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3M – Prairie du Chien 2013 SHWEC Internship Kara Klubertanz

3M – Prairie du Chien 2013 SHWEC Internship Kara Klubertanz. Outline. Sustainability Background (3P) Project Objectives Water Reduction Process A Process B Discharge Investigation Site Wide Water Management. Pollution Prevention Pays (3P).

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3M – Prairie du Chien 2013 SHWEC Internship Kara Klubertanz

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  1. 3M – Prairie du Chien 2013 SHWEC Internship Kara Klubertanz

  2. Outline • Sustainability Background (3P) • Project Objectives • Water Reduction • Process A • Process B • Discharge Investigation • Site Wide Water Management

  3. Pollution Prevention Pays (3P) • Pollution Prevention Pays (3P) program in 1975. • Goal - eliminate or reduce sources of pollution in 3M products and processes • 10,000 3p projects since 1975. • Prevented > 3.8 billion lbs of pollution • Saved > $1.7 billion in their first year.

  4. Project Objectives • Assess water management for potential reuse or reduction • Noncontact and contact cooling water • Main focus • Process A • Process B

  5. Water Reduction • Background • Two processes • Process A • Extrudes resin to form very thin nylon or polyester fibers • Process B • Extrudes resin to form vinyl or Nylon/polyester webbing material • Significant opportunity to improve water management

  6. Process A

  7. Process A • Current water usage • Extruder • 10 GPM • Quench Tanks • 1 tank = 6 GPM • All 8 tanks = 48 GPM • Each tank vol.= 45 Gal. • Orient Tank • Volume = 278 Gal.

  8. Process A • Suggestion • Reduce flow rate in Quench Tanks by 15% • Decrease each Quench Tank volume by 1/3 • Evaluate tank design

  9. Process A • Water Reduced • 2,003,136 gal/yr • CO2 Emission Reduction • 6.016 Tons CO2/yr • Cost Savings • $10,867/yr

  10. Process A • Potential future projects • Automatic valves • Reuse Quench Tank discharge to supply Orient Tank

  11. Process B

  12. Process B • Current water usage • Extruders • 44 GPM • Quench Tank • 6-12 GPM • Temperature dependent • 435 gallon tank

  13. Process B • Replace non-contact cooling water with an Air Cooled Oil Cooler • Cools oil in extruders • Implement in 4.5” extruder

  14. Process B – Heat Exchanger • Water Reduction • 6,082,560 gal/yr • CO2 Emission Reduction • 16.843 tons CO2/yr • Average Cost Savings • $10, 540/yr

  15. Discharge Investigation • Problem • 2Q water bill increased • Research Highlights • Discharge Monitoring Reports • Production Schedules • Inconsistent with chart recorder • Maintenance • Preparing Fire Water Tanks for inspection

  16. Discharge Investigation • Conclusion • Meter • Possible obstruction or mechanical upset • Evaluate data more frequently • Cost Savings • $43,181

  17. Site Wide Water Management • Accurately meter & evaluate usage • Improve as products and operations expand

  18. Thank you to all 3M-PdC employees and to SHWEC Special thanks to David Liebl and Mary Prisby

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