common sense initiative: north carolina update. common sense initiative - basic framework n metal...
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Common Sense Initiative: North Carolina Update
Common Sense Initiative - Basic Framework
Metal Finishers - agree to work toward a series of “Goals” to reduce their discharges.
Municipality - in return provides regulatory incentives and technical assistance where required.
State- technical and regulatory assistance.
Benefits of Strategic Goals Program
LOCAL POTW- reduced pollutant discharge to POTW- better working relationship with industries- less chance of NPDES violations- less time devoted to SIU permits
PLATERS- less burdensome permit requirements- less time and money devoted to environmental permits- technical assistance available
North Carolina Update
4 participating POTWs:- Raleigh, Statesville, Charlotte, Gastonia
8 metal finishers (3 site visits) Additional incentives - Air quality, power
companies, SBA Loans Stakeholder meeting (June 29) Industry Workshop (Fall)
Further Information Division of Pollution Prevention
(919) 715-6515 Greg_Newman@p2pays.org
Surface Finishing Industry Council- SFIC Robert McDowell(716) 425-7500 rmcdowel@rochester.infi.net
EPA Scott Dosick (202) 260-9211 dosick.scott@epamail.epa.gov
Zero Discharge Project at Powder Coating Operation
Hankison International, Newport, North Carolina
Randy DonleyManufacturing Engineer(252) 726-1011
Hankison International 265 employees 31,000 square ft facility Manufactures filter products and
refrigerated air dryers
Background
Established 1947 1995 Installed new powder coater Estimated discharge 1,610 gallons per day Wastewater management options??
Wastewater Management Options
No City Sewer Off site hauling $0.43 per gallon
($173,075 per year) Evaporation - curing ovens generate 3
million BTUs per day which should evaporate 600 gallons per day
Process Flow
Drying Oven Powder Coat Curing Oven
Flow of Work
Metal FormingFive stage
cleaning lineAssembly
Cleaning Line
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
Stage 5: NonChrome Seal
Cleaning Line Modifications
240 gal/shift
390 gal/shift
240 gal/shift
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
City water 740 gal/shift
Float valveFloat valve
Advantages• Greater than 90% reduction in water consumption possible• More efficient rinse - film breakdown• Reuse of dragout solution• National survey - 25% usage
BENEFITSCapital Cost = $500
Water Conservation = 217,500 gallons per year (54%)
City Water Costs = $1,011 per year ($4.65 per 1000 gallons)
Savings on Treatment Costs = $108,576 per year
Ultrafiltration Unit
240 gal/shift
390 gal/shift
240 gal/shift
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
City water 740 gal/shift
Ultrafiltration unit333 gal/shift Filtrate
150 gals/shift
BENEFITS
Capital Cost = $30,000
Water Conservation = 250,000 gallons per year
City Water Costs = $1,162 per year
Savings on Treatment Costs = $124,800 per year
Evaporation System 240 gal/shift
390 gal/shift
240 gal/shift
Stage 1: Washtank
Stage 2: Rinsetank
Stage 3:Phosphatizing
tank
Stage 4: Rinsetank
Ultrafiltration unit333 gal/shift
Filtrate toevaporator
150 gal/shift
City water 740 gal/shift
Evaporation System
Wastewater
Existing ductwork
Hot air from powdercoating furnaces
Compressedair
Filter
Evaporation Chamber3 x 3 x 10
Nozzle
Atomized spray
To atmosphereExisting ductwork
Unevaporated water return
Evaporation SystemBENEFITS
Capital Cost = $10,000
Water Conservation = NA
City Water Costs = NA
Savings on Treatment Costs = $42,000 per year
Financial SummaryModification Capital
cost ($)Annual
Operating costs ($/yr)
Water conserved
(gal/yr)
City water cost
savings ($/yr)1
Savings on
treatment costs ($/yr)
Payback period
(months)
Countercurrent rinse system 500 0 217,500 1,011.40 108,576 0.1
Ultrafiltration unit 30,000 1,000 250,000 1,162.50 124,800 2.9
Evaporation system 10,000 500 na na 420,003 2.9
Totals 40,500 1,500 467,500 2,173.90 275,376 1.8
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