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

5-2

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.

5-4

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.

5-5

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.

5-6

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