Water Efficiency in the Automotive Sector...Volvo Group North America, LLC Water Efficiency in the...
Transcript of Water Efficiency in the Automotive Sector...Volvo Group North America, LLC Water Efficiency in the...
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Volvo Group North America, LLC
Water Efficiency in the Automotive Sector
Steve Pierett, C.E.M., CP EnMS, C.R.M. Environmental Manager
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Volvo NRV Plant – Dublin, Virginia
Area’s Largest Manufacturing FacilityLargest Mfg. Facility in Volvo Family
New River Valley Plant, Dublin, VA
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Volvo NRV Plant – Dublin, Virginia
OVERVIEW
•Examine a decade plus of water savings benefits
•Review two projects•Review water savings versus energy savings
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Volvo NRV Plant – Dublin, Virginia
(80.000)
(60.000)
(40.000)
(20.000)
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20.000
40.000
60.000
80.000
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
x M
illio
n ga
ls O
r Per
cent
Red
uctio
n
By Year
Plantwide Total Water Use 2003 - 2015 est.
Overall, water use efficiency improved 41% since the baseline year of 2003.
Overall, water use efficiency improved 41% since the baseline year of 2003.
Overall, water use efficiency improved 41% since the baseline year of 2003.
Overall, water use efficiency improved 41% since the baseline year of 2003.
Chart1
20042004
20052005
20062006
20072007
20082008
20092009
20102010
20112011
20122012
20132013
20142014
20152015
Overall, water use efficiency improved 41% since the baseline year of 2003.
Overall, water use efficiency improved 41% since the baseline year of 2003.
Overall, water use efficiency improved 41% since the baseline year of 2003.
Overall, water use efficiency improved 41% since the baseline year of 2003.
By Year
x Million gals Or Percent Reduction
Plantwide Total Water Use 2003 - 2015 est.
58.97039
-5.2332787862
48.5354
-22.0025385486
50.16224
-19.3881706812
41.65244
-33.0636075265
34.915635
-43.8898021863
26.7686363636
-56.9822092147
27.24304
-56.2198320768
42.12001
-32.3122121934
26.36419
-57.6321634678
34.931
-43.8651102915
39.7
-36.2012217964
36.71
-41.0062179382
WaterUsage2003-2013
20042004
20052005
20062006
20072007
20082008
20092009
20102010
20112011
20122012
20132013
58.97039
-5.2332787862
48.5354
-22.0025385486
50.16224
-19.3881706812
41.65244
-33.0636075265
34.915635
-43.8898021863
26.7686363636
-56.9822092147
27.24304
-56.2198320768
42.12001
-32.3122121934
26.36419
-57.6321634678
34.931
-43.8651102915
TotalAnnualWaterUse2003-2015est
20042004
20052005
20062006
20072007
20082008
20092009
20102010
20112011
20122012
20132013
20142014
20152015
Overall, water use efficiency improved 41% since the baseline year of 2003.
From the updated baseline of 2008, water use has increased 5.1%.
By Year
x 10 Million gals Or Percent Reduction
Plantwide Total Water Use 2003 - 2015 est.
58.97039
-5.2332787862
48.5354
-22.0025385486
50.16224
-19.3881706812
41.65244
-33.0636075265
34.915635
-43.8898021863
26.7686363636
-56.9822092147
27.24304
-56.2198320768
42.12001
-32.3122121934
26.36419
-57.6321634678
34.931
-43.8651102915
39.7
-36.2012217964
36.71
-41.0062179382
AnnualWaterUsage
YearWater Purchased - 10 Million galsOverall Percent ReductionOverall Percent Reduction from 2008Reduction in Water use - galPlant Cost Avoidance for water and sewerRegional Energy to Produce Clean WaterCost to Process WaterPlant Energy to Operate WW Reuse System
2003 Base62.2276.2232003NAkWhr7.5 cents/kWhr
200458.970-5.25.89720043,256,507$ 30,286594.45
200548.535-22.04.854200513,691,497$ 127,33124918.69
200650.162-19.45.016200612,064,657$ 112,20122016.47
200741.652-33.14.165200720,574,457$ 191,34237428.08
200834.916-43.93.492200827,311,262$ 253,99549737.28
200926.769-57.023.3%2.677200935,458,261$ 329,76264548.40
201027.243-56.222.0%2.724201034,983,857$ 325,35063747.75
201142.120-32.3-20.6%est.4.212201120,106,887$ 186,99436627.45
201226.364-57.624.5%2.636201235,862,707$ 333,52365348.95
201334.931-43.9-0.0%3.493201327,295,897$ 253,85249737.26
201439.700-36.2-13.7%3.970201422,526,897$ 209,50041030.75
201536.710-41.0-5.1%est.thru June3.671201525,516,897$ 237,30746434.83
2015-200325.523.901Average23,220,815$ 215,954
Usage25.5 M gallons2004 to 2015301,870,598$ 2,807,397
Decrease1.82 kWhr/1000 gal
from 2003
NRVWaterUsage
Month/ YearWater UsageNRV Plant GallonsTrucks
gal/truck
Jan-042,2935,057,7302206
Feb-042,4795,599,8902259
Mar-042,0775,369,8302586
Apr-042,0305,321,5302622
May-042,1234,783,9202253
Jun-041,7115,999,7703506
Jul-042,0945,315,9902539
Aug-041,5363,986,0402595
Sep-041,1184,233,4003786
Oct-041,1534,507,6503911
Nov-041,3384,606,3603444
Dec-041,2163,963,2803259
Jan-051,1394,544,3503989
Feb-051,1674,323,1503705
Mar-051,1833,942,4303333
Apr-051,1024,376,2603971
May-051,0404,193,6204033
Jun-058833,561,6604032
Jul-051,1183,284,0502937
Aug-051,1253,876,3403447
Sep-058863,842,6404336
Oct-051,0044,338,0004320
Nov-051,1164,220,4403783
Dec-051,2123,752,4603095
Jan-061,2944,428,1603422
Feb-061,1574,354,2003763
Mar-069614,400,0004,578
Apr-061,0304,098,3103,979
May-068984,356,0404,852
Jun-067223,480,7404,823
Jul-068993,819,8404,247
Aug-061,1723,702,7403158
Sep-068874,075,0504593
Oct-068974,505,6205,022
Nov-061,0544,347,8704,124
Dec-061,2364,376,2603,5411,017Average 2006 gal/truck
Jan-071,7626,185,3903,511
Feb-072,6073,195,8301,226
Mar-072,2102,908,8701,316
Apr-073,1282,853,100912
May-073,9202,951,820753
Jun-072,0152,806,9001,393
Jul-071,5223,324,7002,184
Aug-072,3373,202,2501,370
Sep-071,6203,289,1302,030
Oct-071,4073,765,4502,677
Nov-071,4203,592,3002,530
Dec-071,3203,474,7002,633
Jan-081,5854,619,6502,914
Feb-0801,524,30096
Mar-082,3431,958,740836
Apr-081,3754,292,5603,122
May-081,1362,570,7902,264
Jun-081,4002,357,2301,684
Jul-082,0882,357,2301,129
Aug-082,0722,600,1201,255
Sep-081,6803,236,9201,927
Oct-081,5323,094,0002,019
Nov-082,4593,386,0901,377
Dec-081,8092,905,6651,606
216 VHD's3209 VN's1153 Mack's
NRVMonthlyWaterUsage
37987
38018
38047
38078
38108
38139
38169
38200
38231
38261
38292
38322
38353
38384
38412
38443
38473
38504
38534
38565
38596
38626
38657
38687
38718
38749
38777
38808
38838
38869
38899
38930
38961
38991
39022
39052
39083
39114
39142
39173
39203
39234
39264
39295
39326
39356
39387
39417
39448
39479
39508
39539
39569
39600
39630
39661
39692
39722
39753
39783
NRV Plant Water Usage 2004 - 2008 (gal/truck)
2292.7153218495
2478.9243027888
2076.5003866976
2029.5690312738
2123.3555259654
1711.2863662293
2093.7337534462
1536.0462427746
1118.1722134179
1152.5568908208
1337.5029036005
1216.1030991102
1139.2203559789
1166.8421052632
1182.8472847285
1102.0548980106
1039.8264319365
883.3482142857
1118.1647940075
1124.5546852335
886.2177121771
1004.1666666667
1115.6330954269
1212.4264943457
1294.0268848626
1157.1086898751
961.1183923111
1029.9849208344
897.7823577906
721.6960398092
899.4207676007
1172.4952501583
887.230568256
897.1764237356
1054.2846750727
1235.8825190624
1761.7174594133
2606.7128874388
2210.3875379939
3128.399122807
3920.0796812749
2015.0035893755
1522.2985347985
2337.4087591241
1620.2610837438
1406.5932013448
1419.8814229249
1319.6733763768
1585.3294440631
0
2342.990430622
1374.9391415759
1135.50795053
1399.7802850356
2087.8919397697
2071.8087649402
1679.7716658018
1532.4418028727
2459.0341321714
1809.2559153176
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Volvo NRV Plant – Dublin, Virginia
Cab Leak Test Water Recycling• Baseline water use for cab leak testing -
1100 gallons per truck• System installed to clean and recycle the
water used for cab leak testing. • Investment was $520,000• The benefit of recycling this water for reuse
– Water use savings of 700 gallons per truck
• This represented a plant-wide reduction for water use of 22%
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Volvo NRV Plant – Dublin, Virginia
Process Wastewater Treatment MethodThe reuse system consists of the following components:
To PlantProcesses
Cartridge Filter
UV LightUF FeedStorage
Ultra-Filtration
High Pressure Reverse Osmosis
ReuseWater
StorageUV Light
WWT
WasteWater
Storage
HPRO Feed
Storage
UntreatedWastewater
UV Light
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Volvo NRV Plant – Dublin, Virginia
Process Wastewater Reuse Drivers
• Surfactant issues at the regional authority / foaming• Molybdenum contamination of land-applied sludge • Volvo was proactive to identify its contribution to a
potential issue
Environmental Issues
Volvo Environmental Requirements• Wanted Position: To install water recycling processes
with low water usage and preferably with chemical recycling in closed loop processes
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Volvo NRV Plant – Dublin, Virginia
Process Wastewater Reuse Incentives
• Average incoming water from processes = 12M gal• Average reuse water to processes = 7.4M gal• Average annual reuse rate is 62% for process water
Environmental Sustainability
Environmental Liability / Risk Mgmt. Capital funds invested for recycling water instead of
meeting increasingly stringent environmental regulations. $1.5 MUSD vs 1.1 MUSD
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Volvo NRV Plant – Dublin, Virginia
Process WWTP Specifications
1. Average daily flow from WWTP
36,307 gallons per day
2. Maximum treated flow (WWT) = 500 gpm
3. Storage capacity of untreated wastewater
274,000 Gallons
4. Conventional precipitation system. Treats Nickel and Zinc (0.099 mg/L limit for Ni and 0.6 mg/l limit for Zn)
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Volvo NRV Plant – Dublin, Virginia
Usage Points With a Focus on Process Opportunities E-coat high-purity water (HPW) system required replacement Ran 3-4 months of water testing to baseline system to verify
performance before incorporating process needs Advantage:
Avoid additional capital expense and incorporated e-coat into reuse system instead
Disadvantages: Drives reuse water requirement to lower conductivity More frequent discharge events due to more stringent
water quality requirements
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Volvo NRV Plant – Dublin, Virginia
PROCESS
E-coat System: 15,000 to 20,000 gpd
NON-PROCESS
Humidification: 500 to 1,000 gpd
Parts Wash: 12,000 gpd
Cooling Tower: 4,000 to 6,000 gpd
Usage Points
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Volvo NRV Plant – Dublin, Virginia
System Upgrade in 2015• UltraFilter and High Pressure Reverse Osmosis replaced NF/RO
– When NF permeate conductivity > 2000 µohms/cm, the RO permeate conductivity will exceed 30 µohms for processes.• Resulting in a discharge event
– Install UF and HPRO operating at 800 – 1000 psi allowing treatment of conductivities of 45,000 µohms/cm
• Upstream of WWTP, reduce solids content of wastewater to minimize impact and loading on UF and HPRO– Install filter system to remove E-coat solids and other solids
• Improve Water Balance between production and non-production periods– Added two 17,000 gallon tanks to store clean water for reuse
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Volvo NRV Plant – Dublin, Virginia
Process Wastewater Treatment MethodThe reuse system consists of the following components:
To PlantProcesses
Cartridge Filter
UV LightUF FeedStorage
Ultra-Filtration
High Pressure Reverse Osmosis
ReuseWater
StorageUV Light
WWT
WasteWater
Storage
HPRO Feed
Storage
UntreatedWastewater
UV Light
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Volvo NRV Plant – Dublin, Virginia
Design Specifications and Installation
Ultraviolet Light (254nm) Cartridge Filtration
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Volvo NRV Plant – Dublin, Virginia
Design Specifications and Installation
Ultra-Filtration High Pressure RO
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Volvo NRV Plant – Dublin, Virginia
Process Improvement - 2015• Installed solids removal equipment for E-coat discharge to
reduce impact of process on conductivity/TDS & TSS.
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Volvo NRV Plant – Dublin, Virginia
Process Improvement - 2015
• Expand the storage capacity for reuse water to address losses associated with shutdown periods by addition of two 17,000 gallon pure water storage tanks.
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Volvo NRV Plant – Dublin, Virginia
Process Improvement - 2015• High pressure RO system will address lower conductivity
requirement for E-coat, but allow improved system reuse (provide up to 93% recovery of process water)– Operating at membrane pressures from 800 to 1,000 psi will
allow for treatment of waters with conductivities approaching 45,000 μohms/cm.
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Volvo NRV Plant – Dublin, Virginia
Reference: EPRI- 2013 - Electricity Use and Management in the Municipal Water Supply and Wastewater Industries• Public Water Supply Average w/o CEC data = 1,903 kWh/MG
– Community Surface Source = 1,600 kWh/MG– Community Groundwater Source = 2,100 kWh/MG
• Municipal Wastewater/Secondary Treatment = 2,080 kWh/MG– Greater than Secondary Treatment = 2,690 kWh/MG
• For this analysis:1903 + 2080 = 3983 kWh/MG or 3.983 kWh/1000 gallons
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Volvo NRV Plant – Dublin, Virginia
Impact of Reduction in Water Use
• Plant-wide Baseline Water Use is 62M gal• Water Use Average from 2004 to Present is 39M gal• Average Annual Reduction in Water Use is 23M gal• Plant-wide Average Cost Savings is $216,230 per yr-------------------------------------------------------------------------• WWTP reuse system savings in 2015 is ~$69,000• Increased Energy Use for WWTP reuse system is
136,320 KWH on average or $18,135/year • WWTP reuse system net cost savings is ~$51,000 in
2015
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Volvo NRV Plant – Dublin, Virginia
Nominal Benefit to the County
• County Energy Savings Based on plant water savings• 926 KWH per Year average
• At 7.5 cents/KWH, Average County Cost Avoidance• $69.46 per year
• Overall, nominal energy savings or cost benefit for the County
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Volvo NRV Plant – Dublin, Virginia
Overall Benefits for Wastewater Recycling and Reuse
• Additional energy cost to operate reuse systems is outweighed ~ 4:1 by the savings from reduced water use at county rates
• Improved feed water quality and water balance for processes
• Reduced chemical usage for non-process requirements
• Partial Fulfillment of the Volvo Environmental Goal
• Reduced environmental liability and risk with fewer discharges to POTW
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Volvo NRV Plant – Dublin, Virginia
Thank You
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Steve Pierett, C.E.M., CP EnMS, C.R.M.
Environmental Manager
Volvo Group North America, LLC 540-674-7730
Brian Kidd, Principal
ProChem, Inc.
540-268-9884
mailto:[email protected]:[email protected]
Slide Number 1New River Valley Plant, Dublin, VAOVERVIEWSlide Number 4Cab Leak Test Water Recycling�Process Wastewater Treatment MethodProcess Wastewater Reuse DriversProcess Wastewater Reuse IncentivesProcess WWTP SpecificationsUsage Points With a Focus on Process OpportunitiesUsage Points �System Upgrade in 2015Process Wastewater Treatment MethodDesign Specifications and InstallationDesign Specifications and InstallationProcess Improvement - 2015Process Improvement - 2015Process Improvement - 2015Reference: EPRI- 2013 - Electricity Use and Management in the Municipal Water Supply and Wastewater IndustriesImpact of Reduction in Water UseNominal Benefit to the CountyOverall Benefits for Wastewater Recycling and ReuseThank You Slide Number 24