About FASTT

06 - HAZMAT (Oil/Fuel/Antifreeze) Recycling/Treatment

Antifreeze Recycling

Most activities have the opportunity to recycle more anti-freeze. FASTT identified 10. An example recommendation follows:

Shops remove antifreeze from vehicles and watercraft. Fluids are removed from the shop as HW. An antifreeze recycler could be used to reduce the waste stream and save on procurement costs for new antifreeze.

Automatic Particle Counter

Shop performs patch tests on hydraulic components. The solvent and hydraulic fluid mixture is removed from the shop as a hazardous waste. A hydraulic particle counter would increase throughput of samples and decrease the amount of hazardous waste generated in the shop. A more accurate analysis would also be attained.

Batteries-Management Filter Systems/BMP

Lithium and Magnesium batteries are used in BMU-1 and SBU-12. There is a possibility of recycling these batteries. High speed patrol craft are showing microbial contamination in fuel tanks, which if greater than 5 microns, can cause clogging in the fuel system. Unclogging the fuel system results in tank purging and steam cleaning and generation of waste diesel fuel. Installation of a 5 micron filter at the pier side tank will eliminate excessive microbial contamination. FASTT will provide information on anti-microbial additives.

EOD is testing the use of long life metallic filters for diesel and gasoline engines in light trucks and machinery. These filters will reduce the disposal frequency of used oil. FASTT team will monitor the results of this test for application to Naval Motor pools.

Machine shop changes fluid/filters in equipment per the 3M Manual. MRCs are used to record the work. OPNAV 43P1 is the overall guidance document for machine shop maintenance. OPNAV 43P1 is based on OPNAV 4790.4C, Ships Maintenance of Machine and Material Management (3M), which directs maintenance to be done periodically (i.e. quarterly, annually). This often results in the oil and filters being changed on machinery that is used infrequently. The oil and filters are still in good condition. This results in excessive use of oil, filters, and generation of waste oil. Other activities which replace oil and filters based on actual operation hours generate approximately 90% less waste oil per machine. NAVSEA will contact CNO N43 and discuss several proposed changes to the 3M Manual. The changes are a result of reduced usage of shoreside based machine equipment (less ships to maintain) and the increased maintenance cycles on ship's equipment (less items to machine). Local commands need a change to the 3M Manual that would allow them to maintain equipment based on operating hours instead of the calendar year.

Hydraulic Fluid Filtration

Support Equipment shop services hydraulic equipment on a scheduled basis. The fluid is tested at intervals and discarded as hazardous waste if the fluid is unsatisfactory for continued use. A hydraulic fluid purifier is available that could be used to extend the useful life of the fluids currently being discarded.

Public Works Center maintains a variety of vehicles. A major portion of the work load involves servicing hydraulic actuators and related components of lifting devices, cranes and forklifts. These fluids are drained, stored in 55 gallon drums and sent away. A Hydraulic Fluid filtration system would eliminate handling, storage and transportation associated with present methods.

Hydraulic Fluid Particle Counter/Analyzer

Current test methods for analyzing hydraulic fluid are slow, subjective, and require several repeat tests. The installation of a particle counter to replace the existing "patch test" method would eliminate subjectivity in the analysis, reduce test time from one hour to 20 minutes, and yield a savings of 973 man-hours per year.

Hydraulic Servicing Dispensing Unit

At the Naval Air Station, flightline personnel service aircraft hydraulic systems with a portable Hydraulic Servicing Unit that holds only one gallon cans of hydraulic fluid. Flightline personnel at all locations use 286 one gallon cans per month. This creates a potential for hydraulic fluid spillage. FASTT Team recommends the use of a Hydraulic Fluid Dispensing Unit that uses a 55 gallon system. System can be towed by tractor to various sites on the flightline.

Jet Fuel Recycling

Shop uses JP-8 to fuel jet engines on test stands. Contaminated fuel from here and from pre-flight drains is disposed of at a cost of $1.00/lb. Procurement of a Glannon Fuel Recycling Unit to remove residues, water and acid build up from collected fuels would allow for re-use in ground support equipment, Navy CB equipment or in other applications.

Materials Testing/BMP

Shop checks engine oil on fuel barges weekly using an oil test kit. The kits provide only qualitative results. Simple, accurate testing of engine oil with proper training would provide quantitative test results and eliminate unnecessary oil changes.

Note

Recycling center is recycling about 22% of the activities waste, including used oil filters by use of a filter crusher. These no longer have to be treated as hazardous waste.

Oil Filter Crusher/Recyclers

Power Plant performs maintenance on the engines and propellers on P-3 aircraft. This process generates hydraulic fluid and lube oil spillage and leakage. Lack of a drainage collection system causes the creation of oily sorbent waste and rags. In addition, personnel have to spend additional time cleaning-up the leakage and wiping engine and propeller components. FASTT recommends the use of a larger funnel on top of a rolling 55 gallon drum to collect the leakage off the engine and propellers. FASTT is currently unaware of any large funnels that are commercially available, but will investigate procuring or building a funnel for collecting these fluids. The use of a funnel and drum collection system is estimated to save $1,363 per plane each year.

Vehicle maintenance shop currently drums used oil filters for disposal. An oil filter crusher would help maximize space in the shop by enabling more oil filters to fit in a drum, thereby reducing the number of drums in the shop area.

Oil Filtration/Reuse

Hydraulic fluid from propeller changeouts is currently mixed with JP fuel and burned as waste fuel oil. This hydraulic oil could be recycled and reused with no risk to the equipment. Implementation of a fluid recycling program would reduce hazardous material usage of 2727 gallons per year and a savings if $22,812 dollars per year. Recycling of hydraulic oil is allowed, per the Aviation Hydraulics Tech Manual, NAVAIR 01-1A-17.

Lubrication oil from aircraft change outs is currently mixed with JP fuel and burned as waste fuel oil. The lube oil could be recycled and reused with no risk to the equipment. Implementation of a lube oil recycling program would reduce hazardous material usage by 2055 gallons per year and a result in a savings of $29,000 dollars per year.

Activity currently disposes of turbine oil after performing test runs of engines. Use of an oil filter (or oil purification system) would allow oil to be reused in test cells.

Current preventative maintenance practices require periodic replacement of lube oil in certain machinery. This maintenance practice may be unnecessary. FASTT recommends revising the maintenance schedule so that it is based on the use of a oil filtration system to prolong the life of the oil by removing particulate. The cost of purchasing lube oil could be reduced by 75%. Disposal costs would also be reduced.

Outboard motor test tanks are used to check engine performance. Tanks accumulate oil that must be removed as waste. Carbon deposits also accumulate, this causes a need to prematurely dispose of the water. An oil skimmer and portable filter would extend the life of the tanks and eliminate carbon contamination.

Process Change/BMP

Shop is responsible for supplying auxiliary power to the base whenever power outages occur or utility rate justify use. Power provided by 12 diesel engines. Lubricating oil and coolant are tested monthly. Thus far tests have shown no deterioration of the fluids. Fluids are disposed of as hazardous waste. There is an opportunity to extend fluids life by an additional two years. FASTT recommends continued monthly testing to develop a history for the engines.

Shop is responsible for annual draining and replenishing of gear oil in 37 capstans (55-gallon) located at the waterfront. Visual inspection of the oil upon changeout indicates no apparent deterioration. The changeout frequency appears to be excessive. Consideration should be made to extend the changeout period an additional year. FASTT Team will assist in getting approval.

Machine shop currently disposes of spent lubricating oil. Use of a pump and filtration unit to recycle the lubricating oil in-place instead of wasting it would result in a 90% reduction in waste generation and material purchases.

NALCOOL is required to be used on DDA engines as a rust inhibitor. Ethylene glycol by itself cannot be used. If antifreeze is required, the engine must be drained of the NALCOOL/water mixture and a mixture of water/ethylene glycol/NALCOOL must be used. NALCOOL is a hazardous waste and cannot be recycled when used with ethylene glycol. If ethylene glycol is approved for usage it can be recycled and the NALCOOL/water mixture would not have to be drained when antifreeze is required.

Determination of oil change interval is different for each shop. Methods used include operating hours, calendar time, NOAP analysis, and portable analysis units. A simple, consistent test for oil life would insure proper change intervals. Action would ensure best interval for both HW disposal and engine life.

Shop services 5 vehicles and uses the Safety Kleen system infrequently. The solution is drained once per month whether or not it needs changing, and is treated as a HW. Shop could end Safety Kleen contract and use that of another nearby shop.

Puncturer and Crushers

Used oil filters generated by the entire activity are currently drummed in 55 gallon drums and disposed of as hazardous waste. Use of an oil filter crusher would reduce the volume of filters and remove residual oil. This would result in a 100% reduction of hazardous waste, a 90% reduction in 55 gallon drums used for disposal, and oil which can be recycled. Annual savings anticipated is $12,400, with a payback period of less than a year.

Approximately eight 55 gallon drums of used oil filters are generated each year for vehicle maintenance and are disposed of as bulk solid waste. Oil filters can be recycled. The filters can be crushed to remove most of the oil, which can be recycled, and the metal can be sold for scrap. Use of an oil filter crusher is estimated to provide an annual savings of $608, with pay back achieved in a little over one and a half years.

Recycling/BMP

The activity generates over 20,000 gallons of waste oil annually from vehicles and other machinery. Over one-half million gallons of bilge oily waste water etc., is also generated annually, which if separated can yield an additional 10,000 gallons of waste oil. Currently, the waste oil is given away to private companies. However, waste oil blending with #2 fuel oil for power plant operations is immediately feasible. In fact, six years ago a feasibility study was conducted with positive results. Implementing this process would result in a reduction of 147,000 pounds of hazardous material, 210,000 pounds of hazardous waste, and an annual savings of $14,600.

PWC's current contract for recycling refrigerant, ethylene glycol, used paint cans, oil filters, etc., is scheduled for renewal. FASTT recommends modifying the contract to include: recycling equipment for R-134A refrigerant; an antifreeze recycler; a paint can crusher; and an oil filter crusher. These items will help to reduce or eliminate waste streams.

A premixed outboard motor oil/gas mixture is used to fuel engines for SEAL Team Operations. Mixture remaining in tanks after operations is discarded as HW. SEAL Teams should make use of a recycling drum to collect materials which could be reused by the Marina or other sites which use two cycle oil/gas mixtures. The action would reduce both disposal and purchase expenses.

Work Center is disposing of approx. two 55-gallon drums of MIL-L-23699 per month from engines inducted for maintenance. FASTT recommends evaluating and possibly prototyping the purification and reuse of MIL-L-23699. This action would provide savings in disposal costs as well as procurement of new lube oil.

Refrigerant Recovery

Shop maintains air-conditioning equipment on submarines. Current recovery units are not compatible with new, more environmentally friendly refrigerants in other on-board equipment. Procurement of an oil-less refrigerant recovery unit will save labor by allowing for refrigerant collection by use of the same unit (no disassembly, flushing, reassembly required).

Shop services 200 mini-refrigerators, 5 galley refrigerators and 9 central air conditioners. Maintenance on each requires removal of freon and purchase of new freon in 50 pound containers. Current collection and recharging equipment cannot recycle freon. FASTT Team recommends procurement of a unit capable of capturing, filtering, drying and recharging the old freon.

Solvent Filtration Units

Only half of the existing cleaning stations are equipped with a particulate filter to extend the life of cleaning solvents. FASTT recommends reviewing the Safety Klean contract to see if filters could be installed on the remaining cleaning stations. Wastes from the cleaning stations could be reduced by approximately 480 pounds.

Four Safety Kleen tanks are maintained primarily for cleaning bearings. Safety Kleen periodically replaces the solvents in the tank, but the solvent is manifested as hazardous waste. Solvent parts washers with ultra filtration are available. These units prolong the life of solvents, thereby reducing the frequency of change-outs and generating less waste. FASTT will provide technical information to the activity regarding these systems.

Testing and maintenance of torpedoes generates spent otto fuel and solvents that are considered hazardous wastes. The otto fuel is currently being recycled. Implementing the use of a filtration unit for filtering solvents could extend the life of the solvent by 100%, and result in a savings of $500 through reduced solvent purchase and spent solvent disposal.

Approximately 4,500 gallons of mineral spirits are used per year to clean MK-48 torpedoes. Workshops estimate that it costs approximately $9,675 per year to dispose of used mineral spirits, which are contaminated with byproducts including cyanide and heavy metals. The use of a filtration unit can extend the life of the solvent up to four years, which in turn can reduce new material usage and disposal costs by as much as 75%.

ONR currently using Proline 1220 cleaner to clean paint equipment. The solvent becomes thus contaminated and must be disposed of as hazardous waste. Cleaning solvents can be recycled using a self-contained distillation system. Procurement of system would save on labor and costs for solvents and solvent disposal.

Solvent Recycling

BQ 34 Drone engines are flushed with P-D-680 to clean the engine of residual oil and seawater. The P-D-680 waste is consolidated with corrosion preventative waste in the same waste container, even though it is minimally contaminated with oil and water. FASTT recommended that the P-D-680 waste be segregated and submitted to the CHRIMP Center for reuse. The P-D-680 can be used on any non-specification parts cleaner such as Army Reserve or Navy SEALs. This opportunity could reduce new material costs by $2,085.

Activity maintains a contract with Safety Kleen to supply parts washing and P-D-680 recycling services. The Safety Kleen solvent is recycled off-site, which requires the spent solvent to be manifested as hazardous waste. An additional concern is that P-D-680 produces hazardous fumes. Safety Kleen offers an alternative service which provides a cyclonic separator and filter. Particulates are removed from the solvent and transported off-site. The life of the solvent is extended. The alternative service costs approximately the same as the current service, but will reduce off-site manifesting of hazardous waste by 90% and improve worker safety.

After flushing target motors with P-D-680, 5 gallons of MIL-C-8188 corrosion preventative is flushed through the motor. This material is collected and disposed of a hazardous waste. Recycling the corrosion preventative appears to be feasible in this situation, since the engine has already been drained of oil and seawater and flushed with P-D-680. FASTT is investigating the purity requirements for the corrosion preventative and the suitability of recycling, and will seek approval to recycle the corrosion preventative compound if appropriate. Recycling the MIL-C-8188 can potentially reduce material and waste costs by 75%.