EPA 440/l-76/060h
 Group II
   Development Document for Interim
 Final Effluent Limitatjons^Guidelines
 and Proposed New Source Performance
            Standards for the
      Carbon Black Manufacturing
         Point Source Category
                       \
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY

                APRIL 1976

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             DEVELOPMENT DOCUMENT
                     for
                INTERIM FINAL
       EFFLUENT LIMITATIONS, GUIDELINES
AND PROPOSED NEW SOURCE PERFORMANCE STANDARDS

                   for the

          CARBON BLACK MANUFACTURING
            POINT SOURCE CATEGORY
               Russell E. Train
                Administrator

         Andrew W. Breidenbach, Ph.D.
           Assistant Administrator
      for Water and Hazardous Materials

               Eckardt C. Beck
      Deputy Assistant Administrator for
         Water Planning and Standards
                          \

             Ernst P. Hall, P.E.
Acting Director, Effluent Guidelines Division
              Joseph S. Vitalis
               Project Officer
                     and
               George M. Jett
          Assistant Project Officer
                  April 1976

         Effluent Guidelines Division
   Office of Water and Hazardous Materials
     U.S. Environmental Protection Agency
           Washington, D.C.  20460

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                          ABSTRACT
This document presents the findings of a study of the carbon
black manufacturing point source category for the purpose of
developing effluent limitations and guidelines for  existing
point  sources  and  standards  of performance for new point
sources and pretreatment  standards  for  new  and  existing
point sources, to implement Sections 301 (b), 301 (c) r 304 (b) ,
304 (c) ,  306 (b),  306 (c),  and  307 (b)  of the Federal Water
Pollution Control Act, as-amended  (33  U.S.C.   1251,  1331,
1314,  and  1316,  86  Stat.  816 et. seq., P.L. 92-500  (the
"Act").

Effluent limitations and  guidelines  contained  herein  set
forth  the  degree  of effluent reduction attainable through
the application of the Best Practicable  Control  Technology
Currently  Available   (BPCTCA)  and  the  degree of effluent
reduction attainable through the  application  of  the  Best
Available  Technology  Economically Achievable  (BATEA) which
must be achieved by existing point sources by July 1,  1977,
and  July  1,  1983,  respectively.   The  standards of per-
formance and pretreatment standards  for  existing  and  new
sources,  contained  herein  set forth the degree of effluent
reduction which is achievable through the application of the
Best  Available  Demonstrated  Control  Technology  (BADCT) ,
processes, operating methods, or other alternatives.

The development of data and recommendations in this document
relate  to  the  carbon  black  manufacturing  point  source
category which is one of eight industrial  segments  of  the
miscellaneous   chemicals   point   source  category  study.
Effluent limitations were developed for each subcategory  on
the  basis  of the level of raw waste load as well as on the
degree of treatment achievable.  Appropriate  technology  to
achieve  these  limitations include systems for  reduction in
pollutant loads by in-plant technology.

Supporting  data  and  rationale  for  development  of   the
proposed  effluent  limitations, guidelines and  standards of
performance are contained in this report.
                                  111

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                     TABLE OF CONTENTS


Section                -     Title                    Page

         Abstract

         Table of Contents

         List of Figures

         List of Tables

   I     Conclusions                                    1

  II     Recommendations                                5

 III     Introduction                                   9

  IV     Industrial Categorization                     21

   V     Waste Characterization                        47

  VI     Selection of Pollutant Parameters             51

 VII     Control and Treatment Technologies            61

VIII     Cost, Energy, and Non-water Quality
         Aspects                                       67

  IX     Best Practicable Control Technology
         Currently Available (BPT)                     75

   X     Best Available Technology Economically
         Achievable  (BAT)                              79

  XI     New Source Performance Standards (NSPS)        81

 XII     Pretreatment Standards                        83

XIII     Performance Factors for Treatment Plant
         Operations                                    85

 XIV     Acknowledgements                              87

  XV     Bibliography                                  91

 XVI     Glossary                                     103

XVII     Abbreviations and Symbols                    121

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                      LIST OF FIGURES


Number                   Title                        Page

III-1         U.S. Carbon Black Production by Process   20

IV-1          Carbon Black Bag Filter System            30

IV-2          Bag Filter Cleaning Process               31

IV-3          Bag Filter Operation                      32

IV-4          Process Flow Sheet - Furnace Black
              Process                                   36

IV-5          Simplified Flow Sheet - Thermal
              Black Process                             38

IV-6          Process Flow Sheet - Channel
              Black Process                             42

IV-7          Process Flow Sheet - Lamp
              Black Process                             .42

IV-8          Block Diagram for No Discharge of
              Process Wastewater Pollutants System      45

VIII-1        In-Plant Recycle Cost Model-Step No. 1    70

VIII-2        In-Plant Recycle Cost Model-Step No. 2    71

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                       LIST OF TABLES
Number


1-1.

II- 1

1 1- 2
III- 2

IV- 1

IV- 2

V-11

VI- 1

VII- 1

VII- 2


VIII- 1



VII I- 2



IX- 1

X-1

XI- 1

XVIII
           Title                        Page


Summary Table                              H

BPCTCA Effluent Limitations Guidelines     6

BATEA and BADCT Effluent Limitations
Guidelines                                 7

Domestic Sales of Carbon Black in the
United States By Use                      17

Carbon Black Grades Manufactured          18

Carbon Black Segment Plant Key            23

Plant Key Summary                         26

Raw Waste Loads                           47

List of Parameters To Be Examined  . .      52

Treatment Technology Survey               63

Wastewater Treatment Plant Performance
Data Carbon Black Segment                 65

Wastewater Treatment Costs for BPCTCA,
BADCT, and BATEA Effluent Limitations
for Furnace Black Process                 73

Wastewater Treatment Costs for BPCTCA,
BADCT and BATEA Effluent Limitations
for Thermal Black Process                 74

BPCTCA Effluent Limitations Guidelines    77

BATEA EFfluent Limitations Guidelines     80

BADCT Effluent Limitations Guidelines     82

Metric Table                             125
                               IX

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                         SECTION I

                        CONCLUSIONS
General

The   miscellaneous   chemicals   point   source    category
encompasses  eight  industrial segments grouped together for
administrative purposes.  This document provides  background
information  for  carbon  black  manufacturing  point source
category and represents a  revision  of  a  portion  of  the
initial  contractor's  draft  document  issued  in February,
1975.

In that document it was pointed out that  the  carbon  black
manufacturing  point source category differs from the others
in  raw  materials,  manufacturing  processes,   and   final
products.   Water usage and subsequent wastewater discharges
also   vary   considerably   from   segment   to    segment.
Consequently,  for  the  purpose  of  the development of the
effluent limitations, guidelines and corresponding BPT (Best
Practicable Control Technology  Currently  Available),  NSPS
(Best  Available  Demonstrated  Control  Technology) for new
sources, and BAT   (Best  Available  Technology  Economically
Achievable)    requirements,   each   segment   is   treated
independently.

The carbon black  manufacturing  point  source  category  is
defined  to  include  those  commodities  listed  under  the
Standard Industrial Classification  (SIC) 2895.  Thermal  and
lamp  black  have been included for completeness of coverage
of the carbon black manufacturing processes.  It  should  be
emphasized that the proposed treatment model technology will
be  used only as a guideline.  The cost models for BPT, BAT,
and NSPS were developed to facilitate the economic  analysis
and  should  not be construed as the only technology capable
of  meeting  the  effluent .  limitations,   guidelines   and
stcindards  of  performance  presented  in  this  development
document.,  There are alternative systems which, taken either
singly or in  combination,  are  capable  of  attaining  the
effluent    limitations,   guidelines   and   standards   of
performance recommended in this development document.  These
alternative choices include:

    1.   Various types of end-of-pipe wastewater treatment.
    2.   Various in-plant.modifications and installation  of
         at-source pollution control equipment.
    3,   Various combinations of  end-of-pipe  and  in-plant
         technologies.

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It is the intent of this document to identify the technology
that  can be used to meet the regulations.  This information
also will allow the individual plant to make the  choice  of
what  specific  combination of pollution control measures is
best  suited  to  its  situation  in  complying   with   the
limitations  and  standards of performance presented in this
development document  for  the  carbon  black  point  source
category.

Carbon Black

For   the   purpose   of   developing  recommended  effluent
limitations, guidelines and new source performance standards
for carbon black manufacture, this point source category has
been subcategorized by process as follows:

    A.   Furnace Process
    B,   Thermal Process Including Acetylene Black
    C,   Channel Process
    D.   Lamp Process

The   criteria   used    for    establishing    the    above
subcategorization  included  the  impact  of  the  following
factors on the above groupings:

    1,   Production processes.
    2.   Product types and yields.
    3,   Raw material sources.
    4.   Wastewater quantities, characteristics, control
         and treatment.

The wastewater parameters of significance in the manufacture
of carbon black are total suspended solids, total  dissolved
solids and pH.

Based  on  an EPA survey of the entire carbon black segment,
discussed in Section IV, Industrial Categorization,  it  was
concluded  that complete elimination of discharge of process
wastewater pollutants is achievable for all subcategories of
the carbon black point source category for BPT, BAT and NSPS
effluent limitations, guidelines and new source  performance
standards, (see Tables IV-1 and IV-2).

Based  on the findings of this survey, approximately twenty-
nine  furnace  black  and  four  thermal  black  plants  are
operating  in  the  United  States.  There are also two lamp
black plants and one  channel  black  plant  operating.   Of
these  thirty-six plants surveyed, twenty-four have achieved
no  discharge  of  process  wastewater  pollutants.    These
include  nineteen  furnaces,  three  thermal,  including one

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acetylene black plant, one channel and one lamp black plant.
The thermal and furnace processes that have achieved the  no
discharge  level  manufacture  a  full range of carbon black
grades and  are  found  in  both  water  surplus  and  water
deficient  areas.   The channel black plant is located in an
arid area.  The lamp black plants surveyed  are  located  in
waiter surplus areas.  It is concluded that all subcategories
in  the  carbon black manufacturing should have no discharge
of process wastewater pollutants allowed.   The  summary  of
the   effluent   limitations,   guidelines  and  new  source
performance standards are presented in Table 1-1.

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Subcategories

Subcategpry A
Furnace Black
Subcategory B
Thermal Black
Subcategory C
Channel Black
Subcategory D
Lamp Black



Subcategory A
Furnace Black
Subcategory B
Thermal Black
Subcategory C
Channel Black
Subcategory D
Lamp Black


Contaminants
of Interest

N/A2

N/A2

N/A2

N/A2




N/A2

N/A2

N/A2

N/A2



Flow
L/kkg Product
(gal/1,000 Ibs.)
N/A2

N/A2

N/A2

N/A2


Treatment
Technology
In-plant .

in-plant

in-plant

in-plant

*M)le 1 -1
Sumnary Table

Raw Waste Loads (RWL)
Parameter kg/kkg1 rag/L

No Discharge of PWWP3

No Discharge of PWWP3

No Discharge of PWWP3

No Discharge of PWWP3

BATEA (1983)
Long-Term Average Daily Effluent
Parameter kg/kkg-1- mg/L
No Discharge of PWWP^

No Discharge of PWWP3

No Discharge of PWWP

No Discharge of PWWP



Treatment
.Technology

in-plant

in-plant

. in-plant

in-plant

New Source
Treatment
Technology
in-plant

in-plant

in-plant

in-plant


BPCTCA (1977)
Long-Term Average Daily Effluent
Parameter kg/kkg^- mg/L
• ,
No Discharge of PWWP

No Discharge of PWWP3

No Discharge of PWWP3

No Discharge of PWWP3

Performance Standard 
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                         SECTION II

                      RECOMM ENDATIONS
General

The recommendation for effluent limitations  and  guidelines
commensurate  with  the  BPT,  BAT and NSPS for carbon black
manufacturing are presented in the following text.  Included
are the in-plant controls technology required to achieve the
recommended effluent limitations guidelines.

Carbon Black

Implicit  in  the  recommended  effluent   limitations   and
guidelines  for carbon black manufacturing is the assumption
that process wastes  can  be  isolated  from  uncontaminated
wastes  such  as utility discharges and uncontaminated storm
runoff,  isolation of process wastewater  is  generally  the
first  recommended  step  in  accomplishing  the  reductions
necessary to meet  the  proposed  effluent  limitations  and
guidelines.   Treatment  of  uncontaminated wastewaters in a
treatment facility is not generally cost-effective.  This is
generally not a problem in the carbon black manufacture.

Effluent limitations guidelines commensurate  with  BPT  are
presented for each subcategory of carbon black manufacturing
point  source  category  in Table II-1.  Process wastewaters
subject to these limitations  include  all  contact  process
water  but  do not include noncontact sources such as boiler
and cooling  water  blowdown,  sanitary  and  other  similar
flows,  such as shower and laundry wastewater.  BPT includes
the maximum utilization  of  applicable  in-plant  pollution
abatement technology to achieve the effluent limitations,and
guidelines.  Equipment washout will be considered as process
wastewater.   It  was  found  in  the  EPA  survey  that the
equipment washout along with process area wash  water  could
effectively  be  recycled  as  quench  water for the furnace
black and thermal black processes, resulting in no discharge
of process wastewater.  As a result of  the  survey  of  the
entire  point  source  category  and  based  on the in-plant
changes achievable as demonstrated  in  Section  IV,  it  is
recommended   that   all   subcategories   in  carbon  black
manufacturing   point   source   category   have    effluent
limitations, guidelines and new source performance standards
set  at  "no discharge of process wastewater pollutants" for
BPT, NSPS  and  BAT.   NSPS  and  BAT  effluent  limitations
guidelines are presented in Table II-2.

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                                                 TABLE H  -1

                                   BPCTCA Effluent Limitations Guidelines
Subcategory
   Effluent
Characteristic
                                                                           Effluent Limitations
Average of Daily Values
for 30 Consecutive Days
   Shall not Exceed
                                                           kg/kkg-1
                                                 mg/L
                                                                                               Maximum for
                                                                                               Any One Day
                                                                                             kg/kkgmg/L
A (Furnace Black)


B (Thermal Black)


C (Channel Black)


D (Lamp Black)
                                  N/A


                                  N/A2


                                  N/A2
                                   No Discharge
                                     of pwwp3

                                   No Discharge
                                     of pwwp3

                                   No Discharge
                                     of pwwp3

                                   No Discharge
                                     of pwwp3
                                    No Discharge
                                      of pwwp3

                                    No Discharge
                                      of pwwp3

                                    No Discharge
                                      of pwwp3

                                    No Discharge
                                      of pwwp->
                         Productions is equivalent to lbs/1,000 Ibs Production.
                  N/A = Not Applicable                               '
                 3pwwp = Process Wastewater Pollutants
                                                                      4/30/76

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                                          Table 11-2
                         BATEA AND BADCT Effluent Limitations Guidelines
Subcategory
           Effluent
         Characteristic
                                                                         Effluent Limitations
Average of Daily Values
for 30 Consecutive Days
   shall not Exceed
kg/kkg1            mg/L
                                 Maximum for
                                 Any_0ne Day
                                            mg/L
     A

     B

     C

     D
               NA
               NA
               NA
               NAC
No Discharge -of PWWP"

No Discharge of PWWP:

No Discharge of PWWP:

No Discharge,of
                               No Discharge of PWWP"

                               No Discharge of PWWP:

                               No Discharge of PWWP:

                               No Discharge of PWWP:
okg/kkg productions is equivalent to lbs./l,000 Ibs. production
    = Not Applicable            ,  :                           .
      = Process Wastewater Pollutants
                                                                                                    4/30/76

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                        SECTION III

                        INTRODUCTION
Purpose and Authority

The  Federal  Water Pollution Control Act Amendments of 1972
(the Act)  made  a  number  of  fundamental  changes  in  the
approach   to  achieving  clean  water.   One  of  the  most
significant changes was to shift from a reliance on effluent
limitations  to  water  quality  to  a  direct  control   of
effluents  through  the  establishment  of  technology-based
effluent limitations to  form  an  additional  basis,  as  a
minimum, for issuance of discharge permits.

The Act requires EPA to establish guidelines for technology-
based  effluent  limitations which must be achieved by point
sources of discharges  into  the  navigable  waters  of  the
United  States,   Section  301(b)  of ,the  Act requires the
achievement by not later  than  July  1,  1977  of  effluent
limitations  for  point  sources,  other than publicly owned
treatment works, which are based on the application  of  the
BPT  as  defined  by  the  Administrator pursuant to Section
304(b)   of  the  Act.   Section  301 (b)  also  requires  the
achievement  by  not  later  than  July  1, 1983 of effluent
limitations for point sources,  other  than  publicly  owned
treatment  works,  which are based on the application of the
BAT, resulting in  progress  toward  the  national  goal  of
eliminating  the  discharge of all pollutants, as determined
in accordance with regulations issued by  the  Administrator
pursuant  to  Section 304 (b) of the Act.  Section 306 of the
Act requires the  achievement  by  new  sources  of  federal
standards  of  performance  providing for the control of the
discharge of pollutants, which reflects the greatest  degree
of  effluent reduction which the Administrator determines to
be achievable through the application of the  NSPS  process,
operating  methods,  or other alternatives, including, where
practicable,  a  standard   permitting   no   discharge   of
pollutants.

Section  304(b)  of  the  Act  requires the Administrator to
publish  regulations  based  on  the  degree   of   effluent
reduction  attainable through the application of the BPT and
the  best  control  measures   and   practices   achievable,
including   treatment   techniques,  process  and  procedure
innovations, operation methods, and other alternatives.  The
regulations proposed herein set forth  effluent  limitations
and guidelines pursuant to Section 304(b) of the Act for the
carbon  black  point source category.  Section 304(c) of the

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Act requires the Administrator to issue information  on  the
processes,  procedures, or operating methods which result in
the elimination or reduction in the discharge of  pollutants
to  implement  standards of performance under Section 306 of
the Act.  Such information is to include technical and other
data, including  costs,  as  are  available  on  alternative
methods  of  elimination  or  reduction  of the discharge of
pollutants.

Section 306 of the Act requires  the  Administrator,  within
one  year  after a category of sources is included in a list
published pursuant to Section 306(b) (1) (A) of the Act,  to
propose   regulations   establishing  federal  standards  of
performance for new sources  within  such  categories.   The
Administrator  published  in the Federal Register of January
16, 1973  (38 FR  1624)  a  list  of  27  source  categories.
Publication  of  the  list  constituted  announcement of the
Administrator's intention  of  establishing,  under  Section
306, standards of performance applicable to new sources.

Furthermore, Section 307 (b) provides that:

    1.   The Administrator shall, from time to time, publish
         proposed  regulations   establishing   pretreatment
         standards   for  introduction  of  pollutants  into
         treatment works  (as defined in Section 212 of  this
         Act) which are publicly owned, for those pollutants
         which  are  determined  not  to  be  susceptible to
         treatment by such treatment works  or  which  would
         interfere  with  the  operation  of  such treatment
         works.  Not  later  than  ninety  days  after  such
         publication, and after opportunity for public hear-
         ing,   the   Administrator  shall  promulgate  such
         pretreatment  standards.   Pretreatment   standards
         under  this  subsection  shall  .specify  a time for
         compliance not to exceed three years from the  date
         of promulgation and shall be established to prevent
         the  discharge  of  any pollutant through treatment
         works  (as defined in Section 212 of this Act) which
         are  publicly  owned,  which  pollutant  interferes
         with,  passes through, or otherwise is incompatible
         with such works.

    2.   The Administrator shall,  from  time  to  time,  as
         control  technology,  processes, operating methods,
         or   other   alternatives   change,   revise   such
         standards,  following  the procedure established by
         this subsection for promulgation of such standards.
                                  10

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    3.   When proposing  or  promulgating  any  pretreatment
         standard  under  this  section,  the  Administrator
         shall  designate  the  category  or  categories  of
         sources to which such standard shall apply.

    4.    Nothing   in  this  subsection  shall  affect  any
         pretreatment requirement established by  any  State
         or  local law not in conflict with any pretreatment
         standard established under this subsection.

In order to insure that any  source  introducing  pollutants
into  a publicly owned treatment works, which would be a new
source subject to  Section  306  if  it  were  to  discharge
pollutants,  will  not  cause  a  violation  of the effluent
limitations established for any such  treatment  works,  the
Administrator   is   required   to  promulgate  pretreatment
standards for the category of  such  sources  simultaneously
with  the  promulgation  of  standards  of performance under
Section 306 for the  equivalent  category  of  new  sources.
Such pretreatment standards shall prevent the discharge into
such  treatment  works  of any pollutant which may interfere
with, pass through, or otherwise be incompatible  with  such
works.

The  Act  defines  a  new  source  to  mean  any  source the
construction of which is commenced after the publication  of
proposed  regulations prescribing a standard of performance.
Construction means any placement, assembly, or  installation
of  facilities  or  equipment (including contractual obliga-
tions to purchase  such  facilities  or  equipment)   at  the
premises  where  such  equipment  .will  be  used,  including
preparation work at such premises.

Methods Used for Development of the Effluent Limitations and
Standards for Performance

The  effluent  limitations,  guidelines  and  standards   of
performance  proposed in this document were developed in the
following manner.  The miscellaneous chemicals point  source
category  was  first divided into industrial segments, based
on  type  of  manufacturing   and   products   manufactured.
Determination   was   then   made   as  to  whether  further
subcategorization would aid in description of the  category.
Such  determinations were made on the basis of raw materials
required, products  manufactured,  processes  employed,  and
other factors.

The  raw  waste  characteristics  for  each  category and/or
subcategory were then identified.  This included an analysis
of:  1) the source and volume of water used in  the  process
                                 11

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employed  and  the  sources of wastes and wastewaters in the
plant;   and  2)  the  constituents   of   all   wastewaters
(including  toxic constituents) which result in taster odor,
and color in water or aquatic organisms.   The  constituents
of   wastewaters   which   should  be  subject  to  effluent
limitations, guidelines and standards  of  performance  were
identified.

The   full  range  of  control  and  treatment  technologies
existing  within  each  category  and/or   subcategory   was
identified.   This  included  an identification of each dis-
tinct control and treatment technology, including  both  in-
plant  and  end- of-pipe technologies, which are existent or
capable of being designed for  each  subcategory.   It  also
included  an  identification of the effluent level resulting
from the application of each of the  treatment  and  control
technologies,  in terms of the amount of constituents and of
the chemical, physical, and  biological  characteristics  of
pollutants.   The  problems, limitations, and reliability of
each treatment  and  control  technology  and  the  required
implementation  time were also identified.  In addition, the
non-water quality environmental impacts (such as the effects
of the application of such technologies upon other pollution
problems, including air, solid waste, radiation, and  noise)
were  also  identified.   The energy requirements of each of
the control and treatment technologies were  identified,  as
well as the cost of the application of such technologies.

The  information,  as  outlined above, was then evaluated in
order to determine what levels of technology constituted the
BPT, BAT,  and  NSPS.   In  identifying  such  technologies,
factors considered included the total cost of application of
technology in relation to the effluent reduction benefits to
be  achieved from such application, the age of equipment and
facilities involved, the process employed,  the  engineering
aspects  of  the  application  of  various  types of control
techniques, process changes, non-water quality environmental
impact  (including energy requirements), and other factors.

During the initial phases of the study,  an  assessment  was
made  of  the  availability, adequacy, and usefulness of all
existing data sources.  Data on the identity and performance
of wastewater treatment systems were known  to  be  included
in:

     1,  NPDES permit applications,

     2.  Self-reporting discharge data from various states.

     3.  Surveys conducted by trade associations or by
                                  12

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  ;        agencies under research and development grants.

A  preliminary  analysis  of these data indicated an obvious
need for additional information.

Additional data in the following areas  were  required:   1)
process  raw  waste  load   (RWL)  related  to production; 2)
currently practiced or potential  in-process  waste  control
techniques; and 3) the identity and effectiveness of end-of-
pipe  treatment systems.  The best source of information was
the manufacturers themselves.  New information was  obtained
from  telephone  surveys,  direct  interviews  and  sampling
visits to production facilities.    -

Collection of the data necessary for development of RWL  ana
effluent treatment capabilities within dependable confidence
limits  required  analysis  of both production and treatment
operations.  In a few cases, the plant visits  were  planned
so that the production operations of a single plant could be
studied  in association with an end-of-pipe treatment system
which receives only the wastes from  that  production.   The
RWL for this plant and associated treatment technology would
fall within a single subcategory.  However, the wide variety
of  products  manufactured  by most of the industrial plants
made this situation rare.

In  the  majority  of  cases,  it  was  necessary  to  visit
facilities where the products manufactured fell into several
subcategories.    The   end-of-pipe   treatment   facilities
received  combined  wastewaters  associated   with   several
subcategories   (several   products,   processes,   or  even
unrelated manufacturing operations).  It  was  necessary  to
analyze   separately   the   production    (waste-generating)
facilities and the effluent  (waste  treatment)   facilities.
This  approach required establishment of a common basis, the
raw  waste  load  (RWL),  for  common  levels  of  treatment
technology for the products within a subcategory and for the
translation   of  treatment  technology  between  categories
and/or subcategories.

The selection of wastewater treatment plants  was  developed
from  identifying  information available in the NPDES permit
applications,  state  self-reporting  discharge  data,   and
contacts within the point source category.  Every effort was
made  to  choose  facilities where meaningful information on
both treatment facilities and manufacturing processes  could
fce obtained.

Survey  teams  composed  of project engineers and scientists
conducted the  actual  plant  visits.   Information  on  the
                                  13

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identity and performance of wastewater treatment systems was
obtained through:

    1.   Interviews  with  plant  water  pollution.   control
         personnel and/or engineering personnel.

    2.   Examination   of   treatment   plant   design « .and
         historical  operating data  (flow rates and analyses
         of influent and effluent).

    3.   Treatment plant influent and effluent sampling.

Information on process plant operations and  the  associated
RWL was obtained through:

    1.   Interviews with plant operating personnel.

    2.   Examination of  plant  design  and  operating  data
         (design   specification,  flow  sheets,  day-to-day
         material balances around individual process modules
         or unit operations where possible).

    3.   Individual   process   wastewater   sampling    and
         analysis.

    4.   Historical  production  and  wastewater   treatment
         data.

The  data  base obtained in this manner was then utilized by
the methodology previously described to develop  recommended
effluent    limitations,   guidelines   and   standards   of
performance for the  carbon  black  point  source  category.
References  utilized  are  included  in  Section,, XV of this
report.  The data obtained during the field data  collection
program  are  included in Supplement B.  cost information is
presented in Supplement A.  These  documents  are  available
for  examination  by  interested  parties  at the EPA Public
Information  Reference  Unit,  Room  2922   (EPA   Library),
Waterside Mall, 401 M St. S.W., Washington, D.C.  20460.

The  following  text  describes  the  scope  of  the  study,
technical  approach   to   the   development   of   effluent
limitations  guidelines,  and  the  scope of coverage of the
data base for the manufacture of carbon black.

Carbon Black

    Scope of the Study
                                  14

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The term carbon black  identifies  an  important  family  of
industrial carbons used principally as reinforcing agents in
rubber and as black pigments in inks, coatings and plastics.
Carbon  black,  a  petrochemical derivative, is an extremely
fine soot composed principally of carbon (90 - 99  percent),
with   some   oxygen   and   hydrogen.   Carbon  blacks  are
differentiated from bulk commercial carbons (such  as  cokes
and   charcoals)    by   the  fact  that  carbon  blacks  are
particulate  and  are  composed  of   spherical   particles,
quasigraphitic  in  structure  and  of colloidal dimensions.
The properties of carbon black are determined  primarily  by
the process by which it is manufactured.

All  carbon blacks are produced either by partial combustion
or thermal decomposition of liquid or gaseous  hydrocarbons,
and  are  classified  as  lamp black, channel black, furnace
combustion  black,  and   thermal   black.    The   Standard
Industrial   Classification  number  for  the  carbon  black
manufacture is 2895.  For completeness, the thermal and lamp
black  carbon  black  manufacturing  processes   have   been
included.   Lamp blacks are made by the burning of petroleum
or coal-tar residues in open shallow pans, channel black  by
impingement  of  under-ventilated  natural  gas  flames, and
furnace combustion blacks by partial  combustion  of  either
natural  gas  or  liquid hydrocarbons in insulated furnaces.
Thermal  blacks  are  produced  by   thermal   decomposition
(cracking)   of  natural  gas.   Acetylene  black,  which  is
classified as a thermal black, is produced by the exothermic
decomposition of acetylene.

    Production and Uses

The United states is the largest producer of carbon black in
the world, producing approximately 45 percent of  the  total.
world  output  (3.2  out  of  a  total 7,1 billion pounds in
1972) .

Production in the United States has increased steadily since
the rubber manufacture began using 'carbon black in rubber in
1912.  Figure III-1 illustrates  the  United  States  carbon
black production by process for the period from 1952 - 1972.

The  furnace  process  is responsible for over 90 percent of
the carbon black produced in this country.  At  the  end  of
1974, there were 29 furnace black plants, four thermal black
plants,  including  one  acetylene  black plant, one channel
black plant and two lamp black plants in  operation  in  the
United  States.   At the end of 1972, the total carbon black
production capacity in the U.S. was approximately 11,400,000
pounds per day.  Approximately  45  percent  of  this  total
                                 15

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capacity  was  in  Texasr  34  percent  in Louisiana, and 22
percent in other states.

Originally, plants were established in Texas  and  Louisiana
to  be near the natural gas sources, since no cheap means of
transporting this feedstock existed.   As  emphasis  shifted
from the channel process to the furnace process, it was only
natural  that  furnace facilities would be expanded at these
locations.  In  recent  years,  with  the  emphasis  on  the
furnace   process,   specifically   on   liquid  hydrocarbon
feedstocks, the economics involved in transporting the feed-
stocks and the product  (carbon black) have moved the optimum
sites  for  construction  of  new  facilities  to  locations
between  the  source  of the feedstocks (the oil fields)  and
the major users of the carbon black specifically,  the  tire
manufacturers).

Of  the  total  carbon  black consumed in the United States,
approximately 94 percent is used  in  rubber  manufacturing.
Most  of  the  remainder is used by the printing ink, paint,
paper, and plastics industries.  Table III-1 illustrates the
domestic sales of carbon black in the United States  by  use
from 1963 through 1972.

At present, only channel black is approved for direct use in
foods,  cosmetics,  and non-rubber compounds which come into
contact with foodstuff.  All furnace blacks are approved  up
to  50  percent  by  weight  in  rubber  compounds coming in
contact with foods, and up to 10 percent by weight in rubber
compounds coming in contact with edible oils, milk and  milk
products.   Lamp  and thermal black are not approved for use
in foodstuff and related materials.

The Pood and Drug Administration has set the limits based on
the fact that  carbon  black  contains  solvent  extractable
carcinogens  such  as  benzopyrenes.   The Delaney Amendment
limits carcinogens in foodstuff and material that  comes  in
contact  with  foodstuffs.   The smaller the carbon particle
size, the purer the  product  as  a  result  of  the  higher
temperature of reaction  (approximately 2800 to 3200° F).   As
shown in Table III-2, channel black is the smallest particle
size  black.   Next, furnace, thermal and lamp black in that
approximate order.  Because the particle sizes  are  average
figures, there is overlap for the size diameters as shown in
Table III-2.

The  particle  size  also  indicates the usage.  The smaller
particles, channel and fine furnace black, are used  in  the
paint  and  ink  manufacture.  The medium and larger furnace
black are used in  rubber  and  particularly  in  the  tread
                                  16

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                                                             Table III  -1



                                     Domestic Sales of Carbon Black in the United States - By Use



                                                          (Thousand Pounds)






    Use                 1963        1964        1965        1966        19i7        1968        1969-        1970        1971         1972








 Ink



 Paint



 Paper



 Rubber              1,629,905   1,7?9,432   1,945,459   2,131,169   2,072,543   2,445,550   2,616,166    2,486,146   2,678,151    2,953,779



 Miscellaneous           29,315      50,388      5^,163      64,677      61,428      56,986      65,327       71,^54      77,715*      84,764





   Total              1,727,420   1,911,494   2,072,500   2,277,595   2,216,145   2,588,402   2,777,9^9    2,649,521    2,853,527    3,146,708








Source:  The Minerals Yearbook,  1973                                           -                        ,                             '  '
                                                                       .                            :  . •  -;       '            -    4/30/76
46,471
13,008
8,721
45,688
17,982
* 8,004
5^,333
10,896
7,649
63,682
11,959
6,108
63,963
12,553
5,658
67,721
13,435
4,710
73,077
17,711
5,668
72,824
14,570 •
4,527
75,201
•18,693-
3,767
82,532
21 ,408
4,225

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                            TABLE III -2

                 CARBON BLACK GRADES MANUFACTURED
ASTM DESIGNATION*
         CLASS
 AVERAGE PARTICLE
SIZE (MILLIMICRON)
     N110
     NH6
     N220

     N231
     N242
     N293
     N294
     N330
     N326
     N347
     N440
     N472
     N539

     N550
     N568
     N650

     N683
     N761

     N762
     N765
     N774

     N880
     N990
HPC (Hard Processing Channel)
MPC (Medium Processing Channel)
EPC (Easy Processing Channel)
SAP (Super Abrasion Furnace)
SAF-HS  (High Structure-SAP)
ISAF-LS  (Intermediate Super
 Abrasion Furnace-Low Structure)
ISAF-LM  (Low Modulus-ISAF)
ISAF-HS  (High Structure-ISAF)
CF (Conductive Furnace)
SCF (Super Conductive Furnace)
HAF (High Abrasion Furnace)
HAF-LS  (Low Structure-HAF)
HAF-HS  (High Structure-HAF)
FF (Fine Furnace-HAF)
ECF (Extra Conductive Furnace)
FEF-LS  (Fast Extruding Furnace
 Low Structure)
FEF
FEF-HS  (High Structure)
GPF-HS  (General Purpose Furnace
 HS)
APF (All Purpose Furnace)
SRF-LM  (Semi-Reinforcing Furnace
 Low Modulus)
SRF-LM-NS  (Non-Stain-SRF-LM)
SRF-NS
SRF-NS-HM  (High Modulus-SRF-NS)

FT (Fine Thermal)
MT (Medium Thermal)
       24 average
       26 average
       29 average
    20-25
    20-25

    24-33
    24-33
    24-33
    24-33
    24-33
    28-36
    28-36
    28-36
       40 average
    31-39

    39-55
    39-55
    39-55

    49-73
    49-73

    70-96
    70-96
    70-96
    70-96

  180-2QO
  250-350
*Generally the first number  indicates the particle  size
 range.  The larger the number the  larger the particle
 diameter.
                                       4/30/76
                                      18

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rubber  for  the tire industry.  The larger particle furnace
and thermal  blacks  are  used  in  tire  manufacture.   The
smaller  the  particle size, the harder or more abrasive the
rubber product, so the  tread  requires  smaller  particles.
The  sidewall  requires flexibility, therefore, the particle
size used is larger.

Lamp black carbons  are  of  large  particle  size,  possess
little  reinforcing  ability  in  rubber,  and  are lower in
jetness and coloring power.  They are of  value  as  tinting
pigment  in  certain  paints  and lacquers but are primarily
used in the manufacture of  carbon  brushes  for  electrical
equipment and carbon arcs.

    Scope of Coverage for Data Base

Of  the  36  carbon  black  plants  in operation in the U.S.
twenty-nine are furnace black, four thermal black, two  lamp
black  and one channel black.  The plant visits covered four
furnace plants and two thermal plants.  A  telephone  survey
covered the additional twenty-five furnace, two thermal, two
lamp  and the channel black plants.  Effectively, the entire
carbon  black  segment  was  contacted  and   requested   to
participate in this guideline study.

The  results  of  the  contractor's  study combined with the
telephone  survey  initiated  the  decision  to  issue   all
subcategories   of  the  carbon  black  .industrial  effluent
limitations, guidelines and new source performance standards
as "no discharge of  process  wastewater  pollutants".   The
details  that lead to the no discharge decision are found in
Section IV, Industrial Categorization.
                                 19

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                               FIGURE III  -1

                       U.S. CARBON BLACK PRODUCTION
                                BY PROCESS
2
g
u
a
o
u.
o
to
DQ
DQ
                  FURNACE
                  CHANNEL
                  THERMAL
                  TOTAL
                                                                    11972
                                                               4/30/76
                                  20

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                         SECTION IV

                 INDUSTRIAL CATEGORIZATION


                          General

The goal of  this  study  is  the  development  of  effluent
limitations, guidelines and new source performance standards
for  the  carbon  black  manufacturing point source category
that will be achieved  with  different  levels  of  in-plant
waste  reduction  technology.   These  effluent  limitations
guidelines and  new  source  performance  standards  are  to
specify  the quantity of pollutants which will ultimately be
discharged from a specific facility and will be related to a
common yardstick for  the  category,  such  as  quantity  of
production.

Carbon Black

    Discussion of the Rationale of Cateqorjzation

Manufacturing subcategories were established so as to define
those  sectors  of carbon black manufacturing where separate
effluent  limitations  and  standards  should  apply.    The
distinctions  between  the  subcategories have been based on
the  production  process  and  product  type,  its  quality,
character!sties, and applicability of control and treatment.
The following factors were considered in determining whether
such subcategorizations are justified:

              Manufacturing Process

The manufacturing processes used to manufacture carbon black
consist  of  the  furnace,  thermal, channel, and lamp black
processes.  The final product from each of  these  processes
is  carbon  black,  differing  in  particle size, structure,
application and trace contaminants.

Furnace black is produced by the  incomplete  combustion  of
hydrocarbons.   This  process  is  a  net  user of water and
generally has no process contact wastewaters.

Thermal blacks are produced by cracking of  natural  gas  to
form  carbon  and hydrogen gas.  The major wastewater source
from this process  is  the  blowdown  from  a  recirculating
dehumidifier  system.   Two of the three plants in operation
now recycle this water  as  quench  water  resulting  in  no
discharge  of  process  wastewater.  Acetylene black is also
considered  a  thermal  black  process  bringing  the  total
                                  21

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thermal black, plants operating in the United States to four.
The  single acetylene black plant operating is a dry process
resulting-  in  no  discharge  of  process  wastewater.   The
acetylene, like natural gas, is thermally cracked to produce
hydrogen and carbon.

Channel black is produced by impingement of under-ventilated
natural gas flames on moving, continuously scraped channels.
This is a dry operation resulting in no discharge of process
wastewater.

Lamp  blacks are manufactured by the burning of petroleum or
coal tar residues in open  shallow  pans.   This  is  a  dry
operation  when  using  the  bag filter collection technique
resulting in no discharge of process wastewater.

              Product

The carbon black  segment  manufactures  a  single  product.
Therefore,   subcategorization  by  product  basis  was  not
considered.

              Raw Materials

The raw materials consumed  in  the  manufacture  of  carbon
black consist of hydrocarbons.  Liquid hydrocarbons are used
in  the  furnace  and  lamp black processes.  Natural gas is
used as a raw material in the furnace, thermal  and  channel
black processes.

The  most  desirable  feed stock oil for the furnace process
comes from near the bottom of the  refinery  barrel  and  is
similar in many respects to residual fuel oil.  it is low in
sulfur  and  high  in aromatics and olefins.  Natural gas is
required to obtain and maintain the  reaction  temperatures.
The  raw materials for the lamp black process  are petroleum
or coal tar by-products.  Based on the above, raw  materials
are not a basis for subcategorization.

              Plant size

Based  upon process considerations, the plant size, measured
in terms of production, should be directly  related  to  the
pounds of pollutants produced.  As more product is produced,
the  greater  the  amount  of wastewater generated.  This is
true for the carbon black category but the amount of  quench
water  required  to cool the process stream is also directly
related to the size of that  process  stream.   Because  all
process water can be consumed as quench water, plant size is
not a basis for categorization.
                                  22

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                              TABLE, IV  -1

                          CARBON BLACK SEGMENT
                               PLANT KEY
    Plant
Ashland Oil Co.
Aransas Pass, TX

Ashland Oil Co.
Delpre, OH

Ashland Oil Co.
Mojave, CA

Ashland Oil Co.
New Iberia, LA

Ashland Oil Co.
Shamrock, TX

Cabot Corp.
Big Spring, IX

Cabot Corp.
Eranklin, LA

Cabot Corp.
Pampa, TX

Cabot Corp.
Ville Platte, LA

Cabot Corp.
Waverly, WV

Cities Services
El Dorado, AR

Cities Services
Eola, LA

Cities Services
Franklin, LA
Process



furnace


furnace


furnace


furnace


furnace


furnace


furnace


furnace


furnace


.furnace


furnace


furnace


furnace
Waste Load
 (PWWP)*
no discharge.


discharge


no discharge


discharge


no discharge


no discharge


discharge .


;no discharge


.discharge


discharge


no discharge


discharge


no discharge
Climate***
                                                                4/30/76
                                      23

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                         TABLE IV-1 (continued)

                                 -2-
Cities Services
franklin, LA

Cities Services
Hickok, KS

Cities Services
Marshall, W

Cities Services
Mojave, CA

Cities Services
Seagraves, IX

Cities Services
Seagraves, ix

Cities Services
Swartz, LA

Cormercial Solvent Corp.
Thermatomic Carbon
Sterlington, LA

Continental Carbon Co.
Bakersfield, CA

Continental Carbon Co.
Duinas, IX

Continental Carbon Co.
Ponca City, OK

Continental Carbon Co.
Westlake, LA

J. M. Huber
Baytown, TX

J. M. Huber
Borger, TX

J. M. aiber
Borger, TX
thermal


furnace


furnace


furnace


furnace


channel


furnace


thermal



furnace


furnace


furnace


furnace


furnace


thermal


furnace
no discharge


no discharge


no discharge


no discharge


no discharge


no discharge


discharge****


discharge



no discharge


no discharge


no discharge


discharge


discharge**


no discharge


no discharge
                                                                 4/30/76
                                       24

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                           TABLE IV-1 (continued)

                                      -3-
Monsanto          ,
Camden, NJ

Phillips
Borger, TX

Phillips
Orange, TX

Sid Richardson Carbon Co.
Addis, LA

Sid Richardson Carbon Co.
Big Springs, TX

Sid Richardson,Carbon Co.
Odessa, TX

Union Carbide
Ashtabula, OH

Union Carbide
Postoria, OH
lamp


furnace


furnace


furnace


furnace


furnace
thermal
(acetylene)

lamp
no discharge


no discharge


no discharge


discharge


no discharge


no discharge****


no discharge


no discharge
*     process wastewater pollutants
* *    going to "no discharge" before 7/1/77
**K   +  :  rainfall exceeds evaporation
      -  :  evaporation exceeds rainfall
**«*  research and development plant that operates sporadically
                                                                  4/30/76
                                         25

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                    TABLE IV  - 2

                  PLANT 'KEY 'SUMMARY

   A:   Summary of Carbon Black Segment  Plant Key
        Furnace Black
        Thermal Black
        Channel Black
        Lamp Black
             Total
                       Process
29
 4
 1
 2
   B:   Process Breakdown
        Furnace No Discharge
        Furnace Discharge

        Thermal No Discharge
        Thermal Discharge

        Channel No Discharge

        Lamp No Discharge
      *Water

         4
        10

         2
         1
»*Water -

    15


     1


     1
 ^Rainfall exceeds evaporation
**Evaporation exceeds rainfall
                                                     4/30/76
                              26

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              Plant. Age

The  age of a plant was found to have no significance in the
characteristics of a plant's wastewater.  Plants continually
modify their processes to be more efficient and the plants»s
separation techniques can be upgraded from cyclones and  wet
scrubbers to bag filters.  This has been done because of the
higher   yields   obtainable   with  ,bag  filters  and  the
elimination  of  process  wastewater.   If  rain  runoff  is
controlled  by diking or curbing, the dry cleaning of spills
is practiced, and segregation of sanitary waste is required,
the wastewater will be kept to a minimum allowing the  total
recycle  system  to  be  successful.   Some plants have been
using this scheme successfully for twenty years.   Based  on
these  operational  in-plant  techniques, plant age is not a
basis for subcategorization.

              Plant Location

Inspection of carbon black plants  in  various  geographical
areas  of  the country suggested that location may have some
effect on the quality or quantity of the process  wastewater
streams, see Tables IV-1 and IV-2.

Geographical  location  can  influence  the  use of ponds or
cooling towers.  Areas with a large net evaporation are more
suitable for ponds.  Storm water quantity is  a  significant
factor  in  the  use  of  ponds.  In areas where rainfall is
heavy, plants have successfully diverted the rainfall around
the plant.  The rainfall that falls directly  on  the  plant
can  be  used  as quench water if the operating area is kept
clean.  Therefore,  the  rainfall-evaporation  rate  has  an
effect  on  the technique of handling the process wastewater
but not on  the  raw  waste  load  generated  per  pound  of
product.   In  the water deficient regions of the southwest,
as a result of the high evaporation rate, all seventeen (17)
plants have achieved the no discharge level.   This  amounts
to about 47 percent of the point source category.

About 42 percent of the carbon black plants in water surplus
regions  presently  operate  with  no  discharge  of process
wastewater pollutants.  All grades of  carbon  black  except
channel  black  are  manufactured  at  these locations.  The
channel black process is located in the arid region.

The quality (hardness) of the  water,  which  can  influence
whether  process or storm water can be used as quench water,
is  a  problem  that  had  to  be  investigated.    Although
acceptable  limits  for  this  quench water quality have not
been agreed upon by all  manufacturers,  plants  located  in
                                  27

-------
both   the   water  surplus  and  water  deficient  regions*
manufacturing all grades of carbon black and either using  a
dry  process  or  recycle  system  operate  at a level of no
discharge of  process  wastewater  pollutants.   The  entire
carbon  black  segment was inspected and based on the survey
datar plant location  was  found  not  to  be  a  basis  for
subcategorization.

              Housekeeping

Plant  housekeeping  is  a  factor  that was considered when
comparing the various plants visited and was determined  not
to  be a significant factor.  Good housekeeping is important
to the manufacture because a loss of yield can be associated
with poor housekeeping.  Good housekeeping generally reduces
the. wastewater quantities.  Because of  this  consideration,
the carbon black segment generally practices relatively good
housekeeping.   For  example,  carbon  black spills were dry
vacuumed rather than  washed  down  in  all , of  the  plants
visited and is the general practice throughout the category.

              Air Pollution Control Equipment

In   the   past,  air  pollution  control  equipment  had  a
significant   impact   upon   wastewater   quantities    and
characteristics.   Cyclones  and  wet scrubbers were used to
remove the carbon black from the process stream; however, at
present, the carbon black manufacturers universally use  bag
filters  for this purpose.  Therefore, air pollution control
equipment no longer has an adverse impact and is not a basis
for subcategorization.

Because bag filtration has a significant impact on the waste
abatement  of  the  manufacture  of  carbon  black  a  brief
discussion  of  the  operation  of bag filters is offered to
enable the reader to better understand  the  basis  for  the
effluent limitations specified.

Prior  to  about 1965, most units recovered product from the
quenched  furnace  effluent  by   means   of   electrostatic
precipitators  and  several  stages  of  cyclone  collectors
(usually three) with or without  wet  gas  scrubbers.   With
this  type of recovery system, it was possible to recover up
to about 80 to 92 percent of  the  contained  carbon  black.
The remaining carbon black would be vented to the atmosphere
with the combustion gases.  During this earlier time period,
most drier vents were exhausted directly to atmosphere.

In  order  to  improve  product  yield and reduce emissions,
nearly all furnace type carbon black plants incorporate  bag
                                  28

-------
filters  in the product recovery system.  The bag filter has
either been added on, or replaced  the  precipitator  and/or
the  cyclones  in existing plants.  In addition, bag filters
on the furnace effluent and drier vent streams are  reported
to obtain up to 99.95 percent carbon black recovery.

The  substantial improvement in product recovery obtained by
utilizing bag  filters  on  the  main  process  vent  stream
economically  justifies  the increased investment, utilities
and maintenance cost for this equipment.

A sketch of a typical bag filter design for the main process
vent stream is shown in  Figure  IV-1.   Carbon  black-laden
gases  enter  the  hopper  below  the  bag cell plates.  The
hopper performs as a  distribution  duct  for  the  entering
production  stream.  The process gases and carbon black flow
into the individual bags of each  compartment  through  cell
plates.   The filtered gas flows through the bags and/or the
bag filter stacks.  The entrained carbon black  collects  on
.the  inside  of  these  bags,  and  during  the  cleaning or
repressure cycle of each compartment, the black  is  removed
and  dumped  into the hopper  (repressuring simply means that
the flow of gas through the bags is reversed, Figure  IV-2) .
From the hoppers, the carbon black is usually either dropped
through air locks into a pneumatic conveyor system or fed to
screw  conveyors for transportation to the product finishing
area.                   .; .                    .

Figure IV-1 shows a single stack for the entire bag  filter.
In   some  cases,  the  filters  have  one  stack  for  each
compartment.   .This  makes  it  somewhat  easier  to  locate
leaking bags.

Normally,  the main process vent bag filters contain 6 to 18
compartments and each compartment contains approximately 300
to 400 bags.  Each bag is about 5 1/2  inches   (14  cm.)  in
diameter  and  126  inches  (3.2  meters)  long.  These bags
themselves are a great cost item in  the  bag  filter.   Bag
filter  material used by most major black producers consists
of fiberglass which is coated with a graphite-silicon  film.
Bag  life  would  be  seriously reduced if this coating were
removed, and this can easily happen if operating temperature
is allowed to exceed 450° F.

The average life expectancy of the filter bags is  about  12
to 18 months.  However, it is usually necessary to replace a
few  bags  in  each  compartment  during  this period.  High
sulfur content of the oil or impurities in the quench  water
may shorten this life.
                                  29

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                                                                  FIGURE IV -1

                                                        CARBON BLACK BAG FILTER SYS1B4
                                                                  -Repressuring fan
U)
o
                        Stack gas
                         header
                  Stack valve
Repressuring
   valve
                                           Clean gas
                                             outlet
                                                                                      Screw conveyor
             Access door
                 Trough
                                                                                      Repressuring
                                                                                        header
                                                                                                Access doors
                                                                                     Compartment
                                                                                       partition
                                                           Product
                                                          discharge
                                           • Cell plate
                                                                         Fiberglass,
                                                                         filter bag
I I I I
n *S

[
. A A J» A. A



^

!
                                                                                   Cell plate •	^\     /
                                                                                                    V
                                                                                                                  ,WaIk
                                                                                                                   way
                                                                                                  Cross section

-------
                                            FIGURE IV -2

                                      BAG FILTER CLEANING PROCESS
CO
H
CLEAN GAS
TO STACK
     CARBON  BLACK-
     FILTER  CAKE

                                BAG CAP
                                       CLEAN GAS
                                       TO STACK
                                                  STACK
                                                  GASES
                                       REINFORCINS
                                        -F1BERGLAS
                                         CELL PLATE
                                                         1-BAG CAP
                                                   &ffi%|—\
                                                    •\ '•>*•• "-M'     ^
STACK
GASES
                                                 CARBON
                                                 TO HOPPER—^K'&l
                     FILTERING  CYCLE
                                               CLEA-NING  CYCLE
                                                                                 4/30/76

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                                              FIGURE IV -3

                                          BAG FILTER OPERATION
REPRESSURING
FAN

  REPRESSURING
  INTAKE VALVE-
      CARBON BLACK
      a GASES
                                                                                          STACK
                                                                                          VALVE

                                                                                           REPRESSURING
                                                                                           VALVE
                                                                                            CARBON
                                                                                            BLACK
                                                    *typically 8-12 compartments only 1 cut for cleaning'

                                                                                            4/30/76

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The  bags are normally supported from hangers in the roof of
the filter  compartment  with  metal  caps.   The  caps  are
tapered  on  the  sides  and are slightly larger in diameter
than the hem around the  top  of  the  bag.   The  caps  are
inserted  into  the  bags edgewise.  When the cap is rotated
and pulled outward, the bag is wedged around  the  perimeter
of  the  cap.   The wedging action seals the cap-bag surface
and provides support for the bags.  The bottom of  each  bag
is then secured with a snap ring onto the cell plate.

The  repressuring process is controlled with an electrically
operated  timer.   Figure  IV-3  illustrates  the  principal
operations  of  the  bag  filter.   As  shown, the first two
compartments are filtering carbon black from  process  gases
as  the  No. 3 compartment is being cleaned.  The next event
in the operation will be cleaning of compartment No. 1 while
filteration continues in the No. 2 and No,  3  compartments.
This  step-like rotation is continued until all compartments
have been repressured.  The cycle is then repeated.

The repressuring fan generates enough force to  reverse  the
flow  of  gases.   The  gases used in the cleaning cycle are
taken from compartments on the filtering cycle.   In  Figure
IV-3,  compartments  No.  1  and  No.  2  are  supplying the
repressuring gases for compartment No. 3.  When  compartment
No.   1   is  cleaned,  the  gases  will  be  provided  from
compartment No. 2.  The three-compartment filter illustrated
is merely schematic.  On commercial bag filters, several  of
the compartments are used as a source for repressuring gas.

The  sequence of events which puts compartment No. 3 on-and-
off the cleaning cycle is:

         1.   Stack valve closes.
         2.   Repressuring valve opens.
         3.   Cleaning cycle.
         4.   Repressuring valve closes.
         5.   Stack valve opens.
         6.   Filter cycle.

For cleaning compartment No. 1,  the  sequence  is  slightly
different  because  of  the repressuring intake valve.  When
the stack valve closes,  so  does  the  repressuring  intake
valve;  and  when  the  stack  valve opens, the repressuring
intake valve opens.

Similar type bag filters are used to  recover  carbon  black
from the drier purge vent gas.  Fiber glass bags are used in
these  filters  because  of  the  normal  400°  F and higher
operating temperatures.
                                 33

-------
Corrosion, and its related maintenance cost, is a continuous
problem  in  bag   filters,   especially   in   drier   vent
applications.   This is due to both the sulfur and the water
content of the exit gases.

With a system as described above, it is possible to  recover
up to 99.95 percent of the carbon black manufactured.

              Nature of Wastes Generated

The  furnace  black  and  thermal  black processes have been
examined for type of contact process water usage  associated
with each,  contact process water is defined to be all water
which comes in contact with chemicals within the process and
includes:

    1.   Water  required  or  produced  (in   stoichiometric
         quantities) in a chemical reaction.

    2.   Water used as a solvent or as an aqueous medium for
         reactions.

    3.   Water which enters the process with  any  reactants
         or which is used as dilutent  (including steam) .

    4.   Water used as an absorbent or as a scrubbing medium
         for separating certain chemicals from the  reaction
         mixture.

    5.   Water  introduced  as 'steam   to   strip   certain
         chemicals from the reaction mixture.

    6.   Water used to wash, remove, or  separate  chemicals
         from the reaction mixture.

    7.   Water associated with mechanical devices,  such  as
         steam-jet  ejectors  for  drawing  a  vacuum on the
         process.

    8.   Water used as a quench or  direct  contact  coolant
         such  as  in  a  barometric  condenser  or reaction
         quenching.

    9.   Water used to clean  or  purge  equipment  used  in
         batch type operations.

    Noncontact flows which were not considered include:

    1.   Sanitary wastewaters including laundry
         and shower wastewater.
                                  34

-------
    2.   Boiler and cooling tower blowdowns or once-
         through cooling water.
    3.   Chemical regenerants from boiler feed water
         preparation.
    4.   Stormwater runoff from noii-process plant areas,
         e.g., tank farms.

These  are  now  covered  by  separate regulations or may be
covered at a future date by specific  effluent  limitations,
guidelines and standards.

An evaluation of the furnace process showed that the process
wastewater  source  is  the  quench  water  used to cool the
process stream.  However, all of this water is vaporized and
vented to the atmosphere as steam, resulting in  no  process
wastewater  discharge.  The only wastewater generated by the
furnace process is from equipment washing and has been shown
to be successfully recycled back to the quench water with no
product contamination resulting again  in  no  discharge  of
process wastewater ..discharge.

The thermal black process also uses quench water to cool the
product.   However, in this process, this water is condensed
through further water sprays  in  the  dehumidifier  and  is
usually  recycled  as  quench  water.   Because  no  process
wastewater  is  generated,  this  is   not   a   basis   for
subc at egor i z a ti on .

The  lamp and channel black processes are dry operations and
if dry cleaning and bag filters are incorporated there  will
be no process wastewater discharge from these processes.

              Treatability of Wastewaters

All  process  wastewater  is to be recycled.  Although it is
possible to have wastewaters and  require  waste  treatment,
there  are  no  known  significant  advantages with specific
types   of   treatment   systems.    Therefore,   wastewater
generation  need not occur and treatability of wastewater is
not a basis for subcategorization.

              Summary of Considerations

For  the  purpose  of  establishing  effluent   limitations,
guidelines   and   standards  of  performance  carbon  black
manufacturing was divided  into  four  subcategorie's.   This
subcategorization  was  based  on  distinct  differences  in
manufacturing processes.  The  four  selected  subcategories
are:
                                  35

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                                                     FIGURE IV  -4
CO
cr>
                  FUEL
           STORAGE/BAGGING/HOPPER CAR
                                                 PROCESS FLOW SHEET

                                                FURNACE BLACK PROCESS
                                                AIR
                                             PREHEATER
                                                            STEAM
                                                            VENTED
                                                                      PELLETIZER
                                                         AIR & FUEL    (WET MIXER)
                                                                                          STEAM
                                                                                          VENTED
                                                                                     BAG FILTER
                                                                                             MICRO-PULVERIZER
                                                                                                 4/30/76

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                 Subcategory A - Furnace Black
                 Subcategory B —. Thermal Black, Including
                                 Acetylene Black
                 Subcategory C - Channel Black
                 Subcategory D - Lamp Black

As  discussed  in  Section  III,  the  furnace  and  thermal
processes are those of significance in  the  United  States.
Subcategories C and D have been included for completeness.

         Description of Subcategories

              Subcategory A - Furnace Black Process

This   Subcategory   (Figure  IV-4)   includes  carbon  black
manufactured by the furnace process.  The process is  a  net
user of water.  Process raw waste loads should be zero, with
variations  caused  only by intermittent equipment washdown,
which can be settled, screened and recycled as quench  water
or   evaporated.   Both  techniques  are  practiced  by  the
manufacturers of furnace black.

              Subcategory B - Thermal Black Process

This subcategory (Figure  IV-5)  consists  of  carbon  black
mainufacture  by the thermal process, including the acetylene
black  process.   Process  water  in  the  thermal   process
consists  of  direct  contact  quench  water.   It is judged
feasible to reduce  process  waste  loads  to  zero  through
increased  recycle as quench water in this subcategory as is
practiced by the manufacturers of thermal black.

              Subcategory C - Channel Black Process

This  subcategory  (Figure   IV-6)   covers   carbon   black
manufactured by the channel process.  Channel black is a dry
process which results in no wastewater discharge.

                 Subcategory D - Lamp Black

This  subcategory  (Figure  IV-7)   consists  of carbon black
manufactured  by  the  lamp  black  process.   No  water  is
required  in  this  process  as  bag filters are a tried and
proven technique of  collection  resulting  in  99+  percent
recovery.

         Process Descriptions

              Subcategory A - Furnace Black Process
                                  37

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                                                             FIGURE IV   -5

                                                        SIMPLIFIED FLOW SHEET
                                                        THERMAL BLACK PROCESS
    CQMBUSION GASES    JL
    AND STEAM VENTED
                          I
CO
00
    NATURAL GAS
                              HjGAS
                         THERMAL
                         REACTOR
                               , GAS
                         THERMAL
                         REACTOR
                    COMBUSTION AIR
i
                                          -SB-
                                                  VERTICAL
                                                  COOLER
                                         QUENCH WATER
                                                                           HGAS
                         BAG FILTER
                                                                          CARBON BLACK
STEAM
VENTED
                                                                              BULK STORAGE/
                                                                              HOPPER CARS/
                                                                              BAGGING
                                                                                                          PELLETIZER
                                                                  H2GAS
                                                                          DEHUMIDIFIER
                                                                                                QUENCH
                                                                                                WATER
                                                                                                      SLOWDOWN
                                                       SCREENING*
                                                       DEVICE
                                    SETTLING
                                    LAGOON
         'Screening device may be in the  form of filtration
          if the wter quality requires it.
                                                                  SOLID TO LANDFILL
                                                                         4/30/76

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The  furnace  black  process  produces carbon black from the
incomplete combustion of hydrocarbons oil  or  natural  gas,
see Figure IV-4.

In  the  oil  furnace black process, liquid hydrocarbons are
used.  Yields range from 35 to 65 percent, depending on  the
grade of black being produced.  The most desirable feedstock
for  furnace  black  is similar in many respects to residual
fuel oil.  It is low in sulfur and  high  in  aromatics  and
olefins.   The  rising  cost  of  natural  gas  has  been  a
motivating factor in the shift  to  greater  use  of  liquid
f€iedstock  and to the decline in the use of natural gas as a
source of carbon.  With  this  incentive,  the  oil  furnace
black  process has become very flexible.  Oil furnace blacks
haive nearly replaced channel blacks in most high-performance
applications, notably passenger-car tire treads.   Over  the
past thirty years, carbon black technology developments have
centered  on the oil furnace black process, and today nearly
all carbon black plants use processes of this type.

The gas furnace black process is based on partial combustion
of natural gas in refractory line furnaces.  Yields  of  gas
furnace blacks range from 10 to 30 percent and are lower for
the  smaller  particle size grades.  This process is similar
to  the  oil  furnace  black  process.   Approximately  91.5
percent  of  all  carbon  black  manufactured  in the United
States in 1972 was made by the furnace black,process.

Oil is supplied from the process oil storage.   The  oil  is
usually  preheated  in  a heat exchanger prior to firing the
reactors to recover some of the waste heat from the reactor.
Also, preheated air may  be  supplied  to  the  reactor  for
partial  burning  of  the  fuel.   The  particle size of the
carbon black is controlled by the air supply.

Carbon  black  particles  are  formed  in   refractory-lined
reactor  units  designed  for  the incomplete burning of the
fuel oil.  The carbon black particle is formed in this unit.
The reactor temperature is approximately  3200°F.    (Reactor
design  configurations  are  generally  the  major  area  of
difference between manufacturers and production processes.)

The  combustion  products  (gases  and  carbon  black)  pass
through  the  air preheater (at approximately 1100°F)< and an
oil  preheater   (at  approximately. 800°F) .   In-line  water
spirays  cool  the  gas-carbon  black stream.  The combustion
products then pass through a quench tower where water sprays
further cool the stream to approximately 400°F.  All  quench
water is vaporized and vented to the atmosphere.
                                  39

-------
The  carbon black particles are filtered from the "quenched"
gas stream  by  passing  through  baghouses.   The  captured
carbon  black is collected in hoppers below the baghouse and
passed through a micro-pulverizer to a pelletizer.  Water is
added to the "fluff" and it is agitated and  mixed  to  form
pellets with a higher density.  The "fluff" has a density of
approximately 2 pounds per cu ft, whereas the pellets have a
density of approximately 20 pounds per cu ft.

The  wet  pellets  are then dried in a rotary external fired
direct/indirect dryer.  The indirect exhaust gases from this
drier are vented to the atmosphere and the direct  (contact)
gases are exhausted to a bag filter.  The dried carbon black
pellets  are then conveyed to storage and or bulk loaded.  A
simplified process flow diagram is shown in Figure IV-4.  No
contact process waste streams are generated by this process.
Good housekeeping and/or  roofing  over  and/or  diking  the
process areas will minimize stormwater runoff contamination.

              Subcategory B - Thermal Black Process

Approximately  7.8  percent  of all carbon black produced in
the United States in 1972 was  made  by  the  thermal  black
process.

The  thermal  black  process  produces  carbon  black by the
"cracking" of hydrocarbons (i.e., separation of  the  carbon
from  the  hydrogen).   The  feed stock is generally natural
gas.  Particles from the thermal black process are primarily
large sizes, and yields range from 40 to 50 percent.

Each thermal black unit consists of two reactors.   To  make
the  operation  continuous,  one  reactor  is  automatically
switched to a heating cycle while  the  other  is  producing
carbon   black.    The   reactor  refractory  is  heated  by
separating the carbon black from the hydrogen gas in  a  bag
filter  and  returning  and  burning the hydrogen gas in the
reactor that is in the "heat" cycle.

Each reactor consists of a firing zone and a cracking  zone.
The cracking zone contains refractory brick which stores the
heat  required  to  crack  the  natural  gas into carbon and
hydrogen.  Natural gas is injected into the top of the unit.
The energy supplied by the heated  refractory  brick  cracks
the  natural  gas  to  thermal black and hydrogen gas.  This
mixture leaves the reactor at a relatively high  -temperature
and  at  an  increased standard volume and enters the quench
section  of  the  reactor,  where  the  temperature  of  the
reaction products is decreased by adding water.  Because the
temperature  at  this  point  is  still much higher than the
                                  40

-------
bailing point of water, the quench water is  converted  into
steam.

The  cooled reaction products flow through a vertical cooler
where additional quench water is added for further  cooling.
The  temperature  at  this  point  is still in excess of the
boiling point of water, and therefore the  quench  water  is
converted to steam.

From  the  vertical  cooler, the reaction products enter the
bag filter, where the thermal black is  separated  from  the
hydrogen  gas.   The  filtered  thermal  black  falls into a
conveyor beneath the bag filter.  The filtered hydrogen  gas
anid  water  vapor  pass through a water seal (to prevent ex-
plosions)  into  a  dehumidifier.   Water  sprays   in   the
dehumidifier cool the reformed gases below the boiling point
of water, removing most of the moisture.  Water collected in
the  dehumidifier  flows  to the hot well where it is cooled
and transferred to the cold well.  It is then used to supply
the sprays in  the  dehumidifier.   The  gases  leaving  the
dehumidifier  are  in  excess of the amount required to heat
the reactor and the excess is vented.

The loose thermal black is collected under the bag filter in
a closed screw conveyor and conveyed to a  micro-pulverizer.
The  micro-pulverizer  breaks  up  large  agglomerations  of
thermal black and small pieces of refractory  which  may  be
present.   The  loose  black  from  the  micro-pulverizer is
pelletized to make  it  more  suitable  for  handling.   The
pelletized  black  is  directly conveyed to a hopper car for
shipment or conveyed to bulk  storage.   The  black  can  be
loaded into hopper cars or bagged from bulk storage.

Figure  IV-5  is  a simplified flow diagram illustrating the
thermal black process.  The flow diagram shows a single unit
with its two reactors.

The dehumidifier blowdown  can  be  handled  by  evaporation
ponds,  if  desired,  in water deficient areas and/or can be
recycled as quench water in water surplus regions  resulting
in no discharge of process wastewater from the process.

Good  housekeeping  and/or  a roof over and/or diking around
the  process  areas  will  minimize  the  stormwater  runoff
contamination.

Due to the high cost and lack of natural gas, large-particle
furnace  blacks   (LPF)  may soon replace many of the thermal
black applications.
                                  41

-------
                        Figure TV   -  6
             Channel Black  Process Flow Diagram
          FLAME -
     HOPPERS
                              -CHflNOEL
                                                                 BAGGING
                        Figure IV  - 7
               lamp  Black Process Flow Diagram
Burners
                 I oniphlnck Oil
                 Comtnisliuti pan
                      • Air—
f  feed o'ir.c


nUfiNKFi DETAIL
                              42
                                                           4/30/76

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Acetylene blacks, a type of thermal black, are  produced  by
the thermal decomposition of acetylene.  They possess a high
degree  of  structural or chaining tendency.  They provide a
high elastic modulus and high conductivity in rubber stocks.
At the present time, acetylene  black  is  produced  in  the
United  States at one location and operates at a level of no
discharge of process wastewater.

A typical system for achieving the no discharge  of  process
wastewater pollutants for both the thermal and furnace black
process is depicted in Figure IV-8.

    Channel Black Manufacture

Channel  black  is  a  product  of  incomplete combustion of
natural gas, (Figure IV-6),  Small flames  are  impinged  on
cool  surfaces, or channels, where carbon black is deposited
and then scraped off as the channel  moves  back  and  forth
over  a scraper.  The properties of channel black are varied
by changes in burner  tip  design,  distances  from  tip  to
channel,   and   the   amount  of  air  made  available  for
combustion.    The   process   is   extremely    inefficient
chemically.   For  rubber-reinforcing  grades,  the yield is
only 5 percent; for finer particle size, higher color blacks
such as for use in food  stuffs,  the  yield  shrinks  to  1
percent.   Low  yields  and  rapidly  rising gas prices have
motivated the manufacturers  to  develop  other  methods  of
carbon black production.

At  present,  there  is  only  a  single channel black plant
remaining in operation in the United States, as compared  to
35 plants in 1951.

    Lamp Black Manufacture

Lamp  black is the ancestor of all carbon blacks.  Until the
1870's, it was the only carbon black available commercially,
(Figure IV-7.  The manufacture of lamp black  was  practiced
by  the  Chinese and Egyptians during the pre-Christian era.
Purified resins, fats, and oils were burned beneath inverted
porcelain or pottery cones, and the soot  deposited  on  the
cool surface was carefully brushed off from time to time.

Lamp  black  manufacturers  still follow this basic process.
The  principal  raw  materials  used  today,  however,   are
petroleum  and  coal  tar  by-products, such as creosote and
anthracene oils.  They are burned in open, shallow pans with
restricted air supply.  The resulting carbon smoke  is  then
conducted  to  a  series  of  settling  chambers,  where the
flocculated carbon deposits are periodically recovered.   In
                               43

-------
a  typical  operation,  coal-tar  distillate  or creosote is
burned from pans four feet in diameter  and  six  inches  in
depth.   The  smoke  from  each  pan passes slowly through a
series  of  settling  chambers,  where  most  of  the  black
collects.   The  remainder  is periodically collected by bag
filters from both settling chambers and  filter  systems  by
vacuum  collectors.   Since the gas velocities are very low,
heat is dissipated in the chambers without a need for water-
spray cooling.  No water is associated with this process  if
bag  filtration  collection  technique is employed as is the
situation with one of the two operating plants.

In recent years, this process has undergone some changes and
developments, making it more  similar  to  the  oil  furnace
black  processes.   These  modified lamp blacks more closely
resemble oil and gas furnace blacks  than  traditional  lamp
blacks.   Lamp  blacks  are  of large particle size, possess
little  reinforcing  ability  in  rubber,  and  are  low  in
coloring  power.   They  are of value as tinting pigments in
certain paints and lacquers, but are primarily used  in  the
manufacture of carbon black brushes for electrical equipment
and  carbon  arcs.  In most applications, however, they have
been replaced by furnace blacks.  Because two plants are  in
operation in the United States, this subcategory is included
for completeness.

         Basis jfor Assignment to Subcategories

This  subcategorization  assigns  carbon black products to a
subcategory by the manufacturing process by which  they  are
produced.    It  should  be  noted  that  all  carbon  black
manufacturing processes were subcategorized.

Field sampling was not performed at plants  visited  because
of  the nature of the processes subcategorized.  They either
had  no  discharge,  or  the  discharge  was   intermittent,
consisting   of  occasional  equipment  washdowns  or  other
incidental  flows.   Historical  raw  waste  data  from  the
manufacturers  has  been used and is presented in Section V,
Waste Characteristics.
                                44

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U1
                                                     Figure IV   - 8

                        Block Diagram for No Discharge of Process Wastewater Pollutants System


                              Plant Water Supply
                                Borrow Pit
                                Reservoir
             Water to
             Atmosphere as Steam
Dsphere
            Carbon Black**
              Process
                                                Plant WasMown*
                                                including equip-
                                                ment washout
                                                   Watershed
                                     i
                                 Settling Ponds
                                                                               ***
                                             Screerrmg (Solids to Landfill)
          * Does not include utility blowtown, sanitary, laundry or shower,  or laboratory wastewater.
            These may go to separate sanitary system although some may be acceptable and desirable for
            recycle as quench water.
         ** Process includes both thermal and furnace black.
        *** Screening may be in the form of filtration if water quality requires it.
                                                                                4/30/76

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This Page Intentionally Blank

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                         SECTION V

                   WASTE CHARACTERIZATION
Carbon Black

Unlike  the  other  industries  listed  under  miscellaneous
chemicals,  the  carbon  black  manufacturers produce only a
single major product type.  The various production processes
for manufacturing carbon black were  used  as  a  basis  for
subcategorization of the segment.

Because the discharges from these processes are intermittent
and  highly  dependent  upon  the  immediate  situation,  no
wastewater  sampling  was  performed  for   this   industry.
Available  industrial data, however, were acquired for waste
categorization,

The major wastewater discharge from subcategory  A   (furnace
black),  is  from equipment and process area wash down which
has been shown to be successfully recycled as quench water.

The  major  process  wastewater  stream  for  subcategory  B
 (thermal  process)  is the recirculated dehumidifier stream.
The thermal plant visited for this project had  no  blowdown
from  this  source.   The dehumidifier stream was ponded and
recirculated as quench water in the process.  Data  obtained
from the survey are presented in Table V-1.

                   Table V-1

                 Raw Waste Loads
              Carbon Black Segment

        Process           Water Usage*         TSS**
                            (L/kkg)          (kg/kkg)

       Furnace Black          1,500             2.8
       Thermal Black         72,100             8.9

*99 + % vented as steam
*#Estimated based on plant data

The  furnace  black  process  is  a  net user of water.  The
miscellaneous discharges  occur  on  an  unscheduled  basis.
These discharges from equipment washout and storm runoff are
mixed  with  laboratory  wastewater, utility blowdown and in
some situations mixing of treated sanitary  waste  including
                                  47

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shower  and  laundry  waste.   Therefore,  sampling  was not
practical.                            ,       ;    ,

The thermal waste stream is  probably  representative  of  a
blowdown   stream   that   could   be, expected  from  other
dehumidifier/quench  systems;  however,   the   dehumidifier
blowdown  would  be  only- 1  percent (approximately)  of the
total  72,100  L/kkg  flow  and  has  been   shown   to   be
successfully recycled as quench water.'

The  raw  waste  load   (RWL)  values  for  the furnace black
process was calculated from plant  84,  indicating  a  three
month  average wastewater discharge of 97 gpm.   The data did
not  indicate  whether  all  of  this   flow   was   process
wastewater.   .A... range,: of 8 to 45 gpm with an average of 20
gpm was reported by.  seven  other  furnace  plants  for  the
equipment wash water discharge*  The RWL was calculated from
the  TSS  data of plant 84 and the 97 gpm flow, (Table V-1) .
However, this plant was not exemplary and the  average  flow
of  20  gpm  was  used  to  calculate  the  cost for recycle
equipment  (Table VIII-2).

No discharge  of  process  wastewater  pollutants  is  still
recommended  for the furnace process based on the data shown
in Tables IV-1 and IV-2, where 66  percent  of  the  furnace
plants  currently  have  no discharge of process wastewater.
Furthermore, based on plant data, the average wash water and
other effluent flow rates represent less than 10 percent  of
the average quench water flow rates for those same plants.

No definable process point source waste stream is discharged
from subcategory C (channel black process) and subcategory D
(lamp  black  process).   Bag  filtration is the recommended
collection technique for the lamp black process resulting in
no discharge of process  wastewater  pollutants.   One  lamp
black  plant  surveyed  had a settling pond where the solids
settled out and the liquid percolated into the  ground.   It
is  recommended  that  if  this  settling pond be lined, bag
filters be installed to recover the solids and eliminate the
waste stream.  A second lamp black plant surveyed  uses  the
bag  filter  collection  technique  and  has no discharge of
process wastewater.  The  channel  black  plant  was  a  dry
operation   with   no   discharge   of   process  wastewater
pollutants.

Carbon black spills are  generally  vacuumed  dry,   and  are
therefore  not  a source of contamination.  Dry vacuuming is
used to allow recovery of uncontaminated  dry  carbon  black
and  prevent  wastewater  contamination.   This  carbon  can
sometimes be reused  but  is  generally  incinerated  and/or
                                 48

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landfilled.   Oil  and  grease concentrations in the process
wastewater streams were not observed to  be  a  problem  for
this   point  source  category  due  to  the  high  reaction
temperature required to produce carbon black and the  nature
of all four subcategories.

It has been reported that the properties of carbon black can
be   changed   by   a   variety   of   techniques  including
recirculation of off-gases and injection of additives.   For
example,  use  of potassium and sodium salts (i.e., KNO3 and
NaNO3) at the rate of approximately 0.1  percent  by  weight
have  been  effective  in  the reduction of particle size of
furnace black.  Also aluminum and zirconium salts have  been
added  to the process gas stream to increase refractory life
of the reactors.  These alkali materials  could  attack  the
silicon-graphitized  fabric and destroy the integrity of the
fabric filter bags.  The possible impact on  process  wastes
due to these factors is unknown.
                                   49

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                         SECTION VI

             SELECTION OF POLLUTANT PARAMETERS
General

From   review   of  NPDES  permit,  applications  for  direct
discharge  of  wastewaters   from   various   manufacturers,
industries  grouped  under  carbon  black and examination of
related published data, eight parameters (Table  VI-1)  were
selected  for  all  industrial  wastewaters during the field
data collection program.  All surveyed data  are  summarized
in Supplement B.  Supplement B includes historical data from
plants  visited and surveyed, RWL calculations, and analysis
of historical data.  Supplement A has  design  calculations.
Supplement   A  and  B  are  available  at  the  EPA  Public
Information  Reference  Unit,  Room  2992   (EPA   Library),
Waterside Mall, Washington, D.C.  20460.

The  degree  of  impact  on the overall environment has been
used as a basis for dividing the pollutants into  groups  as
follows:

    1.  Pollutants of significance.
    2.  Pollutants of limited significance.

Particular  parameters have been discussed in terms of their
validity as measures of environmental impact and as  sources
of analytical insight.

Pollutants observed from the field data that were present in
sufficient  concentrations  so  as  to  interfere  with,  be
incompatible with, or pass with inadeguate treatment through
publicly owned treatment works are discussed in Section  XII
of this document.
    Pollutants of Significance

Parameters  of  pollution  significance for the carbon black
segment are TDS and TSS.  Due to the intermittent flow or no
discharge from the waste treatment facilities,  no  sampling
took  place  on  the furnace or thermal processes.  No field
visits were  made  to  either  the  lamp  or  channel  black
manufacturing  sites.  These are dry operations and generate
new  process  wastewater.   The  listing  of  parameters  of
significance  was developed from the carton black industrial
survey.
                                 51

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        Table VI-1



List of Parameters Examined



Total Suspended Solids



Dissolved Solids



Iron



Copper



Manganese



pH, Acidity, Alkalinity
                52

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Total Suspended Solids  (TSS)

Stispended  solids-  include  both   organic   and   inorganic
materials.   The inorganic compounds include sand, silt, and
clay.  The  organic  fraction  includes  such  materials  as
grease,  oil,  tar, and animal and vegetable waste products.
These solids may settle out rapidly and bottom deposits  are
often  a  mixture  of  both  organic  and  inorganic solids.
Solids may be suspended in water for a time, and then settle
to the bed of the stream or lake.  These  solids  discharged
with   man* s  wastes  may  be  inert,  slowly  biodegradable
materials, or rapidly  decomposable  substances.   While  in
suspension, they increase the turbidity of the water, reduce
light  penetration and impair the photosynthetic activity of
aquatic plants.                            '

Suspended solids in water  interfere  with  many  industrial
processes,  cause  foaming  in  boilers and incrustations on
equipment  exposed  to  such  water,   especially   as   the
temperature  rises.   They  are undesirable in process water
used in the manufacture of steel, in the  textile  industry,
in laundries, in dyeing and in cooling systems.

Solids  in  suspension  are aesthetically displeasing,  when
they settle to form sludge deposits on the  stream  or  lake
bed,  they are often damaging to the life in water.  Solids,
when transformed to sludge deposits, may  do  a  variety  of
damaging things, including blanketing the stream or lake bed
and  thereby  destroying the living spaces for those benthic
organisms that would otherwise occupy the habitat.  When  of
an. organic  nature,  solids  use  a  portion  or all of the
dissolved oxygen available in the area.   Organic  materials
also  serve  as a food source for sludgeworms and associated
organisms.

Disregarding any toxic  effect  attributable  to  Substances
leached  out  by  water,  suspended solids may kill fish and
shellfish by causing abrasive injuries and by  clogging  the
gills  and  respiratory  passages  of various aquatic fauna.
Indirectly, suspended solids are inimical  to  aquatic  life
because they screen out light, and they promote and maintain
the   development   of  noxious  conditions  through  oxygen
depletion.  This results in the killing  of  fish  and  fish
food   organisms.    Suspended   solids   also   reduce  the
recreational value of the water.

Dissolved Solids

In  natural  waters,  the  dissolved   solids   are   mainly
carbonates,  chlorides,  sulfates,  phosphates,  and,  to  a
                                 53

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lesser extent, nitrates of calcium, magnesium,  sodium,  and
potassium,   with   traces  of  iron,  manganese  and  other
substances.   The  summation  of  all  individual  dissolved
solids is commonly referred to as total dissolved solids.

Many communities in the United States and in other countries
use  water  supplies  containing  2,000  to  4,000  mg/1  of
dissolved salts, when no better water  is  available.   Such
waters  are  not  palatable,  may not quench thirst, and may
have a laxative action on new users,  waters containing more
than 4,000 mg/1 of  total  salts  are  generally  considered
unfit  for  human  use, although in hot climates such higher
salt concentrations can  be  tolerated.   Waters  containing
5,000  mg/1  or  more are reported to be bitter and act as a
bladder and intestinal irritant.   it  is  generally  agreed
that  the salt concentration of good, palatable water should
not exceed 500 mg/1.

Limiting concentrations of dissolved solids for  fresh-water
fish  may  range  from  5,000  to  10,000 mg/1, depending on
species and prior acclimatization.  Some fish are adapted to
living in more saline waters, and a few  species  of  fresh-
water  forms  have  been found in natural waters with a salt
concentration of 15,000 to 20,000  mg/1.   Fish  can  slowly
become acclimatized to higher salinities, but fish in waters
of  low  salinity  cannot  survive  sudden  exposure to high
salinities, such as those resulting from discharges of  oil-
well brines.  Dissolved solids may influence the toxicity of
heavy metals and organic compounds to fish and other aquatic
life,  primarily  because  of  the  antagonistic  effect  of
hardness on metals.

Waters with  total  dissolved  solids   (TDS)   concentrations
higher  than  500 mg/1 have decreasing utility as irrigation
water.  At 5,000 mg/1, water has  little  or  no  value  for
irrigation.

Dissolved  solids  in industrial waters can cause foaming in
boilers and can cause interference with cleanliness,  color,
or  taste of many finished products.  High concentrations of
dissolved solids also tend to accelerate corrosion.

Specific conductance is a measure of the capacity  of  water
to  convey an electric current.  This property is related to
the total concentration of ionized substances in  water  and
to  the water temperature.  This property is frequently used
as a substitute method of quickly estimating  the  dissolved
solids concentration.

Pollutants of Limited Significance
                                54

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The   following   parameters,  which  were  investigated  in
pcirticular cases, have limited effects on the  applicability
of in-plant treatment technologies.

Iron (Fe)

Iron  is  an abundant metal found in the earth1s crust.  The
most common iron ore is hematite from which iron is obtained
by reduction with carbon.  Other forms  of  commercial  ores
are magnetite and taconite.  Pure iron is riot often found in
commercial  use,  but it is usally alloyed with other metals
and minerals* the most common being carbon.

Iron is the basic element in the  production  of  steel  and
steel alloys.  Iron with carbon is used for casting of major
parts  of machines and it can be machined, cast, formed, and
welded.  Ferrous iron is used in paints, while powdered iron
can  be  sintered  and  used  in  powder  metallurgy.   Iron
compounds  are  also  used  to  precipitate other metals and
undesirable minerals from industrial waste water streams.

Iron is chemically reactive  and  corrodes  rapidly  in  the
presence  of  moist  air  and  at elevated temperatures.  In
water and in the presence of oxygen, the resulting  products
of  iron  corrosion  may  be  pollutants  in water.  Natural
pollution occurs from the leaching  of  soluble  iron  salts
from  soil  and  rocks  and is increased by industrial waste
water from pickling baths  and  other  solutions  containing
iron salts.

Corrosion  products  of  iron  in  water  cause  staining of
porcelain fixtures, and ferric iron combines with the tannin
to produce a dark violet color.  The presence  of  excessive
iron  in  water  discourages  cows  from drinking and, thus,
reduces milk production.  High concentrations of ferric  and
ferrous  ions  in  water  kill  most  fish introduced to the
solution  within  a  few  hours.   The  killing  action   is
attributed to coatings of iron hydroxide precipitates on the
gills.    Iron  oxidizing  bacteria  are dependent on iron in
water for growth.   These  bacteria  form  slimes  that  can
affect  the  esthetic  values  of  bodies of water and cause
stoppage of flows in pipes.

Iron is an essential  nutrient  and  micronutrient  for  all
forms of growth.  Drinking water standards in the U. S. have
set  a  recommended  limit  of  0.3 mg/1 of iron in domestic
water   supplies   based   not    on    the    physiological
considerations,   but   rather   on   aesthetic   and  taste
considerations of iron in water.
                                 55

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Copper (Cu)

Copper is an elemental metal that is sometimes found free in
nature and is  found  in  many  minerals  such  as  cuprite,
malachite,  azurite,  chalcopyrite,  and bornite.  Copper is
obtained  from  these  ores  by  smelting,   leaching,   and
electrolysis.    Significant  industrial  uses  are  in  the
plating,  electrical,  plumbing,   and   heating   equipment
industries.    Copper  is  also  commonly  used  with  other
minerals as an insecticide and fungicide.

Traces of copper are found in all forms of plant and  animal
life,  and  it  is an essential trace element for nutrition.
Copper is not considered to be a cumulative systemic  poison
for humans as it is readily excreted by the body, but it can
cause   symptoms   of   gastroenteritis,   with  nausea  and
intestinal irritations,  at  relatively  low  dosages.   The
limiting   factor  in  domestic  water  supplies  is  taste.
Threshold  concentrations  for  taste  have  been  generally
reported  in  the  range  of  1.0-2.0 mg/1 of copper while
concentrations of 5 to 7.5 mg/1 have made  water  completely
undrinkable.   It  has  been  recommended that the copper in
public water supply sources not exceed 1 mg/1.

Copper salts cause undesirable color reactions in  the  food
industry  and  cause  pitting  when  deposited on some other
metals such as aluminum and galvanized steel.   The  textile
industry  is affected when copper salts are present in water
used for processing  of  fabrics.   Irrigation  waters  con-
taining  more  than  minute  quantities  of  copper  can  be
detrimental to certain crops.  The  toxicity  of  copper  to
aquatic  organisms  varies  significantly, not only with the
species,  but  also   with   the   physical   and   chemical
characteristics   of   the   water,  including  temperature,
hardness, turbidity, and carbon dioxide  content.   In  hard
water,  the  toxicity  of copper salts may be reduced by the
precipitation  of  copper  carbonate  or   other   insoluble
compounds.   The  sulfates of copper and zinc, and of copper
and cadmium are synergistic in their toxic effect on fish.

Copper concentrations less than 1 mg/1 have been reported to
be toxic, particularly in soft water, to many kinds of fish,
crustaceans,   mollusks,    insects,    phytoplankton    and
zooplankton.   Concentrations  of  copper,  for example, are
detrimental to seme oysters above .1 ppm.  Oysters  cultured
in sea water containing 0.13-0.5 ppm of copper deposited the
metal in their bodies and became unfit as a food substance.

Manganese
                                 56

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Manganese  metal  is  not found pure in nature, but its ores
are very common and widely distributed.  The  metal  or  its
salts  are  used  extensively  in steel alloys, for dry-cell
batteries, in glass and  ceramics,  in  the  manufacture  of
paints  and  varnishes,  in  inks  and  dyes, in matches and
fireworks, and in agriculture to enrich  manganese-deficient
soils.   Like  iron, it occurs in the divalent and trivalent
form.  The chlorides,  nitrates,  and  sulfates  are  highly
soluble in water; but the oxides, carbonates^ and hydroxides
are  only  sparingly  soluble.  For this reason, manganic or
manganous ions are seldom present in natural surface  waters
in concentrations above 1.0 mg/1.  In groundwater subject to
reducing  conditions, manganese can fce leached from the soil
arid occur  in  high  concentrations.   Manganese  frequently
accompanies iron in such ground waters and in the literature
the two are often linked together.

The  recommended  limitation for manganese in drinking water
in the U.S. is set at 0.05 mg/1 and internationaly (WHO)  at
0.1  mg/1.   These limits appear to be based on esthetic and
economic considerations rather than  physiological  hazards.
In  concentrations  not causing unpleasant tastes,, manganese
is regarded by most investigators to be of no  toxicological
significance  in  drinking  water.   However,  some cases of
manganese poisoning have been reported in the literature.  A
small outbreak of an encephalitis-like disease,  with  early
symptoms _of  lethargy and edema, was traced to manganese in
the drinking water in a  village  outside  of  Tokyo;  three
persons  died  as  a  result  of  poisoning  by  well  water
contaminated by manganese derived  from  dry-cell  batteries
buried  nearby.   Excess  manganese in the drinking water is
also believed to be the cause of a rare disease  endemic  in
Manchukuo.

Manganese  is undesirable in domestic water supplies because
it  causes  unpleasant  tastes,  deposits  on  food   during
cooking, stains and discolors laundry and plumbing fixtures,
and   fosters   the   growth   of  some  micro-organisms  in
reservoirs, filters, and distribution systems.

Small concentrations of manganese - 0.2 to 0.3 mg/1 may form
heavy encrustations in piping while even small  amounts  may
cause   noticable   black  spots  on  white  laundry  items.
Excessive manganese is also undesirable in water for use  in
many    industries,   including   textiles;   dyeing;   food
processing,  distilling,  brewing;  ice;  paper;  and   many
others.

Acidity and Alkalinity - pH
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Although  not  a  specific  pollutant,  pH is related to the
acidity or alkalinity of a waste water stream.  It is not  a
linear or direct measure of either, however, it may properly
be  used  as  a surrogate to control both excess acidity and
excess alkalinity in water.  The term pH is used to describe
the  hydrogen  ion  -  hydroxyl  ion   balance   in   water.
Technically,   pH  is  the  hydrogen  ion  concentration  or
activity present in a given solution.  pH  numbers  are  the
negative logarithim of the hydrogen ion concentration.  A pH
of  7  generally  indicates  neutrality or a balance between
free hydrogen and free hydroxyl ions.  Solutions with  a  pH
above  7  indicate that the solution is alkaline, while a pH
below 7 indicate that the solution is acid.

Knowledge of the pH of water or waste  water  is  useful  in
determining   necessary   measures  for  corrosion  control,
pollution control, and disinfection.  Waters with a pH below
6.0 are corrosive to water  works  structures,  distribution
lines,  and  household  plumbing fixtures and such corrosion
can add   constituents  to  drinking  water  such  as  iron,
copper,  zinc,  cadmium,  and  lead.  Low pH waters not only
tend to dissolve metals from  structures  and  fixtures  but
also  tend  to  redissolve  or leach metals from sludges and
bottom sediments.  The hydrogen ion concentration can affect
the "taste" of the water and  at  a  low  pH,  water  tastes
"sour".

Extremes  of  pH  or  rapid  pH  changes  can  exert  stress
conditions or kill  aquatic  life  outright.  Evein  moderate
changes   from   "acceptable"  criteria  limits  of  pH  are
deleterious to  some  species.   The  relative  toxicity  to
aquatic  life  of  many materials is increased by changes ift
the water pH.   For  example,  metalocyanide  complexes  can
increase  a  thousand-fold in toxicity with a drop of 1.5 pH
units.  Similarly, the toxicity of ammonia is a function  of
pH.   The  bactericidal  effect of chlorine in most cases is
less  as  the  pH  increases,   and   it   is   economically
advantageous to keep the pH close to 7.

Acidity  is  defined as the quantative ability of a water to
neutralize hydroxyl ions.  It is usually  expressed  as  the
calcium   carbonate   equivalent   of   the   hydroxyl  ions
neutralized.  Acidity should not be confused with pH  value.
Acidity  is  the  quantity  of  hydrogen  ions  which may be
released to react with or neutralize hydroxyl ions while  pH
is  a measure of the free hydrogen ions in a solution at the
instant the pH measurement is  made.   A  property  of  many
chemicals,  called  buffing,  may  hold  hydrogen  ions in a
solution from being in the free state and being measured  as
pH.   The  bond  of most buffers is rather weak and hydrogen
                               58

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ions tend to be  released  from  the  buffer  as  needed  to
maintain a fixed pH value.

Highly  acid  waters  are  corrosive to metals, concrete and
living organisms, exhibiting the pollutional characteristics
outlined above for low pH waters.   Depending  on  buffering
capacity, water may have a higher total acidity at pH values
of 6.0 than other waters with a pH value of 4.0.

Alkalinity;  Alkalinity is defined as the ability of a water
to neutralize hydrogen ions.  It is usually expressed as the
calcium  carbonate   equivalent   of   the   hydrogen   ions
neutralized.

Alkalinity is commonly caused by the presence of carbonates,
bicarbonates,  hydroxides and to a lesser extent by borates,
silicates, phophates and organic substances.  Because of the
nature of the chemicals causing alkalinity, and the  buffing
caipacity of carbon dioxide in water, very high pH values are
seldom found in natural waters.

Excess  alkalinity  as exhibited in a high pH value may make
water corrosive to certain metals, to most  natural  organic
materials and toxic to living organisms.

Ammonia is more lethal with a higher pH.  The lacrimal fluid
of  the  human  eye  has  a  pH  of  approximately 7.0 and a
deviation of 0.1 pH unit from the norm  may  result  in  eye
irritation  for  the  swimmer.   Appreciable irritation will
cause severe pain.

Carbon Black

As discussed in Section V, all subcategories of carbon black
are   no   discharge   of   process   wastewater   pollutant
subcategories.   In  the  thermal  subcategory,  the process
quench water contacts a hot process stream of  carbon  black
and  hydrogen  formed  by  cracking natural gas.  The quench
water is  later  condensed  in  a  dehumidifier  by  further
cooling  by  active  sprays.   This contact water contains a
relatively small amount  of  carbon  black  as  TSS.   Since
carbon  black  consists  of  elemental  carbon  (which exerts
minimal oxygen demand), the only pollutant  of  significance
is TSS.  TSS is measured by the organic and inorganic solids
removed  when  filtered through a preformed glass filter mat
in a Gooch crucible.

One  thermal  plant  visited  had  a  TSS  concentration  of
approximately  124  mg/1  in  the  recirculated dehumidifier
system,  and had no blowdown.  Normally, a blowdown is taken
                                59

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from such a closed-loop system,  but  in  the  carbon  black
manufacture, this blowdown has been successfully recycled to
the  quench  water  with no product contamination resulting.
The TSS concentration of  the  blowdown  would  probably  be
similar  to  the  concentration  measured in the closed loop
that was investigated, but based on the survey this  is  not
necessary in the manufacture of carbon black.  Therefore, no
process wastewater should be discharged from the plant.  The
parameters   discussed  above  may  affect  the  product  as
contamination if the level  of  pollutants  are  high  as  a
result  of  poor settling before recycle, high concentration
in the influent plant water or poor operating procedures.

The raw waste load obtained during the field survey for  the
furnace and thermal black plants are presented in Table V-1.
Raw  waste  load  data was collected from a process from the
historical data collected from a survey of the carbon  black
furnace  and  thermal manufacturers.  Channel and lamp black
are total dry process resulting in  no  process  wastewater.
Raw   waste  data  for  the  thermal  and  furnace  process,
historical and surveyed, are summarized in Table VII-2.
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                        SECTION VII         .

             CONTROL AND TREATMENT TECHNOLOGIES
General    ,              "-_  -        ...-•.- -, •' •  ,•   - .    . :

Control and treatment technology may  be  divided  into  two
major  groupings:   in-plant pollution abatement and end-of-
pipe treatment.

Based on the ability  to  obtain  no  discharge  of  process
wastewater   pollutants   in   this  point  source  category
discussion of end-of-plant treatment is not applicable.

After reviewing the results of the segment-wide carbon black
survey,  conclusions  were  made   commensurate   with   the
following distinct technology levels:

    I.  Best Practicable Control Technology Currently
         Available (BPT)

   II.  Best Available Technology Economically
          Achievable  (BAT)

  III.  Best Available Demonstrated Control Technology
          (NSPS)

To.  assess  the  economic  impact of these proposed effluent
limitations, guidelines and new source performance standards
on each of the subcategories, model treatment  systems  have
been  proposed which are considered capable of attaining the
recommended RWL reduction  before  recycle  is  required  in
order  to  meet the effluent limitations and guidelines.  It
should be noted and understood that the  particular  systems
were  chosen  for use in the economic analysis only, and are
not the only systems  capable  of  attaining  the  specified
pollutant reductions.

There  are  many  possible  combinations of in-plant systems
capable of attaining the  effluent  limitations,  guidelines
and  standards  of performance suggested in this report.  It
is the intent of this study to allow the individual plant to
make the final decision about what specific  combination  of
pollution  control  measures is best suited to its.situation
in complying with the effluent limitations,  guidelines  and
standards.

Carbon Black
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    In-Pi ant Pollution Abatement:

The  elimination  or reduction of in-plant pollution sources
depends upon any one  or  a  combination  of  the  following
factors:

    1,   New plant process selection to minimize  pollution.
Present  corporate environmental awareness requires that the
new  environmental  impact  of  products  and  processes  be
evaluated.

    2.   The modification of process  equipment  to  improve
product recovery or to minimize pollution.

    3.   Maintenance  and  good  housekeeping  practices  to
minimize  pollution.   The competitive nature of the segment
requires that most producers operate  their  plants  in  the
most  efficient  manner  possible.   This  necessitates good
maintenance and housekeeping practices.

    U.   The age of the plant and process  equipment  as  it
affects pollution.  Poorly maintained process equipment does
not  warrant  consideration  of  its age.  An example of the
impact of new technology on carbon  black  manufacturing  is
the  use  of bag filters for carbon black recovery, accepted
as state-of-the-art technology.  In the past,  cyclones  and
wet scrubbers were used, which generate larger quantities of
wastewaters.

Based on the field visits and the telephone survey described
earlier   (Section  III), Tables IV-1 and IV-2 were compiled.
The findings of this survey shows that all subcategories  of.
the  carbon  black  point source category, manufacturing all
grades  of  carbon  black  and  regardless  of  geographical
location  are achieving a no discharge of process wastewater
pollutants level.  The field survey is  presented  in  Table
VII-1.
                                  62

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                        Table VII-1

                Treatment Technology Survey
                    Carbon Black Segment

       Plant   Subcategory     Treatment Technology

         81         A         .Settling/Evaporation

         82         A*         Settling Basin, Gravity
                                  Filtration

         83       A and B      Evaporation/Settling Ponds
                                   (no discharge)

  ;       84         A          Baffled Settling Lagoons/Coke
                                  Breez Filter Bed

         85      A and B       Settling Lagoon
                                   (no discharge)

         86         B          Oxidation Pond/Slurry Storage
                                 Lagoon/Clarification Lagoon

         87         A          Separator Units

         88         A          Surge Basin/Sand Filtration

    1Scheduled to achieve no discharge of process wastewater
      pollutant by 7/1/77.

It  is  important  to  note  that  the  treatment technology
applied  to  subcategory  A  was  not  for  process  contact
sources.  Rather, the technology was applied to treatment of
equipment  washout,  process  area  washdown,  and  in  some
instances, storm water runoff,  utility  water  and  treated
sanitary wastes.  Such technology, however, is applicable to
process contact wastewaters to achieve pollution control and
zero  no  discharge of process wastewater pollutants for the
carbon black segment.

Plant 83 collected stormwater runoff from its  property  and
from  adjoining  property  for  use  as  quench water in its
process.  Also, it was implementing a program to include its
sanitary wastewater within this treatment system.

Plant  82  treated  miscellaneous  utility  discharges   and
stormwater  runoff  by  gravity settling followed by gravity
filtration.   At  the  time  of  the  plant  visit,   little
discharge  was observed.  This facility has plans to achieve
                                 63

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no discharge of process wastewater by the third  quarter  of
1976  solely  with in-plant changes.  Again, this system did
not treat  any  process  contact  water.   Plant  83  was  a
combination  furnace  and  thermal black plant.  All process
contact waters  (from the thermal black dehumidifier  system)
were    collected    in   approximately   seven   acres   of
evaporation/settling ponds.  No discharge occurred from this
system due to the high net evaporation for  the  area.   The
sanitary wastes (including shower water) were also collected
by this system and recycled as quench water.

Plant  84  had  separate  treatment  for  the sanitary waste
including  shower  and   laundry   wastewater.    Laboratory
wastewater,  equipment  washout and storm runoff went to the
baffled settling lagoons then into coke  breez  filter  beds
before  mixing  with  the  plant  sanitary and utility waste
before leaving the plant.  No  treatment  efficiencies  were
known.   Low  intermittent  flow  from  the  filter  bed was
observed.  Spills were dry cleaned.  Bag filters were washed
several times per year.  The waste load from this  operation
was not known.

Plant   85   had  separate  treatment  for  sanitary  waste.
Equipment washout, process area  washdown  and  rain  runoff
from   the  concrete,  curbed  process  area  pads,  was  all
collected  and  sent   to   a   gravity   settling   lagoon,
mechanically  screened  and recycled as quench water for the
process.  Plant 85 is both a  thermal  and  furnace  process
plant.   The  humidifier  scrubber water is sent through the
same treatment system and recycled as quench water resulting
in no discharge of process wastewater  pollutants  for  both
the thermal and furnace processes.  This plant is located in
a  water surplus region.  No historical raw waste water data
was immediately available, but has been requested.

Plants 83 and 85 are considered exemplary plants.

    Gravity Settling and/or Gravity Filtration

During  the  plant  survey  program,   historic   wastewater
treatment   plant   performance   data  were  obtained  when
available.  Table VII-2 is a summary  of  average  treatment
results  attained  by  the  plants  surveyed.  The treatment
processes are identified in Table VII-1.  The information in
Table VII-2 indicates only the relative effectiveness of the
applied treatment technology.

More data has been requested from the manufacturers in order
to better define the wastewaters generated from  the  carbon
black  processes and also to better understand the potential
                                64

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                                                        TABLE VII-2
U1
                                     Wastewater Treatment Plant Performance Data
                                                   Carbon Black Segment
           Plant
           Number   Subcategory   Flow rate, gpm*   Influent TSS, mg/11
Effluent TSS, mg/11
% Removal2

81 ;
84
86
87
88

A
A
B
A
A
Average
18
97
NR3
13
45
Range
12-26
2-200

34 (max)
NR3
Average
40
1800
247
78
38
Range
9-145
120-6300
NR3
16-120
10-85
Average
22
13
51
13
14
Range
13-32
3-24
NR3
70(max)
7-18

70
99
v. 79
83
. 63
           ^Historical data  supplied from manufacturers
           ^Calculated
           3NR  =  Not  reported
                                                                                                  4/30/76

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problem of product contamination as a result of  recycle  as
explained in section IV.

It  must  be  emphasized  that  the data presented above are
significant in that they illustrate the possible performance
of  applied  treatment  technology.   All  plants   received
wastewater  from  many  different sources, including in some
cases sanitary wastewater, utilities and  stormwater.   This
data   does   not   represent   the   application  of  these
technologies to process contact streams.
                                 66

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                        SECTION VIII          . --  .

        COST, ENERGY, AND NON-WATER QUALITY ASPECTS
General

In order to evaluate the economic impact of treatment  on  a
uniform  basis, in-plant treatment models which will provide
the desired level of treatment were proposed for the thermal
and furnace black processes.  In-plant control measures such
as distance from treatment system to quench feed  have  been
evaluated  based  on  the  industrial averages for the cost,
energy, and non-water quality aspects of  in-plant  controls
and  are  intimately  related  to the specific processes for
which they are developed.  Although there,are  general  cost
and  energy requirements for equipment items, these correla-
tions are usually expressed  in  terms  of  specific  design
parameters.   Such  parameters are related to the production
rate and  other  specific  considerations  at  a  particular
production site.

In  the  manufacture  of  a  single  product there is a wide
variety of process plant sizes and  unit  operations.   Many
detailed  designs  might be required to develop a meaningful
understanding   of   the   economic   impact   of    process
modifications.   Such a development is really not necessary,
however-*  because  the  in-plant  models  are   capable   of
attaining  the recommended reduction in the RWL's within the
subcategories  before  recycle  is   required.    The   cost
associated   with  these  systems  can  be  divided  by  the
production rate  for  the  given  subcategory  to  show  the
economic  impact  of the system in terms of dollars per 1000
pound of product.

Non-water quality aspects such as noise levels will  not  be
perceptibly  affected  by  the proposed wastewater treatment
systems.  Most carbon  black  plants  generate  fairly  high
noise  levels.   Equipment  associated with in-plant control
systems would not add significantly to these noise levels.

Annual and capital cost estimates  have  been  prepared  for
carbon  black  in-plant  treatment  models  to  evaluate the
economic  impact  of  the  proposed  effluent:,  limitations,
guidelines  and  new source performance standards.  In-plant
costs  can  be  estimated  using  this  same  framework   of
assumptions   and  unit  values.   The  capital  costs  were
generated on a unit process basis and are  reported  in  the
form  of  cost  curves  in Supplement A for all the proposed
treatment systems.  The following  percentage  figures  were
                                67

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added  on  to  the  total  unit process costs to develop the
total capital cost requirements:

                              Percent of Unit Process
            Item              	Capital Cost	

     Electrical                                 14
     Piping                                     20
     Instrumentation                             8
     Site Work                                   6
     Engineering Design and Construction
       Surveillance Fees                        15
     Construction Contingency                   15

Land costs were computed independently and added directly to
the total capital costs.

Annual costs were computed using the following cost basis:

         Item                    Cost Allocation

Capital Recovery
plus Return             10 yrs at 10 percent

Operations and          Includes labor and supervision.
    Maintenance         chemicals, sludge hauling and dis-
                        posal, insurance and taxes (computed
                        at 2 percent of the capital cost),
                        and maintenance (computed at H per-
                        cent of the capital cost).

Energy and Power        Based on $0.02/kw hr for electrical
                        power and 170/gal for grade 11
                        furnace oil.
The 10-year period used for capital recovery is  that  which
is  presently  acceptable  under  current  Internal  Revenue
Service  regulations  pertaining  to  industrial   pollution
control equipment.

The  following  is  a  qualitative as well as a quantitative
discussion  of  the  possible  effects  that  variations  in
treatment  technology  or  design criteria could have on the
total capital costs and annual costs.

                                            Capital
    Technology or Design Criteria      Cost Differential

1.  Use earthen basins with       1, Cost reduction could
                               68

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    a plastic liner in place
    of reinforced concrete con-
    struction, and floating
    aerators plus permanent-
    access walkways.

2.  Place all treatment tankage
    above grade to minimize
    excavation, especially if
    a pumping station is re-
    quired in any case.  Use
    all-steel tankage to
    minimize capital cost.                        "

3.  Minimize flows and-maximize   3. Cost differential would
          be 20 to 30 percent
          of the total cost.
          Cost savings would
          depend on the in-
          dividual situation.
    concentrations through ex-
    tensive in-plant recovery and
    water conservation, so that
    other treatment technologies,
    e.g., incineration, may be
    economically competitive.
          depend on a number of
          items, e.g., age of
          plant, accessibility
          to process piping,
          local air pollution
          standards, etc.
All cost data were computed in terms of August 1972 dollars,
which corresponds to an Engineering News Records index  (ENR)
value of 1980.

Carbon Black

This section provides quantitative cost information relative
to assessing the economic impact of  the  proposed  effluent
limitations, guidelines and new source performance standards
for  the  carbon  black manufacturing point source category.
Since wastewater is associated with  only  the  furnace  and
thermal black processes, a treatment model was developed for
only  subcategories A and B (furnace and thermal black).  In
order to evaluate the economic impact on a uniform treatment
basis, an in-plant treatment model was proposed  which  will
provide  the  desired  level  of treatment before recycle is
required.  This treatment model is summarized below:
    Technology Level

     BPT, NSPS
     and BAT
      In-PIant
  Treatment Model
Gravity Settling and/or
   Filtration and Recycle
The choice of which in-plant controls are required to attain
no discharge of process wastewater pollutants is left up  to
the individual manufacturer.
                               69

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                                  FIGURE VIII -1

                                 IN-PLANT RECYCLE
                              COST MODEL - STEP NO. 1
                                                                                      COMPOSITE
                                                                                      SAMPLER
COMPOSITE
SAMPLER
                                     SETTLING POND
  SPLITTER
  BOX
EFFLUENT
BOX
TO FILTRATION
OR QUENCH
RECYCLE AS
REQUIRED
                                     SETTLING POND
                                                                                      4/30/76

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                             FIGURE VIII -2

                            IN-PLANT RECYCLE
                         COST MODEL - STEP NO.  2
     TO SETTLING POND
SETTLING POND
EFFLUENT
                           BACK WASH
                          HOLDING TANK
                          txj-l
                          FILTER INLET
                          .   WELL
  FILTER WATER
  HOLDING TANK
                                                                             QUENCH RECYCLE
                                            DUAL MEDIA
                                            FILTERS
BACK WASH
  PUMPS
                                                                                   4/30/76

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    BPT. BAT and NSPS Cost Model

To  evaluate  the  economic  effects of the BPT, BAT and NSPS  effluent
limitations, guidelines  and  new  source  performance  standards   for
carbon  black manufacturing, it was necessary to formulate a treatment
model.  The model selected was  gravity  settling  ponds  and/or  dual
media  filtration,  as  shown  in  Figure VIII-1 and VIII-2.   The  cost
model is in two steps, since the plant water quality may be of a level
that step No. 2 would not be required before being recycled as  quench
water.   In  order  that the cost model include carbon black plants in
all geographical locations, step No. 2 has been included.  Again,  it
should  be  emphasized that step No. 2, the dual media filtration, may
not be necessary but is included for  completeness  in  measuring   the
total  economic  impact that the manufacturers would have to incur for
the complete installation.

    Cost

Annual and capital cost estimates have been prepared for the above in-
plant model.  These costs are presented in Table VIII-1 and VIII-2 for
the furnace and thermal black processes,  respectively.   These costs
show  that  the  economic impact based on the current selling  price of
$220.00 per metric ton to be minimal.  Because  the  majority   of   the
plants  surveyed  have  installed  the  equivalent  of Step No. 1, the
economic impact will generally be less  then  the  calculated   values.
The  detailed  cost  breakdown  by  unit processes are included in the
Supplement A.

    Energy

Since the BPT, BAT and NSPS treatment  models  were  designed   to   use
landfilling  of  gravity compacted sludge, energy requirements will  be
for low horsepower pumps and pond dredging  operations.   The   gravity
filtration  would  require only small horsepower pumps.  Tables VIII-1
and VIII-2 presents the cost for energy and power  for  the treatment
model for BPT, BAT, and NSPS.

    Non-Water Quali ty Aspects

The  non-water  quality considerations for the carbon black segment in
achieving the proposed effluent limitations  guidelines  are   minimal.
The  major consideration will be disposal of the settled carbon black,
which can be done primarily by landfilling or  low  cost  incineration
such as pit burning.

Other non-water quality aspects will not be perceptibly affected.
                                72

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                                                       TABLE  VIII-1
u>
                                              Wastewater Treatment Costs for
                                        BPCTCA,  BADCT and BATEA Effluent Limitations
                                              (ENR 1780  - August,  1972 Costs)
                                                   Furnace Black Process
                                                                RWL
    Average Production
                      C
                     214   kkg/day
                    _470   x 1C-3 Ibs/day)
Production Days     350

Wastewater Flow - kL/Day                                    109
                  (gpd)             ,                     28,800
                  kL/kkg product                              0.5
                  (gal/1,000 Ibs)                           (61)

TSS Effluent Limitations - kg TSS/kkg product3                0.97E

TOTAL CAPITAL COSTS

ANNUAL COSTS                         ,

    Capital Recovery plus return at 10%          .    :
      at 10 years
    Operating + Maintenance
    Energy + Power
    Total Annual Cost
    Cost1   $/l,000 kg Product
           ($/l,000 Ibs Product)

1-Cost based on total annual cost
^Incremental cost over Step No. 1 cost if required
^kg/kkg product is equivalent to lb/1,000 Ib product
^No discharge of process wastewater pollutants allowed
3RWL TSS limit shown is based on average flow rate of 20 gpm
 or 28,800 gpd and TSS concentration from plant 84
                                                                                     TECHNOLOGY LEVEL

                                                                              STEP NO. 1          STEP NO.
                                                                                   -:   0.0"

                                                                                 187,800
                                                                                  30,600
                                                                                   5,000

                                                                                  35,600
                                                                                       0.48
                                                                                       0.22
        4
     0.0

62,000
10,000
 5,000

15^000
     0.20
     0.09
                                                                                                         4/30/76

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                                              TABLE VIII-2
                                      Wastewater Treatment Costs for
                                BPCTCA, BADCT and BATEA Effluent Limitations
                                      (ENR 1780 - August, 1972 Costs)

                                           Thermal Black Process
                                                              RWL
Average Production   68   kkg/day
                  ( 150   x 103 Ibs/day)

Production Days     350

Wastewater Flow - kL/Day
                  (gpd)
                  kL/kkg product
                  (gal/1,000 Ibs)

TSS Effluent Limitations - kg TSS/kkg product3
     49
(13,000)
      0.7
    (86)

      0.089
                           TECHNOLOGY LEVEL

                    STEP NO.  1           STEP NO.  22
0.0^
0.04
TOTAL CAPITAL COSTS

ANNUAL COSTS

    Capital Recovery plus return at 10%
      at 10 years
    Operating + Maintenance
    Energy + Power
    Total Annual Cost
    Costl  $/l,000 kg Product)
          ($/l,000 Ibs Product)

*Cost based on total annual cost
^Incremental cost over Step No. 1 cost if required
        product is equivalent to lb/1,000 Ib product
    discharge of process wastewater pollutants allowed
                     123,800
                      20,200
                       5,000

                      25,200
                          $1.06
                           0.48
              38,500
               6,300
               5,000

              11,300
                   0.47
                   0.22
                                                                                                     4/30/76

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                         SECTION IX

            BEST PRACTICABLE CONTROL TECHNOLOGY
                 CURRENLTY AVAILABLE (BPT)
General

The effluent limitations that must be achieved by all plants
by  1  July,  1977  through  the  application  of  the  Best
Practicable Control Technology Currently Available (BPT)  are
based upon an average of the best  performance  achievements
of existing exemplary plants.

Carbon Black

The effluent limitations guidelines for all subcategories of
carbon  black  manufacturing  has  been established to be no
discharge of process wastewater pollutants for BPT  and  are
presented in Table IX-1.

The  development  of  the  BPT  has  been  based on in-plant
technology for  carbon  black  manufacturing  subcategories.
The effluent limitations commensurate with the BPT have been
established  on  the  basis  of  information in Sections III
through VIII of  this  report,  and  are  presented  in  the
following   sections.    It   has   been  shown  that  these
limitations can be attained through the application  of  BPT
pollution control technology.

Survey  findings  (Table  IV-2)   indicate  that  the furnace
process is a net user of water,   i.e.,  no  process  contact
wastewater  is  discharged  from the process.  Based on this
fact, no  discharge  of  process  wastewater  pollutants  is
recommended for subcategory A.

Survey  findings  also  indicate  that  the  thermal process
(Subcategory B), as a  result  of  in-process  changes,  can
achieve  a  level  of_  no  discharge  of  process wastewater
pollutants.  The single acetylene black plant  has  attained
no   discharge  of  process  wastewater  pollutants  and  is
included for completeness.

The only channel black process (Subcategory C) operating  in
the  United States has achieved the level of no discharge of
wastewater pollutants.

One lamp black plant (Subcategory D)  in  the  United  States
have   achieved   the  level  of  no  discharge  of  process
                               75

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wastewater pollutants.  The other lamp black  plant  has  no
point source discharge due to the type of treatment used.

Based  on  these  facts,  no discharge of process wastewater
pollutants is recommended for subcategories A, B, C and D.

The objective of these effluent limitations guidelines is to
induce in-plant  reduction  of  both  flow  and  contaminant
loadings.   However,  it is not the intent of these effluent
limitations and guidelines to specify the in-plant practices
which must  be  employed  at  the  individual  carbon  black
plants.

The  actual  effluent  limitations  and  guidelines would be
applied  directly  only  to  a  plant  whose   manufacturing
processes  fall within a single subcategory.  In the case of
multi-subcategory plants the effluent limitations guidelines
to be placed upon a plant would represent  the  sum  of  the
individual  effluent  limitations  and guidelines applied to
each of its  subcategory  operations.   This  building-block
approach  allows  the  system  to be applied to any facility
regardless of its unique set of processes.
                                 76

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                                                                  Table  IX -I


                                                     BPCTCA Effluent Limitations Guidelines
Subcategories
Flow
Raw Waste Load (RWL)
BPCTCA Long-Term Average.Daily Effluent
Subcategory A
Furnace Black
Subcategory B
Thermal Black
Subcategory C
Channel Black
Subcategory D
Lamp Black
Subcategory A
Furnace Black
Subcategory B
Thermal Black
Subcategory C
Channel Black
Subcategory D
Lamp Black
L/kkg Product Parameter kg/kkg-1- mg/L
(gal/1,000 Ibs)
NA2 No discharge of PWWP3
. NA2' .. . No discharge of PWWP3
? • . ' ' 1 • ' -
NA No discharge of PWWP
2 ' ' q . . ' .
NA . No discharge of PWWP J
. , Effluent
Average of Daily Value for
Thirty Consecutive Days Shall Not Exceed
Parameter kg/kkg1 mg/L
. No discharge of PWWP3
q
. No discharge of PWWPJ
No discharge of PWWP3
No discharge of PWWP
Parameter kg/kkg-'- . mg/L
- , No discharge of PWWP^ . •
. • • o •
No discharge of PWWPJ ..
o
No discharge of PWWP -
q ......
No discharge; of PWWP
.Limitations
Maximum Value for Any One Day
Parameter kg/kkg-"- mg/L
- 0
No discharge of PWWP
. - No discharge of PWWP3
No discharge of PWWP
.. .', ' ' ' •"• 5 •
: • No - discharge , of PWWP . :- :
      Productions is equivalent to lb/1,000 Ibs Production
  Not Applicable
  =  Process Wastewater Pollutants
                                                                                                                                4/30/76

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                         SECTION X

           BEST AVAILABLE TECHNOLOGY ECONOMICALLY
                      ACHIEVABLE  (BAT)


General

The effluent limitations guidelines to be  achieved  by  all
plants  by  July 1r 1983 through the application of the Best
Available Technology Economically Achievable (BAT) are based
upon the very best control and treatment technology employed
by  the  existing  exemplary  plants  in   each   industrial
subcategory.

Carbon Black

Effluent  limitations  guidelines  commensurate with the BAT
are presented  in  Table  X-1.   BAT  effluent  limitations,
guidelines   and   new   source  performance  standards  are
recommended  to  be  no  discharge  of  process   wastewater
pollutants   for   all   subcategories   of   carbon   black
manufacturing.  These standards are attainable  by  in-plant
chcinges as explained in Sections III to VII and Section IX.
                                 79

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                                                                            O&ble X1 -1

                                                               BMEA Effluent Limitations Guidelines
CO
o
         Subcategories
Subcategory A
Furnace Black

Subcategory B
Thermal Black

Subcategory C
Channel Black

Subcategory D
Lamp Black
                           Flow
         Subcategory A
         Furnace Black

         Subcategory B
         Thermal Black

         Subcategory C
         Channel Black

         Subcategory D
         Lamp Black
                                L/kkg Product
                               (galAjOOO Ibs)

                                    N/A2
                                    N/A2


                                    N/A2
BPCTCA Long-flsrm Daily Effluent
Parameter      kg/kkgJ-     mg/L


    No Discharge of pwwp3


    No Discharge of pwwp
BATEA Long-Term Average Daily Effluent
                                                                                             Parameter
                  kg/kkg-1
    No Discharge of


    No Discharge of pwwp3
     No Discharge of


     No Discharge of


     No Discharge of pwwp3


     No Discharge of
                                                                                        BATEA Effluent Limitations
                                                               Average of Daily Value for
                                                        Thirty Consecutive Days Shall Not Exceed
                                                        Parameterkg/kkglmg/L
                                                        No Discharge of pwwp3


                                                        No Discharge of pwwp3


                                                        No Discharge of pwwp3


                                                        No Discharge, of pwwp-'
                              ikg/kkg = Production is equivalent to lb/1,000 Ibs production
                              5N/A = Not Applicable
                                    = Process Wastewater Pollutants
                                                                                                      Maximum Value for Any One Day
                                                                                                      Parameter .,  kg/kkgl    mg/L
                                                   No Discharge of pwwp'


                                                   No Discharge of pwwp3


                                                   No Discharge of pwwp'


                                                   No Discharge of pwwp3
                                                                                                                                4/30/76

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                         SECTION XI

          NEW SOURCE PERFORMANCE STANDARDS (NSPS)
General

The  term  "new  source"  is  defined  in the "Federal Water
Pollution Control Act  Amendments  of  1972"  to  mean  "any
source,  the  construction  of  which is commenced after the
publication of proposed regulations prescribing  a  standard
of performance11.  Technology applicable to new sources shall
be   the  Best  Available  Demonstrated  Control  Technology
(NSPS)r defined by a determination of what higher levels  of
pollution  control  can  be  attained  through  the  use  of
improved  production  process  and/or  wastewater  treatment
techniques.   Thus,  in addition to considering the best in-
plant and end-of-pipe control technology, NSPS technology is
to be based upon an analysis of how the  level  of  effluent
may be reduced by changing the production process itself.

Carbon Black

New  source performance standards commensurate with NSPS for
carbon black manufacture point source category are presented
in Table XI-1.  The standards  are  attainable  by  in-plant
changes  as explained in Sections III to VII and Section IX.
No  discharge   of   process   wastewater   pollutants   are
recommended for "new source" carbon black plants.
                                 81

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                                                                           Table X3 -1

                                                               BADCT Effluent Limitations Guidelines
00
to
         Subcategories
         Subcategory A
         Furnace Black
                           Flow
         Subcategory B
         Thermal Black
Subcategory C
Channel Black

Subcategory D
Lamp Black
         Subcategory A
         Furnace Black
         Subcategory B
         Thermal Black

         Subeategory C
         Channel Black
         Subcategory D
         Lamp Black
                                L/kkg Product
                               (gal/1,000 Ibs)

                                     NA2
                            NA
                                     NA
BPCTCA Long-Term Daily Effluent
Parameter      kg/kkg-*-     mg/L
                                                        No discharge of PWWP
    No discharge of
                                                                 No discharge of PWWP
                                                                 No discharge 'of PWWP
     BADCT Long-Term Average Dally Effluent
Parameter             kg/kkg-1-


         No discharge of PWIflH


         No discharge of PWWp3


         No discharge of PWWp3


         No discharge of
                                                                                     BflDCT  Effluent Limitations
                                                      Average of Daily Value for
                                               Thirty Consecutive Days Shall Not Exceed
                                               Parameterkg/kkg1mg/L


                                                        No discharge of PWWP3


                                                        No discharge of PWWP

                                                                            3
                                                        No discharge of PWWPJ


                                                        No discharge of PWffr
                                                                                                                Maximum Value for Any One Day
                                                                                                                Parameter    kg/kkgl     mg/L
                                                   No discharge of


                                                   No discharge of PWWP3


                                                   No discharge of PWWP


                                                   No discharge of PWWP^
                                                                                                                                          mg/L
                   kg/kkg = production is  equivalent  to  lb/1,000  Ibs production
                   N/A =  Not Applicable
                   PPWWP = Process" Wastewater Pollutants
                                                                                                                               4/30/76

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                        SECTION XII

                   PRETREATMENT STANDARDS
General

Pollutants  from  specific processes within the carbon black
point source category may interfere with, pass  through,  or
otherwise  be  incompatible  with  publicly  owned treatment
works (municipal system) .  The  following  section  examines
the  general wastewater characteristics of this category and
the pretreatment unit operations which may be applicable  to
carbon black manufacturing.

Carbon Black

Subcategories   A,  B,  C  and  D  should  have  no  process
wastewater discharges.  Presently no carbon black  plant  is
known   to  discharge  process  wastewater  to  a  municipal
treatment system.  The only wastewater from this subcategory
would be sanitary wastewater and utility blowdowns.   If  an
existing   source,   as   a  result  of  these  regulations,
determines that a discharge should be made to a POTW  rather
than recycling the water to guench systems some pretreatment
would  be required.  This pretreatment would be of a type to
prevent excessive oil and grease discharges  to  POTW's.   A
simple  weir  skimmer should suffice and essentially no cost
is involved since existing collection systems can be  fitted
with skimmer weirs and the oil periodically removed.  Proper
operation   and  employee  instruction  should  prevent  any
significant problem.

The need for pretreatment of any industrial waste is related
to the ability of a publicly owned treatment works to remove
pollutant parameters in the waste.   Pretreatment  standards
are  intended  to  prevent  introduction  of pollutants into
publicly owned treatment works which  interfere  with,  pass
through,  or are otherwise incompatible with such works.  It
has been shown in the literature that oil and grease  levels
of  100 mg/1 from petroleum, mineral or unknown origin could
interfere with the normal operations of  POTW's.   For  this
reason  a  pretreatment level of 100 mg/1 oil and grease for
new sources is recommended.
                               83

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                        SECTION XIII

             PERFORMANCE FACTORS FOR TREATMENT
                      PLANT OPERATIONS
Carbon Black

Because all subcategories of the carbon black  manufacturing
point source category are designated no discharge of process
wastewater  pollutants,  performance  factors  for treatment
plants are not applicable.
                                85

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This Page Intentionally Blank

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                        SECTION XIV

                      ACKNOWLEDGEMENTS
This report was prepared  by  the  Environmental  Protection
Agency on the basis of a comprehensive study of this segment
performed  by Roy F. Weston, Inc., under contract No. 68-01-
2932.  The original study was conducted and prepared for the
Environmental  Protection  Agency  under  the  direction  of
Pzroject  Director  James  H.  Dougherty, P.E., and Technical
Project  Manager  Jitendra  R.  Ghia,  P.E.   The  following
individual members of the staff of Roy F. Weston, Inc., made
contributions to the overall effort:

  ;       W. D. Sitman         M. E. Pi roe"
         K.M. Peil           K. Patterson

The  original RFW study and this EPA revision were conducted
under the supervision and guidance of Mr. Joseph S. Vitalis,
Project Officer, assisted  by  Mr.  George  Jett,  Assistant
Project Officer.

Overall guidance and assistance were provided to the project
personnel  by  their  associates  in the Effluent Guidelines
Division, particularly Messrs. Allen Cywin. Director,  Ernst
P.  Hall, Deputy Director, Walter J. Hunt, Branch Chief, and
Dr. W. Lamar Miller, Technical Advisor.  Special recognition
is  acknowledged  to  others  ;in  the  Effluent   Guidelines
Division:   Messrs.  John  Nardella,  Martin  Halper,  David
Becker, Bruno  Maier,  and  Dr.  Chester  Rhines  for  their
helpful  suggestions  and  timely  comments.   EGDB  project
personnel  wishes  to  acknowledge  the  assistance  of  the
personnel  at the Environmental Protection Agency's regional
centers,  who  helped  identify   those   plants   achieving
effective , waste  treatment, and whose efforts provided much
of the  research  necessary  for  the  treatment  technology
review.   A  special thanks is extended to Dr. Raymond Loehr
for his invaluable assistance and  guidance  throughout  the
project.        '...-.                                   .

In  addition  project  personnel  would  like  to extend its
gratitude to the following individuals for  the  significant
inputs  into  the development of this document while serving
as members of the EPA working group/steering committee which
provided detailed review, advice, and assistance:
                               87

-------
    W. Hunt, Chairman, Chief, Effluent Guidelines
         Development Branch
    L. Miller, Technical Advisor, Effluent Guidelines Div.
    J. Vitalis, Project Officer, Effluent Guidelines Div.
    G. Jett, Asst. Project Officer, Effluent Guidelines Div.
    J. Ciancia, NERC, Edison, N.J.
    H. Skovrenek, NERC, Edison, N.J.
    M» Strier, Office of Enforcement
    D. Davis, Office of Planning and Evaluation
    P. Desrosiers, office of Research and Development
    R« Swank, SERL, Athens, Ga.
    E. Krabbe, Region II
    L. Reading, Region VII
    E. Struzeski, NFIC, Denver, Colorado

Appreciation is extended  to  Mr,  Chris  Little  and  James
Rodgers  of  the  EPA  Office  of  General Counsel, for their
invaluable input.

The cooperation of the carbon black manufacturers  who  were
active  in this survey and contributed pertinent information
and   data   is    appreciated.     Alphabetically,    these
organizations are:

    1.   Ashland Chemical Company
    2.   Cabot corporation
    3.   Cities Service Company
    4.   Continental Carbon Company
    5.   J«M. Huber Corporation
    6.   Monsanto Company
    7.   Sid Richardson Carbon and Gasoline Company
    8.   Thermatomic Carbon Company
    9.   Union Carbide Corporation

Manufacturing   representatives   for  the  above  companies
playing significant parts in the success of this study were:

    C. Beck  (2)                 M. Mullins  (6)
    G. Boardman  (7)             D. Robinson, Ph.D. (2)
    JR. Cook  (5)                 R. Sterrett (1)
    P. Flood  (3)                G. Temple  (8)
    N.R. Higgins  (4)            J.S. Whitaker, Ph.D.  (9)
    R. Hardison  (9)             R. Woodley  (8)
    F. Miller  (4)

Furthermore,  the  project  personnel  wishes   to   express
appreciation  to the following organizations and individuals
for the assistance which they provided throughout the study:

    J. Ferguson, EPA Region VI
                               88

-------
    J. E. Stiebing, EPA Region VI
    •J.J. Doyle, EPA, Region VI
    L.B. Evans, EPAr JRTP, N. Carolina
    K.C. Hustvedt, EOA, RTF, N. Carolina
Acknowledgement and appreciation is also given for technical
assistance to Mr. Norman Asher and Mr. Eric Yunker for their
contributions, to Ms. Kay Starr and  Ms.  Nancy  Zrubek  for
invaluable  support  in  coordinating  the  preparation  and
reproduction of this report, to Mrs.  Alice  Thompson,  Mrs.
Ernestine  Christian,  Ms.  Laura  Cammarota  and Mrs. Carol
Swann of the Effluent Guidelines Division secretarial  staff
for  their  efforts  in  the  typing  of  drafts,  necessary
revision, and final  preparation  of  the  revised  Effluent
Guidelines Division development document.
                                89

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This Page Intentionally Blank

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                         SECTION XV           .

                        BIBLIOGRAPHY



Carbon Black

F-1.     An  Introduction  to  Carbon  Black  and  to  Cabot
         Corporation;  Cabot  Corporation, R & D Department,
         Pampa, Texas 1968,                  •

F-2.     Encyclopedia of Chemical Technology,  Kirk  Othmer,
         Interscience  Publishers  Division,  John Wiley and
         Sons, Inc., Second Edition., VOl. 4 (1964).

F-3.     Introduction  to  Rubber  Technology;   Edited   by
         Maurice Morton, Van Nostrand Reinhold, 1959.

F-4.     Minerals yearbook,  U.S.  Department  of  Interior,
         1973.  1974.

F-5.     Morton, Maurice; Rubber  Technology,  Van  Nostrand
         Reinhold Company, 1973.

F-6.     Katherine  Russell,  Editor;  1975   Directory   of
         Chemical  Producers,  The United States of America;
         Chemical Information  Services,  Stanford  Research
     ,    Institute, Menlo Park, California  94055.

F-7.     Shreve,  R.N.,  Chemical  Process  Industries,  3rd
         Edition; McGraw-Hill, New York; pp. 122-138.

F-8.     Supplement A £ B - Detailed Record of Data Base for
         "Draft  Development  Document  for  Interim   Final
         Effluent  Limitations,  Guidelines and Standards of
         Performance  for   the   Carbon   Black   Chemicals
         Manufacturing  Point  Source  Category",  U.S. EPA,
 :        Washington, D.C.  20460, February 1975.

F-9.     U.S. EPA; Draft Development Document  for  Effluent
         Limitations Guidelines and Standards of Performance
         - Miscellaneous Chemicals Industry, Prepared by Roy
         F.  Westdn,  Inc. for Effluent Guidelines Division,
         Washington, D.C.  20460; February 1975.

F-10.    U.S.  EPA,  Engineering  and  Cost  Study  of   Air
         Pollution  Control  for the Petrochemical Industry,
         Volume 1; Carbon Black Manufacture by  the  Furnace
                              91

-------
         Process;  EPA 450/3-73-006-a; EPA Research Triangle
         Park, North Carolina; June 1974.

E-11     U.S. EPA, Treatability of Oil and Grease  Discharge
         to  Publicly  Owned  Treatment  Works,  EPA  440/1-
         75/066; U.S. Environmental Protection Agency, 401 M
         Street, S.W., Washington, D.C. 20460; April 1975.

E-12     U.S. EPA, Draft Document for Standards Support  and
         Environmental Impact Statement, An Investigation of
         the  Best Systems of Emission Reduction for Furnace
         Process Carbon Black Plants  in  the  Carbon  Black
         Industry; Prepared by K. C. Hustvedt, L.B., Evans and
         W.M.  Vatavuk;  EPA  Reserach  Triangle Park, North
         Carolina; April 1976.

General References

GR-1     AICHE Environmental Division;  "Industrial  Process
         Design  for  Pollution Control," Volume 4; October,
         1971.

GR-2     Allen, E.E.; "How to Combat Control  Valve  Noise,"
         Chemical  Engineering  Progress,  Vol.  71,  No. 8;
         August, 1975; pp. 43-55.

GR-3     American  Public   Health   Association;   Standard
         Methods  for  Examination of Water and Waste Water,
         13th Edition; APHA, Washington, D.C.  20036; 1971.

GR-4     Barnard, J.L.; "Treatment  Cost  Relationships  for
         Industrial  Waste  Treatment,"  Ph.D. Dissertation,
         Vanderbilt University; 1971.

GR-5     Bennett, H. , editor; Concise Chemical ajnd Technical
         Dictionary; F.A.I.C. Chemical  Publishing  Company,
         Inc., New York,- New York; 1962.

GR-6     Blecker,  H.G.,  and  Cadman,  T.W.;  Capital   and
         Operating  Costs  of  Pollution  Control  Equipment
         Modules, Volume I. - User Guide; EPA-R5-73-023a; EPA
         Office of  Research  and  Development,  Washington,
         D.C.  20460; July 1973.

GR-7     Blecker,  H. G. ,  and  Nichols,  T.M. ;  Capital  and
         Operating  Costs  of  Pollution  Control  Equipment
         Modules, Volume II - Data  Manual;  EPA-R5-73-023b;
         EPA Office of Research and Development, Washington,
         D.C.  20460; July, 1973.
                               92

-------
GR-8     Bruce, R.D., and Werchan, R.E. ; "Noise  Control  in
         the  Petroleum  and  Chemical Industries," Chemical
         Engineering Progress, Vol. 71, No. 8; August, 1975;
         pp. 56-59,

GR-9     Chaffin, C.M. ; "Wastewater Stabilization  Ponds  at
         Texas Eastman Company."

GR-10    Chemical  Coagulation/Mixed  Media  Filtration   of
         Aerated    Lagoon    Effluent,    EPA-660/2-75-025;
         Environmental   Protection    Technology    Series,
         National  Environmental  Research Center, office of
         Research  and  Development,  U.S.  EPA,  Corvallis,
         Oregon  97330.

GR-11    Chemical Engineering, August  6,  1973;  "Pollution
         Control at the Source."

GR-12    Chemical Engineering,  68  (2),  1961;  "Activated-
         Sludge Process Solvents Waste Problem."

GR-13    Chemical Week, May 9, 1973;  "Making  Hard-to-treat
         Chemical Wastes Evaporate."

GR-14    Cheremisinoff, P.N. , and Feller, S.M.;  "Wastewater
         Solids Separation," Pollution Engineering.

GR-15    Control of Hazardous Material  Spills,  Proceedings
         of  the  1972  National  Conference  on  Control of
         Hazardous Material Spills, Sponsored  by  the  U.S.
         Environmental  Protection  Agency at the University
         of Texas, March 1972.

GR-16    Cook, C.; "Variability in  BOD  Concentration  from
         Biological    Treatment   Plants,"   EPA   internal
         memorandum; March, 1974.

GR-17    Davis, K.E., and Funk, R.J.;  "Deep Well Disposal of
         Industrial  Waste,"  Industrial   Waste;   January-
         February, 1975.

GR-18    Dean, J.A., editor; Lange*s Handbook of  Chemistry,
         11th  Edition;  McGraw-Hill Book Company, New York,
         New York; 1973.

GR-19    Eckenfelder, W.W., Jr.; Water  Quality  Engineering
         for  Practicing  Engineers; Barnes and Noble, Inc.,
         New York, New York; 1970.
                                93

-------
GR-20    Eckenfelder, W.W., Jr.;  "Development  of  Operator
         Training Materials," Environmental Science Services
         Corp., Stamford, Conn.; August, 1968.

GR-21    Environmental Science and Technology, Vol.  8,  No.
         10, October, 1974; "Currents-Technology."

GR-22    Fassell, W.M.; Sludge  Disposal  at  a  Profit?,  a
         report  presented  at  the  National  Conference on
         Municipal    Sludge     Management,     Pittsburgh,
         Pennsylvania; June, 1974.

GR-23    Guidelines for Chemical Plants  in  the  Prevention
         Control  and  Reporting  of  Spills;  Manufacturing
         Chemists Association, Inc., Washington, D.C.  1972.

GR-24    Hauser, E.A.,  Colloidal  Phenomena,  1st  Edition,
         McGraw-Hill Book Company, New York, New York; 1939.

GR-25    Iowa  State  University  Department  of  Industrial
         Engineering  and  Engineering  Research  Institute,
         "Estimating  Staff  and  Cost  Factors  for   Small
         Wastewater Treatment Plants Less Than 1 MGD," Parts
         I  and  II;  EPA  Grant  No. 5P2-WP-195-0452; June,
         1973.

GR-26    Iowa  State  University  Department  of  Industrial
         Engineering  and  Engineering  Research  Institute,
         "Staffing Guidelines  for  Conventional  Wastewater
         Treatment  Plants  Less  Than 1 MGD," EPA Grant No.
         5P2-WP-195-0452; June, 1973.

GR-27    Judd,   S.H.;   "Noise   Abatement   in    Existing
         Refineries,"  Chemical  Engineering  Progress, Vol.
         71, No. 8; August, 1975; pp. 31-42.

GR-28    Kent, J.A., editor; Reigel's Industrial  Chemistry,
         7th  Edition;  Reinhold Publishing corporation, New
         York; 1974.

GR-29    Kirk-Othmer; Encyclopedia of  Chemical  Technology,
         2nd Edition; Interscience Publishers Division, John
         Wiley and  Sons, Inc.

GR-30    Kozlorowski,  B.,  and  Kucharski,  J.;  Industrial
         Waste Disposal; Pergamon Press, New York; 1972.

GR-31    Lindner,   G.   and   K.   Nyberg;    Environmental
         Engineering,  A Chemical Engineering Discipline; D.
                                 94

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         Reidel Publishing  company*  Boston,  Massachusetts
         02116, 1973.

GR-32    Liptak,  E.G.,  editor;  Environmenta1   Engineers'
         Handbook,  Volume  I, Water Pollution; Chilton Book
         Company, Radnor, Pa. ; 1974.

GR-33    Marshall, G.R. and E.J.  Middlebrook;  Intermittent
         Sand  Filtration  to  Upgrade  Existing  Wastewater
         Treatment Facilities,  PR  JEW  115-2;  Utah  Water
         Research  Laboratory,  College of Engineering, Utah
         State  University,  Logan,  Utah  84322;  February,
         1974.

GR-34    Martin, J. D. , Dutcher, V.D.,  Frieze,  T.R. ,  Tapp,
         M.,   and   Davis,   E.M.;   "Waste   Stabilization
         Experiences  at  Union  Carbide,  Seadrift,   Texas
         Plant."

GR-35    McDermott,  G.N. ;  Industrial  Spill  Control   and
         Pollution  Incident  Prevention, J. Water Pollution
         Control Federation, 43 (8) 1629 (1971).

GR-36    Minear,  R.A.,  and  Patterson,  J.W. ;   Wastewater
         Treatment   Technology,   2nd   Edition;  State  of
         Illinois  Institute  for   Environmental   Quality;
         January, 1973.

GR-37    National Environmental Research Center; "Evaluation
         of Hazardous. Waste Emplacement in Mined  Openings;'1
         NERC Contract No. 68-03-0470; September, 1974.

GR-38    Nemerow, N. L. ; Liquid Waste of Industry - Theories,
         Practices and Treatment; Addision-Wesley Pulbishing
         Company, Reading, Massachusetts; 1971.

GR-39    Novak, S.M.; "Biological Waste Stabilization  Ponds
         at Exxon Company, U.S.A. Baytown Refinery and Exxon
         Chemical  Company, U.S.A. Chemical Plant (Divisions
         of Exxon Corporation) Baytown, Texas."

GR"40    Oswald, W.J., and Ramani, R.; "The Fate of Algae in
         Receiving  Waters,"  a  paper  submitted   to   the
         Conference  on  Ponds  as  a  Wastewater  Treatment
         Alternative, University  of  Texas,  Austin;  July,
         1975.

GR-:41    Otakie, G.F.; A Guide to  the  Selection  of  Cost-
         effective  Wastewater Treatment Systems; EPA-430/9-
                                 95

-------
         75-002, Technical Report, U.S. EPA, Office of Water
         Program Operations, Washington, D.C.  20460,

GR-42    Parker, C.L.; Estimating  the  Cost  of  Wastewater
         Treatment  Ponds;  Pollution Engineering,, November,
         1975.

GR-43    Parker,  W.P.;  Wastewater   Systems   Engineering,
         Prentice-Hall,  Inc., Englewood Cliffs, New Jersey,
         1975.

GR-44    Parker, D.S.;  "Performance  of  Alternative  Algae
         Removal   Systems,"   a  report  submitted  to  the
         Conference  on  Ponds  as  a  Wastewater  Treatment
         Alternative,  University  of  Texas,  Austin; July,
         1975.

GR-45    Perry, J.H., et. al.; Chemical Engineers' Handbook,
         5th Edition; McGraw-Hill Book  Company,  New  York,
         New York; 1973.

GR-46    Public Law 92-500, 92nd Congress,  S.2770;  October
         18, 1972.

GR—47    Quirk, T.P.; "Application of Computerized  Analysis
         to Comparative Costs of Sludge Dewatering by Vacuum
         Filtration   and   Centrifugation,"   Proc.,   23rd
         Industrial  Waste  Conference,  Purdue  University;
         1968; pp. 69-709.

GR-48    Riley,  B.T.,   Jr.;   The   Relationship   Between
         Temperature   and   the  Design  and  Operation  of
         Biological Waste Treatment Plants, submitted to the
         Effluent Guidelines Division, EPA; April, 1975.

GR-49    Rose, A., and  Rose,  E.;  The  Condensed  Chemical
         Dictionary,   6th   Edition;   Reinhold  Publishing
         Corporation, New York; 1961.

GR-50    Rudolfs, W.; Industrial Wastes, Their Disposal  and
         Treatment;  Reinhold  Publishing   Corporation,  New
         York; 1953.

GR-51    Sax,  N.I.;  Dangerous  Properties of   Industrial
         Material,   4th   Edition;  Van  Nostrand  Reinhold
         Company, New York; 1975.

GR-52    Seabrook, B.L.; Cost  of  Wastewater  Treatment  by
         Land   Application;   EPA-430/9-75-003,   Technical
                                 96

-------
         Report;  U.S.  EPA,   Office   of   Water   Program
         Operations, Washington, B.C.  20460.

GR-53    Shreve, R.N. ; Chemical  Process  Industries'.,.  Third
         Edition; McGraw-Hill, New York; 1967.

GR-54    Spill Prevention Techniques for Hazardous Polluting
         Substances,   OHM   7102001;   U.S.   Environmental
         Protection Agency^ Washington, D.C. 20460; February
         1971.

GR-55    Stecher,  P.G.,  editor;  The   Merck   Index,   An
         Encyclopedia  of  Chemicals and Drugs, 8th Edition;
         Merck and Company, Inc., Rahway, New Jersey; 1968.

GR-56    Stevens, J.I., "The Roles of Spillage, Leakage  and
         Venting in Industrial Pollution Control", Presented
         at  Second  Annual  Environmental  Engineering  and
         Science conference. University of Louisville, April
         1972.

GR-57    Supplement A j> _B - Detailed Record of Data Base for
         "Draft  Development  Document  for  Interim   Final
         Effluent  Limitations,  Guidelines and Standards of
         Performance   for   the   Miscellaneous   Chemicals
         Manufacturing  Point  Source  Category",  U.S. EPA,
         Washington, D.C.  20460, February 1975.

GR-58    Swanson,  C.L.;   "Unit   Process   Operating   and
         Maintenance  Costs for Conventional Waste Treatment
         Plants;" FWQA, Cincinnati, Ohio; June^ 1968.

GR-59    U.S. Department of Health, Education, and  Welfare;
         "Interaction  of Heavy Metals and Biological Sewage
         Treatment Processes," Environmental Health  Series;
         HEW  Office  of Water Supply and Pollution Control,
         Washington, D.C. ; .May, 1965.

GR-60    U.S. Department of the  Interior;  "Cost  of  Clean
         Water,"  Industrial  Waste  Profile No. 3_; Dept. of
         Int. GWQA, Washington, D.C.; November, 1967.

GR-61    U.S.  EPA;  Process  Design  Manual  for  Upgrading
         Existing  Waste  Water  Treatment  Plants, U.S. EPA
         Technology Transfer; EPA, Washington, D.C.   20460;
         October, 1974.

GR-62    U-S. EPA; Monitoring Industrial Waste  Water,  U.S.
         EPA  Technology  Transfer;  EPA,  Washington,  D.C.
         20460; August, 1973.

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GR-63    U.S. EPA; Methods for Chemical  Analysis  of  Water
         and  Wastes,  U.S.  EPA  Technology  Transfer;  EPA
         625/6-74-003; Washington, B.C.  20460; 1974.

GR-64    U.S. EPA; Handbook for Analytical  Quality  Control
         in  Water  and  Waste  Water Laboratories, U.S. EPA
         Technology Transfer; EPA, Washington, D.C.   20460;
         June, 1972.

GR-65    U.S. EPA;  Process  Design  Manual  for  Phosphorus
         Removal,   U.S.   EPA   Technology  Transfer;  EPA,
         Washington, D.C.  20460; October, 1971.

GR-66    U.S.  EPA;  Process  Design  Manual  for  Suspended
         Solids  Removal,  U.S. EPA Technology Transfer; EPA
         625/1-75-003a, Washington,  D.C.   20460;  January,
         1975.

GR-67    U.S. EPA; Process Design Manual for Sulfide Control
         in Sanitary Sewerage Systems, U.S.  EPA  Technology
         Transfer;  EPA,  Washington,  D.C.  20460; October,
         1974.

GH.-68    U.S.  EPA;  Process  Design   Manual   for   Carbon
         Adsorption,  U.S.  EPA  Technology  Transfer;  EPA,
         Washington, D.C.  20460; October, 1973.

GR-69    U.S.  EPA;  Process  Design   Manual   for   Sludge
         Treatment   and   Disposal,   U.S.  EPA  Technology
         Transfer;  EPA   625/1-74-006,   Washington,   D.C.
         20460; October,  1974.

GR-70    U.S.  EPA;  Effluent  Limitations  Guidelines   and
         Standards of Performance, Metal Finishing Industry,
         Draft  Development  Document;  EPA 440/1-75/040 and
         EPA 440/1-75/040a; EPA  Office  of  Air  and  Water
         Programs, Effluent Guidelines Division, Washington,
         D.C.  20460; April, 1975.

GR-71    U.S.  EPA;  Development   Document   for   Effluent
         Limitations Guidelines and Standards of Performance
         -  Organic  Chemicals  Industry; EPA 440/1-74/009a;
         EPA Office of  Air  and  Water  Programs,  Effluent
         Guidelines   Division,   Washington,  D.C.   20460;
         April, 1974.

GR-72    U.S. EPA; Draft  Development Document  for  Effluent
         Limitations Guidelines and Standards of Performance
         -   Steam   Supply  and  Noncontact  Cooling  Water
         Industries; EPA Office of Air and  Water  Programs,
                                 98

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         Effluent   Guidelines  Division,  Washington,  D.C.
         20460; October, 1974.

GR-73    U.S. EPA; Draft Development Document  for  Effluent
         Limitations Guidelines and Standards of Performance
         -  Organic Chemicals Industry, Phase II Prepared by
         Roy F. Weston, Inc. under EPA Contract  No.  68-01-
         1509;   EPA  Office  of  Air  and  Water  Programs,
         Effluent  Guidelines  Division,  Washington,   D.C.
         20460; February, 1974.

GR-74    U.S. EPA; Evaluation of Land  Application  Systems,
         Technical    Bulletin;   EPA   430/9-75-001;   EPA,
         Washington, D.C.  20460; March, 1975.

GR-75    U.S. EPA; "Projects  in  the  Industrial  Pollution
         Control    Division,"    Envi ronmental   Protection
         Technology   Series;   EPA    600/2-75-001;    EPA,
         Washington, D.C.  20460; December, 1974.

GR-76    U.S. EPA;  Wastewater  Sampling  Methodologies  and
         .Flow  Measurement Techniques; EPA 907/9-74-005; EPA
         Surveillance and Analysis,  Region  VII,  Technical
         Support Branch; June, 1974.

GR-77    U.S. EPA; A Primer on Waste  Water  Treatment;  EPA
         Water Quality Office; 1971.           ,

GR-78    U.S. EPA; Compilation of Municipal  and  Industrial
         injection Wells in the United States; EPA 520/9-74-
         020;  Vol.  I and II; EPA, Washington, D.C.  20460;
         1974.

GR-79    U.S. EPA; "Upgrading Lagoons," U.S. EPA  Technology
         Transfer;  EPA,  Washington,  D.C.   20460; August,
         1973.

GR-80    U.S.  EPA;   "Nitrification   and   Denitrification
         Facilities,"  U.S. EPA Technology Transfer; August,
         1973.                                             ;

GR-81    U.S.  EPA;  "Physical-Chemical  Nitrogen  Removal,"
         U.S. EPA Technology Transfer; EPA, Washington, D.C.
         20460; July, 1974.

GR-82    U.S. EPA; "Physical-Chemical  Wastewater  Treatment
         Plant  Design^"  U.S. EPA Technology Transfer; EPA,
         Washington, D.C.  20460; August, 1973.
                               99

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GR-83    U.S.  EPA;  "Oxygen  Activated  Sludge ,  Wastewater
         Treatment  Systems,  Design  Criteria and Operating
         Experience," U.S.  EPA  Technology  Transfer;  EPA,
         Washington, B.C.  20460; August, 1973.

GR-84    U.S.    EPA;    Wastewater    Filtration     Design
         Considerations;  U.S. EPA Technology Transfer; EPA,
         Washington, D.C.  20460; July, 1974.

GR-85    U.S. EPA; "Flow Equalization," U.S. EPA  Technology
         Transfer; EPA, Washington, D.C. 20460; May, 1974.

GR-86    U.S. EPA; "Procedural  Manual  for  Evaluating  the
         Performance  of  Wastewater Treatment Plants," U.S.
         EPA  Technology  Transfer;  EPA,  Washington,  D.C.
         20460.

GR-87    U.S. EPA; Supplement to  Development  Document  for
         Effluent  Limitations,  Guidelines  and  New Source
         Performance  Standards   for   the   Corn   Milling
         Subcategory,  Grain  Processing, EPA, Office of Air
         and Water Programs, Effluent  Guidelines  Division,
         Washington, D.C.  20460, August 1975.

GR-88    U.S. EPA;  Pretreatment  of  Pollutants  Introduced
         Into  Publicly Owned Treatment Works; EPA Office of
         Water Program Operations, Washington, D.C.   20460;
         October, 1973.

GR-89    U.S.   Government   Printing    Office;    Standard
         Industrial    Classific ation   Manual;   Government
         Printing Office, Washington, D.C.  20492; 1972.

GR-90    U.S. EPA; Tertiary Treatment of  Combined  Domestic
         and    Industrial   Wastes,   EPA-R2-73-236,   EPA,
         Washington, D.C. 20460; May, 1973.

GR-91    Wang,  Lawrence   K.;   Environmental   Engineering
         Glossary (Draft) Calspan Corporation, Environmental
         Systems Division, Buffalo, New York 14221, 1974.

GR-92    Water Quality Criteria 1972, EPA-R-73-033, National
         Academy  of  sciences  and  National   Academy   of
         Engineering;  U.S.  Government Printing Office, No.
         5501-00520, March, 1973.

GR-93    Weast, R., editor; CRC Handbook  of  Chemistry  and
         Physics,  54th  Edition; CRC Press, Cleveland, Ohio
         44128; 1973-1974.
                                100

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GR.-94    Weber*   C.I.,   editor;   Biological   Field   and
         Laboratory  Methods  for  Measuring  the Quality of
         Surface  Waters   and   Effluents,"   Environmental
         Monitoring    Series;    EPA   670/4-73-001;   EPA,
         Cincinnati, Ohio  45268; July, 1973.

GR-^-95    APHA, ASCE, AWWA, and WPCF, Glossary of  Water  and
         Wastewater Control Engineering, American Society of
         Civil Engineers, New York, 1969.
                                 101

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                        SECTION XVI

                          GLOSSARY
Carbon Black

Acetylene-  Black.   Carbon  black  produced  by  the thermal
decomposition  of  acetylene,  possess  a  high  degree   of
structural,   or  chaining,  tendency.   They  provide  high
elastic modulus and high conductivity in rubber stocks.

Amorphous,  without shape.

Slowdown.  Water intentionally discharged from a cooling  or
heating    system   to   maintain   the   dissolved   solids
concentration of the  circulating  water  below  a  specific
critical level.

Ceirbon  Black.   A  family  of  industrial carbons primarily
carbon   (90  to  99%)   contains  some  sulfur,  oxygen   and
hydrogen;  a  petrochemical  used principally as reinforcing
agents in rubber and as black pigments  in  inks,  coatings,
and plastics.

Channel  Black.   Carbon  black  manufactured by the channel
process.  It is produced by  the  incomplete  combustion  of
neitural gas, and is deposited on, then scraped off, a moving
channel.

Colloid.   A  solid, liquid, or gaseous substance made up of
V€>ry small, insoluble, nondiffusible  particles  (as  single
lairge  molecules or masses of smaller molecules) that remain
in suspension in a surrounding  solid,  liquid,  or  gaseous
medium.   All living matter contains collodial material, and
a colloid has only  a  negligible  effect  on  the  freezing
point, or vapor tension of the surrounding medium.

Furnace  Black.   Carbon  black  manufactured by the furnace
process, produced by partial combustion of  hydrocarbons  in
insulated furnaces.

Impingement«  To strike with a sharp collision.

Lamp  Black.   Carbon  black  manufactured by the burning of
petroleum or coal tar residues in open shallow pans.

Quasigraphitic.  Having graphite-like qualities.
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Quench.  To cool a material suddenly or halt  a  process  or
reaction abruptly.

Thermal  Black.   Carbon  black  manufactured by the thermal
process, produced by  thermal  decomposition  (cracking)  of
natural gas.
General Definitions

Abatement.   The  measures  taken  to  reduce  or  eliminate
pollution.

Absorption.  A process in which one material (the absorbent)
takes up  and  retains  another  (the  atsorbate)  with  the
formation  of a homogeneous mixture having the attributes of
a solution.   Chemical  reaction  may  accompany  or  follow
absorption.

Acclimation.  The ability of an organism to adapt to changes
in its immediate environment.

Acid.   A  substance  which  dissolves  in  water  with  the
formation of hydrogen ions.

Acid Solution.  A solution with a pH of less  than  7.00  in
which  the  activity of the hydrogen ion is greater than the
activity of the hydroxyl ion.

Acidity.  The capacity of a wastewater  for  neutralizing  a
base.  It is normally associated with the presence of carbon
dioxide, mineral and organic acids and salts of strong acids
or  weak  bases.   It  is  reported  as  equivalent of CaCO^
because many times it is  not  known  just  what  acids  are
present.

Act.   The Federal Water Pollution Control Act Amendments of
1972, Public Law 92-500.

Activated  Carbon.   Carbon  which  is  treated   by   high-
temperature  heating  with steam or carbon dioxide producing
an internal porous particle structure.

Adsorption.  An advanced method of treating wastes in  which
a material removes organic matter not necessarily responsive
to clarification or biological treatment by adherence on the
surface of solid bodies.

Aerobic.   Ability  to  live, grow, or take place only where
free oxygen is present.
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Algae.  One-celled  or  many-reel led  plants  which  grow  in
sunlit waters and which are capable of photosynthesis.  They
are  a food for fish and small aquatic animals and, like all
plants, put oxygen in the water.

Algal Bloom.  Large masses of  microscopic  and  macroscopic
plant  life,  such  as  green  algae,  occuring in bodies of
water.

Algicide.  Chemical agent used to destroy or control algae.

Alkali.  A water-soluble  metallic  hydroxide  that  ionizes
strongly.

Alkalinity.   The  presence  of salts of alkali metals.  The
hydroxides, carbonates and bicarbonates of  calcium,  sodium
and  magnesium  are common impurities that cause alkalinity.
A  quantitative  measure  of  the  capacity  of  liquids  or
suspensions  to  neutralize  strong  acids  or to resist the
establishment of acidic conditions.  Alkalinity results from
the  presence   of  bicarbonates,  carbonates,   hydroxides,
alkaline  salts  and  occasionally  borates  and  is usually
expressed in terms of the amount of calcium  carbonate  that
would  have  an  equivalent  capacity  to  neutralize strong
acids.

Alum.  A hydrated aluminum  sulfate  or  potassium  aluminum
sulfate  or  ammonium  aluminum  sulfate  which is used as a
settling agent.  A coagulant.

Anaerobic.  Ability to live, grow, or take place where there
is no air or free oxygen present.

Andon.  Ion with a negative charge.

Antagonistic Effects.  The simultaneous action  of  separate
agents mutually opposing each other.

Backwashing.   The  process  of  cleaning  a  rapid  sand or
mechanical filter by reversing the flow of water.

Bacteria.  Unicellular, plant-like  microorganisms,  lacking
chlorophyll.   Any  water  supply  contaminated by sewage is
certain to contain a bacterial group called "coliform".

Bcicterial Growth.   All  bacteria  require  food  for  their
continued  life  and  growth  and  all  are  affected by the
conditions of their environment.  Like  human  beings,  they
consume food, they respire, they need moisture, they require
he;at,   and  they  give  off  waste  products.   Their  food
                                105

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requirements are very definite and have  been,  in  general,
already  outlined.   Without  an adequate food supply of the
type the specific organism requires, bacteria will not  grow
and  multiply at their maximum rate and they will therefore,
not perform their full and complete functions.

(BADCT) NSPS  Effluent  Limitations.   Limitations  for  new
sources  which  are  based  on  the  application of the Best
Available Demonstrated Control Technology.  See NSPS.

Bag Filter.   Apparatus  used  to  attain  a  more  complete
purification of air than is attained by a baffle chamber.

Bag   House.    Large  chamber  for  holding  bags   (usually
synthetic) used in the filtration of gases for the  recovery
of solids suspended in gases.

Base.  A substance that in aqueous solution turns red litmus
blue,  furnishes  hydroxyl  ions  and reacts with an acid to
form a salt and water only.

Batch Process.  A process which has an intermittent flow  of
raw  materials into the process and a resultant intermittent
flow of product from the process.

BAT  (BATEA) Effluent  Limitations.   Limitations  for  point
sources,  other  than  publicly owned treatment works, which
are  based  on  the  application  of  the   Best   Available
Technology  Economically Achievable.  These limitations must
be achieved by July 1, 1983.

Benthic.  Attached to the bottom of a body of water.

Benthos.  Organisms (fauna  and  flora)  that  live  on  the
bottoms of bodies of water.

Biochemical  Oxygen  Demand   (BOD)«  A measure of the oxygen
required to oxidize the organic  material  in  a  sample  of
wastewater  by  natural  biological  process  under standard
conditions.  This test is presently universally accepted  as
the  yardstick  of  pollution  and is utilized as a means to
determine the degree  of  treatment  in  a  waste  treatment
process.   Usually  given  in  mg/1  (or ppm units), meaning
milligrams of oxygen required per liter  of  wastewater,  it
can also be expressed in pounds of total oxygen required per
wastewater  or  sludge batch.  The standard BOD is five days
at 20 degrees C.

Biota.  The flora and fauna  (plant and  animal  life)  of  a
stream or other water body.
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Biological   Treatment:   System.    A   system   that   uses
microorganisms to remove organic pollutant material  from  a
wastewater.

Blowdown.   Water intentionally discharged from a cooling or
heating   system   to   maintain   the   dissolved    solids
concentration  of  the  circulating  water  below a specific
critical level.  The removal of a  portion  of  any  process
flow to maintain the constituents of the flow within desired
levels.  , Process may be intermittent or continuous.  2) The
water discharged from a boiler or cooling tower  to  dispose
of accumulated salts.

BOD5.   Biochemical  Oxygen  Demand  (BOD)  is the amount of
oxygen required by bacteria while  stabilizing  decomposable
organic  matter  under aerobic conditions.  The BOD test has
been developed on the basis of  a  5-day  incubation  period
(i.e. BOD.5) .

Boiler Slowdown.  Wastewater resulting from purging of solid
and  waste materials from the boiler system.  A solids build
up in concentration as a result of water evaporation  (steam
generation) in the boiler.

BPT  (BPCTCA)   Effluent  Limitations.  Limitations for point
sources, other than publicly owned  treatment  works,  which
are based on the application of the Best Practicable Control
Technology  Currently  Available.  These limitations must be
achieved by July 1, 1977.

Break Point.  The point at which impurities first appear  in
the  effluent  of  an  adsorption filter bed, (e.g. granular
carbon).

Brine.  Water saturated with a salt.

Carbonaceous.  Containing or composed of carbon.

Carbonates.  Dibasic salts of carbonic  acid,  HJ^CO^,  e.g.,
potassium carbonate, K2CO_3; the radical, CO3-.

Cation.   The  ion  in  an  electrolyte  which  carries  the
positive charge and which migrates toward the cathode  under
the influence of a potential difference.

Caustic  Soda.   In  its  hydrated  form it is called sodium
hydroxide.  Soda ash is sodium carbonate.

Chemical Oxygen Demand  (COD).  A measure of oxygen-consuming
capacity of organic and inorganic matter present in water or
                               107

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wastewater.   It  is  expressed  as  the  amount  of  oxygen
consumed  from  a  chemical  oxidant in a specific test.  It
does not differentiate between stable and  unstable  organic
matter  and  thus does not correlate with biochemical oxygen
demand.

Chlorides.  Chloride ion  exist  as  salts  of  hydrochloric
acid, e.g. potassium chloride, KCl.

Chlorination.   The application of chlorine to water, sewage
or  industrial  wastes,  generally  for   the   purpose   of
disinfection   but   frequently   for   accomplishing  other
biological or chemical results.

Clarification.  Process of removing turbidity and  suspended
solids  by  settling.  Chemicals can be added to improve and
speed up the settling process through coagulation.

Clarifier.  A basin or  tank  in  which  a  portion  of  the
material suspended in a wastewater is settled.

Clays.   Aluminum  silicates  less  than 0.002mm  (2.0 urn) in
size.  Therefore, most clay  types  can  go  into  colloidal
suspension.

Coagulation.   The  clumping together of solids to make them
settle out of the sewage faster,  coagulation of  solids  is
brought  about  with  the  use of certain chemicals, such as
lime, alum or polyelectrolytes.

Coagulati on  and  Flocculation.   Processes   which   follow
sequentially.

Coagulation  Chemicals.  Hydrolyzable divalent and trivalent
metallic ions of aluminum, magnesium, and iron salts.   They
include  alum (aluminum sulfate), quicklime (calcium oxide),
hydrated lime (calcium hydroxide), sulfuric acid,  anhydrous
ferric  chloride.  Lime and acid affect only the solution pH
which in turn causes coagulant precipitation, such  as  that
of magnesium.

Coliform  Organisms.   A  group  of  bacteria  recognized as
indicators of fecal pollution.

Colloid.  A finely divided dispersion of one material  (0.01-
10 micron-sized particles),  called  the  "dispersed  phase"
(solid), in another material, called the "dispersion medium"
(liquid) .
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Color Bodies.  Those complex molecules which impart color to
a solution.

Color  Units.  A solution with the color of unity contains a
mg/1   of   metallic   platinum    (added    as    potassium
chloroplatinate   to  distilled  water).   Color  units  are
defined against a platinum-cobalt standard and are based, as
are  all  the  other  water  quality  criteria,  upon  those
analytical  methods  described  in  Standard Methods for the
Examination of Water and Wastewater, 12 \ed.,  Amer. , Public
Health Assoc., N. Y. , 1967.

Combined  Sewer.   One  which  carries both sewage and ctorm
water run-off.

Composite Sample.  A combination of  individual  samples  of
wastes  taken at selected intervals, generally hourly for 24
hours,  to  minimize  the  effect  of  the   variations   in
individual   samples.   Individual  samples  making  up  the
composite may be of equal volume or be  roughly  apportioned
to the volume of flow of liquid at the time of sampling.

Concentration.  The total mass of the suspended or dissolved
particles  contained in a unit volume at a given temperature
and pressure.            ,

Con duetivity.   A  reliable   measurement   of   electrolyte
concentration   in   a   water   sample. *  The  conductivity
measurement can be related to the concentration of dissolved
solids and is almost  directly  proportional  to  the  ionic
concentration of the total electrolytes.

Contact  Process  Wastewaters.   These are process-generated
wastewaters which have come in direct  or  indirect  contact
with  the reactants used in the process.  These include such
streams as contact cooling water, filtrates, centrates, wash
waters, etc.

Continuous Process.  A process which has a constant flow  of
raw  materials  into the process and resultant constant flow
of product from the process.

Contract Disposal.  Disposal of waste  products  through  an
outside party for a fee.

Crustaceae.   These  are  small animals ranging in size from
0.2 to 0.3 millimeter long which move very  rapidly  through
the  water  in  search of food.  They have recognizable head
arid posterior sections.  They form  a  principal  source  of
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food  for  small  fish  and  are found largely in relatively
fresh natural water.

Cyclone.  A conical  shaped  vessel  for  separating  either
entrained  solids  or liquid materials from the carrying air
or vapor.  The vessel has a tangential entry  nozzle  at  or
near  the largest diameter, with an overhead exit for air or
vapor and a lower exit for the more dense materials.

Desorption.  The opposite of adsorption.  A phenomenon where
an adsorbed molecule leaves the surface of the adsorbent.

Demineralization.  The total removal of all ions.

Disinfection.  The process of  killing  the  larger  portion
(but  not  necessarily all) of the harmful and objectionable
microorganisms in or on a medium.

Dissolved Oxygen (DO).   The  oxygen  dissolved  in  sewage,
water   or   other  liquids,  usually  expressed  either  in
milligrams per liter or percent of saturation.   It  is  the
test used in BOD determination.

DO  Units.  The units of measurement used are milligrams per
liter (mg/1) and parts per  million   (ppm),  where  mg/1  is
defined  as  the  actual weight of oxygen per liter of water
and ppm is defined as the  parts  actual  weight  of  oxygen
dissolved  in a million parts weight of water, i.e., a pound
of oxygen in a million  pounds  of  water  is  1  ppm.   For
practical  purposes in pollution control work, these two are
used interchangeably; the density of water is so close to  1
g/cm3  that the error is negligible.  Similarly, the changes
in  volume  of  oxygen  with  changes  in  temperature   are
insignificant.   This,  however,  is not true if sensors are
calibrated in percent saturation rather than in mg/1 or ppm.
In that case* both temperature and barometric pressure  must
be taken into consideration.

Dual  Media.   A  deep-bed  filtration  system utilizing two
separate and discrete  layers  of  dissimilar  media  (e.g.,
anthracite  and  sand)  placed  one  on  top of the other to
perform the filtration function.

Ecology.  The science of the interrelations  between  living
organisms and their environment.

Effluent.   A  liquid  which  leaves  a  unit  operation  or
process.  Sewage,  water  or  other  liquids,  partially  or
completely  treated  or in their natural states, flowing out
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of a reservoir basin, treatment  plant  or  any  other  unit
operation.  An influent is the incoming stream.

Entrainment  Separator.    A  device  to remove liquid and/or
solids from a gas stream.  Energy source is usually  derived
from pressure drop to create centrifugal force.

Envi ronmen t.    The  sum  of  all  external  influences  and
conditions affecting the life  and  the  development  of  an
organism.

Equalization  Basin.  A holding basin in which variations in
flow and composition of a liquid are averaged.  Such  basins
are  used to provide a flow of reasonably uniform volume and
composition to a treatment unit.

Eutrophication.  The process in  which  the  life-sustaining
quality  of  a  body  of  water is lost or diminished (e.g.,
aging or filling in of lakes).  A eutrophic condition is one
in which the water is rich in nutrients but has  a  seasonal
oxygen deficiency.

Fauna.   The  animal  life adapted for living in a specified
environment.

Filtrate.  The liquid fraction that is  separated  from  the
solids fraction of a slurry through filtration.

Flocculants.   Those  water-soluble organic polyelectrolytes
that  are  used  alone  or  in  conjunction  with  inorganic
coagulants   such  as  lime,  alum  or  ferric  chloride  or
coagulant aids to agglomerate solids  suspended  in  aqueous
systems  or  both. The large dense floes resulting from this
process permit more rapid and more  efficient  solids-liquid
separations.

Flocculation.   The  formation  of  floes.  The process step
following  the  coagulation-precipitation  reactions   which
consists  of  bringing together the colloidal particles.  It
is the  agglomeration  by  organic  polyelectroytes  of  the
small,  slowly settling floes formed during coagulation into
large floes which settle rapidly.

Flora.  The plant life characteristic of a region.

Flotation.  A method of  raising  suspended  matter  to  the
surface of the liquid in a tank as scum-by aeration, vacuum,
evolution of gas, chemicals, electrolysis, heat or bacterial
decomposition  and  the  subsequent  removal  of the scum by
skimming.
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Grab Sample.   (1)  Instantaneous  sampling.   (2)  A  sample
taken at a random place in space and time.

Grease.   In sewage, grease includes fats, waxes, free fatty
acids, calcium and magnesium soaps, mineral oils  and  other
nonfatty  materials.  The type of solvent to be used for its
extraction should be stated.

Grit Chamber.  A small detention chamber or  an  enlargement
of  a  sewer  designed to reduce the velocity of flow of the
liquid and permit the separation  of  mineral  from  organic
solids by differential sedimentation.

Groundwater.   The  body  of  water  that is retained in the
saturated zone which tends to move by hydraulic gradient  to
lower levels.

Hardness.    A   measure   of  the  capacity  of  water  for
precipitating soap.  It is reported  as  the  hardness  that
would  be  produced  if  a  certain  amount  of  CaCO3.  were
dissolved in water.  More than one ion contributes to  water
hardness.   The  "Glossary  of  Water and Wastewater Control
Engineering" defines hardness as: A characteristic of water,
imparted by salts of calcium, magnesium, and  ion,,  such  as
bicarbonates, carbonates, sulfates, chlorides, and nitrates,
that  causes  curdling  of  soap,  deposition  of  scale  in
boilers, damage in some industrial processes, and  sometimes
objectionable  taste.   calcium  and  magnesium are the most
significant constituents.

Heavy Metals.  A general name given for the ions of metallic
elements,  such  as  copper,  zinc,  iron,   chromium,   and
aluminum.   They  are  normally removed from a wastewater by
the  formation  of  an  insoluble  precipitate   (usually   a
metallic hydroxide).

Hydrocarbon.    A   compound   containing  only  carbon  and
hydrogen.

Incin erat ion.  The combustion (by burning) of matter,  (e.g.
carbon spills).

Influent.   Any sewage, water or other liquid, either raw or
partly treated, flowing into a reservoir,  basin,  treatment
plant,  or  any  part  thereof.    The influent is the stream
entering a  unit  operation;  the  effluent  is  the  stream
leaving it.

In-Piant    Measures.    Technology   applied   within   the
manufacturing process to reduce or eliminate  pollutants  in
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the  raw  waste water.  Sometimes called "internal measures"
or "internal controls".

Ion.  An atom or group of  atoms  possessing  an  electrical
charge.                                                    -

•Lacrimal.  Tear forming fluid.      ,

Lagoons.   An  oxidation  pond that received sewage which is
not settled or biologically treated.

Leach.  To dissolve out  by  the  action  of  a  percolating
liquid, such as water, seeping through a sanitary landfill.

Lime.   Limestone  is  an  accumulation  of  organic remains
consisting mostly of calcium  carbonate.   When  burned,  it
yields  lime  which  is  a  solid.   The  hydrated form of a
chemical lime is calcium hydroxide.

Maximum Day Limitation.  The effluent limitation value equal
to the maximum for one day and is the value to be  published
by the EPA in the Federal Register.

Maximum  Thirty  Day  Limitation.   The  effluent limitation
value for which the  average  of  daily  values  for  thirty
consecutive  days  shall  not  exceed and is the value to be
published by the EPA in the Federal Register.

Microbial.  Of or pertaining to a bacterium.

Molecular  Weight.   The  relative  weight  of  a   molecule
compared to the weight of an atom of carton taken as exactly
12.. 00;  the  sum  of  the  atomic  weights  of the atom in a
molecule.

Mollusk  (mollusca).  A large animal  group  including  those
forms   popularly   called   shellfish   (but  not  including
crustaceans).  All have a soft unsegmented body protected in
most instances by a calcareous shell.  Examples are  snails,
mussels, clams, and oysters.

Navigable  Waters.   Includes  all  navigable  waters of the
United States; tributaries of navigable  waters;  interstate
waters;  .intrastate  lakes,  rivers  and  streams  which are
utilized by interstate travellers for recreational or  other
purposes;  intrastate  lakes,  rivers and streams from which
fish or shellfish are taken and sold in interstate commerce;
and intrastate lakes, rivers and streams which are  utilized
for   industrial   purposes,  by  industries  in  interstate
commerce.
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Neutralization.    The  restoration  of  the   hydrogen   or
hydroxyl  ion  balance  in  a  solution  so  that  the ionic
concentration  of  each  are  equal.   Conventionally,   the
notation "pH"  (puissance d1hydrogen) is used to describe the
hydrogen  ion  concentration  or activity present in a given
solution.  For dilute solutions of  strong acids, i.e., acids
which are considered to be completely dissociate (ionized in
solution), activity equals concentration.

New Source.  Any facility from which there is or  may  be  a
discharge  of  pollutants,  the  construction  of  which  is
commenced after  the  publication   of  proposed  iregulations
prescribing  a  standard of performance under section 306 of
the Act.

Nitrate.  Salt of nitric acid, e.g., sodium nitrate, NaNO_3.

Non-contact Cooling Water.  Water used for cooling that does
not  come  into  direct  contact  with  any  raw   material,
intermediate product, waste product or finished product.

Non-contact Process Wastewaters.  wastewaters generated by a
manufacturing  process which have not come in direct contact
with the reactants used in the process.  These include  such
streams   as   non-contact   cooling  water,  cooling  tower
blowdown, boiler blowdown, etc.

NPDES.  National Pollution Discharge Elimination System.   A
federal program requiring manufacturers to obtain permits to
discharge plant effluents to the nation*s water courses.

NSPS«  New source performance standards.  See BADCT effluent
limitations.

Nutrient.   Any  substance  assimilated by an organism which
promotes growth and replacement of  cellular constituents.

Operations and Maintenance.  Costs  required to  operate  and
maintain  pollution  abatement  equipment  including  labor,
material, insurance, taxes, solid waste disposal, etc.

Oxidation.  A process in which an atom  or  group  of  atoms
loses electrons; the combination of a substance with oxygen,
accompanied  with  the release of energy.  The oxidized atom
usually becomes a positive ion  while  the  oxidizing  agent
becomes a negative ion in  (chlorination for example).

Oxygen,   Available.    The  quantity  of  dissolved  oxygen
available for the oxidation of organic matter.
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Oxygen, Dissolved.  The oxygen (usually  designated  as  DO)
dissolved  in  sewage,  water  or another liquid and usually
expressed in parts per million or percent of saturation.

Parameter.    A   variable   whose   measurement   aids   in
characterizing the sample.

Parts   Per  Million   (ppm).   Parts  by  weight  in  sewage
analysis; ppm by weight is equal  to  milligrams  per  liter
divided by the specific gravity.   It should be noted that in
water   analysis   ppm  is  always  understood  to  imply  a
weight/weight ratio, even though in practice a volume may be
measured instead of a weight.

Percolation.  The  movement  of  water  beneath  the  ground
surface  both  vertically  and  horizontally,  but above the
groundwater table.

Permeability«  The ability of a substance  (soil)  to  allow
appreciable  movement of water through it when saturated and
actuated by a hydrostatic pressure.

pH.   The   negative   logarithm   of   the   hydrogen   ion
concentration  or  activity  in  a  solution.   The number 7
indicates  neutrality,  numbers   less   than   7   indicate
increasing  acidity^  and  numbers  greater  than 7 indicate
increasing alkalinity.

Phosphate.  Phosphate ions exist as  an  ester  or  salt  of
phosphoric   acid,  such  as  calcium  phosphate  rock.   In
municipal wastewater,  it  is  most  frequently  present  as
orthophosphate.

Photosynthesis.   The mechanism by which chlorophyll-bearing
plant utilize  light  energy  to  produce  carbohydrate  and
oxygen  from  carbon  dioxide  and  water  (the  reverse  of
respiration).

Physical/Chemical Treatment System.  A system that  utilizes
physical   (i.e.,  sedimentation, filtration, centrifugatiori,
activated carbon, reverse  osmosis,  etc.)  and/or  chemical
means  (i.e., coagulation, oxidation, precipitation, etc.) to
treat wastewaters.

Phytopiankton.    (1)  Collective  term  for  the  plants and
plantlike organisms  present  in  plankton;  contrasts  with
zooplankton.   (2) The plant portion of the plankton.
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Plankton.   Collective  term  for  the  passively flating or
drifting flora and  fauna  of  a  body  of  water;  consists
largely of microscopic organisms.

Point   Source.   Any  discernible,  confined  and  discrete
conveyance, including but not limited to  any  pipe,  ditch,
channel, tunnel, conduit, well, discrete fissure, container,
rolling  stock,  concentrated  animal  feeding operation, or
vessel or other floating craft, from which pollutants are or
may be discharged.

Pollutional Load.  A measure of the strength of a wastewater
in terms of its solids or  oxygen-demanding  characteristics
or other objectionable physical and chemical characteristics
or  both  or in terms of harm done to receiving waters.  The
pollutional  load  imposed  on  sewage  treatment  works  is
expressed as equivalent population.

Polyelectrolytes.   Synthetic  chemicals  (polymers) used to
speed up the removal of solids from sewage.   These chemicals
cause solids to coagulate or  clump  together  more  rapidly
than do chemicals such as alum or lime.  They can be anibnic
(-charge) ,  nonionic   (+ and -charge)  or cationic (+charge—
the most popular).  They  are  linear  or  branched  organic
polymers.   They  have high molecular weights and are water-
soluble.    Compounds   similar   to   the   polyelectrolyte
flocculants  include  surface-active agents and ion exchange
resins.  The former are low molecular weight, water  soluble
compounds  used  to disperse solids in aqueous systems.  The
latter are high molecular weight, water-insoluble  compounds
used  to selectively replace certain ions already present in
water with more desirable or less noxious ions.

Potable Water.  Drinking water sufficiently pure  for  human
use,

Preaeration.   A  preparatory treatment of sewage consisting
of aeration to remove gas and add oxygen or to  promote  the
flotation of grease and aid coagulation.

Precipitation.  The phenomenon which occurs when a substance
held  in  solution  passes  out  of that solution into solid
form.  The adjustment of pH can reduce solubility and  cause
precipitation.   Alum and lime are frequently used chemicals
in  such  operations  as  water  softening   or   alkalinity
reduction.

Pretreatment.   Any  wastewater  treatment  process  used to
partially reduce the pollution load before the wastewater is
introduced into a  main  sewer  system  or  delivered  to  a
                                 116

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treatment  plant  for substantial reduction of the pollution
load.

Primary  Clarifier.   The  settling  tank  into  which   the
wastewater  (sewage)  first enters and from which the solids
are removed as raw sludge.

Primary Sludge.  Sludge from primary clarifiers.

Primary Treatment.  The removal of material that  floats  or
will settle in sewage by using screens to catch the floating
objects  and  tanks  for the heavy matter to settle in.  The
first major treatment and sometimes the only treatment in  a
waste-treatment    works,   usually   sedimentation   and/or
flocculation and  digestion.   The  removal  of  a  moderate
percentage of suspended matter but little or no colloidal or
dissolved  matter.   May  effect  the  removal  of  30 to 35
percent or more BOD.

Process Wastewater.  Any water which,  during  manufacturing
or  processing,  comes  into  direct contact with or results
from the production or use of any raw material, intermediate
product, finished product, by-product, or waste product.

Process Water.  Any water (solid, liquid  or  vapor)  which,
during  the manufacturing process, comes into direct contact
with any raw  material,  intermediate  product,  by-product,
waste product, or finished product.

Quiesance.  Quiet, still, inactive.

Raw  Waste Load (RWL).  The quantity (kg) of pollutant being
discharged in a plant1s wastewater.  measured  in  terms  of
some  common  denominator   (i.e., kkg of production or m2 of
floor area) .

Receiving Waters.  Rivers, lakes, oceans  or  other  courses
that receive treated or untreated wastewaters.

Recirculation.  The return of effluent to the incoming flow.

Reduction.   A  process in which an atom  (or group of atoms)
gain electrons.  Such a process always requires the input of
energy.

Retention Time.  Volume of the vessel divided  by  the  flow
rate through the vessel.

Saline  Water.   Water  containing  dissolved salts, usually
from 10,000 to 33,000 mg/1.
                              117

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Salt.  A compound made up of the positive ion of a base  and
the negative ion of an acid.

Sanitary  Landfill.   A sanitary landfill is a land disposal
site employing an engineered method of  disposing  of  solid
wastes  on  land  in  a  manner that minimizes environmental
hazards by spreading the wastes in thin  layers,  compacting
the  solid  wastes  to  the  smallest  practical volume, and
applying cover material at the end of  each  operating  day.
There  are  two basic sanitary landfill methods; trench fill
and area or ramp fill.  The method chosen  is  dependent  on
many  factors  such  as  drainage  and  type  of soil at the
proposed landfill site,

Sanitary Sewers.  In a separate system, pipes in a city that
carry only domestic wastewater.  The storm water  runoff  is
handled by a separate system of pipes.

Screening.   The  removal of relatively coarse, floating and
suspended solids by straining through racks or screens.

Scrubber.  A type of apparatus used in sampling and  in  gas
cleaning  in  which  the  gas  is  passed  through  a  space
containing wetted "packing" or spray.

Sedimentation,  Final.   The  settling  of  partly  settled,
flocculated  or  oxidized sewage in a final tank.  (The term
settling is preferred).

Sedimentation, Plain.  The sedimentation of suspended matter
in a liquid unaided by chemicals or other special means  and
without any provision for the decomposition of the deposited
solids in contact with the sewage.   (The term plain settling
is preferred) .

Settleable  Solids.   Suspended solids which will settle out
Of a liquid waste in a given period of time.

Sewageff Raw.  Untreated sewage.

Sewage, Storm.  The  liquid  flowing  in  sewers  during  or
following   a   period   of  heavy  rainfall  and  resulting
therefrom.

Sewerage.  A comprehensive term  which  includes  facilities
for  collecting, pumping, treating, and disposing of sewage;
the sewerage system and the sewage treatment works.

Silt.  Particles with a size distribution of  0.05mm-0.002mm
(2.0mm).  Silt is high in quartz and feldspar.
                                118

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Skimmincr.  Removing floating solids  (scum) .

Solution.   A  homogeneous mixture of two or more substances
of dissimilar molecular.structure.  In a solution, there  is
a  dissolving  medium-solvent  and  a  dissolved  substance-
solute.

Solvent.  A liquid which reacts with a material, bringing it
into solution.

Standard Raw Waste Load (SRWL)«  The raw  waste  load  which
characterizes  a  specific  subcategory.   This is generally
computed by averaging the plant raw  waste  loads  within  a
subcategory.

Stoichiometric.   Characterized  by  being  a  proportion of
substances exactly right for a  specific  chemical  reaction
with no excess of any reactant or product.                •

Sulfate.   The final decomposition product of organic sulfur
compounds.

Surge tank.  A tank for absorbing and dampening the wavelike
motion of a volume of liquid;  an  in-process  storage  tank
that acts as a flow buffer between process tanks.

Suspended  Solids.   The wastes that will not sink or settle
in sewage.  The quantity of material deposited on  a  filter
when a liquid is drawn through a Gooch crucible.

Synergistic.   An  effect  which is more than the sum of the
individual contributors.

Synerqistic Effect.  The  simultaneous  action  of  separate
agents  which,  together, have greater total effect than the
sum of their individual effects.

Total Organic Carbon  (TOG).  A  measure  of  the  amount  of
carbon  in  a  sample  originating from organic matter only.
The test is run by burning  the  sample  and  measuring  the
carbon dioxide produced.

Total  Solids.   The  total amount of solids in a wastewater
both in solution and suspension.

Turbidity.  A measure of the amount of solids in suspension.
The units of measurement are  parts  per  million  (ppm)  of
suspended  solids  or  Jackson  Candle  Units.   The Jackson
Candle Unit  (JCU) is defined as the turbidity resulting from
1 ppm of fuller's earth (and  inert  mineral)  suspended  in
                               119

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water.   The  relationship  between  ppm  and JCU depends on
particle sizer color, index of refraction;  the  correlation
between  the  two  is  generally  not  possible.   Turbidity
instruments utilize a light beam projected into  the  sample
fluid  to effect a measurement.  The light beam is scattered
by solids in suspension, and the degree of light attenuation
or  the  amount  of  scattered  light  can  be  related   to
turbidity.  The light scattered is called the Tyndall effect
and the scattered light the Tyndall light.  An expression of
the  optical  property  of a sample which causes light to be
scattered and absorbed rather than transmitted  in  straight
lines through the sample.

Volatile  Suspended Solids JVSS]_.  The quantity of suspended
solids lost after the ignition of total suspended solids.

Waste Treatment Plant.  A series of tanks, screens, filters,
pumps and other equipment by which  pollutants  are  removed
from water.

Water  Quality  Criteria.   Those  specific  values of water
quality associated with an identified beneficial use of  .the
water under consideration.

Weir.   A  flow  measuring  device  consisting  of a barrier
across an open channel, causing the liquid to flow over  its
crest.  The height of the liquid above the crest varies with
the volume of liquid flow.

Wet  Air  Pollution Control.  The technique of air pollution
abatement utilizing water as an absorptive media.

Zeolite.  Various natural or synthesized silicates  used  in
water softening and as absorbents.

zooplankton.   (1)  The animal portion of the plankton.  (2)
Collective term for the nonphotosynthetic organisms  present
in plankton; contrasts with phytoplankton.
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                         SECTION  XVII

                 ABBREVIATIONS AND SYMBOLS
A.C.      activated
ac  ft     acre-foot
Ag,       silver
atm      atmosphere
ave      average
B.        boron                      ,
Ba..       barium
bbl      barrel
BOD5      biochemical  oxygen demand,  five day
Btu      British  thermal  unit
C         centigrade  degrees
C.A.      carbon adsorption
cal      calorie                ,
cc        cubic centimeter
cfm      cubic foot  per minute
cfs      cubic foot  per second
Cl.       chloride                            ,
cm        centimeter
CN        cyanide                  ,
COiD      chemical oxygen  demand
cone.     concentration
cu        cubic                                       ,
db        decibels
deg      degree
DO        dissolved oxygen
E.  Coli   Escherichia  coliform bacteria
Eq.       equation
F         Fahrenheit  degrees
Fig.      figure
F/M      BODJ5  (Wastewater flow) /  MLSS (contractor volume)
fpm      foot per minute
fps      foot per second
ft        foot
g         gram                                     ,
gal      gallon                       .
gpd      gallon per  day
gpm      gallon per  minute                      ,
Hg        mercury                             :
hp        horsepower
hp-hr     horsepower-hour
hr        hour
in.      inch
kg        kilogram
kw        kilowatt
kwhr      kilowatt-hour
                                121

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L{1)     liter
L/kkg    liters per 1000 kilograms
Ib       .pound
m        meter
M        thousand
me       millieguivalent
mg       milligram
mgd      million gallons daily
min      minute
ml       milliliter
MLSS     mixed-liquor suspended solids
MLVSS    mixed-liquor volatile suspended solids
MM       million
mm       millimeter
mole     gram-molecular weight
mph      mile per hour
MPN      most probable number
mu       millimicron
NO.3      nitrate
NH3-N    ammonium nitrogen
O2       oxygen
POU.      phosphate
p.       page
pH       potential hydrogen or hydrogen-ion index (negative
         logarithm of the hydrogen-ion concentration)
pp.      pages
ppb      parts per billion
ppm      parts per million
psf      pound per square foot
psi      pound per square inch
R.O.     reverse osmosis
rpm      revolution per minute
RWL      raw waste load
sec      second
Sec.     Section
S.I.C.   Standard Industrial classification
SOx      sulfates
sq       square
sq ft    square foot
SS       suspended solids
stp      standard temperature and pressure
SRWL     standard raw waste load
TDS      total dissolved solids
TKN      total Kjeldahl nitrogen
TLm      median tolerance limit
TOC      total organic carbon
TOD      total oxygen demand
TSS      total suspended solids
u        micron
ug       microgram
                               122

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vol      volume
wt       weight
yd       yard
                                123

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                                   TABLE XVIII

                                  METRIC TABLE

                                CONVERSION TABLE
[ULTIPLY  (ENGLISH UNITS)

   ENGLISH UNIT      ABBREVIATION

.ere                     ac
.ere-feet                ac ft
•ritish Thermal
 Unit                   BTU
British Thermal
 Unit/Pound             BTU/lb
ubic feet/minute        cfm
:ubic feet/second        cfs
ubic feet               cu ft
ubic feet               cu ft
ubic inches             cu in
degree Fahrenheit        °F
:eet                     ft
;allon                   gal
;allon/minute            gpm
lorsepower     :          hp
.nches                   in
.nches of mercury        in Hg
>ounds                   Ib
dllion gallons/day      mgd  .
die                     mi
>ound/square
 inch (gauge)           psig
square feet              sq ft
square inches            sq in
:on (short)              ton
rard                     yd
        by

    CONVERSION

      0.405
   1233.5

      0.252
           TO OBTAIN  (METRIC UNITS)

ABBREVIATION      METRIC UNIT
  ha
  cu m

  kg cal
0.555
0.028
1.7
0.028
28.32
16.39
0.555 (°F-32)*
0.3048
• 3.785
0.0631
0.7457
2.54
0.03342
0.454
3,785
1.609
kg cal/kg
cu m/min
cu m/min
cu m
1
cu cm
°C
m
1
I/sec
kw
cm
atm
kg
cu m/day
km
(0.06805 psig +1)*  atm
      0.0929        sq m
      6.452         sq cm
      0.907         kkg
      0.9144        m
hectares
cubic meters

kilogram-calories

kilogram calories/kilogram
cubic meters/minute
cubic meters/minute
cubic meters
liters
cubic centimeters
degree Centigrade
meters
liters
liters/second
killowatts
centimeters
atmospheres
kilograms
cubic meters/day
kilometer

atmospheres  (absolute)
square meters
square centimeters
metric ton  (1000 kilograms)
meter
                 *Actual conversion,  not a multiplier
                                                                              4/30/76
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