[PPT] - Cleaner Production Research at the Cl P d ti R h t th PowerPoint Presentation

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Cl P d ti R h t th Cleaner Production Research at the University of New Orleans, USA y

Presented by:

Bhaskar Kura, Ph. D., P. E.

Director, Maritime Environmental Resources & Information Center Professor of Civil & Environmental Engineering UNIVERSITY OF NEW ORLEANS UNIVERSITY OF NEW ORLEANS NEW ORLEANS, LA, USA Sao Paulo, May 20, 2009

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Discussion Topics Discussion Topics Discussion Topics Discussion Topics

Cleaner production research goals

Case study of maritime industry and development of resources at

Case study of maritime industry and development of resources at UNO UNO UNO UNO S d i i d i i f i d l S d i i d i i f i d l

Student training and training of industry personnel

S

l bilit f h t d lt t th t S l bilit f h t d lt t th t

Scalability of research concepts, resources, and results to other sectors

Management / software tools to effectively transfer the benefits of

Management / software tools to effectively transfer the benefits of CP research CP research

Conclusions

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Clean Technology and Cleaner Clean Technology and Cleaner Production Research Goals Production Research Goals

Be able to rank of materials based on environmental

Be able to rank of materials based on environmental performance (complements US EPA’s “environmentally performance (complements US EPA’s “environmentally preferable purchase to reduce environmental impact”) preferable purchase to reduce environmental impact”) p p p ) p p p )

Understand best process conditions (e.g., feed, mix, pressure;

Understand best process conditions (e.g., feed, mix, pressure; temp nd more) temp nd more) temp, and more) temp, and more)

Develop processes and techniques that aid in energy and

Develop processes and techniques that aid in energy and eve op p ocesses d ec q es d e e gy d eve op p ocesses d ec q es d e e gy d resource conservation resource conservation I d i i ( ffi i ) hi h di l d h I d i i ( ffi i ) hi h di l d h

Improve productivity (efficiency) which directly reduces the

Improve productivity (efficiency) which directly reduces the pollution burden pollution burden

Reduce life cycle impacts and life cycle costs

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Resources Development at UNO: Resources Development at UNO: Clean Technologies Initiati e Clean Technologies Initiati e Clean Technologies Initiative Clean Technologies Initiative

Established collaborations with industries and

Established collaborations with industries and regulatory agencies to understand most critical regulatory agencies to understand most critical processes within the maritime industry processes within the maritime industry processes within the maritime industry processes within the maritime industry

Developed infrastructure to:

Simulate industrial processes within controlled

Simulate industrial processes within controlled environment environment

Monitor productivity and product quality

Monitor environmental performance

Develop mathematical models

Develop mathematical models p

Computer applications to achieve “technology

Computer applications to achieve “technology transfer” transfer”

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C ll b i C ll b i Collaborations Collaborations

U it d St t

E i t l A U it d St t E i t l A

United States Environmental Agency

United States Environmental Agency

Region VI of US EPA

Region VI of US EPA

State environmental regulatory agencies of

State environmental regulatory agencies of Louisiana, Texas, and the Gulf Coast States Louisiana, Texas, and the Gulf Coast States , , , ,

National Shipbuilding Research Program

National Shipbuilding Research Program Offi f N l R h Offi f N l R h

Office of Naval Research

Office of Naval Research

Naval Surface Warfare Center Carderock

Naval Surface Warfare Center Carderock Division Division

Private and Navy Shipbuilding and Ship Repair

Private and Navy Shipbuilding and Ship Repair v d N vy S pb d g d S p p v d N vy S pb d g d S p p Yards Yards

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Industrial Processes Being Investigated Industrial Processes Being Investigated

P b i i i d P b i i i d

Processes being investigated:

Dry Abrasive Blasting

Metal Welding

Metal Cutting

Painting

Air Pollutants:

Air Pollutants: Particulates; Metals; Organics Particulates; Metals; Organics

Health Effects:

Health Effects: Wide ranging effects including Wide ranging effects including Health Effects: Health Effects: Wide ranging effects including Wide ranging effects including cancer (e.g., chromium, nickel etc.) cancer (e.g., chromium, nickel etc.)

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Resources at UNO: ETF with Process and Resources at UNO: ETF with Process and Emissions Monitoring Equipment Emissions Monitoring Equipment Emissions Monitoring Equipment Emissions Monitoring Equipment

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A Case Study A Case Study A Case Study A Case Study Dry Abrasive Blasting: A Surface Dry Abrasive Blasting: A Surface g Preparation Process Preparation Process

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Surface Preparation:

removal of oil, dust, rust, mill scale, paint

prepare surfaces for adhesion / coating

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Dry Abrasive Blasting Dry Abrasive Blasting y g y g Background Information Background Information

Dry Abrasive Blasting:

Dry Abrasive Blasting: y b as ve B ast g: y b as ve B ast g:

Most Effective Surface Preparation Method

Abrasive particles are propelled at high velocities on to the surfaces to be

Abrasive particles are propelled at high velocities on to the surfaces to be cleaned with the aid of compressed air cleaned with the aid of compressed air

Old paint, rust and other surface contaminants are removed and a rough

Old paint, rust and other surface contaminants are removed and a rough profile is developed for good paint adhesion profile is developed for good paint adhesion profile is developed for good paint adhesion profile is developed for good paint adhesion

Generates atmospheric particulate emissions and solid wastes (used

Generates atmospheric particulate emissions and solid wastes (used-

abrasives)

abrasives) Industry Sectors

Industry Sectors

Shipbuilding and Repair

Automobile and Aircraft Manufacturing

Oil Exploration and Refining

St

T k d St l B id St T k d St l B id

Storage Tanks and Steel Bridges

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1. Long Venturi Nozzle 2. Abrasive Sieving 3. Air Filter & Pressure Gauge 4. Exhaust Valve 5. Abrasive Tank 6 Automatic Filling Valve 6. Automatic Filling Valve 7. Abrasive Control Valve 8. Blaster's PPE 9. Antistatic Blast Hose

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Environmental Impact of Dry Abrasive Blasting Abrasive Blasting

Wastes from Dry Abrasive Blasting

Solid / Hazardous (TCLP) Atmospheric Emissions / ( )

Spent Abrasive
Surface Contaminants

p

Particulate Matter (PM)
Metals

Surface Run off and Mixing

Other Impurities

(Studied)

Gaseous Pollutants

(Studied) and Mixing

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Parameters Influencing Performance Parameters Influencing Performance

(Productivity, Consumption and Emissions)

Initial surface

Initial surface conditions conditions

Standoff distance

Fan capacity (indoor

Fan capacity (indoor conditions conditions

Abrasive type

Abrasive grade

Fan capacity (indoor

Fan capacity (indoor blasting) blasting)

Wind speed (open

Wind speed (open air air

Abrasive grade

Blast pressure

Blast pressure Ab i f d Ab i f d

Wind speed (open

Wind speed (open-air air blasting) blasting)

Worker training

Abrasive feed rate

Final surface finish

Worker training

Worker awareness on

Worker awareness on environmental issues environmental issues

Angle of abrasive jet

Blast nozzle size

Blast nozzle size environmental issues environmental issues

Worker weariness

Worker weariness V il i di i V il i di i

Ventilation conditions

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Research Methodology Research Methodology

Productivity:

Productivity: area cleaned per unit time ( area cleaned per unit time (sq.ft/hr sq.ft/hr)

Speed of Cleaning, Process Efficiency & Life Cycle Costs

Consumption:

Consumption: abrasive consumed per unit area cleaned abrasive consumed per unit area cleaned (lbs/sq.ft lbs/sq.ft)

Material Usage, Waste Generation, Landfill Area & Life Cycle

Material Usage, Waste Generation, Landfill Area & Life Cycle Costs Costs

TPM Emission Factors:

Mass of pollutant / unit area cleaned (

Mass of pollutant / unit area cleaned (g/sq.ft g/sq.ft)

Mass of pollutant / unit mass of abrasive used (

Mass of pollutant / unit mass of abrasive used (g/lb g/lb)

Environmental, Health Impacts & Costs (Disposal, Emissions,

Environmental, Health Impacts & Costs (Disposal, Emissions, Compliance) Compliance) Compliance) Compliance)

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Parameters Studied Parameters Studied Parameters Studied Parameters Studied

Abrasives:

Abrasives: Barshot Coal Slag Copper Slag Garnet Barshot Coal Slag Copper Slag Garnet

Abrasives:

Abrasives: Barshot, Coal Slag, Copper Slag, Garnet, Barshot, Coal Slag, Copper Slag, Garnet, Specialty Sand, and Steel Grit Specialty Sand, and Steel Grit

Blast Pressure:

Blast Pressure: 80, 100, and 120 PSI 80, 100, and 120 PSI

Feed Rate:

Feed Rate: 3, 4, and 5 Turns of Schmidt Feed Valve 3, 4, and 5 Turns of Schmidt Feed Valve

Initial Surface Contamination:

Initial Surface Contamination: Rusted and Painted Rusted and Painted Surfaces Surfaces

Final Surface Finish:

Final Surface Finish: Near White Near White

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Multivariate Analysis: Productivity, Consumption and Emission Factors Consumption, and Emission Factors

Total Number of Runs: 3 Pressures X 3 Feed Rates X 3 Repetitions = 27 per abrasive

meters ut Param Outpu 120 5 100 4 5 80 3

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Results Results Results Results

P d i i P d i i

Productivity:

Increases with blast pressure

Increases and decreases with abrasive feed rate (bell shape)

Consumption:

Increases with blast pressure

Decreases and increases with abrasive feed rate (inverse

Decreases and increases with abrasive feed rate (inverse-

bell shape)

bell shape)

Total PM Emissions

Increases with blast pressure

Decreases and increases with abrasive feed rate (inverse

Decreases and increases with abrasive feed rate (inverse-bell shape) bell shape)

Decreases and increases with abrasive feed rate (inverse

Decreases and increases with abrasive feed rate (inverse bell shape) bell shape)

Standard Relationships:

Y = f (P, F) Y = f (P, F)

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Results Results Results Results

Coal Slag: Productivity Variation with Pressure and Feed Rate

190

Coal Slag: Consumption Variation with Pressure and Feed Rate

10 11 100 PSI y = -37.113x2 + 305.69x - 478.93 R2 = 0 94 120 PSI y = -35.118x2 + 295x - 445.59 R2 = 0.96 150 170

s q .ft/h r)

80 PSI 120 PSI y = 2.482x2 - 19.667x + 44.783 R2 = 0.97 8 9 10

(lb s /s q .ft)

80 PSI 80 PSI y = -37.308x2 + 308.71x - 501.42 R = 0.94 110 130

P ro d u c tiv ity (

100 PSI 120 PSI 100 PSI y = 2.019x2 - 15.167x + 35.228 R2 = 0.98 80 PSI y = 1 4765x2 10 91x + 25 787 6 7

C o n s u m p tio n

100 PSI 120 PSI y R2 = 0.94 70 90 2 3 4 5 6 y = 1.4765x2 - 10.91x + 25.787 R2 = 0.6883 4 5 2 3 4 5 6

Feed Rate (number of turns) Feed Rate (number of turns)

Variation of Productivity Variation of Productivity with Pressure and Feed Rate with Pressure and Feed Rate Variation of Consumption with Variation of Consumption with Pressure and Feed Rate Pressure and Feed Rate

Feed Rate (number of turns)

with Pressure and Feed Rate with Pressure and Feed Rate Pressure and Feed Rate Pressure and Feed Rate

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Results Results Results Results

Coal Slag: Emission Factor (g/lb) Variation with Pressure and Feed Rate

40 45

Coal Slag: Emission Factor (g/sq.ft) Variation with Pressure and Feed Rate

300 350 100 PSI 1 275 2 9 6017 45 087 120 PSI y = 3.2833x2 - 25.143x + 81.733 R2 = 0.92 30 35

ion Factors (g/lb)

80 PSI 100 PSI 120 PSI 120 PSI y = 111x2 - 871.77x + 1907.4 R2 = 0.99 100 PSI y = 66x2 - 494.73x + 1109.3 R2 = 0.99 200 250

n F acto rs (g /sq .ft)

80 PSI 100 PSI 120 PSI 80 PSI y = 4.9558x2 - 38.189x + 95.03 R2 = 0.73 y = 1.275x2 - 9.6017x + 45.087 R2 = 0.58 20 25

Emissi

80 PSI y = 77.8x2 - 596.1x + 1263 R2 = 0.99 150 200

E m is sio

15 2 3 4 5 6

Feed Rate (number of turns)

Variation of Emission Factors Variation of Emission Factors Variation of Emission Factors Variation of Emission Factors

100 2 3 4 5 6

Feed Rate (number of turns)

Variation of Emission Factors Variation of Emission Factors (g/lb) with Pressure and Feed (g/lb) with Pressure and Feed Rate Rate (g/sq.ft) with Pressure and (g/sq.ft) with Pressure and Feed Rate Feed Rate

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Summary of CP Research Summary of CP Research – – Abrasive Abrasive Blasting Blasting

UNO’ Cl T h l i I i i i A h i UNO’ Cl T h l i I i i i A h i

UNO’s Clean Technologies Initiative Approach is

UNO’s Clean Technologies Initiative Approach is applicable/scalable to other industrial processes and to applicable/scalable to other industrial processes and to

ther countries
ther countries
ther countries
ther countries

Dry abrasive blasting process was recently fully

Dry abrasive blasting process was recently fully Dry abrasive blasting process was recently fully Dry abrasive blasting process was recently fully

ptimized:
ptimized:

Environmental ranking of six abrasives

Models for Total PM emissions

Models for productivity

Models for abrasive consumption

Results in energy/resource conservation, reduction in

Results in energy/resource conservation, reduction in environmental/health impacts, and life cycle cost environmental/health impacts, and life cycle cost minimization minimization

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How these Clean Technology Initiative How these Clean Technology Initiative d CP R lt B i Utili d? d CP R lt B i Utili d? and CP Results are Being Utilized? and CP Results are Being Utilized?

Life Cycle Cost Reduction

Life Cycle Environmental Impact Minimization

Environmental Compliance through UNO’s Expert

Environmental Compliance through UNO’s Expert EMS EMS

Worker Protection through UNO’s OSHA

Worker Protection through UNO’s OSHA-

CMS

CMS

Public Health Risk Minimization through Health Risk

Public Health Risk Minimization through Health Risk M t/M d li M t/M d li Management/Modeling Management/Modeling

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Life Cycle Costing and Assessment Life Cycle Costing and Assessment

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Expert EMS for Env. Compliance Expert EMS for Env. Compliance p p p p

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Health Risk Models: Exposure Health Risk Models: Exposure Pathways Pathways

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Carcinogenic Health Risk Carcinogenic Health Risk Carcinogenic Health Risk Carcinogenic Health Risk

Lif i i k Lif i i k

Life time cancer risk

Life time cancer risk or

r

Risk Risk = = CDI CDI x x PF PF Where, Where,

Risk

Risk probability of occurrence of probability of occurrence of p y p y cancer over a life time cancer over a life time

CDI

CDI chronic daily intake over a 70 chronic daily intake over a 70-

year lifetime, (mg/kg.d)

year lifetime, (mg/kg.d)

PF

PF potency factor also known as potency factor also known as slope factor, (mg/kg.d) slope factor, (mg/kg.d)-1

1

Limit

Limit 1 in 1 million 1 in 1 million

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Non Non-carcinogenic Health Risk carcinogenic Health Risk Non Non carcinogenic Health Risk carcinogenic Health Risk

HQ or HI

HQ or HI = = CDI / RfD CDI / RfD Q / Where, Where,

HQ or HI

HQ or HI -

HQ or HI

HQ or HI -

hazard quotient or hazard index (non

hazard quotient or hazard index (non-

cancer

cancer risk indicator); risk indicator); risk indicator); risk indicator);

[less than 1 is considered safe (combined

[less than 1 is considered safe (combined effect of all sources in the area not one effect of all sources in the area not one effect of all sources in the area, not one effect of all sources in the area, not one industry)] industry)]

CDI

CDI chronic daily intake over a 70 chronic daily intake over a 70-

CDI

CDI chronic daily intake over a 70 chronic daily intake over a 70 year lifetime, (mg/kg.d) year lifetime, (mg/kg.d)

RfD

RfD reference dose (mg/kg d) reference dose (mg/kg d)

RfD

RfD reference dose, (mg/kg.d) reference dose, (mg/kg.d)

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Uncontrolled TPM

Flow Chart for Residual Risk Evaluation in Abrasive Flow Chart for Residual Risk Evaluation in Abrasive Blasting Blasting

Annual Abrasive

Uncontrolled TPM Emission Factors (kg/kg)

Uncontrolled TPM

PM10 / TPM Fraction

Uncontrolled Respirable Annual Abrasive Usage (kg/yr) Uncontrolled TPM Emissions (kg/yr) PM (PM10) Emissions (kg/yr)

Efficiency

f APCD

(%)

Controlled PM10 Controlled Metal Emissions: C Ambient Long-term (chronic) Metal Concentrations at Emissions (kg/yr)

Metal Fractions in TPM

Cr, Mn, Ni, Pb (kg/yr)

Dispersion

Metal Concentrations at Receptor Locations Cr, Mn, Ni, Pb (µg/m3)

Metal Fractions in TPM Cr, Mn, Ni, Pb (kg/kg) Dispersion Modeling Toxicity Ratings for

Total Inhalation-Induced Cancer = Σ UREi * Conci & Non-cancer Risk = Σ Conci/ RfCi

y g Cr, Mn, Ni, Pb Cancer Non-cancer (URE) (RfC)

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Worker Health Protection through OSHA-CMS

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Worker Health Protection through OSHA-CMS

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Current and Future Studies Current and Future Studies Current and Future Studies Current and Future Studies

Additional work on abrasive blasting

Particle size, metal speciation

Particle size, metal speciation , p , p

Metal welding

F i PM i i f HAP F i PM i i f HAP

Fume generation rates, PM emission factors, HAP

Fume generation rates, PM emission factors, HAP emission factors emission factors

Landfill emission quantification to reuse energy

Landfill emission quantification to reuse energy and reduce GHG emissions [climate change] and reduce GHG emissions [climate change] [ g ] [ g ]

Remote sensing techniques to monitor air

Remote sensing techniques to monitor air li [ id f d b k CP] li [ id f d b k CP] quality [provides feed back to promote CP] quality [provides feed back to promote CP]

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Summary and Conclusions Summary and Conclusions Summary and Conclusions Summary and Conclusions

Research was focused so far on the maritime industry processes

Research was focused so far on the maritime industry processes such as blasting, welding, cutting, and painting such as blasting, welding, cutting, and painting

Developed “cleaner production” concepts are scalable to:

Other Processes

Other Industry Sectors (Auto, Aircraft, Refining, Chemicals..)

Other Geographical Setting

Students trained at UNO continue to promote CP

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UNO welcomes collaboration with UNO welcomes collaboration with international researchers to promote international researchers to promote cleaner production and student training cleaner production and student training cleaner production and student training cleaner production and student training