SN23.1 Hall - Pollution Prevention Success Stories at ......yUsed to remove all abradable thermal spray coatings ¾Rubberized coatings, stripping abradable thermal spray coatings,

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POLLUTION PREVENTION SUCCESS STORIESAT TINKER AIR FORCE BASE

Tinker Air Force Base, Oklahoma

Freddie E. Hall, Jr., PhDChemical Engineer

OKLAHOMA CITY AIR LOGISTICS CENTERENVIRONMENTAL MANAGEMENT DIRECTORATE

POLLUTION PREVENTION BRANCH

POLLUTION PREVENTION SUCCESS STORIESPOLLUTION PREVENTION SUCCESS STORIESAT TINKER AIR FORCE BASEAT TINKER AIR FORCE BASE

Tinker Air Force Base, OklahomaTinker Air Force Base, Oklahoma

Freddie E. Hall, Jr., PhDFreddie E. Hall, Jr., PhDChemical EngineerChemical Engineer

OKLAHOMA CITY AIR LOGISTICS CENTEROKLAHOMA CITY AIR LOGISTICS CENTERENVIRONMENTAL MANAGEMENT DIRECTORATEENVIRONMENTAL MANAGEMENT DIRECTORATE

POLLUTION PREVENTION BRANCHPOLLUTION PREVENTION BRANCH

IAIA04-Paper #154

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Tinker AFB covers 5,031 acresOnly 200 acres are undeveloped

765 Facilities15.3M feet2 of industrial operations

Three Creek Systems700-plus Air Emission Sources200 Underground Storage Tanks11-Miles Industrial Wastewater LinesThree Wastewater Treatment Plants 36 Restoration SitesProvides Logistics Support to USAF Weapon Systems

B-1, B-52, E-3 Sentry, C/KC-135 aircraft

TINKER AFB, OKLAHOMAIntroduction

TINKER AFB, OKLAHOMAIntroduction

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“To reduce pollution at the Source through a Hierarchy of Actions including source reduction, chemical substitution, recycle, reuse, treatment, and disposal”

“To incorporate the Compliance Through Pollution Prevention [CTP2] process into all environmental compliance sites by generating a 5-year Management Action Plan [MAP] to address the top five percent sites annually via Process Specific Opportunity Assessments [PSOAs] to reduce ESOH cost and risk”

POLLUTION PREVENTIONMission Statement

POLLUTION PREVENTIONPOLLUTION PREVENTIONMission StatementMission Statement

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Pollution Prevention Opportunities Purchased 2.1 million pounds of targeted EPA toxic chemicalsPurchased 328,000 pounds of ozone depleting substances [ODSs]Disposed of 12 million pounds of hazardous waste Disposed of 35 million pounds of municipal solid waste Hazardous material pharmacy tracked 5000+ hazardous materials

Pollution Prevention AccomplishmentsReduced chemical purchases by 71% [1.5 million pounds] Reduced ODS purchases by 99.7% [328,000 pounds] Reduced hazardous waste discharges by 67% [8 million pounds] Reduced municipal solid waste by 59% [20 million pounds] Reduced number of chemicals tracked hazmaterial pharmacy

Reduced number from 5000 to 800

POLLUTION PREVENTIONProgram Overview

POLLUTION PREVENTIONPOLLUTION PREVENTIONProgram OverviewProgram Overview

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Environmental BenefitsUse hierarchy of actions including source reduction, chemical substitution, recycle, reuse, treatment, and disposalEliminate / reduce EPA-listed chemicals Minimize waste generationMinimize water usage

Robotic TechnologiesIncrease Worker Safety

Isolate hazardous environment Shorten Process Flow Days

From days / weeks to minutesCost Savings

Eliminated need for abatement control technologies

POLLUTION PREVENTIONOverview of Benefits

POLLUTION PREVENTIONPOLLUTION PREVENTIONOverview of BenefitsOverview of Benefits

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153 CNG Vehicles50,000 gallons with two fill stations Reduced gasoline consumption by approximately 141,000 gallons per year Reduces tailpipe emissions by 80% Fuel economy [cost per mile] equivalent to diesel

12 Electric NEV’s10 Segway units B20 Fuel for diesel

700 vehicles converted to biodiesel Use roughly 180,000 gallon per yearReduces tailpipe emissions by 20%

POLLUTION PREVENTIONAlternative Fuel Efforts

POLLUTION PREVENTIONPOLLUTION PREVENTIONAlternative Fuel EffortsAlternative Fuel Efforts

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Aircraft Radome Chemical DepaintingMEK EPA-listed chemical solvent

TAFB Searched for Alternative Process High-pressure water blastDry media blast [wheat starch, BOSS]Laser coating stripperXenon flashlamp / CO2 pellet blastRadome protective barrier coatingChemical alternatives to MEK

Chemical Alternative TestedCompatible with the radome materials Capable of removing the protective coatings Solvent is a blend of dibasic esters [DBE]

Low vapor pressure and low toxicity

POLLUTION PREVENTIONSuccess Stories

POLLUTION PREVENTIONPOLLUTION PREVENTIONSuccess StoriesSuccess Stories

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Benefits of Aircraft Radome Depainting with Dibasic Esters [DBE]

Ease of use Goes further [less expensive to use]Compatibility with radome materialsNot an EPA-listed material Environmentally compliant Lowers health risks to workforce $0 implementation cost Allows for increased workloadReduces operating costs by $30K Reduces HAP emissions by 78,000 lbs Eliminates abatement requirements [$2M]

POLLUTION PREVENTIONSuccess Stories [CONTD]

POLLUTION PREVENTIONPOLLUTION PREVENTIONSuccess Stories [CONTD]Success Stories [CONTD]

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Alternative EA Chemical Depainting Agents Prototyped EA two-part chemical strippers

Eliminated 800,000 lbs per year Four-fold reduction in health risksSaved $245K annually

Prototyping EA one-part chemical strippersProjecting to save $300K yearly

Eliminated abatement requirement [$6M]



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Alternative Chemical Depaint TechnologyHarsh EPA-listed chemical strippers

Aircraft Component Subsystem [ACS]Robotically controlled36,000 psiSaves $1.3 million Eliminates 140,000 lbs of HAPs

100,000 lbs waste [masking requirements]8.3 million gallons of wastewater 76,000 lbs IWTP hazardous waste sludge330 gallons of ODCs

Removes personnel from hazardous work environment Reduces worker turnover rate Eliminated abatement requirement [$20M]



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Alternative Electroplating TechnologyCadmium EPA-listed chemical Cadmium plating most toxic operation

Ion Vapor Deposition [IVD] Erosion resistance and higher-temperature requirementTemperatures up to 950°F, whereas cadmium is limited to 450°FApplied to high-strength steel without the fear of hydrogen embrittlement 45 minutes compared to over 48 hours Removes personnel from hazardous work environment Eliminates 400 lbs of cadmium Eliminates cyanide products Wastewater is eliminated



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Alternative Electroplating TechnologyChrome EPA-listed chemical Chrome plating accounts for 60% workload

High-Velocity Oxygen-Fuel Flame SprayRobotically controlled technology High-energy thermal spraying processWear / erosion coatings and thermal barriersProduces very dense, hard coatings45 minutes compared to over 48 hours Removes personnel from hazardous work environment HVOF is very flexible

Capable of applying over 23 different coatings Wastewater is eliminated because there are no rinse waters



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Alternative Cleaning TechnologyWater Jet Knife Used to remove all abradable thermal spray coatings

Rubberized coatings, stripping abradable thermal spray coatings, fiberglass, paint, sealants, and adhesives

Robotically controlled technology Operates at 20,000 psi with a flow rate of 20 gpmEliminated the use of 2,360 gallons per year of methylene chloride 20 minutes compared to days / weeks Removes personnel from hazardous work environment



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Alternative Cleaning TechnologyCO2 abrasive blastingRemoves carbon, corrosion, and paintReplacing solvents, acids, and caustics to chemically remove the materialReplaced traditional grit blasting CO2 blasting eliminates the need for masking, since the solid CO2 sublimes to a gas upon impactEliminated the use of 1,700 gallons per year of hazardous chemicals 30 minutes compared to days Minimizes / eliminates hazardous waste generated by toxic chemicals



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Conventional Vapor Degreaser

Hot Oil - Aqueous Cleaning Pilot Test Prototype



Alternative Cleaning TechnologyHot oil aqueous cleaning process Replaces perchloroethylene degreasers

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• Condensate reboiler- rinses w/temp controls

• Microfiltration- alkaline cleaners

• Centralized electrodialysis- Electroless Nickel line

• Fog rinsing - hoist delays

• Conductivity meters

• Hoist enhancements

• Training

SELECTED PSOAs T-230

T-228

T-226

T-224

T-222

T-220

T-218

T-216

T-214

T-212

T-210

T-208

T-206

T-204

T-202

T-200

T-240

T-242

T-244

T-246

T-248

T-250

T-252

T-254

T-256

T-258

T-260

T-262

T-264

T-266

T-268

T-270

T-338

T-336

T-334

T-332

T-330

T-328

T-326

T-324

T-322

T-320

T-318

T-316

T-314

T-302

T-300

T-368

T-366

T-364

T-362

T-360

T-358

T-356

T-354

T-352

T-350

T-348

T-346

T-344

T-342

T-340

T-428

T-426

T-424

T-422

T-420

T-418

T-416

T-414

T-412

T-410

T-408

T-406

T-404

T-402

T-400

T-468

T-466

T-464

T-462

T-460

T-458

T-456

T-454

T-452

T-450

T-448

T-446

T-444

T-442

T-440

T-536

T-534

T-532

T-530

T-528

T-526

T-524

T-522

T-520

T-518

T-516

T-514

T-312

T-310

T-308

T-306

T-304 T-502

T-500

T-512

T-510

T-508

T-506

T-504

T-568

T-566

T-564

T-562

T-560

T-558

T-556

T-554

T-552

T-550

T-548

T-546

T-544

T-542

T-540

T-570

T-572

T-574

T-576 T-001

T-002

T-003

T-004

T-005

T-006

T-007

T-015

T-014

T-013

T-012

T-011

T-010

T-009

T-008

T-614

T-602

T-600

T-612

T-610

T-608

T-606

T-604

T-616

T-630

T-628

T-618

T-620

T-622

T-624

T-626

T-634

T-632

T-967B T-965B T-963B T-961B T-959B

T-969B T-971B T-973B T-975B T-977B

T-981B T-983B T-985B T-987B T-989B

T-979B T-980B

T-722

T-720

T-718

T-716

T-714

T-702

T-700

T-712

T-710

T-708

T-706

T-704

T-736

T-734

T-732

T-730

T-728

T-726

T-724

T-738

T-740

T-742

T-744

T-746

Cyanide Bearing

Recycled

Wastewater Treatment

Chrome bearingDefines a process

Microfiltration

DiffusionDialysis

MembraneElectrolysisFog Rinse

Ion Exchange

THIS AREA TO BE RENOVATED

T-326 ElectrodialysisTanks not used and

could be converted torinsing

Mist Eliminator

CountercurrentRinse

T-274

T-272

T-382

T-384

T-380

T-480

T-580

T-OLD

TITLEPROCESS FLOW SCHEMATICOPPORTUNITIES

DATE

4/18/01FILENAME

PROCES~1.VSD

PAGE

2 OF 5

DESCRIPTION

TINKER AFB PLATING SHOPSCALE

None

DRAWN BY

PETER GALLERANI

Computer model of plating processes, chemistries, water usage, energy utilization, chemicals consumption, etc.

PLATO’s PROCESS PLANNER



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Predictive Source Emission Model developed by EPARecommended for estimating emission rate from IWTP process unitsOnly GFM developed for industrial wastewater collection / treatment processes Requires minimal amount of process unit information and wastewater influent properties

Constituent concentrations, flow rates, physical dimensions of process unit, operating conditions, detention times, biological activity, etc.

Atmospheric Dispersion Model developed by EPAGenerates annual-average & 24-hour maximum concentrationsISC dictated by state protocol for air dispersion modelingEmission source data

Need emission rate [factor] for individual process units Meteorology data

Wind speed, direction, surface conditions, mixing height, etc.Receptor data

Determine impact region, develop grid system, grid spacing, etc.



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PC

D1

D2

OWDOW-N

OW-S

ST-W ST-E

EQ-N

EQ-S MIXSCCN

SCCSBIO

SC-S

SC-N

FENCELINE

2000 2050 2100 2150 2200 2250 2300X-Coordinate, West to East

1700

1750

1800

1850

1900

1950

2000

2050

2100

Y-C

oord

inat

e, S

outh

to N

orth



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Sludge Dewatering Operation at IWTPAccounted for 39% of AFMC hazardous waste stream

Reduced hazardous waste sludge disposal by 6,764,420 pounds annually, [88 percent]Reduced hazardous waste sludge disposal costs by $1,247,630 annually, [88 percent]



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Air-Sparged Hydrocyclone [ASH] Technology Demonstrated on-site Relatively cheap technology

Projected payback < 2 yearsPretreat chemical stripper waste streamRemoves 95+% of metalsRemoves 25-90% of organics AFFF removal of 86%

POLLUTION PREVENTIONProposed Technologies

POLLUTION PREVENTIONPOLLUTION PREVENTIONProposed TechnologiesProposed Technologies

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Geothermal Heat Pump Applications Identify opportunities for implementing geothermal heat pump technology by:

Recovering thermal energy from wastewater used in ground water treatment plant (GWTP)and/or industrial wastewater treatment plant (IWTP) before it is reused or discharged.

Determine potential cost savings and payback using energy efficient technology

Energy recovery of 50-70 percent Projected savings $400K-$500K annually

Incorporating radiant heat technology Funded a more detailed investigation this summer



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Plasma Technology for Pollution ControlLow-temperature air toxics treatment Destroying toxic chemical agents Nitrous and sulfurous oxides [NOx & SOx]Destroying VOC in paint / depaint processesMilitary applications [destroying nerve gas]

Bench-Scale Reactor: Single Reactor Design

Evaluate chemical system parameters: residence time, humidity, temperature, pressure, etc.Evaluate electrical system parameters: electric field, power, electrode configuration, etc.



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Other Expected DOD BenefitsImprove local air quality Develop durable paint systems

Extend operational life of coating system, less field maintenance, etc.

Shorten depot maintenance flow days Reduce operating costs Better corrosion protection for weapon systems

Extend the operational life of weapon system

Eliminate need to install expensive pollution abatement technology Enable the installation to increase workload

POLLUTION PREVENTIONSummary & Conclusions

POLLUTION PREVENTIONPOLLUTION PREVENTIONSummary & ConclusionsSummary & Conclusions

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POLLUTION PREVENTION SUCCESS STORIESAT TINKER AIR FORCE BASE

Tinker Air Force Base, Oklahoma

Freddie E. Hall, Jr.OC-ALC/EMPD

7701 Arnold Street, Suite 204Tinker AFB OK 73145-9100

COM: 405-734-3114DSN: 884-3114

EMAIL: [email protected]

POLLUTION PREVENTION SUCCESS STORIESPOLLUTION PREVENTION SUCCESS STORIESAT TINKER AIR FORCE BASEAT TINKER AIR FORCE BASE

Tinker Air Force Base, OklahomaTinker Air Force Base, Oklahoma

Freddie E. Hall, Jr.Freddie E. Hall, Jr.OCOC--ALC/EMPDALC/EMPD

7701 Arnold Street, Suite 2047701 Arnold Street, Suite 204Tinker AFB OK 73145Tinker AFB OK 73145--91009100

COM: 405COM: 405--734734--31143114DSN: 884DSN: 884--31143114

EMAIL: EMAIL: [email protected]@tinker.af.mil

Documents

SN23.1 Hall - Pollution Prevention Success Stories at ......yUsed to remove all abradable thermal spray coatings ¾Rubberized coatings, stripping abradable thermal spray coatings,