![[logo] US EPA](http://www.epa.gov/epafiles/images/logo_epaseal.gif){kind=logo}
NPEP Success Story: Flowserve Corporation
Flowserve Corporation Eliminates MEK, Saves $45,000 Annually
Flowserve is one of the most recognized and preferred global suppliers of pumps, valves, seals automation and services to the power, oil, gas, chemical and other industries. Flowserve employs over 14,000 employees in more than 56 countries. We combine our global reach with a local presence.
The company was created in 1997 with the merger of two leading fluid motion and control companies, BW/IP and Durco International. Flowserve heritage dates back to the 1872 founding of Byron Jackson, one of the companies that became part of BW/IP. The most recent additions to the Flowserve family include Invensys Flow Control in 2002, Thompsons Kelly & Lewis in 2004, and Interseal in 2005. The 130 year history of Flowserve heritage brands serves as the foundation for the breadth and depth of Flowserve products and services today.
 EPA officials present an NPEP Achievement Award to Bob Hendricks of Flowserve Corporation on October 25, 2005. |
Flowserve's NPEP Goals In order to maintain market share and conduct our worldwide business operation in an environmentally responsible manner, Flowserve has set goals to reduce our hazardous waste generation to less than 90 pounds of waste generation per million dollars revenue. Methyl ethyl ketone (MEK) poses a significant human health and environmental hazard. MEK can burn the skin and eyes, while vapors may cause dizziness or suffocation. If the solvent catches fire, it can produce irritating, corrosive, or even toxic gases. Due to the risks associated with the use of MEK, Flowserve set a goal to completely eliminate the use of MEK and reduce volatile organic compounds (VOCs) by 25 percent and hazardous waste generation by 50 percent. The introduction of a product known as EP-921 was tested and found to be a perfect substitute. |
EP-921's formulation is outside the RCRA hazardous waste regulations.
None of its components are listed in SARA, Title III, Sections 302 or
313. None of its components are listed under CERCLA. Its unique characteristics
allow the product to be recycled and re-used with a life expectancy ten
times greater than MEK.
Hurdles Faced
Initially it was a concern that EP-921 would affect the quality of the
painting process. The reclamation of EP-921 and its ability to separate
paint from the solvent in a closed loop system presented initial doubts
about its effectiveness after one or two applications. The unit was used
and tested at several intervals with paint concentration ranging from
10-50 percent to assist in determining the quality of the cleaning agent.
During the initial set-up and testing phases, the loss of productivity
slightly increased. Once the system was in place, the concerns of quality,
maintenance, and productivity loss showed favorable results.
Waste Minimization Results
The economic and environmental benefits derived from the use of EP-921
were extremely favorable. The elimination of MEK has demonstrated cost
savings of nearly $15,000 annually. Hazardous waste generation has decreased
by nearly 60 percent. Additional savings with loss of productivity, training,
waste management, and regulatory compliance generated an additional $30,000
annually. Net savings with the use of EP-921 the first year yielded over
$45,000 with a payback rate of 1.4 years. And, because EP-921 is a safer, healthier, and more environmentally safe product,
management and, most importantly, the associates who work with EP-921 embraced
the substitute of MEK with positive thinking.
Lessons Learned
Continually improving your process so that it leads to a safer, healthier,
and more environmentally friendly workplace is easily achievable. Identifying
your goals, developing a solid plan, and utilizing your resources allows
you to exceed your own expectations. Incorporating your engineering staff
with line workers provides a smoother transition to a new process.