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GENERAL ELECTRIC COMPANY GAS TURBINE MANUFACTURING FACILITY
WASTE MlNlMlZATlON STUDY
SEC JOB NO. G-1126
JULY 1991
I
SlRRlNE ENVIRONMENTAL CONSULTANTS GREENVILLE, SOUTH CAROLINA
TABLE OF CONTENTS PAGE
1.0 EXECUTIVESUMMARY .............................................. 1
20 DOSnNG WASTE STREAMS .......................................... 6
3.0 RECOMMENDATlONS .............................................. 15
3.1 1.1.1 -Trichloroethane ........................................... 15
3.1.1 Node Degreaser .......................................... 15 3.1.2 H-Bay Degreaser ......................................... 19 3.1.3 Ardrox. Transition Pieces and Detrex Degreasers ................. 20 3.1.4 ~ l m e Spray Degreaser .................................... 20
3.2 Pratt & Whitnev Grinder Swarf .................................... 20 3.3 EDM Sludae ................................................. 21 3.4 Excess Paint Thinners .......................................... 23
. 3.5 Vibrotubs Wastewater .......................................... 25 3.6 Paint Booth VOCs ............................................. 25 '317 Castrol55OP Coolant ........................................... 28 3.8 X-Rdv Silver Recoverv Effluent .................................... 29
#IPPENDICES
APPENDIX A NOZZLE DEGREASER SUBSTITUTES
APPENDIX B H-BAY DEGREASER SUBSTITUTES
APPENDIX C . SEPARATING SOLIDS FROM EDM SLUDGE
APPENDIX D DISTILLATION EQUIPMENT
APPENDIX E PAINT SPECIFICATIONS
APPENDIX F AIRLESS SPRAY EQUIPMENT
APPENDIX 0 FLUID REPOLISHING EQUIPMENT
2 2
Y
Sirrine Environmental Consultants was retained by the GE Gas Turbine Manufacturing Facility in Greenville, South Carolina to identify waste minimization options with recommendations for the various processes at the facility. Cost estimates have been provided whenever possible to allow
costbenefit analyses to be performed. These costs provided are for equipment only and do not
include installation and engineering.
The approach taken to complete this study was as follows:
Understand existing processing techniques.
Identify wastes generated - quantities, hazardoudnonhazardous, source.
Prioritize waste streams based on quantity, toxicity, regulatory compliance and
motivation, and the future potential environmental liability. Identify, evaluate, and develop reduction alternatives.
Recommend actions consistent with regulatory requirements and good management practices.
Based on the prioritization criteria identified, the highest priority waste streams generated at the
facility are:
1, 1, 1 trichloroethane (TCA) waste streams and air emissions
Excess paint thinners
Wbrotubs wastewater
Paint booth VOCs
Castrol55OP coolant
X-ray effluent
Pratt & Whitney swarf
EDM sludge
1
- Table t .1 summarizesthe potential waste reductions which could be recognized by implementing
the various recommendations given in this report. Specific recommendations made are as follows:
TCA Waste Streams and Air Ernisskm - TCA is currently used in degreasers throughout the facility. TCA is a stratospheric ozone depleter and as such is
scheduled for production phase out by 2001. Following GE corporate plans for the
elimination of TCA usage within 2 years, a study was made of various alternatives to the existing vapor degreaser cleaning systems. Aqueous cleaning systems have
been recommended for each of the vapor degreasers throughout the plant. These
recommendations were summarized in a report submitted to GE on May 16,1991.
Various cleaning chemicals are currently under investigation and plant personnel are
studying various equipment for purchase at the Greenville facility.
Excess Paint Thinner - Large quantities of paint thinner with entrained paint solids
are drummed for offsite incineration, The waste is generated when painting
equipment is cleaned after use. Methods of recycling the solvent for reuse have
been investigated and prices for distillation equipment obtained. This equipment,
varying in price from $7,800 to $1 1,600, would allow recovery of 80-1 00% of the
thinner. Yearly operating expenses of $220 to $465 and yearly raw product savings
of $34,OOO to $38,OOO would allow payback periods of 3 to 4 months for distillation equipment.
Wbrotubs Wastewater - Gas turbine parts are deburred in several vibratory machines using a ceramic media flushed with water, The A-Bay vibrotubs represent a substantial hydraulic load on the W plant. Solenoid valves have been added in
the discharge lines of the vibrotubs and reduced the’”wastewater flow by
approximately 50 percent, A recycle system similar to one installed at the GE Vega M a facility could reduce this water flow by an additional 60 to 70 percent.
Equipment costs for this system would total approximately $6,275 and significantly
reduce the plant’s water usage and disposal expenses.
2
Table 1.1 Waste Reduction Potential
GE Gas Turbine Manufacturing Facility Equipmentkwess Waste Stream Existing Projected Reduction
Volume Volume Method
Wastewater Recycle Wastewater
swarf Excess Paint, Thinner
125,000 lb/yr
5,533 gal/yr Solvent Distillation
Usc of Low VOC Paints VOCS TCA Bath Emissions (VOCs)
‘EA, Water SpentTCA
Aqueous Cleaning Chemicals in WastewateP*
TCA Bath Emissions (VOCs) Spent TCA
Aqueous Cleaning Chemicals in WastewateF
TCA Bath Emissions (VOCs) Spent TCA
Aqueous Clcauing Chemicals in wastewatM+*
TCA Bath Emissions (VOCs) SpentTCA
Aqueous Clcaning Chemicals in wastewater**
TCA Bath Emissions (VOCs) Spent TCA
Aqutous Cleaning Chemicals in wastewater**
TCA Bath Emissions (VOCs) Rigidax with TCA
9.9 toIl/yr
2.0 todyr
OgWr
73,000 lb/yr 215,000 lb/yr*
6.3 todyr
None None None
? gal/Yr
Aqueous Cleaning h
Flame Spray Degnascr 16.2 todyr 21 5,000 Ib/yr*
0 gavyr
Aqueous Cleaning
Aqueous Cleaning
Aqueous Cleaning
Aqueous Cleaning
Altcmatc Cleaning Method
CombustionLiner Building None None
11 ton&r 215,000 Ib/yP
ogal/yr
None None ?WY
Transition Pieces D t g ”
BladcsDegnaser .-
Nozzle Dcgnaser
Trace 215,000 lb&P
o*
None None ?gal/yr
None None
550P Coolant, Water 100,000 gaVwk Coolant Repolishing
Recycle Wastewater
Margerle Grinders Lathes,
X-Ray Silver Recovery Cincinnati Mill, Vercicle Lathes
Wastewater
* Total yearly disposal mount from vapor degreasers. ** New waste stream generated as a mult of implementing recommended changes.
.
* Paint Booth VOCs - Significant amounts of VOCs are released during the application
of surface coatings at the Turbine Manufacturing facility. Regulation of the emissions
has been tightened with the I990 amendments to the Clean Air Act. Newly developed EPA compliant "Low VOC" paints are commercially available which would lower GEs paint VOC emissions from the current 10 tons per year to approximately
6.3 tons per year.
Ultimately, even use of these compliant paints may not be sufficient to meet recently
promulgated regulations. For instance, these regulations require 95% control
efficiency plant wide, This efficiency would require the use of Maximum Available
Control Technologies, such as incineration or capture and recovery technology.
This technology is not readily applicable to mobile painting sources such as the D-
Bay traveling paint booth. Such operations may be better controlled with such
processes as totally enclosed robotic paint application, isolated paint booths with fume scrubbers, and/or the use of powdered paints. GE would be well advised to investigate the uses of the traveling paint booth in an attempt to replace it with
stationary, dedicated booths to which control devices can be applied.
Castrd 55op codant - Several pieces of machining equipment at the GE plant use
Castrol 550P cutting fluid as a cooling media. Currently, approximately 80,OOO to *
120,OOO gallons per week of this water based coolant mixture are disposed of offsite. Castrol is currently in the process of providing polishing equipment to allow reuse
of contaminated coolant, This should reduce the disposal quantities by up to 80%.
X-Ray Effluent - The processing of X-Ray film at the GE plant currently generates
approximately 3,400 gallons per day of water which is sent to the WWT plant. This
water contains suspended solids, chromium, aluminum, nickei, and silver. Currently
marketed X-Ray film process water recycling equipment could reduce this water
usage/disposal to approximately 1,200 gallons per day. Depending on the degree
of recovery desired, this equipment would range in price from $4,OOO to $3O,OOO.
4
* Ratt br whitney Grinder Swarf - Metal fines from grinding operations are collected
for offsite disposal. The waste is subject to EPA land ban restrictions because of elevated concentrations of chromium. The preferred method of minimizing the future liability of this waste stream would be to recycle the swarf for its metal content;
however, to date, no acceptable RCRA permitted facility has been identified for recycling purposes.
EDM Sludge - A second surface finishing operation producing significant waste at
the Turbine Manufacturing facility is electrical discharge machining. The tar-like EDM
sludge contains machining oil, graphite and metal fines and is drummed for off-site
incineration. Methods for separating the metal, graphite, and oil have been investigated; however, economic constraints make incineration the best disposal method.
5
I - 20 EXISWGWASTESlREAMS
I The waste streams cunentty generated by the various processes at the GE Gas Turbine
Manufacturing operations are summarized by machine/area in Table 2.1, Waste Matrix. This table
also lists the quantity of each waste stream generated as well as the current disposal method.
In completing a waste minimization survey for facilities with a large waste stream matrix, it is useful to prioritize the Individual waste streams and/or their emission sources. Selection of waste
minimization projects to implement is usually based on capital costs and consideration of direct
monetary benefrts. Indirect costs and benefits also need to be included in the evaluation process. These indirect costs and benefits can be related to:
the characteristics of the waste itself, such as toxicity, persistence, mobility,
concentration, odor, volume and regulatory status the current degree of control and methods of management the visibility and health impact relative to the community around the facility
the existing and future regulatory climate for that waste stream.
Identification of the indirect kosts and benefits allows further efforts to be focused on those
streams which are the most important or which show the most promise for reducing waste
generation. The priorities assigned to the GE waste streams are given in Table 2.2. The highest
priority streams were assigned a priority of 12, the lowest were assigned a 4. In order of
importance, the criteria used include the following:
regulatory compliance and motivation
quantity (volume)
toxicity future potential environmental liability.
Other criteria which influence the setting of priorities include employee safety and health and offsite waste management costs.
6
,
Table 2.1 Waste Matrix
GE Gas Turbine Manufacturing Facility
Machindhea Waste Stream Quantity Disposal Method
Lathes (J Bay) 550 P Coolant Turnings/Chips Rags
Bliss Presses Metal Particulates
1
15 LbNeek
< 1 lb/hr
Recirculated Reclaim Reclaim
Cincinnati Mill 550 P Coolant Recirculated Metal Chips Reclaimed
Verticle Lathes 550 P Coolant Metal Chips
ReCirCulated Reclaimed
Broaches Omega Cutting Oil Metal Chips
Mag. Particle Booth Magnaflux Water (Incl. Kerosene) .500gpd
Paint Booth (BCB) Wastewater (Trench) Water Wash Water
.; vocs
Paint Booth (CIA)
Vertical Boring Metals
X-Ray Booth
Sump Water Wash Water Wash Pump Outs
Metal Chips (Dry)
Wastewater Spent Silver Spent Processing Chemicals
< 3 GalDay
2.2 lb/hr
12,Ooo w e a r
5 "
200 w e a r
Recirculated ReClailned
WWT
WWT Recirculated
Pump Out, to WWT Recirculated
Hazardom waste Recycled
WWT
WWT
Table 2.1 Waste Matrix
GE Gas Turbine Manufacturing Facility - ~- ~
MaChine/Area Waste Stream Quantity Disposal Method
Vacuum Plasma Spray Coating Powder 1 Drum/Month Landfilled (Non-Hazardous) Air Filters < sonear Landfiilled (Non-Hazardous) Noncontact Cooling Water 8-10” WWT Rags 1 Dnun/Month Landfiilled (Non-Hazardous)
Vibrotubs (AJA & AZB) Filter Press Sludge 12 Ton/Week Lancff#ed (Non-Hazardous) Wastewater 45 gpm WWT
Excello Grinders
ELB Grinders
Magerle Grinder
Hand Sanders (AZB)
F’ratt Whitney Grinders
Filter Paper, Swarf waste oil Solvent (PF Degreaser) Grinding Wheels
30 Rolls/Week Reclaimer w/ Swarf Non-Haz. Landfill 2-11,OOO-gal system Recirculated
30 gal/week WWT Landfill (Municipal)
Swarf and Filter Paper Lubricant Recirculating System Grinding Wheels
2 Rolls/Week Reclaimer w/ Swarf Non-Haz. Landfill
Van Smtton Lubricant Recirculating System Swarf and Filter Paper
. ; Grinding Wheels
Dust Collector Waste
Swarf Lubricant Filters Grinding Wheels
1.5 DnundYear
124,OOO Lb/Year
Reclaimer
Hazardous waste
Hazardous waste Centrifuged and Reused
Municipal LanNill
, 1
Table 2.1 Waste Matrix
GE Gas Turbine Manufacturing Facility
MachindArea Waste Stream Quantity DkpvsaI Method
Accessory Test Area
. Traveling Paint Booth "D Bay"
Stationary Paint Booth "D Bay"
Electrical Discharge Machines
Ovens (MBB)
Muriatic Acid Dip Tank .;
Hot Water Dip Tank
Caustic Dip Tank
Maintenance Area
Wastewater Fuels oils Fuels, Oils
Washwater vocs Fi1tel-S
vocs Excess Paint, Thinner, etc. FilteXS Water
EP180 Electro-Lite oil Sludge, Filters
USedRigidax
HCl Used Muriatic Acid Scrubber Blow Down
Wastewater
used caustic
Safety Kleen Solution
30,000 Gal/Year
6,000 GaVDay 4.0 Ib/hr
60 Drumspear
2.4 T/yr 57,000 Lbpear 1,OOO Lb/Month 92,000 Lb/Year
24,OOO Lb/Year
< 1 lb/hr 6000GaVYear
4100 W e e k
6OOO Galnear
5000 Lb/Year
WWT Reused Reused WWT
WWT Dry Filters
Hazardous waste
Hazardous Waste Hazardous Waste Hazardous waste
Recirculated Hazardous waste
Reused
Exhausted through Scrubber WWT WWT
WWT
WWT
Safety Kleen Recycles
.
Table 2.1 Waste Matrix
GE Gas Turbine Manufacturing Facility
MachindArea Waste Stream Quantity Disposal Method
Lathes (L Bay) Oil in Pits Unknown
Vibrotubs Wastewater Combustion Liner Building Filter Press Sludge
-x Degreasers (2) (AHgdy) Zyglo, Emulsifier, Water
TCA Bath Emissions (VOCs)
wastewater Charcoal Filters TCA, Water Spent TCA
Flame Spray D e w TCA Bath Emissions (VOCs) Spent TCA
1500 GavDaY
2.0 T/yr 9945 Lb/Year 1 DnunFlonth 73,000 Lb/Year
215,000 Lb/Year*
16.2 T/Y= .
215,000 Lb/Year*
WWT Landfill @on-Hazardous)
Drummed Hazardous Waste Landfill (Non-Hazardous)
Drummed Hazardous Waste Drummed Hazardous Waste
Drummed Hazardous Waste
Nozzle Degreaser (IvlAB) Rigidax with l,l,l-TCA 5800 Lb/Year Hazardous Waste (Incinerated) TCA Bath Emissions (VOCs) 14.6 T/Year
Combustion Liner Building Spent TCA 215,000 Lb/Year * Hazardous waste TCA Bath Emissions (VOCs) <1 Lb/Hr
*; Zyglo (Pumped out) Hazardous Waste
Transition Pieces Degreaser (KFA) TCA Bath Emissions (VOCs) 2.5 Lb/Hr Spent TCA 215,000 Lb/Year* Drummed Hazardous Waste
Blades Degreaser 0 TCA Bath Emissions (VOCs) Trace Spent TCA 215,000 Lb/Year* Drummed Hazardous Waste
* Total yearly dspssal from vapor degreasers.
.. .. . . -. . ..._- .. .. . . -. . ..._-
.
Table 2.2 Waste Stream Priorities
GE Gas Turbine Manufacturing Facility
WASTE REGULATORY QUANTITY TOXICITY LIABILITY PRIORITY
mewater VPS N/C Cooling Water Vibrotubs MagnanuX Water Paint Booth B CB PaintBoothCIA
Accessory Test Area Traveling Paint Booth (D Bay) '
Stationary Paint Booth (D Bay) Muriatic Acid Tank Hot Water Dip Tank Caustic Dip Tank Scrubber Blowdown
X-Ray Booth
Solvent - PF Degreaser
Spent TCA TCA Air EmissionS (VOCs) ZYglO EDM Sludge Rigidax (Ovens) HCl Vapors Paint Booth VOCs Excess Paint Thinners Paint Booth Filters
Rigidax w/ll 1 TCA .I
Medim High
Medium LOW
LOW
Medium LOW
LOW LOW
LOW
LOW
LOW
LOW
MediUlll High LOW
LOW LOW
Medium LOW
Medium Medium
LOW
LOW
LOW
LOW
LOW
LOW
L O W LOW
. High
LOW
LOW
LOW LOW
LOW LOW LOW
LOW
Medium High Hi&
Medium Medium
MediUUl
Medium High
Medium
High
High (Toxic)
LOW
LOW LOW LOW LOW
LOW LOW
LOW
LOW
LOW
LOW LOW
LOW
MediUm High High High High High LOW LOW
MediUm High High
6 10 5 4 4 6 4 5 5 4 4 4 4
8 12 12 11 9 11 7 7 9 11 9
Table 2.2 Waste Stream Priorities
GE Gas Turbine Manufacturing Facility
WASTE REGULATORY QUANTITY TOXICITY LIABILITY PRIORITY
Swarf (except P/W) Swarf(Pratt-WhirRey) oils/Lubricants Castrol550P Coolant Metal chips Filter Press Sludge Virbrotubs Combustion Liner Building
Grinding Wheels
LOW
High LOW
Medium LOW
Low LOW
LOW
Medium
MediUm High
Medium
High
LOW
LOW
LOW
LOW
High LOW LOW LOW
LOW
LOW
LOW
Medium High LOW
Medium LOW
LOW
LOW
LOW
6 12 5 8 5
4 4 4
After compiling the basic information on the specific wastes and releases and current disposal
methods, the individual waste streams were scored for each criteria. The scores were then evaluated according to a judgement-based semiquantitative analysis. The scoring can be a numerical system but, in this case, a 'high, medium, low" scoring scheme was used. This technique can be further reflned by assigning a weighting factor to each criteria but this further
refining was not deemed necessary in the GE assessment.
In assigning priodtles, the first issue addressed was the regulatory status of each waste stream.
High priority would apply to waste streams currently regulated or in the process of being
regulated, such as VOCs, toxics, metals and hazardous materials. Low priority would apply to
non-regulated waste streams as well as to already regulated streams which have a high degree
of control in use or currently planned.
Second in importance is the volume of waste generated since this adds to the visibility of the
waste. Volumes can be compared to relative quantities for similar classes of wastes as identified
in regulations, Le., 10 tons per year for any toxic compounds from the Clean Air Act amendments.
Existing regulations to reduce or eliminate certain wastes, i.e., land disposal bans, would be
assigned a high priority, The need to comply with existing regulations at some later date, Le.,
when an existing permit is changed, or the need to develop a compliance program for a known
future requirement should be a motivating factor in the need for reduction and would be assigned a medium rating.
Toxicity is a key issue whether related to air, water or solid wastes and can be identified on the basis of human or environmental concerns, The Clean Air Act amendments of 1990 have
identified 189 toxic air pollutants which will be the target of regulatory activity in the next five
years. Toxicity testing of leachates and wastewaters has received considerable attention in the
last two years. The toxicity criteria is also important coupled with the volume criteria in evaluating waste reduction options. If the ultimate goal is to mitigate environmental impacts, the focus
should be on reduction of toxicity rather than volume reduction.
13
Liability focuses on current and future risk associated with the current disposal method. A
current disposal technique, such as off-site land disposal by a third party, poses some future
liabilities for GE and would warrant a medium rating. Consideration is also given to the known
costs of off-site disposal, Le., cost of incineration of one drum (55-gallon) of hazardous waste is currently $200-300.
Specific to the GE processes, a priority grade of high, medium, or low was assigned for each category to each waste stream. Each waste stream was then ranked according to the number
of highs, mediums and lows. For assigning overall priorities, the scoring used was: High - 3, Medium - 2, Low - 1.
Using these scores, the highest priority waste streams from GE processes are the waste streams
containing l,l,I-TCA (Spent TCA, Rigidax with TCA, TCA air emissions), swarf from the Pratt-
Whitney grinders, electrical discharge machines (EDM) sludge, excess paint and thinners, and wastewater from the vibrotubs. Recommendations on minimization techniques for each of these streams are included in the following section.
14
I ' 30 RECOMMENDATlONS I ' 3.1. 1 .I .I -Trichloroethane
Several of the high priority waste streams at GE Greenville result from the use of l,l,l-
trichlorosthane (TCA); these streams are spent TCA, TCA air emissions, and Rigidax with TCA.
TCA is currently used in degreasers throughout the facility including the Nozzle, H-Bay, Ardrox,
Transition Pieces, Detrex, and Flame Spray Degreasers. Table 3.1 summarizes the TCA usage
for each area, the TCA waste generated from each process, and the disposal and purchase costs
assodated with each area. The wastes generated include VOC emissions and drummed waste.
The drummed waste is primarily spent TCA whlch contains the contaminant being removed in the degreaser. The contaminants include cutting oils, fluorescent penetrant, and Rigidax
structural supporting wax. The Ardrox degreasers also generate TCA contaminated water, which
is collected and drummed at the work area.
I I
Recommendations for each of the areas are discussed in the following sections.
3.t.l W e Degreaser
In the M-Bay Ramco degreaser, nozzles are cleaned to remove a tooling compound called
Rigidax. Rigidax is a hydrocarbon based resin used to add strength to thin wall parts or parts
with interrupted cuts. The Rigidax eliminates "chattering" and burring during machining.
Rigidax is purchased from M. Argueso 8t Co. of Mamaroneck, N.Y. Argueso personnel report that
the following cleaning methods have been employed as TCNvapor degreaser substitutes:
N-Met h yl-Pyrrlidone (N MP)
NMP is an industrial solvent for plastics, waxes, resin and paints. It is a cyclic amine
and is included in EPA Toxic Substance Control Act (TSCA) Inventory, 1980.
Argueso personnel report that NMP leaves an oily film which is not easily vaporized. Information about the product is Included in Appendix A.
15
* I
Table 3.1 l,l,l-Trichloroethane Usage - Vapor Degreasers
GE Gas Turbine Manufacturing Facility ~~ ~ - Total
WeaSer ' TCA Usage TCA Cost Emissions Drummed Waste Disposal Cost Yearly Cost Gallons/Year Wear Tons/Year Gallons/Year $/Year $/year
(GallondYear)
Nozzle
H-Bay 0
Transition Pieces (KFA)
D e t r e X 3DegTeasas
(Combustion
8,544
3,780
3,384 t
1,248
.- 876
45,192
19,992
17,904
6,600
4,632
(2,877) Spent TCA 19,440 102,828 43.7 - 2,408 Gallonflear 16,459 119285
(7,761) Spent TCA
5,760 Lbsryear RigidaxfI'CA
330 Spent TCA
1,100 Spent TCA
1,194 H20RCA
578 Spent TCA
Negligible
iner Building, - S P Y (MA) 1,608 8308 16.2 400
2,706 47,898
1,260 2 1 3 2
4,200 26,663
4359
2,207 8,807
4,632
1,527 10,035
- t ,1 -Di(Ortho-Xylyl) Ethane (DXE)
DXE is an aromatic hydrocarbon manufactured by Allco Chemical Corporation of Galena, KS. This product is used at a temperature between 75 and 100°C. These
temperatures would require extensive reworking of the existing vapor degreaser if used as a drop-in TCA replacement. Once the Rigidax is removed, the part would
need to be cleaned again to remove the molasses-like DXE. Due to the requirement
for high temperatures and subsequent cleaning steps, DXE is not recommended for
this application.
Terpene Sotvents
Argueso personnel report their best results at vapor degreaser substitution using a
terpene based solvent, Re-Entry KNI Solvent 2000. This product is manufactured by
Envirosolv Inc. of Jacksonville, FL. Hartnett Associates of Clinton, NY, has
experience at designinghetrofitting cleaning equipment to use Re-Entry to clean
Rigidax. Jim Hartnett described two procedures for Rigidax removal (see Appendix
A). One method involves using an ultrasonic bath containing the solvent followed
by a boiling water rinse. The part would be air dried or dried using a hot air stream.
The second method would involve a high temperature solvent bath with an Inert gas
blanket followed by a boiling water rinse if needed.
Mr. Hartnett said that his company is designing a machine to replace vapor
degreasing equipment which will be available in August 1991. Features of the
machine Include:
- - - Boiling water rinse -
Ultrasonic sweep cleaning of parts in Re-Entry Distillation equlpment to recover Re-Entry
Equipment to ailow rinse water reuse.
1 !
!
1 I
i
I !
j
i !
1
i i
i I I I
I ! i
I
i I !
I !
!
17
Unused terpene solvents are biodegradable and are not considered to be a RCRA
waste. They become hazardous waste when the contaminant they are used to clean is hazardous;’ otherwise, the waste can be sewered. With proper distillation equipment, the Re-Entry and Rigidax can be separated and recycled, thereby
minimizing the waste.
Because of the reduced environmental liabilities, reduced worker exposure risk, and
waste minimizing benefits of this cleaning method, it is recommended that further
study be performed to fully evaluate the cleaning ability and economic justification
of installing equipment for terpene solvent cleaning of GE gas turbine nozzles.
Toluene/Xylene with Ultrasonic Cleaning
Argueso personnel report cleaning success using both toluene and xylene; however, because of their low flash points (40°F and 1oOOF respectively), these solvents present safety concerns. Also, both were included In the EPA TSCA, 1980. Because
of these regulatory and safety concerns, it is not recommended that toluene or
xylene be used for degreasing efforts.
Detergents with Hot Water
Rigidax may be cleaned with boiling water and detergents; however, the process
requires about 8 hours. Therefore, this type cleaning is not practical and it is not
, recommended that this cleaning method be used.
Another option for replacing the nozzle degreaser would be to install a cleaning system
developed by Progressive Recovery, Inc., for the printing industry. $8 cured ink residues
typically dried on press equipment is similar in composition and consistency to hardened Rigidax.
Progressive Recovery’s equipment employs high pressure solvent and oscillating nozzles to strip
the dried ink from metal surfaces, Cart mounted parts are loaded into the unit and sealed shut
by an access door. The parts laden cart is completely enclosed during the cleaning process and
the dirty solvent is collected and distilled for reuse. Progressive Recovery’s local vendor,
18
! Industrial Ted.mdogies of Atlanta, GA, carries 'environmentally friendly" cleaning liquids for use
in the washing equipment. Information about Progressive Recovery's wash system and the ! deaning chemicals is included in Appendix A. ! a12 H-Bay Degresser
The H-Bay Talley degreaser is a dual tank immersion degreaser. Each blade is cleaned in this
degreaser several times durlng the manufacturing process. After broaching and grinding operations, the blades are cleaned of cutting oil prior to laser stamping of identification numbers.
Once the parts are stamped, further machining is done in the Rigid Grinders. Though ultra clean
pats are not necessary for laser stamping, it is required that no film remain on the parts so as
cleaned after Rigid Grinding.
! ! ! I not to compromise the integrity (especially the pH) of the grinder coolant. The blades are again
Because a high quantity of parts is degreased at this station, it is recommended that a
conveyorized cleaning station be purchased for blade cleaning. Included in Appendix B is
information about conveyorized cleaning systems from the following manufactures and vendors.
Manufacturer Vendor
Nmco
Ramco
Detrex ,
Advanced Deburring & Finishing Statesville, NC
Advanced Deburring & Finishing Statesville, NC
Detrex Corporation Bowling Green, KY
Ransohoff Ransohoff Corporatiorl' Hamilton, OH
Several of the cleaning machines are provided with equipment to separate soils from the cleaning
fluid. This equipment will allow reuse or sewering of process water and chemicals, therefore
minimizing hazardous wastes. tt is recommended that further study be done to evaluate the
cleaning' effectiveness and economics of this equipment.
19
I I I
In addition to equipment selection, various chemicals must be evaluated for this cleaning
application. Two such chemicals are Daraclean 282 and Lemon-Clean. Daraclean 282 has been
successfully tested at GE’s Evendale location. Lemon-Clean by Chemical Finishing is biodegradable and can be used at low temperatures. lt has been successfully employed by GE’s Power Delivery Plant, Somersworth, NH. Information is about Lemon-Clean and its use at Power Delivery Is included in Appendbc B.
3.15 Ardrox, Transition Pieces and Detrex Degreasers I
I At GE‘s Greenville plant, six vapor degreasers are used prior to florescent penetrant inspection
(FPI). Parts must be cleaned to high degrees of cleanliness before entering the FPI. Due to
these stringent cleaning requirements, cleaning chemicals are being evaluated at GE’s Power
Generation facility in Schenectady, NY. Larry Rosenzweig, GE Materials Engineer, Is currently
testing three cleaning compounds. Once his work is complete, further study will be done at the
Greenville plant to determine equipment needs at the various FPI stations.
Z1.4 Flame Spray Degreaser
At the AFA vapor degreaser, parts are cleaned prior to flame spray deposition of an aluminum
oxide coating on a small portion of the bucket surface area. The exhaust duct of this degreaser
is located in its vapor zone at the condensing coils. Because of its exhaust location, this
degreaser is one of the plant’s heaviest emitters of TCA.
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The space available for new processing equipment at this work station is limited. Adequate
aqueous cleaning equipment for this area’s needs will likely require more room and possible movement to a new area. In the Interim, It Is recommended that GE move the exhaust duct of
this degreaser away from the vapor zone in order to reduce the emissions from this area.
I 32 pratt 8 Whitnev Grinder Swarf
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As part.of the turbine blade manufacturing process, the blades are machined In Pratt & Whitney
grinders. In these grinders an abrasive belt removes surface metal. Sultran 155P Coolant, a
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hydracarbon cutting oil, is used to flush the grindings and cool the parts. The oil, metal particles,
and grinding bett debris collect In a sump at each machine. Two disposal methods are currently
used for this waste material: incineration as collected (line 014 waste) or Incineration after
removing as much oil as possible by centrifuging the mixture (line 018 waste). During 1990,
120,OOO pounds of line 018 Pratt & Whitney swarf were sent offsite for incineration; no line 014
waste was generated. Both forms of waste are D007 wastes because they contain elevated levels of chromium,
Estimates of the waste composition Indicate that it is 60-75% metal solids, 15-3096 cutting oil, and
15-3096 abrasive media. One way to reduce this waste stream would be to recycle the swarf for
its metal content. Marvin Seigle of Spartan Iron, GE’s current metals recycler, has stated that one
of his buyers Is willing to accept the swarf for its steel content on an experimental basis. This
buyer Is a smelter of mild steel and is concerned that the chromium and other alloy metals may
degrade his final steel quality. tf this Is the case, the swarf would not be accepted by this buyer for recycling.
As mentioned above, the swarf is a hazardous waste (0007). Therefore, the swarf must be
disposed at a RCRA permitted facility even if the disposal method is recycling. Spartan Iron is not a RCRA permitted facility and therefore should not be considered as a viable disposal option for the Pratt & Whitney grinding swarf.
3.3 EDM Sludae
At several locations in A-Bay and M-Bay, turbine parts are ground using electrical discharge
machinery (EDM). For electrical discharge machining, electrical pulses discharge between the
EDM electrode and workpiece to remove fine particles or chips from the;workpiece surface. The electrode tool and workpiece are immersed in a bath containing a dielectric solution. Erosion
of the workpiece surface and the electrode frees small particles which, in sufficient concentration. render the dielectric fluid Ineffective. Currently, the fluid is filtered and the oil reused while the
filtered sludge is drummed for off-site disposal, Plant records indicate that 24,000 pounds of the
drummed sludge are generated per year. This sludge is blended into fuel for incineration at a disposi cost of approximately $1 0,000 per year.
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The EDM sludge has been assigned the EPA waste numbers 0001 for ignitability and DO07 for elevated chromium content. Following are results of analyses performed on the sludge by Rogers and Callcott Engineers:
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Test Results (m@)
Regulatory Parameter Level (mgll) 1 011 990 311 909 711 900
Barium 100.0 .35 4.9 93
Chromium 5.0 37 6.1 . 24,074
Silver 5.0 < .oi 1.2 < 1.0
Plant personnel estimate that the sludge consists of the following components:
EDM Oil 0-25%
Carbon 30-60%
Metal 5-20%
Water 04%
GE's EDMs were manufactured by Easco-Sparkatron of Ann Arbor, MI. Easco's Don Braden was
contacted regarding the EDM operation at the Greenville plant. Mr. Braden stated that the EDM
oil should contain eroded metal and electrode particles in sizes ranging from 10 to 50 microns.
He knows of no maintenance operations which would reduce the sludge generation and said that
the Poko graphite electrodes used by GE are the highest quality rods available. Therefore, waste minimization efforts for this waste stream have focused on further separation of its constituents.
Investigations of methods te separate the particles of ferrsus alloys and graphite from the tar-Ilk6
EDM sludge have focused on centrifugal forcer wringers. These wringers consist of a perforated
tub within a containment vessel. As the tub spins, liquids are forced through the perforations
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* while solids are captured. Elen Learner of Sandborn Environmental Systems, Wrenthan, MA, stated that their centrifuges will capture particles as small as 1 micron. These machines should
be capable of separating GE’s 10-50 micron EDM solids.
Gary Cook of Cook Systems, Inc., Vicksburg, MI, has extensive experience at separating solids
from EDM 011. Included in Appendix C is a copy of a newsletter artlcle describing a machine he
has recently patented. This machine is also capable of separating particulates smaller than a micron. A sample of GE’s EDM sludge was sent to Cook Systems and it was estimated that the
oil content of this waste could be reduced to 4%. Currently, his operations are limited to the
Michigan area. He would require that the sludge be shipped to his location for separation (at
$200/drum) and the constituents returned to GE.
The oi1 content of the sludge is estimated to be approximately 20% oil. Centrifuge vendors state that this content can be reduced to a range of 4 to 10%. This reduced oil content would reduce
the amount of waste sludge generated by about 280 gallons per year. tf the price for disposal remains at $200 per drum, GE would save $1,000 per year in disposal fees. However, the
remaining filter cake will still contain graphite and the ferrous alloys with possible continued
elevated TCLP chromium content. No businesses have been found which will recycle the solids
for either the graphite or chromium content.
Due to economic constraints, ‘it is recommended that GE continue its current practice of
Incinerating EDM sludge. As recent trends indicate that the content of EPA TCLP contaminants
is diminishing, GE should closely monitor this waste for possible downgrading of regulated
status.
3.4 Excess Paint Thinners
Paint/thinner sludge is collected in the D-Bay stationary paint booth for disposal. GE personnel
estimate that this waste stream is composed of 10% paint and 90% IMI 1500 paint thinner.
Approximately 57,000 pounds per year of this waste are drummed and sent for offsite treatment at an @mated $2,500 yearly treatment expense, The majority of this waste is generated during
the Cleaning of spray painting equipment. The solvent used,to clean the equipment is a specially
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formulated thinner used to adjust the paint viscosity. According to GE personnel, the majority
of this thinner purchased for the Greenville plant is used in equipment cleaning.
in order to reduce this waste stream, methods whereby the material may be recycled have been investigated. The preferred method for recycling solvents is using distillation equipment. Distillation systems heat contaminated solvents to their boiling point, thereby vaporizing the solvent and leaving the contamlnants. The solvent vapors are then drawn through a cooling coil
where the vapors condense back to liquid solvent. These machines recover 80-100% of the
solvent. Typically the recovered solvent is 95-99% as pure as virgin product. Therefore, the
Greenville plant can reduce its paint/thinner waste disposal costs and its new thinner purchase
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costs.
Several distillation equipment vendors have provided price and operating expense information for their machines. Purchase prices range from $7,800 to $1 1,600. Included in Appendix D is
information about the following distillation units:
Manufacturef
Giant Distillation & Recovery Company
Solvent Kleene
Progressive Recovery
Hoyt Corporation
Vendor
Maple Systems & Supply Terre Haute, IN (81 2) 234-9330
Solvent Kleene Peabody, MA (508) 531 -2279
Industrial Technologies Company Atlanta, GA (404) 491 -3963
Hoyt Corporation '.- Westport, MA (508) 631 -881 1
It fs recommended that GE install a distillation system to recover the solvent from the waste
sludge. With estimated yearty savings of $34,000-$38,000 and yearly operating expense of $220
to $465,ihese machines will pay for themselves in 3 to 4 months. A calculation of the payback
obtained from an Industrial Technologies Company quotation is included In Appendix D.
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Rotary finishing machines are used for deburring and polishing blades and buckets. The current
system uses water in a *once through” fashion. The wastewater flowrate leaving the A-Bay
vibrotubs used to process buckets was estimated to be approximately 40 gpm. Since that
estimate was made, GE has added solenoid valves in the discharge lines of the vibrotubs and as a result of this change the wastewater flow has been reduced to approximately 15-20 gpm.
The wastewater flow from the buckets vibrotubs can be reduced further by settlng up a recycle
system. This system would include two transfer pumps, two basket strainer/filters in parallel, a surge tank, and interconnecting piping. A typical system flow diagram is shown in Figure 3.1.
Total equipment costs for this system would be approximately $6,275 (excluding piping costs).
Depending on how often the wastewater solution must be emptied, wastewater flow can be
reduced significantly. Assuming the solution can be reused six to seven times before it must be
discarded, it can be reduced from approximately 28,800 gpd to between 4,100 and 4,800 gpd.
A similar system has been installed at the GE Vega Alta facility and has been successful in
reducing the wastewater flow without impacting the product quality. It is recommended that GE Greenville install recycle systems on both the blades vibrotubs and the buckets vibrotubs.
3.6 Paintf3aothVOCs
The Greenville plant’s second highest VOC emitting process is the surface coating operation. At several work stations in the plant two types of paint are applied. These two paints are Roymal high temperature resisting aluminum silicone enamel and Reeve beige primer. According to purchase records for 1990,1,395 gallons of high temperature enamel and 2,950 gallons of primer
are applied per year. The VOC content (VOC ratings) of these two paints are 4.46 Ib/gallon and
4.59 Ib/gallon, respectively. This translates to a loss of approximately 9.9 ton/year of VOCs from
the surface coating operations.
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Figure 3.1 Vibratory Finishing Recycle Flow Diagram
GE Gas Turbine Manufacturing Facility
To Filter Press
,; 40GPMO20’
.. .. --. . _. __ .. ._ - _ _ - .. . . . ,.. , - .. . . . . . - .. . . .. . . -.. . . . -.. . . . . . _ _
I 1 9/64” Perforated
Basket 75 Micron Filter
Surge Tank 4’ x 6’ x 4’
Air Diaphragm Pump 40 GPM @ 10’
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, The current painting operations are carried out in several different locations throughout the plant
at irregular times using mobile paint booths. tt is recommended that GE segregate its painting
activities by location and install dedicated stationary paint booths with appropriate capture and control devices. This level of control will probably be necessary to meet the more stringent requirements of the most recently promulgated regulations regarding air pollution.
Another alternative which could be used in the interim prior to installation of stationary paint
booths would be to use the newly developed high solids, low-VOC paints or to use water based
paints. These paints have lower solvent to pigment ratios than older paints, typically 10-3096
’less, and emit less VOCs per gallon of coating.
The GE process specifications for the painting operations are included in Appendix E. The high
temperature painting specification requires the use of paint from Roymal Coating Co. of Newport, NH. The company’s technical contact, Ray Malool, states that Roymal does not sell a low VOC version of this paint. Niles Chemical Paint Co. of Niles, MI, does manufacture a black colored
high temperature enamel which may be suitable for this application. According to Niles’ Daniel
Williams this paint’s VOC content is 3.5 Ib/gallon. Based on a coverage of about 400 square
feet/gallon, using this paint would lower VOC emissions from high temp applications from the current 3.t tons/yr to 2.4 tonsbear. Information from Niles Is also included in Appendix E.
The GE Alkvd Prime Painting specification used for beige primer application lists several choices
of paint. These include two water reducible paints and a low VOC sotvent based paint
manufactured by the current primer supplier, LA. Reeve Co., Syracuse, NY. According to
Reeve’s representative, Chris Martin, the Greenville plant evaluated the water based paint during
the early 1980’s. During those trials it was determined that the paint dried too slowly and held
up production. The VOC content of the currently used primer and the low VOC primer from
Reeve are 4.59 Ibs/gallon and 3.30 Ibs/gallon, respectively. The coverages per gallon of paint
at one mil thickness are 656 sq ft/gallon and 81 6 sq ft/gallon for the current and low VOC primer,
respectively. Conversion to the low VOC Reeve paint would reduce the operations emissions
from the current 6.8 tonbear to 3.9 tonbear.
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i " The current painting equipment requires compressed air to atomize the paint for application. Low
VOC solvent based paints are best applied with hot air assisted airless spray equipment. The air assisted airless spray equipment pressurizes the paint and it is atomized as it passes through the nonte. Therefore, new equipment would need to be purchased to apply these lower VOC
paints. lncluded In Appendix F are equipment quotes from TAB Industries of Pascagoula, MS, and Air Power of Greenville, SC. Equipment prices range from $4,200 for a single spray gun unit
to $9,700 for a four spray gun unit.
It Is recommended that GE use these low VOC containing paints. At current usage rates, this
will reduce the VOC emissions from painting operations from the present 10 tons/year to 6.3 tons/year.
3.7 castrol55oP coolant
Castrol 55OP cutting fluid is used as a cooling media in the machining operations of several
pieces of equipment at GE. This cutting fluid along with metal chips collect in sumps at each
machine. The chips form barriers which restrict fluid flow and cause stagnation. Also, hydraulic
and lubricating oils from the machinery drip into the sumps. Eventually the coolant stagnation and tramp oil cause the coolant to become rancid. As the coolant begins to smell, facilities
personnel drain h e sumps and refill them with fresh coolant.
The 55OP concentrate is mixed with water at a ratio of 20:l water to concentrate for use in the
plant. Therefore large quantities of water containing oils and 550P are generated. Currently, this
waste is collected for disposal by James Waste Oil Company. Plant estimates place this disposal
quantity between 80,000 and 120,000 gallons per week.
Hany Norton, GE's facilities manager, and Randy Norris, Castrol's local representative, have entered an agreement whereby Castrol is contracted to recondition the cutting fluid on site and,
In doing so, reduce the quantity requiring disposal. During the week of July 4, 1991, Castrol is to install 8 fluid repolisher at the GE plant. Details on this equipment is included in Appendix G.
This repolisher will remove metal chips and coalesce tramp oils from the coolant. Once
repolished,' the fluid will be replenished with any necessary 550P concentrate and/or biocides.
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?he oils separated from the coolant will still require off-site disposal; Mr. Norris estimates that the waste coolant requiring dlsposal will be reduced by 80%.
3.8 X-Rav Silver Recovenr Effiuent
X-Ray inspection is one method of nondestructive testing employed at the GE facility. With this
form of testing, images of components, including flaws and inclusions, are placed on photographic film. This radiographic film must be processed in order to view the x-ray image.
The film is processed in a Kodak Model B X-Ray film processor, This machine operates 16 hours
per day and requires 3.5 gallons per minute of fresh water for both temperature control and
washing away processing chemicals. Daily water usage for this machine is approximately 3,400
gallons.
Currentty, the x-ray effluent is routed through a steel wool filter system for silver recovery prior to discharge to WWT. Samples of this discharge have been analyzed and indicate significant
concentrations of suspended solids, chromium, aluminum, nickel, silver, and total organic
content. If GE is required to meet water quality based limitations for direct discharge of this
waste water to uttle Rocky Creek, "at source" pretreatment may be necessary.
Several commercial units are currently available which allow reuse of processor wash water and significantly reduce the hydraulic load attributed to x-ray film processing. In addition, these
machines remove metals to EPA acceptable discharge limits and recover an otherwise wasted valuable product, silver. Capital costs for this equipment can range from $4,000 to $30,000 depending on the degree of sophistication of the recovery process. These machines typically
reduce x-ray lab water usage and subsequent sewer discharges by as much as 65%. Therefore,
effluent from the units at the GE plant may be reduced to as little as 1,200 GPD. Literature fully describing this equipment is included in Appendix H.
.
lt is recommended that further evaluation be conducted in order to determine the economic
justification of this water recycling equipment.
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