|
Modine Manufacturing Company
Zero Discharge Aqueous
Cleaning Line |
| Industry; SIC Code |
Manufacturer of Heat Transfer Products for
Vehicles, Heavy Equipment Commercial Heating and Ventilating Products for Buildings; SIC
3714, 3583, 3442 |
| Process |
Cleaning or Degreasing of metal prior to
assembly or painting |
| Type of Waste |
Hazardous wastes and emissions from 1,1,1
Trichloroethane (TCA) |
| Strategies |
Eliminate the use of TCA through
implementation of an aqueous cleaning system. The original strategy considered a
conventional alkaline cleaning system with a 11 gallon per minute (GPM) flow to wastewater
treatment. However after careful study it was determined that a zero discharge system was
feasible. |
| Background |
The Modine facility in Racine Wisconsin is
the corporate headquarters and manufacturing research and development center for the
corporation. Extensive prototype work and testing is accomplished at the plant. These
processes require cleaning of sub-components before they are assembled and/or in some
instances prior to painting. The Modine Company used TCA as the
cleaning agent to remove grease and oils from parts in an open top vapor degreaser. |
| Motivation |
The Modine Company has a strong corporate
commitment to reduce waste and emissions wherever possible. In recognition of the costs
and issues associated with TCA it was decided to eliminate the chemical by implementing an
aqueous cleaning process. |
| Changes Implemented |
The schematic demonstrates the general
layout of the cleaning system designed and built by company process chemists and
engineers. Evaporation is incorporated as part of the cleaning system and operates on
demand versus continuos operation. Incoming water is also a demand basis which is driven
by the total amount of water consumed during operation. Permeate from the filtration
system is returned to the cleaning tank. There is zero discharge from this
cleaning system. |
| Problems Encountered |
Selecting the best filtration media for the
process and the actual engineering and design of the iteration system was the most
challenging task. Other considerations were selection of the cleaning chemical and
achieving the supply/consumption balance for water needed to operate the system. |
| Material/Energy Balance |
Original Approach Feedstocks
9,800 lbs./yr TCA
Waste/Disposal
TCA 9,800 lb/yr Emissions
Hazardous waste 55 gal/yr
Cooling Water Discharge
Considered Approach
Feedstocks
275 gal/yr Alkaline Cleaner
Process Water
Wastes/Disposal
90 gal/yr Cleaner/Water
15,840 gal/day Wastewater Treatment
Sludge Unknown lb/yr
Zero Discharge System
Feedstocks
55 gal/yr Alkaline Cleaner
Process Water
Wastes/Disposal
0 gal/yr Cleaner/Water
0 gal/yr Wastewater Treatment
0 lb/yr Sludge |
| Economics |
Original Approach
Operating Costs |
| TCA |
$ 8,900 |
| Cooling Water |
$ 2,200 |
| Chemical |
$ 650 |
| Totals |
$11,560 |
| Capitol Investment |
$ -0- |
| Energy Costs, in BTU/Hour |
Unknown |
|
|
Considered Approach
Operating Costs |
| Alkaline Cleaner |
$ 750 |
| Process Water/Disposal |
$ 8,700 |
| Chemical Disposal |
$ 5,400 |
| Totals |
$14,850 |
| Capitol Investment |
$ 18,510 |
| Energy Costs, in BTU/Hour |
577,980 |
|
|
Zero Discharge System
Operating Costs |
| Alkaline Cleaner |
$150 |
| Process Water/Disposal |
$115 |
| Chemical Consumption |
>$150 |
| Totals |
$450 |
| Capitol Investment |
$59,950** |
| Energy Costs, in BTU/Hour |
110,480 |
|
| Approximate Payback |
Based upon a minimum
annual savings of $14,435 experience in operating costs only, the payback
period on $59,950 capital investment is 4 years. However this pay period does not include
cost savings for labor, avoided costs for handling wastes, reduced time for reporting
emissions and hazardous waste and the liability that was eliminated because there
is no accountable waste from the zero discharge system. |
| Other Minimization Activities |
Modine Manufacturing has had an aggressive
and very effective waste reduction program for several years. The "Shrinking
Drum" is awarded to each facility that achieves the waste reduction goals which
are established by that facility. The Corporate Headquarters in Racine leads this program
by testing new pollution prevention/waste reduction measures such as the zero discharge
system, before they are implemented in the field. |
| Company Address |
Modine Manufacturing Company
1500 Dekoven Avenue
Racine, Wisconsin 53403 |
| Contact Person |
Mr. David Peterson
Process Chemist
414-636-1253Mr. Edward Besaw
Environmental Engineer
414-636-1396
FAX: 414-636-1424 |
| Additional Publications Available |
SHWEC Publications
Pollution Prevention: A Guide to Program Implementation
Industrial Cleaning Source Book
Waste Reduction Assessment for a Fabricated Metal Prod. Ind.
Closed Loop Metal Finishing, factsheetDepartment of
Natural Resources Publications
Contact the Wisconsin Department of Natural Resources, Pollution Prevention Clearinghouse,
P.O. Box 7921, Madison, WI 53707, for a Publication Order Form, PUBL-SW-199, or call
608/2679523.
Suggested publications include:
Aqueous Industrial Cleaning Chemicals,
PUBL-SW-147
Aqueous Part Washing Equipment,
PUBL-SW-148
Guides to Pollution Prevention, The Metal Finishing Industry, EPA/625/R-92/011
Guides to Pollution Prevention, The Fabricated Metal Products Industry, EPA/625/7-90/006
Facility Pollution Prevention Guide, EPA/600/-92/088 |
| Pollution Prevention Resources |
Free, Nonregulatory On-site Technical
Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Pollution Prevention Specialists
Area Code 414 call the Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385Pollution Prevention
Clearinghouse
Wisconsin Department of Natural Resources
Hazardous Waste Minimization Program
608/264-8852, 608/267-9523 or 608/267-3763 |
 |
Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI 53707
608/267-9700
PUBL-SW-281 |
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