Recycling Cost - Tennessee Environmental Conference

Ricky King
Director of Safety & Environmental
Affairs
Lodge Manufacturing Company
Sustainable: using a resource so that the resource is
not depleted or permanently damaged .




Foundries are some of the oldest recyclers.
Foundry scrap can include a general mix of iron
scrap metal that can include a wide variety of cast,
plate & structural materials such as I-Beam, rebar, old
cannons, lampposts, scrap locomotives, track …etc.,
etc.
However, Lodge now uses a very clean metal mix in
melting consisting of domestic pig iron, bushling steel
from Tennessee stamping operations and our own
returned gates, risers and off quality castings.
If you ever wear out your Lodge cast iron skillet, we
will gladly remelt it.
Ancient Castings
9000 B.C.-Earliest metal objects of
wrought native copper are
produced in the Near East.
3000-2500 B.C.-Small objects are
cast via lost wax investment
casting process in the Near East.
3200 B.C. A copper frog, the
oldest known casting in
existence, is cast in Mesopotamia.
3000 B.C. Weapons and cult
objects made of copper
of this age recovered from middle
east and India.
AFS Birmingham
2000 B.C. Iron is discovered.
800-700 B.C. First Chinese production of cast iron.
645 B.C. Earliest known sand molding (Chinese).
500 B.C. First steel products were made in India
233 B.C. Cast iron plowshares are poured in China.
500 A.D. Cast crucible steel is first produced in India
but the process is lost until 1750 when Benjamin
Huntsman reinvents it in England.
Industrialmetalcasting.com


In 1620, the Pilgrims formed the first colony in the
New World at Plymouth.
In 1643, samples of ‘bog iron’ from Saugus mines
were taken to England to search for financing.
1,000 pounds were advanced by various investors
and the “Company of Undertakers for the Iron
Works” was formed. The Saugus Iron Works in
Lynn, MA was the first established in America.
It is the site of the first
integrated ironworks in
North America, founded
by John Winthrop the
Younger and in operation
between 1646 – 1668
Joseph Lodge was born in 1848 near
Philadelphia, PA. Left an orphan while
still a boy, he went to Wilmington,
Delaware where he learned the machinist
trade. He later went to Cuba as a
railroad engineer and was captured with
his crew during one of the “Cuban
Rebellions” until freed by the Spaniards.
Cuba’s Ten Years War for Independence
was from 1868-1878.
After Cuba, Mr. Lodge went to South America and
secured a job as an engineer in the Peru Navy. After a
trip around the Horn, he was appointed chief engineer
on the flag ship.
The “Huascar”, somewhere off the coast of Chile in the late 1870’s (painting by
Peruvian artist Saldivar)
Following a stint in the Peruvian Navy, Mr.
Lodge became a Division Superintendent of the
Railroad building in the Andes.
In 1876, Mr. Lodge returned to the U.S. for a leave. He
received news that a flood had washed the railroad away
and he decided to remain in the U.S.
In 1876, Joseph Lodge went to work for Southern States Coal,
Iron & Land Co. in South Pittsburg, TN as manager for their
saw mill, then master mechanic and later general
superintendent of the blast furnaces.
When Southern States was absorbed by Tennessee
Coal, Iron & Railroad Co. in 1881,
Joseph Lodge remained as President.
While with Tennessee Coal, Mr. Lodge located and
opened the coal mines in Whitwell, TN.
In 1892 Joseph Lodge organized the Shuster Foundry in South
Pittsburg for the manufacturing of soil pipe which was sold to the
Central Foundry Company in 1899.
While at Shuster, Joseph Lodge started Blacklock Foundry in
1896 naming it after the manager, friend and minister, Harry
Blacklock.
Following the sale of Shuster in 1899, Joseph Lodge
became President of Central Coal & Iron Company.
While at Central Coal & Iron, Mr. Lodge located and
opened up coal mines in Kellerman, Al.
Also while at Central, Mr. Lodge built furnaces at Holt, Al.
In 1906 Mr. Lodge became the General Manager of
Woodward Iron Co, in Woodward, Al.
Mr. Lodge returned to South Pittsburg when the
Blacklock foundry burned in 1910 and relocated it three
months later to its current location. At that time he
organized the Lodge Manufacturing Company.
Mr. Lodge was 62 years old.
Lodge Sugar Kettle
Lodge hand pour and floor molding
In 1950, Lodge became more automated.
50’s & 60’s
50’s & 60’s
50’s & 60’s
Cupola, early 90’s
Lodge changed from a Cupola to Electric Induction
Melting in 1992 with the environmental improvement
being the deciding factor. This choice resulted in
winning the1994 Governor’s Award. Lodge became a
Tennessee Pollution Prevention Partner in 2003.



We will replace our two 4 ton per hour induction
furnaces with two 10 per hour induction furnaces
in October 2013.
We will add a new sand system and a 250C
Disamatic Molding Machine in June 2014.
Building construction started in January of this
year.










Sand + clay + water = molding sand
Compress sand into hollow mold
Pour in molten iron
Allow iron to cool
Break the sand and metal apart
Reuse sand for other molds
Clean and grind iron castings
Remelt gates, risers and off quality castings
Season with food grade cooking oil
Sear, fry or braise on the stove, bake in the
oven or blacken on the grill
We reuse molding sand by adding new sand, clay
and water to return it to a good molding condition.
As sand becomes too fine for use or is somehow
considered to be unusable, it is put in our foundry
sand landfill and held for beneficial use under the
TDEC Beneficial Use Policy.
This policy was the result of Industry & Government
working together with help from the University of
Tennessee Center for Industrial Services and the
American Foundry Society.
Non-toxic foundry sand can be beneficially used under the
1996 State of TN Division of Solid Waste Beneficial Use Policy.
EPA Interim Research 2010
The reuse of foundry sand can conserve virgin resources,
and reduce energy use and greenhouse gas emissions.
 212 billion BTUs = The annual electricity for more than
5,500 homes
 20,000 tons of CO2 = Removing 3,469 cars from the road.


Metal concentrations in the samples were very similar to
and often less than metal levels in native U.S. soils.
The risk assessment demonstrated the beneficial reuse of
foundry sand from foundries does not pose a threat to
human health or the environment.
There are two Stormwater Retention Ponds that
were built by Lodge personnel for stormwater
control. One was later expanded and a Weeping Willow
was planted. Ponds help recharge the water table.
A larger pond was later added as a Watershed
Retention Pond at the property edge.
These ponds collect sediment and reduce the
amount that would eventually go to the
Tennessee River.
A simple smart choice to control run-off and also
included a UTCIS consultation.
Lily pads were started with one plant pulled out of a
small Mississippi pond.
Cattails line the sides of the ponds and shallow
ditches to the ponds and were started with cattail
seed provided by a supervisor.
Fish appeared either from coming in on bird’s legs or
Mother Nature rained fish eggs.
Ponds are cleaned out every couple of years and
the fertilized material is put on the landfill surface to
facilitate grass growth.

A recyclable foam was being used to separate
skillets in packing.
Although recyclable, most would not know what to
do with it and they would trash it.
The foam was not biodegradable.
Lodge replaces the foam with paper to increase
recycle potential.
This simple change saved $12,267 the 1st year.
Require a review of the Material Safety Data Sheet
(MSDS) on every new chemical before it comes into
your location.
A hazard determination must be made on each
chemical in your operation. It is simpler to
keep it out of your facility than to deal with it
later. This includes samples.
Vendors must understand that they will need to dispose
of any left over chemicals not used.
Tennessee School Plant Management
Association:
The Truth about Bulb Crushing vs Intact
Recycling 1/17/2011
www.tspma.com/news/2011/01/17/truthabout-bulb-crushing-vs-intact-recycling
Regulations: Packaging regulations per the UW law
Generators may simply place their intact spent
fluorescent tubes back in the original box, (provided
it is in good condition). Tape the box closed and
label the box with one of the following phrases,
“Universal Waste lamps” , “Used Lamps”, or “Waste
Lamps”.
The lamps are now ready to ship to the recycler.
Recycling Cost The cost to properly recycle an intact
4ft. lamp using the State Contract is .16 cents each.
Cost to properly recycle 1000 4ft. Lamps: $160.00
Regulations in Tennessee
Prohibited from diluting or treating universal waste,
except by crushing for volume reduction purposes in
compliance with the Permit-by-rule requirement of
Rule 1200-01- 11-.07(1) (c) 1(iv) or as otherwise
provided in Rule 1200-01-11-.12.
Prohibited from mixing in any hazardous or non
hazardous waste with the crushed Lamps. No filters,
tools, solid waste, etc., shall be placed in the
container of crushed lamps.
Detailed records regarding this operation must be
kept and made available for review for At least three
(3) years, including, but not limited to, the
technology employed for the crushing unit.
The handler immediately transfers any material
recovered from a spill or leak to a container and has
available equipment necessary to comply with this
container that meets the requirements of Rule 1200
01-11-.03(4) (e), requirements.
The handler ensures that the area in which the lamps
are crushed is well-ventilated and monitored to
ensure compliance with applicable Occupational
Safety and Health Administration (OSHA) exposure
levels for mercury.
Employee Training
A handler of universal waste lamps must train all
employees who handle or have responsibility for
managing them in a lamp crusher. The training must
address proper handling and emergency
procedures, including transfer of mercury from
containment devices to appropriate containers.
The crushed lamps are stored in closed, non-leaking
containers that are in good condition (e.g., no
severe rusting, apparent structural defects or
deterioration), suitable to prevent releases during
storage,
handling and transportation.
Labeling/Marking
A handler of universal waste lamps and crushing
device must label or mark the universal waste lamps
or containers as specified below:
1. Universal waste lamps (Le., each lamp), or a
container in which the lamps or crushed lamps are
contained, must be labeled or marked clearly with
anyone of the following phrases: "Universal Waste
Lamp(s)", or "Waste Lamp(s)", or "Used Mercury
Lamp(s),


2. Placing "Crushed ", as appropriate, first on the
label.

Average Start up Cost to Crush
Lamps in Compliance
Avg. DTC Cost
Mercury Air Monitor (Jerome)
Bag filters (2)
Approved 55 gal. Metal drum
Employee Training (per employee)
Total Start up Cost

$3500
$5000
$ 114
$ 65
$ 250
*$8929
Note:*This is the cost before the first lamp is
crushed.
Additional Cost and Recycling Cost
HEPA Bag Filters $57 Ea. (changed twice per drum)
2 for $114
HEPA Cartridge (required to change after 10 Drums)
$136
$136 Ea.
Disposal of Filters *estimated avg. cost
$350
(as hazardous waste)
Recycling Cost (Avg. per drum)
$365
Total Additional Cost
$829
( Approximately1000 4ft tubes)
 Please Note: CFL’s and HID lamps Cannot be run
through a Drum Top Crusher

Regulations: Packaging regulations per the UW law
Generators may simply place their intact spent
fluorescent tubes back in the original box, (provided
it is in good condition). Tape the box closed and
label the box with one of the following phrases,
“Universal Waste lamps” , “Used Lamps”, or “Waste
Lamps”.
The lamps are now ready to ship to the recycler.
Recycling Cost The cost to properly recycle an intact
4ft. lamp using the State Contract is .16 cents each.
Cost to properly recycle 1000 4ft. Lamps: $160.00
VENDORS PROVIDE TOTES FOR
MIXED PAPER AND WILL PICK UP
ON A SCHEDULE OR CALL IN.
CARDBOARD CAN BE BALED
AND SOLD. RECYCLERS CAN
PROVIDE A BALER AS PART
OF AN AGREEMENT.
Labor will be spent to handle cardboard and mixed
paper regardless of what you do with it.
Labor used to haul to the dumpster or to the baler will
be about the same.
Locating a baler closer to the source would reduce
labor time and cost.
Labor used to make money is preferable to labor
used to spend money.
Prices may vary, but landfill costs and hauling will be
saved regardless.
2012 Cardboard/Mixed Paper Recycling:
Income:
Disposal saved:
Hauls @$95 saved:
Baler Rental:
Balance 2012:
$ 4,019 for 109 tons
$ 3,006 at $27.50/Ton
$1,235 for 13 hauls
0
$ 8,260 SAVED
(2011: $9,735 SAVED)
Lodge sells recyclable used oil to a local oil recycler
who picks up on site. This oil is cleaned and recycled
for sale as a clean oil. In 2012, 1,375 gallons of used
oil were sold for $485 and saved us $1,375 in disposal
cost.
The majority of our oily waste is absorbent socks for
soybean oil. We recently contracted Generation Green
Recycling to provide absorbents, collection drums and
pickup service. The oil contained in the absorbent media is
to be drained out and refined. The absorbents are and
brought back to reuse.

Choose Century Gothic Font for your printing whenever
possible. This will reduce the amount of printer ink
usage by extending the life of your ink cartridge. We
donate our cartridges to a local school.
Lodge stopped purchasing disposable Styrofoam coffee
cups at the end of 2012. This saved about $100 a year on
average, but eliminated 3500 coffee cups a year from our
waste.






Use Programmable Thermostats
Replace HID Lights with fluorescent
Replace older florescent lights with higher
efficient lights.
Use motion sensors in low use areas.
Cut off equipment when not needed.
Use monitoring in selected high use areas.
Lodge Manufacturing’s Energy Saving
Efforts and How We’ve Benefitted
From Partnering with Energy Star
Grede Energy Summit
Keith Nunley, CEM
Background
• First Started With Energy Management in 2009
• Our Energy Management program started totally
by accident.
• Joined Energy Star later that same year.
• Started small, just by looking more closely at our
utility bill.
• Started grabbing the “low hanging fruit”
Early Energy Projects
• Installed make-up air units for cooler weather use.
• Conducted Air/Light/Gas audits to help identify
potential savings.
• Started repairing air leaks…This lead to the ability
to shutting down a compressor completely!
• Making sure that equipment was turned off when
not in use or during non-operational times.
• Installed Sub-Meters throughout the plant.
• Demand Control
• Started to utilize the valuable tools provided by
Energy Star.
Energy Star
• Energy Star Partner logo
• Energy Management Matrix – Helps to
identify where you are in your program and
serves as a guide to where you need to be.
• Guideline for Energy Management Overview.
• Energy Tracking Tool
• Challenge For Industry
• Many more tools on the website
Energy Tracking Tool
• Establishes your energy intensity
• Gives you an initial reference point to start from.
• Tracks goals and whether your on target to meet
those goals.
• Provides you with reports like GHG emissions and
savings
• Tracks many forms of energy not limited to electrical
consumption.
• Provides a Statement of Energy Improvement to be
used should your company choose to commit to the
Challenge For Industry.
• Overall, the ETT is a great tool for the energy manager
and helps to keep things organized.
Sub-Meter Screen
Demand Monitoring
Simple Electrical Calculator
ACHIEVEMENTS
Challenge For Industry Award
Statement of Energy Improvement
Electrical Usage
Gas Usage
Total savings including rebates and incentives
• 2010 - $258,712
• 2011 - $256,823
• 2012 - $231,300
• Nearly 6,000,000 kWh’s saved total
We have ordered a Donaldson Torit Mist
Collector to replace the filter system currently
on the season line spray
booths. This change is to
improve mist collection
for recycling back into
the spray system. It
should eliminate the
stacks associated with
the sprayers.
Sustainability –
Reduce,
Reuse,
Recycle,
for the Environment
and
SAVE $$$
The University of Tennessee Center for Industrial
Services provided assistance on several Lodge
Projects. Currently they have a ‘three day’
program for manufacturing with a 50% match
dollar for dollar. Call Harding Aslinger at UTCIS at
423-634-0850 or email
[email protected]
for more information.