Metal Finishing Guide Book

2012-2013

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Annual Costs ($.083/kWh) Original ElectroPrecipitation New RO/DI Net Savings Electric, pumps, etc. $7,160 $3,114 $4,046 Electric, compressed air $8,881 $0 $8,881 Sludge Disposal/Column Regeneration $7,900 $12,000 (-$4,100) Scrubber Maintenance $22,400 $9,600 $12,800 Totals $46,341 $24,714 $21,627 Table 2. Summary of operating costs, old system, new RO/DI system. new expense is offset by the reduced electrical use both in pump motors and in compressed air use (savings of $12,927/year) along with the elimination of sludge disposal ($7,882/year). Scrubber maintenance costs are expected to go down by 50���75% (from every 6 months to up to two years between maintenance cycles) due to a reduction in biofouling by reducing organics in the scrubber water. The combination of environmental improvements, including elimination of hazardous sludge waste and reduction in electricity consumption, resulted in a total annual operating cost savings of $21,627 for Company XYZ. The simple payback after the NYSERDA rebate is expected to be two-and-half years. The overall process control of each rinse tank is much easier with a simple DI tank exchange after the tank reaches saturation. Overall rinse water cleanliness is noticeably better, with even the chrome rinse tanks being clear rather than yellow from the chromic acid dragout. ACKNOWLEDGMENTS Funding for this research project was provided by the New York State Pollution Prevention Institute (NYSP2I) through a grant from the New York State Department of Environmental Conservation (NYDEC) and the New York State Energy Research and Development Authority (NYSERDA). Disclaimer: Any opinions, findings, conclusions or recommendations expressed are those of the author(s) and do not necessarily reflect the views of the Department of Environmental Conservation. NYSERDA has not reviewed the information contained herein, and the opinions expressed in this report do not necessarily reflect those of NYSERDA or the State of New York. BIO David Fister is a senior staff engineer at the New York State Pollution Prevention Institute at Rochester Institute of Technology (RIT). Fister gained 17 years��� manufacturing experience in light industry before he joined RIT. He worked for four years in Manufacturing 721

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