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France - 2005
Process Changes Result in 85% Reduction in Water Usage, Discharge
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Through the installation of closed-loop rinsing and cooling circuits, Alcoa Fastening Systems’ Saint Cosme facility in France has achieved an 85% water consumption and discharge reduction and saved approximately US$40,000 annually in operating costs.
Saint Cosme specializes in the manufacture of nuts, with newly formed parts sitting in a salt bath for hardening purposes. Following the salt-water treatment, the nuts are rinsed with water. Historically, the rinse water was discharged to a nearby creek. Today, this water goes to an evaporator, where the salt is recovered for reuse in the salt-water bath. The now salt-free water is then reused in the rinsing process.
The location also installed a closed-loop system for cooling its furnaces. While the cooling water was previously discharged once its temperature climbed, Saint Cosme today sends that circulated water to a refrigeration unit. Once sufficiently chilled, the water is pumped back to the furnaces.
The two changes have resulted in the facility eliminating the consumption and discharge of approximately 180,000 cubic meters (47 million gallons) of water and 14 tons of salt annually.
“This process change demonstrates that a solution to a technical problem is possible when management makes the commitment and when sufficient resources are made available,” said Alain Verlhac, an engineer with the Loire-Bretagne Water Agency.
The changes have had a positive effect on the local community. Previously, the facility used 40% of the local well water, which was at its maximum capacity. Once the closed-loop systems were implemented, the community had more water available and higher water pressure in the network.
In 2005, the project received an Alcoa EHS Achievement Award.
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