valley chrome plating’s journey to environmental compliance through e.m.s

Valley Chrome Plating’s Journey To Environmental Compliance through E.M.S.

Valley Chrome Plating Company History

Founded 1961

Originally Job Shop Car bumper routes

Production Decorative Electro-Plating

Family Owned

Ray Lucas President: Valley Chrome Plating Inc. Director- at- Large: NAMF Membership Chair

Manufacturer of Truck Bumpers Zero Discharge Hoist Plating Processes 1st Plating Shop in U.S. to be permitted for

Nickel Air Emissions. Participant in Environmental Management

Systems In application process for OSHA VPP Star

Program

Valley Chrome Plating Inc.

High-level of environmental compliance prior to implementing an EMS

EMS was the catalyst for achieving the next level of environmental compliance and significant $$ savings

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

Ion Exchange

Closed Loop Technology Nickel

Counterflow Rinsing Filtration Carbon Treatments Trial & Error Spray Rinsing

Chrome Counterflow Rinsing Evaporation Porous Pots Dummying

Nickel Process Changes

Carbon Anodes Reduction of Nickel Metals

Re-Use of Nickel (post generation)

Dead Rinses Allows for re-use of chemical Each rinse improves water quality 100%

Pre-Plating Improvements Necessary to Achieve Zero

Discharge & Waste Reduction

Ultraviolet light Filtration Ozonator Counter flow rinsing Weirs & Oil Superator Evaporation Batch Treatments

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

Sleep Factor

Amount of Sleep

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(used w ith permission -Jim Miille Chemical Solutions Inc.)

VCP Environmental Goals

Water Reduction Waste Reduction Scrap Metal Reduction Electricity Reduction Storm Water Runoff Capture and Use

E.M.S. = Water Reduction1999 2002 2003 *

3,200,000 986,000 615,5003,200,000

986,000

615,500

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

Gal

lon

s

1999 2002

Annual H20 Use

2003 Projected

Waste Reduction

Waste Hauled by Year

124,253

157,336

99,500105,164

170,379

0

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

19

99

20

00

20

01

20

02

20

03

P

Lb

s o

f W

as

te

1999 2000 2001 2002 2003 P

Scrap Steel Reduction

Scrap Steel Generation

1,148,0501,312,480

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

Year

Lbs

2001 2002

Kilowatt Reduction

1,479,120

1,260,724

1,024,332

1,115,902 1,137,732

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

1,600,000

1,800,000

kw p

er y

ear

2003 P200220012000 Co-Gen Oct 03

Storm Water –The Next Goal Capture & Re-Use

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

EMS 2003 Projected Net Savings

Hazardous Waste = $45,000

Water = $ 2585

Scrap = $25,000

Electricity = $25,000

Total Projected Savings $97,585

Valley Chrome’s Future Role Model For Industry

Sharing of Knowledge

Waste Reduction

ISO 14000

Voluntary Protection Program Safety Hour

100% Capture & Use of Rain H20 Capture H20 from air

US EPA Performance Track

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