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Title: Engineering Analysis of Mixed Waste Thermal Destruction
EPA Project Officer: Dr. C. C. Lee
Project Type: Competitive Contract
Cooperator: EER Corporation
Project Objectives: To develop permit road map for mixed waste treatment processes
Project Status: In the process of developing the 3rd Interagency Agreement
Estimated Completion Date: 4/00

Title: Recycle and Waste Minimization in Ultra-Pure Water Systems
Cooperative Agreement recipient: University of Arizona, Tucson, AZ
EPA Project Officer: Mark Stutsman
Project Type: Cooperative Agreement
Cooperator: University of Arizona at Tucson
Project Objectives:

Background and Statement of Problem
Ultrapure water is the essential fluid used in wafer rinsing during semiconductor manufacturing. Water usage is accelerating at a rapid rate with each generation of new fabrication plants and approaches several million gallons per day in some locations. Therefore, the only practical solution is the treatment of aqueous waste, recovery of water and some chemicals and the implementation of a recycling strategy. At the present time, there is limited recycle in US semiconductor plants. In this respect, the US industry is far behind the Japanese in the development and implementation of recycling technology. The main concerns and risks of recycling are:

  1. The introduction of impurity spikes from uncontrolled discharges of contaminants causing major disturbances in the water quality at the point of use in the manufacturing process.
  2. The buildup and accumulation of recalcitrant organic compounds to relatively high levels caused by recycle of rinse water. This can cause the growth of bacteria and the biofouling of treatment equipment.
  3. Risk of new interactions caused by recycling, for example, the reaction of HF with silica, forming fluoro-silicic acid which promotes silica breakthrough from the ion exchange tanks.

Project Objectives and Approach:

Phase 1 will focus on the recovery and recycling of dilute waste from specific rinse stations accounting for about 80% of the plant's rinse water. Most of the technology required in this phase is available and adequate although not generally used in the industry.

Phase 2 will concern strategies for treatment of nearly all of the rinse water including the 20% not covered in phase 1 because it contains high concentrations of etching chemicals not recycled in phase 1. Implementation of this phase would result in about 70% water recycle in manufacturing.

Phase 3 will include research to reclaim at least 90% of waste water for a typical new plant.
An existing bench-scale unit will be used for the experimental work. This unit handles approximately 10 gallons/minute and simulates closely the Ultrapure purification loop used by the industry. Dilute wastes from rinse stations contain various acids including HF, organic and inorganic alkalis and a range of organic impurities including alcohols, organic acids, surfactants and organic particles like photoresist. During Year 1, a synthetic waste containing the key impurities will be used to simulate a recycle stream. Concentration and composition of the recycle stream will be varied to study the removal of organic and inorganic contaminants to optimize existing methods.

Project Status:

  1. Studies are being performed on the 10 gpm purification loop. The ultrapure water in the loop is being spiked with model compounds to simulate impurities in recycled plant wastewater. These spiking compounds, which are not found in plant inlet water, include chloroform, surfactants and isopropyl alcohol. Each treatment step such as UV oxidation, ion exchange or ozonation is tested individually with one spiking compound. On-line analyzers placed upstream and downstream of the treatment step gather data to determine the efficiency of removal. A titanium-based photo catalyst is being prepared on a filter matrix for use with UV oxidation. Treatment efficiencies will be measured using wavelengths of 185nm and 254nm.
  2. Preliminary work is being done to remove dissolved gases by membranes. This is a new approach which is not currently used in the industry. Using batch equipment which is not part of the test loop, polypropylene membranes are being tested for removing O2 and the CO2 byproduct of oxidation of organics.
  3. A computer model is being prepared which will predict impurity concentrations throughout the loop and efficiencies for each treatment component.
  4. An annual interim report on all activities and results of the first year of work has been prepared and submitted to EPA.

Estimated Completion Date: 9/99

Title: "Physical /Chemical Research Treatment and Control Technology Services Contract"
EPA Project Officer: Dr. George T. Moore
Project Type: Contract
Cooperator: Battelle
Project Objectives: The purpose of this contract is to provide technical support services to the NRMRL in the conduct of research, development, and evaluation. These Services are to advance the state-of-the-art in applying technological systems based on physical and chemical processes to achieving advances in environmental protection technology through improved treatment/control technologies and in place management of contamination. The work will deal with remediating pollution from air, solid media including sludges and sediment, and aqueous media.
The services that are required will be specified through work assignments issued by the CO and technically managed by the PO with assistance from various WAMs.
Project Status: Awaiting award
Estimated Completion Date: Five years from award

Title: Base Catalyzed Dechlorination of Polychlorobiphenyls - New Hydrogen Donors, Transfer Agents/Catalysts
EPA Project Officer: Dr. Fred K. Kawahara/George L. Huffman
Project Type: In-House Research
Cooperator: N/A
Project Objectives: Chemical treatment technologies that are safe, complete and cost-effective are being sought for the destruction of polychlorobiphenyls (PCBs), chlorinated pesticides, pentachlorophenol (PCP), organophosphorus pesticides, nitrated aromatic and other energetic materials (that exist in wastes from explosive production). These wastes pose a health and safety threat even under storage.
Project Status: The use of hydrogen transfer agents and catalysts to improve the base-catalyzed decomposition (BCD) of polychlorinated biphenyls (PCBs) is being investigated. The reaction proceeded only in the presence of base, but the rate of PCB disappearance increased with increasing amount of hydrogen transfer agents and catalysts. Up to 99+% disappearance of 20,000 mg/kg Aroclor 1242 in paraffinic oil was achieved within 1h-4h at 340oC to 350oC. A four-step mechanism is proposed for the formation of biphenyl, the main product: 1) activation of PCBs; 2)hydrogen species generated from the paraffin oil; 3) hydrogenation of aromatic catalysts (phenanthrene, anthracene, and alkyl naphthalenes) to form dihydroaromatics; or adsorption of hydrogen by hexagonal forms of carbon (graphite or carbon black as present in scrap latex) or transition metals (zero-valent iron and stainless steel); 4) transfer of the hydrogen species to the activated PCBs. The product, biphenyl, may be degraded further or form possibly adducts or polymerize. We have written and submitted to a journal a technical manuscript describing the above findings. In addition, we have prepared an employee's report of invention and a disclosure memorandum describing new agents which have reduced the time required for dechlorination and lowered the temperature of reaction for dechlorination at about 100 degrees below the old BCD process of 350oC. Further experimentation involves the firming of the lowering of reaction temperature and seeking other reactions which may improve the decomposition of PCBs.
Estimated Completion Date:

Title: Ceramic Cross flow Filtration (CCF) for Metal Cleaning Solutions Recycling.
EPA Project Officer: David Ferguson
Project Type: Cooperative Agreement
Cooperator: Battelle
Project Objectives: To extend the bath life of metal cleaning solutions using ceramic membranes.
Project Status: Pilot scale testing underway
Estimated Completion Date: 3/00

Title: Marketing Demonstration of the Waste Acid Detoxification and Reclamation (WADR) Recovery Technology in China
EPA Project Officer: David Ferguson
Project Type: IAG
Cooperator: DOE
Project Objectives: To demonstrate the Waste Acid Detoxification and Reclamation (WADR) process in China as part of the Environmental Technology Initiative (ETI).
Project Status: Looking for suitable sites for demonstration.
Estimated Completion Date: 6/00

Title: National Metal Finishing Environmental R&D Plan
EPA Project Officer: David Ferguson
Project Type: Contract
Cooperator: PES
Project Objectives: The National Metal Finishing Environmental R&D Plan (R&D Plan) was developed under the auspices of the Common Sense Initiative (CSI) with the purpose of focusing on the most important environmental-related research needs of the metal finishing industry. This R&D Plan was developed with the input and support of industry, government, and other stakeholders. The CSI Council has six industrial sector subcommittees, including one for the metal finishing industry. This Council, with subcommittees, performs as a Federal Advisory Committee to provide advice and direction to the U.S. Environmental Protection Agency (EPA) Administrator. The Metal Finishing Subcommittee contains seven work groups that were formed to address different environmental issues impacting the metal finishing industry. These seven work groups are:

Project Status: Currently, an update of the plan is underway to incorporate the insights of metal finisher practitioners, experts, and other stakeholders in determining the most current specific needs for the metal finishing sector.
Estimated Completion Date: 6/00

Title: Technology Demo Program: "Approaching Zero Discharge in Metal Plating and Finishing"
Project Officer: David Ferguson
Project Type: IAG
Cooperator: NIST
Project Objectives: The Project is directed at the demonstration of cleaner plating and finishing processes. Zero discharge type technologies will only be considered. By "zero discharge," we mean a technology or group of technologies that have the possibility to reduce or eliminate wastes emitted from a process by greater than 95 percent. The Common Sense Initiative work group on research and technology will be consulted as to the most important technologies to demonstrate.
Project Status: Tested PolyIonix System for zinc metal recovery and waste water reuse. This system combines water soluble, metal binding polymers with ultrafiltration and allows for separation, concentration, and recovery of metal ions. Process worked but was not very cost effective. This portion was completed 12/98. Currently testing a Membrane Electrolysis (ME) process that is expected to reduce sludge volume in hard chromium plating operations by 95% and maintain the bath with reduced labor.
Estimated Completion Date: 10/00

Title: Testing of Picklex™ As A Metal Pretreatment
EPA Project Officer: David Ferguson
Project Type: In-House
Project Objectives: Picklex™™ is a metal surface cleaner/rust converter/inhibitor and metal surface conditioning primer. It has a very low toxicity (advertised as non-toxic) and we are interested in performing further evaluation and testing of the product, as a possible replacement of the hazardous and/or toxic chemicals, presently used for many surface preparation and pre-treatment processes before metal finishing (with no waste disposal).
Project Status: Currently working on a more detailed test plan to evaluate this process further. The economics of the process will also be considered.
Estimated Completion Date: 12/04

Title: Use of Fume Suppressant in Hard Chrome Baths - Part Quality Testing and Emission Testing
EPA Project Officer: David Ferguson
Project Type: In-House
Cooperator: NIST
Project Objectives: This project developed a test protocol to assess and evaluate quality concerns, causes and remedies. The protocol focuses on evaluating a fume suppressant in a hard chrome tank. Various base metals along with varying pre-treatments, current6 densities, and contaminates are investigated to determine if fume suppressants can be used in hard chromium tanks in most applications, without part quality impacts.
Project Status: Further emission testing to meet the MACT Standard is being conducted to determine an acceptable surface tension number for regulatory use. Upon conclusion of this testing, hard chromium platers may be able to report surface tension number much like that of decorative chrome.
Estimated Completion Date: Completed Phase I - 9/99, Phase II at DOD Sites -Estimated Completion 12/01

Title: Sulfate-Reducing Bacteria Demonstration Project
EPA Project Officer: Ivars Licis
Project Type: IAG
Cooperator: Department of Energy, Montana Tech, MSE Inc.
Project Objectives: The goal of this project is to demonstrate that the Sulfate Reducing Bacteria ( SRB ) technology can be utilized to slow or reverse the process of acid generation and improve water quality at Acid Mine Drainage ( AMD ) sites.
Project Status: Phase I ( Pilot-scale testing ) was completed at the Western Environmental Technology Office of DOE in Butte, Montana. Phase II ( Field Demonstration ) began in August 1994 at the Lilly / Orphan Boy mine and is in progress.
Estimated Completion Date: 3/02.

Title: Green Technologies for Metal Cutting Processes
EPA Project Officer: Dave Ferguson
Project Type: Research Grant and IN-House Interagency Agreement Contract
Performing Organization: Institute for Advanced Manufacturing Sciences
Project Objectives: This project is a unique initiative to use those criteria created by industry to establish best practices for pollution prevention in the use of metal working fluids. The criteria will be applied against existing metal working fluids and options (including "dry"machining using no fluids) for which there is a known market demand and availability. The criteria will include life-cycle costing, performance, regulatory requirements, and comparative risk. The objective is to prevent pollution before it is created by facilitating industry's use of cleaner practices for using metal cutting fluids. The approach identifies issues that now impact waste generation and costs associated with metal cutting fluids. Information and processes will be developed that will identify more effective usage. In the short term, the project will permit manufacturers to minimize waste generation through more efficient implementation of current technology. In the long term, a stimulus is set to provide to metal cutting fluid manufacturers a process to develop materials with greater availability that are less expensive, generate less waste and are less harmful to the environment.
Project Status:
Estimated Completion Date: 3/00

Title: Federal Facilities Pollution Prevention Research Support
EPA Project Officer: Dr. George Moore
Project Type: Contract
Cooperator: SAIC
Project Objectives: To provide Federal Facilities (including Tribal Indian Facilities and others with research development/demonstration/evaluation of Pollution Prevention Technologies.
Project Status: On-going
Estimated Completion Date: 9/01

Title: Berkeley Pit Water Characterization
EPA Project Officer: George Huffman
Project Type: IAG
Cooperator: DOE
Project Objectives: To characterize the quality of the Berkeley Pit waters.
Project Status: Final report being peer reviewed
Estimated Completion Date: 12/00

Title: Sludge Stabilization
EPA Project Officer: George Huffman
Project Type: IAG
Cooperator: DOE
Project Objectives: Evaluate long term stability of sludges resulting from neutralization of Berkeley Pit water.
Project Status: Three years of monitoring completed.
Estimated Completion Date: 3/00

Title: Removal of Arsenic as Storable Stable Precipitates
EPA Project Officer: George Huffman
Project Type: IAG
Cooperator: DOE
Project Objectives: To evaluate the removal of arsenic as a phosphoapatite as a replacement for the ferrihydrite arsenic removal process.
Project Status: Lab work underway. Apatite forms have been successfully identified.
Estimated Completion Date: 3/00

Title: Berkeley Pit Innovative Technologies Project
EPA Project Officer: George Huffman
Project Type: IAG
Cooperator: DOE
Project Objectives: To evaluate innovative ideas and to conduct bench scale feasibility of selected concepts for the recovery of metal values from pit water.
Project Status: Proposals evaluated, selection of technologies completed, bench testing is underway.
Estimated Completion Date: 3/00

Title: Environmental Verification Projects
EPA Project Officer: Norma M. Lewis
Project Type: Cooperative Agreement
Cooperator: Civil Engineering Research Foundation
Project Objectives: To verify the environmental performance characteristics of commercial-ready technologies through the evaluation of a third party.
Project Status: EvTEC is moving forward creating an extensive network of stakeholders for environmental technologies and has initiated several Memorandums of Understanding. These entail partnerships with States, Government Agencies, and International Countries. Currently, EvTEC has approximately 10 technologies within the pilot for evaluation.
Estimated Completion Date: October 6, 2001

Title: Pollution Prevention and Waste Treatment Technologies
EPA Project Officer: Norma M. Lewis
Project Type: Cooperative Agreement
Cooperator: California Dept. of Toxic Substances CAL/EPA
Project Objectives: To verify the environmental performance characteristics of commercial-ready technologies through the evaluation of a third party.
Project Status: Two technology projects have been completed along with two reports and verification statements. These have been published. Five projects are currently being evaluated. One is going through final review and will soon be completed for another verification report and statement.
Estimated Completion Date: September 30, 2000

Title: Environmental Technology Verification for Metal Finishing (ETV-MF)
EPA Project Officer: Alva E. Daniels
Cooperator: Concurrent Technologies Corporation (CTC)
Project Objectives: The goal of the ETV-MF (one of EPA/ETV 12 pilots currently operating) is to verify the performance characteristics of metal finishing pollution prevention technologies in commercial use through third-party testing under actual operating conditions in metal finishing shops nationwide.
Project Status: Active
Estimated Completion Date: September, 2003

Title: PARIS II, Program for Assisting the Replacement of Industrial Solvents, Version 2
EPA Project Officer: Paul Harten
Project Type: Cooperative Agreement
Cooperator: Technical Database Services, Inc.
Project Objectives: The objective of the PARIS II software project is to promote and oversee the commercialization of PARIS II software. This includes answering technical questions about PARIS II, and correcting technical problems found. A second project objective is to prioritize and carry-out upgrades to the PARIS II software. This software assists users in finding replacements for a solvent which has hazardous environmental properties. If possible, this is done by finding a less hazardous solvent or a mixture of less hazardous solvents which mimic the physical and chemical properties of the initial solvent to be replaced.
Project Status: PARIS II is now being commercialized by T.D.S., Inc.
Estimated Completion Date: 4/2002

Title: MFFRST II, Metal Finishing Facility Risk Screening Tool, Version 2
EPA Project Officer: Paul Harten
Project Type: In-House
Cooperator: n/a
Project Objectives: The objective of MFFRST II is to expand on the risk screening capabilities of MFFRST, MFFRST considers only the health risk of air pollutants from the electroplating vats on the workers and nearby residents. MFFRST II will be expanded to consider health risks of water pollutants from the same electroplating vats. Some of this translates to considering environmental degradations to the affected waters and soils. Those most influenced by these pollutants are the workers and the facility's downstream neighbors.
Project Status: MFFRST II is in the design stage.
Estimated Completion Date: 10/2003

Title: PARIS III, Program for Assisting the Replacement of Industrial Solvents, Version 3
EPA Project Officer: Paul Harten
Project Type: In-House
Cooperator:
Project Objectives: PARIS III software has a similar mission as PARIS II software, that is to assist users in finding replacements for a solvent which has hazardous environmental properties. PARIS III software uses the Dipper database of chemical solvents used by PARIS II, and also a database of solvents designed from the initial solvent. This database of solvents designed from the initial solvent to be replaced is enabled through the University of Denmark's ability to generate molecules by structure.
Project Status: PARIS III is currently in the design stage
Estimated Completion Date: 04/2004

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