Retired Engineer and Technical Assistance Program (RETAP)
Internship Program Student Project Summary
2004

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Bird's Eye Foods

Kelly Martin, Junior, Mechanical Engineering Student
Grand Valley State University
Project Title:   Reduced Water Consumption and Biological Oxygen Demand (BOD) Loading

Ms. Kelly Martin was assigned to Bird's Eye food, a cannery located in Fennville, Michigan.   The company processes pie fillings and vegetables that are packaged in a variety of media (cans, laminated pouches, etc.) for regional distribution.  Their major operations consist of cookers, fillers, storage containers, pneumatic transport stations, hydro sieves, and other related equipment.

Ms. Martin conducted a water balance study that determined both the water consumption and actual needs throughout the plant.   The study identified excessive water users and flow adjustments that did not sacrifice production performance.  In addition to the study, she conducted preliminary design work for a closed loop cooling tower that allowed the recirculation of water with the potential of significant water/cost savings.  Projected cost for the cooling tower project is approximately $110,000 with a cost-on-return of approximately 19 months.  The project is under serious consideration by management for their 2005 budget.  Similar water studies are now under way at sister plants.  Ms. Martin also identified a number of pump seal leaks as the primary contributor to high BOD loading to the lagoons.  It is estimated that the company can save over $40,000 per year, by repairing the leaks.   Hydra sieves where introduced to remove suspended solids in the wastewater prior to being spray irrigated on company owned fields.

Bronson Methodist Hospital

Kwok Leung, Electrical Engineering, Graduate Student
University of Michigan
Project Title:   Implementing Chemical and Water Usage Strategies

Mr. Kwok Leung was assigned to Bronson Hospital located in Kalamazoo, Michigan.  Bronson Hospital is a medium to large size hospital that offers a variety of medical services in the Kalamazoo region.

Mr. Leung was successful at reducing redundant energy usage throughout the hospital campus.   He suggested lighting retrofits in one of the buildings and implemented an energy monitoring system for the hospital.  The utility rate for electricity was determined to be 5.3¢ per kilo-Watt-hour (kWh), and the expected savings in electricity consumption was around 443,400 kWh ($23,500) for the lighting retrofit and monitoring system combined.  Some of the retrofits included: the removal of redundant lighting; installation of motion sensor controlled lights; and automatic shut-off lighting.  Mr. Leung also made a number of suggestions that would correct the power factor, which could result in additional annual savings of $5,316.

Carbone of America

Willie Powell, Senior, Mechanical Engineering Student
Saginaw Valley State University
Project Title:   Reduced Electrical Energy Consumption at a Graphite Plant

Mr. Willie Powell was assigned to Carbone of America, located in Bay City, Michigan.  The company is a graphite processing plant that produces products for the semi-conductor and aerospace industry.

Mr. Powell was successful at conducting an energy audit that identified practices and equipment changes that reduced utility costs.   The practices included: staggered startup times and weekend (off-peak) operation of curing ovens; removal of redundant energy lighting; and scheduled cleaning of light reflectors.   Equipment changes included T-8 replacements for T-12 lighting; installation of motion sensor controlled lights; and automatic shut-off lighting.  The on-peak utility rate for electricity was determined to be 3.11¢ per kWh.  Switching to the off-peak rate has the potential to reduce energy usage by 10 percent with an associated annual cost savings between $24,000 and $49,000 (if all of the proposed schedules are implemented).

Evans Tempcon, Inc.

John Wenstrom, Junior, Mechanical Engineering Student
Grand Valley State University
Project Title:   Improved Efficiency in a Metal Coating Facility

Mr. John Wenstrom was assigned to Evans Tempcon, located in Grand Rapids, Michigan.  This company produces heating and air conditioning units for service and farm equipment, large trucks, and recreational vehicles.

Mr. Wenstrom identified four target areas that would benefit from pollution prevention (P2) practices.   One of the areas was the company’s coating line; Mr. Wenstrom determined that the most feasible change to the company’s coating operation was to redesign the coating racks for their production line.  This option was more favorable than converting the line to a powder coating system, or subcontracting the work to a powder coating operation.  The estimated cost for 100 racks is $6,250; as a result of redesigning the coating racks, the company drastically increased coating and production efficiency, resulting in significant cost savings.  There is a potential six to eight month return-on-investment, due to associated water and gas savings. 

Mr. Wenstrom also suggested the purchase of a smaller, more efficient boiler for the coating
line vs. installing a heat changer or a heat recovery unit.

He also investigated the purchase of a bailer for shrink wrap and cardboard waste streams that has a potential cost savings of $5,636.76 per year, as well as the installation of a smaller utility boiler for the paint operation, resulting in a net cost savings between $7,300 and $11,000 per year (20 to 30 percent efficiency improvement).

IPS Coatings Corporation

Lucinda Mills, Junior, Chemical Engineering Student
Wayne State University
Project Title:   Researching a Substitute for Trichloroethylene

Ms. Lucinda Mills was assigned to ISP Coatings Corp., a metal automotive parts coating facility that is located in Romeo, Michigan.   ISP Coatings Corp. applies epoxy and nylon coatings to seat belt anchors to enhance safety precautions.

A fluidized bed is the method used to apply primer coating to metal parts.  The project focused on the research and recommendations of implementing more aggressive non-hazardous air pollutant, water based replacement coatings for trichloroethylene, which serves as a thinner for the primer.  There were no “drop-in” solvent replacements for trichloroethylene located; however, Ms. Mills found an aggressive water based primer that required only minor production changes.  The proposed system reduced the solvent based primer usage and trichloroethylene by 11 percent and 14 percent respectively.

Light Corporation

Erol Suleymanoglu, Mechanical Engineering, Graduate Student
Michigan Technological University
Project Title:   Evaluate and Determine Compressed Air Needs

Mr. Erol Suleymanoglu was assigned to Light Corporation, located in Grand Haven, Michigan.  The company manufactures fluorescent light fixtures, and other related equipment.

Mr. Suleymanoglu was successful at upgrading the Light Corporation’s compressed air system.  Over 30 leaks were identified and repaired, and 13 filter systems were installed to remove moisture and other contaminants from the air source; estimating the cost savings of up to $6,000 per year.  There was also an additional benefit from repairing the air leaks; it created an associated 5 to10 percent production performance increase.  Mr. Suleymanoglu also implemented alternative packaging for distributing products; recyclable air cushion systems were used as a substitute for foam products.  The changes produced an estimated cost savings between $15,000 and $25,000 per year.

Michigan Boating Industries Association

Benjamin Upell, Senior, Chemical Engineering Student
Western Michigan University
Project Title:  Case Studies for the Michigan Clean Marina Program

Mr. Benjamin Upell was assigned to the Michigan Boating Industries Association, located in Livonia, Michigan.  Mr. Upell worked with marinas located on West Michigan's coastline in Ottawa and Muskegon Counties.

Mr. Upell has developed case studies that involve environmetnal controls and current P2 practices used at Michigan Marinas.  The case studies show the successful adoption of the most tangible and effective P2 practices that all marinas can incorporate.  The reports focus on waste reduction and cost beneits associated with implementing Best Management Practices and pollution abatement techniques for fueling operations, boat maintenance, and boat bottom washing, as outlined in the Clean Marina Guidebook.  The following are examples of P2 measures that are included in the case studies:

Fueling Operations:   Petroleum absorbent boom materials were placed under the fueling dock to quickly capture any spills as a result of fueling.  Also products were applied that fit over the fuel nozzle to capture spills before they enter the water.  Both of these recommendations were effective and inexpensive methods (about $25 per 10 feet of boom) to control and capture fuel spills.

 

Heated Storage:   The recommendation of heated storage prevents the use of hazardous antifreeze and it also better preserves the boats.  One might think that energy costs would be a huge problem; however, proper insulation of the storage building can greatly limit energy usage.  This practice also benefits the marina by attracting customers who want the best care available for their vessels.

 

Filtration of Bottom Washing:   This process removes paint chips that contain copper, as well as petroleum base products, other metals, and suspended solids.  The filtration system costs approximately $1,500 per unit and the filter replacement media cost $150.  A large benefit of this system is that it can be placed into existing storm drains.  This system can achieve approximately 90 percent removal of hydrocarbons and up to 80 percent removal of suspended solids.  Coupling this practice along with diverting all pressure-wash water to the sewers, will improve the water quality of inland and major lakes.

 

Septic System Upgrades:   Shutoff valves were incorporated into the septic tank pump-out systems located on the marina docks.   This process eliminates spillage when emptying the septic tank systems in marine craft.  This practice reduces the chance of an environmental event on lakes and other waterways.

Michigan Department of Environmental Quality (MDEQ) – Project A

Kurt Best, Senior, Computer Science Engineering Student
Western Michigan University
Project Title:   Redevelopment of the District Office Database

Mr. Kurt Best was assigned to the Michigan Department of Environmental Quality (MDEQ), Environmental Science and Services Division (ESSD), a government agency located in Lansing, Michigan to modify an existing database use by the ESSD, District Field Office.

The database tracks site visitations, P2 performance information, measurement data, and all contacts with industry and the general public.   The changes that Mr. Best incorporated improved the data entry and retrieval used by the ESSD district staff. 

Michigan Department of Environmental Quality (MDEQ) – Project B

Li Xiong, School of Packaging, Graduate Student
Michigan State University
Project Title:   Redevelopment of Sample Package Design

Mr. Li Xiong was assigned to the MDEQ, ESSD, a government agency located in Lansing, Michigan, to redesign the distribution containers used for transporting of laboratory specimens from industry.

Mr. Xiong conducted a study to determine if the current packaging systems used by the ESSD Testing Laboratory could be redesigned to improve field performance.  Several national mail currier packaging systems were studied along with systems used by other government agencies, as well as the current packaging system used by the ESSD laboratory.  After Mr. Xiong tested all of the packaging systems against testing standards approved by the U.S. Environmental Protection Agency, the study results determined that the ESSD's current packaging system was the most economical and the best field performer of all the variations tested.

Michigan Department of Environmental Quality (MDEQ) – Project C

LaToya Morgan, Senior, James Madison College
Michigan State University
Project Title:   Agricultural Pollution Prevention Case Studies

Ms. LaToya Morgan was assigned to the MDEQ, ESSD, a government agency located in Lansing, Michigan to develop P2 case studies for the agricultural community.

Ms. Morgan converted information gathered by Lindsay Brown, a previous 2003 RETAP intern, into an information fact sheet targeting poultry and dairy farmers.  The article covered composting methods, and composting equipment.  Ms. Morgan also review and assisted with the development of draft fact sheets containing P2 activities for marinas which are currently used at working sites located in West Michigan.

Michigan Department of Environmental Quality (MDEQ) – Project D

Colin McMillan, School of Natural Resrouces and Environment, Graduate Student
University of Michigan
Project Title:   Identifying Trends and Distribution of Greenhouse Gases.

Mr. Colin McMillan was assigned to the MDEQ, Air Quality Division, a government agency located in Lansing, Michigan, to research greenhouse gas (GHG) emission factors for industrial sources.  All of the research was conducted at the Center for Sustainable Systems at the University of Michigan.

There were five major categories that were identified as major contributors of GHG: energy, industrial processes, agriculture, forestry, and waste.  Mr. McMillan discovered that energy was the largest contributor to overall GHG emissions; responsible for 87 percent of total emissions, or 50.16 million metric tons of carbon equivalent (MMTCE).  The second major contributor was waste management activities, contributing nearly 5.4 percent of total emissions.   Industrial process ranked third on the list at 3.06 MMTCE, or 4.9 percent of total state emissions.  Agriculture was the only category that exhibited a decrease in emissions, contributing 1.87 MMTCE due to a decrease in domestic livestock populations.  The complete inventory contains emission factors for a wide variety of emission sources, using 1990 data as the base line year and 2002 as the current inventory year.

Michigan State University (MSU), Extension Office – Project A

Erin Thelen, Junior, Biological Systems Engineering Student
Michigan State University
Project Title:   Black Soldier Fly Manure Management System Project

Ms. Erin Thelen was assigned to the MSU, Ottawa Extension Office located in Grand Haven, Michigan, to research and design a poultry waste composting system that would reduce manure volumes, and produce a desirable composting material.   The project is an innovative approach to assist farmers with adopting new technology that promotes P2 Best Management Practices for agricultural related activities. 

Ms. Thelen was successful at researching and completing the preliminary design of a new system/concept for composting poultry and other manure.   The system combines a layer type henhouse with a green house (confined animal feeding operation) that will use the black soldier fly as a means to reduce manure volumes by 50 percent and total nitrogen reductions up to 24 percent while attaching phosphorus (the limiting pollution for land applicant) to the digest manure for a controlled release.  Larvae are self-harvested in the layer system, they can be used as harvested or dried, with a composition of a 42 percent protein and 35 percent fat, they make an excellent feed source for a number of sources (i.e.: fisheries, poultry, etc.).  The sale of harvested larvae can net profits of up to $27,500 per year per layer house.  This is more than the previous system which sells all the manure generated.   Ms. Thelen’s work is currently being reviewed by other agricultural universities for continued research.

Michigan State University (MSU), Extension Office – Project B

Mark DeKliene, Biological Systems Engineering, Graduate Student
Michigan State University
Project Title: Compost Tea Project

Mr. Mark DeKliene was assigned to the MSU, Ottawa Extension Office located in Grand Haven, Michigan, to research, design, and test an innovative method to prevent fungi growth from destroying various types of apples.   The project is an innovative approach to assist farmers with adopting new technology that promotes P2 Best Management Practices for agricultural related activities.

Mr. DeKliene was successful at researching and designing a compost tea brewer that would produce compost tea to be used as a substitute tocommonly used fungicide applications.  Michigan is ranked as the third largest apple producing state in the country; an industry that contributes over $500 million a year to Michigan's economy.  Currently the practices for preventing fungi growth are hazardous chemical applications that can cost over $600 per acre.  Up to 5 percent ($2.3 million) yield loss is associated to apple scab and powdery mildew.   The cost of using compost tea is roughly $25 an acre.   With today’s trend of urbanization farm land with expensive housing projects, human exposure (skin contact, inhalation, or ingestion) due to wind drifts, and ground and water contamination are of growing concerns.  Compost tea is a natural alternative to fight fungus without the risks of human hazard.

Sun Chemical

Ashok Krishnan Anandan, Chemical Engineering, Graduate Student
Wayne State University
Project Title:   Fugitive Dust Control

Mr. Anandan was assigned to Sun Chemical located in Muskegon, Michigan.  This company is a global distributor of various pigments for printing inks.  The company maintains a number of processes that are common among ink and paint suppliers (i.e.: grinding and milling processes, wet and dry processes, pneumatic transfers systems, and other production processes).

Mr. Anandan was successful at identifying leaks in process areas that had significant product losses, and necessary maintenance repairs were made.   He also suggested several process modifications and work practice standards to eliminate fugitive dust emissions plant wide.   Many of the remedies included: replacement of seals at transfer and access areas on equipment, realignment of access and sample doors, replacement of filter bags, incorporation of pressure monitors, and a complete overhaul of the baghouse filter.  The plant also implemented two of Mr. Anandan’s suggestions: the replacement of a knife gate valve to a butterfly valve on four scale hoppers; and the incorporation of relief points with filter media on the dry mill doors that allow even distribution of the product.  The changes resulted in approximately 90 percent reclamation of loss product with associated cost savings of $12,500 per year.