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Pollution Prevention for Machining & Metal Fabrication

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Pollution Prevention for Machining & Metal Fabrication ......................... Pollution Prevention in Machining and Metal Fabrication A Manual for Technical Assistance Providers March 2001 ......................... Acknowledgments NEWMOA is indebted to the U.S. Environmental Protection Agency’s Pollution Prevention Division for its support of this project. The Northeast states provided in-kind support. NEWMOA would also like to thank those who provided advice and assistance, especially those who volunteered to peer review the draft: Vincent Piekunka, Bartley Machine and Manufacturing Company, Inc. David Westcott, Connecticut Department of Environmental Protection Doug DeVries, Hyde Tools Chris Rushton, Maine Department of Environmental Protection Rich Bizzozero, Massachusetts Office of Technical Assistance Joe Paluzzi, Massachusetts Office of Technical Assistance Chris Wiley, Pacific Northwest Pollution Prevention Resource Center Paul Van Hollebeke, Vermont Agency of Natural Resources Greg Lutchko, Vermont Agency of Natural Resources Project Staff/Contributors Andy Bray, NEWMOA Project Manager – Researcher/Author Terri Goldberg, NEWMOA Deputy Director – Managing Editor Lisa Rector, NEWMOA Project Manager – Editor Cynthia Barakatt, Communication Consultant – Copy Editor Beth Anderson, EPA – EPA Project Manager Beverly Carter, Fineline Communications – Cover Design and Layout Disclaimer The views expressed in this Manual do not necessarily reflect those of NEWMOA, US EPA, or the NEWMOA member states. Mention of any company, process, or product name should not be considered an endorsement by NEWMOA, NEWMOA member states, or the US EPA. NEWMOA welcomes users of this manual to cite and reproduce sections of it for use in providing assistance to companies. However, the Association requests that users cite the document whenever reproducing or quoting so that appropriate credit is given to original authors, NEWMOA and US EPA. NEWMOA thanks you for cooperating with this request. Northeast Waste Management Officials’ Association The Northeast Waste Management Officials’ Association (NEWMOA) is a non-profit, nonpartisan, interstate government association. The membership is composed of state environmental agency directors of the hazardous waste, solid waste, waste site cleanup, and pollution prevention programs in Connecticut, Maine, Massachusetts, New Hampshire, New York, Rhode Island, and Vermont. NEWMOA’s mission is to help states articulate, promote and implement economically sound regional programs for the enhancement of environmental protection. The group fulfills this mission by providing a variety of support services that facilitate communication and cooperation among member states and between the states and EPA, and promote the efficient sharing of state and federal program resources. NEWMOA was established by the governors of the New England states as an official interstate regional organization, in accordance with Section 1005 of the Resource Conservation and Recovery Act (RCRA). The organization was formally recognized by the U.S. Environmental Protection Agency (EPA) in 1986. It is funded by state membership dues and EPA grants. NEWMOA established the Northeast States Pollution Prevention Roundtable (NE P2 Roundtable) in 1989 to enhance the capabilities of the member state environmental officials to implement effective source reduction programs. The NE P2 Roundtable’s program involves the following components: (1) managing a regional roundtable of state pollution prevention programs; (2) publishing a newsletter; (3) managing a clearinghouse of books, reports, case studies, fact sheets, notices of upcoming meetings and conferences, and a list of P2 experts; (4) organizing training; and (5) conducting research and publishing reports and other documents. The clearinghouse provides pollution prevention information to state and local government officials, the public, industry, and others. Funding for the NE P2 is provided by the NEWMOA member states and the U.S. EPA. For more information on the Roundtable, contact: Terri Goldberg, NEWMOA Deputy Director, 129 Portland Street, 6th Floor, Boston, MA 02114, (617) 367-8558 ext. 302; 617-367-0449 (fax); [email protected] (email). NEWMOA is part of the Pollution Prevention Resource Exchange (P2Rx). P2Rx is a national network of regional P2 information centers located throughout the US. As part of P2Rx, NEWMOA and the other regional centers are able to access a broader pool of information and expertise when responding to the needs of state and local technical assistance providers. The regional P2 information centers that comprise P2Rx allow for the two-way flow of information from the state and local level to the national level. For more information on P2Rx, contact: Andy Bray, NEWMOA Project Manager, 129 Portland Street, 6th Floor, Boston, MA 02114, (617) 367-8558 ext. 306; (617) 367-0449; [email protected] (email). Printed on Recycled Paper TABLE OF CONTENTS CHAPTER 1.Overview of Metal Fabrication Industry.................... 1 Background ......................................................1 Metal Shaping and Removal Processes ...................................2 Metal Shaping Processes ........................................2 Metal Removal Processes ........................................4 Nontraditional Machining ............................................7 Metalworking Fluid Overview..........................................8 Tool and Workpiece Cooling .....................................8 Chip Removal ................................................8 Lubrication ..................................................8 Fluid Classification ............................................9 Fluid Components ............................................9 Heat Treating ....................................................10 Surface (Case) Hardening ......................................13 Quenching .................................................13 Brazing and Soldering..............................................13 Brazing ....................................................14 Soldering ..................................................14 Adhesive Joining..................................................16 Welding and Weld Cutting...........................................19 Buffing and Polishing...............................................19 Tumbling and Vibratory Finishing......................................19 CHAPTER 2.. Regulatory Overview................................. 21 Common Wastes in Metal Fabrication Facilities ............................21 Wastewater ................................................21 Solid and Hazardous Waste .....................................22 Air Emissions ................................................23 Overview of Federal Regulations Affecting Metal Fabricators...................23 Clean Water Act .............................................24 Management of Used Oil .......................................25 Resource Conservation and Recovery Act ............................26 Toxics Release Inventory Reporting ................................28 Metalworking Fluid Requirement ..................................29 Clean Air Act ...............................................30 State Pollution Prevention and Toxics Use Reduction Laws.....................33 Connecticut ................................................33 Maine ....................................................33 Massachusetts ...............................................34 New Hampshire .............................................34 New Jersey .................................................35 New York ..................................................35 Rhode Island ................................................36 Vermont ...................................................36 CHAPTER 3.. Overview of Pollution Prevention Opportunities and Methods . 37 Metalworking Fluids................................................37 Fluid Selection ...............................................37 Fluid Application .............................................40 Fluid Maintenance ............................................41 Metal Waste Reduction..............................................42 Machine Maintenance/leak Prevention ..................................43 Cleanup Processes/persistent Leaks ...............................43 Parts Cleaning....................................................44 Why Are Parts Cleaned? .......................................44 Tumbling .......................................................44 Heat Treating ....................................................45 Quenching......................................................45 Welding ........................................................46 Brazing.........................................................46 Soldering .......................................................46 Adhesion Joining..................................................47 Buffing and Polishing...............................................47 CHAPTER 4. Pollution Prevention and Metalworking Fluids - Selection, Maintenance, and Application.......................... 49 Fluid Selection....................................................49 Cost ......................................................50 Recyclability/treatability ........................................50 Cleanability/cleaning Bath Life Extension ...........................51 Standardization - Using as Few Fluids as Possible .....................52 Vegetable-based Fluids ........................................52
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