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2002 Technical Summaries
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ABBOTT LABORATORIES
North Chicago, Illinois
Intern: Betty Jurkowski
Bradley University, Peoria
Abbott Laboratories is a major health care company that discovers, develops,
manufactures and markets antibiotics, nutritional supplements, hospital
product IV solutions, diagnostics, and specialty products. The intern
worked on several pollution prevention projects within the facility's
Chemical Pilot Plant and Chemical Manufacturing Areas. During the internship,
the intern was able to explore projects involving phosphorous minimization,
gown recycling, water reduction via globe valves, and solvent containerization.
Results:
The intern made the following recommendations:
- Phosphorous loads to the wastewater treatment plant could be reduced
by approximately 5,000 kg/year by substituting a non-phosphorous based
cleaning agent for the current phosphorous-based agent. Efforts to introduce
alternative cleaning agents will continue.
- Recycling of Tyvek gowns used in sterile manufacturing areas within
the Chemical Pilot Plant has resulted in a $3,750 reimbursement, which
has been donated to a Lake County, IL charitable organization. Expansion
of the program into the Chemical Manufacturing Area would increase donations
as well as reduce the amount of waste otherwise potentially generated.
- Restriction of water flow was accomplished through the installation
of ten globe valves and flow meters in one building of the pilot plant.
This resulted in flow reduction from 5 - 9 gpm to 2 - 4 gpm. Evaluation
for the feasibility to expand this project into other buildings is recommended.
- Total carbon loads associated with post-laboratory activities were
reduced by additional containerization of solvents in laboratories as
well as better material management procedures. This has resulted in
the additional collection of approximately 2000 gallons per year of
solvents. A joint effort between divisions and the use of green chemistry
to replace solvents with environmentally friendly chemicals has begun
and will enhance overall waste reduction efforts.
CATERPILLAR TECHNICAL SERVICES
Mossville, Illinois
Intern: Jason Shelby
Bradley University, Peoria
Caterpillar inc. is the world's largest manufacturer of construction
and mining equipment, diesel and natural gas engines, and industrial gas
turbines. Cat has over 100 facilities in 21 countries. The Technical Services
Division is located at the Technical Center in Mossville. The focus of
this intern was to find and evaluate pollution prevention opportunities
within the metalworking fluid (MWF) system used at the Center. The intern
was tasked with making recommendations based upon his research findings
and evaluating the feasibility of the recommendations. Those recommendations
found worthwhile also would be implemented at other Caterpillar facilities.
Results:
While focusing on P2 in the MWF system at the Caterpillar Tech Center
many P2 opportunities where presented and evaluated. These opportunities
included:
- The use of vegetable based MWF. This would substitute a less toxic
material than is currently in use at Caterpillar. A retrofit device
was tested for mist application of vegetable based MWF.
- P2 opportunities for swarf (excess scrap metal from metalworking)
recycling were presented that would eliminate 1000 tons per month of
swarf from being sent to the landfill. This would also eliminate $96,000
in disposal fees.
- · It was recommended that a micro filtration system be installed
for use with the MWF system in use at the Tech Center. This system would
extend the life of the MWF, and reduce the amount of MWF that requires
disposal.
- Particulate concentrations of metal dusts were measured to estimate
the environmental impacts of dry machining.
COGNIS CORPORATION
Kankakee, Illinois
Intern: Jonathon Loftus
University of Illinois at Urbana - Champaign
Cognis Corporation located in Kankakee is a specialty chemical manufacturer.
The facility operates on 83 acres and employs over 200 people. Cognis
Corporation requested that the intern evaluate opportunities to improve
the performance of its wastewater treatment facility (WWTF) and to improve
WWTF odor control.
Results:
A number of WWTF activated sludge system operating parameters were evaluated
and outlined in a spreadsheet format. A master spreadsheet was designed
to list calculated ratios for volume of food to numbers of microorganisms
(F/M) as well as mean cell residence time (MCRT) to maintain maximum treatment
system efficiency. The current method of control for the activated sludge
system can be improved by remaining within the recommended ranges for
F/M and MCRT. The new method could save up to $47,000/yr in wastewater
discharge surcharge costs, and an additional $20,000/yr could be saved
in reduced use of electricity and sludge disposal costs.
The intern found that control of WWTF odors could be improved by implementing
several new procedures. Among the methods recommended, in order of priority
included minimizing thermal loading, covering WWTF equipment, absorption
of malodorous vapors, and chemical addition.
DANA BRAKE PARTS
Litchfield, Illinois
Intern: Stephen Tonellato
Southern Illinois University, Carbondale
Dana Brake Parts manufactures master and wheel cylinder assemblies for
the automotive and commercial trucking industries at its Litchfield facility
for over 100 years. The facility employs about 500 full time employees
and engages in machining, anodizing, injection molding, and assembly operations
24 hours per day. The goal of the intern project was to identify, quantify,
and recommend potential energy saving opportunities throughout the plant.
Results:
The intern mapped and updated blueprints with appropriate air supply
lines and lighting systems throughout the plant. Air compressor operating
specifications were identified and actual operating conditions were monitored.
- Based on 166 identified compressed air leaks and assuming an audible
air leak ranges from 1/32 to 1/16 of an inch, implementing a compressed
air leak detection and repair program would save over $ 21,000 per year.
- Adequate air compressor ventilation in the summer, cool air intake,
and reducing the working air pressure to 100 psi could save nearly $17,000
annually.
- · Replacing high bay metal halide lights with a combination skylight,
photocell, and fluorescent system known as "daylighting" could reduce
current annual lighting expenses by $166,000. Although the payback period
for this project would be close to 10 years, productivity may increase
due to a positive psychological impact of natural lighting.
- · Eliminating hard wired lighting in offices, conference rooms, hallways,
and restrooms by utilizing an energy conservation program including
switches, occupancy sensors, compact fluorescents, electronic ballasts,
and high efficiency fixtures. Together these options would save about
$25,000 annually. In most cases, these savings would be realized immediately
or with a payback period of less than 6 months.
deCODE GENETICS
Lemont and Woodridge, Illinois
Intern: Dave Norem
University of Illinois at Urbana Champaign
deCODE Genetics has two facilities located in Lemont and Woodridge that
identify synthetic routes and produce pharmaceuticals that minimize expression
of the genetic sources of disorders. The scale of chemistry operations
ranges from microscale combinatorial research chemistry to large-scale
production contract chemistry.
Results:
The intern identified three major avenues for P2 implementation.
- Material Management - Inventory and bulk purchasing have been identified
as opportunities for improvement and cost savings. New inventory systems
are under evaluation and bulk purchasing will be phased in as capacity
increases. Bulk purchases of commonly used chemicals and an enhanced
chemical inventory system could contribute to cost savings.
- Water Resources - Most laboratory water used is purchased in drums,
boxes, or bottles. This results in a large solid wastestream at a costly
per liter price. In house purification systems have been identified
that will make water purchases unnecessary and will result in substantial
savings.
- · Solvent Tracking - Identification of heavy users and reducing the
amount of used solvent can minimize waste costs and can decrease raw
material purchases. The glassware-cleaning lab and a few chemical separation
method labs have been identified as strong candidates for significant
reductions.
THE ENSIGN-BICKFORD COMPANY
Wolf Lake, Illinois
Intern: Jeremiah Dunmyer
Southern Illinois University, Carbondale
The Ensign Bickford Company is one of the largest non-electric detonator
manufacturers in the world. This firm lead the industry by continuously
advancing the quality and dependability of non-electric blast initiation
systems. The facility at Wolf Lake, Illinois, is the main manufacturing
plant for Primadet® final assembly and it also manufactures Primaline®
detcord products. The goal of the intern was to identify, research, and
develop an implementation plan to reduce shock tube waste. In addition,
the intern was to develop an approach to analyze the amount of Primaline®
waste that was being generated.
Results:
Through process familiarization and working with producers, the intern
was able to develop an accurate data collection system that resulted in
useful documentation that correlated waste and cost parameters. Recommendations
included the following:
- Reduction in waste is possible through "low cost" procedural changes
including training operators on best practices to reduce waste generation.
- Operator training and process optimization may reduce waste shock
tube generation over 25%.
- New machine systems being considered for implementation may increase
production capacity and reduce shock tube waste by nearly 25%.
Overall, implementation of operator training and equipment upgrades
may save the company near $14,000 annually.
ILLINOIS WASTE MANAGEMENT and RESEARCH CENTER (WMRC)
Champaign, Illinois
Intern: Andre Ellis
University of Illinois at Urbana-Champaign
WMRC is a division of the Illinois Department of Natural Resources and
is affiliated with the University of Illinois at Urbana-Champaign. The
pollution prevention (P2) services of the WMRC include
- Developing P2 principles and technological solutions to minimize
waste
- Demonstrating how to implement P2 and provide recommendations for
P2 incorporation into existing processes based on evaluations/tests
innovative principles
- · Creating P2 awareness by providing technical presentations, papers,
fact sheets, databases and internet resources to Illinois businesses
and concerns.
Results:
The primary goal of the project was to evaluate the performance of PRO-pHx
manufactured by Wagner Environmental Technologies, LLC, NC. This product
is marketed as a product that can remove metals and or organics from acid
pickling baths without neutralizing the acid. A similar study involved
evaluating the effect of PRO-pHx treatment on acid bath samples from Skild
Plating Corp. and its effect on etching rates.
- Based on the controlled bench test conducted in this study pro-pHx
was not effective in removing dissolved metals namely iron, zinc and
nickel from clean hydrochloric, sulfuric or nitric acids.
- Addition of pro-pHx was found not to affect the acidity of the solutions.
- PRO-pHx was also not effective in removing any zinc from the sulfuric
acid zinc-stripping bath obtained from Skild Plating Corp nor was any
enhancement observed in the stripping rates. Etching characteristics
of the bath appear to be controlled more by acidity and suspended contaminants
rather than by dissolved zinc concentrations up to 50 g/l. Keeping the
bath clean by fine filtration and periodical acid additions alone will
extend the life of the bath.
- A 25 % removal of organic carbon was observed in the treated sample
from Skild Plating Corp. In situations where the type and amount of
organic carbon may affect the efficiency of an acid bath, treatment
with PRO-pHx may remove some of the organic contaminant, which in turn
may extend the life of the bath.
JAMES HARDIE BUILDING PRODUCTS
Peru, Illinois
Intern: William Wachter
University of Illinois at Chicago
James Hardie is a world leader in fiber cement technology as well as
a leading producer of fiber cement products. The facility in Peru, Illinois,
focuses on the manufacturing of fiber cement backerboard and siding, which
has a number of advantages to traditional vinyl products. The Peru facility
treats and disposes of approximately 250,000 gallons of water per day,
and presses and disposes of nearly 56,000 pounds of filter cake per day.
The intern focused on completing a plant-wide mass balance on freshwater
usage and wastewater disposal, as well as a similar balance on the plant's
byproduct processing of sludge. It was initially learned that high levels
of chemical oxygen demand (COD's) were inhibiting the plant from attempting
a closed loop water recycling system, resulting in their need to use large
amounts of freshwater daily.
Results:
The intern drafted a preliminary report and spreadsheet depicting all
sources of freshwater use and wastewater discharge in the plant. It was
determined that between use, treatment, and discharge the plant spends
in excess of $530,000 annually. A mass balance was established. The suggestions
made by the intern included:
- A few minor process changes and simple housekeeping procedures emphasizing
source reduction could reduce the plant's freshwater intake by over
45,000 gallons per day resulting in a savings of over $90,000 annually.
The plant is currently in the process of implementing these suggestions.
- A request for assistance was made to the Illinois Waste Management
Research Center. A trial was proposed and conducted on an ultrafiltration
system to help in reducing Total Suspended Solids (TSS) and COD. Bench
tests showed an 87% reduction in TSS, but were inconclusive with respect
to COD levels. Further studies will be conducted in the future.
- The plant was being billed for the discharge of over 50,000 gallons
per day of effluent that was lost through product or evaporation. The
intern recommended that the company purchase a discharge flow meter,
which would save the company over $30,000 annually. Management approval
is expected soon.
A study of the plant's sludge treatment process showed that its sludge
recycling system was performing at 70% of optimum goals. Further increases
in sludge recycling are tremendously beneficial as the plant currently
spends over $500,000 a year between the cost of raw materials and disposal
of its sludge.
LOVES PARK WATER DEPARTMENT
Loves Park, Illinois
Intern: Steve Burgess
Northern Illinois University, DeKalb
Loves Park is a city of 20,000 people in Northern Illinois and sits
on a shallow sand and gravel aquifer, which puts the city drinking water
more at risk to potential groundwater contamination. An intern was sponsored
by the Loves Park Department of Public Works to inform local businesses
about the benefits of source reduction. Responsibilities included contacting
companies, setting up site visits, conducting waste assessments, and writing
reports showing pollution prevention profitability.
After sending 53 letters and making 44 phone calls to local businesses
the intern was able to set up 9 appointments. Each company received the
intern well and all responses seemed positive. Company's names are not
disclosed for confidentiality purposes.
Results:
The recommendations ranged in scale and initial cost. Some of the recommendations
included the following:
- Replace air nozzle drying with air knife/conveyor process to increase
efficiency by creating a uniform distribution of airflow to wet parts.
The equipment would cost about $3,500 with setup and could generate
$2,000 annual savings within 1-½ years.
- Increase cleaning bath life with the purchase of a mobile cleaning
bath filter. The filter would cost $8,000 with minimal operating costs
but would reduce cleaning chemicals purchased by 80% annually. This
would generate $2,900 a year in savings after 3 years.
- Invest in a water chiller to reuse non-contact cooling water. Currently
the company discharges 4 million gallons of water per month. A water
chiller would create a closed loop system that would constantly reuse
the water. In 1-1/3 years the initial investment of $74,000 would be
retrieved and second year cost saving would exceed $38,000. Each additional
year would generate $56,400 annually. This would include saving $5,000
annually by reducing the amount of non-contact water that would need
to be dechlorinated.
Overall, the intern's recommendations were projected to save $68,000
annually with an average payback period of 1-½ years.
MONTEREY COAL COMPANY
Carlinville, Illinois
Intern: Jolene Jablonski
University of Illinois, Urbana-Champaign
Monterey Coal Company, a division of ExxonMobil Coal USA employs about
330 people at its No. 1 Mine near Carlinville. The mine uses the longwall
method of coal extraction and produced about 3.3 million tons of coal
for sale in 2001. The primary intern project proposed was to determine
the feasibility of using an alternative by-product material to replace
the ground limestone "rock dust" which is applied to the exposed coal
walls and floor to keep coal dust out of the air inside the mine. Other
projects included reducing disposal costs for batteries, aerosol cans,
and universal wastes, and also reducing the mine's use of materials listed
on the SARA Title III Toxic Release Inventory (TRI).
Results:
- Cement kiln dust (CKD) was identified as the best potential alternative
to limestone rock dust for meeting the Mine Safety and Health Administration
requirements for physical attributes and performance. Silica content
is a concern for the use of CKD due to some samples exceeding the allowable
occupational safety limit. If silica content can be controlled or guaranteed,
Monterey Coal Company could use an industrial by-product to replace
virgin material and save over $60,000 annually.
- As an alternative to disposal, a recycling firm was selected which
accepts batteries, lamps, mercury, electronics, and other wastes and
will save the company $6,000 per year.
- Nearly 650 pounds of TRI (Toxic Release Inventory) reportable compounds
were identified and eliminated from the facility though replacement
of paints, janitorial supplies, and anti-freeze.
- A recycling program was identified and implemented for aerosol cans
that removes all residual material from the containers and crushes the
cans for recycling with an annual savings near $1,500.
NORTHWESTERN PLATING
Chicago, Illinois
Intern: Elizabeth Flannigan
University of Illinois at Chicago
Northwestern Plating is a family owned job shop electroplater. Plating
types include: zinc, nickel, copper, and brass. Burnishing and phosphate
application are also performed. The intern worked on chemical reduction
and water conservation.
Results:
The intern recognized the over usage of cleaner in the company's burnishing
department. This department was found to be using approximately twice
the amount of cleaner necessary. Reduction methods were identified that
could lead to an annual savings of at least $6,615. The intern also recommended:
- Installing flow restrictors, reactive/neutralizing rinses, conductivity
meters and training to reduce water usage in different areas throughout
the facility. This could save the company 30% of the annual cost for
water, with a payback of four months.
- Converting to counter-current rinses, which would eliminate some
water inlets.
- Extending the inlet water pipes on rinse tanks, drain boards, covers,
and proper tank sizing. This will also improve the quality of the parts
produced.
NOVEON INC.
Henry, Illinois
Intern: Crystal Johnson
Bradley University, Peoria
Noveon Inc, formerly B.F. Goodrich, is a specialty chemical company
with twenty-eight facilities around the world. Noveon produces chemicals
for diverse applications such as industrial, textile, construction, paper
and packaging, transportation, personal care, food and beverage, pharmaceutical,
electronics and household products. The Henry facility currently has 85
employees. The facility produces rubber accelerators and antioxidants.
The rubber accelerators are used predominately in the tire industry to
help speed up the vulcanization process.
Results:
The intern worked on four main projects that included:
- Reducing organic material emissions from dryer air vents. A contractor
was tasked to develop a design to implement this process change.
- Reducing the volume of organic solvent routed to waste treatment.
Solvent recovery occurs by rerouting condensate from a steam jet to
a tote for decanting. This suggestion has become standard operating
procedure.
- Reducing product loss during filtration and in the scrubber system
by evaluating the effects of different type of filter media. A metal
media is being considered for its cost savings. A new procedure was
put in place to more effectively coagulate product prior to filtration.
It was also suggested to improve scrubber tank maintenance to prevent
product build up.
- The Cure-rite process recovers Methylene Chloride (MeCl2) via a MeCl2
distillation column. Problems with the control loop and feed conditions
caused reduced efficiency of the distillation process. Control loop
parameters were evaluated resulting in the suggestion to improve control
of feed concentrations through the column.
ONDEO NALCO COMPANY
Chicago, Illinois
Intern: Mark Liska
University of Illinois at Chicago
Ondeo Nalco Company is the world leader in commercial and industrial
treatment and process improvement solutions. The company markets a combination
of mechanical, operational, and chemical solutions to help solve water
and energy problems. The purpose of the intern's activities at the Ondeo
Nalco Clearing Plant was to review inefficiencies in the two cooling towers
which were both overflowing large quantities of water and had problems
with scale and bacteria.
Results:
In one of the towers, city water that was used to help cool a compressor,
constantly overflowed. A strainer was unplugged and a stuck valve was
repaired that resulted in a savings of $25,000 per year in lost water.
A scale-inhibiting chemical was added to the system and allowed a higher
conductivity threshold, thereby decreasing the daily water blowdown and
saving more water. A biocide has been added to the tower to keep bacterial
growth down. In addition, the cooling tower fan was replaced saving $7,500
per year in electricity costs. Finally, a small tank is feeding extra
biocide from off spec, expired and pilot plant samples. By using it in
the tower, the facility can save $1,200 yearly in disposal costs. Total
savings from the intern recommendations are estimated to be over $32,000
per year for this cooling tower.
In the other cooling tower, the city water that supplies the tower is
not recirculated and is designed to have a constant overflow. This stream
is also fouled with silica after cooling. A project to use the overflow
stream in the boilers has been recommended. If needed, piping this water
to the boiler softeners and changing the anion exchangers in order to
remove the additional silica will enable the reuse of the water. Benefits
of this project include water conservation as well as steam savings since
the water is pre-heated. Over a two-year period, this project has the
potential to save over $57,000 per year.
PFIZER GLOBAL MANUFACTURING
White Hall, Illinois
Intern: Todd Breuer
Southern Illinois University, Carbondale
Pfizer, Inc., which has a plant located in White Hall, Illinois, is
a major manufacturer of animal health products. Vaccines are manufactured,
mixed, packaged and sent to the market or a sister plant to be mixed in
a final product for marketing. This facility employs approximately 40
people and acquired an intern to provide suggestions for reductions of
natural gas, electricity, and water consumption.
Results:
The intern suggested the following projects with annual savings over
$25,000 and an initial investment around $14,700. The resulting savings
were determined from the calculated annual reductions of 500,000 cubic
feet of natural gas, 36,000 kWh of electricity, and 2.9 million gallons
of water.
- Changing the exit signs from incandescent bulbs to LED's would save
nearly $1,000 annually on energy and maintenance costs. Converting incandescent
bulbs throughout the facility to compact fluorescent lights would save
an additional $500 per year.
- Installing a boiler condensate return system could save the facility
over $16,000 annually in gas and water expenditures with a payback period
less than 6 months.
- Incorporating an existing cooling tower to cool the compressed air
system would save over $2,200 per year on the recycle of non-contact
cooling water.
- Installing a heat recovery system for a cage washing operation would
result in an annual savings of $3,200.
- Turning off computers and printers each day would yield an annual
electric cost savings of nearly $1,000.
In most cases, these savings would be realized immediately or with a
payback period less than 6 months
SOLUTIA, INC
Sauget, Illinois
Intern: Demetrius Barefield Jr.
Tuskegee University, Tuskegee Alabama
The W.G. Krummrich Plant manufactures chemical intermediate products
for Solutia, Astaris, Flexsys, and OxyChem. The Environmental Safety and
Health department acquired an intern for a project to create a Leak Detection
and Repair (LDAR) program to reduce fugitive organic hazardous air pollutant
(OHAP) emissions from process equipment in the rubber chemicals manufacturing
department. Additionally, the intern was to evaluate the process wastewater
stream to determine applicability, group status, and provide options for
reducing point source OHAP emissions.
Results:
- Using engineering flow diagrams, the intern worked with department
engineers to identify the areas of the process to include in the LDAR
program. The intern then compared the diagrams with visual observations
of the entire process, and ensured that each piece of equipment (valves,
pumps, relief devices, connectors, etc.) was represented. Using this
data, the intern created spreadsheets that identified each specific
piece of equipment.
These activities resulted in the development of LDAR inspection forms
with over 950 pieces of affected equipment that manage OHAPs. In addition,
the intern developed a "hit list" that identified missing/mislabeled
equipment or denoted equipment that has been removed.
- Options for reducing wastewater concentrations of OHAPs were identified
and presented to the department that included:
- Utilizing a steam stripper for removal of MEK and MIBK components.
- Reducing in the mass flow rate of OHAPs through process engineering
to recycle materials back into the process.
- Separating OHAP material from the wastewater effluent for recycling
opportunities within the process or off-site.
In the event where process modifications are not feasible, the student
suggested further investigation in the use of a biofiltration system or
designing an ecosystem to remove the OHAP components.
ST. MARY'S HOSPITAL
East St. Louis, Illinois
Intern: Pierre Bull
University of Illinois, Urbana-Champaign
St. Mary's Hospital is a non-profit, 169-bed center employing approximately
300 full-time and 200 part-time staff. The 198,000-ft2 main and 40,000-ft2
medical office buildings house several programs including level 2-trauma
care, psychiatric center, medical-surgical unit, youth program, community
action, and corporate health. The goal of an intern would be to identify
and reduce toxic chemicals, develop an energy efficiency strategy, and
create a recycling program.
Results:
- A 10-year energy reduction plan was developed that requires a capital
investment of $40,000 per year with a cost savings realized after seven
years and an annual savings of $250,000 after the tenth year.
- It was recommended that mercury be virtually eliminated from the
facility by replacing the remaining 12 blood pressure cuffs used at
the hospital. Microbial cleaning of rooms and equipment is performed
with biocides, autoclaves, and ethylene oxide that were determined to
have no practical alternative.
- The hospital's maintenance department adopted a computer based preventative
maintenance program known as "MS 2000". This program utilizes Palm Pilots
to track time, supplies, and task recommendations which are conveyed
to maintenance.
STERLING LABORATORIES, INC.
Harwood Heights, Illinois
Intern: Lissa Aquino
University of Illinois at Chicago
Located in Harwood Heights, Sterling Laboratories has been providing
electroplating services since 1959. With 20 employees and approximately
20,000 square feet, the facility specializes in the following finishes:
gold, silver, nickel, tin, copper, zinc, and chromate finishes; and finished
parts such as screws, washers, fuse caps, and springs.
The purpose of a P2 intern project at the facility was to research new
technology and products that would enhance the pollution control system
as well as locating alternate processes that would reduce chemical use
and disposal costs. Major focus was placed on finding the right polymer
and dosage that would solve the problem of no floc appearing in the clarifiers
when cleaner tanks were dumped; and experimenting with alternatives to
outsource disposal of spent electroless nickel (EN) baths.
Results:
Several samples of polymer and treatment chemicals were sent to the
intern by various vendors.
The following was concluded:
- Treating the holding tank with 5% polymer would cause floc to appear
in the clarifiers.
- An old, unused 55-gallon drum of a second polymer was also found
to be effective in forming floc in the clarifier. Sterling plans to
use this to supplement the first polymer to bring metal concentrations
of the discharged water down, and to get rid of the 3-year-old drum
of unused polymer.
- Currently, outsourcing is the most economically practical way for
the location to dispose of spent EN baths.
UNILEVER BESTFOOD
Chicago, Illinois
Intern: Charmagne Villasin
University of Illinois at Chicago
Unilever Bestfoods is one of the largest food production companies in
the world. The company manufactures such household brand name products
as Lipton, Knorr, Hellmann's and Lever 2000. The Chicago plant manufactures
varieties of Hellmann's and Bestfood's mayonnaise. The high-speed production
lines can fill and carton 2500 cases of mayonnaise an hour. The main focus
of the intern's efforts was a condensate recovery project on the starch
cooking system.
Results:
- The starch cooking system votator was using steam to cook starch
slurry. The condensate from the steam barrel was being piped down the
drain and the excess steam was vented into the atmosphere. By recycling
the condensate, the plant can save potentially $20,000 per year. The
plant can install separate piping and a pump to the existing condensate
collection tank. The existing return lines are at different pressures.
- The intern also suggested that the facility evaluate energy conservation
efforts such as consolidating the items stored in coolers to one unit
instead of two. The plant could save an additional $900 per year by
using one cooler.
- A microbial-based cleanser is being researched to explore its compatibility
within the plant. This product would replace a highly corrosive cleanser
currently being used.
For more information on any of these 2002 intern projects,
contact Rick Reese at (217) 557-8671.
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