Machine coolant recycling system

Machining processes at the 272W Site Fabrication Services (SFS) produce a waste stream consisting of dirty machine coolant. During use the coolant becomes contaminated with metal chips from milling, and oil, dirt and solvents from the machining process. The mixture is designated as a Washington State dangerous waste with WP02 (persistence), D007 (chromium) and D008 (lead) waste codes. This process results in the generation of 13.5 m3 of hazardous waste per year with an annual cost for coolant replacement, waste management and waste disposal of approximately $137,000. To identify alternatives to this situation, ICF Kaiser Hanford Company (ICF KH) North Environmental Services conducted a pollution prevention opportunity assessment (P20A) on the machining processes. A coolant recycler and sump sucker unit were selected as the most cost-effective waste reduction options. In December 1994, ICF KH received return on investment (ROI) funding from the U.S. Department of Energy Richland Operations Office (DOE-RL) to implement this option. The coolant recycling and the sump sucker units were purchased and installed in July 1995 at a total cost of $61,000. The sump sucker removes the dirty coolant from the fabrication machinery and filters it to remove shavings and sludge. The filtered coolant then is transferred to the coolant recycling system for further processing. The coolant recycling system reconditions the filtered coolant for use in the machining equipment, and mixes the concentrated coolant to the correct concentration. As a result of implementing this option, the annual generation of waste coolant was reduced by 12 m3. The annual cost savings exceed $119,000 with an ROI of 186%. Additional benefits include reduced coolant usage; improved tool life, wheel life, finish, size control, corrosion protection, and operator working conditions; increase machine open-quotes up-timeclose quotes; and reduced machine tool maintenance