Solvent Use Reduction Project

Transcription

1 1 Solvent Use Reduction Project University of Missouri Pollution Prevention (P2) Program Engineering Undergraduates Gonzalo Saenz Mechanical Engineering James Kelsey Chemical Engineering Program supported by EPA Region 7 grant Project Goals Determine which processes generate liquid hazardous waste. Develop a proposal that will reduce liquid hazardous waste by 20%. Translate monetary savings to reduction of environmental impact.

2 Gallons Gallons Six Sigma Problem In 2009, the facility purchased 56,076 gallons of paints and solvents at a purchase cost of $1,329,207, while disposing of 29,150 gallons of liquid paint hazardous waste at a cost of $71,550. The volume of hazardous waste was equivalent to 52% of the amount of paint and solvents purchased. Solvents were used only once Paints and Solvents Purchased by Plant, Plant 4 Plant 1 Plant 5 Paint Solvent Hazardous Waste Disposal by Plant, Plant 4 Plant 1 Plant 5 Total: 56k gallons Total: 29k gallons

3 3 Research Historical data reviewed Purchase records Plant Product Waste collection worksheets Volume by plant Interns developed new data on waste generation By material type By plant By operation By equipment

4 Gallons_1 Percent Gallons_1 Percent 4 Waste generation by material type Pareto Chart of Waste Type to Pareto Chart of Solvents to Waste Type Solvent Paint Gallons_ Percent Cum % Material Butyl SS-0013 Acetone Other Gallons_ Percent Cum %

5 5 Waste generation by plant Butyl 13% SS % Plant 1 Waste Composition Alcohol 4% Paint 44% Plant 4 Waste Composition SS % Alcohol 0% Paint 27% Acetone 2% SS % Plant 5 Waste Composition Alcohol 0% Paint 19% Acetone 18% Acetone 33% Butyl 44% Butyl 0%

6 6 Waste generation by operation Robot Paint Booth Paint Line

7 Gallons Percent 7 Waste generation by equipment 1000 Pareto Chart of Equipment Qt Pressure Pot Gal Pot 0 Equipment 2 Qt Pot Bulldog 5 Gal Pot Robot Non Skid Other Gallons Percent Cum % Bulldog

8 8 Conclusion Largest source of LHW was solvents used in cleaning, and generated from the pots used on the painting line and in booths. The amount of solvent used in a cleaning process varied among operators and equipment. Use of 3 different solvent types hampered reuse efforts.

9 9 Recommendations 1. Replace hazardous solvents with one versatile cleaner Recyclable Environmentally friendly Compatibility of solvents with paints & equipment 2. Increase the solvent utilization ratio Washing stations that reuse cleaning solvents Solvent distillation (on-site vs. off-site)

10 10 Experiments Solvent abilities to remove various paints Compatibility with paint equipment Effectiveness of wash stations

11 11 Solvent Evaluation Criteria Health Recyclability Cost Sum Polyurethane Cleaning Sum Polyurethane Epoxy Cleaning Sum Epoxy Weight Options Acetone n-butyl Acetate SS S BM VertecBio Citrus I Ecolink Safe Strip Safety Kleen Crystal Clean Overall Scale 1-5 (3 is baseline) 1 is much worse, 5 is much better 1 Solvents currently in use throughout the facility 2 Score includes use in gun washing station Note: Scores calculated based on heath factors, recyclability, cost, and compatibility to each paint

12 12 Addresses Problem Wash Station Evaluation Criteria CTQ Impact Filtration Initial Cost Cost Savings Sustainability Sum Weight Options Becca Wash Stations Safety-Kleen Wash Stations Crystal Clean Wash Stations Note: Safety-Kleen and Crystal Clean wash stations use solvent blends containing hazardous air pollutants (HAPs), while the Becca system used Vertecbio Citrus 120 cleaner.

13 13 Addresses Problem Distillation Evaluation Criteria CTQ Impact Feasibility Initial Cost ROI Sustainability Sum Weight Options On-Site Distilling Off-Site Distilling

14 14 Solvents Purchased 2009 Item Price/Gal Gallons Cleaning Gals Cost Acetone $ ,160 10,044 $44,696 Butyl Acetate $7.73 6,435 4,967 $38,391 Thinner $ ,311 10,180 $101,392 Total 28,906 25,190 $184,479 New Solvent Requirements Wash Stations and Distillation Wash Stations Only Item Price/Gal Cleaning Gals Cost Cleaning Gals Cost VertecBio $9.60 5,720 $54,912 1,040 $9,984 Acetone $ ,544 $24,671 Butyl Acetate $ ,967 $30,661 Thinner $ ,455 $84,211 Total 5,720 $54, ,005 $149,527 Difference 19,470 $129, ,185 $34,952 Waste Disposal Wash Stations and Distillation Wash Stations Only Price/Gal Gallons Cost Gallons Cost Liquid Hazardous Waste (2009) $ ,150 $71,550 29,150 $71,550 With VertecBio $ ,835 $38,796 22,965 $56,264 Difference 13,315 $32,754 6,185 $15,286

15 15 Capital Investment and Recurring Costs Capital Investment Wash Stations and Distillation Wash Stations Only Equipment Name Vendor Quantity Cost Quantity Cost Becca Next80 Becca 4 $29,740 4 $29,740 Becca 55 gal Solvent Saver Spray Equip 2 $92,126 - $0 Becca HC Solvent Saber Becca 1 $7,050 - $0 VertecBio Startup Solvent VertecBio 825 $7, $384 Total $128,916 $30,124 Recurring Material Expenses Wash Stations and Distillation Wash Stations Only Materials Necessary for Equipment Cost/Unit Qty/Year Cost Qty/Year Cost Filters for Becca Next80 $ $7, $7,920 Recycler Bags for Solvent Saver $ $4,560 - $0 Recycler Bags HC $205 6 $1,230 - $0 Total $13,710 $7,920

16 16 9/28/2011 Cost Analysis Cost Analysis Wash Stations and Distillation Wash Stations Only Current Cost $256,029 $256,029 Yearly Cost for New Method $107,418 $213,711 Annual Savings $148,611 $42,318 Capital Investment $128,916 $30,124 ROI 10.4 months 8.5 months CSI Investment $29,850 $29,850 ROI w/ CSI IRAD 12.8 months 17.0 months LHW Reduction 13,315 gallons (46%) 6,185 gallons (21%)

17 17 Environmental Impacts Chemical Gallons Moles CO2 Acetone 10,000 1,560,000 n-butyl Acetate 5, ,000 SS ,200 1,610,000 Citrus I20 (1,100) (190,000) Total CO 2 Reduced 24,100 3,830, (Tons) CO 2 Equivalent 29 Vehicles 356 Barrels of Oil 18 Homes 32.6 Forest Acres

18 Marie Steinwachs Environmental Assistance Center University of Missouri 200 Engineering Building North Columbia MO

19 P2ric.org/business

20 Contact info for P2 intern programs at P2RIC.org/business