Dealing with Waste

1
Dealing with Waste

• Ad Qual Castech Ltd.

2
Waste Management in UK

• Defra (Department for Environment, Food and Rural
  Affairs)
• Sets UK legislation for the management of waste
• The Environment Agency
• Administers the Acts Regulations
• Issues Licences for carriers and disposal sites
• Monitors all associated activities
• May define best practice (perhaps regardless of
  cost)

3
UK Acts Regulations

• See Defra website at
• http//www.defra.gov.uk/environment/waste/strategy
  /leg_dir.htm
• listing 15 items of legislation relating to
• Waste Management

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Legislation on coating waste

• Some of those regulations relate more directly to
  coating waste
• Hazardous Waste Regulations
• Landfill Directive
• Waste Incineration Directive

5
Coating processes

• Defra works on 2 principles
• The Polluter pays
• Precautionary intervention
• Environmental law says that we are responsible
  for our waste from cradle to grave

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Waste Management

• EA Policies
• Minimising waste by encouraging
• Efficient use re-use at source of materials
• Recycling wherever possible - (links with
  suppliers?)
• Recovery - e.g. as energy
• Disposal only as a last resort with
  responsibility for safe disposal upon those who
  generate it

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How NOT to do it

• Movie

8
Coating process controls

• FIRST AIM Minimising waste at source
• FOR LIQUIDS
• Coverage (sq.m / litre) 1000 x Volume
  Solids content x Efficiency
• 
  Dry Film Thickness
• FOR POWDERS
• Coverage (sq.m /kg) 1000 x
  Efficiency .
• 
  Specific Gravity x Dry Film Thickness
• These factors are controllable by selection of
  the right type of process, equipment and coatings
  for the job and training of personnel to ensure
  they are able to optimise application efficiency
  and DFT - Reducing waste at source

9
Coating process waste

• Hopefully interesting but what we really need to
  consider here is the best way of dealing with the
  materials that dont end up on our components but
  which end up as
• process waste.

10
Coating process waste

• And we arent going to concerned ourselves here
  with such items as packaging, tins, drums, energy
  or controlled stack emissions etc. where other
  strategies are in place

11
Coating processes

• Pretreatments - phosphates mordants etc
• Solvent or water based paints
• 1K or 2K systems
• Powder Coatings

12
Coating waste

• Hazardous wastes identified on the basis of
• Any waste listed as hazardous in
• The List of Wastes (England) Regulations 2005
  
• The European Waste Catalogue
• 20 01 27 - paint, inks, adhesives and resins
  containing dangerous substances
• 20 01 28 - paint, inks, adhesives and resins
  other than those mentioned in 20 01 27
• 08 02 01 - waste coating powders
• Asterisks indicate a hazardous classification

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Why should we bother?

• Well Apart from ethical grounds
• Greater world competition for ever-reducing
  resources
• Therefore increasing prices of raw materials
• And any reduction in waste is of more value

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Why should we bother?

• Waste is an unfortunate by-product of our
  processes but
• The cost of disposal of any waste generated is
  increasing exponentially as waste carriers
  continually find new ways of adding on any extra
  charges they can
• In some cases, disposal cost is greater than
  the original purchase price!

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Why should we bother?

• Increasing limitations on where and how disposal
  can be carried out
• No co-disposal of hazardous waste
• Reduced access to landfill sites
• Increasing costs
• Increasingly re-classification of waste as
  Hazardous you could end up paying to remove
  materials from a landfill site after they were
  wrongly classified
• Defra are to place more emphasis designing in
  recoverability and re-use (e.g. WEEE RoHS)

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Why should we bother?

• Cost of Disposal - Recent examples
• Waste paint washings - 82 per 205 litre drum
• Pretreatment sludge Between 40 and 135 per
  205 litre drum
• Liquid Pretreatment waste between 24 and 48
  per 205 litre drum
• (water costs less than 1 per cu m
  tonne)
• Flammable Solid paint waste 180 per 205 litre
  drum
• Non-hazardous paint Solid waste 50 per 205
  litre drum
• (NOTE Often misclassified)
• Incineration additional 30 to 40 per tonne
• Additional consignment charges Consignment
  notes 20 Carriage charge(?) 45 Transport for
  24 drum minimum load 280 Transport of 24 empty
  replacement drums 120 (1617 for approx 5
  tonne)

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Coating process waste

• Aqueous pretreatment solutions
• rinse water phosphates mordants etc
• Paint solids
• may be chemically reacted / gelled
• - Often as dried films on filters,
• Volatile materials
• often mixed with solids / gel
• Waterbased systems
• some solvent content and additives (often
  environmental hazards)
• Powder
• perhaps contaminated with bits, fibres

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Coating waste treatments

• Aqueous pretreatment solutions
• chemistry to neutralize, precipitate etc
• - Low temperature recycling / distillation
• Paint solids and filter
• incineration / use as fuels? Vitrification
  / Encapsulation
• Volatile solvents
• Recoverable for gun-wash by in-house
  distillation units (cost 3K to 7K)
• Liquid waste from water based paint systems
• ??
• Powder
• re-use on less important products? Specialist
  companies can recycle

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Summary

• We are the experts here.
• We know our industry.
• If we dont become involved, work out
  strategies for dealing with the issues and lobby
  to include them in legislation, the
  politicians will decide for us.