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20 fewer trucks go to the hazardous waste landfill thanks to the work of Prahlad Krishna
Fly ash transportation and disposal costs were rising at the Energy Resources waste wood plant in Stockton, California. A closer look indicated a $158,000 monthly gap between targeted and actual disposal costs. Prahlad Krishna, CI Engineer, and his team were tasked with eliminating this gap.
Using an A3, the team broke down the problem and discovered there was no process in place to control the pH level of the fly ash. A pH of more than 12.44 is considered hazardous waste and many of the fly ash loads exceeded that level, thus requiring more costly transportation and disposal.
Through numerous rapid experiments, the team adjusted the application of calcium chloride to the fly ash to reduce its pH level. A new in-house pH testing protocol was designed and implemented to monitor and maintain pH levels below 12.44. This work eliminated the routing of at least 20 trucks to hazardous waste landfills and saves the plant $105,098 in monthly disposal costs.
Learnings from the experimentation and design criteria for Calcium Chloride treatment was shared with Stockton's sister plant in Woodland.
See the full A3 here.