sustainability program and recycyled water use

SUSTAINABILITY PROGRAM AND
RECYCYLED WATER USE
SHAW DIVERSIFIED SERVICES, INC.
Bill Woyshner
Div. Environmental/Risk Manager
CEO Vision Statement
• VISION – creating a better future: for our
customers, for our people, for our company
and for our communities.
• MISSION – great people, great products,
great service, always.
• VALUES – honesty, integrity, passion
Tuftex Division
• 2 Carpet Manufacturing
Sites in Santa Fe
Springs, CA
• Distribution Center
(Cypress, CA)
• Yarn Mill in Yuma, AZ
• Approx. 630 Associates
Tuftex Customers
Mid to high end
residential carpet
Catering to California
styles and colors
1.
2.
3.
4.
5.
Extrusion
Yarn Mill
Tufting
Dye Application
Finishing
Continuous Dye Range Line
Dye Application
RECLAIM WATER
STARTED IN MID1993
RECLAIM WATER
METER
USES OF
RECLAIM WATER
DYE TANKS
SEAL WATER
EXTRACTOR
VACUUM
PUMPS
USES OF
RECLAIM WATER
 INDUSTRIAL
CLEANING
CAPTURING AND
REUSING DYE 
Water Usage
Program Title:
Environmental Objective:
Environmental Target:
Environmental Aspect(s):
Program Champion:
PLANT WG --WATER USAGE BY WEEK
Date:
3/4/2011
REDUCTION OF WATER USAGE PER POUND PROCESSED (GALLONS USAGED/LB)
X = 2.355 GALLONS/LB; REDUCTION BY 10 PERCENTAGE (2.1195 GAL/LB)
WATER USAGE AND WASTEWATER REDUCTIONS
SCOTT PRICE
I-MR Chart of Water (Gal/lb) by Water-Code
Current (omitted 21 22)
3.5
2009baseline
2010-2
2010-3
End of Project 4/9/2011
2011
Individual Value
1
1
3.0
1
2
2
2
2.5
22
1
1
1
2
2
1
11 1
1
1
1 11
2
2
22
11
2011 Goal = 2.1195 gal/lb
1
2.0
1/10/2009
4/4/2009
6/27/2009
9/19/2009 12/12/2009 3/20/2010
6/12/2010
9/4/2010
UCL=2.502
_
X=2.355
LCL=2.208
11/27/2010 2/26/2011
5/21/2011
Date
Moving Range
2009baseline
2010-2
1
2010-3
1.5
1
1.0
1
11
0.5
22
1
1 1
1
0.0
1/10/2009
4/4/2009
6/27/2009
9/19/2009 12/12/2009 3/20/2010
Date
6/12/2010
9/4/2010
11/27/2010 2/26/2011
5/21/2011
__
UCL=0.181
MR=0.055
LCL=0
Water Usage
Fiscal Year
Total
Industrial
Flow
(MGY)
Potable/
Industrial
Water Flow
(MGY)
Reclaim
ed
Water
Flow
(MGY)
% RW
2008
170
92
78
46%
2009
98
61
37
38%
2010
87
56
31
36%
2011
91
63
28
31%
2012
84
59
25
30%
2013
87
54
33
38%
2013 RECLAIM Water Usage
from CES
2012 Avg
2013 Jan
2013 Feb
2013 Mar
2013 Apr
2013 May
2013 Jun
2013 Jul
2013 Aug
2013 Sep
WG Beck (gal) - reclaim
23,530,636
2,246,392
3,372,955
3,631,032
3,952,694
4,077,618
4,691,767
6,473,119
6,419,764
6,715,256
WG Continuous (gal)
67,382,823
5,978,413
4,817,439
5,332,846
6,089,873
4,236,206
3,705,838
3,393,900
1,845,438
2,028,711
WG Total Water (gal)
90,913,459
8,224,805
8,190,394
8,963,878
10,042,567
8,313,824
8,397,605
9,867,019
8,265,202
8,743,967
Reclaim %
25.9%
27.3%
41.2%
40.5%
39.4%
49.0%
55.9%
65.6%
77.7%
76.8%
Improvement (gal)
Savings
117,610
$113.20
1,253,080
$1,206.09
1,310,960
$1,261.80
1,353,431
$1,302.68
1,925,796
$1,853.58
2,518,261
$2,423.83
3,919,292
$3,772.33
4,280,527
$4,120.02
4,452,103
$4,285.16
Water Cost
Year
RW Rate
($/CCF)
OW Rate
($/CCF)
2009
$
2.29
$
2.69
2010
$
2.57
$
3.15
2011
$
2.96
$
3.62
2012
$
3.23
$
3.95
2013
$
3.18
$
3.74
 RO WATER
SYSTEM
LINT TRAP 
 BOILER
ECONOMIZERS
HEAT RECOVERY
UNIT
Technical & Operation
TPM (Total Productive Maintenance System):
 Schedules and tracks all Work Orders and PM's
Includes all Wastewater cleaning task and Storm Water BMPs
Source testing and tuning of all equipment required by Air District
Boilers Improvements:
 Boiler Economizers
Preheats feed water to DA tank
 RO Water System
Reduces Chemical usage
Minimizes boiler blow-downs
Reduce chemical additives in Dye Processing
RO waste product used in process as wash water
 Heat Recovery Unit
Generates hot water for Boiler feed water
Preheats process wash water
Reduces effluent water temperature going back to city
Technical & Operation
Effluent Wastewater:
 pH controlled by redundant meters
 Temperature controlled
 Flow rates controlled by redundant meters
 Hourly sampling
 Approx. 100,000 gallons per day of wastewater reused for process
operations
Dye Make-up Reuse:
 Excess dye from the process reused back in the dyeing process
(Approx. 500,000 gallons per year)
Data Analysis:
 Extension data analysis system to control process conditions
(Temperature, Peak Flow , COD, TSS, etc)
Tuftex Energy Projects
Plant WW/WG
Savings
MMBtu
Dollars
annual
annual
Project/Opportunity
Boilers and Steam Systems
Stack economizer(s)
Waste water heat recovery
Recover condensate
15,000
45,190
7,800
$75,000
$226,000
$50,200
Reduce exhaust flow
6,000
$40,000
Reduce air pressure
717
$22,900
T5/T8 lighting
Recover seal water
5,518
11,220
$210,000
$148,800
Ovens/Dryers
Compressed Air
Others
Operations & Maintenance
Air Leak Repair
Totals
595
$19,000
104,250 $1,183,813
Waste:“Zero Waste to Landfill”
Landfill Waste Monthly Average
180
160
Landfill
12
36
140
Diverted from Landfill to WTE
(started 4Q 2009)
10
1.6
120
8
100
6
80
1.2
140
1.6
60
4
8.6
1.5
10
40
1.2
5.4
2
0.0
0.0
WG
WW
2013
2013
0.0
2012
2012
0.0
2011
2011
WW
0.0
2010
2010
WG
0
2009
0
2008
0
2007
0
2006
0
2005
2
4
2004
3
5
2009
2006
2005
2004
0
4
8
2008
5
17
4.0
3.9
2.9
2007
20
41
Roadmap to Environmental Excellence
and Sustainability
•
PRIDE:
– People Reaching Individual Daily Excellence
•
GreenEdge Environmental Communication Platform
– www.shawfloors.com
– www.shawgreenedge.com
•
Systems
– Shaw Management Systems
(Quality/Safety/Environmental/Maintenance)
•
6 Sigma
– Lean & 5S
•
Associate/Management Development
– Recognition
•
Work with Vendors/Suppliers
– Benchmark Best Practices
•
Investments
More than just
Environmental
… a
Synergistic
Approach!
Challenges/Initial Barriers
 Initially: All Levels of the
Organization using
Reclaim/Recycled Water
 Cost Difference & Project ROI:
Reclaim Water Cost verses
Incoming Water Cost
 Associate’s Misperceptions:
Quality Problems (Color), Odor,
and Employee Health Concern
 Awareness & Education to
Change
Benefits
 Reclaim/Recycled Water is more
consistent than regular incoming
Industrial Water
 Improvement Projects from Reclaim
Water Usage to Internal Water
Recycling
 Cost Savings (LACSD Surcharge
Rebate, Cost Difference, and
Project Savings)
 Company Environmental
Stewardship and Sustainability
 Employee Involvement (PRIDE)
 Agency Recognition
Awards / Certifications
• Waste Reduction Award Program (WRAP)
• Visionary Stewardship Award (Reclaimed Water)
• Facility of the Year (California Water Environment Association)
• Golden Arrow Award – (California Product Stewardship
Council)
• Industrial Use of Recycled Water (Central Valley Water Basin)
• Environmental Excellence and Sustainability Award (Industrial
Environmental Association)
• LA County Water District Compliance Certification
• Shaw Quality/Environmental/SAFE System Certification –
(similar to ISO 9000, 14001, 18000)