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Cooper Crouse-Hinds

Year Submitted: 2003

Process: Wastewater Treatment

Industry: Foundry

Wastes Reduced: Metals, organics

Location: Amarillo TX

No. of employees: 102

Contact: Linda M. Kelley

Phone: 806/354-7036


Cooper Crouse-Hinds, Amarillo manufactures zinc-plated electrical fittings. The zinc-plating rinse waters are processed through a wastewater treatment system. The system removes the metals as a sludge and discharges the water to the City. The discharge water is permitted for limits of numerous metals including zinc. The original wastewater treatment and plating systems were twenty years old. Several areas of concern were identified: 1) below surface wastewater feed lines, 2) the two below surface sumps – one in plating and one in wastewater and 3) exceedances of zinc in the discharge waters.

P2 Application:

In 2000, all below-surface wastewater feed lines were re-routed to overhead lines, the sumps – one beneath the plating tanks was fitted with a rubber lining and one in the wastewater facility was sealed with an epoxy finish. In April 2001, a new wastewater treatment system was brought online. The new system included the addition of a large capacity equalization (EQ) tank with a mixer, a Dissolved Air Floatation (DAF) system to remove fats, oils and greases (FOG) with the addition of coagulant and flocculent, a lime slurry system for the final pH adjustment and pollution control equipment for the lime dust. The new system utilized the original sludge holding tank, clarifier, sand filters and filter press.

Environmental Benefits:

1)Reduced percent of zinc in discharge effluent >88%; 2)DAF removes emulsified fats, oils, and greases that adversely affect the metals removal process in the clarifier; 3)Greater storage capacity for reprocessing of any waters above in-house limits; 4) Zero exceedances since year 2000; 5) Reduce handling of waste by collecting F006 directly into disposal box.

Details of Reductions

Additional Information :

1) Eliminate the transfer/storage of F006 to a separate facility. Save $6000 yr; 2) Meets proposed MP & M regulations - Potential avoidance of production shutdown; 3) Eliminated a Confined Space with the resizing of the wastewater sump; 4) Regulatory no exceedances –Potential cost avoidance $2,000 to $10,000 annual.

Source: TCEQ

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