valley chrome plating’s journey to environmental compliance through e.m.s
TRANSCRIPT
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Valley Chrome Plating’s Journey To Environmental Compliance through E.M.S.
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Valley Chrome Plating Company History
Founded 1961
Originally Job Shop Car bumper routes
Production Decorative Electro-Plating
Family Owned
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Ray Lucas President: Valley Chrome Plating Inc. Director- at- Large: NAMF Membership Chair
Manufacturer of Truck Bumpers Zero Discharge Hoist Plating Processes 1st Plating Shop in U.S. to be permitted for
Nickel Air Emissions. Participant in Environmental Management
Systems In application process for OSHA VPP Star
Program
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Valley Chrome Plating Inc.
High-level of environmental compliance prior to implementing an EMS
EMS was the catalyst for achieving the next level of environmental compliance and significant $$ savings
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Regulatory Changes
Clean Water Act of 1977 Catalyst for Inspections
Increased Public Scrutiny High Profile Cases
Expanded Regulations Discharge limits 3.5ppm -1.3 ppm
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Ion Exchange
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Closed Loop Technology Nickel
Counterflow Rinsing Filtration Carbon Treatments Trial & Error Spray Rinsing
Chrome Counterflow Rinsing Evaporation Porous Pots Dummying
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Nickel Process Changes
Carbon Anodes Reduction of Nickel Metals
Re-Use of Nickel (post generation)
Dead Rinses Allows for re-use of chemical Each rinse improves water quality 100%
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Pre-Plating Improvements Necessary to Achieve Zero
Discharge & Waste Reduction
Ultraviolet light Filtration Ozonator Counter flow rinsing Weirs & Oil Superator Evaporation Batch Treatments
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Effects of Achieving Zero Discharge
Positive Side Effects Saving H2O No discharge to POTW Re-use of Chemicals
Resulting in $$ savings
Negative Side Effects Poor Rinse Quality Higher reject rate (in house/in field) Higher Waste Treatment Costs
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Sleep Factor
Amount of Sleep
En
viro
nm
enta
l Co
mp
lian
ce /
Red
uct
ion
of D
isch
arg
e
(used w ith permission -Jim Miille Chemical Solutions Inc.)
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VCP Environmental Goals
Water Reduction Waste Reduction Scrap Metal Reduction Electricity Reduction Storm Water Runoff Capture and Use
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E.M.S. = Water Reduction1999 2002 2003 *
3,200,000 986,000 615,5003,200,000
986,000
615,500
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
Gal
lon
s
1999 2002
Annual H20 Use
2003 Projected
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Waste Reduction
Waste Hauled by Year
124,253
157,336
99,500105,164
170,379
0
20,000
40,000
60,000
80,000
100,000
120,000
140,000
160,000
180,000
19
99
20
00
20
01
20
02
20
03
P
Lb
s o
f W
as
te
1999 2000 2001 2002 2003 P
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Scrap Steel Reduction
Scrap Steel Generation
1,148,0501,312,480
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
Year
Lbs
2001 2002
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Kilowatt Reduction
1,479,120
1,260,724
1,024,332
1,115,902 1,137,732
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
1,800,000
kw p
er y
ear
2003 P200220012000 Co-Gen Oct 03
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Storm Water –The Next Goal Capture & Re-Use
Capture & Re-use of all rain water landing on our facility
Environmental Lawsuits will require metals
and other limits in runoff. Use of runoff will help
reduce plant water usage. Elimination of permit and
regulatory reporting requirements
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EMS 2003 Projected Net Savings
Hazardous Waste = $45,000
Water = $ 2585
Scrap = $25,000
Electricity = $25,000
Total Projected Savings $97,585
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Valley Chrome’s Future Role Model For Industry
Sharing of Knowledge
Waste Reduction
ISO 14000
Voluntary Protection Program Safety Hour
100% Capture & Use of Rain H20 Capture H20 from air
US EPA Performance Track
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Plating Industry Future
Sharing of Resources & Solutions
Coordination Between Agencies
Survive together or die together Increased scrutiny by regulators and public Disintegration of supplier base. Disintegration of customer base
Other modes of coating