1. WASTEWATER MINIMIZATION FOR A FIVE STAGE IRON PHOSPHATE SPRAY WASH SYSTEM Colin Kiefer, P 2 AD Engineer and Project Manager Mary Beth Schwefel, Metcam EH&S and Finishing Manager

2. Discussion Outline  What is P 2 AD?  P 2 AD’s Metal Finishing Initiative  Who is Metcam?  Metcam - P 2 AD Partnership  Phase I Discussion & Results Project Background Determining the Full Wastewater Cost Choosing a P2 Technology

3. Discussion Outline  Phase I Discussion & Results Crossflow Membrane Filtration Technical Principles P2 System Conceptual Design P2 System Footprint Pilot Project Results Long-Term Results Lessons Learned

4. What is P 2 AD ? A non-regulatory division of the Georgia Department of Natural Resources P 2 AD provides FREE, confidential assistance to help clients reduce waste and conserve resources Services available to any Georgia business, government agency, or institution Customized assistance to meet clients’ needs

5. P2 Technology Evaluation Project Funding Implementation Assistance How-to Knowledge P 2 AD Metcam, P 2 AD Metcam Assess effectiveness of technology or practice Quantify actual $ savings and P2 capabilities Share results with other metal finishers Metal Finishing Initiative

6. Alpharetta, GA 100,000 ft 2 Facility Precision Metal Fabrication Metal Finishing Light Assembly ISO 9001 Registered ISO 14001 (Coming Soon) 2002 Honorable Mention  Governor’s Award for Pollution Prevention Who is Metcam?

7. Metcam - P 2 AD Partnership Phase I - Alkaline Spray Cleaner & Rinse Bath Life Extension Phase II - Non-Chrome Substitute Aluminum Treatment/Coating Phase III – Join P 2 AD Partnership Program (Implement Environmental Management System)

8. Phase I – Project Background Metcam, Inc. No sewer line; cannot overflow process rinse tanks Using atmospheric evaporators for non-haz. wastewater Five stage iron phosphate washer Oil levels in Stage 2 rinse cannot exceed 10 ml/liter. Stage 2 rinse dumped twice per week (75,000 gal./year). Production increases causing Stage 2 to deteriorate faster! What Should Be Done? 1)Dump Stage 2 daily and purchase another evaporator? 2)Dump Stage 2 daily and ship wastewater offsite? 3)Reduce oil loading rate to Stage 2 rinse?

9. Phase I – Determining the Full Wastewater Cost

10. Average Sludge Concentration Factor = 94% Phase I – Determining the Full Wastewater Cost

11. Choosing a P2 Technology Ozone/Electrolysis  Convert oil and grease into usable surfactants Biological Cleaning  Biodegrade oil and grease to CO 2 and H 2 O Crossflow Membrane Filtration  Physically separate cleaner from oil and grease

12. Crossflow Membrane Filtration

13. By Keeping the Cleaner Bath “Clean” Oil Buildup in Stage 2 is Slower! Crossflow Membrane Filtration Technical Principles Rejected Oil & Solids Permeate Stream: Stage 1 Cleaner Recovered 0.1 Micron Tubular Membrane Stainless Steel - Sintered TiO 2 Retentate Oily Wastewater Dirty Stage 1 Cleaner Solution 50-Gallon Process Tank

14. 13 800 700 600 500 400 300 200 100 Permeate (ml/min.) Production Days 9876543211011121415 Process Tank Batchout & Membrane Cleaning Frequency Crossflow Membrane Filtration Technical Principles

15. P2 System Conceptual Design Stage 2Stage 1 UF Production Flow & Stage 1 Carryover O&G Removal Rinse Reuse & Stage 1 Return Alkaline Cleaner Ultrafiltration & Rinse Counterflow

16. P2 System Footprint Stage 1 Ultrafiltration SystemStage 2 Rinse Counterflow

17. Technology Evaluation Highlights Oil & Grease = 88% Removal Rate Suspended Solids = 93% Removal Rate Cleaner Chemical Usage = 64% Reduction Wastewater Generation = 94.5% Reduction W.W. & Cleaner Costs = 78% Reduction Washer-Related Rejects = 51% Reduction Pilot Project Results January 2003 to June 2003

18. Cleaner Rejuvenation - Visual Appearance METCAM PILOT STUDY STAGE 1 - JANUARY 31, 2003 FILTRATION TEST PERMEATE & 6-MONTH CLEANER BATH Pilot Project Results

19. Economic Analysis - January 2003 to June 2003

20. Pilot Project Results Permeate Flux (gal./ft 2 /day)

21. Pilot Project Results UF Operation & Maintenance Daily permeate flowrate measurements Daily visual inspection of permeate quality and pump seal leakage Daily inlet and outlet pressure checks Weekly inspection of pump connection to bed plate and pump motor alignment Every 3-4 wks. batch out process tank and clean membrane 15 Min./ Day 2 Hours/ Event

22. Pilot Project Results

29. Long-Term Results Stage 2 Wastewater Generation Before Project During Project After Project

30. Before Project During Project After Project 1.83 2.55 1.74 1.30 1.09 1.23 0.96 0.37 0.30 0.32 0.12 0.11 0.13 0.15 0.26 0.00 0.0 0.5 1.0 1.5 2.0 2.5 3.0 Sep- 02 Oct- 02 Nov- 02 Dec- 02 Jan- 03 Feb- 03 Mar- 03 Apr- 03 May- 03 Jun- 03 Jul- 03 Aug- 03 Sep- 03 Oct- 03 Nov- 03 Dec- 03 (Month) (gal./ 1,000 ft 2 ) Long-Term Results Production Normalized Cleaner Usage

31. Washer- Related Parts Rejects Annual Comparison 5.4 ft 2 / 1,000 ft 2 4.9 ft 2 / 1,000 ft 2 BEFOREAFTER Long-Term Results

32. Lessons Learned Implement UF and rinse counterflow at same time to: - Maximize cost savings and process efficiency When rejuvenating a spent cleaner bath expect: - Shorter timeframes between membrane cleanings - Difficulty in restoring permeate flux rates - Increased risk of permanent membrane fouling While rejuvenating cleaner bath, focus on: - Oil removal rates and process/product quality For surfactant recovery testing: - Wait until after bath is rejuvenated Make sure internal components of circulation pump are: - Specified for high pH, oily solutions After every batch out of the process tank: - Clean the membrane before placing it back in service

33. For More Information… Colin Kiefer - P 2 AD (404) 651-5128 Colin_Kiefer@p2ad.org Mary Beth Schwefel – Metcam (770) 475-9633 MaryBeth@metcam.com Raymond Graffia - Arbortech (815) 385-0001 sales@arbortech.com Final Project Report www.p2ad.org/pdfs/MetcamReportFinal.pdf