Common Sense Initiative: North Carolina Update
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Transcript of Common Sense Initiative: North Carolina Update
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Common Sense Initiative: North Carolina Update
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Common Sense Initiative - Basic Framework
Metal Finishers - agree to work toward a series of “Goals” to reduce their discharges.
Municipality - in return provides regulatory incentives and technical assistance where required.
State- technical and regulatory assistance.
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Benefits of Strategic Goals Program
LOCAL POTW- reduced pollutant discharge to POTW- better working relationship with industries- less chance of NPDES violations- less time devoted to SIU permits
PLATERS- less burdensome permit requirements- less time and money devoted to environmental permits- technical assistance available
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North Carolina Update
4 participating POTWs:- Raleigh, Statesville, Charlotte, Gastonia
8 metal finishers (3 site visits) Additional incentives - Air quality, power
companies, SBA Loans Stakeholder meeting (June 29) Industry Workshop (Fall)
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Further Information Division of Pollution Prevention
(919) 715-6515 [email protected]
Surface Finishing Industry Council- SFIC Robert McDowell(716) 425-7500 [email protected]
EPA Scott Dosick (202) 260-9211 [email protected]
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Zero Discharge Project at Powder Coating Operation
Hankison International, Newport, North Carolina
Randy DonleyManufacturing Engineer(252) 726-1011
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Hankison International 265 employees 31,000 square ft facility Manufactures filter products and
refrigerated air dryers
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Background
Established 1947 1995 Installed new powder coater Estimated discharge 1,610 gallons per day Wastewater management options??
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Wastewater Management Options
No City Sewer Off site hauling $0.43 per gallon
($173,075 per year) Evaporation - curing ovens generate 3
million BTUs per day which should evaporate 600 gallons per day
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Process Flow
Drying Oven Powder Coat Curing Oven
Flow of Work
Metal FormingFive stage
cleaning lineAssembly
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Cleaning Line
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
Stage 5: NonChrome Seal
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Cleaning Line Modifications
240 gal/shift
390 gal/shift
240 gal/shift
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
City water 740 gal/shift
Float valveFloat valve
Advantages• Greater than 90% reduction in water consumption possible• More efficient rinse - film breakdown• Reuse of dragout solution• National survey - 25% usage
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BENEFITSCapital Cost = $500
Water Conservation = 217,500 gallons per year (54%)
City Water Costs = $1,011 per year ($4.65 per 1000 gallons)
Savings on Treatment Costs = $108,576 per year
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Ultrafiltration Unit
240 gal/shift
390 gal/shift
240 gal/shift
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
City water 740 gal/shift
Ultrafiltration unit333 gal/shift Filtrate
150 gals/shift
BENEFITS
Capital Cost = $30,000
Water Conservation = 250,000 gallons per year
City Water Costs = $1,162 per year
Savings on Treatment Costs = $124,800 per year
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Evaporation System 240 gal/shift
390 gal/shift
240 gal/shift
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
Ultrafiltration unit333 gal/shift
Filtrate toevaporator
150 gal/shift
City water 740 gal/shift
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Evaporation System
Wastewater
Existing ductwork
Hot air from powdercoating furnaces
Compressedair
Filter
Evaporation Chamber3 x 3 x 10
Nozzle
Atomized spray
To atmosphereExisting ductwork
Unevaporated water return
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Evaporation SystemBENEFITS
Capital Cost = $10,000
Water Conservation = NA
City Water Costs = NA
Savings on Treatment Costs = $42,000 per year
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Financial SummaryModification Capital
cost ($)Annual
Operating costs ($/yr)
Water conserved
(gal/yr)
City water cost
savings ($/yr)1
Savings on
treatment costs ($/yr)
Payback period
(months)
Countercurrent rinse system 500 0 217,500 1,011.40 108,576 0.1
Ultrafiltration unit 30,000 1,000 250,000 1,162.50 124,800 2.9
Evaporation system 10,000 500 na na 420,003 2.9
Totals 40,500 1,500 467,500 2,173.90 275,376 1.8