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CGPP Report 2004/16

AT A GLANCE
As part of its involvement in the Cleaner
Greener Production Programme (CGPP), NN
Euroball set out to convert a hazardous
waste stream into a re-usable resource and
to reduce the volume of hazardous
wastewater hauled off site. In order to
achieve this objective, the company installed
a vacuum pump evaporation unit, which was
designed to recycle up to 90% of all
hazardous wastewater generated by
production-related activities at the plant. By
reducing both the volume of water used by
the plant and the volume of hazardous
wastewater, NN Euroball hoped to achieve a
significant improvement in its overall
environmental performance. Based on
analysis of results to date, the project will
continue to yield environmental benefits, in
addition to producing substantial long-term
financial savings for the company.

NN EUROBALL
IRELAND LTD
The NN Euroball plant, which is located in
Kilkenny city, is a European leader in the
production of high-precision steel balls,
which are used in the manufacture of ball
bearings. Precision-steel balls and rollers are
essential moving parts of anti-friction
bearings, which in turn are integral
components of all machinery with moving
parts.
The process of manufacturing high-precision
steel balls involves the cutting of coiled steel
wire into slug-like shapes. These are then
fashioned into spheres, which are heattreated to increase hardness and improve
resistance to wear and tear.

Printed on recycled paper using water based inks

In the final stage of the manufacturing

process, the spheres are refined to create the
requisite roundness, surface lustre and exact
size tolerance specified by NN Euroballs
client companies in the automotive industry.

COMPANY SUCCEEDS IN CONVERTING

A HAZARDOUS WASTE STREAM INTO
A RE-USABLE RESOURCE
AIMS OF THIS PROJECT

PROJECT DESCRIPTION

The principle aim of this Cleaner Greener

Production Programme (CGPP) project was
to convert NN Euroballs hazardous
wastewater stream into a re-usable
resource. In order to achieve this objective,
the company installed a vacuum pump
evaporation unit (see Fig 2), which was
designed to recycle up to 90% of all
hazardous wastewater generated on the site.

The vacuum pump evaporator (E 6000

FF) is operated on the principle that
water boils at a lower temperature i.e.
38-40oC at reduced atmospheric
pressure i.e. 6-7 kPa.

By implementing this combined resourceconservation and waste-management

initiative, NN Euroball hoped to achieve
significant improvements in the overall
environmental performance of its
Kilkenny-based plant.
The team calculated that while the cost of
purchasing new equipment would be high,
this initiative would yield substantial longterm financial savings for the company as
a result of reducing wastewater haul-off
from the plant.
Remarkably, it was estimated that the
payback period for the 162,317
investment in the new vacuum pump
evaporator equipment would be as little as
11 months.

Fig 1. Process Flow diagram

The evaporator produces two streams: a
distillate, which is recycled during the
production process, and a concentrate,
which is removed for treatment and
disposal off site.
The CGPP project team calculated that
in normal manufacturing conditions the
distillation yield from the evaporator
would be about 90%. The solutions
destined for treatment under vacuum
derive from soluble emulsions mixed
with aluminium oxide, floor washings
and wash waters from alkaline
degreasers.

BETTER BUSINESS IN A BETTER IRELAND

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iii) In addition to yielding significant environmental benefits,

this CGPP project will generate substantial financial
savings for NN Euroball from January 2004 onwards.
These savings are expected to amount to at least
162,000 a year.

185000
180000

euro

175000

Fig 2. Vacuum pump evaporator

160000
155000
150000
without evaporator

Figure
180

i)

Wastewater production is expected to decrease by 95%

in 2004, thus creating a significant reduction in
wastewater haul-off and on-site water consumption.

ii) Tests carried out by the CGPP project team confirmed

that the new evaporator has the potential to be adapted
for the processing of other production-related waste
streams at the plant.

haul-off
before
installation

ct
O

estimated
haul-off after
installation

Ju

tonnes

160
140
120
100
80
60
40
20
0

Ja
n

The most significant environmental benefit arising from this

CGPP project was the successful conversion of NN Euroballs
hazardous wastewater stream into a valuable, re-usable
resource.
Other environmental benefits that accrued from this project
were as follows:

with evaporator

Fig 3. Estimated wastewater haul off costs for 2004 with

and without the vacuum pump evaporator

Pre-treatment processes are required for wastewaters

containing large quantities of solids only.

ACHIEVEMENTS

165000

Ap
r

Vacuum pump evaporation technology is energy-efficient,

low-maintenance and easy to operate. This technology
could be readily applied to any industry that produces large
quantities of water-soluble waste containing a minimum
amount of solids. This could include industrial activities such
as electroplating; pharmaceuticals manufacturing;
ink/printing production, and dairy production. It could also
be applied to processes such as landfill leachate management.

170000

Fig 4. Wastewater haul-off before and after Installation of

vacuum pump evaporation.

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MORE INFORMATION

160
140

For more information on this project contact:

tonnes

120

Water
Consumption
2003

100
80

Estimated
Water
Consumption
2004

60
40

Seamus Scully
Manufacturing/Environmental Engineer
NN Euroball Ireland Ltd
Unit 4,
Purcellsinch Industrial Estate
Kilkenny

20

ov

Tel: 056 777 1000

Fax: 056 777 1007

l
ep
S

Ju

Ja

n
M
ar
M
ay

Fig 5. Water consumption before and after installation of

vacuum pump evaporator.

OBSERVATIONS
Prior to the companys involvement in this CGPP project,
one of the Environmental Management Teams long-term
objectives was to achieve a significant reduction in the
volume of hazardous wastewater being sent for treatment
and disposal off site. The funding that NN Euroball received
for this CGPP project initiative has enabled the
Environmental Management Team to achieve its stated
objective in a shorter timescale than would not have been
possible otherwise.
NN Euroballs participation in this CGPP project has greatly
increased awareness of the benefits of cleaner greener
production among the companys employees, shareholders
and customers.

LESSONS
The companys improved environmental performance is
perceived as a valuable marketing tool. This is because,
increasingly, supply-chain pressure in the automotive industry
demands greater environmental performances at all stages in
the life cycle of motor vehicle manufacture.
Cleaner production methods have enhanced NN Euroballs
image among stakeholders in particular among its
employees and investors.
As well as improving environmental performance, cleaner
production can deliver significant cost efficiencies for small
and medium-sized enterprises.

Email: seamuss@nneurope.com
Website: www.nbr.com

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CLEANER GREENER
PRODUCTION IS
the application of integrated preventive environmental
strategies to processes, products, and services to increase
overall efficiency and reduce risks to humans and the
environment.
Production processes: conserving raw materials and
energy, eliminating toxic raw materials, and reducing the
quantity and toxicity of all emissions and wastes
Products: reducing negative impacts along the life cycle
of a product, from raw materials extraction to its
ultimate disposal.
Services: incorporating environmental concerns into
designing and delivering services.

CLEANER GREENER
PRODUCTION REQUIRES
new attitudes, better environmental management, and
evaluating available technology options. We need to take
good environmental practice to the stage where it is an
inherent part of any business operation.

HOW IS CLEANER GREENER

PRODUCTION DIFFERENT?
Much of the current thinking on environmental protection
focuses on what to do with wastes and emissions after they
have been created. The goal of cleaner, greener production
is to avoid generating pollution in the first place.
This means:

Better efficiency
Better business
Better environmental protection
Lower costs
Less waste
Less emissions
Less resource consumption

WHY IS THE CLEANER

GREENER PRODUCTION
PROGRAMME BEING RUN?

The long-term goal is to ensure that cleaner, greener production

becomes the established norm in Ireland. The programme seeks to
promote environmentally friendly business through increased
resource productivity, waste reduction, recovery of materials,
improved efficiency in a product value chain, energy management,
and a change of culture within organisations.
The programme aims are focussed on avoiding and preventing
adverse environmental impact rather than treating or cleaning up
afterwards. This approach brings better economic and
environmental efficiency.

PROGRAMME MANAGERS:
The Clean Technology Centre (CTC) at Cork Institute of
Technology was appointed to manage the programme in
association with OSullivan Public Relations Ltd, and Energy
Transport Actions Ltd, (ENTRAC).
The CTC was established in 1991 and is now nationally and
internationally regarded as a centre of excellence in cleaner
production, environmental management and eco-innovation across
a range of industrial sectors.

WHERE CAN I GET

FURTHER INFORMATION?
This case study report is one of 29 reports
available from the organisations that
participated in the first phase of the Cleaner
Greener Production Programme. A summary
of all the projects and CD containing all the reports
are also available. More information on the Programme
is available from the Environmental Protection Agency
Ms. Helen Walsh,
CGPP,
Environmental Protection Agency,
Richview, Clonskeagh Road, Dublin 14, Ireland.
Tel. 01 2680100
Website

Fax. 01 2680199

www.epa.ie

select link to cleaner production.

Email. ertdi@epa.ie
Printed on recycled paper using water based inks

The Irish Government, through the National Development

Plan 2000 - 2006, has allocated funds to a programme for
Environmental Research, Technological Development and
Innovation (ERTDI).

The Department of the Environment and Local Government asked

the Environmental Protection Agency (EPA) to run the CGPP as
part of the ERTDI programme. With the programme continuing to
2006 about 60 businesses will be supported to implement cleaner
greener production and to demonstrate their achievements to the
rest of Ireland.