i Waste Minimization and Wastewater Treatment of Metalworking Fluids 7% book is dedicated to ihe manypeople in ouri"y who are committed to fmpmvingenvironmentalqualfly. Waste Minimization and Wastewater Treatment of Metalworking Fluids a publication of the Independent Lubricant Manufacturers Association Research and Development Committee 651 South Washington Street Alexandria, Virginia 22314 Phone 703/684- 5574 Fax 703/836-8503 Research & Development Committee Chair Ralph Kelly, Cincinnati Milacron Research & Development Committee Vice Chair Paul Dacko, Ideas, Inc. Research & Development Project Director Raymond M. Dick, Cincinnati Milacron Copyright 0 1330 Independent Lubricant Manufacturers Association “MetalworkingFluid Additives for Waste Minimization”by Jean C. Childers, Shu-Jen Huang and Michael Romba is reprinted by permission of the Society of Tribologists and Lubrication Engineers. All rights reserved. The information contained herein is being made available by the Independent Lubricant ManufacturersAssou- ation (ILMA) in the interest of disseminating knowledge about waste minimization and wastewater treatment of metalworking fluids. Neither ILMA nor the individual authors make any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained in this publication. ILMA assumes no responsibility for liability or damage which may result from the use of any of this information. Table of Contents Preface ................................................ Introduction ............................................ Chapter One: Definitions of Metalworking Fluids ...................... .1 Definitions ofMetalworking Fluids ....................................... 2 Greg Foltz, Cincinnati Milacron Products Division Metalworking Lubrication Dethitions ..................................... 5 Elliot S. Nachtman, Ph.D., Tower Oil & Technology Co. Chapter 'haEnvironmental Law ............................... .7 Environmental Iaw ................................................ 8 Jeffrey 1. kiter, Fsq., and Robin A. Fastenau, Esq., Collier, Shannon & Scott SARATitleIII .................................................... 12 Brenda Pinkelton, Cincinnati Milacron Products Division Chapter Three: Fluid Management and Waste Minimization ................15 Establishing a Waste Minimization Program At Your Facility ....................... 16 Harry M. Freeman and Mary Ann Curran, US. Environmental Protection Agency Health and Safety ofMetalworking Fluids .................................. .26 Patricia J. Beattie, Ph.D., General Motors Corp. Microbial Control and Its Impact on Waste Minimization of Metalworking Fluids ........... 31 Dianne P. Carmody, Andy B. Law, and Gary L. Willingham, Ph.D., Rohm and Haas Company Selection of Preservatives for Use in Industrial Lubricants and Metalworking Fluids ..........36 Frederick J. Passman, Ph.D., Angus Chemical Co. Biocide Selection for Metalworking Fluids: Factors to Consider ..................... .43 Cheryl B. French, Olin Research Center Cutting Fluids and Odors ............................................ .46 E. 0. Bennett and D. L. Bennett, Department of Biology, University of Houston Metalworking Fluid Additives for Waste Minimization ........................... .51 Jean C. Childers, Climax Performance Materials Corp., and Shu-Jen Huang and Michael Romba, Nalco Chemical Co. An Overview of Filtration Technology .................................... .63 Jean M. Berger and Jill M. Creps, Henry Filters, Inc. Coolant Management: A Users' Introduction and Guide to Waste Minimization ......................... .80 George L. Hoobler, Master Chemical Corp. Chapter Four: Treatment Options ............................... 85 Wastewater Treatment of Metalworking Fluids: Three Options ...................... 86 John M. Burke, Eaton Corp. Treatment and Disposal of Metalworking Fluids .............................. .95 Terrence L. Heller, Mobay Corp. A Recommended Profile for Determining the Environmental Fate of Metalworking Fluids ............................................. .99 Stan Napier, Keil Division, FERRO Corp. V Chapter Five: Chemical Treatment . , . , , , . , . , . , . 103 Chemical Treatment of Metalworking Fluids . , . , . , , , . ,104 Jean M. Gucciardi, Betz MetChem, The Metal Chemicals Division of Betz Laboratories, Inc. Chapter Six: Physical Treatment . , . 109 Recycling SyntheticFluids Using Ultratlne Fi1tration: an Effective Approach to AchievingWaste Minimization Goals . , . , , . .110 Edward E. Heidenreich, EdjeTech Services, Inc. Waste Minimization and Wastewater Treatment of Metalworking Fluids . ,116 George Skells, Castrol Industrial Central Inc., and Robert H. Brandt, Brandt & Associates, Inc. Evaporative Reduction of Waste coolants and Oily Water . , . , , , , . ,119 Richard J. Bigda, Technotreat Corporation Evaporation: Evaporate the Water Portion of CooIants/Water- Based Was- . ,123 Gary Dixon, Samsco Inc. Introduction to Ultratlltration and Reverse Osmosis , . , . , . ,128 David B. Rubin, Sanborn Chapter Seven: Biological Treatment , , , . , , . , , . 131 Biological Wastewater Treatment of Metalworking Fluids , . ,132 Terry M. Williams, Ph.D., and Ann M. Potcher, Rohm and Haas Company Chapter Eight: Recycling and Disposal of Oils . 137 Recovery and Conservation of Oil-Based Metalworking and Industrial Lubricants ThroughReclamatlon .,.,......,, .................................. 138 Ike Tripp, Jr., Etna Products, Inc. Treatment and Disposal of Oils , , , , , . , . , , , . , , , . , . , , , , . , . , . ,144 Derek Wilkinson and David Peel, BresLube Division of Safety-Kleen Canada, Inc. Chapter Nine: Recycling and Disposal of Solvents . ~ . , . 149 Handling and Disposal ofSpent Organic Parts Cleaner Solvents . , , , , . ,150 Paul Dittmar, Safety-Kleen Corp. Safe Recovery of Solvents by Conductivity Heat Transfer . 155 Peter B. Scantlebury, Finish Engineering Co. Chapter Ten: Container Management , , . 159 Responsible Container Management . , . , , . , . , , . , . ,160 Daniel W. Barber, Daniel W. Barber, Inc. Glossary of Terms . , . , , , , , , . , . , , , , , , , , . 163 Appendix: For Further Information . , , , . , , , . 164 vi Preface The Independent Lubricant Manufacturers Association (ILMA), established in 1948, is a national trade association whose 160 Regular member companies manufacture high quality automotive, industrial and metalworking lubricants and greases. Independent lubricant manufacturers are neither owned nor controlled by the companies that explore for, own, or refine crude oil used to produce lubricant base stocks. Independent lubricant manufacturers blend and compound over a quarter of the total volume of all lubricants sold in the U.S. each year. In the highly specialized area of metalworking lubricants, ILMA members manufacture more than two-thirds of the U.S.’s needs. In 1986, Dr. Elliot Nachtman, Tower Oil & Technology Co., established an ad hoc Research and Development Committee within ILMA. In 1988 this ad hoc committee was constituted a full standing committee of the association, and Dr. Nachunan was appointed its first chair. The objective of the committee is to promote and support research and development programs that improve and advance the operations of association members, suppliers and customers. This manual, WasteMtnimtzafionand Wastewater Treatment of Metalworhing Fluids, is one of the first contributions of this committee. These papers provide a single source of information useful in controlling costs, protecting the environment, promoting healthful operating practices as well as complying with federal, state and local laws and regulations. Decisions concerning the choice of clarification, recycling and disposal technology depend upon specific metalworking operating conditions. The papers by experts in the field which comprise the contents of this manual will provide guidance for devebping a waste minimization plan with the ultimate goal of “zero discharge.” This publication was conceived, produced and published by the ILMA Research and Development Committee under the leadership of Chair Ralph Kelly, Cincinnati Milacron; Vice Chair Paul Dacko, Ideas; and Was~eMinimizatlonProjectDirector Raymond Dick, Cincinnati Milacron. The publication was edited by Messrs. Kelly, Dacko and Dick, with assistance from many industry experts and from the ILMA staff. The R & D Committee expresses its thanks to the authors for the papers in this book, without whose outstanding efforts this book would not exist; to the industry volunteers who helped with every step of this publication; and to ILMA President Armen Hampar of Lubricating Specialties Company and the ILMA Board of Directors, for their confidence and support. ILMA Research & Development Committee Chair M.S. in Microbiology From the Univ. of Cincinnati. In addition to his active role in ILMA, Mr. Kelly’s membership include STLE, Board of Directors of Seven Hills Neighborhood Houses, Inc., Ken-Si1 Baseball Assoc., and past member, Cincinnati United Way Board. Mr. Kelly has published ten technical papers and holds 15 patents Cincinnati Milacron is a world leader in advanced manufacturing technologies (machinery, computer controls, software, cells and systems) for the metalworking and plastics processing industries; and in robotics, metrology, inspection, controls and information technologies for Factory automation in general. The company is Ralph Kelly joined Cincinnati imacron as a Senior Microbiologist also a leading producer ofprecision