Presentation on theme: "WASTEWATER MINIMIZATION FOR A FIVE STAGE IRON PHOSPHATE SPRAY WASH SYSTEM Colin Kiefer, P 2 AD Engineer and Project Manager Mary Beth Schwefel, Metcam."— Presentation transcript:
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
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
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
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
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
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?
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)
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?
Average Sludge Concentration Factor = 94% Phase I – Determining the Full Wastewater Cost
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
Pilot Project Results Permeate Flux (gal./ft 2 /day)
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
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
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
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 firstname.lastname@example.org Final Project Report www.p2ad.org/pdfs/MetcamReportFinal.pdf