Case StudiesCase Studies
- Automated Weapons Cleaning System
- Smart Washer Parts Washer
- Shop Towel Recycling
- Ultra Filtration of Aqueous Parts Washer Solution
- Success Story: Ultra Filtration Modified Aqueous Parts Washer (PDF)
- Mercury Fever Thermometer Exchange
Automated Aqueous Weapons Cleaning System
Background Information
The Illinois National Guard first became interested automating their weapons cleaning operations as a means of consolidating the hazardous waste generated during weapons cleaning. Rather than having small amounts of hazardous or potentially hazardous wastes generated at each of their 54 armories, waste would be consolidated and controlled at a single location. This would reduce the transportation costs associated with the disposal of the wastes. The Marseilles Training Area was selected as the point for the Automated Weapons Cleaning System since the majority of the units in Illinois familiarize and qualify with assigned weapons at this facility.
Inquiries sent to unit commanders identified that approximately three (3) manhours were spent cleaning weapons after qualification and training at Marseilles. This included an initial cleaning at Marseilles prior to returning to the home armory and two subsequent cleanings during drill weekends.
An investigation into methods other than the standard soldier cleaning resulted in the selection of an aqueous detergent combined with an ultrasonic agitation system. Aqueous cleaners have been used for cleaning grease, oil and dirt from automotive parts for several years. Ultrasonic agitation is a fairly new approach to cleaning where a void is produced in a liquid. When the void comes in contact with a surface, the void collapses with a force of about 400 atmospheres of pressure. Since the void, or cavitation is small, this force is focused on a small area of the surface.
Studies were performed at the Waste Management and Research Center (WMRC) Cleaners Laboratory to determine the most appropriate aqueous cleaner and to determine the optimum ultrasonic frequency. Initial studies were promising, however problems were encountered with removal of the anodizing from the weapon. After several tries, an appropriate combination of aqueous cleaner and ultrasonic frequency was identified that would remove carbon, oil and dirt from the weapon without damaging the finish on the weapon.
WMRC recommended the introduction of a 0.1 micron stainless Steel Ultra Filtration Membrane to reclaim spent aqueous cleaner and a modification to the commercially purchased UF system to allow for cleaning of the membrane without having to remove the membrane from the UF system.
After several generations of designs and changes to those designs, a final design was accepted by the DMA. This designed consisted of rectangular stainless steel cleaning, rinsing and drying tanks large enough to accommodate a rack of 10 M 16 rifles, a forced hot air blower to dry the weapons, a boiler to heat the cleaning and rinsing tanks, two 25 kHz ultrasonic generators with two stainless steel ultrasonic tubular transducers, a 0.1 micron stainless steel ultra filtration membrane system to reclaim spent aqueous cleaner, a membrane cleaning system, air compressors and pressure tanks to supply compressed air to dry the weapons, pumps, plumbing and wiring to tie the system together.
The final system is capable of cleaning up to 80 weapons per hour. Initial testing of this system identified bottlenecks at the weapon disassembly and assembly points.
New Technology Description
Aqueous Cleaner: SWR-1 concentrated aqueous cleaner less silicon anti-foaming agent. Manufactured by SWR. This cleaner is a caustic cleaner used to remove oils and grease from the surface of the weapon and to keep oils, carbon and dirt in suspension.
Ultrasonic Agitation: Telsonics Ultrasonics CPM-25-3000-R Ultrasonics generator operating at 25 kHz coupled with Telsonics Ultrasonics RS-25-55-2N 24 inch stainless steel tube transducer operating at 3000 watts.
Two of the units described above were used to obtain sufficient power to remove carbon build-up from the surface of the weapons. Tube transducers were selected over transducers that are attached to the walls of the tanks so that they can be replaced without replacing the tanks.
Ultra Filtration: Dynatec mini might ultrafiltration system. This system come with four (4) five foot polymer tubular membranes. These four membranes were replaced with a single three foot 0.1 micron stainless steel membrane. The temperature at which the cleaning system operates could damage the polymer membranes.
Ultra Filtration Membrane Cleaning: The Dynatec system was further modified with a system of valves designed by WMRC to allow for the membrane to be cleaned without removing the membrane from the ultra filtration system.
Environmental Benefits
Hazardous waste is consolidated in a single location rather than being stored in 54 different locations. This allows for better control of the waste. The volume of waste generated by the aqueous cleaning of the weapons is also reduced by the ultra filtration system.
Economic Benefits
Assuming that a 100 man unit spends 300 manhours to clean weapons after each training session and assuming that the average cost per manhour is $ 20.00, the system can provide a return of about $ 6000 per training event. The actual savings is realized in the manhours that are freed-up by using the system and available for other use rather than dollar savings.
Initial Set-up Costs: $ 80,000
Technical POC
Illinois Waste Management and Research Center
Process Developer: Mike Springman
(618) 466-3806
wmrc@piasanet.com
Field POC
Jon Casebeer
Illinois Department of Military Affairs
(217) 761-3794
DSN 555-3794
Field User
Martha Miller
Illinois Department of Military Affairs
(217) 761-3735
DSN 555-3735
Smart Washer Parts Washer
Background Information
Prior to the introduction of the Smart Washer parts cleaning system, the automotive parts that required cleaning to remove varnish, dirt, oil and grease were cleaned using a solvent. The solvent presented several problems when used. It had a low flash point that made it a fire hazard; it was an inhalation hazard for the worker; it caused dermatitis when it came in contact with the skin and it required disposal as a hazardous waste.
Project Description
An aqueous detergent system was purchased to replace the solvent system. The "Smartwasher" system is very similar to the solvent system. In both cases, a solvent (aqueous or petroleum based) is sprayed upon the parts in a sink-type arrangement with a brush available to physically clean the parts. The "Smartwasher" system incorporates a filter that is impregnated with petroleum-consuming microbes. The microbes feed on the petroleum products (lubricants, grease, etc.) and reduce them to carbon dioxide and water as byproducts.
Environmental Benefits
The aqueous detergent is much safer to use than the petroleum solvent. It has a high flashpoint, is not an inhalation hazard and does not have to be disposed of or changed. The microbial action continually cleans the detergent so that petroleum products do not build up. The filter has to be replaced periodically to replenish the microbe colony.
Environmental Deterrents
The filter must be disposed of as a hazardous waste because of heavy metal concentrations that are greater than regulatory levels.
Economic Benefits
The economic benefits of the "Smartwasher" system are realized by not having to dispose of the solvent. A cost is incurred with the filter must be disposed of" Currently, a 30-gallon drum of solvent costs approximately $115.00.
Initial Set-Up Costs
$1317.20
(Includes Smartwasher System, 12 filters and 20 gallons of Ozzy Juice)
Technical POC
Process Developer:
Manufacturer: Chemfree Corporation
Field POC:
Dan Davis, Illinois National Guard
(217) 761-3735
davisd@il-arng.ngb.army.mil
Shop Towel Recycling
Background Information
Prior to initiating this opportunity, the maintenance facilities within the Illinois National Guard used paper or disposable, single-use towels to clean hands and parts. When the towels were used, they were disposed of in the solid waste landfill. This practice increased the amount of solid waste and also introduced oil, grease solvents and heavy metals into the landfill.
New Technology Description
A local industrial laundry was located that would provide a supply of cloth shop towels on a monthly basis. The cloth towels are collected after use and returned to the laundry on a one for one basis. The towels are laundered and returned to service rather than being disposed of in the landfill.
Environmental Benefits
Laundering the cloth towels rather than landfilling the paper towels, reduces the volume of waste disposed of in the landfill and prevents the introduction of petroleum products, solvents and heavy metals into the soil and ultimately the ground and surface waters of the state. An unintentional benefit was the reduction of the overall use of towels by the mechanics. The shop towels are now a controlled item because missing towels must be replaced. The mechanics tend to use the towels longer instead of stopping their work to get a clean towel.
Economic Benefits
The cost of solid waste disposal are reduced because the volume of solid waste is reduced. A typical shop towel recycling monthly cost is approximately $6.00 per month for 100 towels.
Initial Set-Up Costs: $0.00
Field POC:
Dan Davis, Illinois National Guard
(217) 761-3735
davisd@il-arng.ngb.army.mil
Field User:
WO1 David Upmanis
(217) 761-3815
Ultra Filtration of Aqueous Parts Washer Solution
Background Information
A parts washer system is being used that incorporates a pressure spray cabinet with aqueous detergents. Prior to the introduction of the ultra filtration unit, spent aqueous cleaning solution was disposed of in the sanitary sewer. This presented two problems. First, the detergent solution was being disposed of through the oil/water separator. The detergent was designed to strip oil and grease from parts being cleaned and also stripped oil from the separator, rendering the separator useless and carrying the oil that had been collected in the separator into the sanitary sewer system. Secondly, the oil and grease that was washed from the parts contained wear metals. In many instances, the wear metals were present in concentrations that exceeded the sanitary sewer district’s maximum contaminant levels. The introduction of the ultra filtration system physically separates the oil, grease and dirt from the water and detergent. The water and detergent are returned to the parts washer for further use. The oil, grease and dirt are retained for proper disposal.
New Technology Description
The ultra filtration system is a stand-alone unit that incorporates a membrane designed to allow water and detergent molecules to pass through, while the oil, grease and dirt are retained. The spent cleaning solution is first transferred into a concentration tank. The spent cleaning solution is drawn the from this concentration tank into the UF system. As the solution passes across the membranes, a small amount of water and detergent is allowed to pass through. This permeate is collected and returned to the parts washer. The majority of the solution, including the retained oil, grease and dirt, is returned to the concentration tank. As this process is repeated, more water and detergent is separated from the oil, grease and dirt. Eventually, all of the available water and detergent is separated from the spent cleaning solution. The spent cleaning solution, now containing concentrated oil, grease and dirt is drained from the concentration tank and disposed. The concentration of detergent and water in the parts washer is adjusted and washing operations are continued. The entire operation from start to finish takes approximately 2 hours to process 20 gallons of cleaning solution. This system is small enough to be moved from one parts washer to another, eliminating the need for multiple ultra filtration systems.
Environmental Benefits
The introduction of this system has allowed the oil/water separator to perform as it was designed. The transfer of oil from the separator into the sanitary sewer system has been stopped. The introduction of metals into the sewer system has also been stopped. The consumption of water and detergent has been reduced since approximately 80 percent of the water and detergent are returned to the parts washer for further use.
Environmental Deterrents
The concentrated oil, grease and dirt still require proper disposal. This is accomplished by incorporating this waste into the used oil collection container and disposing of it along with used motor oil.
Economic Benefits
The economic benefits of the ultra filtration system are realized by detergent and water savings. Spent cleaning solution disposal costs are also avoided. The payback period for this system was approximately 0.66 years.
Initial Set-Up Costs
$ 5,560.00
(Includes Ultra Filtration System, concentration tank and required hoses and fittings)
Technical POC
Manufacturer: Dynatech Corporation
Process Developer:
Field POC
Mike Springman, Waste Management & Research Center
(618) 466-3806
wmrc@piasanet.com
Field User
Organizational Maintenance Shop # 1
Illinois Army National Guard
Camp Lincoln
Springfield, IL 62702
Mercury Fever Thermometer Exchange
Pollution Prevention, Community and Regulatory Partnership
ANG Peoria Air National Guard Base, IL
Mercury Fever Thermometer Exchange
The 182d Airlift Wing of the Illinois Air National Guard partnered with Illinois Environmental Protection Agency (IL EPA) as well as Peoria and Tazwell County in sponsoring a Mercury Fever Thermometer Exchange in Peoria, Illinois. The 182 Airlift Wing environmental office worked with the Tri-County Green Matters partnership to provide a central location for the exchange in the community. We advertised through the local newspapers and distributed flyers throughout the community with the help of health officials.
We collected 266 mercury fever thermometers from the general public as well as guard members. For a community exchange, the response exceeded the expectations of the IL EPA based on previous fever thermometer exchanges hosted by them. The oldest mercury fever thermometer collected was dated 1944. The mercury fever thermometers were replaced with mercury free fever thermometers made with galinstan. Galinstan is a metal alloy that provides comparable accuracy to mercury in fever thermometers.
Information was given to the public regarding the hazards of mercury contamination with the replacement. The typical mercury fever thermometer contains about 0.7 grams of mercury, which is enough mercury to contaminate all the fish in a lake with a surface area of 20 acres. Mercury fever thermometers contribute 17 tons of mercury discarded annually in municipal solid waste. Due the success of Peoria’s first Mercury Fever Thermometer Exchange we are looking to co-host another exchange in the near future. For further information, contact Major Roxanne Lastoria (309) 633-5277.
