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Colin Kiefer, P 2 AD Engineer and Project Manager

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?

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Colin Kiefer, P 2 AD Engineer and Project Manager

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  1. WASTEWATER MINIMIZATION FOR A FIVE STAGE IRON PHOSPHATE SPRAY WASH SYSTEM Colin Kiefer, P2AD Engineer and Project Manager Mary Beth Schwefel, Metcam EH&S and Finishing Manager

  2. Discussion Outline • What is P2AD? • P2AD’s Metal Finishing Initiative • Who is Metcam? • Metcam - P2AD Partnership • Phase I Discussion & Results • Project Background • Determining the Full Wastewater Cost • Choosing a P2 Technology

  3. 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

  4. What is P2AD ? A non-regulatory division of the Georgia Department of Natural Resources P2AD provides FREE, confidentialassistance to help clients reduce waste and conserve resources Services available to any Georgia business, government agency, or institution Customized assistance to meet clients’ needs

  5. Metal Finishing Initiative How-to Knowledge Project Funding Implementation Assistance P2 Technology Evaluation Metcam Metcam, P2AD P2AD • Assess effectiveness of technology or practice • Quantify actual $ savings and P2 capabilities • Share results with other metal finishers

  6. Who is Metcam? • Alpharetta, GA • 100,000 ft2 Facility • Precision Metal Fabrication • Metal Finishing • Light Assembly • ISO 9001 Registered • ISO 14001 (Coming Soon) • 2002 Honorable Mention • Governor’s Award for Pollution Prevention

  7. Metcam - P2AD Partnership • Phase I - Alkaline Spray Cleaner & Rinse Bath Life Extension • Phase II - Non-Chrome Substitute Aluminum Treatment/Coating • Phase III – Join P2AD Partnership Program (Implement Environmental Management System)

  8. 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? • Dump Stage 2 daily and purchase another evaporator? • Dump Stage 2 daily and ship wastewater offsite? • Reduce oil loading rate to Stage 2 rinse?

  9. Phase I – Determining the Full Wastewater Cost

  10. Phase I – Determining the Full Wastewater Cost Average Sludge Concentration Factor = 94%

  11. Choosing a P2 Technology • Ozone/Electrolysis • Convert oil and grease into usable surfactants • Biological Cleaning • Biodegrade oil and grease to CO2 and H2O • Crossflow Membrane Filtration • Physically separate cleaner from oil and grease

  12. Crossflow Membrane Filtration

  13. Permeate Stream: Stage 1 Cleaner Recovered Dirty Stage 1 Cleaner Solution 50-Gallon Process Tank Rejected Oil & Solids 0.1 Micron Tubular Membrane Stainless Steel - Sintered TiO2 Retentate Oily Wastewater Crossflow Membrane Filtration Technical Principles By Keeping the Cleaner Bath “Clean” Oil Buildup in Stage 2 is Slower!

  14. 800 700 Process Tank Batchout & Membrane Cleaning Frequency 600 500 Permeate (ml/min.) 400 300 200 100 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Production Days Crossflow Membrane Filtration Technical Principles

  15. P2 System Conceptual Design Alkaline Cleaner Ultrafiltration & Rinse Counterflow Production Flow & Stage 1 Carryover Rinse Reuse & Stage 1 Return Stage 2 Stage 1 UF O&G Removal

  16. P2 System Footprint Stage 2 Rinse Counterflow Stage 1 Ultrafiltration System

  17. Pilot Project Results Oil & Grease = 88% Removal Rate Suspended Solids = 93% Removal Rate Cleaner Chemical Usage = 64% Reduction Wastewater Generation = 94.5% Reduction W.W. & Cleaner Costs = 78% Reduction Washer-Related Rejects = 51% Reduction Technology Evaluation Highlights January 2003 to June 2003

  18. Pilot Project Results Cleaner Rejuvenation - Visual Appearance FILTRATION TEST PERMEATE & 6-MONTH CLEANER BATH METCAM PILOT STUDY STAGE 1 - JANUARY 31, 2003

  19. Pilot Project Results Economic Analysis - January 2003 to June 2003

  20. Pilot Project Results Permeate Flux (gal./ft2/day)

  21. 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

  22. Pilot Project Results

  23. Pilot Project Results

  24. Pilot Project Results

  25. Pilot Project Results

  26. Pilot Project Results

  27. Pilot Project Results

  28. Pilot Project Results

  29. Long-Term Results After Project Before Project During Project Stage 2 Wastewater Generation

  30. Long-Term Results Before Project During Project After Project 3.0 2.55 Production Normalized Cleaner Usage 2.5 2.0 1.83 1.74 (gal./ 2 1,000 ft ) 1.5 1.30 1.23 1.09 0.96 1.0 0.5 0.37 0.32 0.30 0.26 0.15 0.13 0.12 0.11 0.00 0.0 Sep- Oct- Nov- Dec- Jan- Feb- Mar- Apr- May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- 02 02 02 02 03 03 03 03 03 03 03 03 03 03 03 03 (Month)

  31. Long-Term Results Washer-Related Parts Rejects Annual Comparison 5.4 ft2/ 1,000 ft2 4.9 ft2/ 1,000 ft2 BEFORE AFTER

  32. Lessons Learned • Implement UF and rinse counterflowat same timeto: • - 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

  33. For More Information… Colin Kiefer - P2AD (404) 651-5128 Colin_Kiefer@p2ad.org Mary Beth Schwefel – Metcam (770) 475-9633 MaryBeth@metcam.com Raymond Graffia - Arbortech (815) 385-0001 sales@arbortech.com Final Project Report www.p2ad.org/pdfs/MetcamReportFinal.pdf

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