GEORGIA TECH RESEARCH INSTITUTE ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY POLLUTION PREVENTION PROJECT

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1 GEORGIA TECH RESEARCH INSTITUTE ENVIRONMENTAL SCIENCE AND TECHNOLOGY LABORATORY POLLUTION PREVENTION PROJECT Company: Contact : Primary Products: Chevrolet-Pontiac-Canada Group Doraville Plant General Motors Corporation 3900 Motors Industrial Way Doraville, GA Don L. Smith Senior Staff Engineer Environmental & Energy Plant Engineering Automobiles (Cutlass Supreme) Project Scope 1. ELPO (Electrodeposition) Paint Filters - DO08 2. Purge Thinner - DO01 3. Waste Paint - DOOl 4. Waste Oil - Non-Hazardous 5. Batteries - Recycled 6. Waste Water Treatment Sludge - Non-Hazardous 7. Paint & Sealer Sludge - Non-Hazardous Due to the limited amount of time, limited amount of resources, previously implemented pollution prevention technologies, plant size and diversity of plant operations, it was decided that a limited project scope was necessary. In addition, the plant has a full-time employee responsible for complying with state and federal regulations as well as evaluating pollution prevention options. Once the above listed possibilities were reviewed, the "ELPO paint filters" study was chosen as the main subject to be analyzed. P- 1

2 Two different kinds of filter system hazardous waste were observed: P a. ELPO Filter Bag - a long cylindrical filter bag with a plastic ring for positioning in the filter pot. Approximately 100 of these bags are used weekly and must be disposed of as DO08 hazardous waste because of the content of leachable lead. b. Ultrafilter Cartridge - cartridge composed of numerous capillary-like tubes encased in a plastic cylinder. Approximately 130 are in use and are required to process the proper amount of filtrate to satisfy the system. Occasionally these are replaced and must be disposed of as DO08 hazardous waste. Sample Laboratory Test Result for ELPO Filter Bag Contaminant Arsenic, mg/l * Barium, mg/l * Cadmium, mg/l * Chromium, mg/l * Lead, mg/l * Mercury, mg/l * Selenium, mg/l * Silver, mg/l * TCLP Results EPA Method # ** Regulatory Limits < < < * Concentration in TCLP Leachate per EPA method ** Individual method for particular metal as specified in EPA SW846. Analytical tests were performed for other parameters (remaining RCRA TCLP Rule organics, herbicides, and pesticides) and indicated levels were below the regulatory limits. The only contaminant of concern is lead and its concentration varied from approximately 50ppm to 175ppm. P-2 1

3 Process Description The following description emphasizes those operations associated with the generation of waste in the paint filtering system. The assembly plant has four basic assembly departments: 1. Body 2. Paint 3. Trim 4. Chassis! \ The body shop assembles and welds all component parts together to form the body-in-white. Once the body-in-white is completely assembled it is then conveyed to the paint department where all painting operations are completed. The first operations are cleaning with organic detergent and the application of a zinc phosphate coating followed by a chromic acid rinse. The body is then air-dried and enters the cathodic electrodeposition tank where it is coated with the corrosion resistant primer containing lead pigments. All excess undeposited paint is removed by subsequent rinsing. The rinsewater is recirculated and constantly filtered to remove any foreign particles. Magnets are also placed in the tanks as well as in some of the filters to remove any ferrous metal particles. Filter bags are replaced weekly and two filter pots are changed at the same time since they are fed by a common pump series. This varies slightly from filter pot to filter pot depending on the pump arrangements. Filters are temporarily isolated from the system by a valve arrangement. The top of the filter pot is removed and each bag is individually taken out of the pot and placed in a plastic bag, which is then thrown into a gondola. The maintenance department then transports the gondola to the hazardous waste storage area where the bags as well as an occasional ultrafilter cartridge are loaded into drums where they will be subsequently shipped to a permitted TSD facility. P-3

4 CLEANING Process Diagram I ZINC 4 PHOSPHATE COATING AIR DRYING I RECIRCULATED DEIONIZED WATER UPPER / LEVEL ULTRAFILTRATE RINSES. -. CATHODIC 1' ELECTROO POSI 1lON TANK -4 I -- -

5 5 The following table gives more details on the types of filters used: Filter Bam Filter Type # of Filter Pots ELPO Re circul a t ing 5 Ahead of Ultrafilters 2 Ultrafiltrate Rinses 2 # of # of Filter Magnets Bags ; Deionized Water Rinse I 01 10! Total # of Filter Bags I I 97 Ultrafilter Cartridpes Filter Type Ultrafilter Bank B Ultrafilter Bank C # of Cartridges Total # of Cartridges P-5

6 Efforts to Reduce Waste Observed efforts related to the paint filter project include: The paint filter bags (D008 Hazardous Waste) were segregated from other non-hazardous paint wastes in order to reduce the paint related wastes that must be handled as hazardous waste. - New state-of-the-art ultrafilter cartridges were purchased which reduces the amount of waste generated since they do not have to be disposed of as often. - An in-house repair program was established. Approximately thirteen ultrafilters had to be disposed of weekly and this number has been reducea to 4 or 5 non-repairable cartridges per year. Recommendations These recommendations are not based on a formal economic analysis. An evaluation of cost data is not included as part of the study. Source Reduction Elimination of Lead in Primer Manufacturers of corrosion resistant primers containing lead pigments have been under considerable pressure from both public and private sectors to eliminate these traditional inhibitive systems due to their toxicity. Formulators are continuously researching and working together with applicators to try to develop new corrosion resistant primers that do not contain lead. The use of lead pigment offers the maximum corrosion protection for the automobile body. No replacement pigments have been found that offer the same corrosion protection for the automotive industry but this should be considered as a long-term goal. P-6

7 Lower Quantity of Foreign Particles that Reach the Filters The material buildup on magnets in the tanks as well as in the filters was analyzed. Under the microscope, it was evident that they were metal particles. By increasing the number of magnets in the tanks, cleaning them more often to reduce buildup, or inspecting and removing any foreign particles from the body-in-white before they enter the tank, the number of foreign particles the filter must capture will be minimized, which may increase the life of the filter bags, and consequently, decrease the number of bags that will have to be disposed. Purchasing More State-of-the-art Ultrafilter Cartridges Some new state-of-the-art ultrafilters are already being used and as the old ones have to be replaced, it is suggested that they be replaced by the new more efficient ultrafilters which do not have to be disposed of as often evdn though the more efficient cartridges are 30% more expensive. Minimize Drag-out Enough time should be allowed for paint drag-out to drain back into the paint filter system. A method for determining the quantitative effect of reducing drag-out would be to weigh the filter bag in a plastic bag before draining, weigh after draining, and determine the amount of time to significantly reduce drag-out. In this way a minimum amount of drain time could be specified. If a significant reduction is observed, a rack could be devised that would fit over the filter pot and raise the bags above the bottom layer of liquid. This would effectively drain the filter bags with minimal employee exposure and effort. A squeegee consisting of spring-loaded rollers that would have enough tension to remove excess paint from filters could also be used to minimize drag-out. However, appropriate measures should be taken to minimize employee exposure. P Recycling/Reu se Recycling The recycling option is not feasible because once the life of the filter bag has expired, it can no longer be efficiently used for filtering. P-7

8 Fuel Substitution It has been proposed that the waste could be used for fuel substitution.fue1 substitution involves using hazardous waste as a fuel in industrial furnaces or in boilers for generation of steam. The hazardous waste may be blended with other non-hazardous wastes and/or fossil fuels. The wastes used for fuel substitution can be handled in a solid, liquid, or gaseous form. The parameters that affect the selection of fuel substitution are (in the case of solid waste): 1. Halogen content of the waste; 2. Inorganic solids content (ash content) of the waste, particularly heavy metals; P 3. Heating value of the waste; and 4. Sulfur content. The heating value of the waste must be high enough (either alone or in combination with other fuels) to maintain combustion temperatures consistent with efficient waste destruction and operation of the furnace. For many applications, only supplemental fuels having minimum heating values of 8,000 to 10,OOO BTU/lb can be considered to be feasible. The ELPO filter bags have a BTU/lb value of approximately 11,000 and fulfills the other prerequisites for fuel blending. This option was more expensive than the current method for treatment and disposal under consideration based on the current purchase order of $293/Drum versus $212/Drum. Treatment Wash the Filter Bags Prior to replacing the filter bags, they could be flushed with water in the filter pot system. The water would then be sent to on-site waste water treatment system where it would be appropriately treated. Further testing is required to determine the amount of leachable lead in the washed filter bags and wastewater treatment sludge, the amount of water necessary to appropriately rinse the bags, and the amount of time required. Research should be conducted to determine the most efficient way to clean the filter bags and to determine whether or not the regulatory limits could be met., P-8

9 Vitrification Glass vitrification is a high-temperature stabilization technology that is applicable for treatment of lead-containing wastes. Glass vitrification is.a process wherein the waste is blended at fairly low concentrations into a mixture of lime, soda ash, silica and other ingredients normally used for glassmaking. The blended waste and glass constituent mixture is then fed to a glassmaking furnace. Material is normally introduced near the top of the furnace and descends to the surface of a pool of molten glass maintained at lloo C to 12OOOC. At these temperatures, organic constituents of the water are combusted, and inorganic constituents dissolve into the glass melt. Molten glass is withdrawn from the base of the furnace and cooled into chunks or blocks. The waste inorganic constituents become physically and chemically incorporated into the glass matrix. A more detailed cost analysis of this option is necessary to determine its feasibility. P Bibliography Barlow, James, et Al. Treatment Technolow Background Document(l989b), EPA/530/SW-89/048A. Environmental Protection Agency, Washington, DC. June Rosengrant, et Al. Final Best Demonstrated Available Technology (BDAT) Background Document for DO08 and P and U Lead Wastes. Volume 23. Versar Inc. Springfield, VA.EPA/53O/SW-90/059W. May P Rosengrant, et Al. Final Response to BDAT Related, Comments Document: DO08 and P and U Lead Wastes. Volume 1-H. EPA7530/SW-90/061J. May P Memorandum, Lasko, T.C., CPC Doraville, to Smith, D., CPC Doraville, June 20, P-9

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