GENERAL ELECTRIC COMPANY GAS TURBINE MANUFACTURING FACILITY

WASTE MlNlMlZATlON STUDY

SEC JOB NO. G-1126

JULY 1991

I

SlRRlNE ENVIRONMENTAL CONSULTANTS GREENVILLE, SOUTH CAROLINA

TABLE OF CONTENTS PAGE

1.0 EXECUTIVESUMMARY .............................................. 1

20 DOSnNG WASTE STREAMS .......................................... 6

3.0 RECOMMENDATlONS .............................................. 15

3.1 1.1.1 -Trichloroethane ........................................... 15

3.1.1 Node Degreaser .......................................... 15 3.1.2 H-Bay Degreaser ......................................... 19 3.1.3 Ardrox. Transition Pieces and Detrex Degreasers ................. 20 3.1.4 ~ l m e Spray Degreaser .................................... 20

3.2 Pratt & Whitnev Grinder Swarf .................................... 20 3.3 EDM Sludae ................................................. 21 3.4 Excess Paint Thinners .......................................... 23

. 3.5 Vibrotubs Wastewater .......................................... 25 3.6 Paint Booth VOCs ............................................. 25 '317 Castrol55OP Coolant ........................................... 28 3.8 X-Rdv Silver Recoverv Effluent .................................... 29

#IPPENDICES

APPENDIX A NOZZLE DEGREASER SUBSTITUTES

APPENDIX B H-BAY DEGREASER SUBSTITUTES

APPENDIX C . SEPARATING SOLIDS FROM EDM SLUDGE

APPENDIX D DISTILLATION EQUIPMENT

APPENDIX E PAINT SPECIFICATIONS

APPENDIX F AIRLESS SPRAY EQUIPMENT

APPENDIX 0 FLUID REPOLISHING EQUIPMENT

2 2

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Sirrine Environmental Consultants was retained by the GE Gas Turbine Manufacturing Facility in Greenville, South Carolina to identify waste minimization options with recommendations for the various processes at the facility. Cost estimates have been provided whenever possible to allow

costbenefit analyses to be performed. These costs provided are for equipment only and do not

include installation and engineering.

The approach taken to complete this study was as follows:

Understand existing processing techniques.

Identify wastes generated - quantities, hazardoudnonhazardous, source.

Prioritize waste streams based on quantity, toxicity, regulatory compliance and

motivation, and the future potential environmental liability. Identify, evaluate, and develop reduction alternatives.

Recommend actions consistent with regulatory requirements and good management practices.

Based on the prioritization criteria identified, the highest priority waste streams generated at the

facility are:

1, 1, 1 trichloroethane (TCA) waste streams and air emissions

Excess paint thinners

Wbrotubs wastewater

Paint booth VOCs

Castrol55OP coolant

X-ray effluent

Pratt & Whitney swarf

EDM sludge

1

- Table t .1 summarizesthe potential waste reductions which could be recognized by implementing

the various recommendations given in this report. Specific recommendations made are as follows:

TCA Waste Streams and Air Ernisskm - TCA is currently used in degreasers throughout the facility. TCA is a stratospheric ozone depleter and as such is

scheduled for production phase out by 2001. Following GE corporate plans for the

elimination of TCA usage within 2 years, a study was made of various alternatives to the existing vapor degreaser cleaning systems. Aqueous cleaning systems have

been recommended for each of the vapor degreasers throughout the plant. These

recommendations were summarized in a report submitted to GE on May 16,1991.

Various cleaning chemicals are currently under investigation and plant personnel are

studying various equipment for purchase at the Greenville facility.

Excess Paint Thinner - Large quantities of paint thinner with entrained paint solids

are drummed for offsite incineration, The waste is generated when painting

equipment is cleaned after use. Methods of recycling the solvent for reuse have

been investigated and prices for distillation equipment obtained. This equipment,

varying in price from $7,800 to $1 1,600, would allow recovery of 80-1 00% of the

thinner. Yearly operating expenses of $220 to $465 and yearly raw product savings

of $34,OOO to $38,OOO would allow payback periods of 3 to 4 months for distillation equipment.

Wbrotubs Wastewater - Gas turbine parts are deburred in several vibratory machines using a ceramic media flushed with water, The A-Bay vibrotubs represent a substantial hydraulic load on the W plant. Solenoid valves have been added in

the discharge lines of the vibrotubs and reduced the’”wastewater flow by

approximately 50 percent, A recycle system similar to one installed at the GE Vega M a facility could reduce this water flow by an additional 60 to 70 percent.

Equipment costs for this system would total approximately $6,275 and significantly

reduce the plant’s water usage and disposal expenses.

2

Table 1.1 Waste Reduction Potential

GE Gas Turbine Manufacturing Facility Equipmentkwess Waste Stream Existing Projected Reduction

Volume Volume Method

Wastewater Recycle Wastewater

swarf Excess Paint, Thinner

125,000 lb/yr

5,533 gal/yr Solvent Distillation

Usc of Low VOC Paints VOCS TCA Bath Emissions (VOCs)

‘EA, Water SpentTCA

Aqueous Cleaning Chemicals in WastewateP*

TCA Bath Emissions (VOCs) Spent TCA

Aqueous Cleaning Chemicals in WastewateF

TCA Bath Emissions (VOCs) Spent TCA

Aqueous Clcauing Chemicals in wastewatM+*

TCA Bath Emissions (VOCs) SpentTCA

Aqueous Clcaning Chemicals in wastewater**

TCA Bath Emissions (VOCs) Spent TCA

Aqutous Cleaning Chemicals in wastewater**

TCA Bath Emissions (VOCs) Rigidax with TCA

9.9 toIl/yr

2.0 todyr

OgWr

73,000 lb/yr 215,000 lb/yr*

6.3 todyr

None None None

? gal/Yr

Aqueous Cleaning h

Flame Spray Degnascr 16.2 todyr 21 5,000 Ib/yr*

0 gavyr

Aqueous Cleaning

Aqueous Cleaning

Aqueous Cleaning

Aqueous Cleaning

Altcmatc Cleaning Method

CombustionLiner Building None None

11 ton&r 215,000 Ib/yP

ogal/yr

None None ?WY

Transition Pieces D t g ”

BladcsDegnaser .-

Nozzle Dcgnaser

Trace 215,000 lb&P

o*

None None ?gal/yr

None None

550P Coolant, Water 100,000 gaVwk Coolant Repolishing

Recycle Wastewater

Margerle Grinders Lathes,

X-Ray Silver Recovery Cincinnati Mill, Vercicle Lathes

Wastewater

* Total yearly disposal mount from vapor degreasers. ** New waste stream generated as a mult of implementing recommended changes.

.

* Paint Booth VOCs - Significant amounts of VOCs are released during the application

of surface coatings at the Turbine Manufacturing facility. Regulation of the emissions

has been tightened with the I990 amendments to the Clean Air Act. Newly developed EPA compliant "Low VOC" paints are commercially available which would lower GEs paint VOC emissions from the current 10 tons per year to approximately

6.3 tons per year.

Ultimately, even use of these compliant paints may not be sufficient to meet recently

promulgated regulations. For instance, these regulations require 95% control

efficiency plant wide, This efficiency would require the use of Maximum Available

Control Technologies, such as incineration or capture and recovery technology.

This technology is not readily applicable to mobile painting sources such as the D-

Bay traveling paint booth. Such operations may be better controlled with such

processes as totally enclosed robotic paint application, isolated paint booths with fume scrubbers, and/or the use of powdered paints. GE would be well advised to investigate the uses of the traveling paint booth in an attempt to replace it with

stationary, dedicated booths to which control devices can be applied.

Castrd 55op codant - Several pieces of machining equipment at the GE plant use

Castrol 550P cutting fluid as a cooling media. Currently, approximately 80,OOO to *

120,OOO gallons per week of this water based coolant mixture are disposed of offsite. Castrol is currently in the process of providing polishing equipment to allow reuse

of contaminated coolant, This should reduce the disposal quantities by up to 80%.

X-Ray Effluent - The processing of X-Ray film at the GE plant currently generates

approximately 3,400 gallons per day of water which is sent to the WWT plant. This

water contains suspended solids, chromium, aluminum, nickei, and silver. Currently

marketed X-Ray film process water recycling equipment could reduce this water

usage/disposal to approximately 1,200 gallons per day. Depending on the degree

of recovery desired, this equipment would range in price from $4,OOO to $3O,OOO.

4

* Ratt br whitney Grinder Swarf - Metal fines from grinding operations are collected

for offsite disposal. The waste is subject to EPA land ban restrictions because of elevated concentrations of chromium. The preferred method of minimizing the future liability of this waste stream would be to recycle the swarf for its metal content;

however, to date, no acceptable RCRA permitted facility has been identified for recycling purposes.

EDM Sludge - A second surface finishing operation producing significant waste at

the Turbine Manufacturing facility is electrical discharge machining. The tar-like EDM

sludge contains machining oil, graphite and metal fines and is drummed for off-site

incineration. Methods for separating the metal, graphite, and oil have been investigated; however, economic constraints make incineration the best disposal method.

5

I - 20 EXISWGWASTESlREAMS

I The waste streams cunentty generated by the various processes at the GE Gas Turbine

Manufacturing operations are summarized by machine/area in Table 2.1, Waste Matrix. This table

also lists the quantity of each waste stream generated as well as the current disposal method.

In completing a waste minimization survey for facilities with a large waste stream matrix, it is useful to prioritize the Individual waste streams and/or their emission sources. Selection of waste

minimization projects to implement is usually based on capital costs and consideration of direct

monetary benefrts. Indirect costs and benefits also need to be included in the evaluation process. These indirect costs and benefits can be related to:

the characteristics of the waste itself, such as toxicity, persistence, mobility,

concentration, odor, volume and regulatory status the current degree of control and methods of management the visibility and health impact relative to the community around the facility

the existing and future regulatory climate for that waste stream.

Identification of the indirect kosts and benefits allows further efforts to be focused on those

streams which are the most important or which show the most promise for reducing waste

generation. The priorities assigned to the GE waste streams are given in Table 2.2. The highest

priority streams were assigned a priority of 12, the lowest were assigned a 4. In order of

importance, the criteria used include the following:

regulatory compliance and motivation

quantity (volume)

toxicity future potential environmental liability.

Other criteria which influence the setting of priorities include employee safety and health and offsite waste management costs.

6

,

Table 2.1 Waste Matrix

GE Gas Turbine Manufacturing Facility

Machindhea Waste Stream Quantity Disposal Method

Lathes (J Bay) 550 P Coolant Turnings/Chips Rags

Bliss Presses Metal Particulates

1

15 LbNeek

< 1 lb/hr

Recirculated Reclaim Reclaim

Cincinnati Mill 550 P Coolant Recirculated Metal Chips Reclaimed

Verticle Lathes 550 P Coolant Metal Chips

ReCirCulated Reclaimed

Broaches Omega Cutting Oil Metal Chips

Mag. Particle Booth Magnaflux Water (Incl. Kerosene) .500gpd

Paint Booth (BCB) Wastewater (Trench) Water Wash Water

.; vocs

Paint Booth (CIA)

Vertical Boring Metals

X-Ray Booth

Sump Water Wash Water Wash Pump Outs

Metal Chips (Dry)

Wastewater Spent Silver Spent Processing Chemicals

< 3 GalDay

2.2 lb/hr

12,Ooo w e a r

5 "

200 w e a r

Recirculated ReClailned

WWT

WWT Recirculated

Pump Out, to WWT Recirculated

Hazardom waste Recycled

WWT

WWT

Table 2.1 Waste Matrix

GE Gas Turbine Manufacturing Facility - ~- ~

MaChine/Area Waste Stream Quantity Disposal Method

Vacuum Plasma Spray Coating Powder 1 Drum/Month Landfilled (Non-Hazardous) Air Filters < sonear Landfiilled (Non-Hazardous) Noncontact Cooling Water 8-10” WWT Rags 1 Dnun/Month Landfiilled (Non-Hazardous)

Vibrotubs (AJA & AZB) Filter Press Sludge 12 Ton/Week Lancff#ed (Non-Hazardous) Wastewater 45 gpm WWT

Excello Grinders

ELB Grinders

Magerle Grinder

Hand Sanders (AZB)

F’ratt Whitney Grinders

Filter Paper, Swarf waste oil Solvent (PF Degreaser) Grinding Wheels

30 Rolls/Week Reclaimer w/ Swarf Non-Haz. Landfill 2-11,OOO-gal system Recirculated

30 gal/week WWT Landfill (Municipal)

Swarf and Filter Paper Lubricant Recirculating System Grinding Wheels

2 Rolls/Week Reclaimer w/ Swarf Non-Haz. Landfill

Van Smtton Lubricant Recirculating System Swarf and Filter Paper

. ; Grinding Wheels

Dust Collector Waste

Swarf Lubricant Filters Grinding Wheels

1.5 DnundYear

124,OOO Lb/Year

Reclaimer

Hazardous waste

Hazardous waste Centrifuged and Reused

Municipal LanNill

, 1

Table 2.1 Waste Matrix

GE Gas Turbine Manufacturing Facility

MachindArea Waste Stream Quantity DkpvsaI Method

Accessory Test Area

. Traveling Paint Booth "D Bay"

Stationary Paint Booth "D Bay"

Electrical Discharge Machines

Ovens (MBB)

Muriatic Acid Dip Tank .;

Hot Water Dip Tank

Caustic Dip Tank

Maintenance Area

Wastewater Fuels oils Fuels, Oils

Washwater vocs Fi1tel-S

vocs Excess Paint, Thinner, etc. FilteXS Water

EP180 Electro-Lite oil Sludge, Filters

USedRigidax

HCl Used Muriatic Acid Scrubber Blow Down

Wastewater

used caustic

Safety Kleen Solution

30,000 Gal/Year

6,000 GaVDay 4.0 Ib/hr

60 Drumspear

2.4 T/yr 57,000 Lbpear 1,OOO Lb/Month 92,000 Lb/Year

24,OOO Lb/Year

< 1 lb/hr 6000GaVYear

4100 W e e k

6OOO Galnear

5000 Lb/Year

WWT Reused Reused WWT

WWT Dry Filters

Hazardous waste

Hazardous Waste Hazardous Waste Hazardous waste

Recirculated Hazardous waste

Reused

Exhausted through Scrubber WWT WWT

WWT

WWT

Safety Kleen Recycles

.

Table 2.1 Waste Matrix

GE Gas Turbine Manufacturing Facility

MachindArea Waste Stream Quantity Disposal Method

Lathes (L Bay) Oil in Pits Unknown

Vibrotubs Wastewater Combustion Liner Building Filter Press Sludge

-x Degreasers (2) (AHgdy) Zyglo, Emulsifier, Water

TCA Bath Emissions (VOCs)

wastewater Charcoal Filters TCA, Water Spent TCA

Flame Spray D e w TCA Bath Emissions (VOCs) Spent TCA

1500 GavDaY

2.0 T/yr 9945 Lb/Year 1 DnunFlonth 73,000 Lb/Year

215,000 Lb/Year*

16.2 T/Y= .

215,000 Lb/Year*

WWT Landfill @on-Hazardous)

Drummed Hazardous Waste Landfill (Non-Hazardous)

Drummed Hazardous Waste Drummed Hazardous Waste

Drummed Hazardous Waste

Nozzle Degreaser (IvlAB) Rigidax with l,l,l-TCA 5800 Lb/Year Hazardous Waste (Incinerated) TCA Bath Emissions (VOCs) 14.6 T/Year

Combustion Liner Building Spent TCA 215,000 Lb/Year * Hazardous waste TCA Bath Emissions (VOCs) <1 Lb/Hr

*; Zyglo (Pumped out) Hazardous Waste

Transition Pieces Degreaser (KFA) TCA Bath Emissions (VOCs) 2.5 Lb/Hr Spent TCA 215,000 Lb/Year* Drummed Hazardous Waste

Blades Degreaser 0 TCA Bath Emissions (VOCs) Trace Spent TCA 215,000 Lb/Year* Drummed Hazardous Waste

* Total yearly dspssal from vapor degreasers.

.. .. . . -. . ..._- .. .. . . -. . ..._-

.

Table 2.2 Waste Stream Priorities

GE Gas Turbine Manufacturing Facility

WASTE REGULATORY QUANTITY TOXICITY LIABILITY PRIORITY

mewater VPS N/C Cooling Water Vibrotubs MagnanuX Water Paint Booth B CB PaintBoothCIA

Accessory Test Area Traveling Paint Booth (D Bay) '

Stationary Paint Booth (D Bay) Muriatic Acid Tank Hot Water Dip Tank Caustic Dip Tank Scrubber Blowdown

X-Ray Booth

Solvent - PF Degreaser

Spent TCA TCA Air EmissionS (VOCs) ZYglO EDM Sludge Rigidax (Ovens) HCl Vapors Paint Booth VOCs Excess Paint Thinners Paint Booth Filters

Rigidax w/ll 1 TCA .I

Medim High

Medium LOW

LOW

Medium LOW

LOW LOW

LOW

LOW

LOW

LOW

MediUlll High LOW

LOW LOW

Medium LOW

Medium Medium

LOW

LOW

LOW

LOW

LOW

LOW

L O W LOW

. High

LOW

LOW

LOW LOW

LOW LOW LOW

LOW

Medium High Hi&

Medium Medium

MediUUl

Medium High

Medium

High

High (Toxic)

LOW

LOW LOW LOW LOW

LOW LOW

LOW

LOW

LOW

LOW LOW

LOW

MediUm High High High High High LOW LOW

MediUm High High

6 10 5 4 4 6 4 5 5 4 4 4 4

8 12 12 11 9 11 7 7 9 11 9

Table 2.2 Waste Stream Priorities

GE Gas Turbine Manufacturing Facility

WASTE REGULATORY QUANTITY TOXICITY LIABILITY PRIORITY

Swarf (except P/W) Swarf(Pratt-WhirRey) oils/Lubricants Castrol550P Coolant Metal chips Filter Press Sludge Virbrotubs Combustion Liner Building

Grinding Wheels

LOW

High LOW

Medium LOW

Low LOW

LOW

Medium

MediUm High

Medium

High

LOW

LOW

LOW

LOW

High LOW LOW LOW

LOW

LOW

LOW

Medium High LOW

Medium LOW

LOW

LOW

LOW

6 12 5 8 5

4 4 4

After compiling the basic information on the specific wastes and releases and current disposal

methods, the individual waste streams were scored for each criteria. The scores were then evaluated according to a judgement-based semiquantitative analysis. The scoring can be a numerical system but, in this case, a 'high, medium, low" scoring scheme was used. This technique can be further reflned by assigning a weighting factor to each criteria but this further

refining was not deemed necessary in the GE assessment.

In assigning priodtles, the first issue addressed was the regulatory status of each waste stream.

High priority would apply to waste streams currently regulated or in the process of being

regulated, such as VOCs, toxics, metals and hazardous materials. Low priority would apply to

non-regulated waste streams as well as to already regulated streams which have a high degree

of control in use or currently planned.

Second in importance is the volume of waste generated since this adds to the visibility of the

waste. Volumes can be compared to relative quantities for similar classes of wastes as identified

in regulations, Le., 10 tons per year for any toxic compounds from the Clean Air Act amendments.

Existing regulations to reduce or eliminate certain wastes, i.e., land disposal bans, would be

assigned a high priority, The need to comply with existing regulations at some later date, Le.,

when an existing permit is changed, or the need to develop a compliance program for a known

future requirement should be a motivating factor in the need for reduction and would be assigned a medium rating.

Toxicity is a key issue whether related to air, water or solid wastes and can be identified on the basis of human or environmental concerns, The Clean Air Act amendments of 1990 have

identified 189 toxic air pollutants which will be the target of regulatory activity in the next five

years. Toxicity testing of leachates and wastewaters has received considerable attention in the

last two years. The toxicity criteria is also important coupled with the volume criteria in evaluating waste reduction options. If the ultimate goal is to mitigate environmental impacts, the focus

should be on reduction of toxicity rather than volume reduction.

13

Liability focuses on current and future risk associated with the current disposal method. A

current disposal technique, such as off-site land disposal by a third party, poses some future

liabilities for GE and would warrant a medium rating. Consideration is also given to the known

costs of off-site disposal, Le., cost of incineration of one drum (55-gallon) of hazardous waste is currently $200-300.

Specific to the GE processes, a priority grade of high, medium, or low was assigned for each category to each waste stream. Each waste stream was then ranked according to the number

of highs, mediums and lows. For assigning overall priorities, the scoring used was: High - 3, Medium - 2, Low - 1.

Using these scores, the highest priority waste streams from GE processes are the waste streams

containing l,l,I-TCA (Spent TCA, Rigidax with TCA, TCA air emissions), swarf from the Pratt-

Whitney grinders, electrical discharge machines (EDM) sludge, excess paint and thinners, and wastewater from the vibrotubs. Recommendations on minimization techniques for each of these streams are included in the following section.

14

I ' 30 RECOMMENDATlONS I ' 3.1. 1 .I .I -Trichloroethane

Several of the high priority waste streams at GE Greenville result from the use of l,l,l-

trichlorosthane (TCA); these streams are spent TCA, TCA air emissions, and Rigidax with TCA.

TCA is currently used in degreasers throughout the facility including the Nozzle, H-Bay, Ardrox,

Transition Pieces, Detrex, and Flame Spray Degreasers. Table 3.1 summarizes the TCA usage

for each area, the TCA waste generated from each process, and the disposal and purchase costs

assodated with each area. The wastes generated include VOC emissions and drummed waste.

The drummed waste is primarily spent TCA whlch contains the contaminant being removed in the degreaser. The contaminants include cutting oils, fluorescent penetrant, and Rigidax

structural supporting wax. The Ardrox degreasers also generate TCA contaminated water, which

is collected and drummed at the work area.

I I

Recommendations for each of the areas are discussed in the following sections.

3.t.l W e Degreaser

In the M-Bay Ramco degreaser, nozzles are cleaned to remove a tooling compound called

Rigidax. Rigidax is a hydrocarbon based resin used to add strength to thin wall parts or parts

with interrupted cuts. The Rigidax eliminates "chattering" and burring during machining.

Rigidax is purchased from M. Argueso 8t Co. of Mamaroneck, N.Y. Argueso personnel report that

the following cleaning methods have been employed as TCNvapor degreaser substitutes:

N-Met h yl-Pyrrlidone (N MP)

NMP is an industrial solvent for plastics, waxes, resin and paints. It is a cyclic amine

and is included in EPA Toxic Substance Control Act (TSCA) Inventory, 1980.

Argueso personnel report that NMP leaves an oily film which is not easily vaporized. Information about the product is Included in Appendix A.

15

* I

Table 3.1 l,l,l-Trichloroethane Usage - Vapor Degreasers

GE Gas Turbine Manufacturing Facility ~~ ~ - Total

WeaSer ' TCA Usage TCA Cost Emissions Drummed Waste Disposal Cost Yearly Cost Gallons/Year Wear Tons/Year Gallons/Year $/Year $/year

(GallondYear)

Nozzle

H-Bay 0

Transition Pieces (KFA)

D e t r e X 3DegTeasas

(Combustion

8,544

3,780

3,384 t

1,248

.- 876

45,192

19,992

17,904

6,600

4,632

(2,877) Spent TCA 19,440 102,828 43.7 - 2,408 Gallonflear 16,459 119285

(7,761) Spent TCA

5,760 Lbsryear RigidaxfI'CA

330 Spent TCA

1,100 Spent TCA

1,194 H20RCA

578 Spent TCA

Negligible

iner Building, - S P Y (MA) 1,608 8308 16.2 400

2,706 47,898

1,260 2 1 3 2

4,200 26,663

4359

2,207 8,807

4,632

1,527 10,035

- t ,1 -Di(Ortho-Xylyl) Ethane (DXE)

DXE is an aromatic hydrocarbon manufactured by Allco Chemical Corporation of Galena, KS. This product is used at a temperature between 75 and 100°C. These

temperatures would require extensive reworking of the existing vapor degreaser if used as a drop-in TCA replacement. Once the Rigidax is removed, the part would

need to be cleaned again to remove the molasses-like DXE. Due to the requirement

for high temperatures and subsequent cleaning steps, DXE is not recommended for

this application.

Terpene Sotvents

Argueso personnel report their best results at vapor degreaser substitution using a

terpene based solvent, Re-Entry KNI Solvent 2000. This product is manufactured by

Envirosolv Inc. of Jacksonville, FL. Hartnett Associates of Clinton, NY, has

experience at designinghetrofitting cleaning equipment to use Re-Entry to clean

Rigidax. Jim Hartnett described two procedures for Rigidax removal (see Appendix

A). One method involves using an ultrasonic bath containing the solvent followed

by a boiling water rinse. The part would be air dried or dried using a hot air stream.

The second method would involve a high temperature solvent bath with an Inert gas

blanket followed by a boiling water rinse if needed.

Mr. Hartnett said that his company is designing a machine to replace vapor

degreasing equipment which will be available in August 1991. Features of the

machine Include:

- - - Boiling water rinse -

Ultrasonic sweep cleaning of parts in Re-Entry Distillation equlpment to recover Re-Entry

Equipment to ailow rinse water reuse.

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j

i !

1

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I ! i

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Unused terpene solvents are biodegradable and are not considered to be a RCRA

waste. They become hazardous waste when the contaminant they are used to clean is hazardous;’ otherwise, the waste can be sewered. With proper distillation equipment, the Re-Entry and Rigidax can be separated and recycled, thereby

minimizing the waste.

Because of the reduced environmental liabilities, reduced worker exposure risk, and

waste minimizing benefits of this cleaning method, it is recommended that further

study be performed to fully evaluate the cleaning ability and economic justification

of installing equipment for terpene solvent cleaning of GE gas turbine nozzles.

Toluene/Xylene with Ultrasonic Cleaning

Argueso personnel report cleaning success using both toluene and xylene; however, because of their low flash points (40°F and 1oOOF respectively), these solvents present safety concerns. Also, both were included In the EPA TSCA, 1980. Because

of these regulatory and safety concerns, it is not recommended that toluene or

xylene be used for degreasing efforts.

Detergents with Hot Water

Rigidax may be cleaned with boiling water and detergents; however, the process

requires about 8 hours. Therefore, this type cleaning is not practical and it is not

, recommended that this cleaning method be used.

Another option for replacing the nozzle degreaser would be to install a cleaning system

developed by Progressive Recovery, Inc., for the printing industry. $8 cured ink residues

typically dried on press equipment is similar in composition and consistency to hardened Rigidax.

Progressive Recovery’s equipment employs high pressure solvent and oscillating nozzles to strip

the dried ink from metal surfaces, Cart mounted parts are loaded into the unit and sealed shut

by an access door. The parts laden cart is completely enclosed during the cleaning process and

the dirty solvent is collected and distilled for reuse. Progressive Recovery’s local vendor,

18

! Industrial Ted.mdogies of Atlanta, GA, carries 'environmentally friendly" cleaning liquids for use

in the washing equipment. Information about Progressive Recovery's wash system and the ! deaning chemicals is included in Appendix A. ! a12 H-Bay Degresser

The H-Bay Talley degreaser is a dual tank immersion degreaser. Each blade is cleaned in this

degreaser several times durlng the manufacturing process. After broaching and grinding operations, the blades are cleaned of cutting oil prior to laser stamping of identification numbers.

Once the parts are stamped, further machining is done in the Rigid Grinders. Though ultra clean

pats are not necessary for laser stamping, it is required that no film remain on the parts so as

cleaned after Rigid Grinding.

! ! ! I not to compromise the integrity (especially the pH) of the grinder coolant. The blades are again

Because a high quantity of parts is degreased at this station, it is recommended that a

conveyorized cleaning station be purchased for blade cleaning. Included in Appendix B is

information about conveyorized cleaning systems from the following manufactures and vendors.

Manufacturer Vendor

Nmco

Ramco

Detrex ,

Advanced Deburring & Finishing Statesville, NC

Advanced Deburring & Finishing Statesville, NC

Detrex Corporation Bowling Green, KY

Ransohoff Ransohoff Corporatiorl' Hamilton, OH

Several of the cleaning machines are provided with equipment to separate soils from the cleaning

fluid. This equipment will allow reuse or sewering of process water and chemicals, therefore

minimizing hazardous wastes. tt is recommended that further study be done to evaluate the

cleaning' effectiveness and economics of this equipment.

19

I I I

In addition to equipment selection, various chemicals must be evaluated for this cleaning

application. Two such chemicals are Daraclean 282 and Lemon-Clean. Daraclean 282 has been

successfully tested at GE’s Evendale location. Lemon-Clean by Chemical Finishing is biodegradable and can be used at low temperatures. lt has been successfully employed by GE’s Power Delivery Plant, Somersworth, NH. Information is about Lemon-Clean and its use at Power Delivery Is included in Appendbc B.

3.15 Ardrox, Transition Pieces and Detrex Degreasers I

I At GE‘s Greenville plant, six vapor degreasers are used prior to florescent penetrant inspection

(FPI). Parts must be cleaned to high degrees of cleanliness before entering the FPI. Due to

these stringent cleaning requirements, cleaning chemicals are being evaluated at GE’s Power

Generation facility in Schenectady, NY. Larry Rosenzweig, GE Materials Engineer, Is currently

testing three cleaning compounds. Once his work is complete, further study will be done at the

Greenville plant to determine equipment needs at the various FPI stations.

Z1.4 Flame Spray Degreaser

At the AFA vapor degreaser, parts are cleaned prior to flame spray deposition of an aluminum

oxide coating on a small portion of the bucket surface area. The exhaust duct of this degreaser

is located in its vapor zone at the condensing coils. Because of its exhaust location, this

degreaser is one of the plant’s heaviest emitters of TCA.

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The space available for new processing equipment at this work station is limited. Adequate

aqueous cleaning equipment for this area’s needs will likely require more room and possible movement to a new area. In the Interim, It Is recommended that GE move the exhaust duct of

this degreaser away from the vapor zone in order to reduce the emissions from this area.

I 32 pratt 8 Whitnev Grinder Swarf

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As part.of the turbine blade manufacturing process, the blades are machined In Pratt & Whitney

grinders. In these grinders an abrasive belt removes surface metal. Sultran 155P Coolant, a

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hydracarbon cutting oil, is used to flush the grindings and cool the parts. The oil, metal particles,

and grinding bett debris collect In a sump at each machine. Two disposal methods are currently

used for this waste material: incineration as collected (line 014 waste) or Incineration after

removing as much oil as possible by centrifuging the mixture (line 018 waste). During 1990,

120,OOO pounds of line 018 Pratt & Whitney swarf were sent offsite for incineration; no line 014

waste was generated. Both forms of waste are D007 wastes because they contain elevated levels of chromium,

Estimates of the waste composition Indicate that it is 60-75% metal solids, 15-3096 cutting oil, and

15-3096 abrasive media. One way to reduce this waste stream would be to recycle the swarf for

its metal content. Marvin Seigle of Spartan Iron, GE’s current metals recycler, has stated that one

of his buyers Is willing to accept the swarf for its steel content on an experimental basis. This

buyer Is a smelter of mild steel and is concerned that the chromium and other alloy metals may

degrade his final steel quality. tf this Is the case, the swarf would not be accepted by this buyer for recycling.

As mentioned above, the swarf is a hazardous waste (0007). Therefore, the swarf must be

disposed at a RCRA permitted facility even if the disposal method is recycling. Spartan Iron is not a RCRA permitted facility and therefore should not be considered as a viable disposal option for the Pratt & Whitney grinding swarf.

3.3 EDM Sludae

At several locations in A-Bay and M-Bay, turbine parts are ground using electrical discharge

machinery (EDM). For electrical discharge machining, electrical pulses discharge between the

EDM electrode and workpiece to remove fine particles or chips from the;workpiece surface. The electrode tool and workpiece are immersed in a bath containing a dielectric solution. Erosion

of the workpiece surface and the electrode frees small particles which, in sufficient concentration. render the dielectric fluid Ineffective. Currently, the fluid is filtered and the oil reused while the

filtered sludge is drummed for off-site disposal, Plant records indicate that 24,000 pounds of the

drummed sludge are generated per year. This sludge is blended into fuel for incineration at a disposi cost of approximately $1 0,000 per year.

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The EDM sludge has been assigned the EPA waste numbers 0001 for ignitability and DO07 for elevated chromium content. Following are results of analyses performed on the sludge by Rogers and Callcott Engineers:

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Test Results (m@)

Regulatory Parameter Level (mgll) 1 011 990 311 909 711 900

Barium 100.0 .35 4.9 93

Chromium 5.0 37 6.1 . 24,074

Silver 5.0 < .oi 1.2 < 1.0

Plant personnel estimate that the sludge consists of the following components:

EDM Oil 0-25%

Carbon 30-60%

Metal 5-20%

Water 04%

GE's EDMs were manufactured by Easco-Sparkatron of Ann Arbor, MI. Easco's Don Braden was

contacted regarding the EDM operation at the Greenville plant. Mr. Braden stated that the EDM

oil should contain eroded metal and electrode particles in sizes ranging from 10 to 50 microns.

He knows of no maintenance operations which would reduce the sludge generation and said that

the Poko graphite electrodes used by GE are the highest quality rods available. Therefore, waste minimization efforts for this waste stream have focused on further separation of its constituents.

Investigations of methods te separate the particles of ferrsus alloys and graphite from the tar-Ilk6

EDM sludge have focused on centrifugal forcer wringers. These wringers consist of a perforated

tub within a containment vessel. As the tub spins, liquids are forced through the perforations

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* while solids are captured. Elen Learner of Sandborn Environmental Systems, Wrenthan, MA, stated that their centrifuges will capture particles as small as 1 micron. These machines should

be capable of separating GE’s 10-50 micron EDM solids.

Gary Cook of Cook Systems, Inc., Vicksburg, MI, has extensive experience at separating solids

from EDM 011. Included in Appendix C is a copy of a newsletter artlcle describing a machine he

has recently patented. This machine is also capable of separating particulates smaller than a micron. A sample of GE’s EDM sludge was sent to Cook Systems and it was estimated that the

oil content of this waste could be reduced to 4%. Currently, his operations are limited to the

Michigan area. He would require that the sludge be shipped to his location for separation (at

$200/drum) and the constituents returned to GE.

The oi1 content of the sludge is estimated to be approximately 20% oil. Centrifuge vendors state that this content can be reduced to a range of 4 to 10%. This reduced oil content would reduce

the amount of waste sludge generated by about 280 gallons per year. tf the price for disposal remains at $200 per drum, GE would save $1,000 per year in disposal fees. However, the

remaining filter cake will still contain graphite and the ferrous alloys with possible continued

elevated TCLP chromium content. No businesses have been found which will recycle the solids

for either the graphite or chromium content.

Due to economic constraints, ‘it is recommended that GE continue its current practice of

Incinerating EDM sludge. As recent trends indicate that the content of EPA TCLP contaminants

is diminishing, GE should closely monitor this waste for possible downgrading of regulated

status.

3.4 Excess Paint Thinners

Paint/thinner sludge is collected in the D-Bay stationary paint booth for disposal. GE personnel

estimate that this waste stream is composed of 10% paint and 90% IMI 1500 paint thinner.

Approximately 57,000 pounds per year of this waste are drummed and sent for offsite treatment at an @mated $2,500 yearly treatment expense, The majority of this waste is generated during

the Cleaning of spray painting equipment. The solvent used,to clean the equipment is a specially

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formulated thinner used to adjust the paint viscosity. According to GE personnel, the majority

of this thinner purchased for the Greenville plant is used in equipment cleaning.

in order to reduce this waste stream, methods whereby the material may be recycled have been investigated. The preferred method for recycling solvents is using distillation equipment. Distillation systems heat contaminated solvents to their boiling point, thereby vaporizing the solvent and leaving the contamlnants. The solvent vapors are then drawn through a cooling coil

where the vapors condense back to liquid solvent. These machines recover 80-100% of the

solvent. Typically the recovered solvent is 95-99% as pure as virgin product. Therefore, the

Greenville plant can reduce its paint/thinner waste disposal costs and its new thinner purchase

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costs.

Several distillation equipment vendors have provided price and operating expense information for their machines. Purchase prices range from $7,800 to $1 1,600. Included in Appendix D is

information about the following distillation units:

Manufacturef

Giant Distillation & Recovery Company

Solvent Kleene

Progressive Recovery

Hoyt Corporation

Vendor

Maple Systems & Supply Terre Haute, IN (81 2) 234-9330

Solvent Kleene Peabody, MA (508) 531 -2279

Industrial Technologies Company Atlanta, GA (404) 491 -3963

Hoyt Corporation '.- Westport, MA (508) 631 -881 1

It fs recommended that GE install a distillation system to recover the solvent from the waste

sludge. With estimated yearty savings of $34,000-$38,000 and yearly operating expense of $220

to $465,ihese machines will pay for themselves in 3 to 4 months. A calculation of the payback

obtained from an Industrial Technologies Company quotation is included In Appendix D.

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Rotary finishing machines are used for deburring and polishing blades and buckets. The current

system uses water in a *once through” fashion. The wastewater flowrate leaving the A-Bay

vibrotubs used to process buckets was estimated to be approximately 40 gpm. Since that

estimate was made, GE has added solenoid valves in the discharge lines of the vibrotubs and as a result of this change the wastewater flow has been reduced to approximately 15-20 gpm.

The wastewater flow from the buckets vibrotubs can be reduced further by settlng up a recycle

system. This system would include two transfer pumps, two basket strainer/filters in parallel, a surge tank, and interconnecting piping. A typical system flow diagram is shown in Figure 3.1.

Total equipment costs for this system would be approximately $6,275 (excluding piping costs).

Depending on how often the wastewater solution must be emptied, wastewater flow can be

reduced significantly. Assuming the solution can be reused six to seven times before it must be

discarded, it can be reduced from approximately 28,800 gpd to between 4,100 and 4,800 gpd.

A similar system has been installed at the GE Vega Alta facility and has been successful in

reducing the wastewater flow without impacting the product quality. It is recommended that GE Greenville install recycle systems on both the blades vibrotubs and the buckets vibrotubs.

3.6 Paintf3aothVOCs

The Greenville plant’s second highest VOC emitting process is the surface coating operation. At several work stations in the plant two types of paint are applied. These two paints are Roymal high temperature resisting aluminum silicone enamel and Reeve beige primer. According to purchase records for 1990,1,395 gallons of high temperature enamel and 2,950 gallons of primer

are applied per year. The VOC content (VOC ratings) of these two paints are 4.46 Ib/gallon and

4.59 Ib/gallon, respectively. This translates to a loss of approximately 9.9 ton/year of VOCs from

the surface coating operations.

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Figure 3.1 Vibratory Finishing Recycle Flow Diagram

GE Gas Turbine Manufacturing Facility

To Filter Press

,; 40GPMO20’

.. .. --. . _. __ .. ._ - _ _ - .. . . . ,.. , - .. . . . . . - .. . . .. . . -.. . . . -.. . . . . . _ _

I 1 9/64” Perforated

Basket 75 Micron Filter

Surge Tank 4’ x 6’ x 4’

Air Diaphragm Pump 40 GPM @ 10’

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, The current painting operations are carried out in several different locations throughout the plant

at irregular times using mobile paint booths. tt is recommended that GE segregate its painting

activities by location and install dedicated stationary paint booths with appropriate capture and control devices. This level of control will probably be necessary to meet the more stringent requirements of the most recently promulgated regulations regarding air pollution.

Another alternative which could be used in the interim prior to installation of stationary paint

booths would be to use the newly developed high solids, low-VOC paints or to use water based

paints. These paints have lower solvent to pigment ratios than older paints, typically 10-3096

’less, and emit less VOCs per gallon of coating.

The GE process specifications for the painting operations are included in Appendix E. The high

temperature painting specification requires the use of paint from Roymal Coating Co. of Newport, NH. The company’s technical contact, Ray Malool, states that Roymal does not sell a low VOC version of this paint. Niles Chemical Paint Co. of Niles, MI, does manufacture a black colored

high temperature enamel which may be suitable for this application. According to Niles’ Daniel

Williams this paint’s VOC content is 3.5 Ib/gallon. Based on a coverage of about 400 square

feet/gallon, using this paint would lower VOC emissions from high temp applications from the current 3.t tons/yr to 2.4 tonsbear. Information from Niles Is also included in Appendix E.

The GE Alkvd Prime Painting specification used for beige primer application lists several choices

of paint. These include two water reducible paints and a low VOC sotvent based paint

manufactured by the current primer supplier, LA. Reeve Co., Syracuse, NY. According to

Reeve’s representative, Chris Martin, the Greenville plant evaluated the water based paint during

the early 1980’s. During those trials it was determined that the paint dried too slowly and held

up production. The VOC content of the currently used primer and the low VOC primer from

Reeve are 4.59 Ibs/gallon and 3.30 Ibs/gallon, respectively. The coverages per gallon of paint

at one mil thickness are 656 sq ft/gallon and 81 6 sq ft/gallon for the current and low VOC primer,

respectively. Conversion to the low VOC Reeve paint would reduce the operations emissions

from the current 6.8 tonbear to 3.9 tonbear.

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i " The current painting equipment requires compressed air to atomize the paint for application. Low

VOC solvent based paints are best applied with hot air assisted airless spray equipment. The air assisted airless spray equipment pressurizes the paint and it is atomized as it passes through the nonte. Therefore, new equipment would need to be purchased to apply these lower VOC

paints. lncluded In Appendix F are equipment quotes from TAB Industries of Pascagoula, MS, and Air Power of Greenville, SC. Equipment prices range from $4,200 for a single spray gun unit

to $9,700 for a four spray gun unit.

It Is recommended that GE use these low VOC containing paints. At current usage rates, this

will reduce the VOC emissions from painting operations from the present 10 tons/year to 6.3 tons/year.

3.7 castrol55oP coolant

Castrol 55OP cutting fluid is used as a cooling media in the machining operations of several

pieces of equipment at GE. This cutting fluid along with metal chips collect in sumps at each

machine. The chips form barriers which restrict fluid flow and cause stagnation. Also, hydraulic

and lubricating oils from the machinery drip into the sumps. Eventually the coolant stagnation and tramp oil cause the coolant to become rancid. As the coolant begins to smell, facilities

personnel drain h e sumps and refill them with fresh coolant.

The 55OP concentrate is mixed with water at a ratio of 20:l water to concentrate for use in the

plant. Therefore large quantities of water containing oils and 550P are generated. Currently, this

waste is collected for disposal by James Waste Oil Company. Plant estimates place this disposal

quantity between 80,000 and 120,000 gallons per week.

Hany Norton, GE's facilities manager, and Randy Norris, Castrol's local representative, have entered an agreement whereby Castrol is contracted to recondition the cutting fluid on site and,

In doing so, reduce the quantity requiring disposal. During the week of July 4, 1991, Castrol is to install 8 fluid repolisher at the GE plant. Details on this equipment is included in Appendix G.

This repolisher will remove metal chips and coalesce tramp oils from the coolant. Once

repolished,' the fluid will be replenished with any necessary 550P concentrate and/or biocides.

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?he oils separated from the coolant will still require off-site disposal; Mr. Norris estimates that the waste coolant requiring dlsposal will be reduced by 80%.

3.8 X-Rav Silver Recovenr Effiuent

X-Ray inspection is one method of nondestructive testing employed at the GE facility. With this

form of testing, images of components, including flaws and inclusions, are placed on photographic film. This radiographic film must be processed in order to view the x-ray image.

The film is processed in a Kodak Model B X-Ray film processor, This machine operates 16 hours

per day and requires 3.5 gallons per minute of fresh water for both temperature control and

washing away processing chemicals. Daily water usage for this machine is approximately 3,400

gallons.

Currentty, the x-ray effluent is routed through a steel wool filter system for silver recovery prior to discharge to WWT. Samples of this discharge have been analyzed and indicate significant

concentrations of suspended solids, chromium, aluminum, nickel, silver, and total organic

content. If GE is required to meet water quality based limitations for direct discharge of this

waste water to uttle Rocky Creek, "at source" pretreatment may be necessary.

Several commercial units are currently available which allow reuse of processor wash water and significantly reduce the hydraulic load attributed to x-ray film processing. In addition, these

machines remove metals to EPA acceptable discharge limits and recover an otherwise wasted valuable product, silver. Capital costs for this equipment can range from $4,000 to $30,000 depending on the degree of sophistication of the recovery process. These machines typically

reduce x-ray lab water usage and subsequent sewer discharges by as much as 65%. Therefore,

effluent from the units at the GE plant may be reduced to as little as 1,200 GPD. Literature fully describing this equipment is included in Appendix H.

.

lt is recommended that further evaluation be conducted in order to determine the economic

justification of this water recycling equipment.

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