 |
Farnam Sealing Systems
Division, Coltec Industries
Substituting methylene
chloride with a less toxic substance |
| Standard Industrial Classification
(SIC) |
Gaskets, packing and sealing devices/3053 |
| Type of Waste |
Methylene chloride |
| Strategy |
Process Modification
Material Substitution |
| Company Background |
Farnam Sealing Systems Division, Coltec
Industries, is located in Necedah, Wisconsin. Today Farnam manufactures sealing systems
for engines and drive trains, transmissions, fuel systems, lubrications systems, cooling
systems and exhaust manifolds, in virtually all vehicles and engine-driven heavy equipment
built by domestically owned manufacturers in North America and for many markets worldwide.
The firm employs about 320 people at its facility. |
| Original Process |
Ninety percent of the methylene chloride
used at Farnam was used as a drying agent in a fluoropolymer coating. The coating was
applied to gaskets destined for shipping to keep them from sticking together. Methylene
chloride is known for its quick drying properties as it evaporates. |
| Motivation |
To stay ahead of every-increasing
regulation and reduce employee exposure to chemicals. |
| Pollution Prevention Process |
On one of its production lines, Farnam now
applies a water-based fluoropolymer coating in combination with drying ovens to compensate
for the quick drying time of methylene chloride. This has reduced the emissions of this
solvent by nearly 50% or 142,000 pounds per year and resulted in a 3,000 pounds/year
reduction in hazardous waste. The firm plans to completely eliminate the use of methylene
chloride by the end of 1994. This will result in an additional reduction of 6,000 pounds
of hazardous waste/year. |
| Material/Energy Balance |
Original Process
Feedstock
292,000 pounds methylene chloride/year used as a reducer for original coatingWaste
methylene chloride/year
283,000 pounds in air emissions, 9,000 pounds in hazardous waste
Disposal
air emissions and hazardous waste
Pollution Prevention Process*
Feedstock
71,000 pounds water reducible fluoropolymer coating/year
Waste
less than 500 pounds/year solid waste**,
800 pounds/year to wastewater treatment
Disposal
non-hazardous waste and wastewater treatment
*Please note that this process is for one production
line only. The company is in the process of switching its other line to using the new
feedstock, as well.
**The generator is responsible for determining
whether or not this solid waste is hazardous |
| Economics |
Capital Costs
Capital equipment costs for new dryers equals $50,000Operational/Maintenance
Costs
New raw material costs are lower but usage is up, resulting in insignificant cost change.
Energy costs for dryers are insignificant, as well.
Payback Period
Less than 4 years |
| Benefits |
Emissions were reduced by more than 50%,
and employee exposure to solvents also was reduced. |
| Obstacles |
A portion of the customers did not allow
Farnam to use the new process and chemical on their product immediately. |
| Technology Transfer |
The process may have many other
applications when coatings are applied to release rubber or plastic parts from their
original molds. |
| Company Address |
Farnam Sealing Systems Division
900 Farnam Drive
PO Box 327
Necedah, Wisconsin 54646 |
| Contact Person |
Barry Brodt, Environmental Engineer
608/565-4253 |
| Pollution Prevention Resources |
Free, On-site Technical Assistance
University of Wisconsin Extension
Solid and Hazardous Waste Education Center
Milwaukee area: 414/475-2845
Remainder of state: 608/262-0385Pollution Prevention
Information 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
TS-014 95 |
|