water efficiency in the automotive sector...volvo group north america, llc water efficiency in the...

Volvo Group North America, LLC

Water Efficiency in the Automotive Sector

Steve Pierett, C.E.M., CP EnMS, C.R.M. Environmental Manager

Volvo NRV Plant – Dublin, Virginia

Area’s Largest Manufacturing FacilityLargest Mfg. Facility in Volvo Family

New River Valley Plant, Dublin, VA


OVERVIEW

•Examine a decade plus of water savings benefits

•Review two projects•Review water savings versus energy savings


(80.000)

(60.000)

(40.000)

(20.000)

-

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.




Chart1

20042004

20052005

20062006

20072007

20082008

20092009

20102010

20112011

20122012

20132013

20142014

20152015





By Year

x Million gals Or Percent Reduction


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


From the updated baseline of 2008, water use has increased 5.1%.

By Year

x 10 Million gals Or Percent Reduction


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


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%


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


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


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


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)


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


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


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


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


Design Specifications and Installation

Ultraviolet Light (254nm) Cartridge Filtration


Design Specifications and Installation

Ultra-Filtration High Pressure RO


Process Improvement - 2015• Installed solids removal equipment for E-coat discharge to

reduce impact of process on conductivity/TDS & TSS.


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.


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.


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


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


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


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


Thank You

Steve Pierett, C.E.M., CP EnMS, C.R.M.

Environmental Manager

Volvo Group North America, LLC 540-674-7730

[email protected]

Brian Kidd, Principal

ProChem, Inc.

540-268-9884

[email protected]

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

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