Common Sense Initiative: North Carolina Update

Common Sense Initiative - Basic Framework

Metal Finishers - agree to work toward a series of “Goals” to reduce their discharges.

Municipality - in return provides regulatory incentives and technical assistance where required.

State- technical and regulatory assistance.

Benefits of Strategic Goals Program

LOCAL POTW- reduced pollutant discharge to POTW- better working relationship with industries- less chance of NPDES violations- less time devoted to SIU permits

PLATERS- less burdensome permit requirements- less time and money devoted to environmental permits- technical assistance available

North Carolina Update

4 participating POTWs:- Raleigh, Statesville, Charlotte, Gastonia

8 metal finishers (3 site visits) Additional incentives - Air quality, power

companies, SBA Loans Stakeholder meeting (June 29) Industry Workshop (Fall)

Further Information Division of Pollution Prevention

(919) 715-6515 Greg_Newman@p2pays.org

Surface Finishing Industry Council- SFIC Robert McDowell(716) 425-7500 rmcdowel@rochester.infi.net

EPA Scott Dosick (202) 260-9211 dosick.scott@epamail.epa.gov

Zero Discharge Project at Powder Coating Operation

Hankison International, Newport, North Carolina

Randy DonleyManufacturing Engineer(252) 726-1011

Hankison International 265 employees 31,000 square ft facility Manufactures filter products and

refrigerated air dryers

Background

Established 1947 1995 Installed new powder coater Estimated discharge 1,610 gallons per day Wastewater management options??

Wastewater Management Options

No City Sewer Off site hauling $0.43 per gallon

($173,075 per year) Evaporation - curing ovens generate 3

million BTUs per day which should evaporate 600 gallons per day

Process Flow

Drying Oven Powder Coat Curing Oven

Flow of Work

Metal FormingFive stage

cleaning lineAssembly

Cleaning Line

Stage 1: Washtank

Stage 2: Rinsetank

Stage 3:Phosphatizing

tank

Stage 4: Rinsetank

Stage 5: NonChrome Seal

Cleaning Line Modifications

240 gal/shift

390 gal/shift

240 gal/shift

Stage 1: Washtank

Stage 2: Rinsetank

Stage 3:Phosphatizing

tank

Stage 4: Rinsetank

City water 740 gal/shift

Float valveFloat valve

Advantages• Greater than 90% reduction in water consumption possible• More efficient rinse - film breakdown• Reuse of dragout solution• National survey - 25% usage

BENEFITSCapital Cost = $500

Water Conservation = 217,500 gallons per year (54%)

City Water Costs = $1,011 per year ($4.65 per 1000 gallons)

Savings on Treatment Costs = $108,576 per year

Ultrafiltration Unit

240 gal/shift

390 gal/shift

240 gal/shift

Stage 1: Washtank

Stage 2: Rinsetank

Stage 3:Phosphatizing

tank

Stage 4: Rinsetank

City water 740 gal/shift

Ultrafiltration unit333 gal/shift Filtrate

150 gals/shift

BENEFITS

Capital Cost = $30,000

Water Conservation = 250,000 gallons per year

City Water Costs = $1,162 per year

Savings on Treatment Costs = $124,800 per year

Evaporation System 240 gal/shift

390 gal/shift

240 gal/shift

Stage 1: Washtank

Stage 2: Rinsetank

Stage 3:Phosphatizing

tank

Stage 4: Rinsetank

Ultrafiltration unit333 gal/shift

Filtrate toevaporator

150 gal/shift

City water 740 gal/shift

Evaporation System

Wastewater

Existing ductwork

Hot air from powdercoating furnaces

Compressedair

Filter

Evaporation Chamber3 x 3 x 10

Nozzle

Atomized spray

To atmosphereExisting ductwork

Unevaporated water return

Evaporation SystemBENEFITS

Capital Cost = $10,000

Water Conservation = NA

City Water Costs = NA

Savings on Treatment Costs = $42,000 per year

Financial SummaryModification Capital

cost ($)Annual

Operating costs ($/yr)

Water conserved

(gal/yr)

City water cost

savings ($/yr)1

Savings on

treatment costs ($/yr)

Payback period

(months)

Countercurrent rinse system 500 0 217,500 1,011.40 108,576 0.1

Ultrafiltration unit 30,000 1,000 250,000 1,162.50 124,800 2.9

Evaporation system 10,000 500 na na 420,003 2.9

Totals 40,500 1,500 467,500 2,173.90 275,376 1.8