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