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1 2’ Pollution Prevention in Mass-Finishing Operations 2\LO/L by Eugene Park, Ijf Chemical Engineering Department, University of Rhode Island, Kingston, R.I

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1 2’ Pollution Prevention in Mass-Finishing Operations 2\LO/L by Eugene Park, Ijf Chemical Engineering Department, University of Rhode Island, Kingston, R.I ‘1 2’ Pollution Prevention in Mass-Finishing Operations 2\LO/L by Eugene Park, iJf Chemical Engineering Department, University of Rhode Island, Kingston, R.I. result of any mass-finishing a variety of manufactured parts and can metal sludge that is usually dewatered operation is the generation of he found in industries such as jewelry with a filter press prior to off-site Awaste in the form of wastewa- and machine tool manufacturing. Vi- disposal as waste and sometimes even ter and sludge. Traditionally, waste bratory and tumbling machines are two hazardous waste. In companies that streams from mass-finishing opera- very common types of mass-finishing rely on other waste-generating proc- tions have been chemically treated to equipment. The waste effluent, esses such as electroplating, the tuh- meet sewer discharge requirements. In whether from a batch or continuous hinglvihratory waste is sometimes most instances, and prior to chemical process, consists of soapy water, pul- mixed with these other streams prior to treatment, mass-finishing wastewater verized media, and both soluble and end-of-pipe treatment. Depending on is mixed with other metal-bearing insoluble metals of the type found in the capacity of the finishing operation waste streams originating from very the metal parts being processed. and any other wastewater-producing different manufacturing operations. Figure 1 describes the flow scheme process in the plant, the costs of these A new, preferred approach toward of a typical mass-finishing operation. chemical-treatment systems vary. minimizing the generation of waste Depending on the finishing operation, Capital and operating costs can vary from mass-finishing operations is the waste solution generated can vary. widely for different waste streams and called pollution prevention. Pollution Analytical tests were carried out on flow capacities. The major capital costs prevention or source reduction means used solutions at different companies. include tanks, controls, pumps, and that waste should be reduced or elimi- Although the results vary, some gen- mixers. The major operating costs in- nated at the source as opposed to eral consistencies are observed. Most clude chemical costs, labor, and sludge end-of-pipe treatment. For the mass- of the solids found in the waste stream disposal. If the sludge is hazardous, the finishing operation, pollution-preven- consist of plastic or ceramic media. operating costs increase significantly tion measures include process modifi- Because the hardness of the metal parts due to higher disposal and labor costs. cation and in-process recycling. Input is much higher than that of most Liabilities are also much greater. Sound materials such as the metal type, plastics and ceramics, the plastic and pollution prevention or source reduction finishing media, and soap should be ceramic media tend to erode faster than measures can result in substantial reduc- studied for possible modification to the metal; however, significant metal tions in costs and liabilities. prevent potential waste. The type of levels of the metal type used in the mass-finishing equipment employed in finishing operation are still observed. POLLUTION PREVENTION the process can also influence the For example, one company manufac- amount of waste generated. In some tures zinc alloy fasteners; the vibratory Pollution Prevention is now the cases, hazardous OT toxic cleaning operation used to clean and polish preferred method for environmental chemicals can be replaced hy the these fasteners produces a waste stream protection. In contrast to the end-of- aqueous-based tuhhing or vibratory that contains 320 mg/L of zinc and pipe waste treatment approach, pollu- operation. Once all possible process 1,770 mgL of total suspended solids tion prevention is defined by the US. modifications are made and waste (TSS). In all of these cases, the solution Environmental Protection Agency as streams segregated, the finishing solu- cannot be discharged to the sewer “the use of materials, processes or tion can be recycled to further mini- without treatment because of high practices that reduce or eliminate the mize waste leaving the operation. In levels of metals, suspended solids, and creation of pollutants at their source.” some applications, the same soap solu- sometimes oil and grease. Traditional Source reduction, the defining theme tion can be reused for up to one year. treatment has included end-of-pipe of pollution prevention, can be carried Soap purchases, waterkewer fees, chemical addition to remove metals out in many ways. Where source and environmental liabilities may all and solids prior to discharge. reduction is successfully used, the need ~ be reduced. In most cases, a reasonable for treatment and disposal is often payback is achieved on equipment TRADITIONAL TREATMENT dramatically reduced. Most of the purchases. Many companies have al- technical-based solutions are process TECHNOLOGIES ~ ready successfully implemented pollu- engineering modifications that require tion prevention into their mass-finish- Chemical-treatment technologies varying amounts of development re- ing operations with excellent results. have been used by many companies to search and testing. As described in produce water clean enough for sewer more detail later in this article, many effective technical solutions have been BACKGROUND discharge. In most cases, different chemicals are used for pH adjustment developed by different organizations; Mass finishing is a mechanical proc- and metal flocculation. The end result this information can he readily shared ess used to deburr, polish, andor clean is metal-free water and precipitated with other companies. Examples of 14 a Copyright Elsevier Science Inc. METAL FINISHING NOVEMBER 1994 Your OneStop-Wter lhattnent-Shop With complex regulatory demands and increasing Services RCRA permitted centralized treatment facility costs for clean water, metal finishers are faced with recovers metals through a unique hazardous waste ion a jungle of water treatment options. With over exchange service, eliminating your capital investment. 5,000 installations and experience in metal finishing since RECYCLE dollars back into your business! 1945, US. Filter knows the regulations, understands your Reuse your aqueous cleaners for signi6cant cost savings requirements and provides cost-effective solutions. Only with the MembraloxO SILVERBACK" system W Combine US.Filter can solve & your water and wastewater problems reverse osmosis and Lancy" pretreatment for closed loop with our variety solutions-service, equipment, turnkey. of wastewater reuse. To meet your requirements and improve your bottom line, let the US. Filter gorilla help you reduce, recover, recycle. YOUR ONE-STOP-SHOP! US. Fiter offers the broadest range of technologies and REDUCE your out-of-pocket expenses! capabilities. From metals recovery and water reuse to con- Eliminate need for chemical regeneration associated ~ ventional water and wastewater treatment to part per billion with deionized water by using portable SDI exchange discharge limits, we provide you the complete solution. canisters (service deionization) or Ionpure CDI (continuous Put a Gorilla on your Team Today! Call 1-800-525-0658 deionization) systems. or 412-772-0044. ~ RECOVER metals! LancyTMion exchangers and electrolytic cells recover -~ high punty metals, such as copper W US. Filter Recovery UNITED STATES FILTER CORPORATION a IONWRE LANCV LYCO MEMBRALOX PERMWIT RECOVERY SuperBlue SERVICES SOLUTIONS THROIIGH TFAMFD TECHNOLOGY Clrcle 078 on reader lnlormatlon card AT HANDY& HARMANWE REALIZE THAT BEING ENVIRONMENTALLYCONSCIOUS IS A MATTER OF MORETHAN JUST WORDS AND PRETTY PICTURES. WE’REEXTREMELY PROUD OF ALL WE HAVE ACCOMPLISHED IN THE ALL-IMPORTANT AREA OF ENVIRONMENTAL SECURITY. WE REGARD IT AS A SERVICE TO OUR CUSTOMERS AND A DUTY TO OUR WORKERS AND TO THE COMMUNITIES IN WHICH WE OPERATE. LOOK AT THE LISTING ON THIS PAGE AND SEE JUST SOMEOF WHAT WE DO TO MAKE OUR PROCESSES BOTH CLEAN AND EFFICIENT. THROUGHOUR WORLDWIDE REFINING NETWORK WE SAFELY PROCESS ALL TYPES OF COLD,SILVER, AND PLATINUM GROUP METAL SCRAP AS WELL AS DORE’AND OTHER MINE OUTPUT. WE ARE EQUIPPED AND STAFFED TO SERVICE SMALL CUSTOMERS’ NEEDS AS WELL AS THOSE OF INDUSTRY GIANTS, EXPERIENCE TRUE CONFIDENCE IN A REFINER. CALL HANDY& HARMAN-DEDICATEDTO EXCELLENCE, TODAY AND TOMORROW. Handy&Harman 300 RYESTREET, SOUTH WINDSOR,CONNECTICUT 06074 TELEPHONE1-800-421-041 1 Clrcle 032 on reader lnformatlon card process modifications include replac- Table I. Pollution Prevention Hierarchy ing waste-generating input materials i Source reductiin Process modification to eliminate or reduce pollutants at the source, e.g.. with other materials that do not pro- wlvent elimination, better housekeeping, in-process recycling of spent duce as much waste. In-process recy- materials cling of spent materials is also consid- Recycling OKsite processing 01 waste materials for reuse, e.&, sludge reclamation ered a viable source reduction measure lor metal recovery since the amount of waste leaving the Treatment and disposal End-of-pipe treatment 01 waste prior to disposal, e.g.. chemical treatment system that treats several waste streams prior to sewer discharge with process is reduced. Off-site recycling, hazardous sludae aeneration such as the reclamation of waste materials at a commercial treatment facility, is considered to be a secondary type of mass-finishing machine must and may require a special permit for option to source reduction. End-of- also
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