The management at this company
realized their several dozen different clientele were capable of requiring
deburring and finishing parts with a variety of incoming contaminants – namely
stamping oils, straight oils, soluble oils, rust inhibitors, parts washing
residue, etc. In short, a wide variety of chemistries and, the potential to
dissolve metals in their process were "typical". Several waste hauling
firms were contacted for haul-away quotes. Only licensed and reputable firms
were invited to quote their services. Prices ranged from 18 cents per gallon +
$75.00 an hour (min. 4 hours) trucking charge to $1.10 per gallon and no extra
trucking charge. Management agreed that the most attractive bid was a flat fee
of 30 cents per gallon. Even so, the prospect of 30 cents per gallon for 10,000
gallons per day equated to $3,000 per day! This new expense would be devastating
to this company.
SOLUTION:
Wastewater Engineers, Inc. proposed an affordable system to handle the stream.
PHASE I:
Create a closed-loop system to replace the pass-through method, which had
been used previously. Because the vibratory process generates degraded media
(various stone, plastic, ceramic, steel, etc.) the solids content was most
challenging.
Various filtration
techniques for sub-micron to larger sized solids particulate would be too costly
and/or too slow. Wastewater Engineers, Inc. engineered a floor sump with a
float-activated pump and a specially engineered baffled settling tank. Here, an
oil skimmer was installed and a magnetic canister-type bag filter was employed.
Thus, 95% of particulate volume and 75% of metal particulate could be settled
and filtered respectively. A (75) GPM, float-activated pump was used on the
settling unit to transfer treated fluid to a clean holding tank.
The entire system now has a total of
2,000 gallons. The above described mechanical methods are approximately 95%
effective in maintaining vibe fluid cleanliness, and allowed for recycling.
Depending on the "dirt
load" of incoming parts and metal burrs, the need to divert (200) gallons
for chemical treatment ranges from (1) to (2) batches per day. To accomplish a
treatment, Wastewater Engineers, Inc. provided a diverter valve, which allows
filling of a RT-200-HO Reactor. The plant custodian is the operator. Wastewater
Engineers, Inc. provided a pre-measured scoop and operator simply starts the
turbine mixer, adds the scoop of powdered reactant and allows (5) minutes of
mixing time. The mixer is then shut off and operator simply opens the drain
valves. Operator attendance is approximately (10) minutes per (200) gallon
batch. Processed fluid is automatically pumped from the RT Reactor to be
recycled in the closed loop system.
This facility has reduced their
tumbling/vibratory fluids ($385.00 per drum) from (4) drums per week to (30)
gallons and has avoided the haul-away costs entirely. Samples of the sludge and
treated fluids were sent to an independent lab for analysis. The sludge passed
TCLP, and the fluid passed local sewer discharge standards.
"I was concerned about
filling out waste manifests for a waste hauler and the possibility of future
liability for a landfill clean-up. With
this system, we are not required to haul away and we have no related paper
work", says Terry Desch, Plant Manager.
"The cost to treat the
system fluids is less than ½ the haul-away fees of our winning bidders charges
and we are saving a substantial amount of
money from our cleaning fluids purchases," says Plant Purchasing
Agent.
Case History # 2:
Fastener Manufacturer
BACKGROUND:
A large (1.2 million sq. ft.) fastener manufacturer and steel coil treatment
facility had a costly problem. This facility has a 150,000 gallon per day
Zinc/Phosphate wastewater treatment system. Despite this capability, oils
contamination from cold heading operations within the facility impose a solids
and oil burden which the waste treatment system cannot process.
The oil spills and leakage from
operating equipment is present on floors adjacent to production machines. Riding
floor scrubbers are in constant operation, (8) hours per shift, (3) shifts per
day, (6) days per week. In addition, each of (200) cold heading machine
operators maintain safe & clean conditions in work areas using mop &
bucket w/cleaner. Total dirty floor cleaner waste is over (1,200) gallons per
day.
PROBLEM: This
facility had been using a (7,000) gal. Capacity floor pit to accumulate cleaner
waste. A liquid waste hauling firm had been contracted to pickup and dispose of
this material, however; solid debris such as sand, dirt, zinc-sterate, scrap
metal particulate, etc., was left behind. Up to 25% solids began to accumulate,
thus; a special arrangement with the hauling service added solids removal to the
pick up service, resulting in a 40 cents per gallon charge. Wastewater
Engineers, Inc. was contracted and requested to propose cost savings.
Investigation and engineering studies indicated an opportunity to reduce costs
and to provide the customer with additional savings via recycling.
SOLUTION:
Wastewater Engineers, Inc. proposed an affordable system to handle the
stream.
PHASE I: Gross
Contaminants Removal. W.E., Inc. designed and built a special receiving box.
This unit features a perforated (removable) screen, which captures larger debris
such as papers, broken pallet wood chips, miscellaneous fasteners, scrap metals
and general debris. The system operator simply dumps accumulations into trash
barrels. A series of baffles in the receiving box promotes dirt settling. A pump
transfers fluids from the receiving box, through a canister type bag filter and
into a (2000) gallon capacity holding tank. The holding tank provides storage
and retention time for oils to precipitate to the surface where a belt-type oil
skimmer removes gross oils.
PHASE II: Polish
Fluids Via Batch Treatment. The riding floor scrubber operator was assigned the
responsibility of operating the treatment system. Upon demand, operator
"starts" a transfer pump to fill an RT reactor unit. W.E., Inc.
provided float & level controls and a "mix tank filled" indicator
light on the RT control panel. This allows the operator freedom to perform other
duties while the RT unit is filling. The Operator pushes "start"
button on RT unit’s turbine mixer, adds WE reactant and allows (5) minutes of
mixing and reaction time. The WE reactant initiates a process of precipitation
and agglomeration of contaminants, and; produces a large "floc" which
results in a complete separation and encapsulation of contaminants. The rapid
settling of the "floc" allows the operator to open drain/filter valves
after only (1) minute automated, operator is required to attend the
reaction/treatment batch process for less than (10) minutes per batch.
Fluids are automatically pumped via
float activated pump from the RT unit to a clean (recycling) tank. Approximately
90% of the active soap ingredients remain intact after the Wastewater Engineers
Inc. process, thus; a reduction in floor cleaning chemical can be realized.
RESULTS: Savings
in Treating Vs Haul Away This facility has saved over 60% Vs haul away and
reduced chemical floor cleaning expense by 90%.
COST SAVINGS
Hauling:
CLEARWATER
TECHNOLOGY
