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Published byMabel Hicks Modified over 9 years ago
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3M – Prairie du Chien 2013 SHWEC Internship Kara Klubertanz
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Outline Sustainability Background (3P) Project Objectives Water Reduction ▫Process A ▫Process B Discharge Investigation Site Wide Water Management
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Pollution Prevention Pays (3P) Pollution Prevention Pays (3P) program in 1975. ▫Goal - eliminate or reduce sources of pollution in 3M products and processes 10,000 3p projects since 1975. ▫Prevented > 3.8 billion lbs of pollution ▫Saved > $1.7 billion in their first year.
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Project Objectives Assess water management for potential reuse or reduction ▫Noncontact and contact cooling water Main focus Process A Process B
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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
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Process A
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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
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Process A Suggestion ▫Reduce flow rate in Quench Tanks by 15% ▫Decrease each Quench Tank volume by 1/3 Evaluate tank design
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Process A Water Reduced ▫2,003,136 gal/yr CO 2 Emission Reduction ▫6.016 Tons CO 2 /yr Cost Savings ▫$10,867/yr
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Process A Potential future projects ▫Automatic valves ▫Reuse Quench Tank discharge to supply Orient Tank
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Process B
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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- 3,317,760 221,792- 443,585 Total13,824,000- 15,482,880 1,848,269- 2,070,062
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Process B Replace non-contact cooling water with an Air Cooled Oil Cooler ▫Cools oil in extruders Implement in 4.5” extruder
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Process B – Heat Exchanger Water Reduction ▫6,082,560 gal/yr CO 2 Emission Reduction ▫ 16.843 tons CO 2 /yr Average Cost Savings ▫$10, 540/yr
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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
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Discharge Investigation Conclusion ▫Meter Possible obstruction or mechanical upset ▫Evaluate data more frequently ▫Cost Savings $43,181
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Site Wide Water Management Accurately meter & evaluate usage Improve as products and operations expand
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Thank you to all 3M-PdC employees and to SHWEC Special thanks to David Liebl and Mary Prisby
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