To Compliance and Beyond Valley Chrome Plating s s Journey to Zero Discharge
Presenter Ray Lucas President: Valley Chrome Plating Inc. Past President: NASF Board Member: M.F.A.N.C. Manufacturer of Truck Bumpers Zero Discharge Decorative Chrome Plating 1st Plating Shop in U.S. to be permitted for Nickel Air Emissions. Participant in Environmental Management Systems In application process for DTSC Model Shop Program
Valley Chrome Plating Company History Founded 1961 Originally Job Shop Car bumper routes Production Decorative Electro-Plating Truck Bumper Manufacturing
Environmental Goals 100 % Compliance 1st Plating Line in U.S. to be permitted for Nickel Emissions - Award of Distinction Zero Discharge VCP as Industry Leader Seminars for S.J. Valley Platers and Regulators, CUPA, EPA. Sharing Vision & Success on National Level
Regulatory Changes Clean Water Act of 1977 Catalyst for Inspections Increased Public Scrutiny High Profile Cases Expanded Regulations Discharge limits 3.5ppm -1.3 ppm
Regulatory Requirements Emergency Emergency Response Response Employee Employee Training Training Facility Facility Inspections Inspections USEPA USEPA DTSC DTSC CUPA CUPA POTW POTW RWQCB RWQCB SCAQMD SCAQMD Cal/OSHA Cal/OSHA Hazardous Hazardous Waste Waste Hazardous Hazardous Materials Materials Process Process Wastewater Wastewater Storm Storm Water Water Air Air Pollution Pollution Worker Worker Safety Safety Used with Permission Chemical Solutions Inc.
general metals wastewater Typical Wastewater Treatment System chelated metal wastewater cyanidebearing wastewater Chelated Metals Treatment Cyanide Destruction Supernatant Precipitation and Settling Sludge Treated Effluent Sample Point chromebearing wastewater Oily wastewater Chrome Reduction Oily Waste Treatment Filter Cake Filter Press Off-site disposal City Sewer
Compliance Approach What Is the Best Approach to Compliance? Traditionally Treat Discharge Dispose A Cost of Doing Business Not a Main Part of the Business More Sensible Approach P2 First! Lower Costs (Ultimately) Lower Liability Better Compliance More Sleep! Used with Permission Chemical Solutions Inc.
What s s the Problem w/ Precipitation? 1. Chemicals to Precipitate A 2. Polymer to Flocculate Clarifier Yikes! Waste Treatment Unit Used with Permission Chemical Solutions Inc.
An Example Zero-Discharge Shop Plating Tanks Water Reuse Flowing Rinse Chelated Tanks Flowing Rinse Water Recycle Spent Baths Condenser Chelate Resin IX Resin Evaporator OPTION: Batch treat concentrates then evaporate. Solids Off-Site Disposal IX Regen Used with Permission Chemical Solutions Inc.
Effects of Achieving Zero Discharge Positive Side Effects Saving H2O No discharge to POTW Re-use of Chemicals Resulting in $$ savings Negative Side Effects Poor Rinse Quality Higher reject rate (in house/in field) Higher Waste Treatment Costs
Pre-Plating Plating Improvements Necessary to Achieve Zero Discharge Ultraviolet light Filtration Counter flow rinsing Weirs & Oil Superator Evaporation Batch Treatments
Superator
Typical Zero Discharge Rinse Set Up Cleaner Dead Rinse Rinse Rinse Spray Nozzle Pump Return to rinse Filtration / Ultraviolet 1) Live rinses are pumped to holding tanks where they are treated & filtered and returned to the rinses every few weeks. Decanted solids are sent to evaporator / waste treatment unit. 2) As Cleaner evaporates, dead rinse is added to cleaner tanks. Counterflow rinses are added to dead rinse so the closest tank to process tanks is always the cleanest.
Typical Rinse Set Up After Ni. Plating Line To Ion Exchange Counterflow Plating Dead Rinse Rinse Rinse Rinse Tank From Ion Exchange Spray Nozzle Pump Carbon Filtration Counterflow 1) Counter flow rinses are kept clean by removing metals through Ion Exchange. Organics are removed by carbon bed. 2) Dead Rinse (Nickel) is filtered with granular carbon at all times. This solution is added back daily to Nickel tanks. 3) Rinses after Nickel Tanks are the same water from 1987 and looks crystal clear. 4) When greenish tinge and TDS go up, Ion Exchange columns are regenerated.
Nickel Process Changes Carbon Anodes Reduction of Nickel Metals Re-Use of Nickel (post generation) Dead Rinses
Ion Exchange Technology Nickel Counterflow Rinsing Filtration Carbon Treatments Trial & Error Spray Rinsing Chrome Counterflow Rinsing Evaporation Porous Pots Dummying
Ion Exchange From rinse tanks Cation Resin Anion Resin To rinse tanks Removes Metals from Rinse Anion Resin 1) Rinse water is cycled through resin which captures metals. (nickel or chrome) 2) Clean rinse water is returned to rinses (pumps). Ion Exchange Unit 3) When resin is saturated with acids, caustic is added to release elements and then sent to evaporator. Cation Resin 1) Rinse water is cycled through resin which 2) Clean rinse water is returned to rinses (pumps). 3)When resin is saturated with metals, acid is added to release metals into holding tank --> reclaim add back to bath.
Going to Zero Discharge STEP 1 Separate waste streams Spent Concentrates Dragout Rinsewater Dilute Rinsewater Chelated Materials Soapy Materials Misc. Low-Volume Wastes (e.g. solvents) Used with Permission Chemical Solutions Inc.
Going to Zero Discharge STEP 2 Apply Source Reduction Measures to Shop Spill controls Flow controls Dragout controls and rinses Spray rinses Bath life extensions Acid Filtration, Weirs, Routine Maintenance (tank bottoms) Training ongoing supervision Used with Permission Chemical Solutions Inc.
Going to Zero Discharge STEP 3 Find a Home for each Waste Stream Increase temperatures of baths Recapture dragout For Example: Spent Concentrates treat or ship Dragout Rinsewater recapture or treat Dilute Rinsewater recycle Chelated Materials pretreat Soapy Materials treat Solvents offsite recycle Used with Permission Chemical Solutions Inc.
Going to Zero Discharge Pt. STEP 4 Develop equipment Scheme Ion Exchange for rinsewater recycle Evaporator for treatment of concentrates Ship offsite for untreatable materials Do your homework! (reduce liability) Pt.IIII Used with Permission Chemical Solutions Inc.
Going to Zero Discharge STEP 5 Build/Install/Startup Readily available equipment Installation relatively simple Startup critical! Used with Permission Chemical Solutions Inc.
Going to Zero Discharge STEP 6 Train Retrain Supervise and test Set training schedule in writing Set expectations for employees Train the employees to train! Used with Permission Chemical Solutions Inc.
New Technology Vendor Showcase 2001 Regulatory Consultation Environmental Management Systems Visiting Other Sites Tradeshows Vendor s s Showcase Sur/Fin AESF Regionals Associations NASF Regional Affiliates / Branches Industry Consultants EMS Program - Bay Area
Storm Water Capture The Next Goal Capture & Re-use of all rain water landing on our facility. Environmental Lawsuits will require metals and other limits in runoff. Use of runoff will help reduce plant water usage. Elimination of permit and regulatory reporting requirements.
Storm Water Capture Collect rain from downspouts (8000 gal cap.) Pump to holding tank @ plating line. Filter water. Pump into rinses to replace evaporated H20 Interior tank has overflow prevention switch. Exterior tanks can overflow if capacity is achieved. Water claimed is Soft Water.
Storm Water Capture Process Roof / Downspouts Meter Auto Float Overflow pipe Carbon Filter To Rinses Pump Capture Tanks Berm 3000 gal. cap. 1500 gal.cap. Overflow Outside Inside Overflow Containment (Alarmed)
Tri-Chrome vs. Hex Chrome Benefits of Hex Chrome Harder, thicker, bluer. Benefits of Tri-Chrome Chrome Environmentally friendly, better throw, no buffing Latest Generation of Tri-Chromes Chromes Thickness, corrosion, hardness CARB Passes New Regulations in California Two year window
Typical Parts that are Trivalent Chrome Plated
Cr +3 Advantages -- Eliminates use of Cr +6 -- Provides environmental benefits -- Enhances worker safety (PEL) -- Affords easier waste treatment -- Reduces solid waste disposal problems -- Is less destructive to processing equipment
Cr +3 Advantages Improves productivity -- Allows for more parts on plating racks because: (a) coverage is better in recessed areas (b) less burning in high current density areas
Cr +3 Advantages Improves productivity -- Fewer rejects because: (a) process is tolerant to current interruption (No chrome white wash ) (b) process is more tolerant to presence of organic films
Hazardous Waste Reduction Waste Hauled by Year 180,000 170,379 160,000 157,336 140,000 124,253 120,000 Lbs of Waste 100,000 80,000 105,164 97,840 87,297 67,255 60,000 40,000 20,000 0 1999 2000 2001 2002 2003 2004 2005
Environmental Compliance Sleep Factor Environmental Compliance / Reduction of Discharge Amount of Sleep (used with permission -Jim Miille Chemical Solutions Inc.)
Plating Industry Future Sharing of Resources & Solutions Coordination Between Agencies Survive together or die together Increased scrutiny by regulators and public Disintegration of supplier base. Disintegration of customer base Other modes of coating
Contact Information Ray Lucas: : Valley Chrome Plating Inc. (559) 298-8094 8094 ray@valleychrome.com