ADEM Pollution Prevention Training Case Studv Exercise

FACILITY PROFILE

United Fabrics Corporation is a textile dyeing and finishing plant for cotton fabric mainiv used in the production of cotton T-shirts. On average. the facility processes 150.000 Ibs of fabric per week. In 1994, the annual ship $2,000.000 The plant, locate e in Cotton City, South Carolina currentlv employs 135 people 5 days a week in three shifts. The plant operates 50 weeks per year with two weeks of downtime for scheduled maintenance

for the facility were valued at

Facility History

The faciiitv was owners purchas were destroveci bv tire in 19 I5 operation in 19 17. Even though there have been a series of rehabilitation projects over the years to overcome buildin

ifferent owners. The current ngs that housed the operation structed and went into

ility deterioration caused by time and usage. the

Facility Layout

The entire facilitv contains 226.673 gross square feet. The main building contains 106.67-3 ntains i 00,000 gross square feet and the warehouse All three buildings are constructed of metal and

ofs and cement floors wi little or no insulation.

The floor pian for the entire facility is shown in Figure 1 Figure 2 through 4 provide more detaiied door pians for the three major buildings ar the facility

Main BI(IIU'IH~

The main buiidin ns the following shops an

The maintenance shop is use includinc becks.

ain all equipment at the facility mixing equipment. and loading sink maintained by a contracted

ly company. storage space for maintenance tools. and storage space for oii. solvents. and rags. There is also a floor drain located in the middle of the room that IS directed IO the sanitary sewer

The phone center is used for receiving orders. The room contains two work space, V, i ~ t i

phones and computers to receive incominz orders

The lunch room is used by the facility staEas a "break" room. The room contains a table, TV, refiigerator. and microwave.

The inspection area is used for inspection of the final product prior to delivery. She room contains a work table, a bin for pre-inspection sampies. and a bin for post-inspection samples.

The finishing process area is used for the fabric finishing process, including padding. extracting, washing. and drying. The following equipment is used in this area:

O 8 stainless steel dryers O 8 stainless steel washers manufactured by Republic Textile Equipment O 4 stainless steel and rubber calenders manufactured by Mega Marketing, Inc. O 4 stainless steel and rubber pads manufactured by Morrison Textile, Inc. The area has 10 floordrains that are used to drain process wastewater and rinsewater. The drains are directed to the main chemical drain that receives on-site pretreatment before it is discharged to the s + sewer.

In the chemical and dye preparation area, workers prepare batches of chemicals and dyes used throughout the facility. The room contains an ACS-Datacolor Weighing System and six stainless steei mixing tanks. Two floor drains are located on opposite sides of the weighing table and a larger drain is located at the base of the mixing tanks. All drains are directed to the ma hemical drain that receives on-site pretreatment.

The boilerhentilation area contains two boilers to produce the facility's steam and hot water. The boilers were manufactured in 1925 by Union Iron Works. Boiler blowdown is drained and discharged di ly to the sanitary sewer. The area also contains an emissions stack for the Finishing Process Area. A few containers of oil and a 55-gallon drum of rags is stored next to the boiiers.

by Proctor and Schwartz, Inc.

The dyehouse is used for the batch dyeing process, including fabric preparation. dyeing, and post-dyeing. The room contains several rows of high-temperature, stainless steel beck and jet machines. Floor drains are located underneath the equipment for draining process wastewater and rinsewater. The wastewater is discharged to the chemical drain and receives chemical treat t. The dyehouse also has a separate chemical storage area used to store oil. su1fi.iric acid. and hydrochloric acid. It also contains an emergency eye wash sink and shower

-- Warchort.~

Behind the main building is the warehouse used for chemical and dye storage, fabric storage. and hazardous and non-hazardous waste storage. Chemicals and dyes are stored in 55-gallon arums and placed on wood pallets Fabric is purchased in rope-form on larse

cylinder roils an0 are aiso placed on wood pallets. Chemicais. dyes, fabric. and wastes are moved tiom the warehouse to the main buiiding and dyehouse with the use of forklifts.

Next to the main building, dyehouse. and warehouse are dock areas used for loading and unloadins cnemicals and cotton fabric.

Plant Utilities

Water atid Wirstewnler Treatmem

Water is drawn from a nearby reservoir in Cotton City. The cost for this water usage is SO071 per gallon and the cost for disposal to the municipal sanitary sewer is S.001 per gallon. The drains for the facility and their discharge locations are provided in Table I and are aiso identified in the floor plans.

Tabie 1 : Discharge Locations DRAINS TYPE

Drain # I Pretreated industnal

Drain 82 Mun itary scwcr

Drain i f3 Storm water

DISCHARGE FROM

Chemical and dye prep arca Dyehousc Maintenance Finishing process arca

Rest rooms Office arca Boiler blowdonn

Parking arca Dock

Electr~c~rl Po\c er

Electrical power to operate process equipment, lighting and air conditioning is provided from transformers located in a substation a mile away. The lighting throughout most of the facility is mercury vapor-proof lighting. Fluorescent fixtures are present in the offices, phone center. lunch room, and inspection area. The phone center, lunch room. fabric inspection area. and all offices arecooled. The facility uses approximately 200,000 kilowatts per vear at a cost of S.07 per kilowatt.

Steam

Stearr for uhe rhroushout the plant is produced by two boilers situated in the main building The boilers produce steam and hot water for uses which include final fabric finishing ana space heating. Approximatelv 900,000 cubic feet per year of natural gas is used to hear rtie water to steam at an operating temperature of 344 degrees Fahrenheit at

250 psig. The average cost for natural gas is S.80 per cubic foot. The boilers use approximately 1 S00.000 gallons of water per year.

MANUFACTURING PROCESS

Manufacturing processes at the main building and dyehouse include the following steps:

Chemical and dye preparation O Batch dyeing process (includes fabric preparation, dyeing and post-dyeing O Final finishing process (includes final rinsing, extracting, and drying)

Each step is described in detail below.

Chemical and Dve Preparation

The facility's fabric finishing and dyeing process begins with chemical and dye preparation. At the beginning of each batch, chemicals and dyes are measured in the chemical and dye preparation area in the mai ding. Containers are transported from the warehouse to the main buildings by fork1 batches of chemicals and dyes on a ACS-Datacolor Weighing System. Because it is difficult to tell how much of a chemical or dye may be required, extra batches are always prepared. Approximately 15 batches of dyes and chemicals are weighed each day.

needed. Chemical and dye prep workers manually weigh

After weighing, chemicals are hand carried in plastic buckets to the appropriate process. Each dye batch is approximately 1 S pounds per batch at a cost of $40.50 per pound. The dye batch is placed in the mixing tank which has a capacity of2.000 _gallons. The prep workers add approximatelv 15 gallons of hydrochloric acid and enough water to fil l the tank to its 2000 yallon capacity. Once the dye color and qualitv is acceptable the dye is pumped directlv to the dyehouse.

Mailttetiarice Operatiom

Buckets and all measuring devices are typically cleaned in a IO-gallon solvent sink at the end of each dav. The spent solvent is removed from the sink approximately every i 5 davs. The mix tank are rinsed with 2 gallons of ethylene glycol ($4.50 per gallon) after each batch. The floor in the chemical and dye preparation area are periodically washed down with discharge going to the floor drains.

Wairr mid l . , l r c ~ ~ . I J'.W<QP

Activities for cnemical ana dye preparation use approximateiy 70.000 gaiions of water per day.

wash? ~d~Fl l l~ lCLIIIOi1

Approximately 43.000 gallons of wastewater is generated each day. Wastewater discharges are tvpically generated fiom "off-spec" dye batches. between batch cleaning. and spills. According to the operators. there is a history of spills in this process area. During the inspection it was noted that some of the dye mixing tanks had holes in them allowing the dye floor drains.

ill on the floor. If any spil occur, these are also washed down the

Monthly estimates for other major wastes generated in this process area include:

O 1 55-galion drum of dye and chemicals O 5 to 10 empty chemical and dye drums

s maintained by a contracted industrial supply company The 150 to replenish solvent every 15 days.

Air emissions are also a significant waste. Dust particles from mixing dye batches, open d uncovered solvent sinks contribute to these emissions.

The wastes are managed in the following manner: the empty drums are rinsed and us waste landfill; waste water is treated on-site prior to xpired solvents and other chemicals are taken to a hazardous ssions are vented directlv into th

Batch Dveing Process

The batch dveing process performed at the facility requires the following activities.

O Fabric preparation (scouring, mercerizing, bleaching) O Dyeing O Post-dyeing

All steps in the batch dveing process are performed in two types ofatmospheric and pressure machines becks and jets the beck machines are stainless steel and built for atmospheric remperatures They consist of a shallow U-shaped box which has a gradual low curvature in the back and a rather high vertical rise in the front About 2 meters above each ro\\ of becks is a driven elliptical reel which transports the fabric througn a solution Becks are filled Ivirh water with hoses and chemical and dve solutions are added by hand

In the jet machines. a pump circulates the solution through the main chamber and the suction at the venturi jet causes the fabric to rotate. Jets are automatically filled with water and are used primarily for dyeing at this facility. The machines operate at 40- 135 degrees Celsius. The jet uses less water than the beck by reducing the cioth to water ratio to 1 : 10 as compared to 1 2 0 for the beck.

Fabric Prsparaiiopi

fabric arrives at the facility in rope form ready for dyeing. The first step in Eabric preparation is scouring which is performed to remove natural fats, oils. and waxes that remain in the fabric from the knitting process. The fabric is placed on a reel that transports the fabric through a series of becks with a 5,000 gallon capacity. The first tank contains water and 50 gallons of perchloroethylene ($4.85 per gallon). The second tank contains water for cooling and the third beck contains water for rinsing.

Mercerization. the second step in the process, is performed in order to minimize the dye machines. The process the tensile strength. luster, sheen. dye on resistance of cotton goods. it is accomplished by soaking the fabric

in caustic soda and water in a second series of becks. The solution causes swelling of the cotton fiber as the alkali is absorbed. M e r the desired period of contact, the caustic is thoroughly washed off in the becks. The operators add approximately 2 pounds of caustic soda per batch at a cost of $0.40 per pound.

Bleaching the third step, is a common finishing process used to whiten cotton. The fabric beck containing hot water to ensure removal of all contaminants. The

fabric passes through the next beck which contains 5 pounds of caustic soda dissolved in water. The material is then rinsed in the next beck with hot water and passed through a third beck with a solution containing water. hydrogen peroxide and sodium silicate. The operators use approximately 4 gallons of hydrogen peroxide at a cost of $0.52 per gallon and 2 pounds of sodium silicate at a cost of S 1.20 per pound. This is followed by a final hot water rinse

Dyeing

In the dyeing process. the dye solution is pumped fiom the dye mixing area directly to the becks and jets. The common practice is to sample the dye after 30-45 minutes at 105- I 10 degrees Celsius ff the quality of the dye is adequate, the fabric is passed through a series of becks and jets to ensure complete dyeing.

In the final batch dveing process. the fabric is treated in becks containing 2 sallons of formaldehvde ( S O 65 per gallon) dissolved in water and 1.5 gallons of acetic acid (S2.29 per gallon) dissolved in water This aftertreatment minimizes problems with bleeding with little or no change in the dye shade

Maintenaiice Operarioirs

Becks and jets are cleaned with perchloroethylene. a chlorinated solvent. after each batch mately 50 gallons of solve residue.

The batch dyeing proces water is required for the batch.

approximately 3 3 0,OO and jets and to wash

Ions of water per day. The

Waste Ideiittfificaticm

Approximatelv 300.000 gallons of process waste the municipal sanitary sewer each day. The wastewater from the becks and jets is contaminated with process chemicals and any remaining oils, lubricants, and natural waxes on the fabric. are located throughout the

is cleaned with p rge going to the flo

er and rinse water are discharzed to

a. At the end of each

noted that several hoses in this area were dripping while not in use.

Final Finishinq

The finishing process performed at the facility includes the following procedures:

O Padding O Extracting

process, non-ionic softeners are applied to the fabric with is passed through a stainiess steel box with a capacity

of 2,000 gallons. down under a roller which is below the solution 1. After passins through the solution, the fabric passes between to medium-density rubber rollers and is wound up to allow the solution to penetrate and fix on the cloth. The operators use water and approximatelv 50 gal gallon) for the solution

in the second st rs and calendars that apply steamheat and pressure order to remove excess ivater. for pre-shrinkage, and to spread the fabric to its final width.

In the third step, the fabric passes through eight wash boxes n i t h a capacity of SO0 for hot and cold washing. Operators add 2 pounds of detergent (54.45 per pound) to eac wash box.

The fourth step. drying, is conducted in gas-fired d y e M e r drying. the fabric is placed on a cylinder immediately. completed. samples of the finished products are taken to the inspection office to ensure product quaiitv.

The facility manage but no buyer has made the request.

"

as considered accepting cylinders from the fa ty's fabric buvers.

Water anid Eniergy Usage

This process uses approximately 150,000 gallons of water per day.

Waste streams inch "off-spec" fabric dis dryers vented from

000 gpd of wastewater. 100 pounds of exhaust heat from the

MAINTENANCE SHOP

Process IAwriprro

The purpose of the maintenance shop is to service and maintain all equipment at the facility including becks. jets, washers. dryers. padding equipment. mixing equipment. and loading equipment The company is reluctant to invest monev in a preventive maintena program and prefers to wait until the equipment breaks. Maintenance is performed bv a crew of two mechanics w ork staggered 8-hour shifts. The shop conducts

Maintaininrz this equipment requires the use of several chemical products including - . . lubricating oil. penetrating oil, gear These chemicals are stored on-site i mable storage lockers. The manag that the shop uses a drum of oil ($50 per drum) and two boxes of disposable per box) each month Information about quantities used and costs for other materials were not a.ai lab] e

Through normal maintenance activities, the maintenance shop generates approximateiy of waste oil a year, one 55-gdlo ed rags a month. 5

m of waste solvent a year, one er year. and 3 to 4 empry

The waste are m hazardous waste or as solid wasre

in the following the used oil and solvent is disposed as as hazardous waste if saturated with oil

e disposed as solid waste.

WAREHOUSEKHEMICAL STORAGE

The purpose of the warehouse is to provide a central storage the facility The warehouse manager maintains all inventory but there is no rracking or inventory system for chemicais taken to other areas of the facility. Anv employee can contact the warehouse manager to order materiais.

Wastes generated in the warehouse include expired chemicals and dves, 40 wooden pallets a year. 100 fabric cylinder rolls per year. and 10 tons of cardboard packaging per week. Wastes senerated at the other chemical locations are not tracked.

Floor drains are located throughout the area in the storage areas. Dyes and chemicals are stored close ro the floor drains and no berms. dikes. or other spill retention is provided, The floors in both areas are periodically washed down with discharge goins to the floor drains.

WASTE MANAGEMENT PRACTICES

The facility produces wastewater, air emissions. and solid wastes. The plant's major waste in terms of volume is the discharged wastewater.

All process u'astewater is sent through the floor drains to a pit where sulhric acid is added for pH adjustment and sodium hypochlorite is added for color removal. Sulfuric acid is added automarically. depending on the pH of the wastestream. Wastewater then passes through a 10.000 gallon holding tank with a circulating pump to allow for mixing and reaction

The faciiitv d ~ r s have an NPDES permit: however. its discharges are regdated by rne Cotton Couilr\. Sewer Use Law under permit number 525 . A wastewater laboraton testing repnn dated December I. 1992 repons chromium at 0.50 m p l ? copper ar U '0

mgA, and zinc at 1.00 my'i. These discharges do not comply with Cotton County's permit requirements.

According to the facility's 1992 TRI submist perchloroethylene, petroleum naptha and d emissions.

e plant released 12 1 pounds of ssions to the air as non-point fUgitive air

The major solid wastes ar non-hazardous solid wast

waste streams are provided in Table 5.

ed of as a ms nor does it

claim any process chem s for hazardous and solid

CASE STUDY EXERCISE

The purpose of this section of the case study exercise is to apply the concepts of pollution prevention to a detailed example. Some opportunities for P2 implementation are easiiv visible. However. in taking a closer look at a facility and it’s waste management problems in stepwise fashion, real opportunities for reduction that might otherwise be overlooked may be realized.

NOTE: This case study represents an actual facility in South Carolina. During an EPA inspection in October of 1993, numerous violations and unsafe conditions were noted and resulted in a large monetary penalty. The company investigated implementing a Supplementary Environmental Project (SEP) to reduce the monetary penalty. Pollution prevention options were identified for this reason and to avoid hture violations. The parent company also realizes that the operation at this facility is extremely costly and that costs could probably be reduced, but has not done a hll analysis and have implemented few cost saving measures. Quantities have been altered to suit the exercise.

Your role is to examine the the facility information collected and presented to you in the preceeding section and answer the questions in the following exercises.

Pollution Prevention Tool: Process Flow Diaprams Exercise

A hand-drawn process flow diagram will provide a visual outline of the facility processes and environmental releases and is an advantageous tool for determining pollution prevention opportunities.

1 . Based on the process descriptions and floor plans for the facility, develop process flow diagrams for one of the following steps:

A. Chemical and dye preparation B. Batch dveinl; process (fabric preparation. dyeing and post-dyeing) C. Final finishing process (includes padding, extracting, washing and drying)

PROCESS FLOW DIAGRAM: CHEMICAL A N . D YE PREPARATION

PROCESS FLOW DIAGRAM: l3A TCH D YEING PROCESS

PROCESS FLOW DIAGRAM: FINAL FINISHING PROCESS i i

Pollution Prevention Tool: Data Collection Techniaues Exercise

Data collection is essential for prep baseline wil impacts associared with the facility proces information was unobtainable from the co batches ofdves are used per day yieiding

1.

*

Use the table provided to identify the following information for each raw material.

2. Use the taole provided to summarize the foilowiny disposal data:

ous wastes, solid w

quantify yenerat identify how wa identify the was

WASTE Q U A " CY PROCESS SOURCE DISPOSAI, DISPOSAL

Solvent (sink) 20 gal * 15 days cheddye prep contractor $2490

*Full Drums

G E N E W E D OF METHOD COSTMX GENERATION

* 250 operating daydl5 d

included in other figures. "Other than waste oil

Cotton City, South Carolina Faciiity

Floor Plans and Facilitv Walk-through

Calculations

Products

150,000 Ibs fabric processedheek = 9.800,OOO Ibs./year or 3900 tonsivr. 1994 shipnienrs ofS2.000.00Q for 7.580.000 Ibs. = finished product value of S.356ilb

Raw Material and Other ODerating Costs NOTE: It is given that the facility operates three shifts daily. It is assumed that the facility operates 5 daydweek and 50 of 52 weekdyear with 2 weeks off for maintenance and vacation.

1. Water Usage = (boilers) 1,500,000 gpy + (chem and dye prep 70,00O/day 5 days * 50 weeks) 17,500,000 gpy + (batch dyeing 33O,OOO/day * 5 days "50 weeks) 82.500.000 gpy + (final finishing 1950 galhatch * 3,750 batches) 7,3 12.500 = 108,8 12,500 gallons of water used per year. The water usage for final processing is calculated only for the pad box and not for steam heat which is included in the amount for the boilers. The yearly cost of thi ater ($.0071/ gallon) is $772,568.75.

2. Electrical Power = 200,000 kw/year for the entire facility * .07/kw = $14,00O/year.

3. Natural Gas = (from boilers for uses including final finishing. space heating, etc.) = 900,000 e.' /year * S.SO/ft.' = $720.000/year.

a1 Batches for dyeing = approximately 15 batches are prepared per day * 5 = 3,750 batches per year (67,500 Ibs/yr.). Each batch is approximarelv

50 batches per year = $2,733.750.

5. Hydrochloric Assuming all 15 equal to

s are added to the mixing tank with each dye batch. sed per dav or 3,750 per year (56,250 gal.), the cost is

n (ACS grade) * 3,750 batches = $562.500.

allons are added to the beck for fabric Treatment in post-dyeing 15 dy batches are usea per day or 3.750 per year (5625 galions 1. gallons * 3.750 batches * S3.20/gallon = 512.375

7. Caustic soda = Combining both the mercerization and bleaching processes. 7 Ibs. are used per batch or 26,250 Ibs. for 3,750 batches per year. Cost = 26,250 Ibs. * Is 40/lb. = $1 O,SOO/year.

8. Ethylene glycol = 2 gallons used to rinse tanks in dye prep process after every batch (7500 gal& ). Assuming all 15 dye batches used per day or 3.750 batches per year. annual cost = 3.750 * 2 gal * $4.50/gal= S33.750.

9. Softening Agent = 50 gailons used per batch in padding process of final finishing. 3,750 batches per year * 50 gallons (187,500 gaI./yr.) * SS.75 gal. = $1,640,625,

10. Detergenr = 2 lbs. used in each of S wash boxes in the \+ashmy process of finai finishing -3.750 batches per year * 16 Ibs. (60.000 Ibs.) *: Is4 4Ylb = $267,000

1 1. Oil = Maintenance Dept. uses approximately one 55-gaiion arum per month "5 12 per drum * I2 months = $660 per year (660 gallons)

12. Rags = Maintenance Dept. uses approximatelv 2 boxes per month * $7.25 per box * 12 months = 5 1 74 per year.

13. Sodium silicate = 3.450 batches per year * 2 Ibs. * $1.20/lb. = 99000 (7500 Ibs.)

14. Formaldehvde = 3,750 batches per year * 4 gal. * $.52/gal. = $7800 (1500 gal.)

15. Perchloroethylene = INCLUDE DISCUSSIONS OF UNKNOWNS IN ALL INSTANCES OF PERC USE and calculate the few values which are given.

DisDosal Costs

1. Solvent in solvent sink in chem and dve prep process is handled by a contractor. Amount calculated = 10 gallonsi i 5 davs or 234 gaUyr (year = 35 1 days) However. the contractor charges $150/15 days instead of per gallon so cost per year= 35 1 daydl 5 days = 23.4 changeouts * $1 50/chanseout = $3.5 I O/yr. You may ais0 calculate by the following although less accurate: 2 changes per month * 12 mos. * S1 5O/change = $3600.

2. Wastewater is pretreated in mixing and reaction tank and then sent to the POTW. Amount calcuiated = Boilers = 1.500.000 yr. = 125,000 gal/ ChedDye prep = 48,00O/day * 250 days = 12,000.000/yr. /12mos. = 1.000,000gal/mo. Batch Dyeins = -300,00O/day * 250 days = 75,000.000/yr. / 12mos. = 6,250,000 gallmo. Final Finishing = 1 2S.OOO/day * 250 davs = 32,000.000/yr. / 12mos. = 3,666,667 3aIimo

= 10,04 1.667 galimo

10,041,667 gaVmo. * 12 mos. = 120,000.004 gaVyr. * $.001/gal

3. Full drums (oil, solvents, etc.) are taken to a hazardous waste incinerator. Amount calculated = Chem/Dye prep = 1 drum (haz. waste liquid) per month (12/year) = $155/ mo. (SI 860/yr.) Maintenance = 1 drum (haz. waste liquid) per year = $155/yr. Maintenance = 2 drums (waste oil) per year * 7S/dntm = $1 56/y TOTALS *Full Drums haz. waste Iiquid) = 12 per year = $201 5 per year **Full Drums (waste oil) = 3 per year = 91 56 per year

= $120,500 yr

4 Emptv drums from Chem/Dye prep and maintenance are rinsed and disposed of as non- hazardous naste in a landfill No specific cost estimates were given for empty drum disposal E::iprv drums come from chemdve prep ( 5 - I O/month) and from maintenance ( 3 -

4yr . ) From this the estimates use 8 drums per month from chem dye prep (%/VI-. 1 and 4 per year fiom maintenance = I00 empty drums per year. (drums are appros. 65 lbs. ) 100 drums * 65 Ibs/drum = 6500 Ibs or 3.25 tons/yr * 100/ton = $325 per year.

5 . Off-spec fabric from final finishing is disposed of as non-hazardous waste in a landfill. Approximatelv IO0 Ibs. of off-spec fabric is disposed of per month = 1200 Ibs.iyr. or 0.6 tons * 100/ton = SBO/yr.

6. Rags are used in maintenance and results in 40 Ib. bundle being produced by month which are disposed of as hazardous waste if saturated with solvents and solid waste if not. Rags = 40 Ibs/mo. * 12 months = 480 lbs/yr or 0.24 tonsjyr. *$I OO/ton = S24yr.. Being conservative and treating these as unsaturated, the 480 Ibs/yr. would incur disposai cost as a non-hazardous soiid waste.

7. Wooden pallets are used in maintenance and warehouse/chemical storage (50/Vr. and 40/yr. respectivelv) They are disposed of as soiid waste in a landfili. No specific cost estimates were given for the disposal of these 90 pallets per year.

8. Fabric cylinder rolls are used in the warehouse to store incoming fabric and are disposed of as solid waste in a IandfilI. No specific cost estimates were given for the disposal of the 100 cylinder rolls per year.

9. Cardboard packaging waste from the warehouse in the amount of 20.000 Ibs/wk. ( 10 tons) is assumed disposed of as non-hazardous in a landfill. No specific cost estimates were given for disposal of this packaging. Cardboard packaging = 20,000 Ibs/wk. * 50 weeks of operation (52-2 for downtime = 50) = 1,000,000 Ibs/vr.

CHEMICAL AND DYE

PREPARATION

FINISHING PROCESS

AREA

MAIN BUILDING

I I

MAINTENANCE I DOCK I OFFICES SHOP

2

E 0 0

I CHEMICALS STORAGE

I - DYE HOUS,E

- -

Y 0 0 P

. .

000 01 0 000000 CHEMICAL

STORAGE STOR SULFUR1

NON-HAZARDOUS/ HAZARDOUS

WASTE STORAGE

I-

&

ROLLS

DOCK

Figure 4. Warehouse and Storage Area