attendees at the various abatement personnel in these five new provision is needed to curb
~
“slipshod” abatement work as build- courses ESTL offers on asbestos disciplines of asbestos detection and control to receive training and accredi- ing owners across the country recog-- detection and control. A recently tation identical to that required by the nize potential asbestos hazards and passed bill may have important Asbestos Hazard Emergency Response move to clean up their properties. ramifications for building owners and Act (AHERA) of 1987. AHERA, which ~~
“The problem is that not all contrac- - asbestos abatement contractors. On applies only to grades K-12 public and tors and workers in the asbestos
October 13,1990, the Senate approved private schools. removal business know what they ar
SB 1893, which reauthorizes the doing,” he said on the Senate floor. federal grant and loan program Metzenbaum’s amendment would “Many are untrained or otherwise established under the 1984 Asbestos extend identical accreditation require- unprepared to undertake the comple
School Hazard Abatement Act ments to all people doing abatement and hazardous job of asbestos re-
(ASHAA). The House gave final work, regardless of the type of facility. moval.” This amendment does not
It would call upon EPA to increase the approval October 26,1990, to an require mandatory inspections or identical version of the bill. required number of hours of training abatement of asbestos hazards in all in some categories of abatement jobs. buildings.
The bill also authorizes $5 million An amendment sponsored by annually over the next five years for Senator Howard Metzenbaum (D- ESTL‘s Asbestos Program already grants to nonprofit training organiza- Ohio) contained new provisions offers training to meet the current tions. These new accreditation require- dealing with training and accredita- AHERA requirements. We will, of ments would take effect one year after tion of abatement personnel, includ- course, continue to meet the training ing inspectors, management planners, enactment of the new legislation. At needs of asbestos detection and abatement project designers, contrac- press time, the bill is awaiting Presi- control personnel. 0 dent Bush‘s signature. tors/supervisors, and abatement
(continued from page 1)
0 flammable liquids and gases;
0 corrosives such as acids, caustics, other chemical reactors;
0 and even acoustical radiation, such as equipment noisy enough to cause physiological harm or a sudden noise that can startle people and cause them to harm themselves.
The lockout/tagout standard joins the hazard communi cation standard as one of the most frequently cited stan- dards during general industry compliance inspections.
OSHA is citing employers for serious violations of the lockout/tagout standard for:
Almost all plants’ operations include the use of machin- ery or systems that pose these potential dangers. The lockout/tagout standard requires employers to examine each system and piece of equipment to determine what needs to be locked out. Employers must develop an energy control program consisting of energy control procedures, periodic inspection, training, and additional requirements for outside contractors, shift changes, and others.
Under normal operation, servicing and maintenance are covered by this standard only if the employee is required to bypass a guard or other safety device or place any part of his/her body into the point of operation or where an associated danger zone exists during machine operation.
0
Failure to have a written program;
0
Failure to conduct training required by the standard;
0
Failure to develop energy control procedures;
0
Failure to have a system for alerting outside contractors to potential hazards and control measures.
-
ESTL has produced a new Tech Guide that provides an‘
~~ overview of the lockout/tagout standard. To receive your copy of Tech Guide Number 6, “Lockout/Tagout: the
- control of hazardous energy,” write or phone Nancy Davis
GTRI/ESTL, OKeefe Building, Atlanta GA 30332,404/894~
8447. For more information about the lockout/tagout standard or for help with bringing your plant into compli- ance with the new regulation, call ESTL safety professiona
Mike Lowish, 404/894-3806.0
Volume 7, Number 2,191

ENVIRONMENTAL
>ver 14 million workers in the iited States are potentially exposed ch year to known or suspected xoductive hazards on the job, imated the Centers for Disease bntrol in 1985. The National Institute
‘
Occupational Safety and Health
IOSH) ranks reproductive disorders
:th among the ten leading work- ated diseases. cals that have adverse reproductive or developmental effects, based on animal and/or human research. The database also indicates that 1,158 chemicals affect male reproductivity,
1,168 chemicals affect female reproductivity, 2,050 chemicals affect the development of the embryo/fetus, and 100 chemicals cause cancer in fetuses. (Animal studies have shown that the majority of carcinogens can cross the placenta and that often the fetus is more sensitive to the carcino- genic effect than adults.)
The subject of reproductive hazards n e to the public’s attention recently
\en a challenge to the Fetal Protec- n Policy (FPP) adopted in 1982 by inson Controls, a Wisconsin-based to battery manufacturer, came fore the Supreme Court.
In this policy, all women capable of iring children are excluded from sitions in the battery-producing
‘ility where there is a likelihood that
!ir blood lead levels could rise w e 30 micrograms per deciliter of iod. According to Johnson Con-
Is, exposures above that level could nsmit lead through the mother’s iodstream to the fetus, where
:essive lead levels could cause
Ibirth, low birth weight, premature livery, and adverse developmental ects.
Most studies have focused on women
Studies investigating suspected reproductive and developmental hazards have generally focused on the hazardous exposures of females, because of a common misconception that reproductive risk is primarily a female phenomenon. Some scientists view this emphasis as discriminatory, since the results of the studies have been used by some companies to justify excluding fertile women from such hazards. The Johnson Controls
Fetal Protection Policy is such a case.
The company believes that fetal itection is a moral imperative as
,I1 as a means of avoiding potential bility for harm caused to unborn ldren through lead exposure. izards may b e reproductive o r velopmental
Although women and their unborn
.ldren are commonly perceived as
.ng the ones at risk from reproduc- e hazards, men are also at risk. The
‘ECS (NIOSHs Registry of Toxic ects of Chemical Substances) nputer database lists 5,379 chemi-
The Johnson Controls case has withstood court challenge by the
United Auto Workers (UAW) in the
US. District Court for the Eastern
District of Wisconsin. The court ruled on September 26,1989, that the
Johnson Control Fetal Protection
Policy (FPP) does not violate Title VI1 of the 1964 Civil Rights Act. It is this case that was appealed to the US.
Supreme Court in Fall 1990; a decision is expected in Summer 1991.
Guidelines for avoiding discrimination charges
The Office of Technology Assess- ment has reviewed previous court decisions involving FPPs and has identified the following general principles:
0
An FPP that applies only to women is presumptively discriminatory.
That is, the mere existence of an
FPP will create Title VI1 liability for the employer in the absence of strongly supportive scientific evidence.
0
To overcome the presumption of discrimination, the employer must be able to prove that the body of scientific evidence supports legal findings that: 1) exposure at the level encountered in the workplace involves a significant risk of harm to the unborn children of women workers; 2) exposure at the level encountered in the workplace does not involve a similar risk of harm to the unborn children of male em- ployees; and 3) the FPP is effective in significantly reducing the risk.
An employer’s subjective but scientifically unsupportable belief in the necessity of the policy is insufficient to defend it.
0
If the employer proves both points
(embryo/fetal risk through mater- nal exposure and lack of embryo/ fetal risk through paternal expo- sure), the plaintiff may nevertheless prevail by proving that an accept- able alternative policy (e.g., engi- neering controls, temporary job reassignment, medical removal protection, paid disability leaves) would promote embryo/fetal health at least as well with a less adverse impact on one sex or by showing that the FPP is a pretext for discrimination.
For more information about repro- ductive hazards, contact ESTL Indus- trial Hygienist Kevin Downes at 404/
894-3806. 0
-
~~~ lume 7, Number 2,1990
~
3

4
Selection of candidates Pollution prevention is a priority in
Georgia. To address that priority, the
Environmental Science and Technol- ogy Laboratory (ESTL), the Georgia
Environmental Protection Division and Georgia industry have forged a new partnership. Together they hope to create an atmosphere in which voluntary toxics reductions and mandatory facility planning will result in real reductions in the amount of toxic chemicals generated and re- leased into the environment.
EPD used its existing databases to identify industry candidates for the program. The Branch Chiefs of EPD- air, water, and land-used compliance data from their respective branches, along with data reported by compa- nies in the Toxic Release Inventory
(TRI) and hazardous waste biennial reports, to create a list of candidates.
0
Chemical Products Corporation,
Cartersville
The Georgia Pollution Prevention
Program includes: technical assistance to industries with significant toxic chemical releases to the air, water, and land; training for EPD inspectors and engineers in pollution prevention concepts and techniques; research and development to improve troublesome industrial processes;
One objective was to select a good cross section of Georgia industry located throughout the entire state.
Companies that appeared on more than one list or that had a simificant problem with releases to a particular environmental medium were selected for the project. Most of the candidates were fairly large companies with high visibility in their communities. Such companies can become ideal "cause champions" for pollution prevention to their suppliers and customers.
Meetings with industry
Industry members have welcomed the opportunity to share their con- cerns about voluntary and mandatory requirements for pollution prevention
EPD has appreciated the candid discussions and has gained insight into the way industry will respond to various approaches.
~
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~
N~~ roles for and industry
~~~~~i~
~
The companies volunteering for this program receive technical assis- tance from Georgia Tech that ad- -
~ dresses the specific processes that caused them to be selected in the first place. We believe that the partnershiF between Georgia Tech, EPD, and industry will result in efficient use of limited technical assistance resources. review of existing environmental regulations for opportunities to include pollution prevention options; public and industry input through participation in a Pollution Preven- tion Task Force; and technology transfer through seminars, conferences, and pub- lished materials.
The candidates were invited to participate voluntarily. To help the companies decide whether to come on board, each company met with the compliance officers from each branch, the EPD Pollution Prevention Coordi- nator, and the ESTL project director.
These meetings marked the first time that a company met with all of its compliance officers at one time.
The companies are giving EPD written summaries of past pollution prevention efforts and explanations 01 how the companies are organized to identify, plan, and implement pollu- tion prevention projects. These summaries are valuable resources to
EPD in designing the implementation strategy for the facility planning requirement.
What makes this program unique is the open exchange of information between selected industries, the regulatory agency (EPD), and Georgia
Tech (ESTL).
The companies participating in the first phase of this project are:
Georgia's Pollution Prevention
Program is a common-sense approach to meeting the state's environmental goals. Success will depend upon the cooperation among the EPD, Georgia
I
Te& and industry. 0
ESTL's goal is to develop a Pollu- tion Prevention Program that will work for Georgia industry as well as achieve the state's goals. EPD recog- nizes that a better understanding of the way industry is already address- ing pollution prevention will lead to a regulatory program in sync with the regulated community.
0
Atlantic Steel, Cartersville
0
Lockheed, Marietta
0
Delta Airlines, Inc., Atlanta
0
Monroe Auto Equipment Com- pany, Hartwell
0
Forstmann & Company, Louisville
O
0
DSM Chemicals, Augusta
Kemira, Inc., Savannah
D~~ Chemical, ~~l~~~
0
Merck & Company, Albany
0
Union Camp, Savannah
Project, ESTL developed the
Georgia Pollution Prevention Guide,
For a copy, call Susan
Hendricks at the Georgia Environ- mental Protection Division, 404/
656-7802.
Volume 7, Number 2,19S

to
dution prevention seminars will be
,esented throughout Georgia starting mid-February, 1991. Locations and ites scheduled so far include:
Atlanta, February 25
Augusta, March 4
Gainesville, March 18
Columbus, March 21
Albany, March 25
Savannah, April 8
Rome, April 16
Macon, April 25
Brunswick, May 23
Still to be scheduled are Carrollton, iuglas, and Madison. For more ormation about any of these semi- rs, call Carol Foley, 404/894-3806.0
We've changed names again.
A recent reorganization of the
Zeorgia Tech Research Institute resulted in the transformation of
:he Environmental Sciences and rechnology Division (ESTD) into
:he Environmental Science and rechnology Laboratory (ESTL).
John Nemeth has a new title, toc no longer Division Chief, he is now
Laboratory Director (which is why
nis column on page 7
is now called
"From the Director's Desk" rather
:han "From the ChiePs Desk.")
Any differences in the way we i o business are purely internal
2nd shouldn't affect our relation- ship with you at all. Our mission
:emains unchanged:
to solve today's problems,
'hrougk environmental science and
'ecknology, while influencing the istabliskment of a technical base for
?nuironmentally sound policy lecisions. lume 7, Number 2,1990
ENVIRONMEmLL
__
ESTL proudly announces the formation of the Indoor Environment Research
Consortium (IERC), which includes Georgia Institute of Technology, Vir- a Polytechnic Institute and State University, and Emory University. is to create and sustain an environment that will search, education, the physical, engi important compo
Inihal research a leaning develop- ination with more energy-efficient techniques; rly the characterization of components avioral responses; identification and sures; the fate and transport of components utside into the indoor environm building and systems de- worker performance and policy
RC will offer graduate certificateprograms in the indoor environ- pending on the school, these programs will require sixteen to uarter hours in iaterdisciplinary core courses,
C, call Dr. Charlene Bayer, IERC's
Thanks to a generous grant from the Exxon Corporation, ESTLs training programs in hazardous materials control and emergency response (HMCER) will be expanded, with new courses added to allow emergency response personnel to get extra training.
Dr. Robert Scala, Senior Scientific Advisor for Exxon Biomedical Sciences,
Inc., sat in on a recent HMCER course and evaluated it to determine whether
ESTL merited Exxon's support. Dr. Scala was particularly well qualified for this task, since he does volunteer emergency response in his own community. He recommended that Exxon award the grant; he also recommended that all Exxon emergency response personnel attend ESTL's HMCER course.
The addition of new courses will allow ESTL to combine related programs for particular disciplines and award certificates for completion. For example, a person who has completed all the courses in a series such as Emergency Re- sponse or Hazardous Materials Management would earn a certificate.
The grant will also be used to develop additional outreach activities related to indoor air quality and "sick building syndrome," to be performed by the Indoor
Environment Research Consortium (see article above).
Exxon recognizes the value to the public of this type of outreach training, not only for those who receive the training, but also for the communities they serve, and Exxon feels that industry should support efforts of this type. 0
5
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6
"The lobster was great," reports ESTL engineer Jim Walsh.
But good food wasn't the only benefit of the sixth annual Pollution
Prevention Conference, "Industry and
Beyond," held June 20.22, 1990, at
Woods Hole, Massachusetts. ''I enjoyed the opportunity to interact with a diverse group of people and share differing viewpoints ina nonadversarial setting," says Walsh.
Presented for the United
States Environmental Protec- tion Agency (EPA) by Dana
Duxbury and Associates and cosponsored by the Massa- chusetts League of Women
Voters, the conference was designed to help EPA find out how industry and the private sector feel about what's going on in pollution prevention.
Approximately one hundred representatives of industry, environmentalist groups, state and national agencies, and academia attended, and the format encouraged the interchange of ideas among these sometimes divergent groups. Participants met in the same pre-assigned discussion groups throughout the conference, but were encouraged to mix with others during meals.
The title "Industry and Beyond refers to the expansion of pollution prevention into areas other than hazardous and toxic waste. Presenta- tions and discussion focused on that area and on the so-called green labeling of products purported to be environmentally safe. Speakers represented all the interest groups present at the conference.
Some areas with potential for pollution prevention include transpor- tation (reducing nitrous oxides and volatile organic compounds), agricul- ture (targeting nonpoint-source pollutants such as fertilizers, pesti- cides, and herbicides), and energy production (reducing emissions, finding beneficial uses for ash). In
Walsh's group, recycling of waste tires was a hot topic. A popular suggestion was to make asphalt from them; the method is more expensive than
Old tires could find new life as asphalt for roadways. conventional asphalt production, but results in a longer-lived road. One obstacle: convincing legislators to tell their constituents they're spending more on roads.
Participants debated whether decisions should come from Washing- ton (that is, be mandated by executive order or be made by an agency such as
EPA) or from the grass roots. The consensus among all the groups at the conference was that some of both is desirable. Moving decisions up from the grass roots level takes longer, but the process is more effective in the long run because people buy into a decision if they've been involved. For example, people might be more willing to pay the higher price of roads made from recycled tires if they wanted to get rid of a local tire dump.
But since local groups might not take on an issue that didn't directly affect them, participants suggested that the national offices of organizations such as the Chamber of Commerce and the
League of Women Voters might -~
~~~ assume the lead in identifying a problem and taking a position on it.
Their local chapters could then act o n - ~
~~ the item, asking for legislation at the
~ state level, as well as lobbying na- tional legislators and introducing motions at national meetings.
~
Determining whether a product is environmentally safe is not a simple matter.
At present, no standards exist and there's no agency to decide what's "green," what's not. Walsh points
OL that a group like ASTM
(American Society for
Testing and Materials) is needed to provide scientifi- cally accurate test methods for determining whether, for example, a plastic is biodegradable. "What is an acceptable test for degrad- ing?" he asks. "If someone comes up with such a test, can it be reDeated?"
Although the conference partici- pants agreed that other countries might provide some guidelines, they questioned whether it was possible tc come up with useful and accurate labeling, and they reached no conclu- sions on how to do so. Any ideas, readers?
"This conference has stimulated a lot of EPA's 'how-tos' over the last si) years," Walsh comments. "And it's helped me personally to see the validity of viewpoints of people I've thought of as opposites. I definitely think it's worth attending."
Although participants are selec- tively chosen to maintain a balance o viewpoints, Walsh says he'll be glad to gather the names of those who are interested in attending and pass the information along. Write Jim Walsh,
GTRI/EDL, OKeefe Building, At- lanta, Georgia 30332, or phone (404)
894-3806.0
~~
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Volume 7, Number 2,199

ENVIRONMENTAL
From
._
he anticipated elevation of the United States Environmental Protection Agency
PA) to Cabinet level elicits in me both hope and, considering the fragmented, nfocused, and underfunded condition of environmental research and educa- sn today, trepidation.
The opportunity that Cabinet status offers EPA is grand indeed. The word iunting also comes to mind. This Department will be squarely in the midst of ajor policy formation and decision-making. Further, EPA will be in a position understand, communicate, and shape national and global environmental sues and priorities and redirect today’s technology toward long-term, clear- inking environmental management and solutions.
The principal challenge to EPA will be to forego its traditional enforcement- cused mission and assume leadership-if you prefer, statesmanship-in the
‘oadest possible context. The principal challenge to the university community ill be to provide the highest quality science and unwavering dedication to eeting the needs of the environment.
To make the partnership of government and university work, a widely pported organizational option is a National Institutes for the Environment
NE). Patterned on the image of the National Institutes for Health (NIH) and ith an umbrella relationship to centers located at research universities across e country, an NIE could b e i n d e e d , may be-the only realistic model avail-
#le.
, .
The intent and mission of such center units should be expressed in their tmes-Environmental Science, Technology, and Policy Centers. They should organized in two ways:
Centers with broad missions should be distributed on the basis of conditions such as natural geography (Gulf Coast, Pacific Northwest, Great Plains), socio-economic geography (“rust-belt” conditions, Los Angeles Basin air quality), and so forth.
Centers having specific missions such as source reduction technology or air pollution research could be established at the sites of the most appropriate expertise.
All the centers should draw participation from federal and state governmen-
I agencies, industry, regional compacts, professional organizations, and the iblic, and thereby utilize joint-effort approaches to leverage capabilities and sources. The centers should have specific accountability and well-defined iliverables attached to funding.
There is much to be considered and planned before effective actions can bear e results we all wish for. I hope that, as EPA and all of us dedicated to the
.vironment arrive at this historic crossroads, we are up to the tasks ahead.
John C. Nemeth, Director
Environmental Science and Technology Laboratory
19 TheOSHAHazard
.
,
Communication Standard,
20, Superfund Amendments and
Reauthorization Act (SARA)
Title 111 Workshops
20-21
.
,
Safety Fundamentals for;
,Supervisors and Mnnagets
2 5 Trenching and Excavation
26-1 Designing Asbestos Response
, , Actions
(Continued on vaae 8 ) tlume 7, Number 2,1990 7

rective Action
ENVIRONMENTAL
Published quarterly by the
Environmental Science and Technology Laboratory,
Georgia Institute of Technology,
G T N / ESTL,
Atlanta, Georgia 30332.
(404) 894-3806
Nancy E . Davis, Editor
. ..
-
.... .~
Lockouthgout saves lives
~
New Tech Guide explains OSHA standard ..................................................p
Fetal Protection Policies may discriminate against women
Men may be at risk too
Consortium formed to research indoor environments
Three universities to collaborate .............................................................
.....p age-
-
Conference expands scope of pollution prevention
Transportation, agriculture, energy are potential areas ...p age
Departments:
Asbestos Action
AHERA requirements to extend to all facilities
Pollution Prevention
Forging a new partnership in Georgia
From the Director's Desk
Future of US. environmental science, technology, and policy
.................
Page
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Page
NONPROFIT
ORGANIZATION
BULK RATE
US. Postage
Permit No.
Copyriphi 1990. Gmrzia Tech Research Corporalion, Centeiinial Resrarck Buildinq, Atlanta, Gro7,yia 30332