Pollution Prevention Case Study

Reynolds Metals Company
Milwaukee Can Plant
Milwaukee, Wisconsin

Reducing Sludge through Training
and Efficient pH Monitoring Processes
Standard Industrial Classification (SIC) Manufacturer of Metal Cans and Shipping Containers SIC 3411
Process Process and rinse waters from can washing.
Type of Waste Wastewater pretreatment sludges.
Strategies To accurately determine pH in process wastewaters prior to and during pretreatment before discharge. Accurate pH determination would then allow reduction of the use of pretreatment chemicals subsequently reducing the total amounts of sludge generated by the pretreatment system.
Company Background The Reynolds Metals Company manufactures over 3 million cans each day at the Milwaukee Plant. Considering the volume of product manufactured, the wastes from the plant are very small. However this has not happened by accident, rather through consistent commitment on the part of the company to reduce waste of all types.

This achievement is reflected through many waste reduction projects both big and small at the plant. The Milwaukee plant actively participates in the Reynolds Corporate program called AWARE, Avoid Waste and Reduce Emissions. This particular case study is a brief example of how a large reduction in non-hazardous sludge was achieved simply by an excellent training program and more attention to the instrumentation used to monitor pH.
Original Process The wastewater pretreatment process at the Reynolds Metals plant is and has been very efficient in removing organic matter and pollutants from the can washing process wastewaters. However the cost of treatment chemicals and disposal costs of the non-hazardous sludge is a significant cost issue for the company. In addition the sludge is a waste and therefore an automatic target for the AWARE program.
Pollution Prevention Process The Environmental Coordinator for Reynolds determined that the accuracy and consistency of pH instrumentation readings could have significant impact on the quantity of sludge generated by the plant. Incorrect readings could cause excessive chemical use during the pretreatment process, further promoting sludge production and wasting expensive treatment chemicals.

Using outside expertise, new instrumentation probes and a new control system was installed. An in-depth training program was developed for plant technicians. Key factors in the training program were how, when and where to place probes so that readings were always accurate and consistent. The program was very effective and resulted in immediate reductions of sludge volume and a better quality effluent from the plant.
Economics
Capital Costs

New Probes    $2,400
Operating Costs
Original Annual Costs New Annual Costs Cost Savings
Sludge $ 23,400 Sludge $ 17,100 Sludge $ 6,300
Treatment $ 84,500 Treatment $ 61,750 Treatment $ 22,750
Transportation $ 13,000 Transportation $ 9,500 Transportation $ 3,500
Service Contract $ -0- Service Contract $ 300 Service Contract ($ 300)
Total Costs $ 120,900 Total Costs $ 88,650 Total Annual Savings $ 32,350
Total Quantity of Waste Reduced or Eliminated
Original Sludge Qty New Sludge Qty Sludge Reduction
1,300,000 lbs/yr 950,000 lbs/yr 350,000 lbs/yr
Payback Period for this project is less than one month !
Other Waste Minimization Activities The company also implemented another project to reduce solvent usage for cleaning and degreasing parts in the maintenance shop. The company switched to an aqueous blend of solvent with a flash point above 150 degrees. The service life of the solvent was extended from 2 weeks to 12 weeks. This project resulted in a minimum annual saving of $7,000 and a significant reduction of hazardous waste. There were no capital costs so payback was immediate for the project.
Company Address and Contact Reynolds Metals Company, Milwaukee Can Plant
Mr. John Balge, Environmental Coordinator
8500 West Tower Avenue
Milwaukee, Wisconsin 53224-2894
Phone 414/357-4233, FAX 414/357-4206
Additional Publications Available SHWEC Publications
Pollution Prevention: A Guide to Program Implementation.
Industrial Cleaning Source Book.

Department of Natural Resources Publications
Contact:
Wisconsin Department of Natural Resources
SW/3 Pollution Prevention Clearinghouse
P.O. Box 7921
Madison WI 53707
for a Publications Order Form, # PUBL-SW-199, or call 608/264-8852.

Suggested publications include:
Aqueous Industrial Cleaning Chemicals, # PUBL-SW-147.
Aqueous Parts Washing Equipment, # PUBL-SW-148.
Facility Pollution Prevention Guide, EPA/600/R-92/088.
Other Pollution Prevention Resources Available Free, Nonregulatory, On-site Technical Assistance

University of Wisconsin-Extension
Solid and Hazardous Waste Education Center
Waste Reduction Specialists
Area Code 414 call the Milwaukee Office at 414/227-3175
Area Code 608 call the Madison Office at 608/262-0385
Area Code 715 call either Madison or Milwaukee for assistance.
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Bureau of Cooperative Environmental Assistance
Wisconsin Department of Natural Resources
P.O. Box 7921
Madison, WI   53707
608/267-9700

PUBL-SW-280