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COOLANT
MANAGEMENT SERVICE

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Fac-Tech Engineering Associates feels proud to say that it manages two Centralized Coolant Systems of Endurance Alloy Wheels plant, Chakan, Pune for the last 5 years. Fac-Tech is one of the prominent solutions for all types of Central Coolant Systems. 

 

What is a Centralised Coolant system?  

Coolant Management offers recycling programs to meet the needs of two major types of clients. The first service we offer is extremely flexible and caters to companies whose service needs are continually changing due to their contracts. The second service we provide is designed for smaller metalworking shops with our on-site, mobile recycling service. Both of our services provide an affordable alternative to purchasing expensive recycling equipment, hiring and/or training personnel, and expensive disposal costs.

Procedure.

Coolant Management Services brings the coolant recycling service to its customers through the mobile recycling system. We offer the following advantages:

  • Recycling coolant service on a regular schedule

  • The proper mixture of coolant with de-ionized water

  • Removal of tramp oil, contaminants, and bacteria

  • Removal of chips, sludge, and particulates on a scheduled basis Scheduled analysis of coolant.

 

Approach

An effective coolant recycling program offers several advantages over the traditional "use and disposes of" type of operation. We recycle and replace the coolant every month.

Savings

If properly maintained, coolant may be used indefinitely. With strict government regulations and expensive disposal costs, the advantage of maintenance over disposal and replacement will be seen from the first service. These savings include:

  • Reduction in purchases of coolant concentrate

  • Drastically reduced or eliminate the need for costly disposal of waste coolant

  • Improved tool and wheel life

  • Increased quality of finished products and fewer rejected parts

  • Reduced machine down time

  • No internal labour cost for coolant mixing or machine cleaning

  • No Permitting required. So there is no related cost

 

  1. Oil Filtration:

Filtering new oil and used oil keeping it clean of particulates and moisture will prolong the life of the oil and keep the equipment protected from wear. Studies have shown that as much as 70 percent of all premature machine failures can be attributed to contamination. The key is to purify the oil new as it comes into the facility and keep it clean throughout its operating life. By establishing an ISO code cleanliness goal and maintaining it you will extend the life of the oil and the equipment. Large and small particles are destructive and the enemy. By removing the particles we can keep the equipment protected from abnormal wear. If you are looking to improve your current lubrication reliability efforts one tool that is a must to have is a portable or dedicated filtration system designed to screen the oil removing large particulates and clean the oil from small particulates.

 

   2. Coolant Disposal :

Even with the best machine coolant management program, machine coolant will not last indefinitely and will eventually require disposal. Environmental regulations are making disposal increasingly difficult.  Generators are responsible for determining if a particular waste generated at their facility is hazardous or nonhazardous.  The waste material must be tested using standard methods or the generator must have sufficient knowledge about the waste to assess whether it is a hazardous waste.  View some of our articles in the Machine Coolant Filtration Index for more information on Machine Coolant Management and for more information on helping you cut costs on Disposal and recycling of Machine Coolant. 

 

Know whether your wastes and wastewaters are a dangerous waste.  Dissolved metals, chlorinated oils, and biocides are among the ingredients that can require machine coolant to be disposed as a dangerous waste.  Avoid chlorinated oils when possible.  Never mix other wastes such as solvents into machine coolants.  Even a small amount of a federally listed solvent can cause a whole container or tank of machine coolant to be a dangerous waste.  Call your local Ecology office for advice. 

 

   3.Machine Coolant and Cleaner Disposal

Industrial wastes such as machine coolants and sump cleaners should never be disposed to a septic or storm system, or drywell. 

Oil-water emulsion machine coolants can often be chemically "split" to separate the oil from the water.  It may be more economical for you to discharge the water to the sewer and recycle the oil portion. 

Check with your local sewer utility before you discharge metalworking liquids to the sewer. 

Processing of a dangerous waste machine coolant for disposal must be done in accordance with regulations for treatment by dangerous waste generators (see Ecology publication #96412, Treatment by Generators). 

Following a hazardous / non-hazardous determination for the waste, an appropriate disposal alternative may be selected. Disposal costs may range anywhere from 25 to 50 cents per gallon for non hazardous waste up to several hundred dollars per drum for hazardous waste. Spent machine coolant that is determined to be hazardous must be disposed by an EPA permitted hazardous waste management company in accordance with applicable federal and state regulations. Selecting a certified hauler and treatment facility registered with the EPA is critical. 

 

   4. Disposal Of Nonhazardous Fluid

If the waste fluid is determined to be nonhazardous, it may be hauled to a treatment facility or, following permission from local wastewater treatment plant authorities, discharged to a municipal sanitary sewer system for disposal. Spent fluid should never be discharged to a septic tank system or dumped on the ground. 

Nonhazardous fluid may also be pretreated on site prior to disposal. Treating or condensing water miscible fluids on site prior to disposal may reduce a shop's disposal costs and environmental liability. Techniques for on-site treatment include chemical treatment, ultra-filtration, and evaporation. Each process involves the removal of metal fines and other solid contaminants, concentrating the oil phase, and discharging the water phase to either the sanitary sewer or the atmosphere. The concentrated oil phase can be managed as a used oil and the solids may be disposed or reclaimed. 

 

Disposal And Pretreatment Alternatives available for non-hazardous water-miscible machine coolant. 

 

Contract Hauling and Disposal Services

Studies have shown that it may be cheaper to have small volumes of waste fluid (less than 200 gallons) hauled away by a waste management company for chemical treatment or incineration.

 

Many large machine shops opt for in-plant waste treatment, since contract hauling and disposal services become cost prohibitive with larger quantities of waste fluid. 

 

Chemical treatment

Chemical treatment is the addition of chemicals, which change the nature of the liquid waste. Simple chemical-treatment methods work well on some wastewater. Metalworking wastes are too complex for most treatment processes. Chemical treatment beyond pH control is generally not an option for small facilities. 

 

Ultra filtration systems

Ultra filtration systems were created for the Metalworking industry to treat such wastes as used machine coolants, detergents, parts washing solutions, and other oily wastewaters. Strict environmental laws require proper treatment prior to discharge. Ultra filtration systems provide effective treatment of this wastewater by separating the water from the oily waste. The quality of water is then ready for sewer disposal. The oily concentrate generated from ultra filtration may be processed for oil recovery or incinerated. 

 

Ultra filtration systems are usually better than chemical treatment, less expensive than incineration and contract hauling, are easily operated and space efficient. Units process from 100 to 300 gallons per day and cost from        Rs 40,000 to Rs.100000. 

 

Evaporators

As water miscible fluids are normally 90 to 95% water, evaporators can be used to remove the water from waste fluid, reducing the volume of waste requiring disposal. The advantages of evaporators include:

1.  Simple to operate.

2.  Use very little space.

3.  Type of fluid used (synthetic, semi synthetic, or soluble oil) is not critical. 

Evaporators are generally suitable for low volumes of waste due to the enormous amount of energy required to evaporate even a small volume of material. Evaporators are also labor intensive when it comes to cleaning the units. Evaporators may be a consideration when other treatment systems do not meet a shop's needs. 

Centrifuges can be used to remove particulates and tramp oil from waste fluid prior to disposal. However, centrifuges are expensive and other contaminant removal methods such as oil skimmers are more economical for small volumes of fluids. 

 

Disposal as wastewater

Following approval by local wastewater treatment authorities, it may be possible to dispose of small amounts of non-hazardous, spent machine coolant to the municipal sanitary sewer system. 

 

A Waste Management Program

We are not attorneys.  We believe this to be a good compliance plan but we do not take any responsibility for its use, misuse or anything else.  The laws change frequently.  Consult an attorney or other expert. 

Program Components

1.    A review of all MSDS sheets for compliance.

2.    A computer check of nine lists and 1,962 chemicals cited in 40 CFR

3.    A document showing matches or no matches.   

4.    An analysis of your used machine coolant done by a government certified laboratory.  

5.    An analysis that can serve as “An analysis of a typical batch” and may make testing of each batch unnecessary.

6.    A determination of the classification of the chrome component of your waste as required by law. 

7.    A review of classification options for your waste.

8.    A recommendation as to the best disposal option for your machine coolant. 

9.    References to the sections of federal law supporting these recommendations.

10.  A list of federal EPA offices and state offices for environmental matters.  

11.  A list of haulers and disposal companies. 

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