Technology demonstration projects are the cornerstone of pollution prevention (P2) technology transfer. They provide the necessary momentum to move a facility towards implementation. Many facilities are aware of the benefits associated with P2: cost savings, raw material reduction, and in some cases even increases in production rates. However, many are reluctant to make the implementation dive. Often it is not from lack of knowledge of processes benefits that adoption is slow or nonexistent. Rather, resistance to implementation of P2 occurs as the result of insufficient funding. Another deterrent is lack of personnel and time due to manufacturing constraints.

DEQ-EAD's solution has been to employ a two-tiered incentive approach to encourage P2 adoption: offering technology demonstration grants and providing summer P2 engineering interns. The programs are outlined below:

Technology Demonstration through Grants

The technology demonstration program managed by DEQ-EAD attempts to rectify implementation deterrents by providing financial incentives for manufacturing facilities to pilot P2 technologies and practices. In 2001 matching grants have been awarded for three metal finishing P2 projects with the ultimate goal of reducing waste at the source before it has been generated and producing measurable reductions. Projects include the following:

• Master Finish is converting from a traditional alkaline soak cleaning system to ultrasonic cleaning to better prepare parts for processing.  This project reduces chemical concentration of the process tank and lowers the bath temperature to lower energy usage.  The project also reduces the need for additional vapor degreasing of improperly cleaned parts.
• Elm Plating is evaluating a new trivalent chrome process as a substitute for an existing hexavalent chrome process. Parts will be chromated and coated. The new process will be evaluated based on hexavalent chromium reductions, process efficiency, quality, ease of use, and ability of trivalent chromium to accept a seal and lube coating. The project also includes an analysis to determine whether the technology meets the automotive industries' standards.
• Wayne State University (WSU) is investigating a rinse water reuse technology at Reilly Plating. WSU will implement the wastewater reduction technology over three phases: (1) perform process analysis and data collection on a zinc chloride barrel plating line; (2) run process simulation software to identify a water reduction solution using empirical data collected from phase 1; and (3) implement and test the wastewater reuse system by installing piping and pumps to physically modify the fresh water inlet flows to facilitate rinse water reuse.
• Marsh Plating is evaluating the effectiveness of a microbial cleaner in removing oil and grease from parts prior to electroplating to reduce waste sludge and energy use. The project will increase solution bath life while achieving equivalent parts cleaning. Part cleanliness, plating adhesion/thickness, and part appearance will be used to compare the new system to a conventional cleaner.
• Alpha Plastics is integrating a closed loop water recycling system into their plastic extrusion operations to dramatically reduce water usage, eliminate wastewater discharges, and improve process, material, and energy usage efficiencies.  The project involves extensive modifications to the current once through, water cooling system including the installation of a chiller, water reservoir, electrical transformer, water treatment systems, and all necessary building modifications, piping, electrical wiring, controls and associated equipment. 

The technology demonstration grants program facilitates P2 implementation at the grant award site and provides industry with a showcase demonstration workshop for each grant. A workshop, hosted and presented by each award site, allows the facility to share results with industrial peers or opinion leaders including the technology evaluation, effect on production, advantages and disadvantages as well as cost analysis. This approach potentially motivates the attendees to pilot the same P2 technology at their own facility. To promote further implementation throughout the industry, financial incentives are provided to interested facilities through the Small Business P2 Loan Program.

Technology Demonstration through Interns

The second approach to facilitating P2 adoption is the P2 Internship Program. Through this program, a manufacturing company is eligible to host a DEQ-EAD sponsored engineering student intern for the summer. The program is designed for the intern to facilitate the implementation of P2 practices and technologies in industry by providing technical assistance. It offers engineering students an opportunity to integrate P2 principles into their engineering skills and gain valuable work experience.

Summer 2001- DEQ-EAD placed two chemical engineering students from the University of Michigan in metal finishing facilities as part of the Metal Finishing Pollution Prevention Initiative. We purchased a conductivity meter for each facility. The intern is facilitating the installation and evaluating its performance. The projects are described below.

• Allied Finishing is installing a conductivity meter in a rinse tank to reduce fresh water use. A conductivity meter is used as an indicator to trigger the flow of fresh water to the tank. With the conductivity meter installed continuous fresh water make up is eliminated. Instead water to the tank flows on and off as a function of tank conductivity. Once the conductivity set point is reached, it relays a signal to the solenoid valve to turn on the water until the lower set point is reached. Then the water is shut off only to start the process all over again. The engineering intern will evaluate the effectiveness of the meter and determine the water savings.
• ElectroPlating Industries, EPI, is also using an intern to install a state-purchased conductivity meter. She will conduct the same analysis as the intern at Allied Finishing (see above.)

The P2 Internship Program provides a facility the opportunity to pilot a P2 technology while using an intern to facilitate its installation and evaluate its performance. All manufacturing sectors are invited to participate and choose a P2 project tailored to their needs. The DEQ-EAD assists the company with project selection. Other projects include registering a facility in the National Strategic Goals Program by determining a company baseline for material use, waste generation, emissions, and energy use; and evaluating the potential for installing a microbial clean in an soak clean tank. Interns will culminate the summer by writing a case study on their P2 project.

For Summer 2002, the DEQ-EAD internship program is expanding to place five to seven engineering students in industry. Those interested in participating in the Summer 2002 program may contact Dale Copedge, (517) 335-0383. Companies are selected on the basis of the P2 project merit, with priority given to those having had a RETAP assessment and participating in a DEQ P2 Partnership. All industrial sectors are encouraged to apply.