CS 2 – Paint Sludge as Alternative Fuel

Situation

  • An automotive assembly plant was being gutted and retooled to build sub-compact cars using a three coat wet-on-wet coating system
  • The plant’s objective was to be “green” and for the sludge system to be landfill-free

Background

  • The paint sludge system was redesigned to utilize 10% of the old system’s capacity to dramatically reduce water usage
  • New sludge consolidation and drying equipment was installed
  • 40 yard roll-off boxes with additional dewatering capabilities were utilized

Solution

  • Paint samples were screened and evaluated in the Galaxy lab for kill, floatation, water clarity and dewatering ability
  • GCC 870, a high-performing liquid paint detackifier, was chosen based on testing and the system mechanics
  • The sludge system and the dewatering and drying equipment were optimized to create dry sludge

Results

  • Paint sludge solids are consistently over 50% and contain greater than 5,500 BTU per pound
  • Sludge is being sent to a local coal fired generating station where it is burned as “alternative fuel”
  • Titanium dioxide in the paint helps reduce mercury emissions from the generating station

CS 2 – Paint Sludge as Alternative Fuel

CS 5 – Water Conservation in Paint Sludge System

Situation

  • Galaxy noticed that the conductivity of a 150,000 gallon sludge pit was not cycling up as it normally should
  • It was suspected the water was being dumped to waste water treatment somehow and the plant was likely losing a lot of water

Background

  • Galaxy was treating an automotive assembly plant paint sludge system
  • Galaxy began to look for ways that the booth water could be getting out of the system because the water chemistry was not cycling up
  • The process was studied and it was found that water was being added to the sludge system when the booth went into entry mode – the reduced air volume allowed water to fill the booth impact pond
  • This dropped the water level in the sludge pit, causing the auto water fill to add fresh water
  • When the booth came out of entry mode, the increased air velocity blew the excess water out of the impact pond
  • This caused the sludge pit level to increase and activated the automatic blow down to waste water

Solution

  • The PLC was programed to disable the make-up water to the sludge system while the booth was in auto mode

Results

  • The automaker verified that over 15.5 million gallons of fresh water was saved on an annual basis
  • The annual flow to the waste treatment plant was reduced by the above amount

CS 5 – Water Conservation in Paint Sludge System

CS 6 – Conversion from Melamine Formaldehyde to GCC 831

Situation

  • A supplier and chemistry change was desired when a new Chemical Manager came in and took over this location
  • The Chemical Manager was looking for a more current technology that was also more environmentally friendly

Background

  • Production was going to increase from roughly 240,000 to 300,000+ units/year
  • No major issues at the plant but the new Chemical Manager knew that there would be benefits to newer chemistries that were more “green”

Solution

  • Better performance by changing over old melamine formaldehyde chemistry to all-organic GCC 831 using their performance criteria

Results

Numerous process improvements were realized by the customer:

  • Water quality to booth improved
    • 23 ppm to 7 ppm suspended solids – 66% Improvement
  • Collection Efficiency Improved
    • 2.1 dry lb. per unit to 3.2 dry lb. per unit – 52% Improvement
  • % Solids Achieved in Sludge Bins
    • 39% baseline melamine
    • 47% with GCC 831 – 20% Improvement
  • Pit Cleanouts
    • Annually with melamine
    • Currently more than 2 years – 100+% Improvement

CS 6 – Conversion from Melamine Formaldehyde to GCC 831

CS 7 – Reduced Air House Filter Changes

Situation

  • An automaker was experiencing filter failure in the recycle air house and deposition in the RTO

Background

  • One of Galaxy’s customers was experiencing higher failure and plugging of the primary, secondary and tertiary filters in the clear coat recycle air house
  • Inspections done by plant personnel showed a little water on the air house floor but clean air coming into the air house

Solution

  • Galaxy verified the day and time of the inspections
  • Galaxy monitored the weekend cleaning and start-up protocol
  • Galaxy determined that the start-up and chemical treatment protocols were causing the plant to start-up under an upset condition.
  • This caused initial foaming and high velocity air to coat the filters
  • Once the plant had run for a few hours, the foaming went away and everything looked normal

Results

  • Once the new protocol was installed, filter life was extended and filter failure stopped
  • An estimated $138,000 in filter costs were realized on an annual basis

CS 7 – Reduced Air House Filter Changes