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FINAL REPORT NO. 05-90
ELECTRIC UTILITY MAINTENANCE SHOP
Developed by
New Jersey Technical Assistance Program for
Industrial Pollution Prevention Hazardous Substance Management Research Center
New Jersey Institute of Technology Newark, New Jersey
December 1990
DISCLAIMER
The statements and conclusions of this report are those of the New Jersey Technical Assistance Program and not necessarily those of the New Jersey Institute of Technology. The mention of commercial products, their source, or their use in connection with material reported herein is not to be construed as either an actual or implied endorsement of such products or their performance.
ACKNOWLEDGEMENT
The New Jersey Technical Assistance Program for Industrial Pollution Prevention is funded by a grant from the New Jersey Department of Environmental Protection’s Division of Hazardous Waste Management; and by a grant from the New Jersey Hazardous Waste Facilities Siting Commission. NJTAP is an important part of fulfilling the mandate of those organizations to protect the environment by reducing the volume of hazardous and toxic wastes generated by New Jersey’s industry.
ABOUT THE STAFF AT NJTAP
Mr. Alan Ulbrecht has over 18 years of experience with industry as a production manager, chemist and environmental compliance manager in the metal finishing industry, most recently with Nesor Alloy. He accepted a position with NJTAP in October, 1990.
Mr. Hanna Saqa is a mechanical engineer with over 30 years of project management and industrial process, design and troubleshooting experience with American Cyanamid’s Lederle Laboratories. He became affiliated with NJTAP in October, 1990.
Mr. Kevin Gashlin managed environmental compliance, industrial liaison and pollution prevention programs for the past 12 years with the New Jersey Department of Environmental Protection before accepting the post as Director of NJTAP in March, 1990.
I. DESCRIPTION OF FACILITIES
The 550 and 5 0 0 megawatt capacity generating stations have
been fired with coal, oil and/or natural gas in their 30+
year history.
one facility have a combined additional 35 megawatt
Two supplementary jet turbine units remote to
capacity.
The facilities generate a variety of RCRA hazardous waste
and some solid, nonhazardous waste of concern. The
hazardous wastes can be classified generically as being from
I1maintenancel1 activities. The following is a description of
those wastes and their origins.
This report combines the waste-related activities of the two
generating stations as they are essentially the same. Where
a distinct operation or applicability is presented it is
denoted using the appropriate code of I1A1l or c lB l l .
11. EXISTING PROCESSES and PROCEDURES
A . Oil and Oil Contaminated Soil and Debris
1. Waste oil - This category is by f a r the largest in volume,
generated primarily from the maintenance of pumps and from
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the waste water plant's oil/water separator. Maintenance
schedules are based upon manufacturer's recommendations
and the extensive experience of the staff. Some lube oil
(such as turbine oil) is filtered to remove solids and
reused when possible, but given the importance of these
pumps and relatively low cost of oil, staff is reluctant
to risk pump failure for the sake of marginally reducing
oil waste. Approximately 10 different types of oil are
used for lubrication, and about 3000 gallons of waste oil
is generated per quarter. Disposal costs about .lO/gallon
for oil; .65/gallon for oil/water mixtures. The waste is
manifested as RCRA waste X726. A summary of RCRA waste
generation from 1987-89 is provided as an appendix to this
report.
2. Oily debris and filters - There is a direct correlation of
maintenance activities and the generation of filter
cartridges. Generation of oily debris such as absorbant
lldiapersll, speedy dry, contaminated soil, etc. are related
to diminimus pump leaks and minor spills of similar
nature. Due to the large number of pumps it is difficult
to quantify these events or their pollution prevention
potential. However, since l1AI1 purchased a unit that
compresses the contents of drums, the volume of these
wastes has been reduced by 80-90%. Oil squeezed out of
this debris is siphoned under vacuum to a nearby drum f o r
I1satelliteg1 accumulation. The compressor is manufactured
5-3
1.
2.
by Compacting Technologies International and generates
approximately 8500 psi. Because "Att pays for disposal by
volume, not by weight, this step has a beneficial
financial effect. Also, volume reduction is significant
because it conserves dwindling landfill capacity.
B. Solvents - There are two basic uses for solvents :
1. Degreasing metal parts; and 2. Painting and Related Activities
Degreasing - Cleaning of metal parts occurs as part of
maintenance or repair activity. A Pennetone Co. petroleum
naptha proprietary formula solvent is used. Approximately
300 gallons of solvent waste is generated/year.
Degreasing occurs by submerging parts into the solvent and
manual brushing to remove the oils. When not in use the
unit is tightly covered. This is an important effort by
the staff as it reduces overall passive air emissions.
Painting and Related Activities - Much of the paint used is solvent based, manufactured by Conlux. This type of
paint is needed where harsh environmental conditions
exist. Inventory and purchasing are said to be
coordinated to reduce redundancy and the need to dispose
of unused, unusable, post shelf-life materials. The
purchasing and inventory systems were not available at the
time of the assessment nor were they reviewed further.
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C.
Most paints are brushed on. Large, exterior jobs may
require spray painting.
Batteries
Flashlights are powered with "DIl size disposable batteries
and are ubiquitous. Vehicle batteries are recharged,
recycled or sent for reclamation off-site.
D. Miscellaneous Wastes
The following are generated periodically:
Corrosive Solids Cleaners and Descalers Wastewater Treatment Plant Sludge Freon Office Residuals
1. Corrosive Solids, Cleaners and Descalers - Both are generated from boiler clean out and general maintenance.
Liquids may be treated through the wastewater treatment
plant. Solids are disposed through the boiler clean-out
contractors as hazardous waste, D002.
2. Wastewater Treatment Plant Sludge - Approximately 6 0 0
cubic yds. is generated every 12-15 months. At some point
the sludge may be classified as hazardous waste since the
Toxic Characteristic Leaching Procedures test (TCLP)
became effective on September 25, 1990. The sludge is
currently disposed of as non-hazardous solid waste.
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3 . Freon - May be discharged by the contractor when service is needed on the office air conditioning system.
4. Office Residuals - Non-hazardous wastes such as cardboard, paper, aluminum cans, bottles etc. are generated by the
administrative staff and discarded through appropriate
recycling outlets where they exist.
111. POLLUTION PREVENTION OPTIONS
The following are technically feasible options being used today
by industry. Where appropriate a reference to vendors or persons
knowledgeable in the specific field is provided in the appendix.
These lists are not necessarily exhaustive but reflect an intent
to provide a representative sample of vendors to you.
A. Oil and Oil Contaminated Soil and Debris
1. Catch Basins - The placement of small, periodically
emptied catch basins or pans under pumps and leaking
connections would greatly reduce the amount of cleanup
debris, absorbant, etc. generated. This method is already
being used successfully at Generating Station IlBll. The
captured oil can be added to the waste lube oil being sent
for off-site reclamation or, if suitable, returned to the
equipment that it came from.
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2. Maintenance Schedules - Changing lube oil based upon the number of hours that equipment is in service is probably a
better variable to use in developing maintenance schedules
than is a static, (weekly, monthly) schedule. As your
consultant suggested, installation of hour meters is a
good way to know how long a pump has been in service.
course if equipment is in service constantly, a static
schedule, developed through manufacturers recommendations
and the experience of staff as is done currently, seems
satisfactory.
Of
3 . Synthetics - More expensive synthetic oils have reportedly been evaluated, without appreciably lengthening the time
between oil changes. It is feasible for the utility to
join with HSMRC to organize and conduct a synthetic oil
replacement research project to evaluate appropriate
substitutes with the Electric Power Research Institute
(EPRI) and the Petroleum Environmental Research Forum
(PERF).
4. Segregation, Recycling and Reuse - In addition to your existing filtration and reuse program all oil/water
mixtures could be separated via a centrifuge separation
process prior to disposal. The oil fraction can then be
sent off-site for reclamation or reclaimed and reused.
The technology used in oil reclamation is relatively
5-7
simple and well established. The question is the quality
of the resulting oil.
oils used, reuse as lube oil would require segregation
prior to recycling. Reuse of reclaimed oil as fuel may be
possible if the oil is not considered to be a hazardous
waste. Three documents are enclosed for your information.
The first is the conference proceedings of the ttOil Waste
Management Symposiall which details a spectrum of options.
The second is "A Risk Communication Manual for
Government.lI For this application, management should use
the manual as an indicator of the type of issues that
concern the public and which the utility would face if
required to obtain a permit to burn hazardous waste. The
water fraction can be routed to the Wastewater Treatment
Plant (WWTP). The cost differential (reported to be
.10/gallon for oil vs. .65/gallon for oil/water mixture)
make this option appear favorable . A list of oil/water
centrifuge separator equipment manufacturers was forwarded
with the draft version of this report.
Because there are a variety of lube
5. Dewatering - Wastewater treatment plant sludge now being
disposed contains approximately 30% solids. Higher
efficiency is possible but may require high capital costs.
Utilization of waste heat to dry sludge and/or improving
existing filter press performance are two dewatering
methods to explore. In light of the relatively long
period between disposal events (12-15 months) it may be
5-a
worthwhile to contract with a vendor to provide a high
efficiency thermal dewatering unit when necessary.
Information concerning the economics of existing disposal
methods vs. proposed capital expenses, labor, permits
maintenance etc. are all factors in the equation that need
to be provided to your consultant for further review.
6 . Compaction - This is an excellent way to reduce expenses if the utility is paying for disposal based on volume, not
weight. It conserves landfill capacity as well. However,
source reduction and recycling measures (as described
earlier) are more effective and should be employed first.
If the utility begins to pay for disposal by weight, a
scale is critical to verify transportation charges. Also,
landfilling this material is the least desirable disposal
alternative in terms of long-term liability and public
perception.
New Jersey suffers from.
remediation (below) should be considered.
It also adds to the capacity imbalance which
Thermal treatment or bio-
7. On-site Remediation Research - Utility management should consider joining HSMRC in a pilot project to evaluate on-
site remedial technologies which show promise in treating
oil contaminated soil. As discussed, it would appear that
the utility has all of the right characteristics needed
for such an undertaking. Several such studies are the
subject of ongoing research projects at HSMRC. Your
5-9
corporate office is encouraged to contact HSMRC Director
Magee or the author to discuss this opportunity.
B. Deqreasinq Solvents - Solvents should be used only when no other suitable cleaner exists (see the draft report's appendix
for a thorough review of solvent alternatives). Generally, the
following options exist.
1. Degreasing - Certain cleaning needs cannot be effectively
met using anything other than chlorinated solvents such as
trichloroethane (TCA). However, substitution is possible
in many cases for removing gross oils or in cases where
quick cleaning is not essential. Some of the more common
options follow.
a. Manual Cleaning - Whatever system is used for final degreasing, a first step should be to manually wipe the
parts to remove gross oil and dirt contamination. This
will extend the life of solvent or caustic baths by
reducing fouling of the solution.
b. Ultrasonic Degreasers - The units utilize a heated,
caustic solution, eliminating the use of solvent, the
associated emissions and disposal problems. See the
appendix of the draft report for further information.
5-10
c. Abrasive Cleaners - Aqueous Cleaners - Less Toxic Solvents - Among the less toxic substitutes for TCA are: aliphatic hydrocarbons (E.G. napthas), Terpenes,
n-methyl-2-pyrrolidone and dibasic acid esters. Each
has benefits and each has problems. More information
about these options was provided in the appendix to the
draft report. Also provided as an appendix to this
report is an EPA project summary which describes
potentially applicable studies regarding solvent
substitution.
d. On-site Solvent Reclamation - Although low volume may make this option cost-prohibitive it is quite possible
to distill spent solvent on-site using a small
commercially available distillation unit. Management
should evaluate the possibility of purchasing one
llpackagell unit that could be easily transported from
facility to facility as needed. A list of
manufacturers was provided in the "Guide to Solvent
Waste Reduction Alternatives" in the appendix to the
draft report. See also the MnTAP Fact Sheet on
IIConsiderations in Selecting a Still" forwarded at this
time.
2. Paint - High temperature and extreme weather conditions may legitimately limit options for latex or water based
5-11
paint substitution but many opportunities to reduce
solvent emissions and health risks do exist. Interior
applications such as those found in office and storage
area environments are examples of this. Those
opportunities should be fully implemented. A list of
paint manufacturers was provided in the draft report's
appendix.
Progress in paint manufacturing formulations have greatly
increased the usefulness of water-based substitutes. Where some
doubt exists you could develop a demonstration project to
determine the potential for substitution. This could be simply
accomplished in side-by-side application of solvent vs water
based paints in field tests as painting is needed. The use of
water-based paints will eliminate the need for purchasing
solvents for use as thinners and for clean-up. However, the
constituents of water-based substitutes should be carefully
reviewed to evaluate potential effects of the clean-up washwater
on the WWTP discharge and sludge. Choose a paint company,
propose the project, ask them to donate the paint, publish the
successful results and implement the pollution prevention paint
program company wide.
In the case of spray painting, transfer efficiency is important
both economically and environmentally. A list of known equipment
manufacturers in the draft report appendix compared transfer
efficiency of different spray painting technologies. Among the
5-12
available technologies being marketed, high volume-low pressure
(HVLP) is probably suitable for the type of painting the utility
needs.
C. Batteries
Rechargeable nickel-cadmium (Ni-Cd) batteries seem to be a
realistic option for flashlights. However, due to the capital
expenses involved for the batteries, chargers and the inventory
system needed, it is recommended that a single shift or single
unit pilot project be established to determine if rechargeables
are practical and economical. Also, eventual disposal of the Ni-
Cd batteries is a potential problem, though recycling through
metal reclaimers is a growing area. If nickel-cadmium batteries
are used at the facility they should be collected separately and
stored until a safe disposal method can be developed in
cooperation with the appropriate county solid waste management
district.
Lead-Acid Batteries that are discarded should be sent to battery
reconditioners for recycling when possible rather than battery
llbreakerstl which reclaim component parts. This not only
conserves resources but reduces the generator's liability.
5-13
D. Miscellaneous Wastes
1. Corrosive Solids, Cleaners and Descalers - Substitution of a less toxic blast media for the corrosive boiler cleaning
agents may eliminate corrosive liquids, thereby reducing
the economic impact. Evaluation of changes in
effectiveness, labor costs and disposal costs are needed
before this issue can be adequately addressed. The
appendix contains a bibliography of references addressing
reduction of boiler cleanout wastes.
2 . WWTP Sludge - This waste is a direct result of the materials and procedures used at the stations. At the
present time the sludge is typically non-hazardous. The
TCLP test may change that. Evaluation of the constituents
in materials purchased and used at company facilities
should be performed to determine if those materials
contain any of the listed TCLP substances. This
evaluation will provide a list of products and materials
to be concerned about. The SARA 313 hazardous materials
inventory list that I1A1' submitted to NJDEP can be used to
begin the project. New materials and substitutes should
be evaluated and approved with this criteria in mind.
5-14
E. Remaininq Information Needs
1. Provide Feedback to Top Management - The company's environmental management is committed to assessing and
implementing pollution prevention options where they make
sense. Your input is critical to that decision and any
changes being contemplated. Talk about the options
presented here. Develop a short and long term
implementation plan.
2. Determine the Level of Commitment by Top Management - Pollution Prevention Philosophy is most useful when
translated to practice. Decisions to implement pollution
prevention alternatives are made for economic, public
perception, short/long term liability, reduced
permit/compliance needs etc, etc. Management must decide
on what. it values as an organization and go from there.
How does the organization make decisions?
What are the criteria considered?
What are the organizations goals?
Has the organization been successful in achieving
stated goals in the past?
5-15
Top management must decide upon the basis for it's commitment and
define the resources to be used to achieve the organization's
goals in reducing waste and wasteful practices.
3 . Economic Information - In order to further evaluate options for these and other facilities it is essential
that you supply the following cost information for 1988,
1989 and 1990 where appropriate to NJTAP or your
consultant.
- Cost per gallon of degreasing solvent and volume purchased. - Cost and volume of flashlight batteries purchased. - Cost of hazardous waste disposal, by waste type. - Manufacturer and model of paint spray system (if any). - Cost, type and volume of paints purchased.
- Cost, by type, and cost per volume and type, of oil purchased.
- Cost of the drum compactor.
A l s o , NJTAP currently working with a research organization to
develop a model Full Cost Accounting procedure for evaluating the
true and total cost of waste to a business. We are actively
seeking participation by New Jersey industries. If you are
interested, I would be happy to discuss the project with you and
a company financial officer.
5-16
4. Employee Involvement - Your employees are the experts. I
strongly urge you to establish an internal pollution
prevention committee with top management support. Mesh it
with health and safety. Encourage corporate management to
offer recognition and monetary awards for implemented
ideas that reduce operating costs. Also, ideas that work
should be shared with other facilities. The catch basins
at llBll and drum compactor at I1Al1 are examples of ideas not
shared that can really have a positive impact on
operations.
5. Office Residuals - I am having the N J D E P Office of
Recycling send lists of paper recyclers and information
about how to establish a successful recycling program.
6. Keep this report with your RCRA records. Refer to it as a
component of your waste reduction plan when you file the
1990 annual report for each facility.
I V . D r a f t Report Appendix
1. List of Known Oil-water Separator Centrifuge Equipment
Vendors
2. List of Paint Manufacturers and Trade Associations
3 . "Guide to Solvent Waste Reduction Alternativesf1 (contains
list of distillation equipment manufacturers).
4. List of Spray Paint Equipment Vendors
5-17
5. Excerpt from an EPA publication "Waste Minimization in Metal
Parts CleaningMv.
6. Summary of Hazardous Waste Activity at BGS 1987-89.
7. MnTAP Fact Sheet "Considerations in Selecting a Stillll.
8. Reprint Ifthe Ultrasonic Cleaning Processll
5-18
List of Oil/Water Centrifugal Separator Manufacturers
Alfa-Lava1 - 2115 Linwood Ave, Fort Lee, NJ 07024, 201-592-7800
Barrett Centrifugals Inc., - PO Box 551, Worcester, MA 01613 617-755-4306
Bird Machine Company Inc., - 100 Neponset St, S. Walpole, MA 02071
617-688-0400
Calude Lava1 Corp., - 1911 N. Helm Ave, Frenso, CA 93727 800-344-7205 or 209-255-1601
Delaval Separator Co., - Poughkeepsie, N.Y. 914-452-1000
Dorr-Oliver Inc., - 77 Havemyer Ln, Stamford, CT 06904 203-358-3200
Glitsch Inc., PO Box 660053, Dallas, TX 75266-0053 800-527-2443 214-63 1-384 1
Griswold Controls, 2803 Barrarca Rd, Irvin, CA 92714, 714-559-6000
Krebs Engineers, 1205 Chrysler Dr., Menlo Park, CA 94025 415-325-0751
Progressive Development Inc., PO Box 15300/2740 S. 32nd St. Milwaukee, WI 53215 414-645-6540
SWECO Inc., 6033 E. Bandini Blvd, Los Angeles, CA 90051 213-726-1177
Sharples-Stokes/Div Pennwalt Corp., 955 Mearns Rd, Warminster, PA 18974 , 215-443-4000
I .
Wright-Austin Co., 3245 Wight St., Detroit, MI 48207 313-259-1925
5-19
Final Report Appendix
1. Drum Compactor Brochure
2. EPA Project Summary on Degreasing Alternatives in Electronic
Capacitor Manufacturing Operating
3. A Risk Communication Manual for Government
4. Project Summary - Removal of oil from oil-waster mixtures.
5. Oil Waste Management Alternatives Symposia - Conference Proceedings
6. Boiler Clean-out Bibliography
5-20