Summary of 1994 Winners
The pollution prevention project undertaken by Dowcraft involves the reduction of air emissions and hazardous waste generation from surface preparation and painting of metal surfaces. Metal parts are painted using a high-solid, low VOC paint. The paint used also has a higher coating capability compared to conventional industrial coating. Therefore, less paint is required to cover parts. New equipment was added to the paint line with a greater transfer efficiency and over spray is captured, adjusted and reused. By improving the scheduling of products to be painted (i.e., projects using similar colors of paint are scheduled together), Dowcraft has reduced the amount of solvent needed to flush paint lines. This has reduced Dowcraft's air emissions of VOCs by 47% and hazardous waste generation by 38% from 1992 to 1993.
KEM Plastic Playing Cards, Incorporated
KEM Plastic Playing Cards, Inc. converted its coating process from a solvent based coating to a solvent-free coating. The original coating was a nitrocellulose base coating with a solids content of 35%. During the coating operation 65% of the coating applied was evaporated to the atmosphere. The volatiles evaporated were a mixture of methyl ethyl ketone (MEK), methyl isobutyl ketone (MIBK), toluene, and isopropyl alcohol. The new coating is 100% solids and is dried with ultraviolet light. Total annual emissions for 1993 of VOCs were reduced from almost 60,000 pounds to zero pounds. Also, generation of solid hazardous waste was eliminated. The new coating with 100% solids resulted in an annual savings of $218,000.
Alcan Rolled Products
Between 1986 and 1993, the hazardous air pollutants (HAP) emissions reduction program implemented at Alcan Rolled Products (ARP) facility achieved a 94% reduction of chlorine and hydrogen chloride emissions from its aluminum melting and holding furnaces. All emission reductions achieved as a result of Alcan's HAP emission reduction program were the result of source reduction measures. Implementation of advanced metal cleaning and degassing technology not only made these reductions possible but also produced significant gains in product quality through improvements in metal cleanliness levels. Reduced chlorine usage rates achieved by the program resulted in a cost savings of approximately $434,000 for 1993.
IBM East Fishkill
The IBM East Fishkill site is a large semiconductor manufacturing and research facility that has made significant accomplishments in the source reduction of wastes. These include: closed-loop recycling of 2.2 million gallons of tetrachloroethylene in 1993, saving over $6 million in virgin chemical costs; elimination of 42,000 gallons/year of a photoresist stripper containing hazardous materials and replacing it with a recyclable material, saving $2.5 million a year in chemical costs; continuous regeneration of an etching bath reducing the consumption of the bath chemicals while increasing the process efficiency and product quality; redesigning a tool cleaning facility eliminating the use of trichloroethylene, methylene chloride and Freon TMS. Total hazardous waste generation for this IBM site went from almost 9,200 tons in 1990 to approximately 5,200 tons in 1992, a 44% reduction.
Weber Knapp Company
Weber Knapp Company is a manufacturer of metal hardware and mechanisms for computer products, office equipment, and home and office furniture. The pollution prevention project involves the replacement of a trichloroethylene (TCE) vapor degreaser with a new powder coating line with on-line cleaning and iron phosphating, a cabinet spray washer for non-ferrous metals, and a major modification by automation of an existing aqueous cleaning line. This project achieves a 100% reduction of TCE (32,946 lbs/year) and TCE-contaminated still bottoms (4,096 lbs/year).
A carbon dioxide cleaning system was adapted by Xerox from a jet-engine cleaning technology and is being used to remove grease, dirt, and oil from used equipment. The raw material is liquid carbon dioxide which is liquefied and pelletized. Upon impacting the dirt layer of the substrate, the pellets sublimate to their next stable state which is gas. The gaseous carbon dioxide travels under the broken layer of dirt and in a "mushrooming" effect lifts the dirt away from the substrate. Approximately 120,000 lbs/year of 1,1,1-trichloroethane (methyl chloroform) has been eliminated from the process and the citrus based cleaner usage has been reduced by 40% to 71,830 lbs/year. The on-going annual cost savings is estimated at $500,000/year.
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