DEVELOPMENT DOCUMENT
for .
EFFLUENT LIMITATIONS GUIDELINES
for the
ELECTRICAL AND ELECTRONIC COMPONENTS
POINT SOURCE CATEGORY
PHASE 2
Anne M. Gorsuch
Administrator
Steven Schatzow
Director
Office of Water Regulations and Standards
I
£
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if
Jeffery Denit, Director
Effluent Guidelines Division
G. Edward Stigall, Chief
Inorganic Chemicals Branch
John Newbrough
Project Officer
ins
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Effluent Guidelines Division
Washington, D.C. 20460
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TABLE OF CONTENTS
SECTION TITLE
EXECUTIVE SUMMARY
CONCLUSIONS
PROPOSED EFFLUENT LIMITATIONS AND STANDARDS
PAGE
1
1
2
1.0 INTRODUCTION 1-1
1.1 ORGANIZATION AND CONTENT OF THIS DOCUMENT 1-1
1.2 SOURCES OF INDUSTRY DATA 1-1
2.0 LEGAL BACKGROUND 2-1
2.1 PURPOSE AND AUTHORITY 2-1
2.2 GENERAL CRITERIA FOR EFFLUENT LIMITATIONS 2-2
2.2.1 BPT Effluent Limitations 2-3
2.2.2 BAT Effluent Limitations 2-3
2.2.3 BCT Effluent Limitaations 2-4
2.2.4 New Source Performance Standards 2-4
2.2.5 Pretreatment Standards for Existing 2-5
Sources
2.2.6 Pretreatment Standards for New Sources 2-5
3.0 INDUSTRY SUBCATEGORIZATION 3-1
3.1 RATIONALE FOR SUBCATEGORIZATION 3-1
3.2 SUBCATEGORIZATION REVIEW 3-1
3.3 CONCLUSIONS 3-1
4.0 DESCRIPTION OF THE INDUSTRY 4-1
4.1 CATHODE RAY TUBES . 4-1
4.1.1 Number of Plants and Production
Capacity 4-1
4.1.2 Product Description 4-1
4.2.3 Manufacturing Processes and Materials 4-7
4.2 RECEIVING AND TRANSMITTING TUBE 4-10
4.2.1 Number of Plants 4-10
4.2.2 Product Description 4-10
4.2.3 Manufacturing Processes and Materials 4-12
4.3 LUMINESCENT MATERIALS
4-15
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4.3.1 Number of Plants 4-16
4.3.2 Product Description 4-16
4.3.3 Manufacturing Processes and Materials 4-16
5.0 WASTEWATER CHARACTERISTICS 5-1
5.1 SAMPLING AND ANALYTICAL PROGRAM 5-1
5.1.1 Pollutants Analyzed 5-1
5.1.2 Sampling Methodology 5-1
5.1.3 Analytical Methods 5-4
5.2 CATHODE RAY TUBES 5-5
5.2.1 Wastewater Flow 5-5
5.2.2 Wastewater Sources 5-6
5.2.3 Pollutants Found and the Sources 5-6
of These Pollutants
5.3 LUMINESCENT MATERIALS 5-23
5.3.1 Wastewater Flow 5-24
5.3.2 Wastewater Sources 5-24
5.3.3 Pollutants Found and the Sources 5-24
of These Pollutants
5.4 RECEIVING AND TRANSMITTING TUBES 5-26
6.0 SUBCATEGORIES AND POLLUTANTS TO BE REGULATED, 6-1
EXCLUDED OR DEFERRED
6.1 SUBCATEGORIES TO BE REGULATED 6-1
6.1.1 Pollutants to be Regulated 6-2
6.2 TOXIC POLLUTANTS AND SUBCATEGORIES NOT 6-5
REGULATED
6.2.1 Exclusion of Pollutants 6-5
6.2.2 Exclusion of Subcategories 6-5
6.3 CONVENTIONAL POLLUTANTS NOT REGULATED 6-7
7.0 CONTROL AND TREATMENT TECHNOLOGY 7-1
7.1 CURRENT TREATMENT AND CONTROL PRACTICES
7.1.1 Cathode Ray Tube Subcategory
7.1.2 Luminescent Materials Subcategory
7.2 APPLICABLE TREATMENT TECHNOLOGIES
7.2.1 pH Control
7.2.2 Fluoride Treatment
7.2.3 Toxic Metals Treatment
7.2.4 Total Toxic Organics Control
7.3 RECOMMENDED TREATMENT AND CONTROL SYSTEMS
7.3.1 Cathode Ray Tube Subcategory
7-1
7-1
7-2
7-2
7-2
7-2
7-4
7-6
7-6
7-6
n
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7.3.2
Luminescent Materials Subcategory
8.0
9.0
7.4 ANALYSIS OF INDUSTRY PERFORMANCE DATA
7.4.1 Cathode Ray Tube Subcategory
7.4.2 Luminescent Materials Subcategory
7.4.3 Statistical Methodology
SELECTION OF APPROPRIATE CONTROL AND TREATMENT
TECHNOLOGIES AND BASES FOR LIMITATIONS
7-7
7-7
7-7
7-8
7-8
8-1
8.1 CATHODE RAY TUBE SUBCATEGORY 8-1
8.1.1 Pretreatment Standards for Existing
Sources (PSES) 8-1
8.1.1 a Alternate Pretreatment Standards for
Existing Sources (PSES)
8.1.2 New Source Performance Standards (NSPS) 8-3
8.1.3 Pretreatment Standards for New Sources 8-4
(PSNS)
8.2 LUMINESCENT MATERIALS SUBCATEGORY 8-4
8.2.1 New Source Performance Standards (NSPS) 8-4
8.2.2 Pretreatment Standards for New Sources 8-5
(PSNS)
COST OF WASTEWATER TREATMENT AND CONTROL 9-1
9.1 COST ESTIMATING METHODOLOGY 9-1
9.1.1 Direct Investment Costs for Land and 9-2
Facilities
9.1.2 Annual Costs 9-4
9.1.3 Items Not Included in Cost Estimate 9-6
9.2 COST ESTIMATES FOR TREATMENT AND CONTROL OPTIONS 9-6
9.2.1 Cathode Ray Tube Subcategory 9-6
9.2.2 Luminescent Materials Subcategory 9-7
9.3 ENERGY AND NON-WATER QUALITY ASPECTS 9-7
10.0 ACKNOWLEDGEMENTS 10-1
11.0 BIBLIOGRAPHY 11-1
12.0 GLOSSARY 12-1
m
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LIST OF FIGURES
NUMBER
TITLE
4-1 Color Television Picture Tube
4-2 Television Picture Tube Manufacture
4-3 CRT Manufacture
4-4 Receiving Tube
4-5 Transmitting Tube
4-6 Receiving Tube Manufacture
4-7 Transmitting Tube Manufacture
4-8 Lamp Phosphor Process
4-9 Blue Phosphor Process
5-1 Plant 30172 Sampling Locations
5-2 Plant 11114 Sampling Locations
5-3 Plant 99796 Sampling Locations
5-4 Plant 101 Sampling Locations
7-1 Theoretical Solubilities of Toxic Metal
Hydroxides
7-2 Recommended Treatment—Cathode Ray Tube
Subcategory
7-3 Recommended Treatment—Luminescent
Materials Subcategory
7-4 Ln Cadmium Concentration vs. Cumulative
Frequency—Plant 30172
7-5 Ln Chromium Concentration vs. Cumulative
Frequency—Plant 30172
7-6 Ln Lead Concentration vs. Cumulative
Frequency—Plant 99797
7-7 Ln Zinc Concentration vs. Cumulative
Frequency—Plant 99797
PAGE
4-3
4-5
4-6
4-7
4-12
4-13
4-14
4-18
4-19
5-1
5-8
5-9
5-27
7-5
7-9
7-10
7-17
7-18
7-19
7-20
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7-8 Fluoride Concentration vs. Cumulative
Frequency — Plant 30172
7-1
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LIST OF TABLES
NUMBER
1
2
3
4
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
6-1
6-2
7-1
7-2
7-3
9-1
9-2
TITLE PAGE
PSES Proposed Regulations for Cathode Ray Tubes 2
*'" *•" - . . L ,.,,.,„
NSPS Proposed Regulations for Cathode Ray Tubes 2
PSNS Proposed Regulations for Cathode Ray Tubes 2
NSPS Proposed Regulations for Luminescent 3
Materials
PSNS Proposed Regulations for Luminescent 3
Materials
Toxic Pollutants 5-2
Cathode Ray Tubes Summary of Raw Waste Data 5-6
Wastewater Sampling Data Plant 30172 5-10
Wastewater Sampling Data Plant 11114 5-13
Wastewater Sampling Data Plant 99796 5-21
Luminescent Materials Summary of Raw Waste 5-25
Data
Wastewater Sampling Data Plant 101 5-29
Wastewater Sampling Data Plant 102 5-33
Wastewater Sampling Data Plant 103 5-34
Pollutants Comprising Total Toxic Organics 6-2
Toxic Pollutants Not Detected 6-6
Performance of In-Place Treatment 7-11
Statistical Parameters for Long-Term Effluent 7-12
Data
Performance of In-Place Treatment Plants 101 7-13
and 102
Option 2 Treatment Costs 9-8
Option 3 Treatment Costs 9-11
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EXECUTIVE SUMMARY
CONCLUSIONS
A study of the Electrical and Electronic Components Industrial
Point Source Category Phase II was undertaken to establish
discharge limitations guidelines and standards. The industry was
subcategorized into segments based on product type. Of the three
subcategories, one has been excluded under Paragraph 8 of the
NRDC Consent Decree, and for two subcategories, regulations are
being proposed. The two subcategories are Cathode Ray Tubes and
Luminescent Materials. The Agency is proposing not to regulate
existing direct dischargers for the reasons described in Section
VI of this document. Therefore, BPT, BAT, and BCT effluent
limitations are not being proposed.
In the Cathode Ray Tube subcategory the pollutants of concern
include cadmium, chromium, lead, zinc, toxic organics, fluoride,
and total suspended solids. Cadmium and Zinc are the major toxic
metals found in phosphors in cathode ray tubes. Sources of these
metals are manufacture, salvage, and phosphor recovery
operations. Chromium occurs .as dichromate, in photosensitive
materials and is found in wastewater from manufacture and salvage
operations. Lead is found in the wastewater from the tube
salvage operation where the lead frit is dissolved in nitric
acid. Toxic organics occur from the use of solvents in cleaning
and degreasing operations. The major source of fluoride is the
use of hydrofluoric acid for cleaning and conditioning glass
surfaces. Finally, total suspended solids result primarily from
the use of graphite emulsions used to coat the tubes.
For the Luminescent Materials subcategory the pollutants of
concern include cadmium, antimony, zinc, fluoride, and total
suspended solids. Cadmium and zinc are major constituents of
blue and green phosphors, and are found in the wastewater from
washing and filtering operations. Antimony is used as an
activator and found in the wastewater from lamp phosphor
manufacture. Fluoride results from the manufacture of an
intermediate lamp phosphor, calcium fluoride. Total suspended
solids occur in wastes from washing and filtration operations.
Several treatment control technologies applicable to the
reduction of pollutants generated by the manufacture of cathode
ray tubes and luminescent materials were evaluated, and the costs
of these technologies were estimated. Pollutant concentrations
achievable through the implementation of these technologies were
based on industry data. These concentrations are presented below
as proposed standards for the Cathode Ray Tubes and Luminescent
Materials subcategories.
PROPOSED EFFLUENT LIMITATIONS AND STANDARDS
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Tables 1 through 5 present proposed regulations for New Source
Performance Standards (NSPS), and Pretreatment Standards for New
and Existing Sources (PSNS and PSES). All standards are
expressed as milligrams per liter.
TABLE 1: PSES PROPOSED REGULATIONS FOR CATHODE RAY TUBES
Pollutant
Daily Maximum
Monthly Average
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
0.046
0.91
1 .13
2.06
0.15
32.6
0.022
0. 26
0. 36
0.49
22.3
TABLE 2: NSPS PROPOSED REGULATIONS FOR CATHODE RAY TUBES
Pollutant
Daily Maximum
Monthly Average
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
TSS
PH
0.046
0.77
0.73
1.18
0.15
32.6
42.9
0.022
0. 22
0. 23
0.28
22.3
16. 1
6-<
TABLE 3: PSNS PROPOSED REGULATIONS FOR CATHODE RAY TUBES
Pollutant
Daily Maximum
Monthly Average
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
0.046
0.77
0.73
1 .18
0.15
32.6
0. 022
0.22
0. 23
0. 28
22.3
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TABLE 4: NSPS PROPOSED REGULATIONS FOR LUMINESCENT MATERIALS
Pollutant
Daily Maximum
(mg/1)
Monthly Average
(mg/1)
pH Range
Cadmium
Antimony
Zinc
Fluoride
TSS
pH
0.48
0.18
2.84
32.6
61 .0
0.23
'• 0.044
,. 0.68
22.3
22.9
- , - . . . ..
6-9
TABLE 5: PSNS PROPOSED REGULATIONS FOR LUMINESCENT MATERIALS
Pollutant
Daily Maximum
(mg/1)
Monthly Average
(mq/1.)
Cadmium
Antimony
Zinc
Fluoride
0.48
0.18
2.84
32.6
0.23
0.044
0.'68
22.3
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SECTION 1
INTRODUCTION
The purpose of this document is to present the findings of the
EPA Phase 2 study of the Electrical and Electronic Components
(E&EC) Point Source Category. The Phase 2 study examines the
Electron Tubes and Luminescent Materials (Phosphorescent
Coatings) subcategories of E&EC, the two subcategories which were
previously deferred from regulatory analysis. EPA 440/1-82/075b
July 1982.* The document (1) explains subcategories and
pollutants are regulated and which are not; (2) discusses the
reasons; and (3) explains how the actual .limitations were
developed. Section 1 describes the organization of the document
and reviews the sources of industry data that were used to
provide technical background for the limitations.
Ill ORGANIZATION AND CONTENT OF THIS DOCUMENT
Data provided by industry are used throughout this report in
support of regulating subcategories or excluding subcategories
from regulation under Paragraph 8 of the NRDC Consent Decree.
Telephone contacts, the literature, and plant visits provided the
information used to subcategorize the industry in Section 3.
These data were also considered in characterizing the industry in
Section 4, Description of the Industry.
Water use and wastewater characteristics in each subcategory are
described in Section 5 in terms of flow and pollutant
concentration. Subcategories to be regulated or excluded are
found in Section 6. The discussion in that section identifies
and describes the pollutants to be regulated and presents the
rationale for subcategory and pollutant exclusion. Section 7
describes the appropriate treatment and control technologies
available. The regulatory limits and the bases for these
limitations are presented in Section 8. Section 9 estimates the
capital and operating costs for the treatment technologies used
as the basis for limitations.
1.2 SOURCES OF INDUSTRY DATA
Data on the two subcategories were gathered from literature
studies, contacts with EPA regional offices, from plant surveys
and evaluations, and through contacting waste treatment equipment
manufacturers. These data sources are discussed below.
*For reasons outlined in section 3.2, EPA has determined that the
Electron Tube subcategory should be divided into Cathode Ray
Tubes (CRT), and Receiving and Transmitting Tubes (RTT)
subcategories. RTT operations do not discharge wastewaters, thus
this document proposes effluent limits only for CRT and
Luminescent Materials subcategories.
1-1
-------
Published literature in the form of books, reports, papers,
periodicals, promotional materials, Dunn and Bradstreet surveys,
and Department of Commerce Statistics was examined. The
researched material included product descriptions and uses,
manufacturing processes, raw materials consumed, waste treatment
technology, and the general characteristics of plants in the two
subcategories including number of plants, employment levels, and
production levels when available.
All 10 EPA regional offices were telephoned for assistance in
identifying plants in their respective regions.
Three types of data collection were used to supplement available
information pertaining to facilities in the E&EC category.
First, more than 150 plants were contacted by phone or letter to
obtain basic information regarding products, manufacturing
processes, wastewater generation, and waste treatment. Second,
based on this information, eleven plants were visited to view
their operations and discuss their products, manufacturing
processes, water use, and wastewater treatment. Third, six
plants were selected for sampling visits to determine the
pollutant characteristics of their wastewater.
The sampling program at each plant consisted of up to three days
of sampling. Prior to any sampling visit, all available data,
such as layouts and diagrams of the selected plant's production
processes and waste treatment facilities, were reviewed. In most
cases, a visit to the plant was made prior to the actual sampling
visit to finalize the sampling approach.
Representative sample points were then selected. Finally, before
the visit was conducted, a detailed sampling plan showing the
selected sample points and all pertinent sample data to be
obtained was presented and reviewed.
Various manufacturers of wastewater treatment equipment were
contacted by phone or were visited to obtain cost and performance
data on specific technologies. Information collected was based
both on manufacturers' research and on actual operation.
1-2
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SECTION 2
LEGAL BACKGROUND
2.1 PURPOSE AND AUTHORITY
The Federal Water Pollution Control Act Amendments of 1972
established a comprehensive program to "restore and maintain the
chemical, physical, and biological integrity of the Nation's
waters," Section 101(a). Section 301(b)(l)(A) set a deadline of
July 1, 1977, for existing industrial dischargers- to achieve
"effluent limitations requiring the application of the best
practicable control technology currently available" (BPT).
Section 301(b)(2)(A) set a deadline of July 1, 1983, for these
dischargers to achieve "effluent limitations requiring the
application of the best available technology economically
achievable (BAT), which will result in reasonable further
progress toward the national goal of eliminating the discharge of
all pollutants."
Section 306 required that new industrial direct dischargers
comply with new source performance standards (NSPS), based on
best available demonstrated technology. Sections 307{b) and (c)
of the Act required pretreatment standards for new and existing
dischargers to publicly owned treatment works (POTW). While the
requirements for direct dischargers were to be incorporated into
National Pollutants Discharge Elimination System (NPDES) permits
issued under Section 402, the Act made pretreatment standards
enforceable directly against dischargers to POTWs (indirect
dischargers).
Section 402(a)(l) of the 1972 Act does allow requirements to be
set case-by-case. However, Congress intended control
requirements to be based, for the most part, on regulations
promulgated by the Administrator of EPA. Section 304(b) required
regulations for NSPS. Sections 304(f), 307(b), and 307(c)
required regulations for pretreatment standards. In addition to
these regulations for designated industry categories, Section
307(a) required the Administrator to promulgate effluent
standards applicable to all dischargers of toxic pollutants.
Finally, Section 501(a) authorized the Administrator to prescribe
any additional regulations "necessary to carry out his functions"
under the Act.
The EPA was unable to promulgate many of these regulations by the
deadlines contained in the Act, and as a result, in 1976, EPA was
sued by several environmental groups. In settling this lawsuit,
EPA and the plaintiffs executed a "Settlement Agreement" which
was approved by the Court. This agreement required EPA to
develop a program and meet a schedule for controlling 65
"priority" pollutants and classes of pollutants. In carrying out
2-1
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this program, EPA must promulgate BAT effluent limitations
guidelines, pretreatment standards, and new source performance
standards for 21 major industries. (See Natural Resources
Defense Council, Inc. v. Train, 8 ERG 2120 (D.D.C. 1976)
modified, 12 ERC 1833 (D.D.C. 1979)).
Several of the basic elements of the Settlement Agreement program
were incorporated into the Clean Water Act of 1977. This law
made several important changes in the Federal Water pollution
control program. Sections 301(b)(2)(A) and 301(b)(2)(C) of the
Act now set July 1, 1984, as the deadline for industries to
achieve effluent limitations requiring application of BAT for
"toxic" pollutants. "Toxic" pollutants here included the 65
"priority" pollutants and classes of pollutants that Congress
declared "toxic" under Section 307(a) of the Act.
EPA's programs for new source performance standards and
pretreatment standards are now aimed principally at controlling
toxic pollutants. To strengthen the toxics control program,
Section 304(e) of the Act authorizes the Administrator to
prescribe "best management practices" (BMPs). These BMPs are to
prevent the release of toxic and hazardous pollutants from: (1)
plant site runoff, (2) spillage or leaks, (3) sludge or waste
disposal, and (4) drainage from raw material storage if any of
these events are associated with, or ancillary to, the
manufacturing or treatment process.
In keeping with its emphasis on toxic pollutants, the Clean Water
Act of 1977 also revises the control program for non-toxic
pollutants. For "conventional" pollutants identified under
Section 304(a)(4) (including biochemical oxygen demand, suspended
solids, fecal coliform, and pH), the new Section 301(b)(2)(E)
requires "effluent limitations requiring the application of the
best conventional pollutant control technology" (BCT)—instead of
BAT—to be achieved by July 1, 1984. The factors considered in
assessing BCT for an industry include the relationship between
the cost of attaining a reduction in effluents and the effluent
reduction benefits attained, and a comparison of the cost and
level of reduction of such pollutants by publicly owned treatment
works and industrial sources. For those pollutants that are
neither "toxic" pollutants nor "conventional" pollutants,
Sections 301(b)(2)(A) and (b)(2)(F) require achievement of BAT
effluent limitations within three years after their establishment
or July 1, 1984, whichever is later, but not later than July 1,
1987.
The purpose of this proposed regulation is to establish BPT, BAT,
and BCT effluent limitations and NSPS, PSES, and PSNS for the
Electrical and Electronic Components Point Source Category.
2.2 GENERAL CRITERIA FOR EFFLUENT LIMITATIONS
2.2.1 BPT Effluent Limitations
2-2
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The factors considered in defining best practicable control
technology currently available (BPT) include: (1) the total cost
of applying the technology relative to the effluent reductions
that result, (2) the age of equipment and facilities involved,
(3) the processes used, (4) engineering aspects of the control
technology, (5) process changes, (6) non-water quality
environmental impacts (including energy requirements), (7) and
other factors as the Administrator considers appropriate. In
general, the BPT level represents the average of the best
existing performances of plants within the industry of various
ages, sizes, processes, or other common characteristics. When
existing performance is uniformly inadequate, BPT may be
transferred from a different subcategory or category. BPT
focuses on end-of-process treatment rather than process changes
or internal controls, except when these technologies are common
industry practice.
The cost/benefit inquiry for BPT is a limited balancing,
committed to EPA's discretion, which does not require the Agency
to quantify benefits in monetary terms. See, e.g., American Iron
and Steel Institute v. EPA, 526 F.2d 1027 (3rd Cir. 1975). In
balancing costs against the benefits of effluent reduction, EPA
considers the volume and nature of existing discharges, the
volume and nature of discharges expected after application of
BPT, the general environmental effects of the pollutants, and the
cost and economic impacts of the required level of pollution
control. The Act does not require or permit consideration of
water quality problems attributable to particular point sources
or water quality improvements in particular bodies of water.
Therefore, EPA has not considered these factors. See
Weyerhaeuser Company v. Costle, 590 F.2d 1011 (D.C. Cir. 1978);
Applachian Power Company et al. v. U.S.E.P.A.- (D.C. Cir., Feb.
8, 1972).
2.2.2 BAT Effluent Limitations
The factors considered in defining best available technology
economically achievable (BAT) include the age of equipment and
facilities involved, the processes used, process changes, and
engineering aspects of the technology process changes, non-water
quality environmental impacts (including energy requirements) and
the costs of applying such technology JJ(Section 304(b)(2)(B)KK.
At a minimum, the BAT level represents the best economically
achievable performance of plants of various ages, sizes,
processes, or other shared characteristics. As with BPT,
uniformly inadequate performance within a category or subcategory
may require transfer of BAT from a different subcategory or
category. Unlike BPT, however, BAT may include process changes
or internal controls, even when these technologies are not common
industry practice.
The statutory assessment of BAT "considers" costs, but does not
require a balancing of costs against effluent reduction benefits
2-3
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(see Weyerhaeuser v. Costle, supra). In developing the proposed
BAT, however, EPA has given substantial weight to the
reasonableness of costs. The Agency has considered the volume
and nature of discharges, the volume and nature of discharges
expected after application of BAT, the general environmental
effects of the pollutants, and the costs and economic impacts of
the required pollution control levels. Despite this expanded
consideration of costs, the primary factor for determining BAT is
the effluent reduction capability of the control technology. The
Clean Water Act of 1977 establishes the achievement of BAT as the
principal national means of controlling toxic water pollution
from direct discharging plants.
2.2.3 BCT Effluent Limitations
The 1977 Amendments added Section 301(b)(2)(E) to the Act
establishing "best conventional pollutant control technology"
(BCT) for discharges of conventional pollutants from existing
industrial point sources. Conventional pollutants
defined in Section 304(a)(4) JJbiological oxygen
are those
demanding
pollutants (BOD), total suspended solids (TSS), fecal coliform,"
and pHKK, and any additional pollutants defined by the
Administrator as "conventional" JJoil and grease, 44 FR 44501
July 30, 1979KK. '
BCT is not an additional limitation but replaces BAT for the
control of conventional pollutants. In addition to other factors
specified in Section 304(b)(4)(B), the Act requires that BCT
limitations be assessed in light of a two-part "cost
reasonableness" test. American Paper Institute v. EPA, 660 F.2d
954 (4th Cir. 1981). The first test compares thecosts for
private industry to reduce its conventional pollutants with the
costs to publicly owned treatment works for similar levels of
reduction in their discharge of these pollutants. The second
test examines the cost-effectiveness of additional industrial
treatment beyond BPT. EPA must find that limitations are
reasonable' under both tests before establishing them as BCT.
In no case may BCT be less stringent than BPT.
2.2.4 New Source Performance Standards
The basis for new source performance standards (NSPS) under
Section 306 of the Act is the best available demonstrated
technology. New plants have the opportunity to design the best
and most efficient processes and wastewater . treatment
technologies. Therefore, Congress directed EPA to consider the
best demonstrated process changes, in-plant controls, and end-of-
process treatment technologies that reduce pollution to the
maximum extent feasible.
2.2.5 Pretreatment Standards for Existing Sources
2-4
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Section 307(b) of the Act requires EPA to promulgate pretreatment
standards for existing sources (PSES) which industry must achieve
within three years ot promulgation. PSES are designed to prevent
the discharge of pollutants that pass through, interfere with, or
are otherwise incompatible with the operation of POTWs.
The legislative history of the 1977 Act indicates that
pretreatment standards are to be technology-based, analogous to
the best available technology for removal of toxic pollutants.
The General Pretreatment Regulations which serve as the framework
for the proposed pretreatment standards are in 40 CRF Part 403,
46 FR 9404 (January 28, 1981).
EPA has generally determined that there is passthrough of
pollutants if.the percent of pollutants removed by a welloperated
POTW achieving secondary treatment is less than the percent
removed by the BAT model treatment system. A study of 40 well-
operated POTWs with biological treatment and meeting secondary
treatment criteria showed that metals are typically removed at
rates varying from 20 percent to 70 percent. POTWs with only
primary treatment have even lower rates of removal. In contrast,
BAT level treatment by the industrial facility can achieve
removal in the area of 97 percent or more. Thus, it is evident
that metals do pass through POTWs. As for toxic organics, data
from the same POTWs illustrate a wide range of removal, from 0 to
greater than 99 percent. Overall, POTWs have removal rates of
toxic organics which are less effective than BAT.
2.2.6 Pretreatment Standards for New Sources
Section 307(c) of the Act requires EPA to-promulgate pretreatment
standards for new sources (PSNS) at the same time that it
promulgates NSPS. These standards are intended to prevent the
discharge of pollutants which pass through, interfere with, or
are otherwise incompatible with a POTW. New indirect
dischargers, like new direct dischargers, have the opportunity to
incorporate the best available demonstrated technologies--
including process changes, in-plant controls, and end-of-process
treatment technologies—and to select plant sites that ensure the
treatment system will be adequately installed. Therefore, the
Agency sets PSNS after considering the same criteria considered
for NSPS. PSNS will have environmental benefits similar to those
from NSPS.
2-5
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SECTION 3
INDUSTRY SUBCATEGORIZATION
3.1 RATIONALE FOR SUBCATEGORIZATION
The primary purpose of industrial categorization is to provide
groupings within an industry so that each group has a uniform set
of discharge limitations. After the Agency has obtained
wastewater data and process information from facilities within an
industry or industrial segment, a number of factors are
considered to determine if subcategorization is appropriate.
These factors include raw materials, final products,
manufacturing processes, geographical location, plant size and
age, wastewater characteristics, non-water quality environmental
impacts, treatment costs, energy costs, and solid waste
generation.
3.2 SUBCATEGORIZATION REVIEW
A preliminary review of each of these factors revealed that
product type is the principal factor affecting the wastewater
characteristics in the Electrical and Electronic Components
industrial category. This is demonstrated by a comparison of
pollutants found in plant effluent with the products made at
those plants. Luminescent Materials (Phosphorescent Coatings)
and Electron Tubes were identified as two of the twenty-one (21)
subcategories comprising the E&EC category.
Under this study, further review of the same factors revealed
that the Electron Tube subcategory is comprised of two distinct
product types employing different raw materials and manufacturing
processes. The products included in the Electron Tube
subcategory are cathode ray tubes, receiving tubes and
transmitting tubes. The production of receiving and transmitting
tubes uses similar raw materials and manufacturing processes and
thus similar wastewaters are generated. Cathode ray tube
manufacture, however, employs unique raw materials and process
operations which generate wastes greatly different from those
encountered in the manufacture of receiving and transmitting
tubes.
3.3 CONCLUSIONS
Based on the review of subcategorization factors, the following
subcategories were established under this study and are addressed
as such in this document.
Cathode Ray Tubes
Receiving and Transmitting Tubes
3-1
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Luminescent Materials
3-2
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SECTION 4
DESCRIPTION OF THE INDUSTRY
This section provides a general description of the subcategories
presented in the previous section. It includes a discussion of
the number of plants and production capacity, product lines, and
manufacturing processes including raw materials used.
4.1 CATHODE RAY TUBES
The Cathode Ray Tube subcategory includes plants which discharge
wastewater from the production of electronic devices in which
high velocity electrons are focused through a vacuum to generate
an image on a luminescent (or phosphorescent) surface. Products
are classified under the Standard Industrial Classification (SIC)
3671 the Cathode Ray Tube (CRT) subcategory's products are
comprised of two CRT types:
o Aperture Mask Tubes which are cathode ray tubes that
contain multiple color phosphors and use an aperture
(shadow) mask. This type of tube will be referred to
as a color television picture tube.
o Cathode ray tubes that contain a single phosphor and
no aperture mask. This type of tube will be referred
to as a single phosphor tube.
4.1.1 Number of_ Plants and Production Capacity
Results of an extensive telephone survey to companies classified
under SIC Code 3671 indicated that an estimated 22 plants are
involved in the manufacturing of cathode ray tubes.
Seven plants produce color television picture tubes with a total
production of approximately 12.5 million tubes per year and an
average plant production of 1.78 million tubes per year. It is
estimated that 12,000 production employees are engaged in color
television picture tube manufacturing. Only one of the seven
manufacturers is a direct discharger. In addition, several
rebuilders of color television picture tubes exist, but because
there is no phosphor removal or reapplication, the rebuilding
process is of little concern under this study.
Fifteen plants manufacture single phosphor tubes with -an
estimated 3,000 employees engaged in production. No single
phosphor tube manufacturers are known to be direct dischargers.
4.1.2 Product Description
Cathode ray tubes are devices in which electrons are conducted
between electrodes through a vacuum within a gas tight glass
4-1
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envelope. Cathode ray tubes depend upon three basic phenomena
for their operation. The first is the emission of electrons by
certain elements and compounds when the energy of the surface
atoms is raised. The second phenomenon is the control of the
movement of these electrons by the force exerted upon them by
electrostatic and electrodynamic forces. The third is the
luminescent properties of the phosphors when excited by
electrons. The two types of cathode ray tubes which are to be
discussed in this section are described below:
o Color television picture tubes function by the
horizontal scanning of high velocity electrons striking
a luminescent surface. The number of electrons in the
stream at any instant of time is varied by electrical
impulses corresponding to the transmitteed signal. A
typical color television picture tube is shown in
Figure 4-1.
The tube is a large glass envelope. A special
composition of glass is used to minimize optical
defects and to provide electrical insulation for high
voltages. The structural design of the glass bulb is
made to withstand 3 to 6 times the force of atmospheric
pressure. The light-emitting screen is made up of
small elemental areas, each capable of emitting light
in one of the three primary colors (red, green, blue).
An electron gun for each color produces a stream of
high..velocity electrons which is aimed and focused by
static and dynamic convergence mechanisms and an
electro-magnetic deflection yoke. An aperture mask
behind the face of the screen allows phosphor
excitation according to incident beam direction.
Commercially available color television tubes are
manufactured in a number of sizes. These tubes are
used in color television sets, arcade games, and
computer display terminals.
o Single phosphor tubes are similar to color television
picture tubes in most respects. They generate images
by focusing electrons onto a luminescent screen in a
pattern controlled by the electrostatic and
electrodynamic forces applied to the tube. The major
difference is that the light emitting screen is
composed of a single phosphor, and a single beam
electron gun is used for phosphor excitation. In
addition, the tube does not contain an aperture mask
for electron beam control.
Single phosphor tubes are manufactured in a variety of
• " sizes but are generally smaller in size than color
television picture tubes. They usually range from 2 to
12 inches in diameter. Single phosphor tubes are
manufactured for usage in display systems such as word
4-2
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phosphor dots
on screen
blue beam \
..three electron beams
special glass bulb
static and dynamic
convergence of
three electron
beams (magnetic)
base
connections
three
electron
guns
. electromagnetic
deflection yoke
high-voltage contact '
fluorescent light-emitting
three-color screen
(with aluminum
mirror backing)
FIGURE 4- 1
'COLOR TELEVISION PICTURE TUBE
4-3
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processors, computer systems, arcade video games,
specialized military units, medical and other
electronic testing and monitoring equipment such as
oscilloscopes.
4.1.3 Manufacturing Processes and Materials
The manufacturing processes and materials used for cathode ray
tube production are described in the following paragraphs. Each
type of cathode ray tube with its associated manufacturing
operations is discussed separately because production processes
differ.
Color Television Picture Tubes — The manufacture of a color
television picture tube is a highly complex, often automated
process as depicted in Figure 4-2. The tubes are composed of
four major components: the glass panel, steel aperture mask,
glass funnel, and the electron gun mount assembly. The glass
panel is the front of the picture tube through which the picture
is viewed. The steel aperture (shadow) mask is used to
selectively shadow the phosphor from the electron beam as the
beam horizontally scans the phosphor-coated glass panel. The
glass funnel is the casing which extends back from the glass
panel and is the largest component of the picture tube. The
mount assembly is attached to the funnel and contains the
electron gun and the electrical base connections.
Manufacture of a color television picture tube begins with an
aperture mask degrease. The aperture masks, often produced at
other facilities, are received by the color picture tube
manufacturer, formed to size, solvent degreased, and oxidized.
Common degreasing solvents used are methylene chloride,
trichloroethylene, methanol, acetone, and isopropanol. The
aperture masks are inserted within the glass panel which is
commonly then referred to as a panel-mask "mate". The panel-mask
mate is annealed and the mask is removed.
The glass panels proceed to panel wash. Panel wash includes
several hydrofluoric-sulfuric acid glass washes and subsequent
water rinses. The panels are then sent to photoresist
application. The photoresist commonly contains dichromate, an
alcohol, and other materials considered proprietary. The glass
panels are coated with a photoresist and the masks are mated to
the panel. The panel is then exposed to light through the mask.
The mask is removed and the panel is developed, graphite-coated,
re-developed and cleaned with a hydrofluoric-sulfuric acid
solution. The panel at this point has a multitude of clear dots
onto which the phosphors will be deposited. Presently, several
manufacturers are using vertical lines as an alternative to dots.
The panels then proceed to phosphor application.
Many proprietary processes have been observed in applying the
phosphors. Generally, the panels first undergo another
4-4
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Aperture Masks
PANEL WASH
Glass Panels
4 !:
Panel and
Mask Mate
X
Mask
Degrease
\
"^
/
Mask
Rejected
Panels
PHOTO-RESISTANT
APPLICATION
PICTURE TUBE RECLAIM
Spent
Picture Tubes
; Panel-Funnel
i Def rit
Light
Exposure
panels N!' \/
APPLICATION ~^
-*
Phosphor
Application
\l/
Panel and
Mask Mate
\l^
Light
Exposure
w
Lacquer
Coat
\k
Aluminize
Mask^ V \1/
\
\l/
Panel and
Mask Mate
• *
Panel
Clean
*
Shield
Attachment
\
Panel-Mask \ Funnel _
Separation ^ Clean
Np ^
^ Panel ^ y^l Mask ^
•? Clean ^ ^' Clean ~
/ \/ \' \'
Return to
Picture Tube Manufacture
, Glass Funnels
K i . -
Electron Shields — ^ J^sh " ^
--> \]/
Degrease
s \k
^
j Electron Gun
V j
Graphite • \[.-
\L Assemble
\|/ .^f3 Frit V
Panel-Funnel
Fusion
n^^iiv-ai-j.^- Mount
^ — J •;? Clean '
\y
Attach Mount
Assembly
_,
c
Mount
Age
Figure 4-2
TELEVISION PICTURE TUBE MANUFACTURE
-- . = Denotes water Flow Path
4-5
-------
Glass Bulb
Wash
Spent CRT
Electron Gun
Removal
\
Phosphor
Application
Electron Gun
Parts Recycle
V
Glass Bulb
Wash
Lacquer
Coat
V
Glass Bulb
Disposal
Electron Gun
Aluminize
V
Attach Mount
Assembly
V
Exhaust
s Seal
V
Age S
Test
V
= Denotes Water
Flow Path
External
Coat
V
Test S
Ship
Figure 4-3
CRT MANUFACTURE
4-6
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Exhaust tip
Get
Screen grid
Suppressor grid
Glass-met-al seal
Mica spacer
Control grid
Cathode
Anode'
Base pin
FIGURE 4-4
RECEIVING TUBE
4-7
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photoresist application. Each of the three color phosphors is
then applied similarly. The phosphor is applied to the panel as
a slurry or as a powder, the mask is attached, the phosphor is
exposed to light through the mask, the mask is removed and the
unexposed phosphor is washed away. After application of the
three phosphors, toluene-based lacquer and silicate coatings may
be applied to seal the phosphors, aluminum is vacuum-deposited to
enhance reflection, the mask is mated with the panel, and the
panel is cleaned.
Glass funnels are cleaned and coated with graphite to prevent
reflection within the tube. Electron shields are degreased and
attached to the panel. Panel-mask assemblies and glass funnels
are then joined together using a heat-fused lead frit, followed
by annealing. The electron gun mount is cleaned, aged, and heat
sealed to the base of the funnel. At this stage the assembled
panel, funnel, and mount are termed a "bulb." The bulb is
exhausted, sealed, and aged by applying current to the cathode.
The tube is tested, an external graphite coating is applied, and
an implosion band is secured to the tube. The tube is retested
before shipment to facilities that assemble television sets.
Panels may be rejected upon inspection at many points along the
manufacturing process. If rejected, panels may be sent back to
the panel wash at the beginning of the manufacturing sequence.
In addition, there is a picture tube salvage operation to reclaim
spent or rejected picture tubes. Salvage operation processes
include a panel-funnel acid defrit, acid cleaning of panels and
funnels, and cleaning of aperture masks. These reclaimed
components are returned to the process for reuse. Electron guns
are usually discarded.
Wastewater producing operations for manufacture of television
picture tubes are unique and sizeable. Process wastewater
sources include both bath dumps and' subsequent rinsing associated
with: glass panel wash, aperture mask degrease, photoresist
application, phosphor application, glass funnel and mount
cleaning, and tube salvage.
Single Phosphor Tubes — Single phosphor tubes have several
manufacturing processes that differ from color television picture
tube manufacturing (Figure 4-3). The tube is usually composed of
a single glass bulb; only a small , percentage of the tubes
manufactured have a separate panel and funnel connected by a heat
fused lead frit.
The one piece tube manufacturing requires no mask and no
photoresist application. The single phosphor is contained within
an aqueous settling solution that is poured into the glass bulb
and allowed to settle onto the face of the bulb. After a
sufficient time the remaining settling solution is decanted off
and a toluene-based lacquer is applied to seal the phosphor.
4-8
-------
In some cases where the bulb face needs a special application,
such as reference lines for an oscilloscope, a separate panel and
funnel are used. A photoresist and mask are used for applying
the reference lines on the panel and then the single phosphor is
applied in the same method as a one piece bulb using a settling
solution that contains potassium silicate and usually an
electrolyte.
In addition, there may or may not be a cathode ray tube salvage
operation. The tube salvage is usually comprised of the removal
of the electron gun by cutting the tube at the gun mount and
recycling parts of the gun. The remaining glass tube is then
discarded. At some facilities the tube is washed to remove the
phosphor before disposal.
The decant from the settling solution and the wash from phosphor
removal are usually the main sources of wastewater in single
phosphor tube manufacturing.
4.2 RECEIVING AND TRANSMITTING TUBES
The Receiving and Transmitting Tube subcategory includes
electronic devices in which conduction of electrons takes place
through a vacuum or a gaseous medium within a sealed glass,
quartz, metal or ceramic casing. Products are classified under
the Standard Industrial Classifications (SIC) 3671, 3673.
4.2.1 Number of Plants and Production Capacity
Results of an extensive telephone survey to companies classified
under the above SIC Codes indicated that an estimated 23 major
plants are involved in the manufacturing of receiving and
transmitting tubes with an estimated 10,000 employees engaged in
production. Several small receiving and transmitting tube
manufacturers probably exist.
4.2.2 Product Description
Receiving and transmitting tubes conduct electrons or ions
between electrodes through a vacuum or ionized gas such as neon,
argon or krypton, which is within a gas-tight casing of glass,
quartz, ceramic, or metal. Their operation is based on the
emission of electrons by certain elements and compounds when the
energy of the surface atoms is raised by the addition of heat,
light protons, kinetic energy of bombarding particles, or
potential energy. The operation also depends on the control of
the movement of these electrons by the force exerted upon them by
electric and magnetic fields.
o Receiving tubes are tnultiterminal devices that conduct
electricity more easily in one direction than in the
other and are noted for their low voltage and low power
applications (Figure 4-4). They are used to control or
4-9
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amplify electrical signals in radio and television
, receivers, computers, and sensitive control and
measuring equipment.
Structurally, electron tubes are classified according
to the number of electrodes they contain. The
electrodes are usually made of-nickel mounted on a base
penetrated by electrical connections and are
encapsulated in a glass or metal envelope which is
normally evacuated.
Voltage is impressed on the tube normally between the
plate (anode) and the cathode. Because large plate
currents are not required for electron emission,
oxide-coated cathodes are used extensively. A separate
filament heats the cathode which usually consists of a
nickel sleeve coated with oxides such as strontium
oxide or barium oxide. There is no electrical
connection between the cathode and filament causing the
cathode to be heated indirectly.
o Transmitting type electron tubes are characterized by
the use of electrostatic and electromagnetic fields
applied externally to a stream of electrons to amplify
a radio frequency signal. There are several different
types of transmitting tubes such as klystrons,
magnetrons and traveling wave tubes. They generally
are high powered devices operating over a wide
frequency range. They are larger and structurally more
rugged than receiving tubes, and are completely
evacuated. Figure 4-5 is a diagram of a klystron tube,
which is typical of a transmitting type tube. In a
klystron tube, a stream of electrons from a concave
thermionic cathode is focused into a small cylindrical
beam by the converging electrostatic fields between the
anode, cathode, and focusing electrode. The beam
passes through a hole in the anode and enters a
magnetic field parallel to the beam axis. The magnetic
field holds the beam together, overcoming the
electro-static repulsion between electrons. The
electron beam goes through the cavities of the
klystron, emerges from the magnetic field, spreads out
and is stopped in a hollow collector where the
remaining kinetic energy of the electrons is dissipated
as heat.
4.2.3 Manufacturing Processes and Materials
The manufacture of a receiving tube is similar to that of a
transmitting tube and is depicted schematically in Figure 4-6.
Raw materials required for receiving tube manufacture include
glass envelopes, kovar and other specialty metals, tungsten wire,
and copper wire. The metal parts are punched and formed,
4-10
-------
chemically cleaned, and electroplated with copper, nickel,
chromium, gold, or silver. The iron or nickel cathode is coated
with a getter solution which will be used to absorb gases. The
metal.parts are hand assembled into a tube mount assembly. Glass
parts for the tube base are cut and heat treated. Copper
connector pins are sealed in the "glass mount" machine. The
glass mount piece is then heat treated by baking in an oven. The
metal tube mount assembly is then hand welded to the glass mount
piece. The upper glass bulb is rinsed. On a "sealex" machine,
the bulb is evacuated to 10ZQ-3 mm of mercury, sealed, and the
glass extensions are cut off. A getter material (usually
magnesium, calcium, sodium, or phosphorus) previously introduced
in the evacuated envelope is flashed. Flashing occurs by
applying an electric current to the electrodes of the tube for
several seconds or by indirect Infrared radiation. The getter
material condenses on the inside surface and absorbs (reacts
with) any gas molecules. The result is that the vacuum within
the tube becomes progressively stronger until an equilibrium
value of 10ZQ-6 mm is reached. The glass exterior is rinsed and
the completed tube is aged, tested, and packaged.
The manufacture of a typical transmitting tube is presented
schematically in Figure 4-7. Intricately shaped and machined
copper, steel, and ceramic parts are cleaned and rinsed. Some of
these parts are then electroplated using materials such as
copper, gold, and silver. Assembly of the electron tube is
generally a manual operation. The electron tube components
consist of the above-described parts, a tungsten filament, a
glass window, and a glass tube. The components undergo a number
of soldering, brazing', welding, heat treating, and polishing
operations. A significant energy user is the heat treating area
with associated non-contact cooling water. The assembled
electron tube " undergoes an extensive series of electrical and
mechanical testing procedures and an aging process before final
shipment. There are specialized types of transmitting type
electron tubes, such as image intensifiers, that are produced in
a manner similar to that described above. However, there are two
wet processes utilized in addition to those depicted in Figure 4-
7. These additional wet processes include alkaline
cleaning/rinsing and alcohol dipping/rinsing of ceramic or glass
envelopes brazed to metal; and acid cleaning of glass tube
bodies. Because these processes are known to exist at only one
facility, they are not included in Figure 4-7 as processes common
to most transmitting type electron tube manufacture.
Process water is used in solutions and rinses associated with
electroplating of anodes, cathodes, and grids. Water is also
used to wash glass and ceramic tube bodies both before and after
seating to the base, or at the conclusion of the manufacturing
process.
Receiving and transmitting electron tube manufacturing processes
produce wastewater discharges primarily through metal finishing
4-11
-------
operations which are covered under the Metal Finishing Category.
A number of ancillary operations such as deionized water
backwash, cooling tower blowdown, and boiler blowdown contribute
sizeable wastewater discharges compared to metal finishing
operations.
In addition, there are some isolated instances of plants
manufacturing specialized transmitting type electron tubes such
as image intensifiers and photomultipliers that require process
water. Alkaline cleaning and acid etching of glass-metal and
ceramic tube components discharge process wastewater as a result
of alkaline and acid bath dumps and their associated water
rinses. These wet processes are similar to several found in
color television picture tube manufacture. There is also a glass
tube rinse (or- rinses) which concludes the manufacture of
receiving tubes. Such rinses are intended to remove surface
particulates and dust deposited on the tube body during the
manufacturing process.
4.3 LUMINESCENT MATERIALS
Luminescent materials (phosphors) are those that emit
electromagnetic radiation (light) upon excitation by such energy
sources as photons, electrons, applied voltage, chemical
reactions, or mechanical energy. These luminescent materials are
used for a variety of applications, including fluorescent lamps,
high-pressure mercury vapor lamps, color television picture tubes
and single phosphor tubes, lasers, instrument panels, postage
stamps, laundry whiteners, and specialty paints.
This study is restricted to those materials which are applicable
to the E&EC category, specifically to those used as coatings in
fluorescent lamps and color television picture tubes and single
phosphor tubes.
4.3.1 Number of Plants
A telephone survey of the industry determined that only five
facilities manufacture luminescent materials, and according to
industry personnel, two of these facilities are the major
producers.
Of the five luminescent materials manufacturers, one manufactures
TV phosphors only; three manufacture both lamp and TV phosphors;
and one manufacture only lamp phosphors. At three facilities
wastewater flow from the phosphor operations amount to less than
twenty percent of the total plant flow. Of the five facilities,
one has no discharge, two discharge to a POTW and the remaining
two discharge to surface water.
4.3.2 Product Description
4-12
-------
collector
fully bunched
electrons
input
coaxial
transmission
line
high
voltage
supply
spreading
electron beam
magnetic.polepiece .
output catcher .
cavity : •
output
.waveguide
output
coupling iris
antibunch
electron bunch
forming
intermediate,,
cascade
-------
Metal Components
Metal
Form
Glass Tubes
Glass
Cut
Lead
Wires
V
Cathode
I
Parts
Clean
Anneal
Getter
Coat
Glass
Mount
Machine
V
Electroplate
Tube Mount
Assembly
Weld
Components
Glass Tube
Rinse
Exhaust &
Seal
Glass Tube
Rinse
Age &
Test
Ship
Denotes Water
Flow Path
FIGURE 4-6
RECEIVING TUBE MANUFACTURE
4-14
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Metal Components
Glass
Tube
V
Glass
Window
Filament
" Metal
Form
Parts
Clean
V
Electroplate
\/
•Solder'
•v
Braze
V
Weld
V
Anneal
Evacuate
s Seal
Polish
Age & Test
Ship
Denotes Water
Flow Path
Figure 4-7
TRANSMITTING TUBE MANUFACTURE
4-15
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The most important fluorescent lamp phosphor is calcium
halophosphate. There are at least 50 types of" phosphors used for
cathode ray tubes (television and other video displays).
However, all are similar to or mixes of the three major color
television powders: red, blue, and green. The red phosphor is
yttrium oxide activated with europium; the blue phosphor is zinc
sulfide activated with silver, and the green phosphor is zinc-
cadmium sulfide activated with copper. The major process steps
in producing luminescent materials are reacting, milling, and
firing the raw material; recrystallizing raw materials, if
necessary; and washing, filter-ing, and drying the intermediate
and final products. The products are then sold and shipped as
powders.
4.3.3 Manufacturing Processes and Materials
Lamp phosphors and TV phosphors with their associated
manufacturing operations are discussed separately because
production processes and raw materials differ. The processes and
materials described were taken from a typical plant; however,
some variations occur between manufacturers. Proprietary
compounds used in process operations are not identified.
Lamp Phosphors — Preparation of calcium halophosphate,
Ca5(F,Cl)(P04)3 involves the production of two intermediate
powders and the firing of the combined intermediate powders
(Figure 4-8).
Calcium phosphate intermediate powder is produced by reacting
calcium salts with anions. These raw materials are first
purified and filter pressed separately. The two streams are then
combined to precipitate the soluble calcium. This resultant
material, CaCQS ZQ. CaHP04, is subsequently filtered and
recrystallized in heated deionized water for particle size
assurance. The material is then filtered and dried. Liquid
waste originates from washing, filtration (precipitation), wet
scrubber blowdown, and filtration of the recrystallized process
stream.
Calcium fluoride (CaF2) intermediate powder is produced by
reacting calcium hydroxide with nitric acid to make calcium
nitrate solution. This is mixed with ammonium bifluoride
crystals dissolved in water, to precipitate calcium fluoride.
Calcium fluoride is washed by decantation, filtered and dried.
Liquid wastes originate from washing, filtering and scrubber
blowdown.
The intermediate powders are milled together, blended, fired,
washed, filtered and dried to produce calcium halo phosphate
phosphor.
TV Phosphors — There are three primary TV phosphors currently
being manufactured: red, blue and green. The manufacturing of
4-16
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both blue and green phosphors requires a two-stage process that
involves the production of an intermediate material and then its
activation and firing. The manufacturing of red phosphor is a
solid state reaction.
Figure 4-9 is a process flow diagram for the production of blue
phosphor, which is primarily a zinc sulfide phosphor activated
with silver (ZnS:Ag). The intermediate material is produced by
dissolving zinc oxide in sulfuric acid. The zinc sulfate
solution is reacted with hydrogen sulfide gas to precipitate zinc
sulfide out of solution. The product is washed, vacuum filtered
and dried. The intermediate powder is blended with the activator
(usually silver), fired, washed, filtered and dried. . Liquid
wastes originate from precipitation, washing, filtration, and
scrubber blowdown.
The green phosphor is produced from zinc-cadmium sulfide that is
activated with copper (Zn(Cd)S:Cu). The intermediate material is
produced by dissolving cadmium oxide in sulfuric acid and
deionized water to produce a cadmium sulfate solution. Sulfide
gas and zinc sulfide that 'was produced in the same method as
described in the blue phosphor, are introduced to the solution.
The precipitate is washed several times and then dried to produce
the cadmium-zinc sullfide intermediate powder. The intermediate
powder is mixed with the activator copper, and fired. The
material is washed, vacuum filtered, and dried to produce, the
final product zinc-cadmium phosphor. Liquid wastes originate
from precipitation, washing, filtration, and scrubber blowdown.
The red phosphor is a rare earth phosphor manufactured from
yttrium oxide that is activated with europium (Y.20?:'Eu(III)).
The production is a solid state reaction in which yttrium oxide,
europium oxide arid certain salts are blended, fired, washed, and
dried to produce the final red phosphor. Liquid waste originates
from washing and scrubber blowdown.
4-17
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Recrystallization
Wet
Scrubber
Calcium Carbonate and
Calcium Phosphate
T
\K
V
Milling & Blending
Firing
V
Washing
Wet Scrubber
V
Filtration
V
Drying
V
Screening & Blending
V
Product
Denotes Water
Flow Path
FIGURE 4-8
LAMP PHOSPHOR PROCESS
4-1)3
-------
Zinc Oxide
•V
Hydrogen ••
,Sulfide gas '
Sulfuric Acid
Zinc Sulfate solution
Zinc Sulfide
Precipitation
Washed
, Vacuum, Filtered
V
Drying
Activator
V
Zinc' Sulfide
Intermediate Powder
V
Fired
^
Washed'
->
\/
Filtration
Drying
V
Product
\
/
, Wet
Scrubber
\^
V
Wet
Scrubber
'
Denotes Water
Flow Path
FIGURE 4-9
BLUE PHOSPHOR PROCESS
4-19
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SECTION 5
WASTEWATER CHARACTERISTICS
This section presents information related to wastewater flows,
wastewater sources, pollutants found, and the sources of these
pollutants for Cathode Ray Tube, Receiving and Transmitting Tube,
and Luminescent Materials subcategories. A general discussion of
sampling techniques and wastewater analysis is also provided.
5.1 SAMPLING AND ANALYTICAL PROGRAM
More than 150 plants were contacted to obtain information on the
three subcategories. Eleven of these plants were visited for an
on-site study of their manufacturing processes, water used and
wastewater treatment. In addition, wastewater samples were
collected at six of the plants visited in order to quantify the
level of pollutants in .raw process wastewater and treatment
effluent.
5.1 .1 Pollutants Analyzed
The chemical pollutants sought in analytical procedures fall into
three groups: conventional, non-conventional, and toxics. The
latter group comprises the 129 chemicals found in the toxic
pollutant list shown in Table 5-1.
Conventional pollutants are those generally treatable by
secondary municipal wastewater treatment. The conventional
pollutants examined for this study are:
pH
Biochemical Oxygen Demand (BOD)
Oil and Grease (O&G)
Total Suspended Solids (TSS)
Non-conventional pollutants are simply those which are neither
conventional nor on the list of toxic pollutants. The non-
conventional pollutants listed below were examined during this
study.
Fluoride
Total Organic
Total Phenols
yttrium
Calcium
Magnesium
Aluminum
Sodium
Titanium
Palladium
Tellurium
Carbon
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Cobalt
Iron
Platinum
Gold
5-1
-------
TABLE 5-1
TOXIC POLLUTANTS
TOXIC POLLUTANT ORGANICS
1. Acenaphthene 47.
2. Acrolein 48.
3. Acrylonitrile 49.
4. Benzene 50.
5. Benzidine 51.
6. Carbon Tetrachloride 52.
(Tetrachloromethane) 53.
7. Chlorobenzene 54.
8. 1,2,4-Trichlorobenzene 55.
9. Hexachlorobenzene 56.
10. 1,2-Dichloroethane 57.
11. 1,1,1-Trichloroethane 58.
12. Hexachloroethane 59.
13. 1,1-Dichloroethane 60.
14. 1,1,2-Trichloroethane 61.
15. 1,1,2,2-Tetrachloroethane 62.
16. Chloroethane 63.
17. Bis(Chloromethyl)Ether 64.
18. Bis(2-Chloroethyl)Ether 65.
19. 2-Chloroethyl vinyl Ether (Mixed) 66.
20. 2-Chloronaphthalene 67.
21. 2,4,6-Trichlorophenol 68.
22. Parachlorometa Cresol 69.
23. Chloroform (Trichloromethane) 70.
24. 2-Chlorophenol 71.
25. 1,2-Dichlorobenzene 72.
26. 1,3-Dichlorobenzene 73.
27. 1,4-Dichlorobenzene 74.
28. 3,3'-Dichlorobenzidine
29. 1,1-Dichloroethylene 75.
30. 1,2-Trans-Dichloroethylene
31. 2,4-Dichlorophenol 76.
32. 1,2-Dichloropropane 77.
33. 1,2-Dichloropropylene 73.
(1,3-Dichloropropene) 79.
34. 2,4-Dimethylphenol 80.
35. 2,4-Dinitrotoluene 81.
36. 2,6-Dinitrotoluene 82.
37. 1,2-Diphenylhydrazine
38. Ethylbenzene 83.
39. Fluoranthene
40. 4-Chlorophenyl Phenyl Ether 84.
41. 4-Bromophenyl Phenyl Ether 85.
42. Bis(2-Chloroisopropyl) Ether 86.
43. Bis(2-Chloroethoxy)Methane 87.
44. Methylene Chloride 88.
45. Methyl Chloride (Chloromethane) 89.
46. Methyl Bromide (Bromomethane) 90.
Bromoform (Tribromomethane)
Dichlorobromoethane
Tr ichlorofluoromethane
Dichlorodifluoromethane
Chlorodibromomethane
Hexachlorobutadiene
Hexachlorocyclopentadiene
Isophorone
Naphthalene
Nitrobenzene
2-Nitrophenol
4-Nitrophenol
2,4-Dinitrophenol
4,6-Dinitro-O-Cresol
N-Nitrosodimethylamine
N-Nitrosodiphenylamine
N-Nitrosodi-N-Propylamine
Pentachlorophenol
Phenol
Bis(2-ethylhexyl)Phthalate
Butyl Benzyl Phthalate
Di-N-Butyl Phthalate
Di-N-Octyl Phthalate
Diethyl Phthalate
Dimethyl Phthalate
1,2-Benzanthr acene (Benzo(A)Anthr acene)
Benzo (A) Pyrene (3,4-Benzo-Pyrene)
3,4-Benzofluoranthene (Benzo(B)
(Fluoranthene)
11,12-Benzofluoranthene (Benzo(K)
Fluoranthene)
Chrysene
Acenaphthylene
Anthracene
1,12-Benzoperylene(Benzo(GHI)-Perylene)
Fluorene
Phenanthrene
1,2,5,6-Dibenzathracene(Dibenzo(A,H)
Anthracene)
Ideno(1,2,3-CD)Pyrene(2,3-0-Phenylene
Pyrene)
Pyrene
Te t r achlor oe thylene
Toluene
Tr ichloroethylene
Vinyl Chloride (Chloroethylene)
Aldrin
Dieldrin
5-2
-------
TABLE 5-1- continued
91. Chlordane (Technical Mixture and
Metabolites)
92. 4,4'-DDT
93. 4,4'-DDE (P,P'-DDX)
94. 4,4'-DDD (P,P-TDE)
95. Alpha-Endolsufan
96. Beta-Endosulfan
97. Endosulfan Sulfate ,
98. Endrin
99. Endrin Aldehyde
100. Heptachlor
101. Heptachlor Epoxide (BHC-Hexachlorocyclohexane)
102. Alpha-BHC
103. Beta-BHC
104. Gamma-BBC
105. Delta-BHC
106. PCB-1242 (Arochlor 1242)
107. PCB-1254 (Arochlor 1254)
108. PCB-1221 (Arochlor 1221)
109. PCB-1232 (Arochlor 1232)
110. PCB-1248 (Arochlor 1248)
111. PCB-1260 (Arochlor 1260)
112. PCB-1016 (Arochlor 1016)
113. Toxaphene
114. Antimony
115. Arsenic
116. Asbestos
117. Beryllium
118. Cadmium
119. Chromium
120. Copper
121. Cyanide
122. Lead
123. Mercury
124. Nickel
125. Selenium
126. Silver
127. Thallium
128. Zinc
129. 2,3,4,8-Tetrachlorodibenzo-P-Dioxin (TCDD)
5-3
-------
5.1.2 Sampling Methodology
During the initial visit to a facility, a selection was made of
sampling points so as to best characterize process wastes and
evaluate the efficiency of any wastewater treatment. The nature
of the wastewater flow at each selected sampling point then
determined the method of sampling, i.e., automatic composite or
grab composite. The sampling points were of individual raw waste
streams, or treated effluent.
Each sample was collected whenever possible by an automatic time
series compositor over a single 24-hour sampling period. When
automatic compositing was not possible, grab samples were taken
at intervals over the same period, and were composited manually.
When a sample was taken for analysis of toxic organics, a blank
was also taken to determine the level of contamination inherent
to the sampling and transportation procedures.
Each sample was divided into several portions and preserved, when
necessary, in accordance with established procedures for the
measurement of toxic and classical pollutants. Samples were
shipped in ice-cooled containers by the best available route to
EPA-contracted laboratories for analysis. Chain of custody for
the samples was maintained through the EPA Sample Control Center
tracking forms.
5.1.3 Analytical Methods
The analytical techniques for the identification and quantitation
of toxic pollutants were those described in Sampling and Analysis
procedures for Screening of Industrial Effluents for Priority
Pollutants, revised in April 197T Y
In the laboratory, samples for organic pollutant analysis were
separated by specific extraction procedures into acid (A)
base/neutral (B/N), and pesticide (p) fractions. Volatile
organic samples (V) were taken separately as a series of grab
samples at four-hour intervals and composited in the laboratory
Tne analysis of these fractions incorporated the application of
strict quality control techniques "including the use of standards,
blanks, and spikes. Gas chromatography and gas
chromatography/mass spectrometry were the analytical procedures
used for the organic pollutants. Two other- analytical methods
were used for the measurement of toxic metals: flameless atomic
Jn!?^10?^*^10^1^1^ couPled ar9on Plasma spectrometric
analysis (ICAP). The metals determined by each.method were-
Flameless AA
Antimony
Arsenic
Selenium
Silver
ICAP
Beryllium
Cadmium
Chromium
Copper
5-4
-------
Thallium
Lead
Nickel
Zinc
Mercury was analyzed by a special manual cold-vapor atomic
absorption technique.
For the analysis of conventional and non-conventional pollutants,
procedures described by EPA were followed. The following
conventions were used in quantifying the levels determined by
analysis:
o Pollutants detected at levels below the quantitation
limit are reported as "less than" (XZ) the quantitation
limit. All other pollutants are reported as the
measured value.
o The tables show data for total toxic organics, toxic
and non-toxic metals, and other pollutants. Total
toxic organics is the sum of all toxic organics found
at concentrations of 0.01 mg/1 or greater.
Blank Entries - Entries were
parameter was not detected.
left blank when the
5.2 CATHODE RAY TUBES
5.2.1 Wastewater Flow
Presented below is a summary of the quantities of wastewater
generated by the manufacturers of color television picture tubes
and other single phosphor tubes.
Number of Plants
Wastewater Discharge (gpd)
Min. Mean - Max.
22
XZ50
135,500
500,000
5.2.2 Wastewater Sources
Process wastewater sources from the manufacture of cathode ray
tubes are sizeable and include wash and rinse operations
associated with: glass panel wash, mask degrease, photoresist
application, phosphor application, glass funnel and mount
cleaning, and tube salvage.
5.2.3 Pollutants Found and the Sources of. These Pollutants
The major pollutants of concern from the Cathode Ray Tube
subcategory are:
pH
Chromium
5-5
-------
TABLE 5-2
CATHODE RAY TUBE
SUMMARY OP RAW WASTE DATA
PARAMETER
Fluoride
CONCENTRATION, mg/1
MINIMUM MAXIMUM MEAN
TOXIC METALS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
Total Toxic Organics*
Oil and Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.036
0.149
<0.001
0.041
0.800
0.012
4.04
0.001
0.020
0.001
0.001
0.001
2.610
0.030
2.158
0.107
21.01
0.196
0.284
0.005
0.626
2.149
0.087
13.00
0.003
0.082
0.007
0.002
0.001
19.72
0.150
16.0
17
380
0.097
0.207
0.003
0.374
1.314
0.038
9.41
0.002
0.065
0.004
0.001
0.001
11.79
0.085
7.72
7.38
185
31.7
970.8
360.6
*3 day sample of one plant
5-6
-------
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5-8
-------
5-9
-------
TABLE 5-3
PICTURE TUBE PROCESS WASTES
Plant 30172
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
11 1,1,1-Trichloroethane
39 Fluoranthene
44 Methylene chloride
55 Napthalene
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
78 Anthracene
81 Phenanthrene
84 Pyrene
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Chromium
Reduction
Influent
1*
440/2790
24
mg/1
<0.010
0.058
<0.010
0.490
<0.010
0.460
0.010
<0.010
<0.010
<0.010
0.029
0.010
1.057
<0.005
0.003
0.006
0.001
<0.002
89.07
0.019
0.125
<0.001
0.006
0.004
0.001
0.017
<0.013
Lead
Treatment
Influent
2
45/285
24
mg/1
Not
Analyzed
<0.005
0.092
0.250
0.004
.070
.670
1.
4.
<0.05
891.
0.001
18.5
<0.020
0.060
0.002
1510.
Ch-romi um
Reduction
Effluent
3*
440/2794
24
mg/1
Not
Analyzed
<0.005
0.044
0.017
<0.001
<0.002
73.33
0.016
0.062
<0.001
<0.005
0.011
<0.001
<0.001
0.02
*Average of three samples.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
PH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
706
2.82
0.70
8.14
0.037
0.006
0.014
0.122
0.03
0.132
0.101
0.042
0.058
0.105
0.005
0.013
7
1.17
5.13
33
8
1.27
87.8
30.9
640
12
5.860
0.161
346
205
1.60
3.010
16.8
2.650
1940
0.319
0.01
<1.0
160
<2.0
11
190
3.83
0.93
60.1
0.039
0.019
0.008
0.162
0.026
0.13
0.83
0.147
0.058
2.13
<0.002
0.013
773.3
0.433
3.1
121
23.7
1.2
5-10
-------
TABLE 5-3
PICTURE TUBE PROCESS WASTES
Plant 30172 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
Lead
Treatment
Effluent
4**
127/268
8
mg/1
Primary
Treatment
Influent
5*
12905/81820
24
mg/1
TOXIC ORGANICS
121 Cyanide
Not
Analyzed
<0.005
Not
Analyzed
0.005
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium "
Zinc
•Average of three samples.
**Average of two samples.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
PH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.069
0.009
<0.001
<0.005
0.022
0.042
0.19
<0.001
0.911
0.006
0.002
<0.01
18.7
29.6
17.3
11950
0.628
0.59
0.017
322.5
10.27
0.214
0.249
<0.01
0.308
0.229
0.032
0.045
5
89
78.5
6.85
11
<1
11
0.153
0.121
<0.001
0.171 .
2.-8 7
0.066
14.17
-------
TABLE 5-3
PICTURE TUBE PROCESS WASTES
Plant 30172 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
121 Cyanide
Primary
Treatment
Effluent
6*
12500/79252
24
mg/1
Not
Analyzed
<0.005
Filter
Effluent
7*
12905/81820
24
mg/1
Not
Analyzed
<0.01
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
0.117
0.009
<0.001
<0.002
0.244
0.015
0.253
<0.001
0.013
<0.005
<0.001
<0.001
0.131
0.120
0.009
<0.001
<0.002
0.208
0.014
0.163
<0.001
0.015
<0.004
<0.001
<0.001
0.075
*Average of three samples.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
PH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
322.5
7.05
132.5
0.397
0.007
0.002
1.97
0.166
0.039
<0.025
0.006
<0.05
0.230
<0.002
0.020
35.5
7.1
7.9
297.33
3.0
3.0
306.3
7.81
145
0.301
0.007
<0.001
2.293
0.144
<0.035
0.07
<0.003
<0.05
0.115
<0.002
0.023
39.67
11.07
7.73
20.67
5.33
3.13
5-12
-------
TABLE 5-4
"PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System I
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
Tube Salvage
Waste Influent
1 .:..-..-
10674/67700
24
mg/1
HF - HNO3
Tube Salvage
Waste Influent
2 :- .
426/2700
Batch
mg/1
Mask Panel
Waste Influent
3
11128/70600
24
mg/1
TOXIC ORGANICS
4 Benzene
23 Chloroform
44 Methylene Chloride
55 Nepthalene
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Trichloroethylene
95 Alpha-Endosulfan
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
Not
Analyzed
.Not
Analyzed
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese'
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium ' .
Cobalt
Iron
Titanium •
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.018
0.058
0.244
<0.005
0.127
0.041
. 0.016
33.500
<0.001
0.042
<0.010
0.003
<0.001
9.080
30.70 .
12.10
495.
9.920
0.006
< 0.001
11.70
0.524
< 0.035
1 < 0.025
1.030
< 0.050
1.880
0.046
0.005
35
780
5.6
38
0
127
0.250
0.520
1.420
<0.005
13.400
3.200
0.950
749.
<0.001
3.240
< 0.050
0.100
0.002
1430.
116.
46.
3040.
62.
0.
0.
280.
54.
0.
0.
23.
0.
0.
' 0.
0
94
2700
3
863
074
0
173
329
7
491
264
567
20
0
68
<0.010
<0.010
<0.010
<0.010
0.020
<0.010
<0.010
<0.010
<0.010
<0.005
0.020
0.009
0.046
0.052
<0.005
0.094
0.735
0.198
0.516
<0.001
0.020
< 0.002
<0.001
<0.001
1.170
19.60
4.850
35.70
9.150
0.012
0.005
11.50
0.397
< 0.035
< 0.025
0.590
< 0.050
1.280
0.127
0.027
139
1923
2.7
1
0
185
5-13
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System I - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
23 Chloroform
44 Methylene Chloride
55 Nepthalene
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium .
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
HF - HN03
Tube Salvage
Post Settle
4
473/3000
Batch
mg/1
<0.010
<0.010
0.010
<0.010
0.130
0.010
<0.010
<0.010
<0.010
0.150
0.185
0.335
0.088
<0.005
1.150
0.024
0.066
2.010
0.001
0.858
<0.010
0.004
<0.010,
47.800
0.792
2.310
13100.
17.3
0.248
0.018
155.
1.90
0.092
0.071
0.043
0.602
0.923
0.139
0.026
187
6950
25
0
75
Pre-Filtration
5
11147/70700
24
mg/1
Not
Analyzed
0.011
0.055
0.078
<0.005
0.206
0.035
0.030
12.000
<0.001
0.076
<0.010
0.001
<0.001
18.800
8.260
8.300
1170.
7.070
0.023
<0.002
21.20
0.289
•=0.036
<0.026
0.358
<0.051
1.600
0.037
0
7
910
6.2
20
12
39
5-14
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System I - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
121 Cyanide
TOXIC INORGANICS
114
115
116
118
119
120
122
123
124
125
126
•127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium-
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Post Filtration
6
11147/70700
24
mg/1
Not
Analyzed
0.185
0.046
0.156
0.005
0.201
0.027
0.015
6.640
<0.001
0.074
0.010
<0.001
<0.001
18.100
. 4
6
1180
6
0
' <0
18
0
<0
<0
0
<0
1
0
0
4
1070
,420
,800
'790
.024
.001
.00
.163
.035
.025
.053
.050
.120
.032
Final Effluent
7
22275/141000
24
mg/1
Not
Analyzed
0.525
0.061
0.064
<0.005
0.370
0.305
0.030
13.800
<0.001
0.111
<0.002
0.002
<0.001
32.800
6.0
20
22
22
8.310
7.730
1200.
7.610
0.048
<0.001
19.40
0.503
<0.035
<0.025
0.049
<0.050
2.040
0.122
0.034
89
1140
6.1
51
0
80
5-15
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System II
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
29 1,1-Dichloroethylene
38 Ethylbenzene
44 Methylene chloride
66 Bis(2-ethylhexyl)phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
126 Thallium
128 Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Other Process
Waste Influent
8
17033/108000
24
mg/1
<0.010
<0.010
<0.010
0.020
0.010
<0.010
<0.010
0.030
0.060
Not Analyzed
0.440
0.266
<0.005
0.076
0.025
0.013
2.570
<0.001
0.014
<0.002
<0.001
<0.001
2.130
26.20
8.270
637.
9.830
0.007
0.002
17.700
1.900
• 0.074
<0.025
0.681
<0.050
1.220
0.453
0
8
1800
2.3
14
0
137
HF - Dump
9
142/900
Batch
mg/1
Not
Analyzed
0.011
27.000
9.000
<0.010
0.975
1.500
0.074
6.820
0.002
0.420
<0.300
0.001
<0.025
10.300
6
2.
5250.
311.
0.
0.
862.
5.
1.
0.
0.
<0.
22.
15.
0.
24
8400
17
0
3350
220
920
540
326
110
840
311
047
100
20
20
008
HF Etch
Settle Effluent
10
20439/86400
16
mg/1
Not
Analyzed
0.003
0.005
<0.005
<0.005
5.580
0.127
<0.050
<0.001
0.144
<0.010
0.001
<0.001
0.194
19.70
7.080
786.
0.121
0.296
<0.001
0.770
0.034
<0.035
<0.025
0.042
<0.050
80
<0.002
0
5
15
7.7
18
16
178
5-16
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System II - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr^-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
44 Methylene chloride
66 Bis(2-ethylhexyl)phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
Post Filtration
11
17033/10800
24
mg/1
Not
Analyzed
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.440
0.191
<0.005
0.018
0.015
0.016
0.883
<0.001
<0.013
0.004
0.002
<0.001
0.605
6.090
3.340
1810.
9.410
0.003
0.003
17.800
0.616
<0.035
<0.025
0.152
<0.051
0.636
0.313
0
10
4000
6.6
18
11
16
System II
Final
Effluent
12
30659/194000
24
mg/1
Not
Analyzed
0.520
0.079
0.062
<0.005
0.006
3.750
0.100
0.315
<0.001
0.097
<0.010
<0.001
<0.001
0.318
15.10.
5.700
1050.
5.060
0.196
0.002
11.00
0.229
0.037
<0.025
0.081
<0.050
56.70
0.112
0
8
700
7.5
10
0
135
HF - Dump
. Effluent
- -. 13
170/1080
Batch
mg/1
<0.010
<0.010
<0.010
<0.010
<0.010
<0.010
3.200
1.570
<0.005
6.031
0.020
0.020
3.190
<0.001
<0.013
<0.025
0.004
<0.010
1.080
3.310
1.190
10800.
62.600
<0.001
0.045
, 193.
1.630
0.087
0.089
0.025 .
0.548
1.050
0.412
0.008
472
4500
17
0
38
'5-17
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System III
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
CONVENTIONAL POLLUTANTS
pH
Total Suspended Solids
<0.001
0.008
<0.005
0.120
3.710
<0.013
<0.050
<0.001
<0.013
<0.010
0.004
<0.001
2.860
0.271
0.496
149.
0.188
<0.001
0.172
0.721
0.012
133
591
0
0
1300.
4.730
<0.001
0.038
5.0
1840
Blue Phosphor
Waste Influent
15
1703/10800
24
mg/1
Not
Analyzed
0.001
0.002
<0.005
0.756
4.480
<0.013
<0.050
<0.001
<0.013
<0.010
0.360
<0.001
1910
5.120
0.794
1280.
1.010
<0.001
<0.001
<0.002
0.151
<0.035
0.111
8.160
<0.050
0.024
<0.002
4.0
2560
Green Phosphor
Influent
16
1703/10800
24
mg/1
Not
Analyzed
<0.001
0.006
<0.005
184.
4.970
0.024
<0.050
<0.001
<0.013
<0.010
0.005
<0.001
1540.
0.481
<0.049
787.
0.426
<0.001
<0.003
2.390
0.825
<0.069
0.123
0.411
0.293
0.093
<0.004
4.9
2450
5-18
-------
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System III - continued
Red Phosphor
Effluent
17
1703/10800
24
ing/I
Blue Phosphor
Effluent
18
1703/10800
24
mg/1
Green Phosphor
Effluent
19
1703/10800
24
mg/1
TOXIC ORGANICS
Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
CONVENTIONAL POLLUTANTS
pH
Total Suspended Solids
Not
Analyzed
<0.001
<0.002
<0.005
0.065
2.620
<0.013
<0.050
<0.001
<0.013
0.020
<0.001
<0.001
0.718
0.157
<0.025
9.930
2.400
<0.001
<0.001
0.383
0.005
<0.035
<0.025
2.460
0.186
0.031
0.007
5.0
8
Not
Analyzed •'
28
<0.001
<0.002
<0.005
0.020
3.750
<0.013
<0.050
<0.001
<0.013
<0.002
0.008
<0.001
31.500
1.110
0.187
20.200
0.158
<0.001
<0.001
0.137
0.552
<0.035
<0.025
0.142
0.193
0.009
<0.002
36
Not
Analyzed
28
0.004
<0.002
<0.005
11.600
2.380
<0.013
<0.050
<0.001
<0.013
<0.002
0.001
<0.001
19.100
0.257
<0.025
18.300
0.021
<0.001
<0.001
0.094
0.538
<0.035
<0.025
0.037
0.212
0.004
<0.002
35
5-19
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System III - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
Total Phosphor
Effluent
20
5110/32400
24
mg/1
Total Plant
Effluent
21
283875/1800000
24
mg/1
TOXIC ORGANICS
4 Benzene
11 1,1,1-Trichloroethane
13 1,1-Dichloroethane
23 Chloroform
29 1,1-Dichloroethylene
30 1,2-trans-dichloroethylene
38 Ethylbenzene
44 Methylene chloride
48 Dichlorobromomethane
51 Chlorodibromomethane'
66 Bis(2-ethylhexyl)phthalate
68 Di-N-butyl phthalate
85 Tetrachloroethylene
86 Toluene
87 Trichloroethylene
102 Alpha-BHC
105 Delta-BHC
Total Toxic Organics
Cyanide
TOXIC INORGANICS
<0.010
<0.010
<0.010
<0.010
<0.010
0.020
<0.010
<0.010
0.030
<0.010
0.050
<0.005
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Not
Analyzed
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Not
Analyzed
0
130
45
505
48
1080
<0.010
0.050
<0.010
<0.010
<0.010
<0.010
0.060
<0.010
<0.010
<0.010
0.090
0.030
<0.005
<0.005
0.023
0.002
0.052
0.037
<0.005
.310
.230
1.
1.
0.045
1.960
<0.001
0.047
0.002
<0.001
<0.001
7.310
23.200
8.380
454.
4.100
0.037
0.002
9.420
0.186
<0.035
<0.025
0.237
<0.050
9.930
0.045
0.046
101
480
7.2
49
71
63
5-20
-------
TABLE 5-5
PICTURE TUBE PROCESS WASTES
PLANT 99796
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
Duration/Hours/Day
TOXIC ORGANICS
23 Chloroform
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Phenols
Flouride
Clarifier
Influent
1
85626/542880
24
mg/1
0.050
0.025
• 0.075
<0.01
0.040
0.030
<0.001
0.637 '
0.776
0.016
20.100
<0.0002
<0.015
<0.010
<0.012
<0.010
31.600
<0.02
34
Clarifier
Effluent
2
85626/542880
24
mg/1
0.035
0.021
0.056
0.02
0.060
<0-. 010
<0.001
0.021
0.150
<0.004
0.400
o:0002
<0.015
<0.010
<0.003
<0.010
0.944
<0.02
32
Clarifier
Influent
3
74950/475200
24
mg/1
0.030
0.030
<0.01
0.040
0.030
<0.001
0.434
0.900
0.012
5.300
0.0004
<0.015
<0.010
<0.015
<0.010
8.77
<0.02
26
CONVENTIONAL POLLUTANTS
Oil & Grease' 5
Biochemical Oxygen Demand 17
Total Suspended Solids 410
5
10
15
5
16
320
5-21
-------
TABLE 5-5
Picture Tube Process Wastes
Plant 99796 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
Duration/Hours/Day
TOXIC ORGANICS
23 Chloroform
44 Methylene Chloride
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Phenols
Fluoride
CONVENTIONAL POLLUTANTS
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Clarifier
Effluent
4
74950/475200
24
mg/1
0.054
0.008
0.008
0.054
<0.01
0.040
<0.010
<0.001
0.021
0.176
<0.004
0.200
0.0004
<0.015
<0.010
<0.006
<0.010
0.345
<0.02
26
Clarifier
Influent
5
84500/535680
24
mg/1
0.124
0.026
0.150
<0.01
0.100
0.50
<0.001
0.807
1.300
0.008
13.600
0.0002
0.030
<0.010
<0.015
<0.010
18.800
0.02
35
Clarifier
Effluent
6
84500/535680
24
mg/1
0.024
0.021
0.045
0.01
0.060
<0.010
<0.001
0.014
0.164
<0.004
0.300
0.0002
<0.015
<0.010
<0.003
<0.010
0.360
0.02
32
<5
15
20
5
18
'410
5
15
10
5-22
-------
TSS
Fluoride
Cadmium
Lead
Zinc
Toxic Organics
The process steps associated with the sources of these pollutants
are described in Section 4. Table 5-2 summarizes the occurrence
and levels at which these pollutants are found based on the
sampling and analysis of wastewater from three television picture
tube manufacturing facilities. Concentrations represent total
raw wastes after flow-proportioning individual plant streams.
Figures 5-1, 5-2, and 5-3 identify sampling locations, and Tables
5-3, 5-4, and 5-5 summarize analytical data and wastewater flows
obtained from each of the plants sampled.
pH — may be very high or very low. High pH results from caustic
cleaning operations. Low pH results from the use of acids for
etching and cleaning operations.
Total Suspended Solids — are common in cathode ray tube
manufacture wastewater and result primarily from graphite
emulsions (DAG) used to coat the inner and outer surfaces of
glass panels and funnels. Sources include both manufacture and
salvage cleaning operations.
Fluoride — has as its source the use of hydrofluoric acid for
cleaning and conditioning glass surfaces. Sources of fluoride in
wastewater include both manufacture and salvage operations.
Cadmium and Zinc — are the major toxic metals found in phosphors
used in cathode ray tubes. Sources for these metals in
wastewater include manufacture, salvage, and phosphor recovery
operations.
Chromium — occurs as dichromate in photosensitive materials used
to prepare glass surfaces for phosphor application. Sources of
chromium in wastewater include both manufacture and salvage
operations.
Lead — is present in high concentration in the solder or frit
used to fuse glass panels and funnels together. The major source
of lead in wastewater occurs in tube salvage operations when
acids are used to dissolve the frit and to clean the panels and
funnels.
Toxic Organics — result from the use of solvents such as
methylene chloride and trichloroethylene for cleaning and
degreasing operations and from toluene-based lacquer coatings
applied as a sealant over phosphor coatings. Only limited
sampling has been conducted for toxic organics in this
subcategory.
5.3 LUMINESCENT MATERIALS
5-23
-------
5.3.1 Wastewater Flow
Presented below is a summary of the quantities of wastewater
generated by the manufacturers of luminescent materials.
5.3.
Number of Plants
5
2 Wastewater Sources
Min.
10,000
Mean
104,000
:jv- \ yf ^ /
Max.
247,000
Process wastewater sources from the manufacture of luminescent
materials include the various crystallization, washing, and
filtration steps in the production of intermediate and final
product powders. Additional sources are wet scrubbers used in
conjunction with firing and drying operations.
5.3.3 Pollutants Found and the Sources of These Pollutants
The major pollutants of concern from the luminescent materials
subcategory are:
pH TSS Antimony Cadmium
Zinc
The process steps associated with the sources of these pollutants
are described in Section 4. Table 5-6 summarizes the occurrence
and levels of these pollutants based on sampling and analysis
data. Concentrations represent total raw wastes after flow-
proportioning individual plant waste streams. Figure 5-4
identifies the sampling location at one facility. Tables 5-7
through 5-9 present the analytical data for three sampled plants
in the luminescent materials subcategory.
pH --may be very low or very high in specific waste streams as a
result of acids used for dissolving raw materials and caustics
used in wet scrubbers.
Total Suspended Solids — occur in wastes from washing and
filtration operations and in wet scrubber wastes. The solids
primarily consist of precipitated product materials and raw
material impurities.
Fluoride -- occurs in wastewaters from lamp phosphor manufacture.
Calcium fluoride, as an intermediate powder product, appears in
wastes from washing and filtration operations.
Antimony — used as an activator in the manufacture of lamp
phosphors was detected at a high concentration in one raw waste
stream.
5-24
-------
TABLE 5-6
LUMINESCENT MATERIALS
SUMMARY OF RAW WASTE DATA
PARAMETER
CONCENTRATION, mg/1
MINIMUM MAXIMUM MEAN
TOXIC METALS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
Total Toxic Organics
Oil and Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.021
0.005
0.003
0.216
0.025
0.005
0.009
0.001
0.025
0.005
0.015
0.027
2.864
0.060
2.64
2
91
6.62
0.020
0.008
9.35
0.067
0.101
0.155
0.005
0.745
0.005
0.044
0.065
350.6
1.292
6.40
8
4008
2.69
0.013
0.005
4.06
0.155
0.051
0.064
0.003
0.322
0.005
0.025
0.041
120.6
0.590
3.01
5
1440
Fluoride
11.05
702
356.5
5-25
-------
Cadmium and Zinc — as the major metals found in blue (Zn) and
green (Zn, Cd) TV phosphors, occur as sulfides in the
intermediate and final products. Therefore they appear in
wastewaters from all washing and filtering operations in the
production of blue and green phosphors.
Other toxic metals which are used in very small amounts as
activators (arsenic in lamp phosphors and silver and copper in TV
phosphors) were detected in very low concentrations.
Toxic Organics — in the form of phthalate esters, were found in
significant concentrations in several process wastes. According
to industry personnel, phthalates are not used in the
manufacturing process. The presence of these organics may be due
to sample contamination, since they also occurred in significant
concentrations in sample blanks, or they may result from the use
of plastic storage containers.
5.4 RECEIVING AND TRANSMITTING TUBES
No plants were sampled in the Receiving and Transmitting Tube
subcategory. Information obtained' from plant surveys and
industry contacts indicated that wastewater generated by the
Receiving and Transmitting Tube subcategory results primarily
from processes associated with metal finishing operations.
-------
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5-27
-------
TABLE 5-7
LAMP PHOSPHOR WASTES
PLANT 101
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
TOXIC ORGANICS
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
126
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Fluoride
CONVENTIONAL POLLUTANTS
Biochemical Oxygen Demand
Total Suspended Solids
Calcium
Intermediate
Powder Wastes
1
26810/170000
mg/1
Not
Analyzed
0.016
0.003
<0.003
0.076
0.070
0.050
<0.020
0.005
0.220
<0.005
0.05
<0.030
0.005
2.704
211.345
2.598
0.029
0.252
0.633
0.402
8.378
0.418
0.230
0.100
0.208
0.127
<3
840
Fluoride
Intermediate
Powder Wastes
2
946/6000
mg/1
Not
Analyzed
0.013
0.024
<0.003
<0.030
0.020
0.020
<0.020
0.004
0.090
<0.005
0.010
<0.030
0.289
0.030
100
1100
5-28
-------
TABLE 5-7
LAMP PHOSPHOR WASTES
PLANT 101
Stream Identification
Sample Number
Flor Rate Liters/Hr-Gallon/day
TOXIC ORGANICS
11 1,1,1-Trichloroethane
23 Chloroform
44 Methylene Chloride
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
70 Diethyl Phthalate
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
NON-CONVENTIONAL POLLUTANTS
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium •
Molybdenum
Tin
Yttrium
Cobalt
Phenols
Total Organic Carbon
Fluoride
Ammonia
CONVENTIONAL POLLUTANTS
Total Suspended Solids
Composites
1 & 2
3
27760/176000
mg/1
<0.010
0.012
0.470
0.960
0.15
<0.010
1.437
<0.004
Not
Analyzed
Fired Lamp
Powder Wastes
4
3785/24000
mg/1
<0.002
8.0
<0.010
<0.010
.011
.200
0.
1.
<0.010
<0.010
1.211
<0.004
14.669
0.116
<0.003
26.210
0.050
0.040
0.080
0.003
0.290
<0.005
0.020
<0.030
0.071
0.680
2.288
1.189
32.250
0.050
1.721
0.040
0.050
0.028
0.037
0.005
<0.002
170
7200
3.4
3200
5-29
-------
TABLE 5-7
TV PHOSPHOR WASTES
PLANT 101
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
TOXIC ORGANICS
11 1,1,1-Trichloroethane
44 Methylene Chloride
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
70 Diethyl Phthalate
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc 2,
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Intermediate
Powder Wastes
5
4732/30000
mg/1
<0.01
0.018
1.100
<0.01
<0.01
<0.01
1.118
<0.004
0.021
<0.001
<0.003
0.077
0.055
0.020
0.050
0.006
0.040
<0.005
0.010
<0.030
590
1.311
0. 083
1. 036
0.015
0.020
<0.001
0. 021
0.007
2.826
0. 224
< 0. 001
0.043
0.417
0.020
<0.002
20
Phosphor
Wastes
6
1577/10000
mg/1
<0.01
0.014
1.200
<0.01
<0.01
1.214
<0.004
0.011
<0.001
<0.003
<0.030
<0.005
0.010
0.020
0.002
<0.020
<0.005
<0.003
<0.030
888.5
2.219
13.670
2.696
0.771
0.026
0.114
0.038
0.004
1.006
0.053
0.037
0.080
0.142
0.007
<0.002
4.0
Scrubber
Wastes
7
1104/7000
mg/1
Not
Analyzed
0.049
0.040
<0.003
0.058
0.080
0.150
<0.020
0.007
1.290
0.005
0.230
<0.030
0.194
2.819
0.035
2.821
0.017
0.201
0.043
0.033
1.903
0.407
0.699
0.068
0.308
0.048
CONVENTIONAL POLLUTANTS
Total Suspended Solids
24,700
1500
1100
5-30
-------
TABLE 5-7
TREATMENT SYSTEMS
PLANT 101
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
TOXIC ORGANICS
Treatment
Influent
8
189270/1200000
mg/1
Not
Analyzed
Primary
Clarifier
Effluent
9
189270/1200000
mg/1
Not
Analyzed
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
126
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Europium
Yttrium
Cobalt
Iron
Titanium
0.029
0.078
<0.030
0.337
1.730
0.150
<0.020
0.003
0.260
<0.005
0.040
<0.030
5.517
302.707
88.120
3.052
0.783
0.804
1.500
0.319
0.958
0.285
<0.05
<2
1.153
133.988
0.095
0.058
<0.001
<0.003
0.091
0.120
0.090
<0.020
0.005
0.330
<0.005
0.010
<0.030
0.419
513.207
129.602
2.399
0.260
0.872
0.948
0.099
0.568
0.257
<0.01
<2
0.373
3.560
0.077
CONVENTIONAL POLLUTANTS
Total Suspended Solids
210
110
5-31
-------
TABLE 5-7
TREATMENT SYSTEMS
PLANT 101 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
TOXIC ORGANICS
Secondary
Clarifier
Effluent
10
189270/1200000
mg/1
Not
Analyzed
Final
Effluent
11
189270/1200000
mg/1
Not
Analyzed
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Europium
Yttrium
Cobalt
Iron
Titanium
0.146
0.156
<0.003
0.512
4.750
0.220
<0.020
0.003
0.450
<0.005
0.060
<0.030
11.409
<2
0.031
0.008
<0.003
0.020
0.050
0.030
<0.020
0.004
0.130
<0.005
0.020
<0.030
0.289
240.200
52.730
0.090
0.107
0.368
0.361
0.091
0.128
0.023
<0.05
<2
0.096
4.237
0.005
CONVENTIONAL POLLUTANTS
Total Suspended Solids
730
45
5-32
-------
TABLE 5-8
TV PHOSPHOR WASTES
PLANT 102
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
TOXIC ORGANICS
23 Chloroform
66 Bis(2-ethylhexyl)phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
126 Thallium
128 2inc
NON-CONVENTIONAL POLLUTANTS
Phenols
Total Organic Carbon
CONVENTIONAL POLLUTANTS
pH 6 23°C
oil i Grease
Luminescent
Material Waste
1
4360/9000
mg/1
0.005
0.060
0.006
0.060
<0.002
0.021
<0.005
<0.005
0.216
<0.025
0.005
0.009
<0.001
<0.025
<0.005
<0.015
0.027
8.450
0.012
31
11.1
6.4
Final Plant
Effluent
2
39430/250000
mg/1
0.260
0.010
0.060
0.33 .
0.004
0.008
<0.005
<0.005
0.200
0.200
0.325
0.004
<0.001
0.190
' <0.005
0.015
0.038
0.468
6.8
6.8
8.0
Biochemical Oxygen Demand
Total Suspended Solids
91
5-33
-------
TABLE 5-9
LAMP PHOSPHOR WASTES
PLANT 103
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Special Phosphors
Wastes
1
79/500
mg/1
Lamp Phosphor
Wastes
2
790/5000
mg/1
TOXIC ORGANICS
1 Acenaphene
4 Benzene
23 Chloroform
39 Fluoranthene
44 Methylene Chloride
66 Bis(2-ethylhexyl)phthalate
67 Butyl Benzyl phthalate
68 Di-N-butyl phthalate
70 Diethyl phthalate
78 Anthrancene
81 Phenanthrene
84 Pyrene
86 Toluene
106 PCB-1242
Total Total Organics
Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
NON- CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
Oil S Grease
Total Suspended Solids
<0.010
<0.010
<0.010
<0.010
0.160
<0.010
<0.160
<0.010
0.036
<0.010
<0.010
<0.010
0.008
0.196
0
0.009
0.006
0.075
0.091
0.266
0.419
1.070
0.003
3.272
<0.005
0.070
<0.030
7.011
8.672
3.016
3.854
0.428
14.812
49.802
0.230
0.462
0.286
10.602
0.117
1.399
0.079
98
1.5
29
270
<0.010
<0.010
0.150
<0.010
<0.010
0.011
0.260
0.010
<0.010
0.018
0.439
0
7.278
0.021
<0.001
10.270
0.047
0.069
0.063
0.004
0.536
<0.005
0.010
<0.030
2.449
432.007
2.070
4.771
0.115
14.060
0.034
0.053
0.283
0.030
0.012
0.019
0.010
0.516
0.010
43
12
0
215
5-34
-------
SECTION 6
SUBCATEGORIES AND POLLUTANTS TO BE REGULATED,
EXCLUDED OR DEFERRED
This section cites the E&EC subcategories which are being (1)
regulated or (2) excluded from regulation. In addition, this
section explains, for those subcategories being regulated, which
pollutants are being regulated and which pollutants are being
excluded from regulation.
6.1 SUBCATEGORIES TO BE REGULATED
Based on wastewater characteristics presented in Section 5,
discharge effluent regulations are being proposed for the Cathode
Ray Tube and Luminescent Materials subcategories.
6.1.1 Pollutants t£ be Regulated
The specific pollutants selected for regulation in these
subcategories are: Cathode Ray Tubes - cadmium, chromium, lead,
zinc, fluoride, TSS, pH and TTO; and Luminescent Materials -
cadmium, zinc, antimony, fluoride, TSS and pH. The rationale for
regulating these pollutants is presented below.
(pH) Acidity or Alkalinity
During cathode ray tube and luminescent materials manufacture,
both high and low pH levels may occur. High pH results from
caustic cleaning operations or caustics used in wet scrubbers
while low pH results from the use of acids for etching and
cleaning operations.
Although not a specific pollutant, pH is a measure of acidity or
alkalinity of a wastewater stream. The term pH is used to
describe the hydronium ion balance in water. Technically, pH is
the negative logarithm of the hydrogen ion concentration. A pH
of 7 indicates neutrality, a balance between free hydrogen and
free hydroxyl ions. A pH above 7 indicates that the solution is
alkaline, while a pH below 7 indicates that the solution is
acidic.
Waters with a pH below 6.0 are corrosive to water works
structures, distribution lines, and household plumbing fixtures;
this corrosion can add constituents to drinking water such as
iron, copper, zinc, cadmium, and lead. Low pH waters not only
tend to dissolve metals from structures and fixtures, but also
tend to redissolve or leach metals from sludges and bottom
sediments. Waters with a pH above 9.9 can corrode certain
metals, are detrimental to most natural organic materials, and
are toxic to living organisms.
6-1
-------
Total Suspended Solids (TSS)
Total suspended solids found in cathode ray tube manufacture
wastewater result primarily from graphite emulsions (DAG) used to
coat the inner and outer surfaces of glass panels and funnels.
Sources include both manufacture and salvage cleaning operations.
The average concentration of TSS in CRT wastewaters is 87.5 mg/1.
TSS concentrations in the effluent from the manufacture of
luminescent materials average 1,440 mg/1. These solids consist
primarily of precipitated product materials and raw material
impurities. Major sources are washing and filtration operations
and wet scrubber wastes.
Suspended solids increase the turbidity of water, reduce light
penetration, and impair the photosynthetic activity of aquatic
plants. Solids, when transformed to sludge deposit, may blanket
the stream or -lake bed and destroy the living spaces for those
benthic organisms that would otherwise occupy the habitat.
Total Toxic Orqanics (TTO)
Total toxic organics (TTO) are found in the wastewaters from
cathode ray tube facilities. TTO is considered the sum of the
concentrations of toxic organics listed in Table 6-1 which are
found at concentrations greater than 0.01 milligrams per liter.
These organics result from the use of solvents (e.g., methylene
chloride, trichloroethylene) for cleaning and degreasing
operations and from toluene-based lacquer coatings applied as a
sealant over phosphor coatings. Maximum TTO concentrations of
0.15 milligrams per liter were found in the process wastes from
cathode ray tube facilities.
Table 6-1
Pollutants Comprising Total Toxic Organics
Toxic Pollutant No.
8 1,2,4-trichlorobenzene 54
11 1,1,1-Trichloroethane 55
21 2,4,6-trichlorophenol 57
23 Chloroform 58
24 2-chlorophenol 64
25 1,2-dichlorobenzene 65
26 1,3-dichlorobenzene 66
27 1,4-dichlorobenzene 67
29 1,1-dichloroethylene 68
31 2,4-dichlorophenol 78
37 1,2-diphenylhydrazine 85
38 ethylbenzene 86
44 methylene chloride 87
isophorone
naphthalene
2-nitrophenol
4-nitrophenol
pentachlorophenol
phenol
bis(2-ethylhexyl)phthalate
butyl benzyl phthalate
di-n-butyl phthalate
anthracene
tetrachloroethylene
toluene
trichloroethylene
Antimony
6-2
-------
Antimony is being regulated only in the Luminescent Materials
subcategory. It is used in small amounts as an activitor in the
manufacture of lamp phosphors and was detected at a high
concentration in a sampled raw waste stream. The mean
concentration of antimony for luminescent materials facilities
was 2.69 milligrams per liter.
Antimony compounds are poisonous to humans and are classed as
acutely moderate or chronically severe. Antimony can be
concentrated by certain forms of aquatic life to over 300 times
the background concentrations. In tests on various fish and
aquatic life, the salts of antimony give mixed results on
toxicity dependent on the salt, temperature, hardness of the
water, and dissolved oxygen present.
Cadmium .
Cadmium is found in the wastewater from both cathode ray tube and
luminescent materials facilities at mean concentrations of 0.374
milligrams per liter and 4.06 milligams per liter, respectively.
Cadmium is one of the major metals found in blue and green TV
phosphors and appears in wastewaters from all washing and
filtering operations in the production of these phosphors. In
the CRT industry, cadmium results from manufacture, salvage and
phosphor recovery operations.
Cadmium is a cumulative toxicant, causing progressive chronic
poisoning in mammals, fish and other animals. It is known to
have marked acute and chronic effects on aquatic organisms. The
compound is highly concentrated by marine organisms, primarily
molluscs. The eggs and larvae of fish are apparently more
sensitive than adult fish to poisoning by cadmium, and
crustaceans appear to be even more sensitive than fish eggs and
larvae. Cadmium in drinking water supplies is extremely
hazardous to humans, and conventional treatment does not remove
it. It also acts synergistically with other metals; copper and
zinc substantially increase its toxicity.
Chromium
Chromium is found in the wastewaters from the Cathode Ray Tube
subcategory. It occurs as dichromate in photosensitive materials
used to prepare glass surfaces for phosphor application. The
mean concentration of chromium in wastewater from manufacture and
salvage operations range was 1.31 milligrams per liter.
Chromium is considered hazardous to man, producing lung tumors
when inhaled and inducing skin sensitizations. The toxicity of
chromium salts to fish, and other aquatic life varies widely with
the species, temperature, pH, valence of chromium and synergistic
or antagonistic effects. It appears that fish food organisms and
other lower forms of aquatic life are extremely sensitive to
chromium, which also appears to inhibit algal growth.
6-3
-------
Lead
Lead is being regulated in the Cathode Ray Tube subcategory. It
is present in the solder or frit used to fuse glass panels and
funnels together. The major sources of lead in CRT wastewaters
are tube salvage operations where acids are used to dissolve the
frit and to clean the panels and funnels. The mean concentration
of lead for CRT facilities was 9.41 milligrams per liter.
Lead levels are cumulative in the human body over long periods of
time with chronic ingestion of low levels causing poisoning over
a period of years. Fish have been shown to have adverse effects
from lead and lead salts in the environment. Small
concentrations of lead may cause a film of coagulated mucus to
form over the fish, leading to suffocation.
Zinc
Zinc is being regulated in both the Cathode Ray Tube and
Luminescent Materials subcategories. As with cadmium, zinc is
one of the major toxic metals found in phosphors. Sources of
zinc are therefore the same as discussed above for cadmium. Mean
zinc concentrations for the two industries are 11.79 milligrams
per liter (cathode ray tube) and 120.6 milligrams per liter
(luminescent materials).
Zinc can have an adverse effect on man and animals at high
concentrations.while lower zinc levels in public water supply
sources can cause an undesirable taste which persists through
conventional treatment. The toxicity of zinc to fish has been
shown to vary with fish species, age and condition, as well as
with the physical and chemical characteristics of the water.
Fluoride
Fluoride is found in the wastewaters of cathode ray tube and
luminescent materials facilities from both manufacture and
salvage operations. The source of fluoride from CRT manufacture
is the use of hydrofluoric acid for cleaning and conditioning
glass surfaces. The mean concentration in CRT process wastes was
360.6. The source of fluoride from luminescent materials
manufacture is an intermediate powder in lamp phosphor
production. The mean concentration of fluoride at luminescent
materials facilities was 356.5 milligrams per liter.
Although fluoride is not listed as a toxic pollutant, it can be
toxic to livestock and plants, and can cause tooth mottling in
humans. The National Academy of Sciences recommends: (1) two
milligrams per liter as an upper limit for drinking water and
watering livestock and, (2) one milligram per liter for
continuous use as irrigation water on acid soils to prevent plant
toxicity and reduced crop yield. Although some fluoride in
drinking water helps to prevent tooth decay, EPA's National
6-4
-------
. .iterim Primary Drinking Water Regulations set limits of 1.4 to
2.4 milligrams per liter in drinking water to protect against
tooth mottling.
6.2 TOXIC POLLUTANTS AND SUBCATEGORIES NOT REGULATED
The Settlement Agreement, explained in Section 2, contained
provisions authorizing the exclusion from regulation, in certain
circumstances, of toxic pollutants and industry categories and
subcategories. These provisions have been rewritten in a Revised
Settlement Agreement which was approved by the District Court for
the District of Columbia on March 9, 1979, NRDC v. Costle, 12 ERC
1833.
6.2.1 Exclusion of_ Pollutants
Ninety-six (96) toxic pollutants are being excluded from
regulation for both the Cathode Ray Tube and Luminescent
Materials subcategories. The basis for exclusion for eighty-
six; (86) of these pollutants is Paragraph 8(a)(iii) which
allows exclusion for pollutants which are not detectable with
state-ofthe-art analytical methods. The basis of exclusion for
another nine of these pollutants is also provided by Paragraph
8{aj(iii) which allows exclusion of pollutants which are present
in amounts too small to be effectively reduced.
The nine toxic pollutants that are being excluded from both
subcategories under Paragraph 8(a)(iii) are: arsenic, beryllium,
copper, mercury, nickel, selenium, silver, thallium, and cyanide.
The eighty-six which are being excluded under 8(a)(iii) because
they were not detected are presented in Table 6-2.
6.2.2 Exclusion of. Subcategories
All subcategory exclusions are based on either Paragraph 8(a)(i),
or Paragraph 8(a)(iv) of the Revised Settlement Agreement.
Paragraph 8(a)(i) permits exclusion Of a subcateogry for which
"equally or more stringent protection is already provided by an
effluent, new source performance, or pretreatment standard or by
an effluent limitation. . ." Paragraph 8(a)(iv) permits
exclusion of a category or subcategory where "the amount and the
toxicity of each pollutant in the discharge does not justify
developing national regulations . . ." These exclusions are
supported by data and information presented in Section 5.
The Receiving and Transmitting Tube subcategory is being excluded
from regulation under the provisions of Paragraph 8(a)(i) on the
basis that the assembly of these tubes is a dry process. Those
unit operations which use water for cleaning, degreasing, and
plating are covered under metal finishing limitations.
6-5
-------
TABLE 6-2
TOXIC POLLUTANTS NOT DETECTED
1. Acenaph thene
2. Acrolein
3. Acrylonitrile
4. Benzene
5. Benzidine
6. Carbon Tetrachloride
7. Chlorobenzene
9. Hexachlorobenzene
10. 1,2-Dichloroethane
12. Hexachloroethane
13. 1,1-Dichloroethane
14. 1,1,2-Trichloroethane
15. 1,1,2,2-Tetrachloroethane
16. Chloroethane
18. Bis(2-Chloroethyl)Ether
19. 2-Chloroethyl vinyl Ether (Mixed)
20. 2-Chloronaphthalene
22. Parachlororaeta Cresol
28. 3,3'-Dichlorobenzidine
30. 1,2-Trans-Dichloroethylene
32. 1,2-Dichloropropane
33. lf2-Dichloropropylene
34. 2,4-Dimethylphenol
35. 2,4-Dinitrotoluene
36. 2,6-Dinitrotoluene
39. Fluorathene
40. 4-Chlorophenyl Phenyl Ether
41. 4-Bromophenyl Phenyl Ether
42. Bis(2-chloroisopropyl) Ether
43. Bis-(2-chloroethoxy) Methane
45. Methyl Chloride
46. Methyl Bromide
47. Bromoform
48. Dichlorobromoraethane
51. Chlorodibromomethane
52. Hexachlorobutadiene
53. Hexachlorocyclopentadiene
56. Nitrobenzene
59. 2,4-dinitrophenol
60. 4,6-dinitro-o-cresol
61. N-nitrosodimethylamine
62. N-nitrosodiphenylamine
63. N-nitrosodi-n-propylamine
69. Di-n-octyl phthalate
70. diethyl phthalate
71. dimethyl phthalate
72. Benzo(a)anthracene
73. Benzo(a)pyrene
74. 3,4-benzofluorathene
75. Benzo(k)fluoranthane
76. Chrysene
77. Acenaphthylene
79. Benzo(ghi)perylene
80. Fluorene
81. Phenanthrene
82. Dibenzo(a,h)anthracene
83. Ideno(l,2,3-cd)pyrene
84. Pyrene
88. Vinyl Chloride
89. Aldrin
90. Dieldrin
91. Chlordane
92. 4,4'-DDT
93. 4,4'-DDE
94. 4,4'-ODD
95. A-endosulfan-Alpha
96. B-endosulfan-Beta
97. Endosulfan Sulfate
98. Endrin
99. Endrin Aldehyde
100. Heptachlor
101. Heptachlor Epoxide
102. A-BHC-Alpha
103. R-BHC-Beta
104. BBC-Gamma
105. BHC-Delta
106. PCB-1242
107. PCB-1254
108. PCB-1221
109. PCB-1232
110. PCB-1248
111. PCB-1260
112. PCB-1016
113. Toxaphene
116. Asbestos
129. 2,3,4,8-tetrachlorodibenzo-
p-dioxin
6-6
-------
Existing direct dischargers in the Cathode Ray Tube subcategory
are being excluded from regulation under the provisions of
Paragraph 8(a)(iv). Only one plant of the 22 plants in the
Cathode Ray Tube subcategory is a direct discharger and that
plant has precipitation/clarification plus filtration treatment
in place. The discharge of toxic pollutants is insignificant,
less than 2 pounds/day after current treatment.
All existing dischargers in the Luminescent Materials subcategory
are being excluded from regulation. Of the five plants in this
subcategory, only two are direct dischargers. These two plants
discharge after treatment less than one pound/plant of toxic
metals per day. For this reason, exclusion under the provision
fo paragraph 8(a)(iv) is proposed. In the case of the indirect
dischargers, exclusion under the provision-of paragraph 8(b)2 is
proposed on the basis that the amount of toxic pollutants
introduced into POTW's is insignificant.
6.3 CONVENTIONAL POLLUTANTS NOT REGULATED
BOD, and oil and grease are not being regulated for either
subcategory because they were found at concentrations below
treatability. BOD was found at an average of 7.4 milligrams per
liter in cathode ray tube facilities and 5 milligrams per liter
in luminescent materials plants; oil and grease was found at an
average concentration of 9.1 milligrams per liter in cathode ray
tube plants and 3.0 milligrams per liter in luminescent materials
plants; and fecal coliform was not present in the process
discharge from either subcategory.
6-7
-------
-------
SECTION 7
CONTROL AND TREATMENT TECHNOLOGY
The wastewater pollutants of concern in the manufacture of
cathode ray tubes and luminescent materials, as identified in
Section 5, are pH, suspended solids, fluoride, antimony,
chromium, cadmium, lead, zinc, and toxic organics. A discussion
of the treatment technologies currently practiced and most
applicable for the reduction of these pollutants is presented
below followed by an identification of three recommended
treatment and control systems and an analysis of the performance
of these systems.
7.1 CURRENT TREATMENT AND CONTROL PRACTICES
Pollutant control technologies currently used in the cathode ray
tube and luminescent materials industries include both in-process
and end-of-pipe technologies. In-process waste control
technologies are meant to remove pollutants from process
wastewater by treatment at some point in the manufacturing
process, or to limit the introduction of pollutants into process
wastewater by control techniques. End-of-pipe treatment is
wastewater treatment at the point of discharge.
7.1.1 Cathode Ray Tube Subcategory
In-process Control — In-process control techniques with
widespread use in this subcategory are collection of spent
solvents for resale, reuse or disposal, and segregation of spent
acid wastes for contract hauling. Contract hauling refers to the
industry practice of contracting a firm to collect and transport
wastes for off-site disposal.
All color television tube manufacturing plants are known to
collect spent solvents for either contractor disposal or reclaim.
Two plants also have their lead-bearing nitric acid wastes
contract-hauled. Three plants have in-process treatment of
chromium wastes, and two of these plants also have in-process
treatment of strong lead-bearing wastes. Information from single
phosphor tube manufacturers indicates that in-process control of
pollutants at these facilities is limited to collection and
contract hauling of solvent wastes.
End-of-Pipe Treatment — Six of the seven color television tube
manufacturers use end-of-pipe precipitation/clarification for
control of toxic metals. The one plant which currently only
neutralizes its discharge is planning a new treatment system for
control of metals. The one direct discharger also filters its
treated process wastewater prior to discharge.
7-1
-------
Information from single phosphor tube manufacturers indicates
that most facilities only neutralize their wastes. Some small
plants have provisions for solids removal prior to discharge.
Two plants have combined treatment systems designed to treat
metal finishing wastes from other plant manufacturing operations.
7.1.2 Luminescent Materials Subcateqory
In the Luminescent Materials subcategory the two direct
dischargers have combined end-of-pipe treatment systems that
utilize precipitation/clarification technologies. Of the three
other plants in the subcategory, one evaporates its liquid waste
and has no industrial discharge, one neutralizes its wastes end-
of-pipe and the third uses precipitation/clarification technology
to control toxic metals prior to discharge.
7.2 APPLICABLE TREATMENT TECHNOLOGIES
7.2.1 • p_H Control
Acids and bases are commonly used in the production of cathode
ray tubes and luminescent materials and result in process waste
streams exhibiting high or low pH values. Acids and bases are
used frequently in cleaning operations for cathode ray tube
manufacture. In the production of luminescent materials, acids
are used to dissolve raw materials and bases are used in alkaline
scrubbers.
Several methods can be used to treat acidic or basic wastes.
Treatment is based upon chemical neutralization usually to pH 6-
9. Methods include: mixing acidic and basic wastes, and
neutralizing high pH streams with acid or low pH streams with
bases. The method of neutralization used is selected on the
basis of overall cost. Process water can be treated continuously
or on a batch basis. Neutralization is often used in conjunction
with precipitation of metals..
Hydrochloric or sulfuric acid may be used to neutralize alkaline
wastewaters; sulfuric acid is most often chosen because of its
lower cost.
Sodium hydroxide (caustic soda), sodium carbonate (soda ash), or
calcium hydroxide (lime) may be used to neutralize acidic
wastewater. The factors considered in selection include price,
neutralization rate, storage and equipment costs, and
neutralization end products. Sodium hydroxide is more expensive
than most other alkalis but is often selected due to its ease of
storage, rapid reaction rate and the general solubility of its
end product.
7.2.2 Fluoride Treatment
7-2
-------
Fluoride appears in cathode ray tube manufacture wastewater
because of the use of hydrofluoric acid for cleaning and
conditioning glass surfaces. In the production of luminescent
materials fluoride appears as ammonium bifluoride in the raw
material used, and as calcium fluoride in intermediate and final
products.
The most common treatment procedure practiced today in.the United
States for reducing the fluoride concentration in wastewater is
precipitation by the addition of lime followed by clarification.
Calcium fluoride is formed by the following reaction:
Ca(OH)ZX2 + 2FZQ- = CaFZX2 + 20HZQ
The solubility of calcium fluoride in water is,7.8 mg fluoride
ion per liter at 18ZJC. The precipitate forms slowly, requiring
about 24 hours for completion and the solubility of calcium
fluoride soon after its formation is about ten milligrams of
fluoride per liter.
Data from the Cathode Ray Tube subcategory indicate that plants
using precipitation and clarification treatment technologies are
achieving an average effluent concentration of 20 milligrams per
liter fluoride.
Hydroxide precipitation has proven to be an effective technique
for removing many pollutants from industrial wastewater. Metal
ions are precipitated as hydroxides and fluoride is precipitated
as insoluble calcium fluoride. The system operates at ambient
conditions and is well suited to automatic control. Lime vis
usually added as a slurry when used in hydroxide precipitation.
The slurry must be kept well mixed and the addition lines
periodically checked to prevent blocking, which may result from a
buildup of solids. The use of hydroxide precipitation does
produce sludge requiring disposal following precipitation.
The performance of a precipitation system depends on several
variables. The most important factors affecting precipitation
effectiveness are:
1. Addition of sufficient excess chemicals to drive the
precipitation reaction to completion. If treatment
chemicals are not present in slight excess
concentrations, some pollutants will remain dissolved
in the waste stream.
2. .Maintenance of an alkaline pH throughout the
precipitation reaction and subsequent settling.
3. Effective removal of 'precipitated solids.
Removal of suspended solids or precipitates by gravitational
forces may be conducted in a settling tank, clarifier, or lagoon.
7-3
-------
However, the performance of each is a function of the retention
time, particle size and density, and the surface area of the
sedimentation chamber. Accumulated sludge can be removed either
periodically or continuously as in the case of a clarifier.
The effectiveness of a solids settling unit can often be enhanced
by the addition of chemical coagulants or flocculants which
reduce the repulsive forces between ions or particles and allow
them to form larger floes which are then removed more easily.
Commonly used coagulants include ferric sulfate and chloride;
commonly used flocculants are organic polyelectrolytes.
7.2.3 Toxic Metals Treatment
Toxic metals appear in process wastewaters from the manufacture
of luminescent materials and cathode ray tubes. Zinc and cadmium
are major constituents of phosphors and, as such, appear in most
process waste streams at luminescent materials manufacturing
plants and in many waste streams at cathode ray tube plants.
Lead, found in the solder used to fuse cathode ray tube panels
and funnels, appears in tube salvage wastes at these plants.
Chromium, a constituent of photoresist materials, is found in the
hexavalent form in several wastes at cathode ray tube plants.
The most commonly used method to remove toxic metals from
wastewaters is to precipitate the metals as hydroxides or
carbonates and then remove the insoluble precipitates by
clarification or settling.
Hydroxide precipitation uses lime or caustic soda to supply the
hydroxide ions. The chemistry of the process is simple but must
be understood for each metal. The pH must be in the optimum
range to avoid forming soluble complexes. A simple form of the
reaction may be written as:
MZQ++ + 20HZQ- = M(OH)ZX2
The treatment levels attainable by hydroxide precipitation can be
forecast from a knowledge of the pH of the system. Figure 7-1
shows the theoretical solubility of those toxic metals which form
insoluble hydroxides. It is clear from the figure that for
wastewaters containing more than one metal, no single optimum pH
exists. For successful application as a wastewater treatment
technology, careful control of pH must be practiced if the best
removals are to be achieved. In practice, hydroxide
precipitation is often supplemented by the use of coagulating
agents to improve solids removal.
Sodium carbonate is often the reagent of choice for the treatment
of lead-bearing wastes. Lead carbonate or lead hydroxide/
carbonate precipitates are formed which allow improved settling
characteristics for this metal.
7-4
-------
I 1 1 1 1
10
FIGURE 7-1
Theoretical solubilities of toxic metal hydroxides/oxides
as a function of pH.
NOTE: Solubilities of metal hydroxides/oxides are from data by
M.Pourbaix, Atlas of Electrochemical Equilibria in Aqueous
Solutions,Pergamon Press, Oxford, 1966.
7-5
-------
Depending on the quantity of waste liow, the treatment can either
be a batch or continuous operation, with batch treatment favored
for small flows. In batch treatment the equipment usually
consists of two tanks, each with the capacity to direct the total
wastewater volume. For large daily flows, a typical continuous
flow scheme consists of an equalization tank, flash mixer,
flocculator, settling unit or clarifier and a sludge thickening
unit.
Further removal of fine precipitates can be achieved by the
addition of a filtration unit. A filtration unit commonly
consists of a container holding a filter medium or combination of
media such as sand or anthracite coal, through which is passed
the liquid stream. The unit can operate by gravity flow or under
pressure. Periodic backwashing or scraping of the media is
necessary to remove particles filtered from the liquid stream and
prevent clogging of the filter. The proper design of a
filtration unit considers such criteria as filter flow rate
(gpm/sq ft), media grain size, and density.
Chromium Reduction — Hexavalent chromium (e.g. CrOZX4ZQ= and
CrZX20ZX7ZQs) is very toxic and soluble, and must be reduced to
the trivalent form (CrZQ+++) before it can be removed from
wastewater by precipitation and clarification. A number of
chemicals can be used to reduce chromium from the hexavalent to
the trivalent form. A typical method uses sodium bisulfite and
sulfuric acid at low pH. The reduction reaction is:
3SOZX3ZQ*
4HZX20
+ CrZX20ZX7ZQ= + 8HZQ+ = 2CrZQ+++ + 3SOZX4ZQ= +
Following this reduction step, the trivalent chromium is now in a
form that can be treated using hydroxide precipitation/
clarification technology.
7.2.4 Total Toxic Orqanics Control
The sources of toxic organics in the Cathode Ray Tube subcategory
are solvents used for cleaning and degreasing operations and
toluene-based coatings used to protect phosphors. The primary
technique in this subcategory for controlling the discharge of
toxic organics is the segregation of spent solvents for contract
hauling (disposal) or for sale to companies which purify the
solvents in bulk for resale. This control technology of solvent
management also includes good housekeeping practices such as
controlling leaks and spills.
7.3 RECOMMENDED TREATMENT AND CONTROL SYSTEMS
Based on the pollutants of concern in the Cathode Ray Tube and
Luminescent Materials subcategories, applicable treatment
technologies for the control of these pollutants, and the current
7-6
-------
technologies observed within the two subcategories, three options
for control and treatment have been identified.
7.3.1 Cathode•Ray Tube Subcategory ,
Option 1 treatment consists of neutralization for.pH.control.
Option 2 treatment consists of Option 1 treatment with the
addition of: chromium reduction with the use of sulfuric acid
and sodium bisulfite; chemical precipitation and clarification of
all metals-bearing process wastes using lime, sodium carbonate, a
coagulant and polyelectrolyte; and sludge dewatering. Option 2
is presented schematically in Figure 7-2.
Option 3 treatment consists of Option 2 treatment with the
addition of multi-media filtration technology. Option 3
treatment is also depicted in Figure 7-2.
Option 4 consists of solvent management for control of toxic
organics. Solvent management is not a treatment system, but
rather an in-plant control to collect used solvents for resale or
contract disposal.
7.3.2 Luminescent Materials Subcateqory
Option 1 treatment consists of neutralization for pH control.
Option 2 treatment consists of Option 1 treatment with the
addition of: chemical preecipitation and clarification of all
metals-bearing process wastes using lime, sodium carbonate, a
coagulant and polyelectrolyte; and sludge dewatering. Option 2
is presented schematically in Figure 7-3.
7.4 ANALYSIS OF INDUSTRY PERFORMANCE DATA
The following subsections present data on the performance of in-
place treatment systems in the Cathode Ray Tube and Luminescent
Materials subcategories as they relate to the identified options
presented in Section 7.3. Also presented are the results of
analyses of available long-term effluent monitoring data and a
discussion of the statistical methodology used to analyze the
data.
7.4.1 Cathode Ray Tube Subcateqory
Table 7-1 presents a summary (average influent and effluent
concentrations) of the performance of Option 2 and Option 3
treatment technologies from results of the three-day samplings of
color television picture tube manufacturing plants. Plant 30172
uses chromium reduction of concentrated chromium wastes and
carbonate precipitation and settling of concentrated lead-bearing
wastes. The effluents from these two treatment units are then
7-7
-------
combined with other process wastes and sent through a
precipitation/clarification/filtration treatment system. The
treatment system effluent is then combined with dilute process
wastes and cooling water in a holding lagoon prior to direct
discharge (see Figure 5-1). Within a primary tank, Plant 99796
performs chromium reduction on an acid waste that contains
dissolved chromium. A concentrated lead bearing waste is
periodically batch discharged to the primary tank for treatment.
Overflow from the primary tank is combined with a caustic stream
in a secondary tank and sent through a clarification system. The
treatment system effluent enters a holding lagoon prior to
indirect discharge (see Figure 5-3).
Also sampled was Plant 11114, a color television picture tube
plant which has three separate treatment systems serving
different areas of the plant (see Figure 5-2). The sampling
results indicated that, although some components achieve
pollutant reduction, wastewater treatment is generally
ineffective at Plant 11114. For this reason, treatment
performance data from this plant are not presented.
In addition to sampling data, long-term effluent self-monitoring
data were submitted by three plants. Plant 30172 monitors the
treatment system effluent following filtration. Plants 99797 and
99798 monitor the final effluents from their
precipitation/clarification treatment systems.
Table 7-2 presents the results of statistical analyses of long-
term data from the three plants. The derivation of the
variability factors presented in Table 7-2 is discussed under
statistical methodology in Section 7.4.3.
7.4.2 Luminescent Materials Subcateqory
Table 7-3 presents a summary (average influent and effluent
concentrations) of available Option 2 performance data for the
Luminescent Materials subcategory. Both Plants 101 and 102 have
combined treatment systems which treat wastes from many
manufacturing operations. The treatment systems consist of flow
equalization, precipitation, clarification and pH adjustment.
Influent and effluent data were taken on three days of sampling
conducted under this study.
7.4.3 Statistical Methodology
To establish effluent guideline limitations for the Electrical
and Electronic Components Category, the available data were
examined statistically to determine the performance levels that
were attained by properly operated treatment systems in that
industry. Two distinct sets of sampling data were available for
this assessment. The first set consists of raw and effluent
concentration data that were collected during sampling visits to
representative plants in the industry. Typically, these data
7-8
-------
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7-10
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Parameter
TABLE 7-3
PERFORMANCE OF IN-PLACE TREATMENT
Luminescent Materials Subcategory
Option 2 Treatment
Plant 101
Influent
mg/1
Effluent
mg/1
Plant 102
Effluent
mg/1
Toxic Metals
Antimony
Cadmium
Zinc
Other Pollutants
TSS
0.029
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12
7-13
-------
cover a period of 3 days of sampling. The other data consisted
o£ sets of longer term self-monitoring data (usually effluent
concentration only) that were submitted by plants in the Cathode
Ray Tube subcategory. Analysis of the data for visited plant!
yielded mean effluent concentration values for each pollutant
parameter (Tables 7-1 and 7-3). More information (than mean
concentrations) is available from the longer term discharge
monitoring data (Table 7-2) which allows a quantitative
?!??^Sn ?f .the viability of effluent concentrations
following wastewater treatment. This data reflect the fact that
even properly operating treatment systems experience fluctuations
iLm?°J Utant .concentrations discharged. These fluctuations
result from variations in process flow, raw waste loading of
pollutants, treatment chemical feed, mixing effectiveness during
treatment, and combinations of these or other factors.
It has been found that the day-to-day variability in effluent
concentrations includes occasional large changes while averages
lor each month s data experience smaller fluctuations The
variability in the monthly average is usually well described by
-phL™rmad distrib"tj°n as predicted by the Central Limit
Theorem. However, daily fluctuations are most often described by
a«?0gnormaj distribution. This reflects the fact that an
effluent value may rise considerably from the mean level but may
°.nly «.to th\ value of zero. To quantify this variation in
concentration of a pollutant, a daily and a monthly
fac*°.r (a value always greater than 1.0) were derived
«n- i u SfJ m°mtoring data. These factors were then
multiplied by the mean pollutant concentration (derived from the
visited plant data) to yield a daily and a monthly effluent
limitation, respectively.
The following paragraphs describe the statistical methodology
used to calculate the variability factors for pollutants of
concern in the Cathode. Ray Tubey and Luminescent Materials
limitati°- ^r pollutant
CALCULATION OF VARIABILITY FACTORS
Variability factors are used to account for effluent concen-
tration fluctuations in the establishment of reasonable effluent
limitations. Calculation of these factors is discussed here
while their application is discussed under the next heading A
vJrJLiT3?11™? Yariability' fact°r and a ^nthly average
?K 25iJtfy W6re calculated for each pollutant parameter.
The monthly average was calculated based on a 22-day month
because these plants normally operate five days per week.
ii .Variability Factors— These calculations were based on the
following three assumptions: (1) monitoring at each plant was
conducted using standardized testing procedures such that the
resulting measurements can be considered statistically
7-14
-------
independent and amenable to standard statistical procedures; .(2)
treatment facilities and monitoring techniques at each plant were
'substantially constant throughout the monitoring period; (3) the
daily pollutant concentration data follow a distribution with
characteristics that can be verified as lognormal or normal.
The first two assumptions, which concern self consistency of the
data were supported by direct examination of the data and by
consideration of supplemental information accompanying the data.
In the cases of cadmium, chromium, lead and zinc, the
distribution of daily data were verified as lognormal through the
use of graphical plots and the Kolomogorov-Smirnov test for
goodness of fit. Examples of these plots are shonw in Figures
7-4 through 7-7. .A straight line plot confirms lognormal
distribution of the data.
Once lognormality was verified, the daily maximum variability
factor was calculated from the equation
In VF = 2.326(8') - 0.5 (S1) .
In this equation, 2.326 is the 2 value corresponding to the 99th
percentile point for the distribution and S' is the estimated
standard deviation of the natural logarithms of the
concentrations. S1 is calculated as the square root of In (l.rO +
(CV)ZQ2) where CV is the coefficient of variation.
In the case of fluoride, daily concentration data were better fit
by a normal distribution. 'The normal distribution was verified
by the use of graphical plots (See Figure 7-8) and the
Kolomogorov-Smirnov test for goodness of fit.
Monthly Variability Factors—Since the monthly averages follow a
normal distribution, the monthly variability factors for all
pollutants were calculated from the equation
VF* = 1.0 + 1.645 (S/M)
In this equation, 1.645 is the Z value corresponding to the 99th
percentile point for the distribution; S is the estimated
standard deviation of the monthly average, obtained by dividing
the standard deviation of the daily pollutant concentrations by
the square root of22; and M is the mean value of the daily
pollutant concentrations.
CALCULATION OF EFFLUENT LIMITATIONS
The effluent limitations are based on the premise that a plant's
treatment system can be operated to maintain effluent
concentrations equivalent to those concentrations observed at
plants visited during the sampling program. As explained in the
introduction, day-to-day concentrations will fluctuate below and
7-15
-------
above average concentrations. Thus an effluent limitation must
be set far enough above the average concentration so that plants
with properly operated treatment systems will not exceed the
limit (99 percent of the time in the case of daily data, 95
percent of the time in the case of monthly averages).
Effluent limitations are obtained for each parameter by
multiplying the average concentration (based on visit data) by
the appropriate daily and monthly variability factors (based on
historical data). Expressed as an equation
L = VF x A
Where L is the effluent limitation, VF is the variability factor,
and A is the Average concentration based on plant visit data.
7-16
-------
LN CADMIUM CONCENTRATION VS. CUMULATIVE FREQUENCY
L
N
C
A
D
K
I
U
M
C
0
N
C
E
N
T
R
A
T
1
0
N
I
-3.7 +
I
I
-3.8 +
I
I
-3.9 +
I
I
-4.0 +
I
I
-4.2 +
-4.6
-4.9
I
I
4-
I
I
I
I
-5.0 +
I
...4.
1
.+ + + + + 4- + '•+ •»••
27 15 30 50 70 85 93 98
CUMULATIVE FREQUENCY, PERCENT
99
FIGURE 7-4
PLANT 30172
7-17
-------
L
N
C
H
R
0
M
I
U
M
C
D
N
C
E
N
T
R
A
T
I
0
N
1.2
0.9
0.6
0.3
0.0
-0.3
-0.6
-0.9
-1.2
-1.5
-1.8
LN CHROMIUM CONCENTRATION VS. CUMULATIVE FREQUENCY
I
7 15 30 50 70 85 93
CUMULATIVE FREQUENCY, PERCENT
FIGURE 7-5
PLANT 30172
98 99
7-18
-------
LN LEAD CONCENTRATION VS.CUMULATIVE FREQUENCY
0.6
0.3
0.0
L
N
L -0.3
E
A
D
-0.6
C
0
N
C -0.9
E
N
T
R -1.2
A
T
I
0 -1.5
N
-1.8
-2.1
-2.4
.+„_..+ ...
1 2
7 15 30 50 70 85 93
CUMULATIVE FREQUENCY, PERCENT
FIGURE 7-6
PLANT 99797
98 99
7-19
-------
LN ZINC CONCENTRATION VS. CUMULATIVE FREQUENCY
I
3 +
L
N 1
Z
I
N
C 0
c
0
N
C -1
E
N
T
R
A »2
T
I
0
N
-5
7 15 30 50 70 85 93
CUMULATIVE FREQUENCY, PERCENT
FIGURE 7-7
PLANT 99797
98
99
7-20
-------
FLUORIDE CONCENTRATION VS. CUMULATIVE FREQUENCY
21
20
19
F
L
U
0 18 +
R
I
D
E 17
C
0
N 16
C
E
N
T 15
R
A
T
I 1*
0
N
13
12
11 +
7 15 30 50 70 85 93
CUMULATIVE FREQUENCY, PERCENT
FIGURE 7-8
PLANT 30172
98
99
7-21
-------
-------
SECTION 8
SELECTION OF APPROPRIATE CONTROL AND TREATMENT
TECHNOLOGIES AND BASES FOR LIMITATIONS
Proposed discharge regulations for the Cathode Ray Tube
subcategory and the Luminescent Materials subcategory are
presented in this section. The technology bases and the
numerical bases are also presented for each regulation. The
statistical methodology used to develop limitations was presented
in Section 7.4.
8.1 CATHODE RAY TUBE SUBCATEGORY
The Agency is proposing not to regulate direct dischargers in the
Cathode Ray Tube subcategory for reasons presented in Section
6.2. Therefore, BPT, BAT and BCT limitations are not being
proposed.
8.1.1 Pretreatment Standards for Existing Sources (PSES)
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
Long Term
Average
(LTA)
(mq/1)
0.019
0.20
0.28
0.34
20.5
Monthly
VF
1 .
1 .
1 .
1 .
1 .
Average
Limit
15
32
28
45
09
(mq/1)
0.022
0.26
0.36
0.49
*
22.3
Daily Max
VF Limit
2.42
4.54
4.05
6.05
1 .59
imum
(mg/1)
0.046
0.91
1.13
2.06
0.15
32.6
*The Agency is not proposing monthly limitations for reasons
presented below.
EPA is proposing PSES based on Option 2 which consists of solvent
management to control toxic organics, neutralization, and
precipitation/clarification of the final effluent to reduce toxic
metals and fluoride. Solvent management is widely practiced at
cathode ray tube facilities as is neutralization. Precipita-
tion/clarification technology is known to be currently practiced
at nine CRT facilities. Option 1, neutralization, was not
selected because it will not control toxic metals or fluoride.
Option 3 was not selected because the demonstrated pollutant
reduction beyond that achieved by Option 2 is considered
insignificant. Precipitation/clarification technology achieves
8-1
-------
97-98 percent reduction of toxic metals, whereas filtration
technology will only achieve an additional 0.6 percent reduction.
If Option 3 was selected, the following limits would apply.
(Alternate) Pretreatment Standards for Existing Sources
8.1.1
(PSES)
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
(LTA)
(mg/1)
0.019
0.17
0.18
0.195
20.5
VF
1 .15
1 .32
1 .28
1 .45
1 .09
Monthly
Average
Limit (mg/1)
0.022
0.22
0.23
0.28
*
22.3
Daily
VF Limi
2.42
4.54
4.05
6.05
1 .59
Maximum
t (mg/1)
0.046
0.77
0.73
1.18
0. 15
32.6
Toxic Metals and Fluoride — The proposed limitations for toxic
metals (cadmium, chromium, lead and zinc) and fluoride are based
on demonstrated performance at CRT plants employing precipita-
tion/clarification treatment technologies. As described in
Section 7, both on-site sampling and long-term effluent
monitoring data are reflected in the limitations. They therefore
incorporate both the plant-to-plant variations in raw wastes and
treatment practices and the day-to-day variability of treatment
system performance. The concentrations shown are all applicable
to the treated effluent prior to any dilution with sanitary
wastewater, noncontact cooling water, or other non-process water.
The achievable long-term average concentrations used to develop
the proposed limitations are based on sampling data presented in
Table 7-1. The averages for chromium, lead, and zinc represent
the average effluent concentrations following Option 2 treatment.
The average for cadmium reflects the average effluent
concentration at only one of the sampled plants since the other
plant had uncharacteristically low cadmium levels in its
effluent. The average for fluoride incorporates the filtered
effluent fluoride concentration from Plant 30172 rather than the
clarifier effluent concentration. Since the sampling data from
this plant show increased fluoride levels following filtration,
and since the fluoride levels are low, the data more likely
reflect maximum performance for Opti-on 2 technology.
The variability factors used to develop the proposed limitations
are based on statistical analyses of long-term monitoring data
submitted by three plants and summarized in Table 7-2. For
cadmium, chromium, zinc, and fluoride, the median of three
variability factors were selected. For lead, the higher of two
variability factors were selected.
8-2
-------
Total Toxic Organics (TTO) — A daily maximum limit of 0.15 mg/1
is being proposed. This limit reflects the highest concentration
of TTO found at the sampled plants. Because only limited TTO
data are available from the CRT industry, the Agency reviewed
data from other industries, including other E&EC subcategories,
to assess the reasonableness of this limitation. In the metal
finishing industry, data indicate that
precipitation/clarification technology reduces TTO by 80 percent.
In the semiconductor subcategory, raw waste TTO levels at plants
practicing good solvent management occur at from 0.03 to 1.4
milligrams per liter. Thus, if the CRT industry were to exhibit
raw waste TTO levels within the range observed at semiconductor
plants, reduction of TTO through Option 2 technology would result
in effluent TTO levels near the proposed 0.15 milligram per liter
limitation. The Agency has chosen not to establish a monthly
average limitation primarily because solvent management is not a
treatment technology and solvent management would not be expected
to vary significantly from the daily maximum.
8.1.2 New Source Performance Standards (NSPS)
Long Term
Average Monthly
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
TSS
PH
(LTA)
(mg/1)
0.019
0.17
0.18
0.195
20.5
..12.8
range
Average
VF Limit
1 .15
1 .32
1 .28
1 .45
1 .09
1 .26
from 6 to 9
Daily Maximum
(mg/1)
0.022
0.22
0.23
0.28
22.3
16.1
VF
2.42
4.54
4.05
6.05
1 .59
3.35
Limit (mg/1)
0.046
0.77
0.73
1 .18
0.15
32.6
42.9
The Agency is proposing NSPS based on Option 3. This technology
consists of neutralization and solvent management plus end-ofpipe
precipitation/clarification followed by filtration. The addition
of filtration is expected to further reduce toxic metals in the
effluent over that expected from precipitation/clarification
(Option 2). Because no significant reduction in fluoride or TTO
is expected, the proposed limitations for these pollutants do not
change from PSES.
Toxic Metals — The basis for proposed limitations for the toxic
metals is sampling data from one CRT facility practicing
filtration of its final effluent. The percent reduction of each
8-3
-------
metal following filtration as calculated from Table 7.1 was
applied to the long term average concentrations in PSES to
develop the achievable long-term average. Variability factors
are the same as those derived for Option 2 technology.
Total Suspended Solids (TSS) — Proposed TSS limitations
represent a transfer of technology from the Metal Finishing
industrial category. The rationale for transferring technology
from this industry is (1} the raw waste TSS concentrations are
similar to those found in CRT wastes, and (2) the treatment
technology used for solids reduction in the metal finishing
industry is the same as that proposed for cathode ray tubes.
The average effluent concentration of 12.8 milligrams per liter
was derived from EPA sampling data from several metal finishing
plants practicing solids removal by clarification and filtration
technology. Excluded from the data base were plants with
improperly operated treatment systems. The variability factors
of 1.26 and 3.35 each represent the median of variability factors
from 17 metal finishing plants with long-term monitoring data.
pH — Properly operated end-of-pipe neutralization of wastewater
will ensure discharges in the pH range of 6 to 9.
8.1.3 Pretreatment Standards for New Sources (PSNS)
Long
Term
Average
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
(LTA)
(mg/1)
0.
0.
0.
0.
20.
019
17
18
195
5
VF
1 .
1 .
1 .
1 .
1 .
Monthly
Average
Limit
15
32
28
45
09
(mg/1)
0.
0.
0.
0.
22.
022
22
23
28
3
Daily
VF
2.
4.
4.
6.
1 .
Maximum
Limit
42
54
05
05
59
(mg/1)
0.
0.
0.
1 .
0.
32.
046
77
73
18
15
6
The Agency is proposing PSNS based on Option 3. This technology
consists of neutralization and solvent management plus end-ofpipe
precipitation/clarification followed by filtration. As with NSPS
the addition of filtration is expected to further reduce toxic
metals in the effluent over that expected from
precipitation/clarification (Option 2), but no significant
reduction in fluoride or TTO is expected.
8-4
-------
The basis for the toxic metals, total toxic organics (TTO) and
fluoride limitations were presented under NSPS. These
limitations do not change for PSNS.
8.2 LUMINESCENT MATERIALS SUBCATEGORY
The Agency is proposing not to regulate existing dischargers in
the Luminescent Materials subcategory for reasons presented in
Section 6.2.
8.2.1 New Source Performance Standards (NSPS)
Long Term
Average
(LTA)
Pollutant
Cadmium
Antimony
Zinc
Fluoride
TSS
pH
(mg/1)
0.
0.
0.
20.
18.
20
03
47
5
2
range
Monthly
Average
VF Limit (mg/1)
1 .
1 .
1 .
1 .
1 .
from
15
45
45
09
26
6-9
0.
0.
0.
22.
22.
23
044
68
3
9
Daily Maximum
VF Limit (mg/1)
2
6
6
1
3
.42
.05
.05
.59
.35
0
0
2
32
61
.48.
.18
.84
.6
.0
EPA is proposing NSPS based on Option 2 technology which consists
of precipitation/clarification and neutralization. This
technology controls pH, total suspended solids (TSS), fluoride,
cadmium, antimony, and zinc. All but one of the dischargers in
the Luminescent Materials subcategory are currently practicing
this technology. Option 1 was not selected because it will not
control toxic metals and fluoride.
The bases for pH and fluoride limitations were presented in
Section 8.1 for cathode ray tubes. The proposed limitations for
these pollutants are the same for luminescent materials. The
bases for toxic metals and suspended solids limitations are
presented below.
Toxic Metals — The proposed NSPS limitations for toxic metals
(cadmium, antimony and zinc) are based on sampling data from two
luminescent materials plants employing
precipitation/clarification technologies. Because the available
data are limited, the higher value of each toxic metal from the
two plants was selected as the achievable long-term average.
Variability factors for cadmium and zinc are the same as those
derived for the CRT industry, which practices the same treatment
technology. These variability factors are discussed in Section
8.1.1.
3-5
-------
Because no long-term monitoring data were available for antimony,
the higher of the variability factors for the other metals, those
for zinc, were applied for antimony.
Total Suspended Solids (TSS) — Proposed TSS limitations
represent a transfer of technology from the Metal Finishing
industrial category. The rationale for transferring technology
from this industry is (1) the raw waste TSS concentrations are
similar to those found in luminescent materials wastes, and (2)
the treatment technology used for solids reduction in the metal
finishing industry is the same as that proposed for luminescent
materials.
The average concentration of 18.2 milligrams per liter was
derived from EPA sampling data from numerous metal finishing
practicing solids removal by clarification technology. Excluded
from the data base were plants with improperly operated treatment
systems. The variability factors each represent the median of
variability factors from 17 metal finishing plants with long-term
monitoring data.
8.2.2 Pretreatment Standards for New Sources (PSNS)
Pollutant
Cadmium
Antimony
Zinc
Fluoride
Long Term
Average
XLTA)
(mg/1)
0.
0.
0.
20.
20
03
47
5
Monthly
Average
VF Limit (mg/1)
1
1
1
1
.15
.45
.45
.09
0.
0.
0.
22.
23
044
68
3
Daily Maximum
VF Limit (mg/1)
2.
6.
6.
1 .
42
05
05
59
0
0
2
32
.48
.18
.84
.6
For PSES, the Agency is proposing limitations based on Option 2,
neutralization and end-of-pipe precipitation/clarification for
control of toxic metals and fluoride. Option 1 was not selected
because it will not control toxic metals or fluoride.
Proposed PSNS limitations for luminescent materials producers are
the same as those proposed for NSPS except that pH and TSS are
not regulated for pretreatment. The basis for limitations were
presented in Section 8.2.1.
8-6
-------
SECTION 9
COST OF WASTEWATER TREATMENT AND CONTROL
This section presents estimates of the costs of implementation of
wastewater treatment and control systems for the Cathode Ray Tube
and Luminescent Materials subcategories of the Electrical and
Electronic Components category. The systems for which cost
estimates are presented are those options identified in Section
7. The cost estimates then provide the basis for possible
economic impact of regulation on the industry. The general
approach or methodology for cost estimating is presented below
followed by the treatment and control costs.
9.1 COST ESTIMATING METHODOLOGY
Costs involved in setting up and operating a wastewater treatment
unit are comprised of investment costs for construction,
equipment, engineering design, and land, and operating costs for
energy, labor, and chemicals. There are also costs for disposing
of sludge and for routine analysis of the treated effluent.
The costs presented in this section are based on model plants
which closely resemble the types and capacities of waste
treatment facilities needed for each product subcategory. Model
plants are not set up as exemplary plants, but as typical of
sufficient design to represent the range of plants and treatment
facilities present in the industry. Data are based on plant
visits and contacts with industries to verify treatment
practices and to obtain data on size, wastewater flow, and solid
waste disposal systems. The differences in treatment capacities
are reflected in the choice of model plants which are presented
for different flow rates covering the existing range of flows at
average concentrations of pollutants.
Unit process equipment costs were assembled from vendors and
other commercial sources. Information on the costs of equipment,
the present costs of chemicals and average costs for hauling
sludge was developed with data from industry, engineering firms,
and equipment suppliers. Appropriate factors were applied to
determine total investment costs and annual costs.
The costs which will actually be incurred by an individual plant
may be more or less than presented in the cost estimate. The
major variations in treatment costs between plants result from
differences in pollutant concentrations and site dependent
conditions, as reflected in piping lengths, climate, land
availability, water and power supply and the location of the
point of final discharge. In addition, solids disposal costs and
material costs will vary depending on geographical locations.
9-1
-------
The following assumptions were employed in the cost development:
1. All non-contact cooling water was excluded from
treatment and treatment costs.
2. Source water treatment, cooling tower and boiler
blowdown discharges were not considered process
wastewater.
3. Sanitary sewage flow is excluded.
4. The treatment facilities- were assumed to operate 24-
hours per day five days per week.
5. Excluded from the estimates were any costs associated
with permits, reports or hearings required by regulatory
agencies.
Investment costs are expressed in mid-year 1982 dollars to
construct facilities at various wastewater flow rates.
Operation, maintenance, and amortization of the investment are
expressed as base level annual costs.
9.1.1 Direct Investment Costs for Land and Facilities
Types of direct investment costs for waste treatment facilities
and criteria for estimating major components of the model plants
are presented below.
Construction Costs — Construction costs include site
preparation, grading, enclosures, buildings, foundations,
earthworks, roads, paving, and concrete. Since few if any
buildings will be utilized, construction costs have been
calculated using a factor of 1.15 applied to the installed
equipment cost.
Equipment Cost — Equipment for wastewater treatment consists of
a combination of items such as pumps, chemical feed systems,
agitators, flocculant feed systems, tanks, clarifiers and
thickeners. Cost tables for these items were developed from
vendor's quotations for a range of sizes, capacities and motor
horsepowers. Except for large size tanks and chemical storage
bins, the cost represents packaged, factory-assembled units.
Critical equipment is assumed to be installed in a weatherproof
structure. Chemical storage feeders and feedback controls
include such items as probes, transmitters, valves, dust filters
and accessories. Critical pumps are furnished in duplicate as a
duty and a spare, each capable of handling the entire flow.
Installation Costs (included in equipment-in-place costs) —
Installation is defined to include all services, activities, and
miscellaneous material necessary to implement the described
9-2
-------
wastewater treatment and control system, including piping,
fittings, and electrical work. Many factors can impact the cost
of installing equipment modules. These include wage rates,
manpower availability,- who does the,job (outside contractor or
regular employees), new construction versus modification of
existing systems, and site-dependent conditions (e.g., the
availability of sufficient electrical service). In these
estimates, installation costs were chosen for each model based
upon average site conditions taking into consideration the
complexity of the system being installed. An appropriate cost is
allowed for interconnecting piping, power circuits and controls.
Monitoring Equipment — It is assumed that monitoring equipment
will be installed at the treated effluent discharge point. It
will consist of an indicating, integrating, and recording type
flow meter, pH meter, sensor, recorder, alarms, controls and an
automatic sampler.
Land — Land availability and cost of land can vary
significantly, depending upon geographical location, degree of
urbanization and the nature of adjacent development. Land for
waste treatment is assumed to be contiguous with the production
plant site. For the purpose of the report land is valued at
$24,000 per acre.
Investment Costs for Supporting Services — Engineering design
and inspection are typical services necessary to advance a
project from a concept to an operating system. Such services
broadly include laboratory and pilot plant work to establish
design parameters, site surveys to fix elevation and plant
layout, foundation and groundwater investigation, and operating
instructions, in addition to design plans, specifications and
inspection during construction. These costs, which vary with job
conditions, are often estimated as percentages of construction
costs, with typical ranges as follow: •
Preliminary survey and construction surveying
Soils and groundwater investigation
Laboratory and pilot process work
Engineering design and specifications
Inspection during construction
Operation and maintenance manual
1 to 2 %
1 to 2 %
2 to 4 %
7 to 12%
2 to
3 %
1 to 3
From these totals of 14 to 26 percent, a value of 17 percent of
equipment cost has been used in this study to represent the
engineering and design cost applied to model plant cost
estimates.
The Contractor's Fee and Contingency — These costs are usually
expressed as a percentage of in-place construction cost, includes
such general items as temporary utilities, small tools, field
office overhead and administrative expense. The contractor is
entitled to a reasonable profit on his activities and to the cost
9-3
-------
of interest on capital tied up during construction. Although not
all of the above cost will be incurred on every job, an
additional 50 percent of the in-place construction cost has been
used to cover related cost broadly described as contractor's
fees, incidentals, overhead, and contingencies.
9.1.2 Annual Costs
Operation and Maintenance Costs — Annual operation and
maintenance costs are described and calculated as follows:
Labor and Supervision Costs:
Personnel costs are based on an hourly rate of $20.00. This
includes fringe benefits and an allocated portion of costs for
management, administration and supervision. Personnel are
assigned for specific activities as required by the complexity of
the system, ranging from 1-8 hours per day.
Energy Costs:
Energy costs are based on the cost of $306.00 per horsepower
operating 24 hours per day and 350 days per year. For batch
processes appropriate adjustments were made to suit the
production schedule. The cost per horsepower year is computed as
follows:
Cy = 1.1 (0.745 HP x Hr. x Ckw)/(E x P)
where Cy « Cost per year
HP = Total Horsepower Rating of Motor (1 HP = 0.7457 kw)
E = Efficiency Factor (0.9)
P = Power Factor (1.00)
Hr. = Annual Operating Hours (350 x 24 = 8400)
Ckw « Cost per Kilowatt-Hour of Electricity ($0.040)
Note: The 1.1 factor in the equation represents allowance for
incidental energy used such as lighting, etc. It is assumed that
no other forms of energy are used in the waste treatment system.
Chemicals:
Prices for the chemicals were obtained from vendors and the
Chemical Marketing Reporter. Unit costs of common chemicals
delivered to the plant site are based on commercial grade of the
. strength or active ingredient percentage with prices as follows:
Lime (Calcium Hydroxide) Bulk
Sulfuric Acid
Flocculant
$54/Ton
'$84/Ton
$ 2/Lb
9-4
-------
Sodium Bisulfite
Soda Ash
Calcium Chloride
$0.32/Lb
$0.14/Lb
$0.24/Lb
Maintenance:
The annual cost of maintenance is estimated as ten percent (10%)
of the investment cost, excluding land.
Taxes and Insurance:
An annual provision of three percent of the total investment cost
has been included for taxes and insurance.
Residual Waste Disposal:
Sludge disposal costs can vary widely. Chief cost determinants
include the amount and type of waste. Off-site hauling and
disposal costs are taken as $50/ton for bulk hauling, with
appropriate increases for small quantities in steel containers.
Information available to the Agency indicates that the selected
technologies for controlling pollutants in this industry will not
result in hazardous wastes as defined by RCRA.
Monitoring, Analysis and Reporting:
The manpower requirements covered by the annual labor and
supervision costs include those activities associated with the
operation and maintenance of monitoring instruments, recorder and
automatic samplers as well as the taking of periodic grab
samples. Additional costs for analytical laboratory services
have been estimated for each subcategory assuming that sampling
takes place three times a week at the point of discharge. A cost
of $7500/year has been used for monitoring analyses and
reporting.
Amortization:
Amortization of capital costs (investment costs) are computed as
follows:
CA = B (r(lt-r)ZQn)/(.(l+r)ZQn -1)
where CA = Annual Cost
B = Initial amount invested excluding cost of land
r = Annual interest rate (assumed 13 percent)
n = Useful life in years
9-5
-------
The multiplier for B in equation (1) is often referred to as the
capital recovery factor and is 0.2843 for the assumed overall
useful life of 5 years. No residual or sludge value is assumed.
9.1.3 Items not Included i.n Cost Estimate
Although specific 'plants may encounter extremes of climate, flood
hazards and lack of water, the cost of model plants have been
estimated for average conditions of temperature, drainage and
natural resources. It is assumed that any necessary site
drainage, roads, water development, security, environmental
studies and permit costs are already included in production
facilities costss. Therefore, the model costs are only for
facilities, suppliers and services directly related to the
treatment and disposal of waterborne wastes, including land
needed for treatment and on-site sludge disposal. Air pollution
control equipment is not included, except for dust collectors
associated with treatment, chemical transfer and feeding. Raw
wastes from various sources are assumed to be delivered to the
treatment facility at sufficient head to fill the influent
equalization basin, and final effluent is discharged by gravity.
Cost of pumps, pipes, lines etc., necessary to deliver raw
wastewater to the treatment plant or to deliver the treated
effluent to the point of discharge are not included in the cost
estimates.
9.2 COST ESTIMATES FOR TREATMENT AND CONTROL OPTIONS
9.2.1 Cathode Ray Tube Subcateqory
Option 1 treatment is defined as neutralization for pH control.
Minimal, if any, costs are associated with this option. All
plants in the data base currently practice neutralization of
their effluent.
Option 2 treatment is
addition of: chromium
clarification of all
dewatering. The capital
presented in Table 9-
flows reflects the range
subcategory. Figure 9
versus plant wastewater
defined as Option 1 treatment with the
reduction; chemical precipitation and
metals-bearing wastes; and sludge
and annual costs for this option are
1. The range of model plant wastewater
of flows that currently exist in the
-1 graphically presents the annual costs
flow for this option.
Option 3 capital and annual costs for adding multi-media
filtration to Option 2 treatment are presented in Table 9-2.
Figure 9-2 graphically presents the annual costs versus plant
wastewater flow for this option. The costs are incremental and
therefore only reflect the additional costs of adding filtration
technology end-of-pipe.
Option 4 is defined as solvent management, segregation and
collection of solvents for resale or contractor disposal. The
9-6
-------
collection of waste solvents
practiced in this industry.
for resale or disposal is widely
9.2.2 Luminescent Materials Subcategory
Option 1 treatment is defined as neutralization for pH control.
This option is currently practiced by both direct dischargers.
Therefore no costs are associated with this option.
Option 2 treatment is defined as Option 1 treatment with the
addition of chemical precipitation and clarification of all
metals-bearing wastes, and sludge .dewatering. All but one
luminescent materials manufacturing plant are currently
practicing Option 2 technology or its equivalent. Model plant
costs for this option were therefore not developed. The costs to
install Option 2 treatment at the one facility were developed
specifically for that 25,000 gpd plant. The capital investment
cost is $93,400; the annual cost is $57,500.
Option 3 capital and annual costs for adding filtration to Option
2 treatment are presented in Table 9-2 and Figure 9-2. These
model costs are the same as the costs developed for the Cathode
Ray Tube subcategory.
9.3 ENERGY AND NON-WATER QUALITY ASPECTS
Compliance with the proposed regulations will have no effect on
air, noise, or radiation pollution and will only result in
minimal energy usage. The amount of solid waste generated will
be approximately 1200 metric tons per year. It has not been
determined whether the solid wastes generated at CRT and
luminescent materials manufacturing plants are hazardous as
defined in the Resource Conservation and Recovery Act (RCRA).
However, it is believed that further testing will find the waste
to be nonhazardous. Energy requirements associated with these
regulations will be 24,000 kilowatt-hours per year or only 6.4
kilowatt-hours per day per facility. Based on the above non-
water quality impacts from these regulations, EPA has concluded
that the proposed regulations best serve overall national
environmental goals.
9-7
-------
TABLE 9-1
OPTION 2 TREATMENT COSTS
PLOW
A. INVESTMENT COSTS
10,000
GPD
Construction 7,080
Equipment in place
including piping,
fittings, electrical
work and controls... 78,588
Monitoring equipment
in place 6,000
Engineering Design
and inspection 2,950
Incidentals, overhead,
fees, contigencies.. 4,720
Land 6,000
TOTAL INVESTMENT COST 105,338
B. OPERATION AND
MAINTENANCE COST
Labor and supervision 10,000
Energy 180
Chemicals 1,220
Maintenance 9,950
Taxes and insurance. 3,160
Residual waste
disposal 1,550
Monitoring, analysis
and reporting 7,500
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
33,560
28,240
61,800
50,000
GPD
15,000
170,000
6,000
11,000
92,000
6,000
300,000
25,000
900
6,000
29,000
9,000
5,000
7,500
82,400
83,600
166,000
100,000
GPD
37,000
410,000
6,000
26,500
205,000
6,000
690,500
30,000
1,900
12,800
68,450
20,850
11,000
7,500
183,800
194,600
378,400
9-8
-------
TABLE 9-1 continued
OPTION 2 TREATMENT COSTS
FLOW
A. INVESTMENT COSTS
200,000
GPD
500,000
GPD
Construction 61,000 82,000
Equipment in place
including piping,
fittings, electrical
work and controls... 680,000 915,000
Monitoring equipment
in place 6,000 6,000
Engineering Design
and inspection 43,000 60,000
Incidentals, overhead,
fees, contigencies.. 370,000 498,000
Land 6,000 6,000
TOTAL INVESTMENT COST 1,166,000 1,567,000
B. OPERATION AND
MAINTENANCE COST
Labor and supervision 40,000 40,000
Energy 3,000 9,000
Chemicals 24,000 60,000
Maintenance 116,000 156,000
Taxes and insurance. 35,000 47,000
Residual waste
disposal 22,000 58,000
Monitoring, analysis
and reporting 7,500 7,500
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
247,500
331,500
579,000
377,500
445,500
823,000
9-9
-------
OJ
o
Annual Cost ($/1000)
en
O
_2 i
o
JL
I
o
?
U)
o
U1
o-
i
I-1
o
o
o
o-
o
to
s-
9-10
-------
TABLE 9-2
OPTION 3 TREATMENT COSTS
FLOW
10,000
GPD
50,000
GPD
100,000
GPD
A. INVESTMENT COSTS
Construction
Equipment in place
including piping,
fittings, electrical
work and controls...
Monitoring equipment
in place
Engineering Design
and inspection
Incidentals, overhead,
fees, contigencies..
Land
TOTAL INVESTMENT COST
B. OPERATION AND
MAINTENANCE COST
Labor and supervision
Energy
Chemicals
Maintenance
Taxes and insurance.
Residual waste
disposal
Monitoring, analysis
and reporting.
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
400
4,500
270
5,170
500
150
650
1,470
2,120
1,000
7,000
4,000
12,000
1,200
400
1,600
3,500
5,100
4,000
26,250
13,000
43,250
4,300
1,300
5,600
12,300
17,900
9-11
-------
TABLE 9-2 continued
OPTION 3 TREATMENT COSTS
FLOW
200,000
GPD
500,000
GPD
A. INVESTMENT COSTS
Construction 7,000 14,000
Equipment in place
including piping,
fittings, electrical
work and controls... 48,000 96,000
Monitoring equipment
in place - -
Engineering Design
and inspection - -
Incidentals, overhead,
fees, contigencies.. 27,500 55,000
Land - -
TOTAL INVESTMENT COST 82,500 165,000
B. OPERATION AND
MAINTENANCE COST
Labor and supervision - -
Energy - -
Chemicals - -
Maintenance 8,300 16,500
Taxes and insurance. 2,500 5,000
Residual waste
disposal - -
Monitoring, analysis
and reporting - -
TOTAL OPERATION AND
MAINTENANCE COST
AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
10,800
23,500
34,300
21,500
47,000
68,500
9-12
-------
Annual Cost ($/1000)
H. to
1° i F i
Ul
p
cr>
o
Ln
O-
1-1
o
o
o
10
o
o~
9-13
-------
-------
SECTION 10
ACKNOWLEDGEMENTS
The Environmental Protection Agency was aided in the preparation
of this Development Document by Jacobs Engineering Group Inc.
Jacobs' effort was managed by Ms. Bonnie Parrott. Major
contributions were made by Mr. Thomas Schaffer, Mr. Robert
Mueller, and Ms. Suzanne Phinney.
Mr. John Newbrough of EPA's Effluent Guidelines Division served
as Project Officer during the preparation of this document. Mr.
Jeffrey Denit, Director, Effluent Guidelines Division, and Mr.
Gary E. Stigall, Branch Chief, Effluent Guidelines Division,
Inorganic Chemicals Branch, offered guidance and suggestions
during this project.
Finally, appreciation is extended to the plants that participated
in and contributed data for the formulation of this document.
10-1
-------
-------
SECTION 11
BIBLIOGRAPHY
Amick, Charles L., Fluorescent Lighting Manual, McGraw-Hill, 3rd
ed., (1961).
Bogle, W.S., Device Development, The Western Electric Engineer,
(July, 1973).
Buchsbaum, Walter H., Fundamentals of Television, 2nd ed., Hayden
Book Co., (1974).
Cockrell, W.D., Industrial Electronics Handbook, McGraw-Hill
(1958).
Elenbaas, W., Fluorescent Lamps and Lighting, (1959).
The New Encyclopedia Americana, International Edition, Grolier
Inc. Vol. 10pp. 179-184 (1982).
Forsythe, William, E., Fluorescent and Other Gaseous Discharge
Lamps, 1948).
Gray, H.J., Dictionary of Physics, Longmans, Green and Co.,
London (1958).
Hall, Edwin, "Flat Panels Challenge CRTs for Large-Area
Displays," Electronic Design, pp. 61-68., May 28, 1981.
Helwig, Jane T. and Council, Kathryn A., SAS Users Guide, SAS
Institute IAC (1979).
Hewitt, Harry, Lamps and Lighting, American Elsevier Publishing
Co. (1966).
Hickey, Henry V. and Villings, William M., Elements of.
Electronics, 3rd ed., McGraw-Hill, (1970).
Henney, K. and Walsh, C., Eds., Electronic Components Handbook,
McGraw-Hill (1975).
IEEE Standards Committee, IEEE, Standard Dictionary of. Electrical
and Electronic Terms, J. Wiley and Sons (Oct., 1971).
Illuminating Engineering Society, IBS Lighting Handbook, 3rd ed.,
(1962).
Kirk and Othmer, Encyclopedia of. Chemical Technology,
Interscience, 2nd ed., Vol. 8, pp. 1-23, (1967).
11-1
-------
Kirk and Othmer, Encyclopedia of Chemical Technology
Interscience, 2nd ed., Vol. 12, ppT 616-631, (19677! ^^
McGraw-Sili f?968)?P6dia ~ ChemiCal Techn°l°™- Volume 17,
-tionary of Scientific and Technical Terms, 2nd
McGraw-Hill, Encyclopedia of Science and Technology. McGraw-Hill
\ I you i, ——________.__
Probability and Statistical
-Wesley Publishing Company,2nded77
for
The NSE Encyclopedia Britannica. Wilbur Denton Publish., Vol. 6,
pp .oo/ — 691.
Simon and Schuster, The Way Things Work, An Illustrated
Encyclopedia of Technology. Simon and SchHs"ter~( 1 967 )
Upton, Monroe, Inside Electronics. Devin-Adair Co. (1964).
U.S. Government Public Law 94-469, Toxic Substances Control Act,
\ we t . II, 19/6). ————— _____
Warring, R.H., Understanding Electronics. TAB Boooks (1978).
New Collegiate Dictionary. G & C Merriam Co.
/ f?974)d H
-------
SECTION 12
GLOSSARY
Absorb - To take up matter or radiation.
Act - Federal Water Pollution Control Act.
Activate - To treat the cathode or target of an electron tube in
order to create or increase the emission of electrons.
Adlustable Capacitor - A device capable of holding an electrical
charge at any one of several discrete values.
Adsorption - The adhesion of an extremely thin layer of molecules
(of— gas, liquid) to the surface of solids (granular
activated carbon for instance) or liquids with which they
are in contact.
Aging - Storage of a permanent magnet, capacitor, meter or other,
—device (sometimes with a voltage applied) until the
characteristics of the device become essentially constant.
Alqicide - Chemicals used to retard the growth of phytoplankton
(algae) in bodies of water. ,
Aluminum Foil - Aluminum in the form of a sheet of thickness not
exceeding 0.005 inch.
Anneal - To treat a metal, alloy, or glass by a process of
heating and slow cooling in order to remove internal
stresses and to make the material less brittle.
Anode - The collector of electrons in an electron tube. Also
known as plate; positive electrode.
Anodizing - An electrochemical process of controlled aluminum
oxidation producing a hard, transparent oxide up to several
mils in thickness.
Assembly or Mechanical Attachment - The fitting together of pre-
viously manufactured parts or components into a complete
machine, unit of a machine, or structure.
Autotransformer - A power transformer having one continuous wind-
ing that is tapped; part of the winding serves as the
primary coil and all of it serves as the secondary coil, or
vice versa.
12-1
-------
Ballast - A circuit element that serves to limit an electric
current or to provide a starting voltage, as in certain
types of lamps/ such as in fluorescent ceiling fixtures.
Binder - A material used to promote cohesion between particles of
carbon or graphite to produce solid carbon and graphite rods
or pieces.
Biochemical Oxygen Demand - (1) The quantity of oxygen used in
the biochemical oxidation of organic matter in a specified
time, at a specified temperature, and under specified
conditions. (2) Standard test used in assessing wastewater
quality.
Biodegradable - The part of organic1 matter which can be oxidized
by bioprocesses, e.g., biodegradable detergents, food
wastes, animal manure, etc.
Biological Wastewater Treatment - Forms of wastewater treatment
in which bacteria or biochemical action is intensified to
stabilize, oxidize, and nitrify the unstable organic matter
present. Intermittent sand filters, contact beds, trickling
filters, and activated sludge processes are examples.
Breakdown Voltage - Voltage at which a discharge occurs between
two electrodes.
BjjJLb - The glass envelope which incloses an incandescent lamp
an electronic tube.
or
Busbar ~ A heavy rigid, metallic conductor, usually uninsulated,
used to carry a large current or to make a common connection
between several curcuits.
Bushing - An insulating structure including a central conductor,
or providing a central passage for a conductor, with
provision for mounting on a barrier (conducting or
otherwise), for the purpose of insulating the conductor from
the barrier and conducting current from one side of the
barrier to the other.
Calcining - To heat to a high temperature without melting or
fusing, as to heat unformed ceramic materials in a kiln, or
to heat ores, precipitates, concentrates or residues so that
hydrates, carbonates or other compounds are decomposed and
volatile material is expelled, e.g., to heat limestone to
make lime.
Calibration - The determination, checking, or correction of the
graduation of any instrument giving quantitative
measurements.
12-2
-------
Capacitance - The ratio of the charge on one of the plates of a
capacitor to the potential difference between the plates.
Capacitor - An electrical circuit element used to store charge
temporarily, consisting in general of two conducting
materials separated by a dielectric materials.
Carbon - A nonmetallic, chiefly tetravalent element found native
or as a constituent of coal, petroleum, asphalt, limestone,
etc.
Cathode - The primary source of electrons in an electron tube; in
directly heated tubes the filament is the cathode, and in
indirectly heated tubes a coated metal cathode surrounds a
heater.
Cathode Ray Tube - Anelectron-beam tube in which the beam can be
focussed to a small crosss section on a luminescent screen
and varied in position and intensity to produce a visible
pattern.
Central Treatment Facility - Treatment plant which co-treats
processwastewaters from more than one manufacturing
operation or co-treats process wastewaters with noncontact
cooling water or with non-process wastewaters (e.g., utility
blow-down, miscellaneous runoff, etc.).
Centrifuge - The removal of water in a sludge and water slurry by
introducing the water and sludge slurry into a centrifuge.
The sludge is driven outward with the water remaining near
the center. The dewatered sludge is usually landfilled.
Ceramic - A product made by the baking or firing of a nonmetallic
"mineral such as tile, cement, plaster, refractories, and
brick.
Chemical Coagulation - The destabilization and initial
aggregation of colloidal and finely divided suspended matter
by the addition of a floe-forming chemical.
Chemical Oxidation - The addition of chemical agents to
wastewater for the purpose of oxidizing pollutant material,
e.g., removal of cyanide.
Chemical Oxygen.Demand (COD) - (1) A test based on the fact that
all organic compounds, with few exceptions, can be oxidized
to carbon dioxide and water by the action of strong
oxidizing agents under acid conditions. Organic matter is
converted to carbon dioxide and water regardless of the
biological assimilability of the substances. One of the
chief limitations is its inability to differentiate between
biologically oxidizable and biologically inert organic
matter. The major advantage of this test is the short time
12-3
-------
required for evaluation (2 hours). (2) The amount of oxygen
required for the chemical oxidation of organics in a liquid.
Chemical Precipitation - (1) Formation of insoluble materials
generated by addition of chemicals to a solution. (2) The
process of softening water by the addition of lime and soda
ash as the precipitants.
Chlorination - The application of chlorine to water or wastewater
generally for the purpose of disinfection, but frequently
for accomplishing other biological or chemical results.
Circuit Breaker - Device capable of making, carrying, and
breaking currents under normal or abnormal circuit
conditions.
Cleaning - The removal of soil and dirt (including grit and
grease) from a workpiece using water with or without a
detergent or other dispersing agent.
Coil 7 A number of furns of wire used to introduce inductance
into an electric circuit, to produce magnetic flux, or to
react mechanically to a changing magnetic flux.
Coil-Core Assembly - A unit made up of the coil
transformer placed over the magnetic core.
windings of a
Coking - (1) Destructive distillation of coal to make coke. (2)
A process for thermally converting the heavy residual
bottoms of crude oil entirely to lower-boiling petroleum
products and by-product petroleum coke.
Colloids - A finely divided dispersion of one material called the
'dispersed phase" (solid) in another material called the
"dispersion medium" (liquid). Normally negatively charged.
Composite Wastewater Sample - A combination of individual samples
of water or wastewater taken at selected intervals and mixed
in proportion to flow or time to minimize the effect of the
variability of an individual sample.
Concentric Windings - Transformer windings in which the low-
voltage winding is in the form of a cylinder next to the
core, and the high-voltage winding, also cylindrical,
surrounds the lowvoltage winding.
Conductor - A wire, cable, or other body or medium suitable for
carrying electric current.
Conduit - Tubing of flexible metal or other
which insulated electric wires are run.
material through
12-4
-------
Contamination - A general term signifying the introduction into
water of microorganisms, chemicals, wastes or sewage which
renders the water unfit for its intended use.
Contractor Removal - The disposal of oils, spent solutions, or
sludge by means of a scavenger service.
Conversion Coating - As metal-surface coating consisting of
compound of the base metal.
Cooling Tower - A device used to cool manufacturing process water
before returning the water for reuse.
Copper - A common, reddish, chiefly univalent and bivalent
metallic element that is ductile and malleable and one of
the best conductors of heat and electricity.
Core (Magnetic Core) - A quantity of ferrous material placed in a
coil or transformer to provide a better path than air for
magnetic flux, thereby increasing the inductance of the coil
or increasing the coupling between the windings of a
transformer.
Corona Discharge - A discharge of electricity appearing as a
bluishpurple glow on the surface of an adjacent to a
conductor when the voltage gradient exceeds a certain
critical value; caused by ionization of the surrounding air
by the high voltage.
Curing - A heating/drying process carried out in an elevated-
temperature enclosure.
Current Carrying Capacity - The maximum current that can be
continuously carried without causing permanent deterioration
of electrical or mechanical properties of a device or
conductor.
Dag (Aauadag) - A conductive graphite coating on the inner and
outer side walls of some cathode-ray tubes.
Decreasing - The process of removing grease and oil from the
surface of the basis material. ,
Dewatering - A process in which water is removed from sludge.
•Dicing - Sawing or otherwise machining a semiconductor wafer into
small squares or dice from which transistors and diodes can
be fabricated.
Die - A tool or mold used to cut shapes to or form impressions on
materials such as metals and ceramics.
12-5
-------
Cutting (Also Blanking) - Cutting of plastic or metal sheets
into shapes by striking with a punch.
the
Dielectric - A material that is highly resistant to
conductance of electricity; an insulator.
Dl-n-octyl-phthalate - A liquid dielectric that is presently
being substituted for a PCB dielectric fluid.
Diode (Semiconductor). (Also Crystal Diode, Crystal Rectifier) -
A two-electrode semiconductor device that utilizesthe
rectifying properties of a p-n junction or point contact.
Discrete Device - Individually manufactured transistor, diode,
etc.
Dissolved Solids - Theoretically the anhydrous residues of the
dissolved constituents in water. Actually the term is
defined by the method used in determination. In water and
wastewater treatment, the Standard Methods ,tests are used.
Distribution Transformer - An element of an electric distribution
system located near consumers which changes primary
distribution voltage to a lower consumer voltage.
Dopant - An impurity element added to semiconductor materials
used in crystal diodes and transistors.
Dragout - The solution that adheres to the part of workpiece and
is carried past the edge of the tank.
Dry_ Electrolytic Capacitor - An electrolytic capacitor with a
paste rather than liquid electrolyte.
Drying Beds - Areas for dewatering of sludge by evaporation and
seepage.
Dry_ Slug - Usually refers to a plastic-encased sintered tantalum
slug type capacitor.
Drv Transformer - Having the core and coils neither impregnated
with an insulating fluid nor immersed in an insulating oil.
Effluent - The quantities, rates, and chemical, physical,
biological and other constituents of waters which are
discharged from point sources.
Electrochemical Machining - Shaping of an anode by the following
process: The anode and cathode are placed close together
and electrolyte is pumped into the space between them. An
electrical potential is applied to the electrodes causing
anode metal to be dissolved selectively, producing a shaped
anode that complements the shape of the cathode.
12-6
-------
Electrolyte - A nonmetallic electrical conductor in which current
is carried by the movement of ions.
Electron Beam Lithography - Similar to photolithography - A fine
beamof electrons is used to scan a pattern and expose an
electronsensitive resist in the unmasked areas of the object
surface.
Electron Discharge Lamp - An electron lamp in which light is
producedby passage of an electric current through a
metallic vapor or gas.
Electron Gun - An electrode structure that produces and may
control, focus, deflect and converge one or more electron
beams in an electron tube.
Electron Tube - An electron device in which conduction of
electricity is accomplished by electrons moving through a
vacuum of gaseous medium within a gas-tight envelope.
Electroplating - The production of a thin coating of one metal on
another by electrode position.
Emissive Coating - An oxide coating applied to an electrode to
enhance the emission of electrons.
Emulsion Breaking - Decreasing the stability of dispersion of one
liquid in another.
End-of-Pipe Treatment - The reduction and/or removal of.
pollutants by chemical treatment just prior to actual
discharge.
Epitaxial Layer - A (thin) semiconductor layer having the same
crystaline orientation as the substrate on which it is
grown.
Epitaxial Transistor - Transistor with one or more epitaxial
layers.
Equalization - The process whereby waste streams from different
sources varying in pH, chemical constituents, and flow rates
are collected in a common container. The effluent stream
from this equalization tank will have a fairly constant flow
and pH level, and will contain a homogeneous chemical
mixture. This tank will help to prevent unnecessary shock
to the waste treatment system.
Etch - To corrode the surface of a metal in order to
composition and structure.
reveal its
12-7
-------
Extrusion - Forcing the carbon-binder-mixture through a die under
extreme pressure to produce desireable shapes and
characteristics of the piece.
Field-effect Transistors - Transistors made by the metal-oxide-
semiconductor (MOS) technique, differing from bipolar ones
in that only one kind of charge carrier is active in a
single device. Those that employ electrons are called n-MOS
transistors; those that employ holes are p-MOS transistors.
Filament - (l) Metallic wire which is heated in an incandescent
lamp to produce light by passing an electron current through
it. (2) A cathode in a fluorescent lamp that emits
electrons when electric current is passed through it.
Filtering Capacitor - A capacitor used in a power-supply filter
system to provide a low-reactance path for alternating
currents and thereby suppress ripple currents, without
affecting direct currents.
Fixed Capacitor - A capacitor having a definite capacitance value
that cannot be adjusted.
Float Gauge - A device for measuring the elevation of the surface
of a liquid, the actuating element of which is a buoyant
float that rests on the surface of the liquid and rises or
falls with it. The elevation of the surface is measured bv
a chain or tape attached to the float.
Floe - A very fine, fluffy mass formed by the aggregation of fine
suspended particles.
Flocculation - In water and wastewater treatment, the
agglomeration of colloidal and finely divided suspended
matter after coagulation by gentle stirring by either
mechanical or ..hydraulic means. In biological wastewater
treatment where coagulation is not used, agglomeration may
be accomplished biologically.
Flocculator - An apparatus designed for the formation of floe in
water or sewage.
Flow-proportioned Sample - A sampled stream whose pollutants are
apportioned to contributing streams in proportion to the
flow rates of the contributing streams.
Fluorescent Lamp. - An electric discharge lamp in which phosphor
materials transform ultraviolet radiation from mercury vapor
lonization to visible light.
Formin? ~ Application of voltage to an electrolytic capacitor
electrolytic rectifier or semiconductor device to produce a
1-2-S
-------
desired permanent change in electrical characteristics as
part of the manufacturing process.
Frit Seal - A seal made by fusing together metallic powders with
a glass binder for such applications as hermatically sealing
ceramic packages for integrated circuits.
Funnel - The rear, funnel-shaped portion of the glass enclosure
of a cathode ray tube.
Fuse - Overcurrent protective device with a circuit-opening
fusible part that would be heated and severed by overcurrent
passage.
Gate - One of the electrodes in a field effect transistor.
Getter - A metal coating inside a lamp which is activated by an
electric current to absorb residual water vapor and oxygen.
Glass - A hard, amorphous, inorganic, usually transparent,
~ "brittle substance made by fusing silicates, and sometimes
borates and phosphates, with certain basic oxides and then
rapidly cooling to prevent crystallization.
Glow Lamp - An electronic device, containing at least two
electrodes and an inert gas, in which light is produced by a
cloud of electrons close to the negative electrode when a
voltage is applied between the electrodes.
Grab Sample - A single sample of wastewater taken at an "instant"
in time.
Graphite - A soft black lustrous carbon that conducts electricity
and is a constituent of coal, petroleum, asphalt, limestone,
etc.
Grease - In wastewater, a group of substances including fats,
waxes, free fatty acids, calcium and magnesium soaps,
mineral oil and certain other nonfatty materials. The type
of solvent and method used for extraction should be stated
for quantification.
Grease Skimmer - A device for removing grease or
surface of wastewater in a tank.
scum from the
Green Body - An unbaked carbon rod or piece that is usually soft
and quite easily broken.
Grid - An electrode located between the cathode and anode of an
electron tube, which has one or more openings through which
electrons or ions can pass, and which controls the flow of
electrons from cathode to anode.
12-9
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Grinding - The process of removing stock from a workpiece by the
use of abrasive grains held by a rigid or semi-rigid binder.
Hardness - A characteristic of water, imparted by calcium,
magnesium, and ion salts such as bicarbonates, carbonates,
sulfates, chlorides, and nitrates. These cause curdling of
soap, deposition of scale in boilers, damage in some
industrial processes and sometimes objectionable taste.
Hardness may be determined by a standard laboratory
procedure or computed from the amounts of calcium and
magnesium as well as iron, aluminum, manganese, barium,
strontium, and zinc, and is expressed as equivalent calcium
carbonate.
Heavy Metals - A genral name given to the ions of metallic
elements such as copper, zinc, chromium, and nickel. They
are normally removed from wastewater by an insoluble
precipitate (usually a metallic hydroxide).
Holding Tank - A reservoir to contain preparation materials so as
to be ready for immediate service.
Hybrid Integrated Circuits - A circuit that
and part discrete.
is part integrated
Impact Extrusion - A cold extrusion process for producing tubular
components by striking a slug of the metal, which has been
placed in the cavity of the die, with a punch moving at high
velocity.
of
Impregnate - To force a liquid substance into the spaces
porous solid in order to change its properties.
Incandescent Lamp - An electric lamp producing light in which a
metallic filament is heated white-hot in a vacuum by passage
of an electric current through it.
Industrial Wastes - The liquid wastes from industrial processes
as distinct from domestic or sanitary wastes.
Influent - Water or other liquid, either raw or partly treated,
flowing into a reservoir basin or treatment plant.
In-Process Control Technology - The regulation and conservation
of chemicals and rinse water at their point of use as
opposed to end-of-pipe treatment.
Insulating Paper - A standard material for insulating electrical
equipment, usually consisting of bond or kraft paper coated
with black or yellow insulating varnish on both sides.
Insulation (Electrical Insulation) - A material having high elec-
trical resistivity and therefore suitable for separating
12-10
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adjacent conductors in an electric circuit or preventing
possible future contact between conductors.
Insulator - A nonconducting support for an electric conductor.
Integrated Circuit
Assembly of electronic devices
interconnected into circuits.
Interleaved Winding - An arrangement of winding coils around a
transformer core in which the coils are wound in the form of
a disk, with a group of disks for the low-voltage windings
stacked alternately with a group of discks for the high-
voltage windings.
Intermittent Filter - A natural or artificial bed of sand or
other fine-grained material onto which sewage is
intermittently flooded and through which it passes, with
time allowed for filtration and the maintenance of aerobic
conditions.
Ion Exchange - A reversible chemical reaction between a solid
(ion exchanger) and a fluid (usually a water solution) by
means of which ions may be interchanged from one substance
to another. The superficial physical structure of the solid
is not affected.
Ion Exchange Resins - Synthetic resins containing active groups
(usually sulfonic, carboxylic, phenol, or substituted amino
groups) that give the resin the ability to combine with or
exchange ions with a solution.
Ion Implantation - A process of introducing impurities into the
near surface regions of solids by directing a beam of ions
at the solid.
Junction - A region of transition between two different
semiconducting regions in a semiconductor device such as a
p-n junction, or between a metal and a semiconductor.
Junction Box - A protective enclosure into which wires or
are led and connected to form joints.
cables
Knife Switch
Form of switch where moving blade enters
stationary contact clips.
Klystron - An evaculated electron-beam tube in which -an initial
velocity modulation imparted to electrons in the beam
results subsequently in density modulation of the beam; used
as an amplifier in the microwave region or as an oscillator.
Lagoon - A man-made pond or lake for holding wastewater for the
removal of suspended solids. Lagoons are also used as
retention ponds after chemical clarification to polish the
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effluent • and to safeguard against upsets in the clarifier;
for stabilization of organic matter by biological oxidation;
for storage of sludge; and for cooling of water.
Landfill - The disposal of inert, insoluble waste solids by
dumping at an approved site and covering with earth.
Lapping - The mechanical abrasion or surface planing of the
semiconductor wafer to produce desired surface and wafer
thickness.
Lime - Any of a family of chemicals consisting essentially of
calcium hydroxide made from limestone (calcite) which is
composed almost wholly of calcium carbonates or a mixture of
calcium and magnesium carbonates.
Limiting Orifice - A device that limits flow by constriction to a
relatively small area. A constant flow can be obtained over
a wide range of upstream pressures.
Machining - The process of removing stock from a workpiece by
forcing a cutting tool through the workpiece and removing a
chip of basis material. Machining operatings such as
tuning, milling, drilling, boring, tapping, planing,
broaching, sawing and cutoff, shaving, threading, reaming,
shaping, slotting, hobbing, filling, and chambering are
included in this definition.
Magnaflux Inspection - Trade name for magnetic particle test.
Make-up Water - Total amount of water used by any process/process
step.
Mandrel - A metal support serving as a core around which the
metals are wound and anealled to form a central hole.
Mask (Shadow Mask) - Thin sheet steel screen with thousands of
apertures through which electron beams pass to a color
picture tube screen. The color of an image depends on the
balance from each of three different electron beams passing
through the mask.
metal insulator
Metal Ox ide Semiconductor Device - A
semiconductor structure in which the insulating layer is an
oxide of the substrate material; for a silicon substrate,
the insulating layer is silicon dioxide (Si02).
Mica - A group of aluminum silicate minerals that are
characterized by their ability to split into thin, flexible
flakes because of their basal cleavage.
Miligrams Per Liter (mg/1 - This is a weight per
designation used in water and wastewater analysis.
volume
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Mixed Media Filtration - A filter which uses two or more filter
materials of differing specific gravities selected so as to
produce a filter uniformly graded from coarse to fine.
MOS - (See Metal Oxide Semiconductor).
Mount Assembly - Funnel
electron gun(s).
neck ending of picture tube holding
National Pollutant Discharge Elimination System (NPDES) - The
federal mechanism for regulating point source discharge by
means of permits.
Neutralization - Chemical addition of either acid or base to a
solution such that the pH is adjusted to approximately 7.
Noncontact Cooling Water - Water used for cooling which does not
come into direct contact with any raw material, intermediate
product, waste product or finished product.
Oil-Filled Capacitor - A capacitor whose conductor and insulating
elements are immersed in an insulating fluid that is
usually, but not necessarily, oil.
Outfall - The point or location where sewage or drainage
discharges from a sewer, drain, or conduit.
Oxide Mask - Oxidized layer of silicon wafer through which
"windows" are formed which will allow for dopants to be
introduced into the silicon.
Panel_ - The front, screen
"cathode ray tube.
portion of the glass enclusre of a
PCS (Polychlorinated Biphenyl) - A colorless liquid, used as an
insulating fluid in electrical equipment. (The future use
of PCB for new transformers was banned by the Toxic
Substances Control Act of October 1976).
p_H - The negative of the logarithm of the hydrogen ion
concentration. Neutral water has a pH value of 7. At pH
lower than 7, a solution is acidic. At pH higher than 7, a
solution is alkaline.
p_H Adjustment - A means of maintaining the optimum pH through the
use of chemical additives. Can be manual, automatic, or
automatic with flow corrections.
Phase - One of the separate circuits or windings of a polyphase
system, machine or other appartus.
Phase Assembly - The coil-core assembly of a single
transformer.
phase of a
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Phosphate Coating - A conversion coating on metal, usually steel,
produced by dipping it into a hot aqueous solution of iron,
zinc, or manganese phosphate.
Phosphor - Crystalline inorganic compounds
when excited by ultraviolet radiation.
that produce light
Photolithography - The process by which a microscopic pattern is
tranferred from a photomask to a material layer (e.g., Si02)
in an actual circuit.
Photomask - A
film or
images,
glass negative that has many high-
used in the production of semiconductor
resolution
devices and integrated circuits.
Photon - A quantum of electromagnetic energy.
Photoresist - A light-sensitive coating that is applied to a sub-
strate or board, exposed, and developed prior to chemical
etching; the exposed areas serve as a mask for selective
etching.
Picture Tube - A cathode ray tube used in television receivers to
produce an image by varying the electron beam intensity as
the beam scans a fluorescent screen.
Plate - (1) Preferably called the anode. The principal electrode
to which the electron stream is attracted in an electron
tube. (2-) One of the conductive electrodes in a capacitor.
Polar Capacitor - An electrolytic capacitor having an oxide film
on only one foil or electrode which forms the anode or
positive terminal.
Pole Type Transformer - A transformer suitable for mounting on a
pole or similar structure.
-,
Poling - A step in the production of ceramic piezoelectric bodies
which orients the oxes of the crystallites in the preferred
direction.
Polishing - The process of removing stock from a workpiece by the
action of loose or loosely held abrasive grains carried to
the workpiece by a flexible support. Usually, the amount of
stock removed in a polishing operation is only incidental to
achieving a desired surface finish or appearance.
Pollutant - The term "pollutant" means dredged spoil, solid
wastes, incinerator residue, sewage, grabage, sewage sludge,
munitions, chemical wastes, biological materials,
radioactive materials, heat, wrecked or discarded equipment,
rock, sand, cellar dirt and industrial, municipal and
agricultural waste discharged into water.
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Pollutant Parameters - Those constituents of wastewater
determined to be detrimental and, therefore, requiring
control.
Pollution Load - A measure of the unit mass of a wastewater in
terms of its solids or oxygen-demanding characteristics, or
in terms of harm to receiving waters.
Polyelectrolytes - Synthetic or natural polymers containing-ionic
constituents, used as a coagulant or a coagulant aid in
water and wastewater treatment.
Power Regulators - Transformers used to maintain constant output
current for changes in temperature output load, line current
and time.
Power Transformer - Transformer used at a generating station to
step up the initial voltage to high levels for transmission.
Prechlorination - (1) Chlorination of water prior to filtration.
(2) Chlorination of sewage prior to treatment.
Precipitate - The discrete particles of material settled
liquid solution.
from a
Pressure Filtration - The process of solid/liquid phase
separation effected by passing the more permeable liquid
phase through a mesh which is impenetrable to the solid
phase.
Pretreatment - Any wastewater treatment process used to reduce
pollution load partially before the wastewater is introduced
into a main sewer system or delivered to a treatment plant
for substantial reduction of the pollution load.
Primary Feeder Circuit (Substation) Transformers - These
transformers (at substations) are used to reduce the voltage
from the subtransmission level to the primary feeder level.
Primary Treatment - A process to remove substantially all
floating and settleable solids in wastewater and partially
to reduce the concentration of suspended solids.
Primary Winding - Winding on the supply (i.e., input) side of a
transformer.
Priority Pollutant - The 129 specific pollutants established by
the EPA from the 65 pollutants and classes of pollutants as
outlined in the consent decree of June 8, 1976.
Process Wastewater - Any water which, during manufacturing or
processing, comes into direct contact with or results from
12-15
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the production or use of any raw materials, intermediate
product, finished product, by-product, or waste product.
Process Water - Water prior to its direct contact use in a
process or operation. (This water may be any combination of
a raw water, service water, or either process wastewater or
treatment facility effluent to be recycled or reused.)
Pyrolysis - The breaking apart of complex molecules into simpler
units by the use of heat, as in the pyrolysis of heavy oil
to make gasoline.
Quenching - Shock cooling by immersion of liquid of molten
material in a cooling medium (liquid or gas). Used in
metallurgy, plastics forming, and petroleum refining.
Raceway - A
busbars.
channel used to hold and protect wires, cables or
Rapid Sandfilter - A filter for the purification of water where
water which has been previously treated, usually be
coagulation and sedimentation, is passed through a filtering
medium consisting of a layer of sand or prepared anthracite
coal or other suitable material, usually from 24 to 30
inches thick and resting on a supporting bed of gravel or a
porous medium such as carborundum. The filtrate is removed
by a drain system. The filter is cleaned periodically by
reversing the flow of the water through the filtering
medium. Sometimes supplemented by mechanical or air
agitation during backwashing to remove mud and other
impurities.
Raw Wastewater - Plant water prior to any treatment or use.
Rectifier - (1) A device for converting alternating current into
direct current. (2) a nonlinear circuit component that,
ideally, allows current to flow in one direction unimpeded
but allows no current to flow in the other direction.
Recycled Water - Process wastewater or treatment facility
effluent which is recirculated to the same process.
Resistor - A device designed to provide a definite amount of
resistance, used in circuits to limit current flow or to
. provide a voltage drop.
Retention Time - The time allowed for solids to collect in a
settling tank. Theoretically retention time is equal to the
volume of the tank divided by the flow rate. The actual
retention time is determined by the purpose of the tank.
Also, the design residence time in a tank or reaction vessel
which allows a chemical reaction to go to completion, such
12-16
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as the reduction of hexavalent chromium or
of cyanide.
the destruction
Reused Water - Process wastewater or^treatment facility effluent
which is further used in a different manufacturing process.
Rinse - Water for removal of dragout by dipping, spraying,
fogging etc.
;
Sanitary Sewer - A sewer that carriers liquid and water wastes
from residences, commercial buildings, industrial plants,
and institutions together with ground, storm, and surface
waters that are not admitted intentionally.
Sanitary Water - The supply of water used for sewage transport
and the continuation of such effluents to disposal.
Secondary Settling Tank - A tank through which effluent from some
prior treatment process flows for the purpose of removing
settleable solids.
Secondary Wastewater Treatment - The treatment of wastewater by
biological methods after primary treatment by sedimentation.
Secondary Winding
transformer.
- Winding on the load (i.e. output) side of a
Sedimentation - Settling of matter suspended in water by gravity.
It is usually accomplished by reducing the velocity of the
liquid below the point at which it can transport the
suspended material.
Semiconductor - A solid crystalline material whose electrical
conductivity is intermediate between that of a metal and an
insulator.
Settleable Solids - (1) That matter in wastewater which will not
stay in suspension during a preselected settling period,
such as one hour, but either settles to the bottom or floats
to the top. (2) In the Imhoff cone test, the volume of
matter that settles to the bottom of the cone in one hour.
Sewer - A pipe or conduit, generally closed, but normally not
flowing full, for carrying sewage and other waste liquids.
Silvering - The deposition of thin films of silver on glass, etc.
carried by one of several possible processes.
Skimming Tank - A tank so designed that floating matter will rise
and remain on the surface of the wastewater until removed,
while the liquid discharges continuously under walls or scum
boards.
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Sludge - The solids (and accompanying water and organic matter)
which are separated from sewage or industrial wastewater.
Sludge Cake - The material resulting- from air drying or
dewatering sludge (usually forkable or spadable).
Sludge Disposal - The final disposal of solid wastes.
Sludge Thickening - The increase in solids concentration of
sludge in a sedimentation or digestion tank.
Snubber - Shock absorber.
Soldering - The process of joining metals by flowing a thin
(capillary thickness) layer of nonferrous filler metal into
the space between them. Bonding results from the intimate
contact produced by the dissolution of a small amount of
base metal in the molten filler metal, without fusion of the
base metal.
Solvent - A liquid capable of dissolving or
more other substances.
dispersing one or
Solvent Degreasing - The removal of oils and grease from a
workpiece using organic solvents or solvent vapors.
Sputtering - A process to deposit a thin layer of metal on a
solid surface in a vacuum. Ions bombard a cathode which
emits the metal atoms.
Stacked Capacitor - Device containing multiple layers of
dielectric and conducting materials and designed to store
electrical charge.
Stamping - Almost any press operations including blanking,
shearing, hot or cold forming, drawing, blending, or
coining.
Steel - An iron-based alloy, malleable under
containing up to about 2% carbon.
proper conditions,
Transformers - (Substation) - A transformer in which
the AC voltages of the secondary windings are lower than
those applied to the primary windings.
Step-Up Transformer - Transformer in which the energy transfer is
from a low-voltage primary (input) winding to a high-voltage
secondary (output) winding or windings.
Studs - Metal pins
mask is hung.
in glass of picture tube onto which shadow
12-18
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Substation - Complete assemblage of plant, equipment, and the
necessary buildings at a place where electrical energy is
received {from one more power-stations) for conversion
(e.g., from AC to DC by means of rectifiers, rotary
converters), for stepping-up ': or down by means of
transformers, or for control (e.g. by means of switch-gear,
etc.).
Subtransmission (Substation) Transformers - At the end of a
transmission line, the voltage is reduced to the
subtransmission level (at substations) by subtransmission
transformers.
Suspended Solids - (1) Solids that are either floating or in
suspension in water, wastewater, or other liquids, and which
are largely removable by laboratory filtering. (2) The
quantity of material removed from wastewater in a laboratory
test, as prescribed in "Standard Methods for the Examination
of Water and Wastewater" and referred to as non-filterable
residue.
Tantalum - A lustrous, platinum-gray ductile metal used in making
dental and surgical tools, penpoints, and electronic
equipment.
Tantalum Foil - A thin sheet of tantalum, usually less than 0.006
inch thick.
Terminal - A screw, soldering lug, or other point to which
electric connections can be made.
Testing - A procedure in which the performance of
measured under various conditions.
product is
Thermoplastic Resin - A plastic that solidifies when first heated
under pressure, and which cannot be remelted or remolded
without destroying its original characteristics; examples
are epoxides, melamines, phenolics and ureas.
Transformer - A device used to transfer electric energy, usually
that of an alternating current, from one circuit to another;
especially, a pair of multiply-wound, inductively coupled
wire coils that effect such a transfer with a change in
voltage, current, phases, or other electric characteristics.
Transistor - An active component of an electronic circuit
consisting of a small block of semiconducting material to
which at least three electrical contacts are made; used as
an amplifier, detector, or switch.
Trickling Filter - A filter consisting of an artificial bed of
coarse material, such as broken stone, clinkers, slats, or
brush over which sewage is distributed and applied in drops,
12-19
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films, or spray, from troughs, drippers, moving distributors
or fixed nozzles and through which it trickles to the
underdrain giving opportunity for the formation of zoogleal
slimes which clarify the oxidized sewage.
Trimmer Capacitors - These are relatively small variable
capacitors used in parallel with larger variable or fixed
capacitors to permit exact adjustment of the capacitance of
the parallel combination.
Vacuum Filter - A filter consisting of a cylindrical drum mounted
on horizontal axis, covered with a filter cloth revolving
with a partial submergence in liquid. A vacuum is
maintained under the cloth for the larger part of a
revolution to extract moisture and the cake is scraped off
continuously.
Vacuum Metalizing - The process of coating a workpiece with metal
by flash heating metal vapor in a high-vacuum chamber
containing the workpiece. The vapor condenses on all
exposed surfaces.
Vacuum Tube - An electron tube vacuated to such a degree that its
electrical characteristics are essentially unaffected by the
presence of residual gas or vapor.
Variable Capacitor - A device whose capacitance can be varied
continuously by moving one set of metal plates with respect
to another.
Voltage Breakdown - The voltage
failture.
necessary to cause insulation
Voltage Regulator - Like a transformer, it corrects changes in
current to provide continuous, constant current flow.
Welding - The process of joining two or more pieces of material
by applying heat, pressure or both, with or without filler
material, to produce a localized union through fusion or
recrystallization across the interface.
Wet Air Scrubber - Air pollution control device which uses a
liquid or vapor to absorb contaminants and which produces a
wastewater stream.
Wet Capacitor - (See oil-filled capacitor).
Wet
Slug Capacitor - Refers
where the anode is placed in a metal
electrolyte and then sealed.
to a sintered tantalum capacitor
can, filled with an
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Wet Tantalum Capacitor - A polar capacitor the cathode of which
is a liquid electrolyte (a highly ionized acid or salt
solution).
Wet Transformer - Having the core and coils immersed in.an
insulating oil.
Yoke - A set of coils placed over the neck of a magnetically
deflected cathode-ray tube to deflect the electron beam
horizontally and vertically when suitable currents are
passed through the coils.
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