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 Another significant waste characteristic not represented  in
 Table  V-1 is trace quantities of explosives.   The following
 concentrations of explosives have been reported:
               Explosives

                   NG
                   TNT
                   RDX
                   HMX
 Effluent Concentration

1,800 mg/1
70-350 mg/1
7.9 mg/1
2.6 mg/1
 In  addition  to  these  manufactured  explosives    in    the
 effluent,   there  are  significant concentrations of  unwanted
 isomers  such as  DNT (dinitrotoluene)  in the  wastewater.   The
 possibility of these small   concentrations   accumulating   in
 the    environment  and  the   toxicity  of   these wastes
 necessitates adequate  treatment  prior to discharge.

     Kanges  of Concentration

 A  key  waste characterization is  the range of   concentration
 for      significant     pollutant    parameters.     Average
 concentrations  are   presented    in    Table   V-4.    These
 concentrations  can be  very misleading, since non-contact
 cooling  waters cannot  be distinguished  from  process  waters
 in every case.

 The  following ranges of pollutants-based on  the survey and a
 review of the historical data are for subcategory A:
EOD5 - 20.0 to  1,100 mg/1
COD  - 60 to 3,500 mg/1
TSS  - 8.0 to 1,300 mg/1
TOC  - 12.0 to  1,500 mg/1
   N03-N  -  20.0  to  6,800 mg/1
   TKN    -  5.0 to 3,700 mg/1
   SOU    -  50 to 2,100 mg/1
The   following  pollutant  concentration  ranges  generally
characterize subcategory B:
COD  - 200 to 1,200 mg/1
TSS  - 100 to 1,000 mg/1
TOC  - 30 to 130 mg/1
  N03-N  -  1.0 to 11,000 mg/1
  TKN    -  1.8 to 60 mg/1
  S04    -  300 to 900 mg/1
The  pollutant  concentration  ranges  for
generally fall into the following ranges:
              subcategory
BODS - 0 to 12 mg/1
COD  - 8.0 to 220 mg/1
TSS  - 1 to 770 mg/1
TOC  - 2.0 to 480 mg/1
  N03-N - 0.4 to 12 mg/1
  TKN   - 2.0 to 6.0 mg/1
  SOU   - 50 to 85 mg/1
                             72

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                                  Table V-4
                         Concentration of Pollutants
                             Explosives Industry
Category

   A
   B
   C
   D
BOD.5
mg/L
871
2371
<1
340
COD
mg/L
2,310
4421
45
7,210
TKN
mg/L
489
222
12
3
Nitrates
mg/1
1,490
1442
9
6.0
SO.
*t
mg/L
4,120
7151
232
1 ,060
TOC
mg/L
972
1632
2
975
TSS
mg/L
489
2421
523
56
1 Historical Data, Plant No.  47
2Survey Data, Plant No. 47
                                     73

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The   above   ranges  for  BODS,  COD  and TOC represent different
data   populations   because  the   complete   data   for   all
parameters were  not available from  each plant.

The   pollutant data points generally fall into the following
concentration ranges for subcategory D:
BODS -  100 to  12,000 mg/1
COD  -  300 to  50,000 mg/1
TSS  -  1.0 to  60,000 mg/1
TOC  -  50 to 15,000 mg/1
NO3-N - 0.5 to 5,000 mg/1
TKN   - 4.0 to 1,000 mg/1
S04   - 5 to 120,000 mg/1
It is evident that  the  concentrations  for  subcategory  B
appear  similar  to A; however, the amounts of raw pollutant
per  1,000 pounds of .product differ greatly.  Tables V-1  and
V-2a through v-2d provide more detailed data to substantiate
this observation.
Plants   falling  in  subcategory  c  appear  to  be  widely
scattered with regard to pollutant concentration.  It should
be noted that the average flow in this  category  was  about
6,800 gpd, even though the concentrations are very small.

Wasteloads  from  plants  in  subcategory  D  appear  to  be
variable in concentration.  This is borne out by the  nature
of  this  category.  For example, if a sample were extracted
when the batch process is being dumped, it would have a high
concentration.  Also, a plant  that  discharges  a  specific
process  effluent  once  every  three weeks was sampled. The
result was extremely high concentrations  of  pollutants  on
some days, followed by long periods of low concentration.
                                74

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                         SECTION VI

             SELECTION OF POLLUTANT PARAMETERS
General

From   review   of  NPDES  permit,  applications  for  direct
discharge   of   wastewaters   from    various    explosives
manufacturers  and  examination  of  related published data,
twelve parameters (listed in Table VI-1) were  selected  and
examined  for  all  industrial  wastewaters during the field
data cpllection  program.   In.  addition,  several  specific
parameters were examined for each of the subcategories.  All
field   sampling   data  are  summarized  in  Supplement  B.
Supplement B includes laboratory  analytical  results,  data
from  plants  visited,  RWL  calculations,  historical data,
analysis of historical data,  computer  print-outs  (showing
flows,  production,  and  pollutants,  performance  data  on
treatment    technologies    and    effluent     limitations
calculations).    Supplement   A  has  design  calculations,
capital cost calculations,  and, annual  cost  calculations.
Supplements  A  and  B  are  available  at  the  EPA  Public
Information  Reference  Unit,  Room  2922   (EPA   Library),
Waterside Mall, Washington* B.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 signi-ficance.
    3.  Pollutants of specific significance.

The rationale and justification for pollutant categorization
within  the  foregoing  groupings, as discussed herein, will
indicate the basis for  selection  of  the  parameters  upon
which  the  actual  effluent limitations and guidelines were
postulated for each point source.  In  addition,  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 inadequate treatment through
publicly  owned treatment works are discussed in Section XII
of this document.
                          75

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    Pollutants of Significance

Parameters  of   pollution   significance   for   explosives
manufacturing point source category are BOD5, COD, TOC, TDSr
TSS,  nitrates,  .sulfates,  total Kjeldahl nitrogen, ammonia
nitrogen, lead and pH.

BOD5, COD, and TOC  have  been  selected  as  pollutants  of
significance  because  they  are the primary measurements of
organic  pollution.   In  the  survey  of   the   industrial
categories,  almost  all of the effluent data collected from
wastewater' treatment  facilities  were  based  upon   BOD5,
because  almost all the treatment facilities were biological
processes.   if  other  processes  (such   as   evaporation,
incineration,  or activated carbon)  are utilized, either COD
or TOC may be a more appropriate measure of pollution.
                         76

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        Table VI-1
List of Parameters Examined
Biochemical Oxygen Demand
Chemical Oxygen Demand
Total Organic Carbon
Total Suspended Solids
Dissolved Solids
Lead
Mercury
Nitrogen Compounds
pH, Acidity, Alkalinity
Sulfates
Oil and Grease
Color
            77

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 BOD

 Biochemical  oxygen  demand  (BOD)  is usually   defined  as  the
 amount    of    oxygen    required   by    microorganisms  while
 stabilizing   decomposable  organic  matter   under   aerobic
 conditions.    The  term "decomposable"  may be interpreted as
 meaning  that the  organic matter  can serve as  food   for  the
 microorganisms   and    that  energy   is derived  from  this
 oxidation. '

 The BOD  does not  in itself cause direct  harm  to   a  water
 system,   but  it  does exert an indirect effect by depressing
 the oxygen content  of the wafer";  Organic effluents  exert  a
 BOD during their  processes of decomposition which can have a
 catastrophic effect on  the ecosystem  by depleting the oxygen-
 supply. ^  Conditions  are sometimes reached where all of the
 oxygen is used, and the continuing decay process causes  the
 production of gases, such as hydrogen sulfide.  Water with a
 high BOD indicates  the  presence   of decomposing organic
 matter and subsequent high bacterial  counts that degrade the
 quality  and  potential use of the water.

 Dissolved oxygen  (DO)  is a water quality  constituent  that,
 in  appropriate concentrations, is essential not only to keep
 organisms living  but  also to sustain  species reproduction,
 vigor,  and   the-  development  of  populations.    Organisms
 undergo   stress   at reduced DO. concentrations that make them
 less competitive  and   less  capable   of  sustaining  their
 species   within  the   aquatic   environment.   For  example,
 reduced DO concentrations have been shown to interfere  with
 fish population  through  delayed hatching of eggs, reduced
 size and  vigor of embryos, production of deformities in  the
young,  interference  with  food  digestion, acceleration of
blood clotting, decreased tolerance  to  certain  toxicants,
reduced  food  efficiency and growth rate, and reduced maximum
 sustained swimming speed.  Fish food organisms are likewise
affected  adversely in conditions with suppressed DO.   Since
all  aerobic   aquatic  organisms  need  a  certain amount of
oxygen, the  consequences of total lack  of  dissolved  oxygen
due  to   a  high  BOD can kill all aerobic inhabitants of the
affected  area.
The  BOD
Chemical
          •test   (Standard  Methods,  1971;  Methods  of  the
	  Analysis  of Water and Wastes, 1971)  has been used
to gauge the pollutional strength of a wastewater  in  terms
of   the  oxygen  it  would  demand  if  discharged  into  a
watercourse.  Historically, the BOD test has also been  used
to   evaluate   the  performance  of  biological  wastewater
treatment facilities and to  establish  effluent  limitation
                            78

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values.  However, objections to the use of the BOD test have
been raised.  The major objections are:

    1.   The  standard  BOD5 test takes five days before the
results are available.

    2.   At the start of the BOD test,  a  seed  culture  of
microorganisms  is  added  to  the  BOD bottle.  If the seed
culture were not acclimated  (i.e.,  exposed  to  a  similar
wastewater   in   the   past),   then  it  may  not  readily
biologically degrade the waste, and a low BOD value  may  be
reported.   This  situation  may  occur  when  dealing  with
complex industrial wastes.

    3.   The BOD test is sensitive to  toxic  materials,  as
are all biological processes.  Therefore, if toxic materials
are present in particular wastewater, the reported BOD value
may be erroneous.  This situation can be remedied by running
a  microorganism  toxicity test, i.e., subsequently diluting
the sample until the BOD value reaches a plateau  indicating
that  the  material  is  at  a concentration which no longer
inhibits biological oxidation.

However, some of the previously cited weaknesses of the  BOD
test  also  make  it  uniquely  applicable.   It is the only
parameter now available which measures the amount of  oxygen
utilized  by  microorganisms  in  metabolizing  organics  in
wastewater.

The use of COD or TOC  to  monitor  the  efficiency  of  BOD
removal in biological treatment is possible only if there is
a good correlation between COD or TOC and BOD.  Under normal
circumstances,  two correlations would be necessary, one for
the raw wastewater and one for the treated effluent.  During
the field data analysis, varying correlations between COD or
TOC and BODJ5 were evident between subcategories.   In  spite
of  some disadvantages, this industry should continue to use
the EOD5 parameter as one of its pollution indicators.

The EOD5 test is essentially a bioassay procedure  involving
the measurement of oxygen consumed by living organisms while
utilizing  the  organic  matter  present  in  a  waste under
conditions as similar as possible to  those  that  occur  in
nature..    It  is  extremely  important  that  environmental
conditions be suitable for the living organisms to  function
in  an  unhindered  manner  at  all times.  This requirement
means  that  toxic  substances  must  be  absent  and   that
accessory  nutrients  needed  for  microbial growth  (such as
nitrogen, phosphorus, and certain trace  elements)  must  be
present.   Biological  degradation  of  organic matter under
                            79

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 natural conditions is brought about by a  diverse  group  of
 organisms   that   carry   the   oxidation   essentially  to
 completion.   Therefore, it is important that a  mixed  group
 of  organisms commonly called "seed" be present in the  test.
 For a few industrial wastes,  this "seed" should  be  allowed
 to  adapt to  the  particular  waste  (acclimate)   prior to
 introduction of the culture into the BOD5 bottle.

 The EODJ5 test may be considered as a wet oxidation procedure
 in which the  living  organisms  serve  as  the  medium  for
 oxidation of the organic matter to carbon dioxide and water.
 ft  quantitative  relationship  exists  between the amount of
 oxygen required to convert a  definite amount  of  any  given
 organic  compound  to carbon  dioxide and water,  which can be
 represented  by a generalized  equation.   On the basis  of this
 relationship,  it is possible  to interpret BOD5_ data in  terms
 of organic matter that is present as well as in terms of  the
 amount of oxygen used during  its oxidation.   This  concept is
 fundamental  to an understanding of the rate  at which  BODS  is
 exerted.                                                ~~

 The oxidative  reactions involved in the BOD5_  test are  the
 result  of  biological  activity,   and the rate  at which  the
 reactions proceed is governed  to  a  major   extent  by  the
 microbial   concentration  and   temperature.   Temperature
 effects are  held constant by  performing the   test   at  20°C,
 which  is an  approximate median value for natural bodies of
 water.

 The predominant^organisms responsible  for the   stabilization
 of  most  organic matter in natural  waters are native to the
 soil.   The rate of their metabolic  processes  at   20°C  and
 under   the    conditions  of    the  test (total   darkness,
 quiescence,  etc.)  is  such that   time  must be   measured  in
 days.    Theoretically,   an  infinite  time   is   required for
 complete  biological oxidation of organic  matter, but  for all
 practical purposes  the reaction  may  be   considered  to  be
 complete^  in  20  days.   A BOD test  conducted over  the 20 day
 period   is   normally   considered  a  good  estimate  of  the
 "ultimate"   BOD.    However,  a   20-day  period is too long to
 wait   for results   in  practice.   -It  has  been   found  by
 experience   with  domestic  sewage  that   a reasonably large
 percentage of   the  total  BOD   is   exerted  in  five  days.
 Consequently,   the  test  has been developed on the  basis of a
 5-day  incubation   period.    It   should   be   remembered,
 therefore, that 5-day  BOD values represent only a portion of
 the   total  BOD,   The  exact   percentage  depends  on  the
 character of the  "seed"  and  the  nature  of  the  organic
matter, and  can be  determined only by experiment.
                            80

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COD

The   chemical   oxygen  demand  (COD)   test  represents  an
alternative to the BOD test, and  in  many  respects  it  is
superior  to  the  BOD  test.  COD is widely used and allows
measurement of a waste in terms of  the  total  quantity  of
oxygen  required  for  oxidation to carbon dioxide and water
under severe chemical and physical conditions.  It is  based
on   the  fact  that  all  organic  compounds,  with  a  few
exceptions,  can  be  oxidized  by  the  action  of   strong
oxidizing agents under acid conditions.

During  the  COD test, organic matter is converted to carbon
dioxide   and   water   regardless   of    the    biological
assimilability  of the substances; for instance, glucose and
lignin are both  oxidized  completely.   As  a  result,  COD
values   are   greater   than  BOD  values  especially  when
significant amounts of biologically-resistant organic matter
are present.

One drawback of the COD test is that  its  results  give  no
indication  of  the  rate  at  which the biologically active
material would be stabilized under conditions that exist  in
nature.    High   levels  of  chloride  interfere  with  the
analysis.  Normally,  mercuric  sulfate  is  added  to  each
sample.  being   analyzed  for  chemical  oxygen  demand  to
eliminate the chloride interference.

The major advantage of  the  COD  test  is  the  short  time
required  for  evaluation.  The determination can be made in
about  3  hours  rather  than  5  days  required   for   the
measurement of BOD.  Furthermore, the COD test requires less
sophisticated  equipment,  smaller  working  area,  and less
investment  in   laboratory   facilities.    Another   major
advantage  of  the  COD  test  is  that  there  is  no  seed
acclimation problem.

TOG

Total organic carbon  (TOC) is a measure  of  the  amount  of
carbon  in the organic material in a-wastewater sample.  The
TOC  analyzer  withdraws  a  small  volume  of  sample   and
thermally  oxidizes it at 150°C.  The water vapor and carbon
dioxide from the combustion chamber  (where the  water  vapor
is  removed) are condensed and sent to an infrared analyzer,
where the carbon dioxide is monitored.  This carbon  dioxide
value  corresponds  to  the  total inorganic value.  Another
portion  of  the  same  sample  is  thermally  oxidized   at
temperatures  above 950°C.  This latter value corresponds to
                            81

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 the -total carbon value.  TOC is  determined  by  subtracting
 the inorganic carbon from the total carbon value.

 TSS

 All undissolved solids in water,  unless they have  settled to
 the  bottom in one hour,  are suspended solids.   The  fraction
 of undissolved solids that are settleable  is  dependent  on
 quiescence,    temperature,     density,   stability,    size,
 flocculation, and many other factors.   Suspended solids  are
 a  vital and easily determined measure of pollution  and also
 a measure of the material that may  settle  in   tranquil  or
 slow-moving streams.

 Suspended   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)  fats.

 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.

 Total  suspended  solids   (TSS) discharged in the  biological
 treatment system effluent consists  of  biological solids   and
 other  suspended  solids   carried  over through  the treatment
 facilities.   Total  suspended solids, when   discharged  to a
 watercourse,   settle   to  the bottom and can blanket spawning
 grounds  and interfere  with fish propagation.    In  addition,
 the  solids which  are organic will be metabolized and exert
 an oxygen demand on the  body  of   water.   Total  suspended
 solids,   in    large   .concentrations,   can    impede  light
 transmittance  and interfere  with   aquatic  photosynthesis,
 thereby  affecting the  oxygen content of a  body  of water.

 Solids   in  suspension  are usually aesthetically displeasing.
 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.

In addition to 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
                             82

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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.

Pollutants of Limited Significance

Dissolved Solids

In  natural  waters,  the  dissolved   solids   are   mainly
carbonates,  chlorides,  sulfates,  phosphates,  and,  to  a
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.
                            83

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 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.

 Lead (Pb)

 Some natural waters contain lead in solution, as much as O.U
 to  0.8  mg/1 where mountain limestone and galena are found.
 In the U.S.A., lead concentrations  in  surface  and  ground
 waters  used for domestic supplies range from traces to 0.04
 mg/1,  averaging about  0.01 mg/1.

 Foreign to the human body, lead tends  to  be  deposited  in
 bone  as  a  cumulative  poison.    The  intake  that  can be
 regarded as safe for everyone cannot be  stated  definitely,
 because  the  sensitivity  of  individuals  to  lead differs
 considerably.    Lead  poisoning  usually  results  frorr.  the
 cumulative  toxic  effects of lead after continuous consump-
 tion over  a long period of time,  rather than from occasional
 small  doses.    Lead is  not  among  the  metals  considered
 essential  to the nutrition of animals or human beings.

 Lead may enter the  body through food,  air,  and tobacco  smoke
 as  well as from water and other  beverages.   The exact  level
 at which the intake of lead by the human  body  will  exceed
 the  amount  excreted   has  not  been   established,   but  it
 probably lies  between  0.3 and 1.0  mg   per  day.    The   mean
 daily   intake   of  lead  by adults  in  North America is  about
 0.33 mg per day,  which  is  derived   from  water  used   for
 cooking and drinking.

 Lead   in an amount  of  0.1  mg ingested  daily over a  period  of
 years  has  been reported to cause   le"ad  poisoning.   On  the
 other  hand,  one reference  considered 0.5 mg  per  day  safe for
 human   beings,   and  a  daily  dose  of  0.16  mg/1  over  long
 periods of time have   apparently   been  non-poisonous.   The
 mandatory   limit for   lead  in  the   USPHS  Drinking  Water
 Standards  is 0.05 mg/1.   Several  countries use 0.1  mg/1  as a
 standard.

Traces  of   lead  in  metal-plating  baths  will  affect  the
 smoothness  and  brightness  of  deposits.  Inorganic lead salts
                             84

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in  irrigation  water  may  be toxic to plants and should be
investigated further.  It is not unusual for  cattle  to  be
poisoned  by  lead  in  their  water.   The  lead  need  not
necessarily be in solution, but may be  in  suspension,  as,
for  example,  oxycarbonate.   Chronic  lead poisoning among
animals has been caused by 0.18 mg/1 of lead in soft  water.
Most  authorities agree that 0.5 mg/1 of lead is the maximum
safe limit for lead in a potable supply  for  animals.   The
toxic concentration of lead for aerobic bacteria is reported
to be 1.0 mg/1, and for flagellates and infusoria, 0.5 mg/1.
The  bacterial  decomposition of organic matter is inhibited
by 0.1 to 0.5 mg/1 of lead.

Studies indicate that in water containing lead salts, a film
of coagulated mucus forms, first over the  gills,  and  then
over  the  whole body of the fish, probably as a result of a
reaction between lead and an organic constituent  of  mucus.
The  death  of the fish is caused by suffocation due to this
obstructive layer.  In soft water, lead may be  very  toxic;
in  hard  water  equivalent  concentrations of lead are less
toxic.  Concentrations of lead as low as 0.1 mg/1 have  been
reported  toxic or lethal to fish.  Other studies have shown
that the toxicity of lead  toward  rainbow  trout  increases
with  a  reduction  of the dissolved-oxygen concentration of
the water.

Mercury  (Hg)

Mercury is an elemental metal that is rarely found as a free
metal.  The most distinguishing fe%ature  is  that  it  is  a
liquid  at  ambient conditions.  Mercury is relatively inert
chemically and is insoluble in water.  Its  salts  occur  in
nature chiefly as the sulfide  (HgS) known as cinnabar.

Mercury can be introduced into the body through the skin and
the  respiratory system.  Mercuric salts are highly toxic to
humans   and   can   be   readily   absorbed   through   the
gastrointestinal  tracts.  Fatal doses can vary from 3 to 30
grams.

Mercuric salts are extremely toxic to fish and other aquatic
life.   Mercuric  chloride  is  more • lethal  than   copper,
hexavalent chromium, zinc, nickel, and lead towards fish and
aquatic  life.   In the food cycle, algae containing mercury
up to 100 times the concentration  of  the  surrounding  sea
water  are  eaten  by  fish  which  further concentrates the
mercury and predators that eat the fish in turn  concentrate
the mercury even further.

Nitrogen Compounds
                             85

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 Ammonia   nitrogen  (NH3-N)  and  total  Kjeldahl nitrogen  (TKN)
 are two  parameters  which have received a substantial  amount
 of  interest  in the  last decade.  TKN  is the  sum  of  the  NH3-N
 and organic  nitrogen   present in the sample.   Both  NH3  and
 TKN are  expressed in  terms  of equivalent nitrogen values   in
 mg/1 to  facilitate  mathematical manipulations of the  values.

 Organic   nitrogen  may   be  converted in the environment to
 ammonia  by saprophytic   bacteria  under  either  aerobic   or
 anaerobic conditions.   The  ammonia nitrogen  then becomes  the
 nitrogen  and   energy  source  for   autotrophic   organisms
 (nitrifiers).   The  oxidation  of ammonia to nitrite  and  then
 to   nitrate  has  a  stoichiometric  oxygen  requirement   of
 approximately-4.6 times the  concentration   of   NH3-N.    The
 nitrification   reaction is  much slower than  the  carbonaceous
 reactions, and, therefore,  the  dissolved oxygen  utilization
 is  observed  over  a  much longer  period.

 Ammonia   is  a  common  product  of the decomposition of  organic
 matter.   Dead  and decaying  animals and  plants  along  with
 human and animal  body wastes  account  for much of the  ammonia
 entering the  aquatic ecosystem.   Ammonia exists in its non-
 ionized  form only at higher pH  levels and is the most toxic
 in   this state.  The lower the pH, the more ionized  ammonia
 is  formed and   its  toxicity  decreases.   Ammonia,   in   the
 presence of dissolved  oxygen,  is converted  to nitrate  (NO3)
 by   nitrifying  bacteria.   Nitrite  (NO2),  which    is    an
 intermediate   product between ammonia and nitrate,  sometimes
 occurs in quantity when depressed oxygen conditions   permit.
 Ammonia   can   exist  in several other chemical combinations,
 including ammonium chloride and other salts.

 Infant^  methemoglobinemia,  a    disease   characterized   by
 specific blood   changes and cyanosis, may be caused  by high
 nitrate  concentrations   in  the water used  for   preparing
 feeding   formulae.   While  it   is  still impossible to state
 precise  concentration limits, it has  been widely recommended
 that water containing more  than 10  mg/1 of nitrate  nitrogen
 (NOJ3-N)  should not be used  for  infants.

 Nitrates  are also harmful  in fermentation processes and can
 cause disagreeable tastes in beer.  In  most  natural  water
the pH range is such that ammonium  ions (NH4+)  predominate.

In   streams  polluted  with  sewage,  up  to one-half of the
nitrogen  in the sewage may be in the  form of  free  ammonia,
and  sewage  may  carry up to 35 mg/1 of total nitrogen.  It
has been  shown that at  a  level  of   1.0  mg/1  non-ionized
ammonia,  the ability of hemoglobin  to combine with oxygen is
impaired   and   may  cause  fish  to  suffocate.   Evidence
                              86

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indicates that ammonia exerts a considerable toxic effect on
all aquatic life within a range of less than 1.0 to 25 mg/lf
depending on the pH and dissolved oxygen level present.

Ammonia  can  add  to  the  problem  of  eutrophication   by
supplying  nitrogen  through  its  breakdown products.  Some
lakes in warmer climates, and others that are aging quickly,
are  sometimes  limited  by  the  nitrogen  available.   Any
increase will speed up the plant growth and decay process.

pH, Acidity and Alkalinity

Acidity  and  alkalinity  are  reciprocal terms.  Acidity is
produced  by  substances  that  yield  hydrogen  ions   upon
hydrolysis,  and  alkalinity  is produced by substances that
yield hydroxyl ions.  The term "total  acidity"  and  "total
alkalinity" are often used to express the buffering capacity
of a solution.

Acidity  in  natural  waters  is  caused  by carbon dioxide,
mineral acids, weakly dissociated acids, and  the  salts  of
strong acids and weak bases.  Alkalinity is caused by strong
bases and the salts of strong alkalies and weak acids.

The term pH is a logarithmic expression of the concentration
of  hydrogen  ions.  At a pH of 7, the hydrogen and hydroxyl
ion concentrations are essentially equal and  the  water  is
neutral.   Lower  pH  values  indicate acidity, while higher
values indicate alkalinity.  The relationship between pH and
acidity or alkalinity is not necessarily linear or direct.

Waters  with  a  pH -below  6  are  corrosive  to  waterwork
structures,   distribution  lines,  and  household  plumbing
fixtures, and can thus add  such  constituents  to  drinking
water as iron, copper, zinc, cadmium, and lead.

The  hydrogen  ion  concentration  can  affect  the taste of
water.  At a low pH water tastes sour.  As pH increases, the
bacterial  effect  of  chlorine  is  weakened,  and  it   is
advantageous to keep the pH close to. 7.

Extremes  of  pH  or  rapid  pH  changes  can  exert  stress
conditions  or  kill  aquatic  life  outright.   Dead  fish,
associated  algal  blooms,  and  foul stenches are aesthetic
liabilities of any waterway.   Even  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  in the water pH.  The
availability of many nutrient  substances  varies  with  the
                            87

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alkalinity  and  acidity.   Ammonia  is  more  lethal with a
higher pH.

The  lacrimal  fluid  of  the  human  eye  has   a   pH   of
approximately  7,  and  a  deviation of 0.1 pH unit from the
norm may* result in eye irritation or severe pain.

Sulfates  (SOU)

Sulfates occur naturally  in  waters,  particularly  in  the
western  United States, as a result of leachings from gypsum
and other common materials.  They also occur  as  the  final
oxidized  state  of  sulfides,  sulfites  and  thiosulfates.
Sulfates may also  be  present  as  the  oxidized  state  of
organic  matter  in  the sulfur cycle, but they in turn, may
serve as sources of energy for  sulfate  reducing  bacteria.
Sulfates  may  also  be  discharged  in  numerous industrial
wastes, such as those from  tanneries,  sulfate-pulp  mills,
textile  mills,  and  other  plants  that  use  sulfates  or
sulfuric acid.

In moderate concentrations, less than 500 mg/1 sulfates  are
not  harmful, yet concentrations greater than 1000 mg/1 tend
to  have  a  -laxatives   effect   on   humans.    Irrigation
concentrations  less than 336 mg/1 are considered to be good
to excellent.

Oil and Grease

Oil and grease exhibit an oxygen demand.  Oil emulsions  may
adhere  to  the  gills  of fish or coat and destroy algae or
plankton.  Deposition of oil in  the  bottom  sediments  can
serve  to  exhibit normal benthic growths, thus interrupting
the aquatic food chain.   Soluble  and  emulsified  material
ingested by fish may taint the flavor of the fish flesh.

Water-soluble components may be toxic to fish.  Floating oil
may  reduce  the  re-aeration  of  the  water surface and in
conjunction  with  emulsified   oil   may   interfere   with
photosynthesis.

Water-insoluble components damage the coats of water animals
and  the  plumage of waterfowl,   oil and grease in water can
result in the  formation  of  objectionable  surface  slicks
preventing  the  full aesthetic enjoyment of the water.   Oil
spills can damage the  surface  of  boats  and  destroy  the
aesthetic characteristics of beaches and shorelines.
                             88

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Color

Color   in  water  may  be  of  natural  mineral or vegetable
origin,  caused  by metallic   substances,   such  as  iron  and
manganese  compounds,  humus material, peat, tannins, algae,
weeds,   and   protozoa.   Waters  may  also  be  colored   by
inorganic  or  organic  soluble  wastes from many industries
including the explosives industry.

Color in the  explosives point  source category  results   from
the  manufacture  of TNT; either from the purification steps
or the  equipment and/or manufacturing area clean-up.

Color is defined as either "true" or "apparent"  color.   In
Standard Methods for the Examination of Water and Wastewater
 (4),  the  true color  of water is defined as "the color of
water from which the turbidity has been removed".   Apparent
color   includes "not  only  the  dolor due to substances in
solution, but also due to suspended matter".

Color bodies  interfere with the transmission of light within
the visible spectrum which  is absorbed  and  used  in  the
photosynthetic  process of micrcflora.  Color will affect the
aquarian ecosystem  balance by changing the amount of light
transmitted and may lead to  species turnover.

This is because light intensity at which  oxygen  production
in  photosynthesis  and oxygen consumption by respiration of
the plants concerned are equal is known as the  compensation
point,   and the depth at which the compensation point occurs
is called the compensation  depth.   For  a  given  body  of
water,   this  depth varies with several conditions, including
season,  time  of day, the extent of cloud cover, condition of
the water, " and the  taxonomic  composition  of  the  flora
involved.   As  commonly used, the compensation point refers
to that intensity of light which is such  that  the  plant's
oxygen   production  during  the  day  will  be sufficient to
balance the oxygen  consumption  during  the  whole  24-hour
period.   '
t
Color   bodies  discharged  to  waterways  alter  the natural
stream  color  and  thereby  become  an  aesthetic  pollutant.
Unnatural  receiving  water  color  detracts from the visual
appeal  and recreational value  of the waterways.

Color   when   discharged  to  receiving   waters   also   has
detrimental   effects  on downstream municipal and industrial
water users.  Color is not treated for in conventional water
treatment systems and when passed to  users  may  result  in
consumer discontent  and may  also interfere with industrial
processes which demand high quality water.
                             89

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Pollutants of Specific Significance

In addition to the parameters already discussed,  there  are
pollutants  specific to various individual categories of the
miscellaneous chemicals point source category.   These  will
be  covered  as  applicable to the discussions as is done in
the following text for the explosives point source category.

Explosives Manufacturing

General   parameters   of   significance    in    explosives
manufacturing  are  BODS,  CODr  TOC,  TSS,  lead,  mercury,
dissolved solids, color  and  nitrogen  compounds  including
nitrates and TKN.  Of special significance is the problem of
trace quantities of the explosive products themselves.

Explosives  such  as  TNT,  NG,  RDX,  and  HMX  can  all be
considered significant, because of their  potential  hazard,
toxicity,  or  inhibitory  effect on microorganisms.  NG has
been shown to be amenable to biological  treatment  by  some
investigators  while  others  have found little success with
biological treatment.

Of particular interest to this segment  are  the  pollutants
associated, whith  the manufacture of TNT, the production of
which far  exceeds  any  other  explosive  in  the  military
sector.   These  include  color,  sulfates,  and  saturation
levels of TNT.  The color problem is manifested in  the  red
and  pink  water  previously  discussed  in Section IV.  The
sulfate problem is associated with the red water  condition.
Saturation  concentration  of  TNT  in  the  effluent  is an
obvious problem and must be abated.

The major problem with  nitrocellulose  (NC)   is  NC  fines,
which  generally  are  present in quantities large enough to
cause a significant TSS  problem.    These  fines  have  been
shown  to  be successfully removed with centrifugation and a
portion of the waste liquor can  then  be  recycled  to  the
system.
                      90

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                         SECTION VII

             CONTROL AND TREATMENT TECHNOLOGIES
General

The  entire  spectrum  of  wastewater  control and treatment
technology  is   at   the   disposal   of   the   explosives
manufacturing  point  source  category.   The  selection  of
technology  options  depends  on  the  economics   of   that
technology   and   the   magnitude  of  the  final  effluent
concentration.  Control  and  treatment  technology  may  be
divided   into  two  major  groupings:   in-plant  pollution
abatement and end-of-pipe treatment.

After discussing the available  performance  data  for  this
segment,  conclusions will be made relative to the reduction
of  various  pollutants  commensurate  with  the   following
distinct technology levels:

    1.  Best Practicable control Technology Currently
         Available (BPCTCA)
    2.  Best Available Technology Economically
         Achievable (EATEA)
    3.  Best Available Demonstrated Control Technology
         (EADCT)

To  assess  the  economic  impact of these proposed effluent
limitations and guidelines,  model  treatment  systems  have
been  proposed which are considered capable of attaining the
recommended  RWL  reduction.   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 and end-of-
pipe  systems  capable of attaining the effluent limitations
guidelines and standards of performance recommended in  this
report.   The  complexity of this segment,  however, dictated
the use of only one treatment model for each subcategory for
each effluent level.

It is the responsibility of each 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 limitations and standards presented in
this report.
                           91

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Explosives Manufacturing

    Iii-plant, Pollution Abatement

A   significant   amount   of  pollution  abatement  can  be
accomplished   in   explosives   manufacturing   simply   by
consistent  adherence  to good housekeeping practices.   Many
of the final products such as ANFO and NCN  are  dry  mixed,
while  others  involve  only limited water use such as water
gels and slurries.  Wastes generated from these products are
primarily  from  spills,  careless  handling,   leaks,    and
washdown  of  machinery  and  floors.   Such wastes have the
potential to be almost completely eliminated by dry cleanup/
i.e., procedures involving sweeping and vacuum cleaning.

Off-site' mining  and  construction  captive   blending   of
ammonium  nitrate  and fuel oil is a minor pollution problem
and abatement  cost  would  be  negligible.   The  treatment
models  do not apply to this point of use activity.  On-site
blending of ammonium nitrate  into  explosive  end  products
such  as  NCN  and  ANFO at primary explosives manufacturing
plants is included in the present data base.   The  existing
treatment  model  does  apply.   Examples  of  locations now
included in the data base are plant no. 49 and plant no. 50.

Process changes to reduce hydraulic loadings do not  have  a
great  potential  in  the  commercial  sector  of explosives
manufacturing, because of the  difference  in  the  products
produced.  Process changes to reduce hydraulic loadings have
shown  promise  in the military manufacturing sector such as
the NC fine centrifugation system described in  section  VI.
In  the  manufacture  of  propellants,  large  quantities of
waters are used to transport explosive materials safely  and
to purify the product from one process step to another.  For
this task, high-quality water is not required.  Hence, water
reuse   with  perhaps  slight  treatment  has  a  tremendous
potential to reduce the  hydraulic  loading.   For  example,
wastewater  reductions  for nitrocellulose production in one
of the plants visited could reduce total plant discharge  by
95  percent  and  overall  propellant  production wastewater
discharge by 87 percent.  This change  is  in  the  planning
stage at that location.

The  production  of  TNT  is  another area where significant
reduction of hydraulic loading can be attained.  As  a  part
of the military modernization program", 100 percent reduction
of  current  process  water  use  is  possible  and  will be
implemented  within  the  near  future  at  a   large   army
ammunitions plant.
                          92

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 In general, good water management, with a  focus on  recycling
 process and cooling water, can have a significant effect  on
 hydraulic  loading  and would significantly reduce  treatment
 costs.  For example at one AAP in the current  study, overall
 plant water reduction  (including cooling as well as  process
 water)  reached 6 percent.  This saved an  estimated $900,000
 per year in pumping and treatment costs.   Such  substantial
 savings  show  that  water  conservation   practices  can  be
 economical as well ecologically favorable.

 Separation  of  process  and  non-contact  waters   is   not
 practiced  universally.   This  is  technically feasible and
 reduction of the hydraulic loading at a treatment   plant  is
 an essential first step in economical pollution abatement.

 Studies  documented  in  Section  XV  have shown explosives
wastes to be treatable with  present  technology.   However,
 prior  to  end-of-pipe  treatment,  certain in-plant control
 measures will be  mandatory.   Such  measures  will  require
neutralization   facilities,   catch   tanks   on  finishing
 explosives  lines,  and  other  pretreatment  facilities  to
 ensure  compatability  of raw waste load with the subsequent
 treatment system.

    Treatment and Control Technology

In  developing  potential  treatment  technology  for   each
 subcategory, sources of information were laboratory studies,
pilot   plants,  demonstration  projects,  facilities  under
construction, and facilities in operation.   First,  control
technology  will be discussed from the viewpoint of effluent
water quality.   After reviewing what has   been  accomplished
and  what  is  feasible, control technology will be outlined
for each subcategory for BPCTCA,  BATEA,  and BADCT.

    p_H

The control technology for pH is  neutralization.   The pH  of
a  discharge can vary over extreme ranges; from plant visits
it was observed to range from 1 to 12.   An example  of  such
ranges  can  be  seen  from the manufacture of NG,  where the
initial washing of NG  produces  an  acidic  wastewater  and
subsequent  sodium  carbonate  washings   yields  an alkaline
flow.

The  problem  of  high-alkaline  flows  is  significant   in
subcategory  D   due to the discharges from PETN,  lead azide,
and diazo production.   The  problems  of  acidic   flows  are
generally  associated  with  the   manufacture  of  nitric and
sulfuric  acids  as  raw  materials  in   the  production  of
                             93

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           Table VIJ -1
Summary of Treatment'-Investigations
Type of
*»fc . . •. 4
Study
Pilot
(3 months)

Operational



Laboratory



Laboratory


Laboratory


Laboratory


Laboratory




Operational

Laboratory










Laboratory





Pilot


Laboratory
Demonstra-
tion
Lab Unit
(Pilot)


Reference
U.S. Army
(PE249)

Operational



Clark, Dtetz
Eng. Rept.
HAAP

Clark, Dletz
Eng. Rept.
HAAP
Clark, Dtetz
Eng. Rept.
HAAP
Clark, Dletz
Eng. Rept.
HAAP
Clark, Dletz
Eng. Rept.



Operational

U.S. Army
PE 249
Phase 11

U.S. Army
PE 249
Phase 1 1
U.S. Army
PE 249
Phase 1 1

U.S. Army
PE 249
Phase II



U.S. Army
PE 249
Phase II
U.S. Army*
PE 249
Phase II
U.S. Army
PE 249
Phase II
&*p i vja i vca muuairy
Percent Reduction
Treatment BOD COD TOC TKN N03 SO^
Activated 86.7 78.3
Sludge
(NG Waste)
Activated 92.8 ' 71.5 ' 90 2 Increase 96 2 None
Sludge
(Propellent
Waste)
(Explosive Failed -(Filamentous Organism)
Waste)
Activated
SI udge
Trickling 83.7 72.9
Filters

Fixed Film 41.4 gif.g
Denltrof Icatlon

Dual Media
Filtration

A. C. -Note 77.6
Removes all
explosives
down to 0.0
mg/L
(Propel lant 72. O1 78.9' 88.7 * 96.6 2 increase 59.4 '
waste( Lagoon
Sp. Irr.
(NG Waste) (Successful in Decomposing 350 mg/L NG S- 130 mg/L ONG)
Decompose
NG S. DNG by
Na2S
Using Lime Successful Decomposition


Oxidating
Agent
Ozone NG 20
DNG 100
(Propellant Excellent Removal of Dissolved Organics
Wastes)
Activated
Carbon
Inorganic 97.5
504
NC Fines
Separation S-
Centrifuge
Reverse 75 gg
Osmosis

Blodenitrlf I cation 94 70-90


                                                                      TSS
                                                                     88.4
                                                                     75
                                                                     77.8
                                                                     99

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Type of
Study
Pilot
Operation
Operation
Pilot and
Laboratory
Commercial
Demonstra-
tion
Laboratory
Laboratory.
Pilot
Laboratory
Laboratory
Treatabillty

Reference
Pollution
Abatement
Review Aug.
1973
Pol lutlon
Abatement
Review Aug.
1973
Pollution
Abatement
Review Aug.
1973
Harris, 1973
Pol lution
Abatement
Review
Aug. 1973
Pollution
Abatement
Review
Aug. 1973
Harris, 1973
Harris, 1973
Harris, 1973
Harris, 1973
Table VII -1
(Continued)
Percent Reduction
Treatment BOD COD TOC TKN N03 SO^
Reverse Osmosis Impractical Due To High Pressure
Treatment of Red.
Water
(Pinkwater) 95 91.5-92.7 None
Activated
Carbon
(Reduction of TNT
99.5%)
(Pinkwater) -Data not available-
Activated
Carbon
Blodenttrlf !- 70-97
cation
Ion Exchange . 90-99
Reverse go
Osmosis
Biodenitrl- 95-99
f icatlon
Ion Exchange 98.8 95.4
Countercurrent
Reverse go 95
Osmosis
Calcium ppt of successful
sulfate waste
                                                                                                                 TSS
                                                                                                                 67
and Pilot
Laboratory   Harris, 1973
Tests

Bench        U.S. Navy
Scale        1972
Pilot Plants
  Survey Data
AC adsorption
Regeneration of 'carbon is feasible
TNT wastes
Activated Sludge
Aerated Lagoon
Trickling Filter
Chemical Precipitation
Activated Carbon
       Not successful
       Not successful
       Not successful
       Not Successful
                  98
                                                     95

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explosives.   However, as these materials are not explosives
they are covered under the major inorganic industrial  point
source category.

There are many acceptable methods for treating either acidic
or  alkaline  wastes,  including   mixing acids and alkaline
wastes and  using  chemicals,  such  as  lime,  caustic,  or
sulfuric  acid, to neutralize the wastewaters.  Equalization
is very useful in pH control.   Plants  that  practice  this
operation  have  better  control of the pH in the discharge.
This is particularly important if the wastewater  is  to  be
biologically  treated.   Biological  systems  operate over a
narrow pH range  (usually  6  to  9)  and  the  inclusipn  of
equalization  before  biotreatment is an effective technique
of operating a successful treatment system.

    BODS and COD

Current emphasis in  treatment  technology  for  both  these
areas   is   on  biological  treatment.   Activated  sludge,
lagooning,  and  spray  irrigation  are  combined   at   one
commercial  plant  treating  propellant  wastewater and this
treatment  technique  attains   excellent   and   consistent
results.   One military installation is currently completing
the design of biological treatment facilities based on pilot
plant test data.

    Solids

High dissolved  solid  concentrations  come  from  the  high
nitrate,  sulfate,  and  carbonate levels, and these will be
addressed separately.  Suspended solids generally are low in
explosives manufacturing; however, catch tanks and sumps are
usually  employed  to  catch  trace  explosives   prior   to
discharge.    An   exception  to  low  suspended  solids  in
explosives manufacturing wastewaters is in  the  manufacture
of  nitrocellulose.   Here, large concentrations of NC fines
are present in the waste  discharge  from  the  purification
process.   Treatment  technology  focuses  on sedimentation,
dissolved air flotation, flocculation, granular  filtration,
and  centrifugation.   centrifuging  has  produced excellent
results in pilot studies at a military' installation and will
be implemented shortly.

    Nitrates

The U.S. Army has investigated several methods for abatement
of nitrates.  Among these  methods  are  biodenitrification,
algae    harvesting,    ion   exchange,   reverse   osmosis,
distillation,   and   land   application.    After   initial
                              96

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feasibility  studies,  the Army selected biodenitrification,
ion  exchange,  and  reverse  osmosis  as  having  the  most
potential.    Current  engineering  emphasis  is  placed  on
biological denitrification, for which at  least  two  plants
have  plans for design.  Pilot plant treatability studies of
biodenitrification on nitrocellulose.waste have indicated 80
to 90 percent reduction of nitrates on a  consistent  basis.
Influent  nitrate values ranged from 600 to 800 mg/1 and the
detention time was about one day.

Additional engineering studies have been performed utilizing
reverse osmosis and ion exchange.  Excellent  removal  rates
of  90  percent  have  been  obtained at a pilot plant using
reverse osmosis.  Reverse  osmosis  can  be  used  to  treat
sulfates  as well.  At neutral pH, removal rates of 90 to 99
percent  for  nitrates  and  sulfates,  respectively,   were
observed during this same pilot investigation.  For nitrates
it  appears  that  the  economical  limit of nitrates in the
effluent is approximately 20 mg/1 as NO3-N.  Hence,  reverse
osmosis  could  be  a  means  of  nitrate recovery, while an
additional step such as biodenitrification may be  necessary
to  reduce  the  smaller  concentration  of nitrates to more
acceptable levels.

Problems associated with reverse osmosis are sensitivity  of
membranes  to  acid, and concentrate disposal.  Ion exchange
studies have shown concentrations as high as 1,200  mg/1  to
be   reduced   99   percent,   resulting   in   an  effluent
concentration of 10 mg/1.  Chemicals used  for  regeneration
of  the  resin  are  nitric  acid  and  ammonium  hydroxide.
Ammonium nitrate,  a  raw  material  in  certain  explosives
(ANFO, NCN, etc.) can be recovered in the regeneration step.

    Sulfates

Present in the water because of the use of sulfuric acid or,
in the case of TNT production, the sellite wash (red water),
sulfates  have  only  recently  received  any attention as a
pollutant.  Hence, abatement studies are only in the initial
assessment    stages.     Existing    abatement     involves
incineration.   However, incineration leads to air pollution
(SOx), and the sodium sulfate ash disposed  of  in  landfill
causes  .leaching  problems.   Several chemical processes are
being considered for reusing the ash.   The  most  promising
involves  a  fluidized-bed reduction system which utilizes a
reducing gas to liberate hydrogen sulfide from the ash.   The
hydrogen sulfide can then be  used  to  manufacture  sellite
and,   hence, complete recycling is accomplished.   Additional
methods under consideration  for  controlling  high  sulfate
discharge  are  reverse  osmosis,   ion exchange,  evaporation
                            97

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        TABLE VII-2  Sample Analysis of NG Process Wastewater
                      Pollutants from Acid Separator  and
                      Nitrator Tub
         Sample Analysis  (Facilities in Operation at Full  Capacity)
PH
BOD*  (mg/1)
COD*  (mg/1)
TOC*  (mg/1)
Nitrates  (mg/1)
Sulfates  .(mg/1)
Total Alkalinity
  (mg/1, CaCO,)
Spec. Cond.  (/mhos/cm)
Susp. Solids  (mg/1)
Dissolved Solids  (mg/1)
Total Solids  (mg/1)
Color (units)
Ml troglycer'in  (mg/1)
Dinitroglycerin  (mg/1)
Lead  (mg/1)
*BOD - Biological Oxygen  Demand
*COD - Chemical Oxygen  Demand
*TOC - Total Organic Carbon
Flow from nitrator 15,200 gpd at  2k hour  full  capacity w/one line.

*13,000 gpd for clean-up, not included  in  sampling  analysis
Min.
8.4
1.5
1,000
100
7,500
534
9,000
8,000
3.0
68,000
68,000
600
800
520
0.2
Avg.
8.6
4.5
1,228
230
1 3 , 280
1,416
12,700
13,000
23.0
81,626
81,650
650
1,300
850
1.0
Max.
9.2
6.5
1,400
300
20,000
3,550
16,400
19,000
63.3
98,950
99,000
700
1 ,800
1,180
2.8
It is expected that clean-up water will not  contain  appreciable  wastes,
                                   98

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          TABLE VH-3
Sample Analysis of NG Process Wastewater
from Emulsifier Transfer Operations'
           From the N/G being removed from storehouse  (emulsifier)
 NG  Store Houses
 a.   Significant Components
     Ni troglycerin
     Dini troglycerin
     Sodium Carbonate
     Nitrates
     Lead

 b.   Sample Analysis
PH
BOD  (mg/1)
COD  (mg/1)
TOC  (mg/1)
Nitrates  (mg/1)
Sulfates  (mg/1)
Alkalinity  (mg/1  CaCO,)
Spec. Cond.  (Xmhos/cm)
Susp. Solids  (mg/1)
Dissolved Solids  (mg/1)
Total Solids  (mg/1)
Color (units)
Nitroglycerin  (mg/1)
Dinitroglycerin  (mg/1)
Lead (mg/1)
Hin.
10.Z
2.4
460
200
270
20
7,500
1,280
3.3
2,952
2,955
200
83
41
0.2
Avq.
10.5-
3-2
912
477
477
130
1 1 ,400
5,340
11.3
13,905
13,916
477
266
130
0.8
Max.
n.j
4.1
1,456
630
665
179
18,000
8,100
22.1
30,848
30,870
630
490
248
2.4
Avg. Flow = 14,800 gpd, 24 Hour <2> full  capacity.
                                99

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                     TABLE VII-4
Raw Tfeste Load for the Continuous
NG Process Excluding Wash. Water
for Plant 43
     Continuous N/G Manufacturing  (Biazzi Process)
                  Production

                 KKg/day
                 '(1000 Ib/day)

                    24.90)
                   (55.0)
              Flow
        KKL/day
         (mgd)
         (.03)
 L/KKg
(gal/1000 Ib)

   4,560
   (545)
                  Nitrator
               flow .0152 mgd
    Store House
  flow .0148  mgd
                 1b pol1utant
Cone, mq/1 1 b/Day
BOO
COO
TOC
Nitrates
Sul fates
Total Alk.
SS
OS
Lead
4.5
1,228
230
13,280
1,416
12,700
23
81,626
1.0
.570
156
29.2
1,680
180
1,610
2.92
10,300
.127
Cone, mq/1
3.2
912
477
477
130
11,400
11.3
13,905
.8
1 b/Day
.395
113
58.9
58.9
16.0
1 ,410
1.39
1,720
.0987
1 b/Day
.965
' 269
88.1
1740.
196
3,020
4.31
12,000
.226
1000 Ib. prod.
0.175
4.89
1.60
31.6
3.56
54.9
0:078
218
0.0041
(1)
   At full  production 55,000 Ib/day of N/G - 1975 level was only 15% of this.
                                      100

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TABLE VII-5
Comparison of NG Batch Process
vs NG Continuous Process Raw
Waste Loads

BOD
COD
TOC
Nitrate
Sulfate
Total Alk.
SS
DS
Lead
Plant 43
0.175
4.89
1.69
31.6
3.56
54.9 -
.078
218.
.0041
Plant 49
Batch
163
4.88
1.05
23.0
46.4
57.8
.002
25.2
.003.6
Ratio
Cont/Batch M
1.07
1.0
1.52
1.37
.077
.950
39.0
8.65
1.14
Plant 50.
Batch
—
3.14
1.64
6.12
2.10
38.2
.026
90.3
-~
Ratio
Cont/Batch
_
1.56
• .98
5.16
1.69
1.44
3.0
2.4
—
                101

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                       TAELE VII-6
Comparison of Continuous NG
Process Effluent Loading to
Range of Loadings for Explosives
Subcategory A


BOO
COD
TSS
TOC
N0-
so.

Ranqes (1
6
10
10
k
9
116


) lb/1000 Ib
.35 -
• 6 -
.7 -
.T3 -
.a -
• "~
.085
.300
.054
.24
.31
.28

Cont. lb/1000 Ib
.0175
4.89
.078
1_60
31.6
3'. 56
Fall in
Range?
No (Low)
OK
OK
OK
No (High)
OK
(1)
   From  Table VE-2  (Subcategory A)
                                   102

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(combined with reverse osmosis to reuse sulfuric acid),  and
calcination (precipitation with lime then heating to recover
sulfuric acid and lime).

Reverse osmosis has been investigated at the pilot level, in
combination  with  nitrate  removal.   High  sulfate removal
efficiences (99 percent or  better)   are  reported  even  at
acidic  pH.   However, membrane hydrolysis at low pH greatly
decreases useful membrane life.   In  the  absence  of  more
resistant membranes, neutralization would likely be required
for  the  reverse  osmosis  feed stream.  This may result in
precipitation and fouling of the membranes by solids.

The most technically feasible method "of  sulfate  treatment
appears  to  be  calcination.   However,  the  solubility of
calcium sulfate is  high  and  lime  treatment  may  not  be
feasible  for more stringent effluent requirements.  The use
of barium to precipitate sulfate has been suggested  in  the
literature,  but  cost  and the possibility of exceeding ef-
fluent barium levels appear to be major disadvantages.    The
economic   and   technical   difficulties   associated  with
treatment for pollutants such as sulfate have led to several
applications  for  waste  disposal  by  land  irrigation  in
explosives  manufacturing.  One such plant that goes through
biological activated sludge, lagooning, and spray irrigation
is currently achieving 95 percent removal of sulfates.

    Trace Quantities of Explosives

Unique pollutants such as NG, TNT, and RDX are hazardous and
toxic.

    Nitroqlycerin (NG)

Treatment technology universally used for NG  washwaters  is
catch tanks.  The catch tanks make it possible to recover by
sedimentation  any  NG that comes out of solution.  However,
this leaves the supernatant waters at their saturation point
upon discharge.  At room temperature, 20°C,  the  solubility
of NG is recorded as 1,800 mg/1.  (Table VII-1.)   Therefore,
during  warm  summer  weather  without .further treatment, NG
wastewater  could  pose  a  safety  problem,  especially  if
discharged into a cool mountain stream.  If cooling water is
available,  the  cooling  of  NG  prior  to  discharge could
recover additional  product  and  decrease  the  waste  load
significantly.    For   a  detailed  comparison  of  process
wastewater  pollutants  from   batch   and   continuous   NG
operations  refer  to  Tables VII-2, VII-3, VII-4, VII-5 and
VII-6.
                              103

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 Additional technology for the treatment of  wastes   high  in
 nitroglycerin  is only in the experimental stage.   NG wastes
 containing 900 to 2,100 mg/1 have been shown to be   amenable
 to  activated  sludge  treatment.  In one study, Koziorowski
 and Kucharski report  consistent  success  in  treatment  of
 influent  wastes  containing  400  to  500  mg/1 of NG  at a
 detention time of 16 hours.   NG can  also  be  destroyed  by
 quicklime.     Lime  (up  to   200  mg/1)   was  added  to   the
 wastewater and allowed to react for three days;   the  result
 was  a   non-explosive  sludge,   but  the effluent was highly
 alkaline.  The Army has conducted experiments on the treata-
 bility   of  NG   by   biological,   physical/chemical,    and
 ozonization    methods.     With    wastewater   containing
 concentrations of NG and DNG (dinitroglycerin) .of 1,500.  mg/1
 and 850  mg/1,  respectively,  the results show that NG can  be
 treated   biologically  and chemically,  although with varying
 degrees  of  success.   NG waste should be handled biologically
 together with other plant waste.

     TNT

 TNT has  been shown  to  interfere  with  biochemical   oxygen
 demand,   and    produces  an  inhibiting  or  toxic   effect.
 Biological  treatment of wastes  high in  TNT and DNT  (red   and
 pink water)  was performed by  the Navy (1972).   Reduction has
 been successful  only  in  the  laboratory  using   specific
 cultures and nutrients.   At  crane Naval   Ammunition   Center,
 treatability   studies   using    activated   sludge    proved
 unsuccessful.   Numerous other treatability studies at Crane
 Naval Ammunition Center included activated carbon,  aerated
 lagoon,   trickling  filtration,    and   physical/    chemical
 mechanisms.    Of  these,  activated carbon adsorption  process
 was recommended.   Spent carbon  from  the   adsorption   column
 cannot   be   regenerated  at   the  present  time  and  must be
 incinerated  or  landfilled.   The  reason  is  that   in   the
 regeneration  step  the adsorbed TNT  detonates,  reducing  the
 active sites on  the  carbon molecules.

 The  Army has reached a  similar  conclusion regarding TNT.  In
 tests of reverse  osmosis, ozonization, and  activated  carbon,
 only  the  latter   proved    effective,    reducing    initial
 concentrations   of TNT  in the range of 100  mg/1 down  to 0.05
 mg/1.   The  Army recommended   development  work   in    the
 regeneration   of   carbon, but it  is uneconomical at present.
A promising  method involves dissolving the  TNT  in  toluene
then   crystallizing    it  by   a   drop  in  temperature  and
 filtration to  separate the carbon.

If  ^regeneration  of  carbon   cannot   be   achieved,   the
incineration  of  the   spent  carbon is necessary.  However,
                             104

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incineration, -though inactivating TNT and  its  derivatives,
produces   a  waste  high  in  sulfates  (from  the  sellite
purification process resulting in red and pink water).  This
ash  causes  a  major  solid  waste  disposal  problem.   In
addition,  leachate  from its storage can cause ground water
contamination.    Reclamation   of   this   ash   is   being
investigated  by  the Army.  A fluid-bed reduction system is
being  tested  presently  with  the  focus  of  regenerating
sellite.

    RDX and HMX

The present removal of RDX and HMX from wastewaters by catch
basins  has only partially alleviated the problem.  The Army
is investigating the following treatment methods at  Holston
AAP: reverse osmosis, activated carbon adsorption, polymeric
column  adsorption,  and  biological treatment.  Since these
treatment techniques are still  being  studied,  a  definite
statement as to their success cannot be drawn.  However, one
conclusion  can  be  drawn: biological treatment is feasible
and will break down as much as 99 percent of the  explosives
present.

    End-of-pipe Treatment

Due  to  the  current industrial practices of failure to use
available effective treatment in all but  exceptional  cases
in  explosives  manufacturing,  treatment  systems  will  be
proposed  for  all  subcategories  based  on  the  preceding
discussion    of    laboratory    studies,    pilot    plant
investigations, demonstrated projects, facilities  designed,
facilities under construction, and facilities in operation.

Treatment   systems   were   developed  for  the  explosives
industrial  sutcategories  for  the  following   levels   of
treatment technology:

         1.  Best Practicable control Technology Currently
              Available  (BPCTCA) .
         2.  Best Available Technology Economically
              Achievable  (BATEA).
         3.  Best Available Demonstrated Control
              Technology BADCT).

The treatment systems presented for each level of technology
are  not  the  only  systems that are capable of meeting the
effluent limitations  prescribed.   The  objective  of  this
section   is  not  to  prescribe  but  to  suggest  feasible
treatment systems that will satisfy the effluent limitations
and guidelines developed in this report.
                              105

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     BPCTCA Treatment System

 Of  the  six  plants   visited  during  the   survey,  only  one
 operated  a treatment   system  other than  neutralization and
 sedimentation.   This is  felt  to be a result of many  factors
 such, as  lack   of   technology  on how to treat the explosive
 waste,  a changing industry  profile such  as  the  advent  of
 ammonium  nitrate compounds  replacing  dynamite  and black
 powder,  a  variable operation  as a result   of  war  or  peace
 time product  demand but  primarily on the fact that there
 were no  regulations   before   1972   requiring   effluent
 limitation.  Effluent treatment cost money to implement.  As
 a   result   of  these and other  factors, the average existing
 treatment  systems are   inadequate   to  meet  safe  effluent
 standards.   Therefore,  the  levels of treatment for BPCTCA
 for sufccategories A,  B and  D  will   be  based  on  the  per-
 formance   of    this  existing  activated   sludge  plant.
 Laboratory and   pilot plant  investigations  summarized  in
 Table    VII-1  will   be  used  to  verify  these  levels  of
 treatment.   In the case  of  subcategory   C,  the  level  of
 treatment    is    based   on  technology  transfer  from  the
 performance  on   waste   waters   with    expected   similar
 characteristics.   Two   distinctly
 waters were  encountered in  this
 production of NCN and ANFO,  where fuel oil'is"utilized, the
 waste waters were characterized as high in oil  and  grease
 and low  in suspended solids.  In contrast from other load,
 assemble and pack operations,   the   waste  waters  contained
 high  suspended   solids  but low oil  and grease content.  The
 level of treatment for BPCTCA will be based on  an  extended
 aeration packaged plant  which includes screening, biological
 treatment, clarification with skimming and chlorination.

The results of nine months of data for this activated sludge
treatment  system is shown in  the summary tabulation below.
This treatment system was designed for  a  propellant  waste
having typical waste characteristics as indicated in Section
V.   The BPCTCA treatment level indicated below includes the
survey data as well  as historical data.
    different types of waste
    subcategory.   From  the
    BPCTCA Treatment Level For Subcatecrories A, B and D


         Parameter
Percent Reduction
	Of RWL
           BOD5
           COD
           TOC
           TSS
     93*
     721
     902
     882,3
                               106

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i Based on historical data
a Based on 24- hour composites from survey.
3 Except the average of daily values for 30 consecutive days
  shall not exceed 50 mg/1 and the maximum for any one day
  is 150 mg/1.

The EPCTCA treatment level for subcategory C was selected as
below.

                s  Effluent Limitations
Average of Daily Values
for 30 Consecutive Days
_ Shall Not Exceed
Parameter          mg/L

TSS                 50*
Oil and Grease      20 2
     Maximum for
     Any One Day
Parameter        mg/L

TSS               150*
Oil and Grease     602
1 Based on technology transfer from the fertilizer manu-
  facturing point source category and the inorganic
  chemicals manufacturing point source category.
2 Based on technology transfer from the petroleum
  refining point source category.

    Pretreatment Requirements for BPCTCA Treatment System

Certain waste flows will have  to  be  pretreated  prior  to
discharging  to a central treatment facility such as the one
proposed for  BPCTCA.   The  following  problem  wastewaters
should be considered in that category:

         1.  Discharges high in sulfate
         2.  Discharges high in TNT  (red water, yellow
              water, pink water).
         3.  Discharges higti in NC fines
         u.  Heavy metals

Although  discharge  to  municipal  systems was not observed
during the study suggested  methods  of  abatement  will  be
explored for completeness.

High   sulfate   concentration   can  disrupt  a  biological
secondary treatment system.  Therefore, the removal of  high
sulfate  concentration  by  calcination  may  be a necessary
pretreatment technique.  TNT is suspected of being toxic  or
an  inhibitor  of  biological processes.  Wastes high in TNT
may, therefore, require activated carbon adsorption prior to
discharge to a biological system  to  remove  the  dissolved
explosive  and  its  isomers.   High  concentrations  of  NC
                             107

-------
 suspended  solids could  also  disrupt   a. biological  system.
 Removal  by  the  use   of  centrifuging has been shown to be
 economical.

 Heavy metals concentration can be  toxic  to  microorganisms
 and, subsequently, disrupt the activated sludge process.  If
 heavy  metals are a problem, some means of physical/chemical
 pretreatment will necessarily have to  be implemented.

 High concentrations of  oil and grease  can be  disruptive  to
 municipal  systems.  An upper limit of 100 mg/1 is indicated
 for this parameter as the pretreatment standard.

    BATEA Treatment System

Out of six explosives plants visited, only one had any  kind
 of  treatment that could be considered as exemplary.  Hence,
operational performance data from this facility was used  to
 establish EATEA treatment levels; these levels were verified
by laboratory and pilot studies.

     BATEA Treatment Levels For Subcateqories A, B and D
                                Percent Reduction of
                               BPCTCA Waste Effluent

                                    '72
                                     79
         Parameter

           BOD5
           COD
           IBS

1 Except the average of daily values for 30 consecutive days
  shall not exceed 10 mg/1 and the maximum for any one day
  is 20 mg/1.

BATEA treatment level for subcategory C.
         Parameter

           BOD5
           COD
           TSS
           Oil and Grease
                             Percent Reduction of
                               BPCTCA Effluent

                                     72
                                     79-
                                     601
                                     802
  Except the  average  of daily values  for  30  consecutive  days
  shall not exceed  20 mg/1  and the  maximum for any  one day
  is  40 mg/1.
  Except the  average  of daily values  for  30  consecutive  days
  shall not exceed  10 mg/L-and the maximum for  any one day
  is  20 mg/1.
                               108

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This percent reduction  is  based  on  lagooning  and  spray
irrigation   as  a  treatment  system.   However,  a  system
specifically designed  to  remove  dissolved  and  suspended
explosive  organics  would  be  preferable.   Therefore, for
subcategories A, B and D,  a  system  using  filtration  and
activated  carbon  added to BPCTCA treatment system has been
recommended for BATEA.  In  addition,  treatment  technology
from  the  inorganic  chemicals  manufacturing  point source
category, the fertilizer manufacturing point source category
and the petroleum refining point source category  have  been
transferred to arrive at acceptable effluent limitations for
TSS  and  O&G,  respectively.  In the case of subcategory C,
chemical coagulation  and  filtration  to  BPCTCA  treatment
system has been recommended for BATEA.  Laboratory and pilot
plant  investigations in the area of activated carbon  (Table
VII-1) have shown it to  attain  comparable  percentages  of
removal.

    BADCT Treatment Systems

Not  enough  information could be gathered to quantify BADCT
from   process   changes   in   explosives    manufacturing.
Therefore, any recommendations made must be based on general
experience  in  related  industries.   New  explosive plants
initiating production between now and 1983 should  attain  a
level  of  treatment somewhere between BPCTCA and BATEA.  It
is recommended that for subcategories A, B and D  dual-media
filtration  be  used  as  an additional step after BPCTCA to
comply with BADCT.

For subcategory C, a packaged dual-medai  filtration  system
is  recommended  to  be  added to BPCTCA treatment system to
comply with BADCT.

On the basis of information derived  from  the  contractor's
previous  experience  and  EPA  publications,  the following
percent reductions are used for dual-media filtration:

     BADCT Effluent Reductions For -Subcategories A, B and D
         Parameter
           COD
           TSS
Percent Reduction of
   BPCTCA Effluent

       8.0
      13.0
      60.O1
  Except  the average of daily values for 30 consecutive days
  shall not exceed  20 mg/1 and the maximum for any one day
  is  40 mg/1.
                          109

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     BACCT Effluent Reductions For Subcateaorv C
         Parame-fcer

           TSS
           Oil and Grease
Percent Reduction of
   BPCTCA Effluent

      60»
      802
1 Except the average of daily values for 30 consecutive days
  shall not exceed 20 mg/1 and the maximum for any one day
  is HO mg/1.                      .
2 Except the average of daily values for 30 consecutive days
  shall not exceed 10 m/gl and the maximum for any one day
  is 20 mg/1.
                             110

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                        SECTION VIII

        COST, ENERGY, AND NONrWATJBR QUALITY ASPECTS
General

In  order  -to evaluate the economic impact of treatment on a
uniform  basis,  end-of-pipe  treatment  models  which  will
provide  the  desired  level  of treatment were proposed for
each subcategory.  In-plant control measures have  not  been
evaluated  because  the  cost, energy, and non-water quality
aspects of in-plant controls are intimately related  to  the
specific processes for which they are developed.

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 changes  in  process
conditions,  effluent  limitations  at  the RWL* s within the
subcategories of  explosives  manufacturing,  although  many
variations of technology and control can actually be used.

A  design  for  an  end-of-pipe  treatment  model  has  been
provided, for costing purposes  only.   This  model  can  be
related  directly . to  the  range  of influent hydraulic and
organic loading within each subcategory, and the  costs  as-
sociated with these systems can be divided by the production
rate  for  any given subcategory to show the economic impact
of the system in terms of dollars per pound  of  product  or
per  1000  pounds of product.  The actual combination of in-
plant controls and end-of-pipe treatment used to attain  the
effluent   limitations  and  guidelines  presented  in  this
document should be a decision made by the  individual  plant
based generally upon economic considerations.

The  major  non-water  quality consideration associated with
in-process  control  measures  is  the  means  of   ultimate
disposal  of  wastes.   As  the volume of the process RWL is
reduced,   alternative   disposal   techniques    such    as
incineration,   pyrolysis   and   evaporation   become  more
feasible.  Recent regulations tend to limit the use of ocean
discharge and deep-well injection because of  the  potential
long-term detrimental effects associated with these disposal
procedures.    Incineration   and   evaporation  are  viable
alternatives for concentrated waste streams,  considerations
involving air pollution  and  auxiliary  fuel  requirements,
depending  on  the  heating  value  of  the  waste,  must be
evaluated individually for each situation.
                               Ill

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 Other non-water quality aspects such as  noise   levels   will
 not  be  perceptibly  affected  by  the  proposed wastewater
 treatment systems.   Equipment associated with in-process and
 end-of-pipe control systems would not add  significantly  to
 these noise levels.

 Extensive  annual  and  capital  cost  estimates  have   been
 prepared  for  the   end-of-pipe  treatment  models  to   help
 evaluate  the  economic  impact  of  the  proposed  effluent
 limitations guidelines.   The capital costs were  generated on
 a unit process  basis  (e.g.r  equalization,  neutralization,
 etc.)   and  were used  in the form of cost curves for all the
 proposed treatment  systems.   The particular cost curves  used
 in the treatment models  for  explosives  manufacturing   are
 shown  later in this  section under paragraphs titled BPCTCA
 cost  model and  BATEA cost model.   The  following  percentage
 figures  were  added  on  to the total  unit process  costs 'to
 develop  the total capital  cost  requirements  for    all
 subcategories   except   subcategory C,   which   utilized a
 packaged treatment  model for BPCTCA and BADCT:
             Item
      Percent of Unit Process
      	Capital Cost
     Electrical
     Piping
     Instrumentation
     Site Work
     Engineering Design and Construction
       Surveillance Fees
     Construction contingency
                        14
                        20
                         8
                         6

                        15
                        15
Land costs were computed independently and added directly to
the total capital costs.

Annual costs were computed using the following cost basis:
         Item

Capital Recovery
plus Return

Operations and
    Maintenance
Energy and Power
         Cost Allocation
10 yrs at 10 percent

Includes labor and supervision,
chemicals, sludge hauling and dis-
posal, insurance and taxes (computed
at 2 percent of the capital cost),
and maintenance (computed at 4 per-
cent of the capital cost).

Based on $0.02/kw hr for electrical
                              112

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                        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.
    Technology or Design Criteria

    Use aerated lagoons and
    sludge de-watering lagoons
    in place of the proposed
    treatment system.

    Use earthen basins with
    a plastic liner in place
    of reinforced concrete con-
    struction, and floating
    aerators with permanent-
    access walkways.

    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.

    Minimize flows and maximize
    concentrations through ex-
    tensive in-plant recovery and
    water conservation, so that
    other treatment technologies,
    e.g., incineration, may be
    economically competitive.
       Capital
  Cost Differential

The cost reduction
could be 20 to 40 per-
cent of the proposed
figures.

Cost reduction could
be 20 to 30 percent
of the total cost.
Cost savings would
depend on the in-
dividual situation.
Cost differential would
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  1780.   Current  capital  cost  of  the  packaged
treatment  model for BPCTCA and BADCT for subcategory C have
                             113

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 been reduced from an ENR index value of 2276 for  1975  back
 to  a  value  of 1780 for 1972 in order to keep a consistent
 cost basis for all subcategories.

 Explosives Manufacturing

 This section provides quantitative cost information relative
 to assessing the economic impact of  the  proposed  effluent
 limitations on explosives manufacturing.

 In  order  to  evaluate  the  economic  impact  on a uniform
 treatment basis, end-of-pipe treatment models were  proposed
 based  on  design criteria that provide the desired level of
 treatment.   A summary of the treatment models follow:
                               End-of-pipe
                               Treatment Model

                               Equalization,  Neutralization,
                                  and Activated Sludge

                               Extended Aeration Packaged
                                 Plant with Screening,
                                 Clarification,  Skimming and
                                 Chlorination

                               Equalization,  Neutralization,
                                 Activated Sludge  and
                                 Filtration

                               Extended Aeration Packaged
                                 Plant with Screening,
                                 Clarification,  Skimming and
                                 Chlorination plus
                                 Package Dual-Media Filtration

                               Equalization,  Neutralization,
                                 Activated Sludge, Filtration
                                 and  Carbon Adsorption

                               Extended Aeration Packaged
                                 Plant with Screening,
                                 Clarification,  Skimming and
                                 Chlorination  plus
                                 Package Dual-Media Filtra-
                                 tion,  Chemical  Coagulation,
                                 and Carbon Adsorption.

The treatment technology shown above  is  intended  to  attain
the    effluent   limitations    and    guidelines   proposed.
Technology Level

BPCTCA for subcat-
egories A, B and D

BPCTCA for subcat-
egory C
BADCT for subcat-
egories A, B and D
BADCT for subcat-
egory C
BATEA for subcat-
egories A, B and D


BATEA for subcat-
egory C
                              114

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 Individual plants may attain effluent limitations guidelines
 through  in-plant  controls  or  by  different   end-of-pipe
 treatment  than  is  shown.   The decision is left up to the
 manufacturer to determine which is the most cost-effective.

    BPCTCA Cost Models

 To evaluate the ecpnomic effects  of  BPCTCA  on  explosives
 manufacturing,  BPCTCA treatment models were developed.  The
 treatment model is described in Table VIII-1.  As  shown  in
 Figure  VIJI-1,  there  are two parallel treatment trains in
 the proposed system for subcategories A, B and D.   This  is
 to  ensure  operating flexibility and reliability.  As shown
 in  Figure  VIII-1ar  subcategory  C  has  a  single   train
 treatment  system,  except  for  duplicate pumps.  Treatment
 systems involving very low flow may not be able to use  this
 parallel mode.

 The  following  is  a  brief  discussion  of  the  treatment
 technology available and the rationale for the selection  of
 the   unit   processes  included  in  the  described  BPCTCA
 treatment system.

 The topography of a particular plant site will  dictate  the
 type of pumping equipment required.  Equalization facilities
 are  provided  for.  subcategories  ft,  B  and  D in order to
 minimize short interval (e.g., hourly)  fluctuations  in  the
 hydraulic  loading  to  the  treatment  plant  and to absorb
organic sludge loads from reactor cleanouts  and  accidental
 spills  and  minimize the usage of neutralization chemicals.
 Equalization will provide continuous (seven days  per  week)
 operation of the wastewater treatment facilities even though
 the  manufacturing facilities operate only five days a week.
 In  the  case  of  subcategory  C,   separate   equalization
 facilities will not be required because of the small flow.

Since  many  of  the  explosives  waste streams have extreme
values  of  pH,  neutralization  is   necessary.    Alkaline
neutralization   is   provided   in  the  model  system  for
 subcategories A, B and  D  in  the  form  of  hydrated  lime
 storage and feed facilities.

In the case of subcategories A, B and D, an activated sludge
 process was selected for the biological treatment portion of
the  system;   however,   for  plants  located  in  areas with
available land space,   aerated  lagoons  with  clarification
could  provide  a  viable  treatment  alternative.    For the
purpose of cost estimates,  activated  sludge  was  selected.
For  subcategory C,  an extended aeration packaged system was
selected.
                               115

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                               Table VIII-1
                  BPCTCA Treatment System Design Summary
                            Explosives Indusry

 1.  Subcategory A, B and D

EqualJzation

    For plants with  less than 2k hour/day and 7 day/week production,
    a minimum holding time of 1.5 days  is provided with continuous
    discharge from the equalization basin over 2k hours.

    For plants with  less than 2k hour/day and 5 days/week production,
    two day equalization is provided.   Discharge from the basin will
    be continuous over the seven days.  For plants with 2k hour/day
    and 7 day/week batch production, one day holding capacity  is pro-
    vided.  For continuous processes  (2k hours/day, 7 days/week) no
    equalization is  required except under special cases.

    Protective liners are provided, based on the following criteria:

        Influent pH                       Type of Liner Required
        Greater than 6
        Between k.Q and 6.0
        Between 2.0 and k.O
        Below 2.0
  No Lining
  Epoxy Coating
  Rubber or Polypropylene
  Acid Brick Lining
Neutralization
    The size of the two-stage neutralization basin is based on an average
    detention time of 10 minutes.  Lime and acid handling facilities are
    sized according to acidity/alkalinity data collected during the sur-
    vey.  Bulk lime-storage facilities (20 tons) or bag storage is pro-
    vided, depending on plant size.  Sulfuric acid storage is either
    by 55-gallon drums or in carbon-steel tanks.  Lime or acid addition
    is controlled by two pH probes, one in each basin.  The lime slurry
    is added to the neutralization basin, from a volumetric feeder.  Aci'd
    is supplied by positive displacement metering pumps.

Primary Flocculation Clarifiers
    Primary flocculator clarifiers with
    square feet are rectangular units wi
    1  to k.  The side water depth varies
    flow rate varies between 600 and 800
    size.  Clarifiers with surface areas
    are circular units.  The side water
    and the overflow rate varies between
    pending on plant size.  Polymer addi
surface areas less than 1,000
th a length-to-width ratio of
 from 6 to 8 feet and the over-
 gpd/sq ft depending on plant
 greater than 1,000 square feet
depth varies from 7 to 13 feet
 600 and 800 gpd/sq ft, de-
tion facilities are provided.
                                116

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                           Table VII I  -1
                            (continued)
Nutrient Addition
    Facilities are provided for the addition of phosphoric acid to the
    biological system to maintain the ratio of BOD:N:P at 100:5:1.

Aeration Basin/Aerated Lagoons

    The size of the aeration basins is based on historical treatability
    data collected during the survey.  Mechanical surface aerators are
    provided.

    The necessary design criteria for the aeration basins are:
        Oxygen Utilization:  Energy
        Oxygen Utilization:  Endogenous
        Oxygen transfer
        Motor Efficiency
        Minimum Basin D.O.
0.8 Ibs 07/lb BOD removed
6 Ibs 0-/fir/1,000 Ibs MLVSS
0.75   Z
0.90               ,

3.5 Ibs O./hr/shaft HP at
   20°C and zero D.O. in
   tap water
85 percent
2 mg/L
    Oxygen is monitored in the basins using D.O. probes.

Secondary Flpeculator Clarifiers

    The design basis for secondary flocculator clarifiers is the same
    as discussed previously for primary fIocculator"c1arifiers except
    for overflow rate.  Secondary flocculator clarifiers are designed
    for an overflow rate of 600 gpd/sq ft.  Feed facilities for anionic
    polymer addition are provided.

Sludge Thickener

    The thickener provided was designed on the basis of a solids load-
    ing of 6 Ibs/sq ft/day.

Aerobic Digester

    The size of the aerobic digester was based on a hydraulic detention
    time of 20 days.  The size of the aerator-mixers was based on an
    oxygen requirement of 1.6 Ibs 0 /lb VSS destroyed and a mixing re-
    quirement of 165 HP/mg of digester volume.

F?na1  SIudge D?sposa1

    For small  plants sludge is disposed of at a sanitary landfill.
    Sludge incineration facilities are provided for larger plants.
                                 117

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                       Table VIII - 1 (Continued)

                          BPCTCA Treatment

2.   Subcategory C

     General

       Subcategory C generally includes two types  of plants
       combined operation plants and stand alone mix plants.
       A combined operations plant is one located  at the
       same site as the explosive manufacturing facilities,
       and the wastewater from this type of plant  could
       be treated at the waste treatment plant for the
       manufacturing facilities.

       For the stand alone mix plant separate waste treat-1
       ment facilities will be required.  This cost model
       is developed for that type of plant.

     Extented Aeration Package Plant

       The stand alone mix plant wastewaters are characte-
       rized as containing either high oil content (ANFO and
       NCN production)  or high suspended solids content or
       both.  The flow is small or intermittent therefore
       an extended aeration package plant which includes
       screening, biological treatment,  clarification with
       skimming and chlorination has been selected.  The
       sludge from the unit will be disposed at a  certified
       landfill capable of handling such wastes.
                              118

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                         Table VIII-2

               BATEA and BADCT Treatment System
                        Design Summary

                      Explosives Industry
Dual Media Filtration

    Filters were sized using the criteria of 3 gpm/sq ft.  Backwash
    rates used were 20 gpm/sq ft for 10 minute duration.  In case
    of subcategory C chemical coagulation facility is included.

Carbon Adsorption

    The unit is designed as a downflow fixed bed.  Pretreatment for
    removal of suspended solids is provided so as to thwart clogging
    of the carbon column.  Carbon contact time was set at 30 minutes.
    Hydraulic loading rates used were 4 gpm/sq ft.  The spent carbon
    to be regenerated was calculated on a 0.5 Ib of COD/lb carbon.
    The regeneration furnace itself was designed for 2.5 Ibs/sq
    ft/hr.
                           119

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The  sludge  handling scheme for subcategories A, B and D is
shown in Figure VIII-1.  The aerobic digester will produce a
nonputrescible sludge which  can  be  thickened  and  stored
before   being   trucked   to  a  certified  landfill.   For
subcategory C, as the sludge quantity will be small, it will
be trucked to a certified landfill.

It should be noted that the activated  sludge  process  cost
model  cannot  be  justified for the dilute waste streams of
subcategory C.  However, since some load, assemble and  pack
operations are part of larger plant operations which include
manufacturing   activities   in   the  other  subcategories,
activated  sludge  remains  a  viable  technology  for   the
combined  wastes  and the incremental cost for subcategory C
becomes minimal in this case.

    BATEA Cost Model

For the purpose of the economic evaluation of BATEA, it  was
necessary  to formulate a BATEA waste treatment model (Table
VIII-2).  The model,  composed  of  dual-media  filters  and
activated  carbon  adsorption,  is  added  on  to the BPCTCA
treatment system for subcategories A, B and  D.   The  model
for  subcategory  C  consists  of  chemical  coagulation and
filtration added to the BPCTCA  extended  aeration  packaged
treatment system.

Dual-media  filtration  is  intended to remove the suspended
solids to avoid clogging of  the  activated  carbon  column.
The   down-flow   fixed   bed  system  was  selected.   Such
regeneration of activated carbon has been a problem  in  TNT
waste  streams,  however,  these  wastes  will  be part of a
combined waste stream  at  an  explosive  plant  and  it  is
expected that activated carbon can be used with the combined
wastes.   Such  development  should be done by each plant to
assure  the  most  economical  situations  to  achieve   the
necessary   level   of  in-plant  controls  and  end-of-pipe
technology for pollution control.  End-of-pipe technology is
capable of attaining the recommended  effluent  limitations,
guidelines  and  new source performance standards.  To date,
no studies have shown it to be a problem in composite  waste
streams.

    BADCT Cost Model

For  the purpose of the economic evaluation of BADCT, a cost
model (Table VIII-2)  was formulated consisting of dual-media
filtration  added  to  the  BPCTCA  treatment   system   for
subcategories  A, B and D.  A packaged dual-media filtration
                           120

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LU




1
             <
             w
             LU
>0 = uj  -
   O
         cc
      it; H
      — LU
      Q. g


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        CQ
    LU


    5
                                                  121