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Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

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Page 1: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Utah Pollution Prevention (P2) Association

Pacific States Cast Iron Pipe Company

Achievements in Pollution Prevention

Page 2: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Brief History of Pacific StatesPacific States Cast Iron Pipe Company was established in 1926 as the western

operating subsidiary of McWane Cast Iron Pipe Company. This foundry is located in Provo and serves thirteen western states, western Canada and the Pacific Rim.

Ductile iron pipe is used to move pressurized culinary (drinking) water.

Product sizes—6” thru 30” Pipe joints—7 bell configurations Pipe pressure class types—12 Lining materials—cement or epoxy

linings Epoxy lining for non-potable water

Page 3: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Key Process Hot iron is poured into

Casting Machines and pipe are cast using the Delavaud method of centrifugally casting pipe in a water cooled steel mold.

Cast approximately 600 ton of pipe daily.

Page 4: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

CoatingGreater than 98% of all pipe are either cement or

epoxy lined and are painted inside and out.

Page 5: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Volatile Organic Compounds (VOC) Substitution of waterbased, emulsified asphalt

for standard blown, oxidized solvent based asphalt Results in > 95% reduction in VOC emissions Costs about $0.60 /gal more than solvent based

about $200,000 in 2007

Page 6: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Product SubstitutionWater-Based Emulsified Asphalt

0

50

100

150

200

250

2003 2004 2005 2006 Projected 2007

To

ns

tons VOC kTons Pipe

Page 7: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Lining Process Epoxy lined pipe used typically in sewer

applications Contained 0.92 lb/gal xylene Reformulated to 0.025 lb/gal xylene

Xylene emissions reduced by more than 97% Main savings is in emission fees Ensure not falling into both the iron & steel

MACT and surface coating MACT

Page 8: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Product ReformulationRemove Xylene

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

2003 2004 2005 2006 Projected 2007

To

ns

tons xylene kTons Pipe

Page 9: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Sand Coating Coated sand is used to form cores that provide

the interior relief of the bell. Critical to have good quality to prevent iron loss

Page 10: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Sand Coating Sand source is critical

Purchased coated sand grain structure is rounded Alternative is to coat our own sand

Our source is sub-angular grain structure

Projected savings is > $40,000 year in material costs

Reduction of about 4,200 lbs in 2007

Page 11: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Product Suplement

0

5

10

15

20

25

30

2003 2004 2005 2006 Projected 2007

To

ns

Sand Made x100 Resin Used x10 Phenol Emissions

Page 12: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Water Reduction

Page 13: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Water Reduction—Desire to close ponds Water originates in the basement area To close ponds water needs an alternative

place to go Need to build a treatment plant Minimize the amount of water to be treated!

Page 14: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Water Reduction Shut off water—Tag out so operations people will

know Use of Spring Valves (“Auto shut-off”) on hoses Rework trough coating circulation system Improve pipe mold inspections Identify combinations of equipment that work well

together on minimizing leaks and study (copy) those tolerances

Add gaskets Identify major causes of leaks and address them.

Page 15: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Water Reduction

Cast Machine #749%

Other Sources22%

Cast Machine #629%

Average Estimated Basement Waste Water Flow Rate

-

20,000

40,000

60,000

80,000

100,000

120,000

140,000

160,000

180,000

2/2/06 3/24/06 5/13/06 7/2/06 8/21/06 10/10/06 11/29/06

Day

Ave

rag

e E

stim

ated

(g

pd

)

Since Kaizen

29 kgal17 kgal

13 kgal

Page 16: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

Water Reduction Stop placing water in basement Casting Machine #6

Capital cost for new water box as old is warped Casting Machine #7

Resize catch basin, pumping & control logic Estimated to have < 10,000 gpd

Originally estimated to have about 90,000 gpd Wanting to use water internally as no desire to treat &

discharge. Can find uses in good weather. Need to plan for cold

Page 17: Utah Pollution Prevention (P2) Association Pacific States Cast Iron Pipe Company Achievements in Pollution Prevention

QUESTIONS?