Coolant by decree

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									                                   Cutting Fluids

Overview
Coolant is widely used in the cutting operations to reduce the heat generated from friction
between the object and the blade. In our experience, savings from coolant are generally
high and the payback is short. The purpose of this report is to make metal working
operations more profitable and environmentally friendly.

When trying to identify coolant savings opportunities, we seek to:
1) Minimize coolant replacements
2) Reduce man-hours for machine cleaning
3) Reduce foaming in coolant
4) Reduce bacterial growth

In most cases coolant is thrown away due to the following reasons,
1) Due to the formation of tramp oil
2) Due to bacterial growth
3) Due to the accumulation of suspended particles
4) Due to change of color

Methods to Reduce Machine Coolant Costs

1) Use of Pure Water for Coolant Make-up
   The minerals that are present in the tap waters react with, and use up, the emulsifiers
   in the coolant. They build-up residues on the machine tools and workpieces and
   contribute to their corrosion. They also increase the bacterial and fungi growth in the
   coolant, which shortens the life of the coolant. Water hardness is primarily due to the
   presence of calcium and magnesium salts in the water. One U.S. grain per gallon of
   hardness is equivalent to 17.1 ppm of calcium carbonate in ionic strength. One grain
   of hardness present in the plant‟s water supply will reduce the coolant efficiency by
   one percent. Water with a low mineral content may cause foaming. To reduce
   foaming a mixture of 25% tap water to 75% hard water is recommended.

2) Maintaining Coolant Concentration and pH
   Coolant concentration can be determined with a refractometer. The reading on the
   refractometer is to be converted into percentage concentration for the coolants by
   conversion factors. For most machine coolants pH should be held between 8.8 and
   9.3. bacterial growth increases exponentially when pH falls below 8.3 and carbon
   steel can rust when pH is less than 7.5. Dilute potassium hydroxide (KOH) and
   alkalies, such as borax, can be used to raise pH.

3) Formation of Tramp Oil
   The accumulation of unwanted oils is due known as tramp „oil‟. This tramp oil is the
   oil that is formed when droplets of lubricating oils, grease, and hydraulic fluids fall
   from metal working machinery into coolant. It is also caused by oily, corrosion
    protective coatings on workpieces. The lubricants, hydraulic fluids and corrosion
    protective coatings should not ordinarily emulsify or dissolve in water otherwise their
    intended use is not achieved. But, because they do not emulsify readily, the droplets
    collect together as floating covers on coolant surfaces, which is a primary cause of
    coolant contamination.

    Recommendation
   Buy coolants that do not readily emulsify lubricating and hydraulic oils and buy
    water-resistant lubricating oils, waterproof greases and water displacing corrosion
    inhibitors. Coolant recycling is more effective and coolant quality can be maintained
    for longer periods when coolants readily separate from the other fluids.
   The lubricants, hydraulic fluids and corrosion protective coatings are best if they are
    not folly compatible so that they can readily separate after mixing.
   Even with the best prevention measures, some tramp oil and process contaminants
    will be present in machine coolants. Contaminants may be removed by processing the
    coolant with an in-line (continuous flow) or an off-line (batch type) coolant recycling
    system. Both are equally effective. The system works this way: used coolant flows
    directly to a recycling system and cleaned coolant flows directly k to the
    metalworking machines with an in-line system. But where as in an off-line system
    used coolant must be physically removed from the metal working machines and
    returned after recycling with off-line systems. With both systems the recycling
    systems consist of various combinations of filters, coalescers, separators, skimmers,
    and high-speed centrifuges to remove tramp oil, fine particulate matter and bacteria.
    The in-line system requires significantly high equipment investment than off-line
    systems due to the added cost of a centralized filtration system.
   The tramp oil can be prevented from entering coolant by stopping the leaks, replacing
    defective bushings, seals and gaskets.

    Methods of removing Tramp Oil.
    Installation of coalescers:
    The implementation cost of the coalscers would range from about $1,000 to $5,000.
    These help the formation of tramp oil globules in coolant and thereby assist in
    separating tramp oil from the base coolant. They accelerate the formation of floating
    oil layers and facilitate skimming. They work best with low speed coolant flow. The
    equipment consists of oil attracting material through which the coolant is pumped.
    The tramp oil collects on the oil attracting surfaces, forming droplets that join
    together to form globules which float on the coolant surface. These coalscers remove
    only non-emulsified oils.

    Installation of an Oil Skimmer
    The implementation cost of an oil skimmer is about $600.

    Installation of gravity separators:
    The implementation cost of gravity separators range upto about $2,000. These are
    tanks into which dirty coolant is allowed to be idle for several hours due to which the
    non-emulsified tramp oils floats to the surface and other metal fines sink to the
  bottom of the tank. The equipment has one or more weirs, which separates clean
  coolant from tramp oil and other contaminants. The equipment usually includes a
  means for conveying accumulated metal chips and fines from the bottom to a
  recycling receiver. They may also be equipped with heaters for effective control of
  bacterial growth.

  Installation of Ultrafiltration units:
  The implementation cost of an ultrafiltration unit ranges from about $3,000 to
  $10,000. These units are capable of processing 100 gallons per day of waste fluids.
  For lowest disposal costs, it is necessary to separate emulsion type coolants into oil
  and water fractions. It does not make sense to pay to have water disposed. The value
  of the oil increases with decreasing water content, as the oil reclaimers pick-up fees
  decrease with increasing Btu value.
  Other least expensive methods could be split coolants chemically in which a sulfate
  salts (E.g. Epsom salt) or sulfuric acid is added to coolant, which destroy emulsions.
  These emulsions split into an oil layer and a water layer and evaporation of water
  with heat.


Example Recommendations
AR X: Install Oil Skimmer for Coolant

                              Present          Recommended          Annual Savings
Purchase cost                  $284                $28                  $256
Disposal cost                   $36                 $4                   $32
Maintenance cost               $450                $45                  $405
Net                                                                     $693
Implementation Cost:                                                    $600
Simple Payback:                                                       10 months

Analysis
According to the management, the coolant costs $ 9.47 per gallon. One part of coolant is
mixed with 9 parts of water to form the coolant solution. The management also estimates
that 15 gallons of coolant solution put into the machine every 2.5 weeks and 9 gallons of
coolant solution are disposed of every 2.5 weeks.

Recommendation
We recommend that an oil skimmer be installed to reduce the frequency of coolant
replacements.

Estimated Savings
Present
The purchase cost of coolant is about:

 $9.47 x 1 gal cool x 15 gal sol x 50 wks = $284 /yr
gas cool 10 gal sol    2.5 wks       yr

According to the management, the cost of disposal is $.20 /gal sol. The disposal cost is
about:

 $.20 x 9gal sol x 50 wks = $36 /yr
gal sol 2.5 wks      yr

According to the management, the maintenance time required to change the coolant ia
about 1.5 hour. The average cost of labor, including benefits, is about $15 per hour. The
maintenance cost is about:

 1.5 hrs x 50 wks x $15 = $450 /yr
2.5 wks     yr      hr

The total cost is about:

$284 /yr + $36 /yr + $450 /yr = $770 /yr

Recommended
The management estimates that an oil skimmer would reduce the frequency of coolant
changeouts to once every 25 weeks. The present cost would be about:

 $9.47 x 1 gal cool x 15 gal sol x 50 wks = $28 /yr
gal cool 10 gal sol    25 wks        yr

The disposal cost would be about:

 $.20 x 9 gal sol x 50 wks = $4 /yr
gal sol 25 wks        yr

The maintenance cost would be about:

1.5 hrs x 50 wks x $15 = $45 /yr
25 wks     yr      hr

The total cost is about:

$28 /yr + $4 /yr + $45 /yr = $77 /yr

Estimated Implementation Cost
According to management an oil skimmer could be installed for about $600.

Estimated Simple Payback

SP =        $ 600       x 12 mo/yr = 10 months
       $693 /yr savings
AR X: Installation of Deionizer to Produce Pure Water for Coolant
      Mixup

                               Present          Recommended        Annual Savings
Labor cost                     $2,063               $338              $1,725
Disposal cost                   $885                 $0                $885
Coolant cost                   $2,062                $0               $2,062
Net                                                                   $4,672
Implementation cost:                                                   $200
Simple Payback:                                                      7 months

Analysis
According to billing records, the average cost of coolant is $10.85 per gallon. One part
of coolant is mixed with 50 parts of water to form the coolant solution. Management also
estimates that about 500 gallons of coolant solution are disposed of every 3.5 weeks.

According to the Montgomery Sanitary Engineering Department the water they supply
contains,

1.   9 grains per gallon (a measure of hardness).
2.   Calcium content = 70 to 80 mg/lt.
3.   Magnesium content = 74 mg/lt.
4.   Iron content < .05 mg/lt.
5.   Aluminum content < .05 mg/lt.

Water hardness is primarily due to the presence of calcium, magnesium, iron and
aluminum salts. To increase the coolant life, water with a low mineral content should be
used. However, water with an extremely low mineral content can cause foaming. The
Ohio EPA recommends mixing of 25% hard (tap) water with 75% pure water to reduce
foaming. According to the Ohio EPA(1) “for every grain of hardness present in the
plant‟s water supply the annual consumption of the coolant is increased by one percent”.

(1). “Metal Working Fluids Pollution Prevention Information Packet”, Office of Pollution
Prevention, Ohio EPA, September 1995.

Recommendation
We recommend that the current deionizer be used to pretreat the water mixed with the
coolant. This would reduce the frequency of coolant replacements.

Estimated Savings
Present
The labor cost is about:

11 machines x 3 changeouts x 2.5 hrs x $25 = $2,063 /yr
               machine-yr changeout hr
According to the billing records, the purchase cost of coolant is about $2,062 /yr

According to the billing records, the disposal cost of coolant is about:

$295 x 3 pickups /yr = $885 /yr
pickup

Total cost = $5,010 /yr

Recommended
Currently, the water has 9 grains. If 25% of tap water were mixed with 75%
Deionized water, water would have:

.25 x 9 grains + .75 x 0 grains = 2.25 grains.

The change in hardness would be:

9 – 2.25 = 6.75 grains.

The coolant savings would be about:
6.75 grains x 1% savings x $5,010 /yr = $338 /yr
                grains

Estimated Implementation Cost
We estimate that the coolant mixing process through the deionizer would cost about
$200.

Estimated Simple payback
SP = $200 x 12 mo = 7 months
     $338 /yr  yr
AR X: Share Paper Filter Between Two Grinders

                              Present          Recommended        Annual Savings
Annual cost of labor           $188                $100               $88
Disposal cost                   $89                 $0                $89
Annual cost of new              $24                 $0                $24
Coolant
Net                                                                    $201
Implementation cost:                                                   $200
Simple Payback:                                                      12 months

Analysis
According to the management, coolant used in the grinders costs $8.12 per gallon. One
part of coolant is mixed with 50 parts of water to form the coolant solution. Management
also estimates that 500 gallons of coolant solution are disposed of every 3.5 weeks.

Recommendation
We recommend that the present paper filter on the Okamoto grinder be shared with the
adjacent Thompson grinder to reduce the frequency of coolant replacements.

Estimated Savings
Present
The annual cost of labor for coolant changeouts on the Thompson grinder is about:

  2.5 hr x 3 changeouts x $25 = $188 /yr
changeout       yr         hr

According to the management, the cost of disposal is $295/pick up. Each changeout,
about 50 gallons of coolant solution are placed. The disposal cost is about:

 $295 x 1pick up x 3 changeouts x 50 gals = $89 /yr
pick up 50 gals         yr       changeout

The annual cost of the new coolant is about:

150 gal sol x 1 gal coolant x $8.12 = $24 /yr
     yr        50 gal sol    gal coolant

The total cost is about:

$188 /yr + $89 /yr + $24 /yr = $301 /yr

Estimated Savings
The total Savings would be about:
Savings = $301-$100 = $201 /yr
The cost per changeout is about:
$301 x      yr       = $100 /changeout.
 yr     3changeout

Recommended
Management estimates that a paper filter would reduce the frequency of coolant
changeouts to once a year.

Estimated Implementation Cost
We estimate that the implementation cost for rearranging and repiping the grinders would
be about $200.

Estimated Simple Payback
SP = $200 x 12 mo = 12 months.
     $210 /yr yr
AR X: Installation of Paper Filter for the 7 CNC Machines

                               Present          Recommended           Annual Savings
Purchase Cost                $11,995 /yr          $3,000 /yr            $8,995 /yr
Maintenance Cost             $17,640 /yr          $4,410 /yr           $13,230 /yr
Paper roll Cost                 $0 /yr             $600 /yr             -$600 /yr
Net                                                                    $21,625 /yr
Implementation cost:                                                     $2,800
Simple Payback:                                                        1.5 months

Analysis
According to the management, the coolant costs $6.12 per gallon. The management also
estimates that 40 gallons of coolant is put into the 7 CNC machines every week and all of
the used coolant is disposed through the drain.

Recommendation
We recommend that a paper filter be installed for the 7 CNC machines to reduce the
frequency of coolant replacements. As the coolant flows into the paper filter the paper
roll advances collecting the suspended particles. The filtered coolant gets collected in a
trough at the bottom of the paper filter, which is again re-circulated.

Estimated Savings
Present
The purchase cost of the coolant is about:

  $6.12 1changeout 40galcool 49wk
                                 $11,995 /yr
 galcool    wk      changeout   yr

According to the management, the cleaning of the 7 CNC machines is done on Saturdays.
The management also estimates that it takes 3 men for 5 hours per week to clean all the 7
CNC machines. The average man-hours per year is about:

          5hours 49wk
 3man                735 man  hours /yr
            wk     yr

According to the management, the average overtime cost of labor on Saturdays is $24 per
man-hour. The maintenance cost is about:

   $24       735 man  hours
                             $17,640/ yr
man  hour         yr

The total cost is about:

$11,995 /yr + $17,640 /yr = $29,635 /yr
Recommended
We estimate that if a paper filter for the 7 CNC machines would reduce the frequency of
coolant changeouts to once every 4 weeks. The purchase cost of the coolant would be
about:

  $6.12 1changeout 40galcool 49wk
                                 $3,000 /yr
 galcool   4wk      changeout   yr

According to the paper filter manufacturing company, a paper roll costs about $150. We
recommend that the paper roll be changed every 3 months. The purchase cost of the paper
roll would be about:

  $150      4paperroll
                       $600 /yr
paperroll      yr

The maintenance cost would be about:

1changeout      $24       735man - hours
                                        $4,410 /yr
   4wk       man - hour        yr

The total cost would be about:

$3,000 /yr + $4,410 /yr + $600 /yr = $8,010 /yr

Savings
The savings would be about:

$29,635 /yr - $8,010 /yr = $21,625 /yr

Estimated Implementation Cost
The estimated initial implementation cost of a paper filter is about $2,800.

Estimated Simple Payback

         $2,800      12months
SP                           1.5 months
       $21,625 /yr      yr
AR X: Installation of 3 Paper filters for the Outside Diameter Grinders

                              Present          Recommended           Annual Savings
Purchase Cost                $4,123 /yr          $1,031 /yr            $3,092 /yr
Maintenance Cost             $7,056 /yr          $1,764 /yr            $5,292 /yr
Paper roll Cost                $0 /yr             $600 /yr              -$600 /yr
Net                                                                    $7,784 /yr
Implementation cost:                                                      $8400
Simple Payback:                                                        13 months


Analysis
According to the management, the coolant costs $6.12 per gallon. The management also
estimates that 13.75 gallons of coolant is put into the Outside Diameter machines every
week and all of the used coolant is disposed through the drain.

Recommended
We recommend the 3 paper filters be installed to reduce the frequency of coolant
replacements. As the coolant flows into the paper filter the paper roll advances collecting
the suspended particles. The filtered coolant gets collected in a trough at the bottom of
the paper filter, which is again re-circulated.

Estimated Savings
Present
The purchase cost of the coolant is about:

 $6.12 1changeout 13.75galco ol 49wk
                                   $4,123 /yr
galcool    wk      changeout      yr

According to the management, the cleaning of the Outside Diameter machines is done on
Saturdays. The management also estimates that it takes 3 men for 2 hours per week to
clean all the Outside Diameter machines. The average man-hours per year is about:

         2hours 49wk
3man                294man  hours /yr
           wk     yr

According to the management, the average overtime cost of labor on Saturdays is $24 per
man-hour. The maintenance cost is about:

   $24       294man  hours
                            $7,056 /yr
man  hour         yr

The total cost is about:

$4,123 /yr + $7,056 /yr = $11,179 /yr
Recommended
We estimate that 3 paper filters for the Outside Diameter machines would reduce the
frequency of coolant changeouts to once every 4 weeks. The purchase cost would be
about:

 $6.12 1changeout 13.75gal     49wk
                                  $1,031 /yr
galcool   4wk      changeout     yr

According to the paper filter manufacturing company, a paper roll costs about $150. We
recommend that the paper roll be changed every 3 months. The purchase cost of the paper
roll would be about:

  $150      4paperroll
                       $600 /yr
paperroll      yr

The maintenance cost would be about:

 1changeout 6man  hours 49wk      $24
                                         $1,764 /yr
    4wks     changeout     yr   man  hour

The total cost would be about:

$1,031 /yr + $1764 /yr + $600 /yr = $3,395 /yr

Savings
The savings would be about:

$11,179 /yr - $3,414 /yr = $7,784 /yr

Estimated Implementation Cost
The estimated initial implementation cost for the 3 paper filters is about $8,400.

Estimated Simple Payback

        $8,400      12months
SP                          13 months
       $7,765 /yr      yr
AR X: Installation of Container and a Paper Filter for all the Collected
Coolant from the Blanchards and Band Saws

                               Present          Recommended            Annual Savings
Purchase Cost                $61,775 /yr           $15,444                $46,331
Paper roll Cost                 $0 /yr             $600 /yr              -$600 /yr
Net                                                                       $45,731
Implementation Cost:                                                       $2,800
Simple Payback:                                                         0.7 months

Analysis
According to the management, the coolant costs $6.12 per gallon. The management also
estimates that a total of 206 gallons of coolant is put into the Blanchards and the Band
Saws every week out of which 165 gallons of coolant alone comes from the Blanchards
and the rest of the 41 gallons comes from the Band Saws and all of the used coolant is
disposed through the drain.

Recommendation
We recommend that all of the used coolant coming from the Blanchards and the Band
Saws be collected in a container and a paper filter be installed to filter all the suspended
particles to reduce the frequency of coolant replacements. As the coolant flows into the
paper filter the paper roll advances collecting the suspended particles. The filtered
coolant gets collected in a trough at the bottom of the paper filter, which is again re-
circulated.

Estimated savings
Present
The purchase cost of the coolant is about:

 $6.12 1changeout 206galcool 49wk
                                $61,775 /yr
galcool    wk      changeout   yr

Recommended
The purchase cost of the coolant would be about:

 $6.12 1changeout 206galcool 49wk
                                $15,444 /yr
galcool   4wk      changeout   yr

According to the paper filter manufacturing company, a paper roll costs about $150. We
recommend that the paper roll be changed every 3 months. The purchase cost of the paper
roll would be about:
  $150      4paperroll
                       $600 /yr
paperroll      yr

The total cost would be about:

$15,444 /yr + $600 /yr = $16,044 /yr

Savings
The savings would be about:

$61,775 /yr - $16,044 /yr = $45,731 /yr

Estimated Implementation Cost
The estimated initial implementation cost is about $2,800.

Estimated Simple Payback

          $2,800      12mo
 SP                       0.7 months
        $45,731 /yr     yr
   AR 1: Evaporate Water from Coolant to Reduce Disposal Cost(520)
                                   Present        Recommended         Annual Savings
      Coolant                   43,000 gal/yr      4,300 gal/yr     38,700 gal; $9,675
      Natural Gas                     0            6,243 ccf/yr     -6,243 ccf; -$3,371
      Maintenance                     0               $1,000             -$1,000
      Net                                                                 $5,304
      Implementation Cost:                                               $14,840
      Simple Payback:                                                   34 months

Analysis
Last year, the facility paid $0.25 per gallon to dispose of about 43,000 gallons of coolant.
The coolant is a mixture of 19 parts water to 1 part concentrated coolant, plus some tramp
oil and contaminants. Because of the coolant‟s high water content, evaporating most of
the water before sending the residual to the recycler could reduce the cost of disposal.

Recommendation
Following a recommendation by the process engineer, we recommend purchasing an
evaporator to reduce the volume of coolant sent to the recycling company. Based on
product literature, we conservatively estimate that an evaporator could reduce the volume
of coolant sent to the recycler by 90%.

Estimated Savings
The annual cost of coolant disposal is about:

43,000 gal/yr x $0.25 /gal = $10,750 /yr

Assuming the evaporator can reduce the volume of coolant by 90%, disposal costs would
be reduced to about:

43,000 gal/yr x $0.25 x 0.10 = $1,075 /yr

To evaporate water from the coolant, all of the coolant must first be brought up to the
boiling point temperature. Next, additional heat must be added to evaporate the water.
Assuming that the density of the coolant is similar to the density of water (8.32 lb/gal),
the mass of the coolant and water evaporated are about:

Mass of coolant = 43,000 gal/yr x 8.32 lb/gal = 357,760 lb/yr
Mass of water evaporated = 357,760 lb/yr x 0.90 = 321,984 lb/yr

Assuming that the coolant is originally at 65 F and has thermal properties similar to water
(specific heat = 1 Btu/lb F, heat of vaporization = 1,000 Btu/lb and boiling point
temperature = 212 F), the amount of natural gas required by a 60% efficient boiler would
be about:
357,760 lb / yr x1Btu / lbF x (212  65) F  321,984 lb / yr x 1,000 Btu / lb x      1 ccf
                                                                                                     6,243 ccf / yr
                                      0.60                                            100,000 Btu

The cost of the natural gas for the evaporator would be about:

6,243 ccf/yr x $0.54 /ccf = $3,371 /yr

There may also be a cost associated with the added handling of the coolant and
evaporator. If the added maintenance cost were $1,000, the net savings would be about:

$10,750 /yr - $1,075 /yr - $3,371 /yr - $1,000/yr = $5,304 /yr

Estimated Implementation Cost
Assuming 8,400 operating hours per year, coolant is currently disposed of at a rate of
about:

43,000 gal/yr / 8,400 hours/yr = 5.1 gal/hr

One evaporator advertises that it is capable of handling about 8 gallons per hour. Based
on information from the manufacturer, the total installed cost of this evaporator would be
about:

$11,840 (first cost) + $3,000 (estimated installation and accessories) = $14,840

Simple Payback
SP = $14,840 / $5,304 /yr x 12 mo/yr = 34 months

Note
The planned addition of 4 new machining tools will likely increase the quantity of
coolant and increase the savings estimated above.
AR 3054: Install Mobile Coolant Cleaning Equipment
                                  Present           Recommended       Annual Savings
Coolant purchase                 $1,320 /yr            $660 /yr           $660
Coolant disposal                  $958 /yr             $479 /yr           $479
Net                              $2,278 /yr           $1,139 /yr         $1,139
Implementation Cost:                                                     $3,000
Simple Payback:                                                         32 months

Analysis
Coolant is used for the part cutting operation to reduce heat generated due to friction.
The used coolant is periodically hauled away.

Recommendation
We recommend installing a mobile coolant cleaner. For example see Model TS/3, Como
Industrial Equipment, Inc., P.O Box 1671, Janesville, Wisconsin-53547.
Fax: 608-756-1262, Ph: 608-756-3838, Toll free: 1800-451-0028.

Estimated Savings
Present
According to management, three 55-gallon drums of coolant is purchased every year at a
price of $8 per gallon. The annual purchase cost of the coolant is about:

 $8 165 gals
             $1,320 /yr
 gal   yr

According to the management, 1-gallon of coolant is mixed with 15-gallons of water to
make the coolant solution. The annual quantity of water used for coolant solution make-
up is about:

165 gals
          15  2,475 gals /yr
   yr

The annual quantity of coolant solution is about:

165 gal/yr + 2,475 gal/yr = 2,640 gal/yr

The used coolant solution is disposed at a price of $0.363 per gallon. The disposal cost
of coolant solution is about:

 $0.363 2,640 gals sol
                       $958 /yr
 gal sol      yr


The total cost of the coolant operation is about:
$1,320 /yr + $958 /yr = $2,278 /yr

Recommended
The EPA reports that improved cleaning can more than double the life of coolant solution
(Metalworking Fluids Pollution Prevention Information Packet, September 1995, Ohio
EPA.). If so, the total savings would be about:

$2,278 /yr
            $1,139 /yr
    2

We estimate that the time spent cleaning the coolant is about the same as the time
presently spent flushing old coolant. Thus, there are no additional labor costs.

Estimated Implementation Cost
According to a manufacturer the cost of the equipment is about $3,000.

Estimated Simple Payback

        $3,000      12 mo
SP                       32 months
       $1,139 /yr     yr
 AR 3104: Recycle Hydraulic and Cutting Oils
                                 Annual Savings                  Project       Simple
                         Resource CO2 (lb)      Dollars           Cost        Payback
Hydraulic oil purchase                           $505
Hydraulic oil disposal                           $567
Cutting oil purchase                            $1,851
Cutting oil disposal                            $2,417
Net                                             $5,340            $4,000      9 months

 Analysis
 According to management about three 55-gallon drums of hydraulic oils and 11 55-gallon
 drums of cutting oils are purchased and disposed of every year. A hazardous waste
 management company periodically picks up the used oils.

 Recommendation
 We recommend purchasing a mobile oil cleaner such as that pictured in Figure 5.1.
         According to the manufacturer, a mobile oil cleaner can recover about 75% of
         the oil. It is fully automatic, removes ultra-fine contaminants from the oils and
         can be easily moved from job to job. This would save money and reduce the
         quantity of waste generated by the plant.
Figure 5.1. Model 130, Como Industrial Equipment, Inc., P.O Box 1671, Janesville,
         Wisconsin 53547, Fax: 608-756-1262, Ph: 800-451-0028,
         http://www.comoindustrial.com/.

Estimated Savings
According to management, hydraulic and cutting oils are purchased at a price of $4.08
per gallon. If so, the annual purchase cost of the hydraulic oil is about:

$4.08 55gals 3 drums
                    $673 /yr
 gal   drum     yr

The annual purchase cost of the cutting oil is about:

$4.08 55gals 11 drums
                     $2,468 /yr
 gal   drum      yr

According to management, the used hydraulic oil is hauled away for $252 per drum. If
so, the annual disposal cost of hydraulic oil is about:
$252 3 drums
             $756 /yr
drum    yr

According to management the used cutting oil is disposed at a price of $293 per drum. .
If so, the annual disposal cost of cutting oil is about:

$293 11 drums
              $3,223 /yr
drum     yr


The total annual purchase and disposal cost of the oils is about:

$673 /yr + $756 /yr + $2,468 /yr + $3,223 /yr = $7,120 /yr

According to manufacturer, about 75% of the oil can be recovered. If so, the purchase
and disposal cost would be about:

$7,120
         25%  $1,780 /yr
  yr
The total annual savings would be about:

$7,120 /yr - $1,780 /yr = $5,340 /yr

Estimated Implementation Cost
According to a manufacturer the cost of the equipment is about $4,000.

Estimated Simple Payback

         $4,000     12 months
SP                           9 months
       $5,340 /yr       yr

								
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