Water Usage Reductions At
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Transcript of Water Usage Reductions At
Manchester Tank & EquipmentElkhart, IN
Steve Jacobson , CHMMEnvironmental Manager
MTE – Facility InformationLocation: Elkhart, IndianaEmployees: 148Products: Portable Steel and Aluminum Cylinders
Propane, Refrigerant, Chemical, Fire SuppressionProcesses: Metal Fabrication and Finishing
Press DepartmentWeldingShot BlastingMetal FinishingPowder Coating
600,000 to 800,000 Cylinders Annually
MTE – Facility Information (cont.)Permits and Legal Requirements
Hazardous Waste (CESQG)Air Permit (FESOP) Particulate MatterOil Storage (SPCC)Storm Water Permit (SWPPP)Industrial Wastewater Permit (City of Elkhart)
National Categorical Pretreatment Standards: Metal Finishing Point Source Category (PSNS)
MTE – Facility Information (cont.)Regulated Pollutants
Cadmium, Chromium, Copper, Lead, Nickel, Silver, Zinc, Cyanide, Total Toxic Organics (TTO)
Local Ordinance PollutantspH, Total Suspended Solids, cBOD5, Ammonia,
Total Phosphorus, Fats – Oil - GreaseSampling Requirements (End of Pipe)
Bimonthly Reduced to quarterly with 2009 permit renewal!
Where Were We In 2006?
A number of environmental impacts had already been addressedVOCs and Hazardous Waste
Began full implementation of an Environmental Management System (EMS) in September, 2006Needed an environmental “Goal” for 2007
One significant environmental aspect that had not been addressed was “water usage”
Very busy! Lots of production on two shifts
So Why Pick Water Reduction?2006 Water & Sewer Bills = $22,505
Only 2% of Utility CostsRelatively low cost to implementInstallation performed by maintenance staffNeeded better “water balance” information
POTW Permit RenewalCorporate Compliance Audit
Low Hanging Fruit!
Goal: Reduce Water Consumption by 15%
5,995,621 gallons used in our baseline year (2006)7.28 gallons used per cylinder
2007 - Action PlanInstall process meters at specific locations
Leak testing stations, parts washers, cooling towers Facility already had four different City meters
Install discharge meters at sump locations Facility had never measured discharge before
Start monitoring daily meter readingsUse data to identify “true” water needs
Parts Washer DesignWashes Soap Lubricant Off Formed Steel
Prepares Cylinders For Painting
Parts Washer Cross SectionAn overhead
conveyor takes a cylinder through a series of stages comprised of water or chemical and water.
Water, temp. and chemical concentration are controlled with electronic systems
Process WaterInstalled 6
new metersPictured is a
Neptune Trident T-10
Added a digital display to several meters when the location of the meter made data collection difficult
Discharge WaterSignet 2551
MagmeterSignet 8550
Transmitter
Sump LayoutThe process water
from each plant is directed to a sump with a float-activated sump pump.
Waste water must remain in contact with Magmeter sensor (use loop, check valve or combination)
Other “Handy” SuggestionsRemove the handles from flow control valves
(Universal solution from maintenance dept.)Discourages employees, vendors, etc. from
increasing flow to fix a temporary problemAdd solenoid switches to the flow valves
which are interlocked with the main power to a locationVery useful when combined with removing
handles
How Much Did This Cost?Approximately $3,000
Three sump meters (eventually added a fourth)Six process input meters
Used existing labor to install metersMaximum of 10 minutes needed to read meters
and update “flow” data each dayInstallation took one months to complete and
trouble-shootDigital meters require calibrationDial meters purchased had different units displayed
(gallons, 100 gallons, cubic feet)
What Does The Data Look Like?What we used
to know
What we know now
Results2007
4,733,660 gallons used 1,261,961 gallon
reduction 4.8% normalized
reduction 6.93 gallons per tank
Missed 15% GoalContinue in 2008!
20083,149,291 gallons
used 1,584,369 gallon
reduction 22.3% normalized
reduction 5.39 gallons per tank
Two Year reduction of 2,846,330 gallons26% normalized
reduction
Results (cont.)Decreased chemical consumption
Phosphoric AcidPotassium Hydroxide
Decreased natural gas consumption @ four parts washers3 million fewer gallons of water that need to be
heated from 60 degrees to 120 degreesDecreased the number of required sampling
events from six to four each yearCoincided with permit renewal
Reduction of ChemicalsParts Washers Chemicals5-Stage Washer
Phosphoric AcidPotassium HydroxideFluorozirconic Acid
4-Stage WasherPhosphoric AcidFluorozirconic Acid
2-Stage Washer (no chemical)
2-Stage WasherPotassium Hydroxide
Phosphoric AcidPotassium HydroxideFluorozirconic AcidMineral OilPre-Cleaner
Reduction of Chemicals (cont.)2007 to 2008
17,000 pounds less corrosives purchased
$26,766 less spent
2008 to 200921,452
pounds less corrosives purchased
$42,718 less spent
Decreased Natural Gas Usage2-Year Savings
2,846,330 gallons from 60oF to 120oF
1,366 million BTU$10,780 ($7.89 per
mmBTU)Parts washers
require heated water to function
Per Tank Savings1.89 gallons per
tank from 60oF to 120oF
907 BTU$0.0072 per
cylinder
Reduced Required Sampling2004 to 2009 Permit 2009 to 2014 Permit
Bimonthly Sampling (6)$200 average per event
laboratory feesPreparation of
submissionCOC, signature of
responsible official, etc.$1,200 per year plus
time
Quarterly SamplingFewer chances for
something to go wrong$800 per year plus time
Savings SummaryResources Dollar$Water
7.3 gallons per cylinder ‘06
5.4 gallons per cylinder ‘08
Reduced annual consumption by almost 3 million gallons
Natural GasAnnual reduction of 693
million BTUChemicals
Annual reduction of 15,000 to 20,000 pounds of corrosives
Water Reduced water and sewer
bills by $3,000 annuallyNatural Gas
Reduced natural gas consumption associated with water heating by $5,390 annually
Chemicals Reduced chemical purchases
by an average of $28,000 annually
Total Average yearly savings:
$36,390 Per cylinder savings: $0.05
Of NoteCleaning frequency of washer stages stayed at
approximately 3 monthsWe expected this to increase, but it stayed the same.
Reducing flow may cause other problems so proceed slowlyQuality issues (none yet)NOVs (we had to implement weekly vacuuming of
one washer / sump where FOG is a problem)Involve your supplier
Training, usage reports, they can be great advocates
RecommendCommunicate Results
Periodic updates to management and supervisors Lets them know something is being measured!
Frequent updates to maintenance staff and supervisors If you know what is “normal”, you typically find
problems before operations folks notice.Periodic updates to all employees
Keep beating the drum that water conservation is important. That creates a plant full of people looking for wasted resources.
P2 and Water ReductionFor MTE, this project
began with low expectations (it was low hanging fruit).
Expect pleasant surprises if you begin to measure and reduce water consumption.Immediate $aving$Stop wasting
chemicalsReduced risk with
handling hazardous materials
P2 and Water ReductionWould we have decreased the flow of water
through our processes without this goal?Not likely. Usage was a function of time (rate
based) and chemical concentrations chase the water.
If we had not set this goal in more prosperous times, we could still be spending $112k on chemicals instead of the $19k we expect to spend this year.
Would Also Suggest JoiningIndiana Partners for Pollution PreventionEnvironmental Stewardship Program (EMS)Both programs help provide validity to your
claims of P2 in a sea of green-washing.Both programs require annual reports that
will help you identify some of these “unexpected” results.
Questions?Special Thanks To:
The Indiana Partners for Pollution PreventionAmercio Chemical