3M – Prairie du Chien 2013 SHWEC Internship Kara Klubertanz

Outline Sustainability Background (3P) Project Objectives Water Reduction ▫Process A ▫Process B Discharge Investigation Site Wide Water Management

Pollution Prevention Pays (3P) Pollution Prevention Pays (3P) program in ▫Goal - eliminate or reduce sources of pollution in 3M products and processes 10,000 3p projects since ▫Prevented > 3.8 billion lbs of pollution ▫Saved > $1.7 billion in their first year.

Project Objectives Assess water management for potential reuse or reduction ▫Noncontact and contact cooling water  Main focus  Process A  Process B

Water Reduction Background ▫Two processes  Process A  Extrudes resin to form very thin nylon or polyester fibers  Process B  Extrudes resin to form vinyl or Nylon/polyester webbing material ▫Significant opportunity to improve water management

Process A

Current water usage ▫Extruder  10 GPM ▫Quench Tanks  1 tank = 6 GPM  All 8 tanks = 48 GPM  Each tank vol.= 45 Gal. ▫Orient Tank  Volume = 278 Gal. Gal/yrFt 3 /yr Extruder2,764,800369,654 Quench Tanks 13,271,0401,744,338 Orient Tank 26,6883,568 Total16,062,5282,117,560

Process A Suggestion ▫Reduce flow rate in Quench Tanks by 15% ▫Decrease each Quench Tank volume by 1/3  Evaluate tank design

Process A Water Reduced ▫2,003,136 gal/yr CO 2 Emission Reduction ▫6.016 Tons CO 2 /yr Cost Savings ▫$10,867/yr

Process A Potential future projects ▫Automatic valves ▫Reuse Quench Tank discharge to supply Orient Tank

Process B

Current water usage ▫Extruders  44 GPM ▫Quench Tank  6-12 GPM  Temperature dependent  435 gallon tank Gal/yrFt 3 /yr Extruders12,165,1201,626,477 Quench Tank 1,658,880- 3,317, , ,585 Total13,824, ,482,880 1,848,269- 2,070,062

Process B Replace non-contact cooling water with an Air Cooled Oil Cooler ▫Cools oil in extruders Implement in 4.5” extruder

Process B – Heat Exchanger Water Reduction ▫6,082,560 gal/yr CO 2 Emission Reduction ▫ tons CO 2 /yr Average Cost Savings ▫$10, 540/yr

Discharge Investigation Problem ▫2Q water bill increased Research Highlights ▫Discharge Monitoring Reports ▫Production Schedules  Inconsistent with chart recorder ▫Maintenance  Preparing Fire Water Tanks for inspection

Discharge Investigation Conclusion ▫Meter  Possible obstruction or mechanical upset ▫Evaluate data more frequently ▫Cost Savings  $43,181

Site Wide Water Management Accurately meter & evaluate usage Improve as products and operations expand

Thank you to all 3M-PdC employees and to SHWEC Special thanks to David Liebl and Mary Prisby