Pollution Prevention from Texas Industries - InfoHouseinfohouse.p2ric.org/ref/03/02600.pdf ·...

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ST E X A S N A T U R A L R E S O U R C E C O N S E R V A T I O N C O M M I S S I O N

GI-246 (8/98)

I N D U S T R I E S

F R O M T E X A S

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P R E V E N T I O N

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Case

Study

Compendium

Preface ............................................................................................................. i

Introduction: TNRCC’s Pollution Prevention and Recycling Programs ... 1

Pollution Prevention: Making It Work .......................................................... 1

Pollution Prevention Pays ........................................................................ 1

Pollution Prevention Techniques ............................................................. 1

Product Modification ............................................................................. 1

Changes to raw materials ................................................................. 2

Modifications to process .................................................................. 2

Improvements to operation and maintenance procedures ........... 2

Source Control ....................................................................................... 2

Recovery, Reclamation, and Reuse ..................................................... 2

In-plant recovery and reuse ............................................................. 2

Off-site recovery ................................................................................ 2

Inter-industry exchanges ................................................................. 3

Treatment and Energy Recovery ......................................................... 3

Pollution Prevention Case Studies .............................................................. 3

Development of Case Studies .................................................................. 3

Call for Case Studies ................................................................................. 3

Submission of Case Studies .................................................................... 4

Case Studies .................................................................................................. 7

Appendix A, Index by Company ............................................................... A-1

Appendix B, Index by Industry ................................................................. B-1

Appendix C, Index by Waste Stream ........................................................ C-1

Appendix D, Index by Process ................................................................. D-1

TABLE OF CONTENTS

PREFACEThe Texas Natural Resource Conservation Commission

(TNRCC) provides this compendium of successful wastereduction projects to help businesses and industries with theirown efforts. The TNRCC’s Office of Pollution Prevention andRecycling (OPPR) compiles this compendium as part of itssource reduction and waste minimization efforts. These wastereduction case studies were submitted by companies that areconcerned about their waste output, are doing something aboutit, and are willing to share their experience. All case studies inthis document were written and edited by employees of thefacilities where the projects were implemented. The TNRCCwishes to thank all the companies that contributed to this effort.

Any mention of products, services, or vendors does not implyendorsement or recommendation by the TNRCC. Furthermore, thereader should not assume that processes discussed in this book areexempt from formal permitting or are unregulated by the TNRCC.

Eighty-three case studies are included in this publicationdemonstrating that many facilities are placing emphasis onpollution prevention. Along with these success stories, morethan 200 case studies from previous versions of this compendiumare posted on the Southwest Pollution Prevention Clearing-house Web site at http://www.P2.utep.edu.

The case studies in this compendium illustrate that pollutionprevention not only improves the environment, but also savesmoney, improves worker safety, and makes businesses moreeconomically competitive. You will notice that many of the casestudies are simple, low-cost solutions to common problems.Simple, low-cost solutions, often called “low hanging fruit,” areusually applicable to a wide range of facilities. We hope you findthis compendium useful; please do not hesitate to let us knowhow we can improve it in the future.

For technical assistance with specific pollution preventionquestions or for further information about this publication,please contact:

Office of Pollution Prevention and Recycling, MC-112Texas Natural Resource Conservation Commission

P.O. Box 13087Austin, TX 78711-3087

Phone: 512/239-3100Fax: 512/239-3165

E-mail: [email protected]: http://www.tnrcc.state.tx.us/exec/oppr/ppc_sec.html

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Published and distributedby the

Texas Natural Resource Conservation CommissionPO Box 13087

Austin TX 78711-3087

Barry R. McBee, ChairmanR. B. “Ralph” Marquez, Commissioner

John M. Baker, Commissioner

Jeffrey A. Saitas, Executive Director

Authorization for use or reproduction of any original material contained in thispublication—that is, not obtained from other sources—is freely granted. Thecommission would appreciate acknowledgment.

The TNRCC is an equal opportunity/affirmative action employer. The agency does not allow discrimination on the basisof race, color, religion, national origin, sex, disability, age, sexual orientation or veteran status. In compliance with theAmericans with Disabilities Act, this document may be requested in alternate formats by contacting the TNRCC at(512)239-0028, Fax 239-4488, or 1-800-RELAY-TX (TDD), or by writing P.O. Box 13087, Austin, TX 78711-3087.

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INTRODUCTION:TNRCC’S POLLUTIONPREVENTION ANDRECYCLING PROGRAMS

The TNRCC’s OPPR was established in January1992 to carry out Senate Bill 1099, the Waste ReductionPolicy Act (WRPA), and Senate Bill 1340, the OmnibusRecycling Act. To help Texans voluntarily prevent pollu-tion and minimize waste, the OPPR creates partnershipswith industrial facilities; small and large businesses; fed-eral facilities; federal, state and local governments; com-munities; schools; organizations; and individual Texans.Staff members provide regional workshops, on-site tech-nical assistance, hands-on training, and a variety of infor-mational materials.

The OPPR works to prevent pollution and waste, andto reuse or recycle what is generated. In particular, theprogram has partnered with federal facilities all over thestate to identify innovative options. CLEAN TEXAS 2000 isa statewide OPPR initiative to educate and inspire citi-zens, and to recognize achievements. EE2000 is a na-tional environmental education effort for grades K-12,which the OPPR is coordinating for the state of Texas.Recycling market development is another priority, withstaff working to create and enhance markets for Texasrecyclables. In addition to preserving natural resources,and protecting human health and the environment, OPPRprograms help Texans save money by conserving rawmaterials and avoiding disposal costs—savings that mul-tiply over time and promote economic development.

Texas law states that pollution prevention is thepreferred waste management approach for Texas indus-try. The OPPR offers results-oriented training, technicalassistance, publications, and services to aid Texas in-dustries in their efforts to prevent and/or reduce waste.As part of this effort, the OPPR has a program to pro-vide free technical assistance to facilities. Calling orwriting the OPPR will connect you with staff who cananswer questions or send you useful pollution preven-tion information.

POLLUTION PREVENTION:MAKING IT WORKPollution Prevention Pays

Can you afford the ever-increasing cost and liabilityfor disposing of your waste? Many companies havefound a solution in the concept of Pollution Prevention

Pays. They are saving millions of dollars each year inwaste management, disposal, and raw material costs.Many projects lead to direct savings. Others cost the com-pany, but pay back indirectly with reduced regulatorycompliance requirements and improved public image.

Conventional approaches to waste managementstress “end-of-pipe” treatment or “out-the-back-door”attitudes. These technologies usually remove the wastefrom one medium and place it in another. For example,conventional wastewater treatment technologies removewastes from the water as a sludge, thus creating a solidwaste disposal problem. This waste sludge is disposed ina landfill, creating a potential groundwater problem.

The Pollution Prevention Pays concept is verysimple. The costs associated with managing a waste canbe significantly reduced by improving processes to moreefficiently use all raw materials or by recovering thespent material for reuse. The concept is based on twoprincipals:1. Waste residuals from a production process represent

losses of valuable materials and energy; and2. Energy, manpower, materials, and capital must be

used to manage process wastes.

An increasing number of industries manage theirwastes by implementing reduction and minimizationstrategies. This compendium documents the projects ofvarious industries in Texas and Northern Mexico thathave applied the Pollution Prevention Pays concept toincrease their profitability while reducing their wastegeneration and/or disposal.

Pollution Prevention TechniquesSource reduction, recycling, and treatment are the

three general techniques for developing a pollution pre-vention program. Product modification and source con-trol are two subsets of source reduction while recovery,reclamation, and reuse are subsets of recycling. The fol-lowing paragraphs give examples of source reduction,recycling, and treatment projects.

Product ModificationProducts can be modified in several ways to reduce

the production of waste and accomplish source reduction.These modifications fit into the following categories:■ changes to raw materials■ modifications to process■ improvements to operation and

maintenance procedures

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Changes to raw materials - The formulation ofchemical products can be modified to eliminate the use ofhazardous materials. One example of product reformula-tion is the elimination of barium from lubricating oils. Inorder to prevent the generation of a hazardous waste fromspent lubricating oil, Texas Eastman Company contactedtheir oil supplier and arranged to purchase a substitute oilthat does not contain barium. This project prevents thegeneration of approximately 95,000 gallons per year ofhazardous waste at the facility.

Modifications to process - Modifications to produc-tion processes can reduce waste generation rates. New,more efficient equipment that generates less waste can beinstalled, or existing equipment can be modified to takeadvantage of new production techniques. For example,waste streams from five processes at Texas Eastman inLongview are now recycled rather than disposed. Thecaustic waste streams are piped for reuse in a permittedhazardous waste pretreatment unit that requires the addi-tion of caustic as a raw material. This project reduces thegeneration of spent caustic, a hazardous waste, by ap-proximately 21,000,000 pounds per year. It also elimi-nates the requirement for this waste to be treated and dis-charged to the Sabine River. Savings are $468,000 peryear with a payback period of 1.25 years.

Improvements to operation and maintenance pro-cedures - The quantity of material lost through leaks,spills, overflows, process dumps, and rejected parts canbe significantly reduced by the establishment of strict op-eration and maintenance procedures. Additionally, theproduction process must be optimized so that raw materi-als are used more efficiently. E.I. du Pont de Nemours &Company reduced its waste disposal costs by installingsolenoid valves to control packing gland flush water. Thenew valves mean that flush water flows only when thepumps are running. The estimated wastewater reductionis approximately 57,000,000 gallons per year.

Source ControlSource control accomplishes source reduction

through segregation. Segregation includes techniques toseparate the hazardous portion of a waste from the non-hazardous portion. Source control is the simplest, lowest-cost waste reduction technique. The total volume of haz-ardous waste can be reduced by segregating and handlingthe hazardous portion of a waste separately from the non-hazardous portion. Additionally, the overall quantity ofprocess waste can be reduced by segregating materials thatcan be recovered and reused. The Amoco Chemical Com-pany, Chocolate Bayou Plant, has reduced its annual rawmaterial and waste disposal costs through segregating and

reusing waste material. These steps saved the plant and itsapproximately 900 employees more than $200,000 in1990. They also earned the Environmental ExcellenceAward from EPA in 1989.

Recovery, Reclamation and, ReuseRecovery, reclamation, and reuse are examples of

ways to recycle wastes or other residuals from productionprocesses. These can be further divided into the follow-ing categories:■ in-plant recovery and reuse■ off-site recovery■ inter-industry exchanges

In-plant recovery and reuse - In many cases, thebest place to recycle process wastes is within the produc-tion process itself. Contaminated raw materials are excel-lent candidates for in-process recovery. Such recoverycan significantly reduce raw material purchases and therelated production costs.

For example, FMC in Pasadena developed a newprocess to recover methanol from a hydrogen peroxideunit. The distillation of methanol solvent is a standardprocess; however, the distillation of methanol contami-nated with hydrogen peroxide requires special consider-ation. Hydrogen peroxide in an organic solution presentsa decomposition hazard. As a result, a team of FMC en-gineers and scientists modified the conventional distilla-tion with direct steam injection. Steam injection is a moreefficient way to transfer energy into the column and pro-vides the necessary dilution to lower the hydrogen perox-ide concentration.

Spent methanol, a hazardous waste at the FMCBayport plant, has been eliminated. Based on 1992 pro-duction rate, FMC estimated that 318,000 gallons(2,271,000 pounds) of hazardous waste were eliminated.This resulted in annual savings of $276,000 from avoideddisposal costs and a $108,000 savings from the reducedpurchase of new raw materials.

Off-site recovery - Wastes can be recovered at anoff-site facility when the equipment is not available torecover waste on-site, or not enough waste is generatedto make an in-plant system cost effective. Off-site recov-ery techniques are similar to those available for on-siteuse, but benefit from magnitude-of-scale considerations.Waste solvents and oils are good examples of wastes thatare commonly recovered off-site. Other good candidatesinclude materials that cannot be directly reused by an on-site process, but can be used by another industry.

For example, Anheuser-Bush, Inc. in Houston gener-ates a waste stream containing a concentrated thick syrup

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with approximately 50 percent total solids. This syrup issold to a liquid animal feed producer that blends it withmolasses and whey to produce a high quality animalfeed. This process reduces annual sewer costs by ap-proximately $1,500,000 while increasing fuel, water, andelectric costs a small amount. Some revenues are gener-ated from the sale of the brewer’s condensed solids.

Inter-industry exchanges - In many cases, wastematerials from one facility can be transferred to anotherfor use as a raw material. The inter-industry exchangebenefits both companies by reducing waste disposal costsfor one while reducing raw material costs for the other.One Texas company currently earns $10,000 annuallythrough an ongoing inter-industry transfer of spent ure-thane material. In addition, the company avoids $40,000in waste disposal costs.

The Resource Exchange Network for EliminatingWaste (RENEW) at the TNRCC was established as a freeservice to help bring interested companies together forinter-agency exchanges. The RENEW waste exchangeprogram can be reached at 512/239-3171 or you cancheck its online listings at http:/www.tnrcc.state.tx.us/exec/oppr/renew/renew.html.

Treatment and Energy RecoveryTreatment and energy recovery are examples of the

broader category of treatment. Treatment always comesat the end of a process and will always cost the companymoney because they are driven by regulatory complianceor company image. When the waste has a high heatvalue, treatment in the form of energy recovery can offera partial payback. Industrial boilers and cement kilns aretypical energy recovery units for treating hazardouswastes.

Thermal oxidation units are often used to control va-pors from process units and storage tanks. Texas Eastmanin Longview vents two process units and more than 40tanks to a thermal oxidation unit preventing more than100,000 pounds of Toxics Release Inventory (TRI) emis-sions from being released to the atmosphere. This tech-nology can be expensive to operate and does not allowfor potential cost savings from the capture and reuseof vapors.

POLLUTION PREVENTIONCASE STUDIESDevelopment of Case Studies

The pollution prevention case studies in this compen-dium contain brief summaries of projects for reducingwaste generation and increasing cost savings. By usingthe methods discussed in the previous section, these fa-cilities are saving millions of dollars in raw material andwaste disposal costs. Furthermore, they have signifi-cantly reduced the volume of wastes they release to theair, land, and water.

The Texas Legislature, in the Solid Waste DisposalAct (Texas Health and Safety Code, Chapter 361)enacted a waste disposal hierarchy for those facilities thatgenerate, treat, store, and dispose of hazardous waste.The following waste disposal hierarchy is ranked in theorder of preference and should be followed based on eco-nomic and technologic feasibility:1. minimization of waste production (source reduction)2. reuse or recycling of waste, or both3. treatment to destroy hazardous characteristics4. treatment to reduce hazardous characteristics5. underground injection6. land disposal

Case studies identify the waste hierarchy position ofpollution prevention projects along with other importantcost savings information like energy recovery, and theconservation of water or electricity. The case studies canbe from any industrial sector including chemical, elec-tronic, metal finishing, general manufacturing, and ser-vice. All case studies are indexed by company, industry,waste, and process to help facilitate the usefulness ofthis manual.

Call for Case StudiesTexas industries are some of the largest generators of

hazardous waste in the nation. Some facilities have gonebeyond obeying the laws by devising new, innovative,and profitable ways to reduce waste and emissions. Theenvironment in Texas benefits when facilities share infor-mation and techniques about pollution prevention. Casestudies demonstrate the efforts industry leaders have madein pollution prevention and provide a means of sharing thisuseful information. Case study projects may include sourcereduction, energy and water conservation, recycling, wasteexchange, reuse, reclamation, or treatment.

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Submission of Case StudiesTo submit a case study, prepare a one-page typed

summary of the project using the attached format.Please include a description of the project or process,explain any innovative application of technology, dis-cuss the environmental impact, and quantify the finan-cial benefits. A blank form is included for your use incompleting and submitting a case study and an environ-mental accounting worksheet is included to help youwith the financial analysis of your project. A PC-basedsoftware version of this worksheet is available if youcontact the OPPR’s Engineering and Technical Assis-tance Team at 512/239-3100. Case studies can also besubmitted on diskette or through the Internet as either atext file or a WordPerfect file.

After your final approval, the case study becomespublic information and will be included in the compen-dium. Each case study is also posted to the SouthwestPollution Prevention Clearinghouse Web site at http://www.utep.edu/im3/p2. Case studies in this Web site aresearchable by waste, substance, industry, process, andequipment.

Please submit case studies to :

Engineering and Technical Assistance TeamTNRCC/OPPR, MC-112

PO Box 13087Austin TX 78711-3087

Phone: 512/239-3100FAX: 512/239-3165

E-mail: [email protected]

Use the following format to submit a case study:

1. General InformationCompany name:

CLEAN INDUSTRY 2000 member? ❑ Yes ❑ NoCLEAN TEXAS STAR member? ❑ Yes ❑ NoTexas’ (formerly Governor’s) Environmental

Excellence Award Winner? ❑ Yes ❑ NoLocation:Number of employees:Industry:Waste reduced:Process:Contact person: (Include name, phone number,

and e-mail address of a person who can answerquestions about the project)

2. Description of the ProjectDescribe the environmental problem, waste stream, oremission of concern and point out the waste hierarchylevel. In general terms, describe the techniques, equip-ment (including name of vendor), processes, procedures,or management programs developed or utilized in yourproject. Projects must be in place, not proposed or un-der construction. Do not include proprietary or confi-dential process information; general concepts are suffi-cient. Also, describe any regulatory issues, if applicable,related to the project. If the project included an innova-tive management tool, describe how the organizationbenefited in addition to the benefit to the environment.

3. Innovative Application of TechnologyDescribe any novel or innovative advances in technologyor management. Feel free to identify sources of equip-ment or services used.

4. Environmental BenefitsDescribe the environmental or safety benefits resultingfrom implementation of your project. Include quantitativeinformation about the total reductions (weight or volume)of waste, raw materials, energy, or emissions. In addition,indicate any regulatory requirements that have been re-duced or eliminated by implementation of this pollutionprevention project.

5. Cost Savings/BenefitQuantify the following:1. pay-back period of the project;2. cost savings due to avoided disposal costs;3. savings from reduced material or energy usage; and4. savings from reduced regulatory requirements,

reduced environmental liability, or other hiddencosts. Use the environmental accounting worksheetor software to help simplify your calculations. Costsavings information is essential in promotingpollution prevention.

Company Name: __________________________________________CLEAN INDUSTRY 2000 Member? ❑ Yes ❑ No

CLEAN TEXAS STAR Member? ❑ Yes ❑ NoTexas’ Environmental Excellence Award Winner? ❑ Yes ❑ No

1. GENERAL INFORMATION

Location: ___________________________________________________________

Number of Employees: ________________________________________________

Industry: ____________________________________________________________

Waste Reduced: ______________________________________________________

Process: ____________________________________________________________

Contact Person _______________________________________________________

(name, telephone number and e-mail)

2. DESCRIPTION OF THE PROJECT

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

3. INNOVATIVE APPLICATION OF TECHNOLOGY

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

4. ENVIRONMENTAL BENEFITS

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

5. COST SAVINGS/BENEFIT

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

CASE STUDIES

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Alpha Omega Recycling, Inc.alpha.97


Location: Longview Number of Employees: 26Industry: Metal RecyclingWaste Reduced: Spent Chromic Acid SolutionProcess: Purification/Reduction/RecoveryContact Person: Wayne Wilson, (903) 297-7272Information Current as of: January 1998

2. DESCRIPTION OF PROJECT

Surplus, spent, and waste chromic acid are typically disposed of through deep well injectionor stabilization/landfill. Until recently, Alpha Omega Recycling accepted this material in smallquantities and recovered the metals using costly reagents and time consuming processes. In1995, equipment was installed to shorten the processing time, but expensive reagents werestill required. Recently, waste, off-spec, and surplus materials have been used successfullyto recycle the contained metals and eliminate a very toxic hazardous waste disposal problem.


Waste chromic acid solution usually contains several metals other than chromium. Thesemetals are removed by simple neutralization and filtration leaving a pure sodium chromatesolution. At this point, waste, off-spec, and surplus acids, along with scrap iron materials areused to reduce the chrome to the trivalent state. After neutralization, the resulting ferro-chromium solid is marketable for use in the steel industry. The need for this service is sogreat that dedicated equipment is being installed to increase capacity.

4. ENVIRONMENTAL BENEFIT

Since waste chromic acid solutions are extremely toxic, and land disposal by stabilization ordeep well injection is not a long-term solution, the process is an environmentally soundalternative. By reusing the chromium, a very serious threat to the environment is eliminated.At the same time, scrap iron and waste acids are consumed in the process.

5. COST SAVINGS/BENEFITS

The program is cost competitive with other disposal methods and will continue to provide asound recycling venue for waste chromic acid for many years.

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Amocoamoco2.97


Location: Alvin - Chocolate Bayou PlantNumber of Employees: 800Industry: Olefins and Polypropylene ProductionWaste Reduced: BenzeneProcess: RecyclingContact Person: Brian Dinsmoor, (713) 581-3201Information Current as of: January 1998


The project goal was to recycle, rather than treat, benzene waste. The option of recyclingbenzene was chosen over treatment to minimize exposure to personnel and reduce potentialfuture liabilities and operating costs associated with treatment.


Total benzene in waste generated was 370 tons per year. A major waste stream is a closedhydrocarbon blowdown system that collects benzene containing materials from the olefinsunits for direct recycling to the process. Some large water streams, representing anothermajor benzene stream, are directly piped from process equipment to a storage tank and arefed to recovery columns to recycle and produce a clean wastewater stream. Small volume,low benzene concentration streams continue to go to the process sewer. These streams,containing less than six tons per year of benzene, are also sent to the benzene recoverycolumns. The benzene and other hydrocarbons recovered from all these streams are recycledto the olefins process.


Total benzene emissions to air from wastewater have been reduced by about 100 tons peryear. Most of this reduction is due to recycling of benzene containing streams before theyenter wastewater. Furthermore, 140 tons per year of other hydrocarbons (toluene, xylene,etc.) are recycled along with this benzene. Since most streams are recycled through a closed-loop process, benzene exposure potential to our plant personnel is greatly reduced.


The initial capital cost was $50 million. The cost savings are due to reduced hazardous wastedisposal and regulatory burden, but environmental and employee benefits are greater.

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APAC-Texas, Inc., Trotti & Thomson Divisionapac.97


Location: BeaumontNumber of Employees: 150Industry: Highway Heavy ConstructionWaste Reduced: 55-gallon steel drumsProcess: Concrete Paving OperationsContact Person: Roger Tutt, (409) 866-1444Information Current as of: January 1998


APAC-Texas, In., Trotti & Thomson Division, converted from 55-gallon steel drums toreusable bulk containers for concrete curing compound. By purchasing concrete cure in 250-gallon reusable totes, we were able to eliminate the handling, storage, and most importantlythe disposal of the 55-gallon steel drums.


N/A


Since the 55-gallon drums were not reusable and could not be recycled because theycontained a resin-based concrete cure, we were able to eliminate the disposal ofapproximately 100 drums per year into the local landfills. The disposal of the compoundresidue in the drums had to be handled separately and placed in injection wells. Both theseprocesses were eliminated.


The savings in disposal costs from the drums and the curing compound residue resulted in asavings of approximately $6,000 per year.

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ASARCO Incorporatedasarco.97


Location: Amarillo Copper Refinery (ACR)Number of Employees: 610Industry: Copper RefineryWaste Reduced: Purchase of Aquifer WaterProcess: Storm Water Runoff UtilizationContact Person: Pat Donovan, (806) 381-3134Information Current as of: January 1998


The storm water runoff at this site has historically been managed as two parts: east side runoffand west side runoff. All of the runoff is channeled via earthen ditches into a series of earthenretention ponds. The runoff from the east side of the plant contains metals, primarily copper.This project was conceived so that ASARCO can recover the metals and reuse the water.


The storm water runoff utilization project will catch the east side runoff in a double linedpond of approximately five million gallon capacity. This pond will have leak detection andwill allow water to run freely into it due to the elevations of the property and ditches. Thewater will be pumped to a filter press and then to the boiler plant for use as makeup water.


Water is a vital resource in the Texas panhandle. This project will reduce the amount ofwater that is currently pumped from the Ogallalla aquifer and from Lake Meredith for use atASARCO. The water can be used beneficially rather than be lost to evaporation. Waterconservation is a very sound environmental practice.


When there is a storm event, there will be a significant savings in the amount of waterpurchased from the city. A two year storm event will generate 4.7 million gallons of runoff.This runoff is softer water than the purchased lake water and should also create a savings inwater treatment at the boiler plant.

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BP Chemicals, Inc.bpchem1.97


Location: Port LavacaNumber of Employees: 150Industry: ChemicalsWaste Reduced: WastewaterProcess: PipingContact Person: Van A. Boone, (512) 552-8642Information Current as of: January 1998


A project was initiated in 1995 to install a full containment system for an abovegroundpipeline called the “Sleeperway Corridor”. The transfer pipeline is approximately one milelong and extends from the manufacturing unit to the barge terminal. The new concretecontainment system is designed to collect major and/or minor spills of products, rawmaterials, or wastewater from the pipeline. It will also prevent spills from contaminatingstorm water, groundwater, soil, and the Victoria Barge Canal.


The corridor was paved with post-tensioning concrete which reduces the number ofexpansion joints from one every 20 feet to one every 200 feet. Two concrete containmentstructures were designed to hold the volume from a 9.5 inch rainfall event and the largest pipebursting at the same time. The one mile expanse of newly concrete lined corridor cradles theseries of pipelines and is 50 feet wide at its base and approximately 20 feet deep with slopingwalls. The corridor will empty into one of two 1.5 million gallon concrete containmentstructures.


The containment unit will prevent an accidental release from entering ecologically sensitivesurface waters and will also prevent extensive soil and groundwater contamination resultingfrom a potential spill from the corridor.


The initial capital cost was $4 million, but the benefit of this project is not measured in termsof annual cost savings. The success is measured in terms of the potential to eliminateenvironmental degradation and the cost of spill remediation.

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Corpus Christi Army Depotccad1.95


Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Autoclave Body/Skin PanelsContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


The project consisted of installation of three electric autoclaves (pressure vessels) forrepairing and recycling damaged helicopter body/skin panels. By using the autoclave, lesssolid wastes are generated. The first of the three went on-line in 1982. The other two wereinstalled in November of 1991.


The electric powered autoclave operates up to 900 degrees Fahrenheit, 300 psi, with avacuum of 20 inches of mercury. This process allows for the recycling and reuse ofequipment instead of disposal of defense sensitive equipment. The body/skin panel life hasincreased 8 fold and has lowered operating costs. Lower hazardous wastes are due to sourcesubstitution from higher to lower VOC adhesives and autoclave use.


The autoclave uses less toxic, lower VOC content film adhesives that activate undertemperature and pressure. Field repair autoclaving would use more toxic, higher VOCcontent, wet - two part adhesives containing listed hazardous carrying agents that functionat room temperature. Therefore, through the new process there are less emissions andpotential hazardous wastes.

5. COST SAVINGS

Initial capital costs were $2 million. They are saving $850,000 a year due to reduced scrapgeneration and hazardous material costs. The payback is just over one year.

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Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous WastesProcess: PharmacyContact Person: Steve R. Connor, (512) 939-2733Information Current as of: January 1998


The development and implementation of a comprehensive pollution prevention program. Thisproject was aimed at reducing the amount of hazardous substances produced by it’soperations. There was no system in place for tracking chemicals after delivery. Manychemicals were shelved and forgotten about until they were expired and then thrown out ashazardous waste. Numerous man hours were spent searching the 155-acre depot for a neededchemical.


In 1993 a hazardous materials management system was implemented. All chemicals weregathered for an inventory. The old materials were disposed of as hazardous waste and newmaterials were bar coded. Ten new buildings were installed around the depot for issuingchemicals. Networked computers were installed in each to keep track of all chemicals.Computers keep track of user, dates of use, shelf life, and where the chemical is located onthe depot.


Reduced excessive quantities of chemicals ordered from $6.5M to $4.7M each year. Reducedwaste associated with chemicals being lost and expiring on the shelves. Improved workersafety by reducing hazardous waste exposure.


Fiscal year 1993 was used as a baseline year. Gross recovery for fiscal year 1994 was $1Mwith initial investment cost of $360,000. Net yield was $690,000. The majority of the initialinvestment went to the computer tracking system. Gross recovery for fiscal year 1995 was$2.58M with investment of $285,000. Net recovery was $2.23M.

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Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Chrome Oxidation & Recovery SystemContact Person: Chuck Gains, (512) 939-4170Information Current as of: January 1998


In November of 1991, a system was designed to reduce the amount of hazardous wastegenerated by installing 5 additional electrodialysis units to process, collect, recycle and purifyheavy metal plating solutions. This unit was “hard piped” into the manufacturing process andoperated continuously as part of the plating process.


A system that reclaims chromium from plating bath solutions and rinse tanks by oxidizingchromium oxide from the trivalent form to the hexavalent form which can be more readilyreused.


The new process lowers hazardous material procurement due to reuse. Hazardous wastegeneration has been reduced by 88% due to the internal recycling of media.

5. COST SAVINGS

Initial capital cost was $340,000 with a payback period of 5 years. Savings come from loweroperating costs, decreased part rework, improved process maintenance and control, and lowerprocurement costs.

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Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Waste OilProcess: Reclamation UnitContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


In November of 1992 a system was designed to reduce the amount of off-set transfers ofgenerated waste lube oils. Three mobile recovery units were installed to recycle and extendthe life of lubrication oils.


This process was designed to purify and remove dirt, solids, and moisture from processmachines during their actual productive use and without shutdown. The machine and lubeoil life increased up to 3 fold.


The waste oil reclamation unit decreased hazardous materials generation through the internalrecycling of media.

5. COST SAVINGS

The initial capital cost was $88,000 with a savings of $20,000 annually. The savings are dueto lower operating costs, the reuse of waste oil, the increased life of the machine, and thereduction of costs associated with used oil regulations. The payback period is 4 years.

16



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Autoclave Helicopter BladesContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


An autoclave pressure vessel was installed in November of 1995 that allows for full serviceand comprehensive rebuilding of entire helicopter blades. It also has the capability ofreplacing de-icing mats and removing moisture from main and tail rotor blades during thecuring process.


Corpus Christi Army Depot (CCAD) installed the largest national gas fired autoclave in theUnited States. It is 10 feet in diameter and 50 feet long. The autoclave operates at 650degrees Fahrenheit, 165 psi, with a full vacuum of 29 inches of mercury. It allows forrecycling and reuse of defense sensitive equipment which was previously disposed of. Thissystem decreases blade scrap generation and hazardous air pollutant emissions while loweringhazardous material usage, due to source substitution from higher to lower VOC adhesives andautoclave use.


This system uses less toxic, lower VOC content, film adhesives that activate undertemperature and pressure. Field repair would use more toxic, higher VOC content, wet - twopart adhesives containing listed hazardous carrying agents that function at room temperature.Therefore, reducing emissions, potential hazardous wastes, and solid wastes.

5. COST SAVINGS

The initial capital cost was $2 million. CCAD saves over $850,000 in scrap metal, hazardouswaste generated, and air emissions. The payback period is just over one year.

17



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Nitrogen Ion SystemContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


The Corpus Christi Army Depot (CCAD) installed a machine designed to harden drills andcutting surfaces in order to extend wear life. This process increased machine tool life 2 to 4fold causing operating costs to decrease. All functions of this unit are controlled by a fullydiagnostic computer.


Ions of one element are implanted into the atomic structure of metal objects being treatedwithout affecting the underlying, substrate’s structure. Parts are placed in a 3 foot by 3 footvacuum chamber on a rotating plate and implanted, at the speed of light, by acceleratednitrogen ions from an electronic source (100,000 volts - 40 milli amperes). Nitrogen ionsbombard and penetrate the steel surface of the parts and become trapped between the steelmolecules.


Ion implantation on a molecular level strengthens the mechanical properties such as hardness,tensile strength and corrosion resistance of metals. This strengthening extends the life andreduces machine tool scrap and parts disposal. Ion implantation also replaces other methodsof tool sharpening which use oils and hazardous substances.

5. COST SAVINGS

The initial capital cost was $332,000 with a yearly savings of $133,000 per year. Thesesavings are credited to extended life of tools and parts, decrease in scrap disposal, anddecrease in hazardous substance use. The payback period is approximately 2 ½ years.

18



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Laser Paint StrippingContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


In December of 1995, CCAD replaced a manual method of stripping paint of helicopterblades with a laser paint stripping method. The laser removes some or all of the coatingsdown to substrate material without damage to the blade. The process replaces a minimumlabor cost of two man days per blade and lowers operating costs.


This is the first such unit in the world. A pulsed carbon dioxide laser removes paint, primer,adhesive, and an abradable coating. This system is equipped with a spectral camera whichprovides real-time monitoring of the laser and the progress of paint removal. The laser hasthe capability to remove any coating on a helicopter blade on a depth selective basis (layer bylayer possibility).


Hazardous waste generation and recyclable residues are reduced by 90%. Since it removesonly the paint necessary, hazardous wastes and air emissions are reduced.

5. COST SAVINGS

Initial capital costs were $1.8 million with an annual savings of $390,000 per year. Thesesavings were due to reductions in hazardous wastes, residue, and air emissions. The paybackperiod is approximately 4 ½ years.

19



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Ultrasonic CleaningContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


A system was installed in April of 1994 that replaced the current solvent-based degreasers andparts washers. The old equipment used 1,1,1 Trichloroethane (TCE) which is a hazardouswaste.


The installation of ultrasonic cleaning equipment replaced a process that ceased productionas of December 31, 1995. CCAD has experienced lower operating costs since theimplementation of this equipment.


Reduced or eliminated hazardous wastes from cleaning units that used chlorinated solventdegreasers and cleaners. TCE is a volatile solvent resulting in a high evaporation rate andrelease of volatile organic compounds (VOC). The removal of this substance eliminates aClass I ozone-depleting substance.

5. COST SAVINGS

Initial capital costs were $487,000 with a yearly savings of $198,000. The savings are dueto a reduction in hazardous waste regulations and disposal. The payback period isapproximately 2 ½ years.

20



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Aqueous-Based CleanersContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


A system was installed in December of 1994 that reduced the amount of hazardous wastesgenerated by solvent-based degreasers and parts washers. The old equipment used 1,1,1Trichloroethane (TCE) which is a hazardous waste.


The installation of 6 agitated aqueous units and 7 high pressure aqueous spray units replaceda process that ceased production as of December 31, 1995. CCAD has experienced loweroperating costs since the implementation of this equipment.


The system reduced or eliminated hazardous wastes from cleaning units that used chlorinatedsolvent degreasers and cleaners. TCE is a volatile solvent and is considered an ozonedepleting organic compound. The removal of this substance eliminates a Class I ozonedepleting substance and reduces hazardous waste volumes.

5. COST SAVINGS

The initial capital costs were $577,000 with a yearly savings of $248,000. The savings arefrom the reduction of hazardous waste regulations and disposal. The payback period isapproximately 2.3 years.

21



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: VOC EmissionsProcess: Plastic Media Blasting RoomContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


In September of 1994 a system was installed to reduce the amount of volatile organic carbon(VOC) emissions into the atmosphere from chlorinated solvents used in chemical strippingof parts and components. The system provides a walk-in blast booth in the airframe cleaningshop to remove paint from large helicopter parts after disassembly and before rebuilding.Noise levels outside the booth have been measured at 80 db, below the OSHA threshold limitof 85 db.


This system can remove polyurethane, epoxy, epoxy/phenolic coatings from titanium, steel,magnesium and fiberglass substrates. The blast booth can operate continuously for a periodof 4 hours before reloading. An automated pneumatic floor recovery system can returnusable blast media without interruption of the operation of the unit. The blast booth measures10 foot by 10 foot by 10 foot and can handle large aircraft sections such as a helicopter door.


Once the blast media can no longer be reused, the plastic media containing paint wastes areshipped off-site for disposal as nonhazardous waste. Besides the internal recycling of media,the new system replaces methylene chloride which is a hazardous waste. CCAD nowproduces zero hazardous air pollutant (HAP) emissions with this new technology.

5. COST SAVINGS

Initial capital cost was $122,000 with an annual savings of $11,000. Savings are fromimproved paint stripping rates, more selective stripping processes, lower operating costs, andreduction of hazardous waste regulations and disposal costs.

22



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: Stripping of Metal Spray CoatingsContact Person: Chuck Gawanes, (512) 939-4170Information Current as of: January 1998


A high pressure water jet stripping project was implemented in March of 1995. This projectis designed to remove metal spray coatings, flame spray, and corrosion off of metal engineand transmission parts.


This process replaces inorganic acid solutions which take more time. The system uses a55,000 psi at 3 gallons per minute robot-operated water jet in a 3 foot diameter treating area.The water jet is pre-programmable and can clean up to five parts in one operation.


The new process which only takes 15 to 20 minutes is nonhazardous and replaced a chemicalstripping process that took 24 hours with metal bearing material as a hazardous waste. Thewastewater stream has been reduced by 90% with the internal recycling of media.

5. COST SAVINGS

The initial capital cost was $900,000 with a yearly savings of $1.3 million. The savings aredue to faster stripping rates, lower operating costs, and reduction in hazardous wasteregulations and disposal. The payback period is 8 months.

23



Location: Corpus ChristiNumber of Employees: 3,500Industry: Helicopter MaintenanceWaste Reduced: Hazardous SubstancesProcess: High Pressure Water Jet Paint StrippingContact Person: Chuck Gawanes (512) 939-4170Information Current as of: January 1998


By February of 1996 a new method for removing paint coatings and corrosion off of metalengine and transmission shipping containers was implemented. The new system replaced theinorganic acid solutions which took more time.


The high pressure water jet system removes paint coatings in 15 to 20 minutes while thechemical stripping took 24 hours with metal bearing material as a hazardous waste. Thesystem uses a 55,000 psi at 3 gallons per minute robot-operated water jet. The waterjet ispre-programmable and can clean up to three parts in one operation.


Process wastewater is now closed-looped through a purification system with only solid metalsas a waste by-product.

5. COST SAVINGS

The initial capital costs were $1.5 million with a payback period of less than three years.Savings are generated through the faster stripping rates, lower operating costs, and reductionof hazardous waste.

24

Dickson Weatherproof Nail/CDC Coatingscdc1.97


Location: ChannelviewNumber of Employees: 70Industry: Manufacture & Mechanical Galvanizing of FastenersWaste Reduced: Sulfuric Acid, Caustic Cleaners, Oily WastewaterProcess: Machine & Process ModificationContact Person: Gary R. Edwards, (281) 452-4511 ext.205Information Current as of: January 1998


Nails to be galvanized were contaminated with cutting oil from an upstream process. Thenails were cleaned prior to galvanizing in a 150EF-200EF bath containing alkali- andsurfactant-based cleaners. The final cleaning step involved a sulfuric acid dip. Nails that werenot properly cleaned resulted in poor adhesion of the coating. These nails had to be strippedin the sulfuric acid and then recleaned as described previously. During a modification to theupstream machines that was intended to increase the productivity, it was noted that thecutting oil was no longer needed. Since the nails entering the galvanizing process werecleaner, only a brief surface preparation in the galvanizing tumbler was required. Since thissurface preparation step in the intial step in the galvanizing process anyway, no loss ofproduction or increase in chemical use was observed.

Some adhesion problems still occasionally arose, so there was reluctance to eliminating thecleaning line entirely. Further experiments showed that, by increasing the drying oventemperature slightly, the adhesion problems could be completely eliminated. This allowed forthe elimination of the cleaning line and the acid stripping bath.


N/A


This project eliminated the generation of 9.4 tons per year of sulfuric acid waste and aboutthree tons per year of caustic waste. In addition, the generation of an oily wastewater waseliminated and control of the wastewater treatment system improved.


A savings of $4,200 per year was realized from the reduction in the use of sulfuric acid andthe elimination of the caustic cleaner. Other cost savings include about $500 per year incutting fluid and about $5,000 per year in natural gas used to heat the caustic tank.

25

Dickson Weatherproof Nail/CDC Coatingscdc2.97


Location: ChannelviewNumber of Employees: 70Industry: Manufacture & Mechanical Galvanizing of FastenersWaste Reduced: TRI Zinc and Lead Compounds in WastewaterProcess: Process Improvements and Water ReuseContact Person: Gary R. Edwards, (281) 452-4511 ext.205Information Current as of: January 1998


Currently, zinc is precipitated out of wastewater from the galvanizing department and“released” to the environment when it is land-filled as a component of sludge. Some zinc isalso released through a permitted outfall. Trace amounts of lead, found as a contaminant ofzinc, are also released in both sources. Improvements in the efficiency of the galvanizingprocess through the use of proprietary chemicals and a purer grade of zinc reduced theconcentration of both lead and zinc in the wastewater and hence in the sludge.

In a process integral to galvanizing, about 20,000 gallons per day of fresh water were usedto pump a slurry. It was found that fresh water was not needed for this purpose, so a totallyenclosed system was constructed by rerouting existing pipe and reallocating existing tankstorage. This reduced the wastewater flow by 20,000 gallons per day and resulted inimproved control of the wastewater system.

Further reductions in the wastewater flow were realized by using treated wastewater in non-critical applications, such as preliminary rinses, solution make-up in galvanizing, and polymerand caustic dilution in the wastewater treatment system. This reduced the wastewater flowby another 10,000 to 15,000 gallons per day.


Through the use of treated wastewater in non-critical applications and using a totally enclosedsystem for pumping the slurry, wastewater flow was reduced by 30,000-35,000 gallons perday.


A reduction in the wastewater flow brought us well into compliance with our permittedwastewater discharge. The lower flow rates improved the performance of the wastewatertreatment system, thus reducing the amount of zinc and lead released through the out fall.

Improved zinc use efficiency in the galvanizing operation not only reduced zinc and leadconcentrations in the wastewater but also in the sludge. The improvements lead to a

26

reduction of about 12,000-15,000 pounds per year of lead and zinc released to theenvironment, primarily in the sludge.


Cost savings were realized primarily from the improvement in zinc use efficiency. Estimatesare in the range of $42,000 per year. Improved compliance with our discharge permit andreduced environmental impact were the main driving forces behind these projects.

27

Dallas Area Rapid Transitdart1.97


Location: East Dallas Equipment ServicesNumber of Employees: 84Industry: Service, TransportationWaste Reduced: SolventProcess: Solvent Vat FiltersContact Person: Joe Coker, (214)828-6791Information Current as of: January 1998


Dallas Area Rapid Transit (DART) maintains a fleet of buses which require filtering of theirfuel systems. The fuel systems are connected to a vat which is responsible for cleansing thevehicle systems with solvent. In the past, this technology alone was not efficient enough.


The same fuel filters as used on buses were installed on the Safety Kleen solvent vats to filtersolvent. The filters are changed weekly so that the life of the solvent is prolonged, thuscleaning numerous systems before disposal.


This technology is a significant factor in the reduction of the solvent waste stream, ahazardous threat to the water in the environment.


Reduction of solvent purchase and disposal reduces the level of the solvent waste stream byextending the life of the solvent by 20%.

28

Dallas Area Rapid Transit dart2.97


Location: East Dallas Equipment ServicesNumber of Employees: 84Industry: Service, TransportationWaste Reduced: AntifreezeProcess: RecyclingContact Person: Joe Coker, (214)828-6791Information Current as of: January 1998


Dallas Area Rapid Transits (DART) fleet of buses, service vehicles, and other vehicles utilizelarge amounts of ethylene glycol (antifreeze). In order to reduce the amount ofcoolant/antifreeze purchased and used, DART needed a solution to reuse this material.


An in-house antifreeze recycling machine has been introduced to all DART facilities to checkand reuse spent antifreeze. The spent material is deposited into a yellow drum which is sentto another part of the facility for testing. After all levels are checked, fresh additives areadded to replenish the antifreeze to a state of safe reuse.


DART has significantly reduced a serious waste stream common to this industry, antifreeze.This reduction is beneficial to the environment as well as this facility.


The reduction of pure usage has allowed DART to excavate all of their underground tanks.These were 4,000 or 6,000 gallon capacity tanks. The tanks are being either totallyeliminated or replaced with double lined above ground tanks or smaller capacity (1,000gallon) underground tanks. In the elimination situations DART is focusing on using so littleantifreeze that they can operate out of a few 55-gallon drums on site.

29

Dallas Area Rapid Transitdart3.97


Location: East Dallas Body SupportNumber of Employees: 33Industry: Service, TransportationWaste Reduced: SolventProcess: RecyclingContact Person: Billy England, (214) 828-6755Information Current as of: January 1998


In the paint and body shop of Dallas Area Rapid Transit (DART), solvent is used in largequantities for cleaning paint guns. A solvent recycling machine was needed to handle andreuse the spent materials.


The “Sidewinder”, an evaporative solvent recycling machine, was purchased to recycle thespent solvent to a state of safe reuse. This reduces the amount of fresh solvent needed to bepurchased as well as the amount of spent solvent to be disposed of.


This technology is a significant factor in the reduction of the solvent waste stream, ahazardous threat to water in the environment.


Since implementation of the project, DART saves money on the purchase of fresh solvent aswell as disposal fees. Since they purchase less than 50 gallons of solvent per month, they areable to remain a small quantity generator and avoid additional regulation associated with largequantity generator designation.

30

Dow Chemical Companydowchem.97


Location: FreeportNumber of Employees: 6,000Industry: ManufacturingWaste Reduced: PolystyreneProcess: Recycling/OutreachContact Person: Carrie Brown, (409) 238-7409Information Current as of: January 1998


To ensure the success of the polystyrene business, a team was formed in 1992 to documentthe positive environmental impact of polystyrene use and recycling. This project wasexpanded to include the Houston Dow Center, Dow La Porte, Dow International, and someof the Dow Chemical Company’s vendors and outside organizations.


The project was set up to be as convenient and easy as possible for employees to participate.The technology is simple: recycle bins are put near trash cans and people are educated to thereasons for recycling and the products that can be produced from recycled polystyrene. Thisallows the program to be easily transferred to other industries. The outside activities of thisteam are manned by volunteers who give some of their own time to support this effort.


Reduction in the amount of polystyrene foam going to landfills. It also serves as a model foremployees to take these recycling concepts home and become involved in other recyclingprograms. To date, over 73,000 lbs. or 14.5 million polystyrene cups have been recycled.Approximately 95% of the cups purchased by Texas Operations are recycled each month.


The cost of this project is the container and lid that are used to collect the cups. Thecombination costs approximately $40.00 a set. There have been 450 bought by TexasOperations to date. This brings the cost to $18,000. If the trash was going to an outsidelandfill there would be a definite savings, but in this instance it is the knowledge of doing theright thing.

31

E.I. du Pont de Nemours & Company, Inc.dupont1.97

1. GENERAL INFORMATION CLEAN INDUSTRIES 2000 Member

Location: La PorteNumber of Employees: 1,100Industry: Agricultural ChemicalsWaste Reduced: ChlorineProcess: Mass Transfer During ReactionContact Person: Daniel J. Littlefield, (281) 470-3122Information Current as of: January 1998


We use a chlorination reaction in the manufacture of agricultural chemical intermediates. Theoff-gas from this reaction is vented to a caustic scrubber. The spent caustic scrubber wasteis incinerated at the on-site incinerator. The amount of waste generated by the process isdirectly related to the amount of chlorine that passes through the reactor without reacting.In 1994, we installed a dip tube to improve the gas/liquid mixing in the reaction. We alsoredesigned the control system to minimize the quantity of chlorine vented.


Installation of a bottom-entry short-radius lined dip tube in a glass lined reactor.Use of waste minimization as the primary control strategy for the chlorination reaction.


Because of these improvements, we have reduced the spent scrubber waste by close to 90%;almost six million pounds per year.


Savings related to the incineration costs and reduced raw material consumptions is about$500M/yr. The opportunities provided by this waste reduction incinerator consolidation,improved incinerator performance, higher rates, have not been quantified but are very large.

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III Corps and Fort Hoodfthood1.97

1. GENERAL INFORMATION CLEAN TEXAS STAR MemberCLEAN CITIES 2000 MemberCLEAN TEXAS 2000 Partner

Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: SolventsProcess: Closed-Loop Parts WashingContact Person: Bill Bodkin, (254) 287-8713Information Current as of: January 1998


Current washer stations in the helicopter maintenance area at Fort Hood use PD-680 whichis a hazardous solvent. The installation researched alternative technologies for replacementand discovered that a terpene based alternative met specific needs of the military.


Inland Technology’s “Breakthrough” was chosen as the alternative to the previoushydrocarbon-based solvent. This solvent performs as well or better than PD-680. While“Breakthrough” appears to be an acceptable alternative, the real advantage being evaluatedat Fort Hood is the use of “Breakthrough” in new parts washer stations that include on-boardclosed-loop filtration technology. These stations are used to clean aviation equipment,weapons, and ground equipment.


By using parts washer stations with a solvent filtering mechanism, Fort Hood expects toextend the use of solvent from 16 months to two or more years.


To date, Fort Hood has reduced solvent purchases by more than 70%.

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Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: AntifreezeProcess: Antifreeze Turnkey Recycling SystemContact Person: R.J. Holley, (254) 287-7145Information Current as of: January 1998


In November 1996, Command Policy at Fort Hood mandated the 100% use of recycledantifreeze. A program was established to facilitate the transaction to 100% recycledantifreeze. In order to ensure an easy transition, the Fort Hood supply system was set up toallow for local purchase of recycled antifreeze for motor pool use. In turn, spent antifreezeis collected onsite at designated collection sites and is picked-up by a qualified recyclercapable of returning a 50-50 antifreeze/water mixture that conforms to military specifications.


N/A


Implementation of the antifreeze recycle program resulted in the total elimination of wastemanagement associated with spent antifreeze. Disposal of antifreeze through traditionalwaste management methods was replaced 100% by a recycle effort. This effort representsa total waste reduction of approximately 150,000 pounds of spent antifreeze per year.


This project represents a total cost avoidance for the disposal of spent antifreeze. Thequalified recycler picks up spent antifreeze at no cost to Fort Hood, and sells recycledantifreeze back at the same price as the new military specification antifreeze.

34



Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: BatteriesProcess: Battery RechargingContact Person: R.J. Holley, (254) 287-7145Information Current as of: January 1998


Fort Hood spends $3 million annually on the purchase of lead-acid batteries. A BatteryManagement Plan has been implemented for the entire installation. The base intends tochange their battery supply and disposal program, the manner batteries are tested at eachlevel, and the manner batteries are recharged.


Fort Hood’s Battery Management Plan will become a Standard Operating Procedure (SOP).This plan includes the use of Pulse Tech’s Solargizer unit, brass battery connectors, and thepurchase of prefilled and precharged batteries. The Solargizer unit trickle charges thebatteries which aids in keeping the lead plates inside batteries free of corrosion. To date, over7,000 Solargizers have been installed and 26 units of the 1st Calvary Division have beentrained in battery management.


Extending the life of lead-acid batteries means less lead released into the environment.


Through full implementation of the Battery Management Plan, Fort Hood expects that thepurchases of lead-acid batteries can be cut in half. This will translate into $1.5 million insavings in purchases alone.

35



Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: Aerosol CansProcess: ReplacementContact Person: Bill Bodkin, (254) 287-8713Information Current as of: January 1998


A number of aerosol cans are used at Fort Hood to accomplish daily missions. The goal ofthe project was to eliminate all aerosol cans from the base, since many of the cans containhazardous compounds.


Fort Hood is converting all of its aerosol cans to pressurized delivery containers for liquidcleaners. The post is working to get this type of system, particularly Air Jet 32 made byInland Technology, into the army supply system so that it is readily available by NationalStock Number (NSN). The Air Jet 32 uses compressed air for propellant and can deliver afine mist to a pinpoint spray. This feature makes it useful for a variety of purposes at FortHood.


By eliminating the use and disposal of aerosol cans, fewer hazardous compounds and a fewernumber of waste cans will be released into the environment.


Implementation of this pollution prevention project is in the works. Actual savings have notyet been documented. Simplified supply and control will offer some savings, but reductionsin disposal costs and propellant purchase are the most promising. Use of pump orpressurized delivery systems will ease use and eliminate aerosol handling, storage, anddisposal problems.

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1. GENERAL INFORMATION CLEAN TEXAS STAR MEMBER

CLEAN CITIES 2000 MEMBER

CLEAN TEXAS 2000 PARTNER

Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: Spent Petroleum Naptha SolventProcess: Parts Washer Needs AssessmentContact Person: Alex Kachura, (254) 287-8711Information Current as of: January 1998


This project involved performing a Parts Washer Needs Assessment Survey to identify thelocation, use, and distribution of parts washers for general maintenance parts cleaning anddegreasing. The goal was to eliminate any parts washer that was not required for overallmaintenance. The criteria used to determine whether a parts washer was needed included:

C Establishing a standard per maintenance bay distribution standard for partswashers and removing excess units.

C Identifying standby parts washers and targeting all standby units for removal.C Identifying and removing all parts washers not used for general maintenance

parts cleaning and degreasing.

As a result of the Assessment Survey the number of parts washers on Fort Hood was reducedfrom 512 to 311.


N/A


The amount of parts washer solvent used and managed on Fort Hood was reduced by 39%without affecting overall maintenance operations. The project is also expected to reducespent solvent management and disposal by 25%.


Reduces the contract requirement by approximately $87,000 per year.

37



Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: Spent Petroleum Naptha SolventProcess: Parts Washer Waste MinimizationContact Person: Alex Kachura, (254) 287-8711Information Current as of: January 1998


Fort Hood uses a contractor provided parts washing system with a nonhazardous (high flash-low VOC) solvent. The washer is capable of minimizing waste generation by separatingcontaminants from the solvent; however, full waste minimization has not been realized. Aspart of the Parts Washer Needs Assessment Survey performed, improper managementprocedures that interfere with the maximum efficiency of the unit were identified. Theseprocedures included:

C Use of parts washer for other than maintenance operations (i.e. cleaning paint-related equipment)

C Improper use of other solvents (carburetor cleaners, brake cleaners) with partswashers.

C Improper servicing of the units by contractor.

These practices accounted for 50% of the parts washers identified as contaminated andrequiring disposal of the contaminated solvent as hazardous waste. As a result of thefindings, a solvent management plan has been established. This management planincorporates the following procedures to ensure maximum efficiency of parts washers:

C Routine surveillance and inspection of all parts washers during and betweenservice intervals.

C Users are held accountable for units found to be contaminated by an outsidesource or from practices not associated with general maintenance partscleaning.


This project incorporates management techniques to maximize the existing wasteminimization potential of existing parts washer systems.

38


Proper management of the waste minimization parts washer units extends solvent life byminimizing the frequency of changing out the solvent; therefore, extending the useful life ofthe solvent is expected to result in a reduction of approximately 9,000 gallons of solventmanifested per year. Long term expectations include:

C Decreasing the frequency of servicing units.C Minimizing contamination of parts washer solvent.C Maximizing the efficiency of maintenance operations by maximizing the

effective use of parts washers.


Extending solvent life and minimizing solvent change-out in parts washers can result in animmediate reduction of service costs of approximately $10,000 per year.

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Location: Fort Hood, Bell CountyNumber of Employees: 45,000Industry: National DefenseWaste Reduced: Flammable Gas CylindersProcess: Smokeless Gas Flare ProjectContact Person: Randy Doyle, (254) 288-7627Information Current as of: January 1998


Fort Hood generates approximately 1,200 lecture bottles containing gas residues annually,with a cost of disposal of approximately $130,000. The smokeless gas flare burns off gasesby flaring small flammable lecture bottles including disposable propane, ether, butane, MAPP,and other flammable gas residues. The process uses standards set forth in TNRCC StandardExemption #80. Once gases are burnt off, valve stems can be removed, and the bottles canbe recycled as scrap metal. Fort Hood has submitted this procedure to the Army Idea ofExcellence Program.


This project was developed using industry standards for the hook-up and use of propanetanks, and to meet the requirements of waste minimization. The project design uses amultiple lecture bottle hook-up system to allow for the burning off of up to ten bottles atonce. Total cost to fabricate the unit was $338. The process allows for minimal time to bespent on the process. For example, the initial burn of 205 lecture bottles took a total of 12man hours during a three day period. Fire, safety, and air emission consideration were takeninto account by constructing an enclosure in which to conduct burns. The process has beenapproved and forwarded for Army wide use.


This process has enabled Fort Hood to eliminate waste generated as a result of lecture bottlescontaining residues and converts the major part of the waste stream into metal recycling.


The project was placed into operation in August of 1996. To date, 865 lecture bottles havebeen processed for a savings in disposal costs of $94,285.

40

General Instrument/Jerrold Communicationsgeninst1.97


Location: Matamoros, MexicoNumber of Employees: 1,000Industry: Electronics ManufacturingWaste Reduced: Solvent, TCEProcess: SubstitutionContact Person: J. MartinezInformation Current as of: January 1998


This manufacturing facility produces cable T.V. converters. The manufacturing processconsists of a wave soldering machine that generates waste composed of spent thinner andflux. The process used 1,1,1 trichloroethane (TCE) for cold cleaning of P.C. board.


The 1,1,1 trichloroethane was completely eliminated, thus generated waste was eliminated.The purchase of modern equipment has cut generated waste in half. The new machines havetighter programmable process controls; thus, excessive waste is eliminated.


By eliminating 1,1,1 trichloroethane and reducing the solvent usage in the process, the facilityreduced generated waste. Implementation of this project can only be beneficial to theenvironment.


By eliminating 1,1,1 trichloroethane, General Instrument reduced cost by $10,038 per year.The calculated reduction is based on consumption in previous years.

The project resulted in an immediate pay-back for the company. General Instrument is alsosaving an additional $6,600 on disposal costs.

The most significant benefit resulting from the elimination of 1,1,1 trichloroethane isenvironmental health and safety of the employees.

41

H.E. Butt Grocery Co.heb.97


Location: San AntonioNumber of Employees: 45,000Industry: Food & DrugWaste Reduced: Parts Washer SolventProcess: DistillationContact Person: Tommy Johns, (210) 938-5628Information Current as of: May 20, 1998


With the installation of the Valvaline SYSTEM-ONE parts washer with distillation unit, HEBfleet maintenance was able to totally eliminate the hazardous waste stream of parts washersolvent. The system uses a high flash solvent (>140 degrees Fahrenheit) that does not containany carcinogens or any listed material.

The process uses a 30-gallon system that separates contaminated solvent from clean solvent.With only a four minute downtime, the operator is able to flush the five gallons of usedsolvent into the vacuum distillation unit and begin the recycling process, while at the sametime replenish the five gallons of used solvent with clean solvent. The distillation processtakes about six hours; however, you are able to use the parts washer in only four minutes.After the unit has completed the distillation of the solvent, the operator is able to dump thestill bottoms into the waste oil, which is then recycled.

Pure solvent is always readily available on demand without the need to wait for periodicdeliveries and hazardous waste disposal services.


The system eliminates waste recovery services and could avoid classification as a wastegenerator. It also eliminates potential liabilities for improper handling, storage, andtransportation of waste material.

SYSTEM-ONE is a totally enclosed treatment that separates solvents from oil and otherimpurities. The resultant residue meets the regulatory definition of used oil under 40 CFR260.10 and may be managed as a used oil and is exempt from hazardous waste disposalregulation. But remember, the responsibility for proper chemical management rests with theuser. The user must ensure that the solvent is never contaminated with a hazardous materialor waste.

42


This system will allow HEB to eliminate a large hazardous waste stream. The new solventdoes not exhibit any characteristics of hazardous waste therefore eliminating a hazardouswaste stream into the environment.


The system will save $49,000 in service and disposal costs over a period of 60 months. Thedisposal costs will never be zero. The elimination of the hazardous waste stream will keepsome of our sites Small Quantity Generator Conditionally Exempt.

43

Hoechst Celanese Chemical Group, Inc.hoechst6.97


Location: Pampa PlantNumber of Employees: 700Industry: Chemical ManufacturingWaste Reduced: Hazardous SubstancesProcess: Oxidizer, Closed-Dome Car, VentsContact Person: Brian Nelson, (806) 663-4287Information Current as of: January 1998


A Waste and Release Reduction (WARR) project was initiated company wide in 1992 whenupper management decided the company should make a concerted effort to reduce releases.The Pampa Plant, the first to implement a WARR project, installed three new processes tomeet a minimum goal for reducing Superfund Amendment Reauthorization Act (SARA)releases by at least 75%.


The WARR project applied catalytic oxidation technology to a high pressure air oxidationreaction process. Traditional incineration would not work well in this application because ofthe low VOC concentration and high concentration of unburnable nitrogen in the gas stream.

A closed-dome rail car loading system was implemented. This special rail car captures andtreats the VOC vapors displaced while loading other rail cars with liquid chemical products.

Process vents and tank controls were installed at the various point source locations. Theindividual vents and controls were tied into larger vent collection systems and air pollutioncontrol devices.


Overall SARA releases have been reduced 85%, 10% more than required. The projectssignificantly reduce point source air emissions and generate an additional 3 Mega Watts ofelectricity.


The initial capital costs were $6.5 million with an annual savings of $400,000. The savingsare due to reductions in costs due to compliances with hazardous waste regulations,hazardous waste disposal, and air emissions. The payback period is 16 years.

44

Howell Hydrocarbons & Chemicalshowell1.97


Location: ChannelviewNumber of Employees: 50Industry: Toll Chemical ProcessingWaste Reduced: Process Chemicals, GasolineProcess: Dry DisconnectsContact Person: George Freda, (281) 457-2768Information Current as of: January 1998


In the past, when Howell transferred chemicals from storage tanks to tanker trucks or viceversa they had a lot of leakage, both gaseous and liquid. In order to reduce releases ofchemicals when transferring, Howell placed dry disconnects at all transfer points.


Dry disconnects have drip-free designs that minimize leakage and reduce exposure to fluidsor vapors during fluid transfer. When leaks or releases occurred in the past they werecaptured and washed down a drain to the wastewater treatment system. Due to the widerange of chemicals processed at Howell, dry disconnects with special Viton® gaskets wereselected rather than the standard rubber gaskets.


Dry disconnects reduce employee exposure to hydrocarbons and chemicals. The reductionin chemical releases has reduced the amount of time for clean up and the volume ofwastewater treatment from clean up water. While releases during transfer of chemicals ishighly variable and hard to measure, Howell estimates that dry disconnects have reduced leaksto only a few pounds a year.


The primary savings of this project come from increased employee safety and health. Cleanup and treatment costs have been reduced by lowering the amounts of lost chemicals.Releases represent a loss of product or feedstock; therefore, a reduction in leaks produces adirect increase in the volume of product available for sale or the volume of feedstock availablefor processing.

45

Howell Hydrocarbons & Chemicalshowell2.97


Location: ChannelviewNumber of Employees: 50Industry: Toll Chemical ProcessingWaste Reduced: VOC EmissionsProcess: Equipment Modifications, Storage TanksContact Person: George Freda, (281) 457-2768Information Current as of: January 1998


Howell produces many chemicals and stores them on site. A normal storage tank has thecapability of releasing volatile organic compound (VOC)emissions into the atmosphere. Inorder to reduce fugitive emission of VOCs from storage tanks, Howell installed floating roofsinside their two tanks.


Floating roofs made of aluminum were designed and installed by Howell. These roofs act aspontoons that remain on top of the chemical in the storage tank. Howell has two storagetanks, the largest can hold 80,000 barrels and the smaller tank can hold up to 30,000 barrelsof liquid. The floating roof has a rubber seal between the roof and the wall of the tank.These roofs are virtually maintenance free and are easy to install.


Floating roofs and the seals that surround them reduce the fugitive emissions that wouldotherwise escape into the atmosphere. The largest tank has reduced about 300,000 lbs ofVOC emissions. This project also reduces employee exposure to the gases.


The initial capital cost was around $100,000 with a relatively short payback period. Costsavings are due to reduced loss of reagents and with reduction of VOCs. Both of thesereduce regulatory costs and paperwork.

46

Intercontinental Manufacturing Companyinter1.97


Location: GarlandNumber of Employees: 300Industry: Metal FabricationWaste Reduced: Solid Waste-Ferrous MaterialsProcess: RecyclingContact Person: Scott Jetter, (972) 276-5131Information Current as of: January 1998


In the process of cleaning metal cases, wheelaborator steel shot used for impact is pulverizedto a fine dust. Formerly, the waste dust was collected in reusable containers that weretransferred into a sealed dumpster for transport to landfill. Recently the metal scrap recycleragreed to accept the material in steel drums for recycling. The dust is now collected in steeldrums, sealed, and shipped away for processing.

(While most all of the scrap metal is recylced, this very heavy, fluid-like metal dust materialis difficult to handle unless it is in sealed containers.)


N/A


Monthly pick-up of approximately 11 steel drums of steel shot dust for scrap recyclingreduces our Class 1 landfill disposal volume by at least 33 cubic yards of solid waste annually.The transportation distance is about one-fifth and the scrap ferrous material requires muchless energy to process than the virgin iron ore.


Annual savings in landfill disposal costs are approximately $2,650. Annual income from scrapsale may be as much as $10,000 (estimates range from $8,000 to $11,000 based on partialyear’s record).

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Laughlin AFBlaughln1.97


Location: Del RioNumber of Employees: 5,000Industry: Air Force BaseWaste Reduced: Hazardous WastewaterProcess: Chemical Cleaning Water Filtration SystemContact Person: 2Lt. Gary Gaulke, (830) 298-4389Information Current as of: January 1998


Laughlin Air Force Base (LAFB) uses a parts washer to clean their aircraft engine parts ofhazardous debris and metallic content. As an effort to reduce the amount of hazardous waste,LAFB implemented an innovative closed-loop water recycling system. The Jet Washing unitis an aqueous-based aircraft parts washing unit that utilizes nonhazardous washing media. LAFB is currently using Natural OrangeTM, a citrus based nonhazardous cleaning product.


The new parts washer is a chemical cleaning water filtration system that filters the spentwashwater and restores it to reusable quality. The unit filters spent washwater from theparts washer so that it may be reused without replacement.


Prior to installing the new system, LAFB disposed of approximately twelve 55-gallon drumsof hazardous debris per year. The new process has reduced waste to only two 55-gallondrums of spent filters each year. Water usage has been reduced by 50% and soapconsumption by 25%.


LAFB has experienced $12,500 in labor savings and has reduced total hazardous wastedisposal by 3,200 lbs (a savings of $3,200).

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Location: Del RioNumber of Employees: 5,000Industry: Air Force BaseWaste Reduced: AlodineProcess: Replacement with Paint ThinnerContact Person: 2Lt. Gary Gaulke, (830) 298-4389Information Current as of: January 1998


Laughlin AFB’s largest waste stream in 1995 was chromic acid. The acid was generated froma process that utilizes alodine (chromic acid, hydrofluoric acid, and potassium ferricyanide)to prepare aluminum surfaces for priming and then painting.


Laughlin purchased an alodine evaporation system to concentrate the chromic acid wastestream. Instead of disposing of the entire mixture as a hazardous waste, Laughlin isevaporating the water out and reducing amount of alodine for disposal.


Laughlin AFB generated 57 55-gallon drums of alodine prior to this project. This project hasreduced the amount to two drums of waste for disposal.


Initial capital cost of the project was $54,000 with a payback period of 1 year. Laughlin AFBrealized a disposal cost savings of $41,330. This amount stems from reducing the totalweight of 25,228 lbs generated to only 916 lbs of that being disposed of. That is a reductionof 24,312 lbs at $1.70/lb.

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Location: Del RioNumber of Employees: 5,000Industry: Air Force BaseWaste Reduced: Hazardous MaterialsProcess: Smart WashersContact Person: 2Lt. Gary Gaulke, (830) 298-4389Information Current as of: January 1998


Aircraft maintenance at Laughlin Air Force Base (AFB) produces a fair quantity of hazardouswaste through parts washing operations.


Bioremediation systems are based on the ability of certain enzymes to eat oil and grease andis similar to the process used to clean up large oil spills and slicks. The SmartWasherTM

system made by ChemFree Corporation and the Zymo system made by ABS, Inc. areinnovative enzyme-based parts washing systems that have only recently become available.Nonpathogenic enzymes are used by the process to eat oil and grease while larger pieces ofgrime are captured on a 10 micron microbe-impregnated filter.


Reduction in hazardous waste disposal.


Reduced hazardous waste by 600 lbs per year.

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Location: Del RioNumber of Employees: 5000Industry: Air Force BaseWaste Reduced: Aerosol CansProcess: Paint SticksContact Person: 2Lt. Gary Gaulke, (830) 298-4389Information Current as of: January 1998


Laughlin Air Force Base conducts small paint jobs on aircraft and other subassembly parts inaircraft maintenance. The accessory repair shop utilizes several aerosol products for a varietyof applications. A dye is utilized in this shop that contains xylene and methyl isobutyl ketone(MIBK). Since this material is hazardous and also creates vapors that personnel are exposedto, LAFB implemented a new application.


LAFB replaced aerosol cans with paint sticks for their small paint jobs.


Reduction of aerosol emissions and disposal.


The use of aerosol paints was reduced by approximately 1,200 lbs/year.

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Lower Colorado River Authority - Fayette Power Project Facilitylcra1.97


Location: La GrangeNumber of Employees: 350Industry: Electrical UtilityWaste Reduced: SolventProcess: Aqueous Parts WasherContact Person: Mark Johnson, (512) 473-3200Information Current as of: January 1998


This project involves the use of an aqueous cleaning system that will help reduce citrussolvent use at LCRA. The facility generates an average of 949 gallons of waste solvent eachyear. The waste coordinator estimated that in 1994, LCRA will generate 4.6 tons.


The implementation of this project should not stop or slow production. Training will berequired for all employees which use the equipment. For most employees, the training willbe limited to observing the system in use. Some individual employees may need additionaltraining associated with the cleaning of the equipment and management of waste. There areno regulatory barriers to the implementation of this project. The implementation of thisproject will not require any additional permits.


FPP generates an average of 3.65 gallons of spent citrus per day. The use of an aqueous-based cleaning system that utilizes a closed-loop water circulating system has the potentialto reduce solvent usage by approximately 25 percent or 1.1 tons.

The implementation of this project alleviates several environmental problems such as reducedhazardous waste and reduction of a hazardous materials inventory. The project will alsoreduce the human health risks at the facility by reducing the exposure of employees to solventuse.


The cost savings of this project relate to the savings in solvent purchased, labor spent cleaningparts, and waste management costs. Basing calculations on an average of 1500 gallons ofcitrus used per year at a total purchase and disposal cost of $22,266 per year. The aqueouscleaning unit has the potential to reduce this volume by 25 percent saving more than $5,566per year. The equipment will cost between $6,000 and $17,000 depending on the size of unitpurchased. The estimated pay back will be 3 years or less.

52



Location: La GrangeNumber of Employees: 350Industry: Electrical UtilityWaste Reduced: Paint ThinnerProcess: Paint Gun WasherContact Person: Mark Johnson, (512) 473-3200Information Current as of: January 1998


All waste paint and paint contaminated materials generated at the Fayette Power Project(FPP) are considered F-listed hazardous wastes due to the chemical composition of thethinner that is currently used.


In an effort to reduce the cost of disposal and to promote recycling of these wastes, theFacility Improvement Team (FIT) should recommend the purchase of a closed-loop paint gunwashing system. The system will be self-contained, easy to use, and reduce both the volumeof thinner purchased and the volume of waste produced. They selected Inland TechnologiesIT-300 paint gun washer for use in the facility. The LCRA’s independent evaluation indicatesthat labor hour savings is one of the greatest assets of using this type of paint gunwasher/recycler. It is estimated that up to 25 paint guns can be washed before the tank willrequire cleaning and then approximately 1 gallon of thinner is required.


The unit will reduce 130 gallons of waste solvent per year. The unit also reduces risksassociated with long-term employee exposures to thinners associated with the manualcleaning of equipment.


It is anticipated that the unit can be purchased for less than $1,700 and will pay for itselfwithin six months. Most of the savings will come from reduced labor used to clean the gunsmanually. The purchase of the equipment can be offset by the reduced costs associated withlabor, product, and waste disposal costs.

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Location: La GrangeNumber of Employees: 350Industry: Electrical UtilityWaste Reduced: Aerosol CansProcess: Aerosol Can PuncturingContact Person: Gail Byler, (409) 249-8426Information Current as of: January 1998


Aerosol cans are considered hazardous waste when under pressure and containing productresidue. In 1994, to better manage aerosols, three Aerosolv brand aerosol can puncturingunits were purchased. This enabled the facility to puncture aerosol cans, capture the residuefor disposal, filter emissions through a charcoal filter, and recycle the empty can as scrapmetal.


The Aerosolv aerosol can puncturing unit was a newly marketed technology in 1994 as aresponse to industrial waste management requirements.


As a result of the aerosol can puncturing, an estimated 307 pounds of hazardous waste isreduced per year. The empty aerosol can is recycled as scrap metal which contributes to thetotal revenue from scrap metal sales.


The estimated savings total approximately $3,230 per year with a payback period of 0.7 years.

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Location: La GrangeNumber of Employees: 350Industry: Coal Fired Power PlantWaste Reduced: Hazardous SolventProcess: Solvent ReuseContact Person: Gail Byler, (409) 249-8426Information Current as of: January 1998


Solvent is used at the plant to degrease and clean parts and equipment. The facility installeda distillation unit in 1995 to reclaim solvent for reuse. In addition, filtering systems wereinstalled on parts washers to reduce solvent usage and replacement. By filtering and distillingthe used solvent, less hazardous waste was generated to require offsite disposal or treatmentand the purchase of new solvent was reduced.


Distillation is not new to industry as a method to reclaim material for reuse, but the reductionof waste disposal has made the process more cost effective.


The reclaimed solvent is used instead of purchasing new material which conserves naturalresources. The distillation of used solvent resulted in the reduction of an estimated 6,900pounds of waste per year to be disposed of off-site.


The distillation unit and installation of filtration units on parts washers save approximately$21,645 annually. The payback time for this project is estimated to be 1.5 years.

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Lower Colorado River Authority - Fayette Power Project Facility lcra6.97


Location: La GrangeNumber of Employees: 350Industry: Electrical UtilityWaste Reduced: Hazardous Paint ThinnerProcess: Nonhazardous Paint ThinnerContact Person: Gail Byler, (409) 249-8426Information Current as of: January 1998


After painting operations were completed, thinner was commonly used in the clean up ofequipment. A nonhazardous product was located and tested to replace the thinner forcleaning. The product was tested and it performed as well as thinner in most situations. Theprocedure was changed at the facility to use the nonhazardous replacement for thinner toclean painting equipment when possible. A paint gun washer was purchased that would makeit possible to recycle the nonhazardous paint equipment solvent.


The nonhazardous product to replace thinner for cleaning equipment, Safe-Strip, was new onthe market when the project was implemented.


By requiring the purchase of nonhazardous painting equipment cleaner, approximately 1,800pounds of hazardous waste was reduced annually. In addition, the alternate product, Safe-Strip, is non-toxic to employees and has a flashpoint of 197 degrees Fahrenheit.


The change to a nonhazardous alternative product resulted in an estimated savings of $4,572per year with a 0.8 year payback.

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Location: La GrangeNumber of Employees: 350Industry: Electrical UtilityWaste Reduced: Hazardous LampsProcess: Fluorescent Lamp ReplacementContact Person: Gail Byler, (409) 249-8426Information Current as of: January 1998


Fluorescent lamps used at the facility were considered hazardous waste when spent. Analternative nonhazardous fluorescent lamp, manufactured by Phillips was tested andrecommended for purchase by the Facility Resource Management Team. Hazardous wastegeneration was reduced as a result of lamp replacement.


The Philips low mercury lamp was manufactured in response to industry requiring a lesshazardous alternative to the standard fluorescent lamps.


By requiring the purchase of nonhazardous, low mercury, fluorescent lamps, 3,648 poundsof hazardous waste per year from fluorescent lamps are eliminated.


The change to low mercury fluorescent lamps saves an estimated $5,820 per year with a 0.1year payback.

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Louisiana-Pacific Corporationlp1.97

1. GENERAL INFORMATION CLEAN INDUSTRIES 2000

Location: Lufkin, Angelina CountyNumber of Employees: 340Industry: Softwood Veneer and PlywoodWaste Reduced: WastewaterProcess: Log WettingContact Person: Scott Jacobs, (409) 633-2490Information Current as of: January 1998


Logs are steam heated and wetted in chests to soften the wood prior to peeling. The wettingprocess previously discharged all chest water from each batch. This required a large volumeof make-up water.


Louisiana-Pacific constructed a recycling loop which continually reuses approximately 99percent of the chest water.


Reduced the total water usage requirements of the facility as well as wastewater dischargeby approximately 30,000 gallons per day or 10,950,000 gallons per year.


Annual wastewater discharge costs were substantially decreased.

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Millennium Petrochemicals, Inc.millen1.97


Location: La PorteNumber of Employees: 1,100Industry: PetrochemicalsWaste Reduced: Hazardous Aggregate Filter MediaProcess: Removal of Spent Aggregate Filter MediaContact Person: K.M. Holmes, (713) 209-7157Information Current as of: January 1998


The facility’s Permanent Pollution Prevention Planning Team reviewed the generationmechanics of spent aggregate filter media. It was determined the hazardous constituentscould be separated from the filter media, returned to the process, and eventually to a by-product stream before the media is removed from the filter vessel. The filter media could thenbe classified as a TNRCC nonhazardous Class I waste material that was acceptable for useas aggregate in asphalt paving material.


N/A


This project eliminates the need to incinerate and landfill 56 tons of hazardous waste.


Approximately 26 million dollars per year are saved, representing a 0.5 year payback.

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Location: La PorteNumber of Employees: 1,100Industry: PetrochemicalsWaste Reduced: Spent Process HydrocarbonsProcess: Feedstock SubstituteContact Person: K.M. Holmes, (713) 209-7157Information Current as of: January 1998


The manufacturing process for “synthesis gas” (carbon monoxide and hydrogen) at thislocation uses natural gas as a feedstock. Synthesis gas is a valuable basic “building block”chemical product used in producing a myriad of chemicals and chemical intermediates. Byproviding suitable handling equipment, the facility was able to utilize virtually anyhydrocarbon that met feedstock acceptance criteria.


Hydrocarbon materials from virtually all company locations, as well as materials from othercompanies, that meet feedstock acceptance criteria, but would otherwise be managed aswastes, have been successfully used as alternate feedstocks to produce synthesis gas.


The need to burn a secondarily derived hydrocarbon resource for energy recovery with itsassociated emissions is no longer required. The manufacturing process partially oxidizes thefeedstock to form synthesis gas with virtually no fugitive emissions being formed since the“emissions” of the partial oxidation process are the product.


The estimated annual savings associated with this project are $800,000.

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Location: La PorteNumber of Employees: 1,100Industry: PetrochemicalsWaste Reduced: Excess Laboratory ChemicalsProcess: Laboratory Sample Size ReductionContact Person: K.M. Holmes, (713) 209-7157Information Current as of: January 1998


Excess process and out-of-date shipment retain sample size containers are emptied into alarge container and taken to the production facility’s hazardous waste incinerator fortreatment with the sample containers being disposed via landfill. (It is not cost effective oranalytically appropriate to clean and reuse sample containers due to high purity of productsproduced.)

The sample size requirements were reviewed by the plant laboratory personnel. It was foundthat substantially smaller samples could be used to perform the required analyses. The use ofsmaller sample containers was initiated.


N/A


The sample bottle size reduction resulted in reduced landfill disposal requirements (24 cubicyards) and 7,400 pounds less material requiring on-site incineration.


The estimated annual savings associated with this project from incinerator operating costs,landfill costs, recovered product, and decreased labor are $11,200.

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Precision Tube Finishing Inc.pretube1.97


Location: HoustonNumber of Employees: 16Industry: Electrochemical FinishingWaste Reduced: Concentrated Mixed AcidsWaste Reduction Process: Alternative Use for ChemicalsContact Person: Jim Toney, (281) 856-7400Information Current as of: January 1998


Precision Clean Piping, Inc., electrochemically cleans stainless steel piping components forhigh-purity applications in the microelectronics, biotechnology, pharmaceutical and healthcare industries, using a specialized electropolishing process. Tubing diameters typically rangefrom 1/8-inch to 1-inch. The process drives large electric currents through the componentsby means of a strong, circulating electrolyte (a blend of concentrated phosphoric and sulfuricacids).

Metals diffused into the electrolyte eventually increase its viscosity. Because tubing diametersare small, viscosity is the limiting factor with respect to the mixed acid’s usefulness, not itselectrolytic suitability. Hence, the solution reservoir needs to be replaced after only about25–50 % of its useful life expectancy as an electropolishing electrolyte. The used electrolytewas disposed of as a hazardous waste. Deep well injection, the method of disposal, was (nopun intended) wasteful.


The solution to the problem was to make the electrolyte suitable for other related processesand find other users to whom it could be passed on. The main objections held by potentialusers of the solution was that it contained sediments and that its iron content was too high.Those problems are mitigated by modifying the electrolyte reservoir, adding a “V” bottom fordrainage and a series of baffles to encourage settling of the most egregious solids where theycan be drained off and otherwise disposed. A self-cleaning, spiral-wound, stainless steelprefilter is being installed to remove fine particles.

Rather than shipping off-site as a waste, the solution is now sold to local bulk electropolishingcompanies, for whom the viscosity is not a limiting factor.


Approximately 20 tons of solution can be sold for reuse rather than being deep-well injectedas a hazardous waste.

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Revenue from acid sales is minimal, but avoided disposal and handling costs are well over$30,000 per year. In addition, steps taken to improve purity of used electrolyte in order towin loyalty of potential “reusers” are expected to generate quality improvements in the tubingpolishing process itself. Finally, useful life-expectancy of the electrolyte is expected toimprove by about 1/3 without reducing its subsequent value to other users.

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Precision Tube Finishing Inc.pretube2.97


Location: HoustonNumber of Employees: 16Industry: Electrochemical FinishingWaste Reduced: Concentrated Mixed AcidsWaste Reduction Process: Alternative Use for ChemicalsContact Person: Jim Toney, (281) 856-7400Information Current as of: January 1998


Using a specialized electropolishing process, Precision Clean Piping, Inc. electrochemicallycleans stainless steel piping components for high-purity applications in the microelectronics,biotechnology, pharmaceutical and health care industries. Tubing diameters typically rangefrom 1/8-inch to 1-inch. The process drives large electric currents through the componentsby means of a strong, circulating electrolyte (a blend of concentrated phosphoric and sulfuricacids). Ultra high purity deionized water is used in a clean room to rinse aggregate residuefrom piping components after they have been processed.

The resulting rinse water is hazardous by virtue of its low pH (pH 0.9 to 1.8, typical) andheavy metals content. Prior to this project the wastewater was concentrated via evaporationprior to deep-well injection.


Precision Clean Piping, Inc., developed a four stage continuous neutralization andprecipitation treatment system that eliminated the disposal of nearly all hazardous waste. Thefirst stage adds ferrous sulfate and sodium hydroxide to reduce any water soluble hexavalentchromium to insoluble trivalent chromium and to form sodium phosphate that is soluble atlow pH.

The next stage raises the pH from 4 to 6 using calcium hydroxide, forming calcium sulfatethat is soluble at that pH. The third stage adds an inorganic flocculent resin powder(Chemsorb-500®) which raises the pH to 8.8 and precipitates the phosphates and sulfates,as well as precipitating and stabilizing the metals. The suspended solids are thenagglomerated by adding trace amounts of an anionic polymer and separated using an inclinedplane rake clarifier and filter press.

The effluent water not only meets all discharge limits, but could be used as input water forthe Softener/RO/DI system feeding the Class 100 Clean Room after pretreatment by filtrationto reduce TDS beneath the typical values for Municipal Utility District (MUD) water. Thefilter cake passes RCRA TCLP leaching tests and is a Class 2 waste that can be disposed ina land fill.

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Precision Clean Piping, Inc., has been able to eliminate the disposal of 130-140 tons ofhazardous waste per year and return 1.6 million gallons of water to the MUD for reuse. Solidwaste contribution to Class 2 landfills is less than 30 cubic yards per year.


Hardware costs for this system are approximately $40,000, and daily operating costs nowabout $30 per day, are expected to decline to $18 per day. The partially depreciatedevaporator, which cost $60 a day to use and maintain, was sold to recover a large portion ofits original costs. Precision Clean Piping, Inc., was able to go from being a Large QuantityGenerator of hazardous wastes to Conditionally Exempt Small Quantity Generator (CESQG).Being CESQG has reduced regulatory activities by over 70%, or about $10,000 per year.The annualized savings for rinse water disposal costs alone are greater that $70,000 per year.

65

Reynolds Metals Companyreynolds.97


Location: Corpus ChristiNumber of Employees: 850Industry: Chemicals, InorganicWaste Reduced: WastewaterProcess: Water RecoveryContact Person: Tom Ballou, (512) 777-2352Information Current as of: January 1998


The project will focus on beneficial use of municipal wastewater treatment plant residues,both solid and liquid effluents, to accomplish three significant goals.

1. Amendment and vegetation of large areas of historic bauxite tailings.

2. Conservation of fresh water through sequential reuse of wastewater treatment plantliquid effluent as industrial process water.

3. Reduction of municipal solid waste disposed in area landfills.


Reynolds Metal Company has conducted a limited test involving application of treatedmunicipal wastewater plant residues to a tract of historic bauxite tailings totaling 25 acres.All water associated with the residue as well as rainfall and supplied irrigation water wascollected and used to supplement the plant process raw water supply.


The environmental potential of this project is substantial. Besides for use of solid and liquidmunicipal waste, thus freeing up valuable landfill space, water presently used to control dustcould be used to expand the local industrial base. In addition to eliminating use of freshwaterfor dust control, they also recover about 60% of the effluent for use as process water afterit leaches through the tailings. The mere presence of vegetation has virtually eliminated thedust.


The two cities involved have averaged saving $50,000 per year in alternative sludge dying,handling and disposal costs.

66

The Sabine Mining Companysabine.97


Location: HallsvilleNumber of Employees: 180Industry: Lignite Surface MiningWaste Reduced: Hazardous SubstancesProcess: Replace Dragline LubricantsContact Person: Murleen Pirtle, (903) 660-3665Information Current as of: January 1998


Evaluation began in November of 1993 to replace the dragline lubricants which contained1,1,1 Trichloroethane (TCE), a toxic substance, with a chlorine free product and upgrade thelubricating system. As the draglines begin to age, Sabine Mining experiences an increase inlubrication and waste generation. In May 1995, both draglines were equipped with lubricantpoint injectors and bulk lube systems. These new lubricating systems reduced the frequencyof grease injection to the walking cam draglines and generated less waste.


In conjunction with their supplier, Sabine Mining began testing cam lubricants. Theseproducts were developed and tested exclusively at Sabine. This effort led to the developmentof a grease which exhibited all the required lubricating capabilities and contained nohazardous ingredients. All waste grease being generated from the draglines is nownonhazardous and is being recycled for fuel. The amount of nonhazardous waste greasegenerated has decreased 49% within six months.


By March of 1995, Sabine had completed a change over to non-chlorinated grease with onlyeight drums (2.5 tons) of hazardous waste generated through October 31, 1995. The amountof hazardous waste grease generated had decreased 95.5% in eight months.


Total capital cost of the project was $74,000 with a payback period of approximately 1 ½years. The savings are due to reduction in hazardous and nonhazardous waste disposal, labor,cleanup, and lubricant purchase.

67

Shell’s West Hollow Technolgy Centershelldv1.97


Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: SolventsProcess: Substitute for Commercial ProductContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Used solvent is sent to our manufacturing facility in the form of a substitute for a commercialproduct. All solvents from pilot plant operations, scale-up, and glass washing operations inlabs are segregated and collected to be returned to the refinery for reprocessing. Lab-to-labaudits were performed to ensure acceptable materials were segregated for this process.


The project required personnel training and lab-to-lab audits of the 450 labs. It also includedadditional communications of electronic mail and newsletters to convey the best methods ofmaterial segregation in order to maximize the benefits of resuse.


The project eliminates waste disposal of 800 tons of material and provides profit to themanufacturing facility. The purity level of material cleans the manufacturing lines and tanks.


Cost savingd are approximately $750,000. No additional capital was needed.

68

Shell’s West Hollow Technolgy Centershelldv2.97


Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: Air EmissionsProcess: Revamp of the Solvent RacksContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Redesign of the glass wash solvent racks to eliminate all air emissions. The design completelycaptures all materials and eliminates all solvent vapors. The waste solvent is recycled by ourmanufacturing facility.


The solvent racks were either eliminated or redesigned in all the areas to meet everyone’sneeds.


The redesign will eliminate air emissions by 50-75% and yield a reduction of up to 5 tons.


Costs associated with the redesign were $30,000 of capital investment. Since the solvent isrecycled, there are no disposal fees for the recovered solvents.

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Shell’s West Hollow Technology Centershelldv3.97


Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: Air EmissionsProcess: Vacuum Loading of Tank TrucksContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Vacuum trucks arrive onsite clean and under vacuum. Product is loaded in a closed systemto eliminate all VOCs. Approximately 70 trucks are loaded per year with a 5,000 galloncapacity limit.


Cheap system in order to meet compliance and was chosen over trying the flare system orabsorbent-type canister system.


Elimination of 1 ton emissions and personnel exposure, or approximately 30 pounds pertruck.


Elimination of flare tie-in of $150,000.

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Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: Air EmissionsProcess: Internal Tank FloatsContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Thirty-seven petroleum storage tanks (with capacities from 600-10,000 gallons) have hadinternal tank floats installed.


This was not a requirement and just done to eliminate emissions.


Reduction of 4 to 5 tons of VOCs.


Elimination of product losses which equals 8000 pounds per year or 60% reduction. Savingsof product are about $1,000 per year.

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Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: Lab ChemicalsProcess: Chemical InventoryContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


All chemicals are bar-coded as they are received at the dock. Each chemical is entered intoa system by chemical name, manufacturer, CAS number, user name and room number. Thissystem is visible to everyone and encourages sharing versus purchase. This system currentlymanages 37,000 different chemicals over 450 lab areas.


This system was designed in-house by a team of end users and computer personnel in amanner to phase in requirements and provide all the necessary data elements for minimalcosts. This system had only required areas keyed into the system and the remainder of theMaterial Safety Data Sheet was scanned into the system. The system was functional in sixmonths from scratch to finish.


We are able to ensure compliance for the haz com standard/lab standard as the chemicalinventory links to the Material Safety Data Sheets. The inventory provides remote access tothe lab area and chemicals in case of emergency. The inventory provides personnel exposureinformation per work area.


Reduction in waste disposal costs equal about $40,000. Purchase cost reduction equals about$10,000.

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Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: Chlorine Gas CylindersProcess: UV Wastewater TreatmentContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Shell Development used an ultraviolet system to disinfect effluent before discharging into thebayou.


UV irradiation (245 NM) disinfects by direct cleavage of bonds and subsequentdenaturization of metabolic molecules within the cells and viruses. Lamps are arranged soall effluent passes within ½ inch of any lamp to ensure adequate UV exposure. The systemwas commissioned March 1992, as the last step in treating effluent before discharging it intothe ditch. The system that replaced the original chlorine disinfection system met the 1992permit requirements including the no more than 0.1 mg/L of residual chlorine in the effluentstream.


Elimination of one ton chlorine gas cylinders which posed a safety issue as well asenvironmental hazard. The cylinders were changed out approximately every three months.This was used to treat 200 gal/min of effluent. No aquatic toxic effects are associated withusing the UV system.


This system received acceptance by the operators compared to chlorination/dechlorinationprocess. This system offers over $1,000 per month savings.

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Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: EnergyProcess: Cold Water Storage To Reduce Peak LoadingContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Shift on peak electric demand hours to off peak hours by use of cold water storagetechnology. Shift 6,390 kW of peak electrical use to off peak hours.


Use of a cold water storage tank with special internal laterals which keeps the warm waterseparated from the cold.


Reduce the need for Houston Lighting and Power to construct additional plant capacity forpeak demand usage.


Houston Lighting and Power gave a rebate of $300 per kW of on peak demand reduction, fora rebate of $1,900,000. Construction costs were approximately $900,000.

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Location: HoustonNumber of Employees: 1,600Industry: Oil/Gas/Chemical SupportWaste Reduced: Water ConservationProcess: A/C Condensation ReuseContact Person: Marty Pierce, (281) 544-7254Information Current as of: January 1998


Reuse of treated wastewater from A/C condensation for sprinklers.


N/A


Reuse of 60,000 gallons of A/C condensate water per day for sprinklers.


N/A

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Spohn Hospital Shorelinespohn.97


Location: Corpus ChristiNumber of Employees: 1,800Industry: Health CareWaste Reduced: ETO and CFC EmissionsProcess: Hydrogen Peroxide SterilizationContact Person: Bob Pegg, (512) 881-3002Information Current as of: January 1998


The environmental improvement committee identified emissions from the Operating Room’ssterilizers as an opportunity to improve environmental conditions. The sterilizers use a 12/88mixture of ethylene oxide (ETO) and chlorofluorocarbon (CFC) to heat moisture sensitivesurgical instruments. ETO is classified as carcinogenic and CFC adversely affects theatmosphere.


A hydrogen peroxide system was selected as the best method for providing effective surgicalinstrument sterilization, while eliminating hazardous emissions. The sterilizer system useshydrogen peroxide in its gas plasma state to fuel the sterilization process. The new system’senvironmentally safe by-products are water vapor and oxygen.


The sterilization process no longer emits hazardous vapors.


Operating costs were directly reduced by over $1,000 per month. Additional indirect costswere also realized from the elimination of ETO training, monitoring, alarm systemmaintenance, and other administrative expenses. This change was a definite winner for theemployees, hospital, and environment alike.

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Star Enterprise Refinerystar2.97


Location: Port ArthurNumber of Employees: 1,097Industry: Petroleum RefiningWaste Reduced: Hazardous SubstancesProcess: Segregated Wastewater ProjectContact Person: Rebecca Demeter, (409) 989-7174Information Current as of: January 1998


This project was initiated to reduce risk of releasing untreated wastewater to public watersand to reduce risk of groundwater contamination. The antiquated system consisted of open,earthen ditches collecting storm and wastewater from more modern closed sewers servingthirty processing areas scattered over 1,000 acres. In addition, over 300 acres of open,earthen reservoirs provided flow equalization and storm surge for the commingled storm andwastewater from these areas plus associated tank farms. These waters are treated in anActivated Sludge Treating Unit (ASTU) before discharge into public waters.


To reduce quantity and risk of untreated wastewater discharges by segregating cleanstormwater and contaminated wastewater, Star Enterprise built a leak-free and vapor tightwastewater collection system from every process to the ASTU. Star Enterprise collected andtreated vapors produced in the wastewater collection system and process wastewater andstormwater from “potentially contaminated” areas. To further reduce risk clean stormwateris impounded and tested before being released to public waters. Remediation of existingditches and reservoir sludges from the old earthen system while installing the new system.


Segregation reduced the risk of groundwater contamination, reduced the quantity of airemissions and minimized risk of discharging contaminants from spills and leaks into the cleanstormwater system. Generation of wastewater sludges was reduced to a level that cancurrently be recycled through the Delayed Coking Unit (DCU) rather than disposed of offsite.In addition, significant increases in quantity and variety of wildlife is a positive indicator ofoverall environmental improvement resulting directly from the installation of these facilities.


The initial construction was $150 million plus the cost of associated wastewater sludgeremediation. Economic benefits are minimal.

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Sulzer (Medica) Intermedicssulzer.97


Location: AngletonNumber of Employees: 1500Industry: PacemakersWaste Reduced: Isopropyl Alcohol (IPA)Process: Sold IPA to Solvent Blending CompanyContact Person: Joe Bob Garner, (409) 848-4407Information Current as of: January 1998


Prior to this project, disposal of spent isopropyl alcohol (IPA) neared 8 tons annually.


The innovative aspect of this project was the communication that took place between SulzerIntermedics and solvent blending company to determine the purity of the material. Thus,reducing a large waste stream.


As a result of the project, IPA disposal was reduced by 8 tons and the solvent blendingcompany eliminated the need for buying virgin material .


By implementing the IPA exchange program, Sulzer Intermedics saved $6,000 per year indisposal costs alone and reduced their standing from large quantity generator to small quantitygenerator.

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Sunbelt Transformersunbelt.97


Location: TempleNumber of Employees: 75Industry: Electrical TransformersWaste Reduced: Scrap MetalProcess: SegregationContact Person: Christi Hicks, (254) 771-3777 ext.237Information Current as of: January 1998


Rather than recycling scrap metals as mixed material, Sunbelt Transformer began segregatingwaste metals.


The recycler gave Sunbelt Transformer approximately $0.01 for every pound of mixed metalmaterial. By segregating the material, Sunbelt Transformer received $0.18 - $0.91 per poundof scrap metal. In fact, the additional segregation effort increased total revenue from metalrecycling by more than $100,000 in 1995.


In addition to the 335,000 pounds of scrap metal recycled per year, Sunbelt Transformerrecycles over 800,000 pounds of other materials. This translates into 1,135,000 pounds ofmaterials kept from our landfills per year.


The company earned a combined savings of $1,144,000 per year in revenue earned anddisposal costs by segregating various scrap metal.

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Texas Army National Guardtang1.97


Location: TwoIndustry: MilitaryWaste Reduced: Paint Stripping WastesProcess: Sodium Bicarbonate Paint StrippingContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In 1994, the Texas Army National Guard purchased an Accu Strip Machine Model 13 fromARMEX Cleaning and Coating Removal Systems. In 1995, two additional units werepurchased for Combined Support Maintenance Shop #1, Saginaw, Texas and the Mobilizationand Training Equipment Site, North Fort Hood, Texas.


Accu Strip Machine Model 13 is designed to deliver a sodium bicarbonate (baking soda)blasting media to remove paint and other coating from metallic and composite surfaces. Itis a pneumatic variable blast pressure (30-90 psi) system that avoids ingression of the mediainto the blasting surface.

Accu Strip Machine Model 13 allows for adjustable flow for different degrees of paintremoval. It is effective yet gentle. It does not damage glass or thin gauge metal. It produceslittle residue for removal, which makes it ideal for cleaning heavily greased and oiledequipment. It works well for removing grease, oil, carbon process residue or surfacecorrosion from stainless steel, aluminum, galvanized metal, concrete, ceramic tile, glass,rubber, neoprene, and composite materials. Manufacturer's patented ARMEX Blast Mediamust be used, at a cost of $17.50 per 50 lb bag.


The cleaning system drastically reduces or eliminates solvent cleaning or hand tooling. TheARMEX baking soda media is a non-toxic and water soluble media. It does not have theenvironmental hazards associated with solvents, caustic chemicals, toxic fumes, sand blastingand high pressure operations. (Workers are still required to wear protective clothing andmasks for protection from particulates in the air.) A $27,000 zero discharge waste waterrecycling system was purchased to eliminate discharge of heavy metals (lead) to the PubliclyOwned Treatment Works (POTW).


The systems costs approximately $15,000. Estimated payback period is less than 6 months.

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Location: NineIndustry: MilitaryWaste Reduced: SolventProcess: Parts WashersContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


The goal of the Texas Army National Guard is to reduce hazardous waste generation in allmaintenance areas. A significant waste stream has been solvent wastes from shopmaintenance activities. The Model Number 65 Kleer Flo parts washer reduces solvent wastegeneration by 90%. The parts washers are located at nine Organization Maintenance Shops.


Model 65 has a 33"x22" agitated immersion chamber. It weighs 160 pounds and requires 115volts to run. The parts basket lowers into tank for automated, hands-off cold immersioncleaning. It attaches to upper baskets for rinsing or washing under the stay-put hose. Dirtyparts washer solvent can be reused indefinitely by periodic recycling through the Kleer-FloRecycler. Duel-filtration keeps the working solution clean and helps remove abrasiveparticles that could damage bearings or other critical parts. A stay-put hose has continuouscirculation and an adjustable flow control. The filter cartridges must be replaced periodically.The vendor recommends use of their solvent to maximize efficiency and longevity of partswasher cleaner.


In 1996, an estimated 600 gallons of solvent have been saved using these units.


These systems have saved $5,130 in solvent disposal costs and $3,150 in purchase of newsolvent. At $770 per unit the units pay for themselves in reducing purchase and disposal ofas little as 60 gallons of solvent.

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Location: EightIndustry: MilitaryWaste Reduced: Lead Acid BatteriesProcess: Vehicle BatteriesContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In April 1994, the Texas Army National Guard purchased 240 Solargizer BatteryMaintenance Systems from Pulse Tech Products Corporation. Solargizers are used on allwheeled and tracked vehicles from the 3rd Battalion, 141 Infantry, Texas Army NationalGuard. Units are located in Austin, McAllen, San Benito, Gatesville, Brownsville, Donna,Edinburgh, and Laredo. Periodic nature of use in the guard is hard on battery life.


Complete units consist of a solar panel connected to a transducer which is in turn connectedto the lead acid battery. The Solargizer Battery Maintenance System is designed to prolongbattery life. It is a patented, solar-powered, electronic device that may be permanentlyattached to 12 or 24 volt lead-acid battery for a variety of vehicles and equipment. Theobjective of the Solargizer is to prevent sulfate build-up. When a Solargizer is attached topositive and negative battery terminals and placed in sunlight, it converts solar energy into ahigh-frequency, low-amperage pulsating electrical current within the battery. Pulsatingenergy surges continually clean battery plates of sulfate residue by causing sulfate moleculesto break away from a battery's lead plate. After breaking away, sulfate crystals return to thebattery's electrolyte solution.

Low currents put into batteries during this process are sufficient to keep the battery fullycharged with minimal solar exposure. Lead acid battery life expectancy is increased by 300%.In addition, the evaluation indicated that the use of this device provided a 300% increase inequipment availability, resulting in a significant increase in available training time. Retrofitof equipment is required. Estimated labor is 1 hour for combat vehicles (tracked) and 30minutes for wheeled vehicles. Mechanical skills are required for installation


Using the Solargizer Battery Maintenance System, each battery is expected to last four timesas long, thereby reducing battery waste and maintenance. Combined with the new Optimabattery, battery life will be approximately equal to the vehicle life expectancy. At 76 lbs perbattery (with 2.5 years life expectancy) and two batteries per vehicle, this amounts to ahazardous waste reduction of 60 lbs per year per vehicle.

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The cost per unit was about $100. Regular batteries cost about $65. Maintenance, paperwork for purchase and disposal costs are about $200 per battery change out. Over the 10year life expectancy, the system will save almost $800 per battery or $80 per year.

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Location: FourIndustry: MilitaryWaste Reduced: FreonProcess: Freon RecoveryContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In January 1993, the Texas Army National Guard purchased four Model 17500B RefrigerantRecovery/Recycling Stations from ROBINAIR. The units are located at Combined SupportMaintenance Shop #1, Saginaw, Texas; Combined Support Maintenance Shop #2, Austin,Texas and Mobilization and Training Equipment Site, North Fort Hood, Texas.


Model 17500B is designed to recover and recycle refrigerant in either vapor or liquid form.The unit will recycle R-12, R-22, R-500, R-502 and R-134A Ester Oil Systems. The unit isdesigned for heavy duty multi-refrigerant recovery and recycling and has the heat exchangecapacity to handle large amounts of refrigerant.

During recovery, refrigerant is pulled from the system, through an intake filter andevaporator, then to an accumulator oil separator. Acid that may have developed in the systemis concentrated in the oil, and by separating the oil from refrigerant, over 95% of the acid isremoved. Since stored refrigerant must be condensed to a liquid, after passing through thecompressor, refrigerant proceeds to the return oil separator, through the condenser and intothe storage tank. The recycling process removes moisture, air and remaining acid from therefrigerant. A liquid pump, magnetically coupled to prevent heat generation, circulatesrefrigerant through the filter repeatedly until clean, dry and ready for reuse. Filter-drier coresremove refrigerant contaminants, and requires 110 volt 60 Hz power. Operating personnelmust be licensed by EPA and certified by the Texas Natural Resource ConservationCommission. Training is required to operate this unit.


In 1995 and 1996, almost 700 pounds of Freon R-12 and R-22 were recycled.


The units cost $4,000. In 1993, replacement Freon cost $2.00 per pound. In 1994,replacement Freon cost jumped to $10.00 per pound. Estimated payback period is one year.

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Location: TwoIndustry: MilitaryWaste Reduced: Aerosol CansProcess: Aerosol Can PuncturingContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


The Dallas Army Aviation Support Facility (AASF) used Dallas Naval Air Station's aerosolcan puncturing system to deplete their paint cans in 1995. In 1994 the Austin Army AviationSupport Facility and the Austin Combined Support Maintenance Shop (CSMS) #2 eachpurchased one of these aerosol can puncturing systems. These systems have depleted over500 aerosol cans in the last two years.


DRM266, which is used to puncture most domed aerosol cans, mounts on a 30 or 55 gallonsteel drum with standard 2" and 3/4" bung openings. Fluids from the punctured can arecollected in the drum and any VOCs present are captured in the coalescing/carbon cartridge.The DRM266 accepts most industrial sized domed aerosol cans (16-24 oz., standard 12 oz.and small 1" diameter 6- 8 oz. mini cans). The device requires replacement of activatedcarbon cartridges and gaskets. Gaskets with more chemical resistance are required for moreaggressive contents. Seals must be maintained to prevent leaking of material.


The device allowed depletion of cans with broken or frozen valves regardless of quantity ofpaint remaining in can. The waste paint is collected in the drum. Punctured empty cans maybe placed with normal trash for landfill disposal. It is estimated it would take 5 to 10 yearsto accumulate a drum of waste paint at an aviation facility.


Solid waste disposal of aerosol cans averages $5 per can. The cost of the unit ($639) can berecouped after puncturing as few as 130 cans.

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Location: TenIndustry: MilitaryWaste Reduced: Parts Washing SolventsProcess: Bio-Parts WasherContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In August 1995, the Texas Army National Guard purchased ten Smart Washer Parts CleaningSystems (Chemfree Corporation) for distribution among Organizational Maintenance Shopsand Unit Equipment Training Sites. These units eliminate the creation of spent solvents thatmust be disposed of as hazardous waste.


The Smart Washer system uses a surfactant degreaser to lift and clean the contaminants awayfrom dirty parts generated from vehicle maintenance. The system employs a nonpathogenichydrocarbons enzyme that bioremediates the oil and grease. The parts washer is molded fromplastic to work with the nonpathogenic enzymes. A built-in heater keeps fluid at 105 degreesFahrenheit. A 10 micron microbe-impregnated filter traps the larger pieces of grime. Thedirty fluid drains to the base where the enzymes digest the petroleum contaminants. TheSmart Washer System requires the purchase of bioremediation products and filters from themanufacture.


The Smart Washer System eliminates the need to haul away contaminated cleaner. Thesystem is nontoxic, nonflammable, noncaustic, and nonhazardous. The system uses no toxicchemicals. In 1996 the unit eliminated the use and disposal of 600 gallons of solvent.


The units costs approximately $1,400. The system pays for itself after reducing purchase anddisposal of as little as 100 gallons of solvent.

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Location: Camp Mabry, AustinIndustry: MilitaryWaste Reduced: AntifreezeProcess: Antifreeze RecyclingContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In November 1993, the Texas Army National Guard purchased Model C-1 Cool'r Clean'rCoolant Purification System from Kasco Fuel Maintenance. The unit was placed in operationin December 1993.


The Model C-1 is designed to recycle 55 gallons of antifreeze to military specifications ineight hours. This unit is multi functional. It can process bulk cold coolant or hot coolantdirectly from the vehicle. Model C-1 uses both a filtration and deionization process. Itremoves all contaminant, including all dissolved solids.

The Model C-1 requires the purchase of new additives and operators must have experienceon how much to add to recycled antifreeze to meet military specifications. Additives areneeded for every three hundred gallons at a cost of $96 per two ionizing tanks. Volumes ofcoolant may vary slightly due to filter conditions.


The C-1 unit is recycling an average of 1,300 gallons per year of antifreeze.


The C-1 unit was purchased for $10,000 in 1993. Pure ethylene glycol is purchased at$4.50/gallon and mixed at a 50-50 ratio with water for antifreeze. Used antifreeze costs$.25/gallon for disposal. Chemical additives are approximately $.32 per gallon of antifreezeprocessed. At these costs the unit pays for itself after processing 1,718 gallons of antifreeze.It takes 12 hours to recycle one 55-gallon drum.

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Location: North Fort HoodIndustry: MilitaryWaste Reduced: AntifreezeProcess: Antifreeze RecyclingContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


A Glyclean ARS-100 unit was purchased in 1994 to recycle antifreeze. The unit is locatedat the Mobilization and Training Equipment Site, North Fort Hood, Texas.


The Glyclean ARS-100 is designed to store and recycle up to 100 gallons of antifreeze in lessthan 30 minutes. It refines used ethylene glycol and water mixtures with an additive toneutralize acid and replace inhibitors to a like new condition. The unit incorporates tworeplaceable filters. The final filter is capable of removing suspended matter of 5 microns orlarger. The unit has the ability to provide aeration for oxidation and removal of dissolvedmetals.

The approximate quantity of additive is from 1 to 4 gallons per 100 gallons of solutiondepending on the condition of the used antifreeze. Glyclean ARS-100 requires filterreplacement every 100 gallons. Cost of chemicals is $90 per 500 gallons of antifreeze.


The ARS-100 unit is averaging 3,100 gallons per year.


The ARS-100 unit cost $2,600 to purchase. Pure ethylene glycol is purchased at $4.50/gallonand mixed at a 50-50 ratio with water for antifreeze. Used antifreeze costs $.25/lb fordisposal. Chemical additives are approximately $.18 per gallon of antifreeze processed. Atthese costs, the unit pays for itself after processing 460 gallons of antifreeze.

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Location: ThreeIndustry: MilitaryWaste Reduced: SolventProcess: Solvent DistillationContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In October 1992, the Texas Army National Guard purchased four SRS-50 solvent distillationunits for $14,995 per unit from Solvent Recovery Systems, Inc.. The units were placed inoperation in January of 1993.

Four units are strategically placed throughout Texas. One is at the Combined SupportMaintenance Shop in Saginaw which has recycled lacquer thinner, aircraft thinner, andnaphtha. The second is at the Mobilization and Training Equipment Site in North Fort Hoodwhich has recycled varsol. Two are located at Combined Support Maintenance Shop #2which have recycled toluene, acetone, and Naptha.


The SRS-50 is designed to recycle 50 gallons of solvent in an 8 hour period. Depending uponthe boiling point (recycles up to 500 degrees) and contamination of the solvent, recovery ratecan reach up to 125 gallons in a 12-16 hour period. The unit is equipped with a vacuum pumpassembly. The vacuum assisted process maintains a continuous flow, accelerates productionof recycled product, and lowers the distillation temperature of the solvent. Some of thepositive features include stainless steel construction, explosion proof circuitry, pressurerelease valves, and automatic shut-off features. The continuous operation function allows themachine to siphon from the contaminated drum into a clean drum for recycled solvents. Atraining tape explaining how to operate the unit was made for the Texas Army National Guard.Co-mingled solvents with different boiling points have caused the distiller to recycle only onesolvent. The distiller is used to recycle one solvent at a time since commingled solvents withdifferent boiling points may cause some difficulties.


Since 1993, over 10,000 gallons of solvent have been recycled for reuse.

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The four units now cost $22,500 each (total of $90,000). Disposal of hazardous solvent wouldhave cost $72,500 and purchase of new solvent would have been $91,400. The break evenpoint is after processing approximately 1,400 gallons of solvent per unit. The unit doesrequire maintenance people to continuously monitor its operation.

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Location: Camp Mabry, AustinIndustry: MilitaryWaste Reduced: DieselProcess: Filtration of Diesel ContaminationContact Person: LTC Don Tryce, (512) 465-5001ext 5717Information Current as of: January 1998


In 1993 and 1995, the Texas Army National Guard purchased four Gulf Coast FilteringSystems. The units are mounted on tandem trailers which allows them to be towed to anyfacility to recycle diesel and solvent. The units have successfully recycled diesel and PD-680Type 1. The units are located at the Mobilization and Training Equipment Site in North FortHood Combined Support Maintenance Shop #1 in Saginaw and Combined SupportMaintenance Shop #2 in Austin. Because of the periodic nature of operations, diesel fuel issometimes left for months in tanks where it can become contaminated with condensation.


The Gulf Coast Filter System removes condensate water and particulate from diesel andsolvent by filtering it through 12 rolls of normal paper towels. On an average, the towels willlast three months depending on the contamination level of the diesel or solvent. An air pumpis used to move the product through the filtering system. The Gulf Coast Filter System isdesigned to thoroughly clean diesel and solvent product at a rate of 48 gallons per minute.It removes water and particles from the product using paper towels as the filtering element.The paper towels are inexpensive and readily available. This keeps the cost of service to thesystem at a minimum. An air compressor is used to move the product through the filteringsystem thus keeping the system explosion proof and easy to use in the field. The system hasa water seperator and large particle remover that extracts contamination before it reaches thesystem to help extend the life of the filter elements.


Since 1993, 107,600 gallons of diesel have been filtered and recycled for use.


The two units cost approximately $37,000. The cost for disposal would have been $26,900and the cost of fuel was $105,500. The units pay for themselves after processingapproximately 6,171 gallons of fuel.

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Location: FourIndustry: MilitaryWaste Reduced: SolventProcess: Parts WashingContact Person: LTC Don Tryce, (512) 465-5001 ext 5717Information Current as of: January 1998


In September of 1995, the Texas Army National Guard purchased nine jet washing systems:three Model F-3000-P's, three Model F-4000-P's, and three Model T-5000-P's. The units arelocated at Camp Swift in Bastrop, the Mobilization and Training Equipment Site (MATES),in North Fort Hood and the Combined Support Maintenance Shop #1 in Saginaw. The threeF-4000-P’s and the three T-5000-P’s are located at MATES, the Combined SupportMaintenance Shops # 2 in Austin and #1 in Saginaw. The units are used to clean engine partsand weapons.


Jet Washing systems are designed for all metal cleaning applications without use of harmfuldetergents. Parts are loaded into the washers and cleaned for 1-15 minutes with a solute ofbiodegradable detergent and water at 130-200 degrees F in solution, then filtered andrecirculated through the unit. All Models purchased by the Texas Army National Guardincorporate optional "purifier" filtration systems that trap sludge for easy removal and askimmer to remove free oil.

Both the F-3000-P and F-4000-P are front loading washers, while the T-5000-P is a toploading washer. The F-4000-P (1,500 lbs. turnable capacity) handles approximately twice theamount as the F-3000-P (750 lbs. turntable capacity). The top loading model does not havea door that swings out ; therefore, the top loading model utilizes space better than the frontloading washer. There is also an increased capacity in turntable diameter, tank size, and horsepower in the T-5000-P. Personnel must be trained to operate the equipment properly. Alloils are removed.


No hazardous waste is produced in this process. The units save labor because maintenancepersonnel can perform other activities as parts are being cleaned. The workers are notexposed to toxic chemicals and protective gloves are not needed for the aqueous cleaner.

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The units costs between $7,500 and $15,000. The units pay for themselves by reducing thepurchase of fresh solvent and eliminating the need to dispose of 500 to 1,000 gallons of usedsolvent as a hazardous waste.

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Location: Camp Mabry, AustinIndustry: MilitaryWaste Reduced: Lead Acid BatteriesProcess: Vehicle BatteriesContact Person: LTC Don Tryce, (512) 465-5001ext 5717Information Current as of: January 1998


In December 1993, the Texas Army National Guard received approval from the TankAutomotive Command to purchase and test the Optima 800 battery in tactical wheeledvehicles. Four hundred and forty (440) units were purchased and installed in a variety ofequipment for units throughout Texas. The periodic nature of vehicle use in the guard is veryhard on battery life.


The Optima battery delivers 800 cold cranking amps (850 for 6 volts) plus 120 minutes ofreserve capacity. Its unique spiral construction provides higher voltage than conventionalbatteries. The acid is bound within a fiberglass-mat so there is no "free acid" that can leak outor spill. Unlike flat-plate, flooded batteries, hydrogen gas can't build up inside the casing andcause an explosion, even when severely overcharged.

The Optima 800 can be operated effectively in any position, even upside down, without anyrisk of leakage. It is a maintenance free battery; therefore it contains no free acid to spill. Ifthe battery is accidentally cracked open as a result of a collision, no acid will run out or splash.In addition, there is no boil over which corrodes posts, connectors, and cables. The batteryis primarily a starter battery and not recommended for electrical equipment.


The batteries are expected to last 12 years as compared with a 2.5 year lifetime of the batteriespresently used. The extended life batteries will reduce waste disposal by a factor of almost5. There is no “free acid” that can leak and cause environmental damage. At 40 pounds thebattery is almost half the weight of a conventional battery, thus reducing waste and making itmuch easier to handle.

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The purchase cost for each Optima 800 battery is about $100 compared to $65 for regularbatteries. It costs about $200 in maintenance, administration, and disposal to change a batteryout regardless of the type of battery. In the three years since these have been installed only 13have needed replacement, whereas all the regular batteries would have been changed out. Bydrastically reducing the number and frequency of battery change out, an estimated $27,000or $60 per battery has been saved even if the Optima 800 batteries do not last the full 12 years.

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Texas Department of Criminal Justicetdcj1.97


Location: HuntsvilleNumber of Employees: N/AIndustry: Textile ManufacturingWaste Reduced: Cotton, Poly-CottonProcess: RecyclingContact Person: Tony D’Cunha, (409) 294-6061Information Current as of: January 1998


Texas Department of Criminal Justice (TDCJ) Industrial Division generates a tremendousamount of cotton waste in the form of garment scraps, inmate uniforms, etc. These wastesare currently sold for a pittance to “free-world” vendors. Technology is currently availableto convert wastes into reusable cotton fibers that can be blended with raw cotton, spun andwoven into clothing material for escalating inmate populations. TDCJ investigated optionsof fabric reclamation. After thorough investigation of current technologies, TDCJ decidedto purchase a waste fabric reclamation unit manufactured by Laroche S.A. of France.


TDCJ can recycle all 100% cotton fabric wastes into reusable fibers that can be convertedback into inmate clothing. Fabric wastes are returned to their natural state for the making ofnew garments and other products at a substantial discount. Reclaimed fabric wastes are beingused for garment making, and mop string heads. Plans include using reclaimed fabric wastesfor jacket insulation and fill material for items such as pillows and mattresses.


The project will eliminate 100% cotton fabric from reaching landfills statewide at TDCJprison locations. Recycled fibers will be blended, opened, carded, spun and woven back intoclothing for the ever increasing TDCJ inmate population.


Yarn spun with 25 percent recycled fiber blends would cut the number of 500-pound cottonbales purchased yearly by one fourth. Other products such as mop string heads can bemanufactured with a 50 to 60 percent blend of reclaimed fibers. Spinning yarn with a 20 to25 percent blend of reclaimed fibers would save the system more than $1 million/year based

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on current prices of cotton. The estimated savings on virgin cotton purchases are $1 million per year.The capital cost of the Laroche S.A. fabric reclamation unit is approximately $500 thousandtherefore, the project payback time would be 6 months. As textile production increases in responseto growing inmate populations, cost savings will increase in proportion to increase in production.

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TXI Operations, L.P.txindus.97


Location: Midlothian PlantNumber of Employees: 120Industry: Cement ManufacturingWaste Reduced: Groundwater UsageProcess: Storm Water Recycling ProjectContact Person: Eric Tiemeyer, (972) 647-3879Information Current as of: January 1998


Nearly one million gallons of potable groundwater are utilized each day in a process tomanufacture portland cement. Design involves construction and operation of acomprehensive storm water collection and recycling system to collect all stormwater runofffrom plant process areas and return it to production processes. An additional project is apipeline from City of Midlothian Wastewater Treatment Plant (CMWTP) to the cement plantthat conveys city treated wastewater effluent to the TXI plant to replace an additional 50-75% of the plant’s process water requirement.


The new pump station consists of two 1,500 gpm pumps located at the sedimentation basinwhere all runoff is collected. Storm water is then transferred to one of two 2 million gallontanks. The tanks store water and are equipped with a pump station to transfer water to themanufacturing process. A new pump station consisting of one 1,500 gpm pump will alsotransfer storm water from raw material and coal storage areas into the two storage tanks.The second system is a pipeline that will transfer treated effluent from the treatment plant tostorage tanks. CMWTP effluent provides 500,000 to 750,000 gallons of water per day. Thiseffluent, combined with storm water, will almost completely replace the groundwatercurrently used in the manufacturing process.


Elimination of storm water discharges from the plant will reduce any potential environmentaldegradation to a receiving stream. Reuse of runoff from the cement plant will replace nearly25% of the required volumes of process water resulting in a 200,000 gallon per day reductionin potable groundwater usage. With a pipeline system from CMWTP to the cement plant,almost one million gallons per day of groundwater will be conserved. In addition, dischargeof treated effluent from CMWTP will be eliminated.

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Initial capital cost of the storage and pump system was approximately one million dollars,while the pipeline will cost approximately $700,000. Cost savings arise from reducedgroundwater pumping and less liability for wastewater discharges.

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Union Carbide Corporationuncarb.97


Location: Seadrift PlantNumber of Employees: 1,000Industry: Organic Chemicals and PlasticsWaste Reduced: Air EmissionsProcess: Wastewater Treatment ReactorContact Person: Rick R. Curtis, (512) 553-2435Information Current as of: January 1998


In December of 1993, the primary wastewater treatment system at Union Carbide’s SeadriftPlant was replaced with new and innovative technology that not only exceeded the regulatoryrequirements but eliminated an offensive odor as well.


This project is the replacement of two earthen water treatment lagoons with a state-of-the-art,fully enclosed, 5.5 acre wastewater treatment reactor. The new wastewater treatment reactoris double-lined and covered with an anaerobic biological treatment unit used to decomposeorganic chemicals in the plant’s wastewater. The base of the impoundment consists of acompacted three foot thick impermeable clay barrier topped with two 60 mil High DensityPolyethylene (HDPE) membrane liners. In between the two HDPE liners is a drainage layerwhich allows any leaks in the top liner to be detected, collected, and removed from the linersystem. The installation is 820 feet long by 320 feet wide and has an average depth ofapproximately 18 feet. The unit holds approximately 25 million gallons of biologically activewaste water at normal operating levels.


This design ensures protection of the underlying soil and groundwater by providing multiplebarriers between the wastewater and the surrounding environment. The HDPE cover collectsand directs the gases produced in the lagoon to an emission control system which treats boththe gases and the odors in the water before water is discharged to the polishing ponds. Thiscover has reduced hydrogen sulfide releases by 95% while improving outfall water quality.


The initial capital cost was $14.5 million with benefits to the environment.

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Wilsonart International, Inc.wilsart1.97


Location: TempleNumber of Employees: 3,100Industry: Manufacture of Laminated Countertop MaterialWaste Reduced: Defect Laminated CountertopsProcess: Plastic Laminate RecyclingContact Person: Coleman Kavanagh, (254) 207-7000 Ext. 2949Information Current as of: January 1998


Wilsonart has entered into a five year venture with a worldwide distributor of oilfield-relatedproducts and chemicals to produce a product designed to stop circulation losses of expensivedrilling muds into the environment. The product, known as Pheno Seal, is made entirely fromrejected, ground plastic laminate materials once destined to be decorative countertop surfaces.This project was developed in an effort to reduce the weight and bulk of waste.


Drilling muds are essential to cool and lubricate the cutting bit of the bore shaft. Many stratathat overlay oil bearing zones are extremely porous. Pheno Seal chips are added to thedrilling mud in a borehole at the surface and forced into the bore shaft under pressure, alongwith the drilling mud. In porous areas, the chips prevent the loss of expensive oil-based andwater-based drilling muds by blocking the porous openings.


A substantial amount of costly waste is diverted from the solid waste stream flow into amarketable, profitable product (Pheno Seal). Another benefit is the untold amount ofpollution prevented by the cessation of drilling mud seepage into otherwise virgin soil matter.It is also conceivable that over time the cumulative effect of such pollution prevention willserve to guard both groundwater and surface waters against contamination by drilling mudseepage.


The initial capital cost was approximately $55,000. The payback period is approximately oneyear due to the contractually guaranteed annual sales.

T E X A S N A T U R A L R E S O U R C EC O N S E R V A T I O N C O M M I S S I O N

The TNRCC is an equal opportunity/affirmative action employer. The agency does not allow discrimination on the basis of race, color, religion, national origin, sex, disability, age, sexualorientation or veteran status. In compliance with the Americans with Disabilities Act, this document may be requested in alternate formats by contacting the TNRCC at (512)239-0028,

Fax 239-4488 or 1-800-RELAY-TX (TDD), or by writing P.O. Box 13087, Austin, TX 78711-3087.

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