Pollution Prevention Training for the Automotive Industry

Pollution Prevention Trainingfor the Automotive Industry

Presented by

Ellen SchultePollution Prevention SpecialistHazardous Materials DivisionCounty of San Diego, Department of Environmental HealthPhone: (619) 338-2324Fax: (619) 338-2139Email: [email protected]

What is Pollution Prevention?

• Using materials and resources efficiently (including water and energy) to reduce the generation of waste = Source Reduction

• The most cost-effective form of environmental protection.

Self-audit Checklists

“Compliance with laws and regulations is the first step towards pollution prevention.”

The Stormwater Link

• Preventing pollution protects public health and our environment.

Automotive RelatedPollution Prevention

Web Sites1. Aqueous Products Vendors List:

www.aqmd.gov/business/water2. Information on health effects of chemicals:

www.dhs.ca.gov/ohb/hesis3. Chlorinated auto product ban:

www.arb.ca.gov/toxics/amr.htm4. Recycled antifreeze standards: www.astm.org5. Green trends in the auto industry:

www.cleancarcampaign.org6. Automotive environmental assistance:

www.ccar-greenlink.org7. Alternative fuel information: www.afdc.doe.gov8. Clean Cities Program: www.ccities.doe.gov

Workshop Topics• New Regulation Update• Aqueous Parts Cleaning• Aqueous Brake Cleaning• Aqueous Case Studies• Waste Antifreeze• Oil and Water Separators• Spill Control and Cleanup

New Regulation Update

• California EPA, Air Resources Board banning all use of chlorinated auto products containing:

Perchloroethylene, Trichloroethylene,Methylene chloride

• Effective December 31, 2002. CCR Title 17, section 93111.


• California EPA, Department of Toxic Substances Control adopts new regulations for cathode ray tubes to be managed as universal waste. CCR Title 22, section 66273.6,8, and 9.


• Conditionally Exempt Small Quantity Generators (CESQG) can now self-haul hazardous waste to local facilities for proper disposal. CA Health & Safety Code, Article 10.8 Call 1-800-714-1195 to participate.

Aqueous Parts Cleaning

Baseline: Mineral Spirits• Pro’s

Cleans wellTurnkey

• Con’sVOC emissionsHaz wasteWorker safetyNeed-it-or-not servicing

P2 Alternatives

• Sink-Top

• Immersion Unit

• Spray Cabinet

• Ultrasonic Unit

Microbial Sink-Top• Same design as solvent unit• Solution = 110 to 120o F• Applicable for light-duty and

quick cleaning jobs• Microbes reduce waste

generation • Difficult to clean heavily

soiled parts• Cost: $1,000 to $1,500

Immersion Unit• Offers option to soak parts

or manually scrub

• Solution = 110 to 120 oF

• Applicable for light to moderate soil buildup

• Heavily soiled parts may require longer soak times

• Cost: $1,700 to $3,500

Spray Cabinet• Solution = 130 to 190 oF• Pressures of 40 to 60 psi• Applicable for heavily-

soiled and large volumes of parts

• High level of cleaning • Reduces cleaning labor by

up to 80%• Cost: $1,700 to $50,000*

Ultrasonic Unit• Microscopic scrubbing action

• Solution = 130 to 190 oF

• High level of cleaning

• Cleans blind areas -transmissions and carburetors

• Cost: $5,000 to $12,000

Summary of Aqueous Alternatives

• Microbial Sink-Top – light duty

• Immersion Unit – when soaking is needed

• Spray Cabinet – heavy duty/saves labor

• Ultrasonic Unit – transmissions/carburetors

Making It Work• Prevent rusting

rust inhibitorswipe or blow dry

• Maximize solution lifefilter skim oiluse microbes

• Keep your microbes happydon’t overloaddon’t use aerosolskeep warm

Maximize Solution Life: Filtration

Maximize Solution Life:Oil Removal

Aqueous Unit Servicing

• Add water / chemical

• Skim oil

• Replace filter

• Drain / replace solution

Range: 30 minutes - 4 hours per month

Waste Management• Spent Filters

Dispose as hazardous wasteReusable filter

• OilsSkim and recycle with used oil

• Spent SolutionSend off-site as hazardous waste (0 to 4 times per year)Include sludge

Waste Stream Analysis• Spent solution - 15 spent baths tested

Ten exceeded metals content (Cu, Pb, Cd, Zn)Seven contained VOCsThree exhibited fish toxicityNone met City of LA discharge limits (O&G, Cu, Pb, Zn)

• Spent filters - two testedOne hazardous due to metals

Comparison of P2 OptionsEquipment

TypeProduct

FormulationHand/Auto Applications Cost

Sink-top Neutral Hand scrub Replaces singlesolvent sink

$500-1,500

Microbial Neutral Hand scrub Replaces singlesolvent sink

$1,000-1,500

Immersion Neutral Hand scrub For parts that needsoaking

$800-1,700

Spraycabinet

Neutral oralkaline

Automated Aggressive cleaning $2,000-6,000

Ultrasonic Neutral oralkaline

Automated Aggressive cleaningfor intricate parts

$3,000-12,000

Take Home Messages• Aqueous cleaning works!

• Implement multiple units to meet all your needs

• Demonstrate units before purchasing

• Maximize solution life to lower waste management costs

Aqueous Brake Washing

Baseline: Solvent Brake WashingOption 1: Aerosol cans of brake cleanerOption 2: Roll-up solvent washersEnvironmental Concerns• Solvent emissions cause smog formation

• Spent solvents are hazardous waste

• Aerosol product use increases worker exposure

• Empty aerosol cans - bulky, nonbiodegradeable waste

• Solvent-contaminated rags

P2 Alternative:Aqueous Brake Cleaning

• Avoid final shot of aerosol brake cleaner

• Use compressed air for drying

• Consider units that adjust in height

Waste Management• Shop manager is responsible for

determining whether waste is hazardous• Some vendors will dispose of solution for

you• Avoid contaminating with aerosol

products

• Informal Bay Area Survey: solution change every 3 years

Typical Scenario• > 20 brake jobs / month• Payback < 2 years• Assumptions

Aerosol brake cleaner $2 / can1 can / job

Aqueous unit $800Aqueous cleaner $25Disposal: solution and filters $30/ yr.

Case Studies

• 1997 - Southern California• Shop size: small to large (3-35

employees)• Number of brake jobs per week: 3-25• Baseline annual cost of aerosol &

mineral spirit cleaning: $117 - $1957

Case Studies

• Types of cleaning units tested:heated or coldwheeledbatch and single job

• Variety of cleaners used: enzymedetergent based

Case StudiesAnnual Cost Savings

• About 20% to 80% annual cost savings for all test shops

compared to aerosol brake cleaners• Highest volume shop: about 80%

annual cost savings• Full report and 1 page case studies:

http://home.earthlink.net/~irta/rprt0005.html

Chlorinated Product Ban• Automotive maintenance and repair facilities• State regulation bans the sale and use of:

Perchloroethylene (Perc)Methylene chloride (MeCl)Trichloroethylene (TCE)

• Aerosols and bulk liquid product ≤ 2 gal.• Effective dates, beginning:

Sale: July 1, 2001Use: January 1, 2003

Chlorinated Product Ban

• Regulations and More Information - ARBRulemaking Update http://www.arb.ca.gov/regact/regup00.htm#amr

Fact Sheet, Workshop Summary http://www.arb.ca.gov/toxics/amr.htmFinal Rulemaking• Approved and Filed April 4, 2001• http://www.arb.ca.gov/regact/amr/amr.htm

Caution!!Alternatives to Chlor. Solvents

• Phase out of chlorinated solvents may result in the increased use of other products -can cause adverse health effects

• Many automotive products contain Hexanebrake cleaners, degreasersaerosol and bulk

• Debilitating illness can result from exposure to Hexane - Peripheral Neuropathy

Hexane - Caution• mixture of isomers

20-80% n-hexane (normal hexane)

• n- hexane - well documented neurotoxin• Inhalation - main route of exposure

dermal contact exposure

• Exposure Symptoms:numbness in extremitiesdecreased grip strength - dropping tools

Hexane Worker Exposures• California DHS - OHB, Health Evaluation

Systems and Information Services (HESIS)Case Studies - chronic exposures

Working with Machinists Union

Publications - n-hexane health advisory http://www.dhs.ca.gov/ohb/HESIS/nhexane.pdf

• Aqueous cleaning system = alternative

Take Home Messages

• Performance ≥ other methods

• Lower / no worker exposures

Pay attention to substitutions

• Do not cross-contaminate

• Can save $$ compared to aerosols

Case Study 1: MUNI Demonstration

• City and County of San Francisco Municipal Railway (MUNI)

• 14 different aqueous units

• 3-month demonstration period

• Three different facilities

Case Study 1: MUNI Electric Bus Facility

• Light-duty repairs, preventive maintenance

• Light cleaning needs• 4 solvent units, • 0.8 hours/day cleaning

labor

Demonstrated a microbial sink-top and spray cabinet


Microbial Sink-Top Spray Cabinet


• Conversion2 solvent units => 2 microbial sink-top2 solvent units => 1 spray cabinet

• ResultsAnnual savings = $13,250Capital cost = $14,030Payback period = 1.1 years

Case Study 2: MUNI Diesel Bus Facility

• Heavy-duty rebuilding and repair

• Heavy cleaning needs

• 13 solvent units

• 18 hours per day cleaning labor


Spray Cabinet

Ultrasonic Unit


Immersion Unit Aqueous Sink Top


• ConversionFrom (solvents): To (aqueous):

8 => 3 spray cabinets2 => 1 ultrasonic2 => 3 microbial sink-top1 => 2 immersion unit

Total: 13 => 9 units• Results

Annual Savings = $134,810Capital Cost = $33,400Payback Period = 3 months

• Background: Aqueous cleaning optimization

• Demonstration FacilitiesGeneral Services 7th StreetPolice Department Piper TechWorld AirportsPolice Department CentralRecreational Parks Equipment Repair

Case Study 3: City of Los Angeles

General Services 7th StreetFacility Conversion

From To(Existing Aqueous Units) (Alternative Aqueous

Units)1 large agitating unit 1 spray cabinet3 sink-top units 1 spray cabinet2 carburetor cleaners 1 spray cabinet10 immersion units 7 immersion

unitsTotal = 16 aqueous units 10 aqueous units

Current Annual Cost = $393,705Modified Annual Cost = $215,726

Annual Savings = $177,980

Police Department Piper Tech Facility Conversion

From To(Existing Aqueous Units) (Alternative Aqueous Units)

4 sink-top units 4 sink-top units4 sink-top units 4 immersion units6 sink-top units 3 ultrasonic units

Total = 14 aqueous units 11 aqueous units


Annual Savings = $322

World Airports Fleet Maintenance Facility Conversion


6 sink-top units 4 sink-top units4 immersion units 7 spray

cabinetTotal = 10 aqueous units 5 aqueous units


Annual Savings = $13,068

Police Department CentralFacility ConversionFrom To

(Existing Aqueous Units) (Alternative Aqueous Units)

2 sink-top units 2 sink-top units4 sink-top units 4 immersion units

Total = 6 aqueous units 6 aqueous units



Recreation and Parks Equipment RepairFacility Conversion


2 immersion units 2 immersion units

1 carburetor cleaner 1 ultrasonic unitTotal = 3 aqueous units 3 aqueous units



Glenmoor Auto Repair• Full-service shop

Two techniciansEight bays

• Previous solvent useOne solvent sink-topServiced every 16 weeks1 hour cleaning labor per week

• Demonstrated microbial sink-top and spray cabinet

Glenmoor Auto Repair

• Microbial sink-topUsed for 60% of partsTwo filters per yearNo spent solutionPositive worker response

Glenmoor Auto Repair• Spray cabinet

Used for larger, more soiled parts25 gallons solutionSolution changeout once per year“Parts so clean they shine”

Glenmoor Solvent Cleaning Costs

One Solvent Unit Annual CostLeasing/waste management $ 690Cleaning labor $2,600Electricity $ 120Total annual cost $3,410

Glenmoor Aqueous CleaningAqueous Microbial Sink-Top Annual CostPurchase price (one-time) $1,300Annual O&M $ 534

Aqueous Spray CabinetPurchase price (one-time) $1,700Annual O&M $1,238

Total Capital Cost = $3,000 Annual Savings = $1,638

Payback Period = 1.8 years

Larry’s Autoworks• Full-service shop

Six techniciansFourteen bays

• Solvent parts cleaning baselineTwo solvent sink-topsServiced every 6 weeks12 hours cleaning labor per week

Conversion Strategy = microbial sink-top + spray

cabinet

Larry’s Autoworks• Microbial Sink-Top

Used for 10 % of partsSmall parts and painted partsSolution Life > 16 monthsCapital cost = $1,300

Larry’s Autoworks• Spray Cabinet

Used for 90% of partsReduced cleaning labor by 60%Solution change every 6 monthsPurchased used for $1,600

Larry’s Autoworks

Cost Analysis• Capital Cost = $2,900

• Annual Savings = $14,874

(driven by labor reductions)

• Simple Payback = 2.5 months

Waste Antifreeze Recycling

Antifreeze Properties• Base (≈95%) used for freeze & boil

protectionEthylene GlycolPropylene Glycol

• Additives (≈5%)Corrosion InhibitorspH BuffersAnti-foaming Agents

Antifreeze Environmental Concerns

• Ethylene and propylene glycols are manufactured from natural gas and crude petroleum, nonrenewable resources.

• Ethylene glycol is a toxic chemicalSARA Title III, Section 313 Section 66261.24(a)(8), 22 CCR

• Any waste antifreeze may contain heavy metals such as lead, cadmium, chromium, iron, copper, and zinc.

Recycling Technologies

• Distillation - produces clean glycol base• Reverse Osmosis - filters out contaminants and

additives, produces glycol and water• Ion Exchange - removes ions (ie, chlorides,

sulfates, additives) usually part of a process• Chemical Treatment - flocculation, organic

removal• Filtration - removes contaminants, typically

down to approximately 5 microns (sometimes to 1 or 1/2 micron)

Onsite Recycling Costs

On-Site Closed Loop (filtration or ion exchange)• Capital Cost: $2,500 to $13,800• Capacity: 4-5 gal/hr• Filtration = $3 to $4.50/gal• Ion Exchange = $4.45 to $7.20/gal

On-Site Batch (filtration or distillation)• Capital Cost: $3,700 to $18,000• Capacity: 4-100 gal/hr• Recycling Costs: $0.74 to $4.50/gallon

Mobile and Off-site Recycling Costs

Mobile Service (filtration or reverse osmosis)• Capacity: 55-210 gal/hr• Recycling Costs: $1.75 to $3.00/gal

Off-Site Recycling (distillation)• Capacity: 375-500 gal/hr• Recycling Costs: $2.00 to $3.70/gal

Recycled Antifreeze Standards

• Automobile & Light Duty: www.astm.orgRecycled antifreeze standards are ASTM 6471 & 6472Similar to virgin antifreeze standards (ASTM 3306 & 5216) except for electrochemical pitting and storage stability testsMust meet chloride and sulfate standards of 33 ppm and 140 ppm respectively, or complete fleet testingUser, not equipment manufacturer, must meet standard!

• Heavy Duty: www.astm.org• No recycled antifreeze standards at this time.• Virgin antifreeze standards are ASTM 6210 and 6211

http://www.astm.org/








Recycled Antifreeze Standards

• Dept. of Food and Agriculture - Division of Measurement Standards (916) 229-3000

Usually adopts ASTM antifreeze standards for those persons selling or distributing antifreeze in the State of CA.Will adopt the new ASTM antifreeze recycling standards by January, 2002Until adoption of new standards, existing CA. Law allows variance for chloride levels of up to 149 ppm if certain requirements are met.References: Section 13710, Business and Professions Code, and Title 4, Division 9, Chapter 6, Article 7, Section 4161

What About OAT?

• In 1999, about 30% of new passenger, 5% of heavy duty vehicles, factory-filled with Organic Acid Technology (OAT)

• OAT is glycol-based with long-lasting additive package

• OAT can be recycled, but chemical replenishment is critical

Case Study USPS Huntington Beach

• 1,030 vehicles70 – 100 coolant changes/month

• Baseline2,250 gallons waste coolant/year$18,900/year antifreeze purchase and disposal

Case Study USPS Huntington Beach

Antifreeze recycling

Batch distillation unit: $8,500Additives, O&M: $4,310/year

Payback Period: < 7 months

Take Home Messages

• Waste antifreeze can be recycled!• Recycling costs are favorable• Ensure recycled antifreeze meets ASTM or

CA. Measurement Standards• Ask Questions: See Antifreeze Recycling

Factsheet

Oil / Water Separators

What is an OWS?

Making It Work

• Reduce your disposal costs

• Reducing your permit and regulatory requirements

• Reducing your service intervals

P2 Alternative: OWS BMPs

MINIMIZE• Solids: sediments, trash, sand

• Contaminants: antifreeze, fuel, solvents, paint

• Wastewater, storm water, wash water

INSPECT

Bioremediate

Minimize Solids: Grates and Screens

Minimize Contaminants• Eliminate or minimize floor drains• Use “dry” cleanup techniques • Be aware of potential contaminant sources

- antifreeze - paints - oils- solvents - fuels

• Heavy vs. light contaminants• Avoid emulsifying detergents

Minimize Wastewater• Mitigate introduction of storm water with

berms and washrack covers.

• Reroute roof drains and condensate from air conditioning and air compressors

• Use high-pressure, low-volume sprays for vehicle washing

Inspection and Clean Out• Implement regular inspection

– Sludge depth – Contaminants (odors, sheens)

– Floating oil – Solids on grates

• Perform regular cleanoutDetermine need for cleanout based on inspection, not calendarRemove oil from collection trough or from surface using reusable absorbent padsRefill OWS with water before returning to service

Making Bioremediation Work• Periodic “microbe dosing” of OWS

replenishes microbe population

• Keep pH level < 8.5

• Harsh chemicals can kill microbes

• Vendors can provide equipment, microbes, and labor as part of service agreement ($75 to $130 per month)

Case Study 1: Salem BoysChallenge: Reduce $1,000 cost of OWS

cleanout incurred every 3 monthsApproach: • Install screens and 1/4” expanded steel

mesh to existing OWS grates

• Use pigs and sloping pavement to settle out sediment

• Use “oil-only” absorbent pads to collect floating oil from OWS water surface

Case Study 1: Salem Boys

• Dose OWS with microbes every 4 hours (service costs $75 per month)

• Use removable screens in vehicle bay to remove debris

Case Study 1: Salem BoysResults:

reduced cleanout frequency by 75% -from once every 3 months to once/yearsaved approximately $3,000/year in sludge cleanout and disposalmicrobe dosing costs $900/yeardebris grates and absorbents cost $250/year

Case Study 2: USPSHuntington Beach, CA

• Discharge violations

• 80% reduction of effluent hydrocarbons with bioremediation

Take Home Messages• Understand how your OWS works

• Source reduction and segregation

• Bioremediation works

• Save $$ by reducing clean-out frequency and violations

Spill Prevention and Floor Cleanup

Baseline: Safety Hazards and Contaminated Wash Water

Environmental Concerns• Sanitary sewer discharges

metals in treatment sludge“pass through” contaminants

• Storm drains discharge directly to surface water

• Dry well discharges can contaminate groundwater

P2: Use Roll-Around Drip Pans

P2: Use Sloped Drum Covers

P2: Secondary Containment

P2: Overhead Bulk Delivery

P2 Alternative: Dry Shop

• Use dry clean up methods

• Use launderable rags for small spills

• Segregate spill wastes (4-step method)

• Use absorbents sparingly

• Epoxy-seal floor to reduce cleaning needs

Making It Work

Q1: Gasoline or solvent spill?If Yes AbsorbentsIf No Q2

Making It Work

Q2: Cleanup with ≤ 3 rags?If Yes Use the ragsIf No Four-step floor cleanup

Four-Step Floor Cleanup

MOP WATER

Step 1: Oil Spill?

Use hydrophobic mop.

Step 2: Antifreeze Spill?

COOLANT ONLY

Use dedicated antifreeze mop.

Step 3: Dry Surface

Wipe up with rags. Do not saturate.

Step 4: Wet Mop

Use mild, non-caustic detergent.

Making It WorkMinimize Absorbents

• Disadvantages:Spilled oil and antifreeze cannot be recoveredMust be purchased repeatedlyMay be a hazardous waste Contaminants may be released to environment

• Reserve absorbents for large spills and emergencies

• Where possible, use reusable pads and pigs

Making It Work Epoxy-Seal the Shop Floor

• Won’t absorb spills as a concrete floor does

• Makes spill cleanup easier

• Requires less time and water to clean

• Lasts for years and reduces long-term liability for floor contamination

• Looks great to customers and worker

Making It WorkPower Washing

• Is wash water properly disposed?

• Even if a contractor power washes the floor, you can be held liable for illegal disposal.

Take Home Messages

• Stop if there’s a drop!

• Source segregation

• Use absorbent sparingly

• Epoxy floors make this easy

Pollution Prevention Training for the Automotive Industry

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