Case Studies | Cesco Solutions
Case Studies | Cesco Solutions
The following case studies demonstrate specific challenges we have effectively addressed through our comprehensive and customized service solutions.
A large international medical waste treatment company ...
Improving Operations, Costs and Wastewater Discharge for Medical Waste Treatment
… Cesco surveyed the wastewater process and current treatment strategy to determine improvements that could be made to help better process the medical waste at the facility. The Cesco survey discovered an overly complex and costly treatment program with no less than 12 different chemicals being used onsite. Cesco and the medical waste treatment facility both agreed that a simpler, less costly program that allowed the facility to discharge cleaner water to the environment was desirable.
Cesco started by evaluating the current polymers being used for treatment. The incumbent vendor used an anionic polymer to settle out solids prior to the filter press and a cationic polymer prior to Dissolved Air Floatation (DAF). Discharge records and jar tests indicated results could be improved. Cesco jar tests substantiated that Cesco PF-622CH was the best performer. A subsequent full-scale trial showed significantly improved effluent results from the DAF unit.
Cesco then evaluated the anionic polymer used for settling out the medical waste solids. After some trial work, it was determined that Cesco PF-852AH provided a dramatic reduction of polymer usage and improved liquid-solid separation. Tests confirmed 2 parts per million (PPM) of Cesco PF-852AH performed as good as 50 PPM of the incumbent polymer.
The combination of Cesco PF-622CH and PF-852AH greatly reduced the cost and volume of chemicals needed, while improving wastewater treatment at the medical wastewater treatment facility. As a result of savings and performance, Cesco was requested to work on other improvement opportunities for the company.
Within the year, Cesco identified significant other cost, operational and environmental advantages to be gained at the medical waste facility. As a result, Cesco now provides an inorganic coagulant, caustic, metals precipitant, defoamer, diatomaceous earth and inorganic acids at a lower use cost.
Environmentally, Cesco was able to replace hazardous chemistries used for drains and odor control with a new biological solution. Cesco Clean Flow E2 (a non-pathogenic bacteria/enzyme/fungi blend) is now used for clean drains and odor control. Also, Cesco White Fog (a quat sanitizer/disinfectant) approved and certified for effectively killing viruses (i.e. COVID-19), bacteria and parasites is now used for sanitizing surfaces at the facility.
As a result of improved operations, wastewater and costs, Cesco now provides all solution chemistries at this medical waste treatment facility and the corporation is now looking for our company to improve results at several other plants here in the United States.
The transportation industry has struggled for years ...
Improve Asphalt Release, Costs and the Environment
with Cesco AR-400T HF or AR400VT
… to meet environmental regulations that require companies to replace diesel that has historically been sprayed onto dump truck beds as an asphalt release during road paving operations. While diesel is cheap (about $2.50/gallon) and effective as an asphalt release agent, it is a hazardous (combustible) liquid and toxic to aquatic life. When used in excess, significant run-off can endanger the environment (soils and water ways) and cause problems with the asphalt aggregate itself. Cesco recently developed Cesco AR-400VT and Cesco AR-400T HF, both of which are Department of Transportation (DOT) approved release agents that are cost effective and environmentally friendly.
Cesco AR-400VT is a water-based biodegradable release agent that delivers a proprietary mixture of surfactant and silicone to create a barrier on surfaces to promote release and slip. Cesco AR-400VT is approved by the State of Texas as a release agent to replace diesel, “using NTPEP data and in accordance with Departmental Materials Specification DMS-6410.” Because Texas has such stringent testing requirements, this assures that the release is effective and does not cause issues with the integrity of the asphalt aggregate itself. Additionally, high temperatures in the South encourage many asphalt paving companies to blend an aggregate that is rubberized, making the release from dump truck beds that much more difficult. Cesco AR-400VT performs excellent as a cost-effective release agent when diluted 9:1 with water for asphalt carrying Truck Beds and Other Paving Equipment. When compared to diesel at $2.50/gallon, each use concentration gallon of Cesco AR-400VT will cut application costs by 50% or more, while protecting the environment.
Cesco AR-400T HF is a high foaming water-based biodegradable release agent that delivers a proprietary mixture on surfaces to promote release and slip. Cesco AR-400T HF is used in the Northwest (i.e. Washington) by asphalt paving companies, as a release agent to replace diesel. Cesco AR-400T HF is effective and does not cause issues with the integrity of the asphalt aggregate itself. It also works for an aggregate that is rubberized, improving the release from dump truck beds. Cesco AR-400VT performs excellent as a cost-effective release agent when diluted 12:1 with water for Truck Beds and Other Paving Equipment. When compared to diesel at $2.50/gallon, each use concentration gallon of Cesco AR-400T HF will cut application costs by 50% or more and protecting the environment.
A Northwest Dairy that produces Milk and Ice Cream ...
Reducing Food Processing Costs While Improving Safety & Results
… was frustrated with excessive chemical costs and poor service from their large international specialty chemical provider. Their monthly spend had increased substantially over time and service was lacking with their newly assigned account manager. The Plant Manager contacted Cesco to initiate an evaluation survey of his entire cleaning and sanitizing program.
Cesco Survey and Identification of Problems (Improvement Opportunities):
During the Cesco survey, several improvement opportunities were identified as follows:
- Chemical Supply – The dairy had limited space and was forced to carry excessive inventory to prevent running out of cleaners and sanitizers. At times, they needed to “borrow” from another dairy nearby when products did not arrive in time
- Costs – The monthly spend had doubled in cost during just a few years. While the previous chemical supplier tracked usage, their cost control efforts were ineffective
- Chemical Storage and Application Equipment – Full and empty cleaners and sanitizer containers were causing significant space and disposal problems. In addition, application equipment was in poor condition and fell short of needed requirements, forcing the cleaning crew to carry buckets of hazardous chemicals through the plant to points of use
- Safety and Training – Several hazardous conditions were identified that were placing the cleaning crew at risk. Also, they had not received recent or adequate chemical use and safety training from the supplier
Cesco Solutions:
After identifying the above improvement opportunities, Cesco generated a Cost Optimization Plan (COP) that provided meaningful solutions for the above:
- Chemical Supply – The Cesco COP provided more effective crossover chemistries and assured supply with better inventory management and deliveries with its specialized fleet owned trucks
- Costs – With lower overhead and raw costs, Cesco was able to provide the Dairy with pricing that provided immediate savings. Additionally, the amount of chemicals needed was reduced via the COP – improving cleaning and sanitizing results and generating >25% monthly savings
- Chemical Storage and Application Equipment – The Cesco COP provided Bulk Safe-Tanks, reducing chemical storage space and drum disposal. New application feed pumps were tied into CIP systems, doorway foaming equipment, double containment feed lines and other specialty chemical systems were provided
- Safety and Training – The Cesco COP scheduled and provided bi-lingual training for improving the dairy safety, cleaning, sanitizing and titration methods. The dairy now enjoys significantly improved safety and results (thanks to the Cesco COP)
A large Midwest company that processes Polyethelyne terephthalate (PET) recyclable plastic ...
Cesco Wastewater and Production Cost Optimization – PET Plastics Recycling
… was frustrated with excessive chemical costs and the performance of their wastewater treatment system. Their monthly spend on chemicals had increased substantially over time, regardless of excellent pricing with their chemical vendors. Although “they had tried every chemical supplier imaginable,” service was inadequate and treatment costs continued to climb (chemical and wastewater costs exceeded $50,000.00/month). The Company VP and Plant Operations Manager contacted Cesco to initiate an evaluation survey of their operations and wastewater chemical programs.
Cesco Survey and Identification of Problems (Improvement Opportunities):
During the initial Cesco survey, there were multiple improvement opportunities identified:
- Excessive Chemical Inventory – The PET recycler had limited space, but was forced to carry excessive inventory of caustic, acid, defoamer, surfactant and wastewater polymers to prevent supply outages
- Usage Costs – The monthly usage and spend had continued to climb for years, regardless of doing a good job of negotiating pricing. The PET recycler chemical suppliers cost control efforts had been tried numerous times without success
- Chemical Storage and Application Equipment – Full and empty containers were causing significant space and disposal problems. In addition, application equipment was in poor condition and in need of replacement and/or repair
- Wastewater Results – The PET recycler was unable to meet municipal wastewater discharge requirements, exceeding Total Suspended Solids (TSS), Oil and Grease and Chemical Oxygen Demand (COD) limits, causing monthly surcharges
- Safety and Training – Several hazardous conditions were identified that were placing the operations and wastewater operators at risk. The PET recycler had not received adequate chemical use and safety training from their suppliers
Cesco Solutions:
After analyzing the above, Cesco generated a Cost Optimization Plan (COP) that guaranteed the PET recycler 35% savings ($18,900/month reduction) and full wastewater compliance:
- Chemical Inventory – Cesco took full control of all the PET recycler chemical applications with the COP. Through improved chemical management, caustic, acid, defoamer, surfactant and wastewater chemical inventories were reduced
- Usage and Costs – The COP provided quarterly reductions in chemical usage and costs to achieve 35% monthly savings by year end
- Chemical Storage and Application Equipment – At no cost to the PET recycling customer, Cesco provided new chemical pumps and feed lines, bulk chemical storage, polymer make-down equipment and online inventory management
- Wastewater Results – The PET recycler now meets all municipal wastewater discharge requirements for TSS, Oil and Grease and COD, eliminating the previous monthly surcharge costs
- Safety and Training – The Cesco COP included regular management meetings for improvements and bi-lingual training about hazardous chemicals and conditions for the PET recycling operators. The operators were also better instructed on how to control chemical usage and costs – which provided improved operational and wastewater results, saving thousands of dollars each month for their company
A Northwest Refinery producing petroleum products was experiencing excessive hydrogen sulfide odors ...
Controlling Hydrogen Sulfide Odors and Improving Tank Farm Spill Containment Systems with Cesco Liquid Alive
… and runoff every time they sprayed “tank bottoms” for sealing their tank farm dike spill containment system. The refinery was receiving odor complaints from workers and community members, as well as concerns about residual run-off during the application process. Complaints had increased over time and the service contract provider was seeking an environmentally friendly solution to mitigate the odor and improve the tank bottoms dike sealant process. The contractor contacted Cesco to initiate an evaluation survey of the problem.
Cesco Survey and Identification of Problems (Improvement Opportunities):
The Cesco survey identified improvement opportunities with the contractor as follows:
- Hydrogen Sulfide Odors – Like many refineries, tank bottoms (sludge) are utilized like asphalt to create a water-proof barrier that is sprayed onto the dikes, sealing the spill containment for the tank farm. As the sludge is sprayed onto the surface and dries, hydrogen sulfides gas off and create severe “rotten egg” like odors that are irritating to workers and the community
- Hydrocarbon Run-off – The tank bottoms are inherently wet and runny until it dries and sets up by being exposed to the outside environment. During this solidifying process, heavy rains could cause run-off that has undesirable levels of hydrocarbons.
- Worker Safety and the Environment – In addition to the odor issue, the contractor was wanting to find a chemical solution that was safe to use by his personnel and environmentally friendly
Cesco Solutions:
After identifying the above improvement opportunities, Cesco evaluated a selection of its most environmentally friendly chemistries and biological solutions. Cesco Liquid Alive, a non-pathogenic blend of enzymes, bacteria and fungi designed to mitigate undesirable fats, oils (i.e. hydrocarbons) and odors was determined to be the most promising and addressed the identified improvement opportunities as follows:
- Hydrogen Sulfide Odors – Immediately after spraying the tank bottoms onto the surface, a 1-2% dilution of Cesco Liquid Alive was sprayed onto the dike area. This immediately counteracted the hydrogen sulfides odor and any further gassing off. Worker and community odor complaints “disappeared”
- Hydrocarbon Run-off – The biological action of the Cesco Liquid Alive “polymerized” the wet and runny liquid, hardening it quickly to prevent future heavy rains from releasing residual hydrocarbons into the environment via any run-off
- Worker Safety and Environment – Cesco Liquid Alive has a neutral pH, pleasant natural scent and is non-pathogenic, keeping workers and the environment safe