Development Document for Effluent Limitations Guidelines
and New Source Performance Standards for the
INSULATION FIBERGLASS
Manufacturing Segment
of the
Glass Manufacturing
Point Source Category
JANUARY 1974
\
? U.S. ENVIRONMENTAL PROTECTION AGENCY
Washington, D.C. 20460
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DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES
and
NEW SOURCE PERFORMANCE STANDARDS
for the
INSULATION FIBERGLASS
MANUFACTURING SEGMENT OF THE GLASS
MANUFACTURING POINT SOURCE CATEGORY
Russell E. Train
Administrator
Roger Strelow
Acting Assistant Administrator for Air S Water Programs
Allen Cywin
Director, Effluent Guidelines Division
Michael w. Kosakowski
Project Officer
January 1974
Effluent Guidelines Division
Office of Air and Water Programs
U.S.. Environmental Protection Agency
Washington, D. c, 20460
For sale by the Superintendent of Documents, XT.S. Government Printing Office, Washington, D.C. 2M02 - price $1.60
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ABSTRACT
This document presents the findings of an extensive in-house study of
the insulation fiberglass manufacturing segment of the glass
manufacturing category of point sources by the Environmental Protection
Agency for the purpose of developing effluent limitations guidelines and
Federal standards of performance for the industry to implement Sections
30U, 306 and 307 of the Federal Water Pollution Control Act, as amended
(33 U.S.C. 1251, 1314 and 1316, 86 Stat. 816 et.seg.) (the "Act").
Effluent limitations guidelines contained herein set forth the degree of
effluent reduction attainable through the application of the best
practicable control technology currently available and the degree of
effluent reduction attainable through the application of the best
available technology economically achievable which must be achieved by
existing point sources by July 1, 1977, and July 1, 1983, respectively.
The standards of performance for new sources contained herein set forth
the degree of effluent reduction which is achievable through the appli-
cation of the best available demonstrated control technology, processes,
operating methods, or other alternatives. The proposed regulations for
all three levels of technology set forth above establish the requirement
of no discharge of process waste water pollutants to navigable waters.
Exception is granted in the 1977 standard for discharges resulting from
advanced air emission control devices.
Supportive data and rationale for development of the proposed effluent
limitations guidelines and standards of performance are contained in
this report.
iii
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CONTENTS
Section
I Conclusions
II Recommendations
III Introduction
IV Industry Categorization
V Waste Characterization
VI Selection of Pollutant Parameters
VII Control and Treatment Technology
VIII Cost, Energy and Nonwater Quality Aspect
IX Effluent Reduction Attainable Through the
Application of the Best Practicable Control
Technology Currently Available — Effluent
Limitations Guidelines
X Effluent Reduction Attainable Through the
Application of the Best Available Technology
Economically Achievable — Effluent Limitations
Guidelines
XI New Source Performance Standards and Pretreatment
Standards
XII Acknowledgments
XIII Bibliography
XIV Glossary
1
3
5
25
29
47
A3
71
83
89
91
93
95
97
v
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FIGURES
I Flame Attenuation Process
II Rotary Spinning Process
III How Insulation Fiberglass Is Made
IV Wire Mesh Chain Cleaning
V Size Distribution of Insulation Fiberglass Plants
VI General Water Flow Diagram for an Insulation
Fiberglass Plant
VII Biological Treatment at Plant A
VIII Water Flow Diagram of Plant A
IX Schematic Diagram of Plant B
X Water Flow Diagram of Plant B
XI Water Flow Diagram of Plant D
XII Water Flow Diagram of Plant E
XIII Chain Cleaning at Plant E
XIV Water Flow Diagram of Plant F
XV Flow Chart for Plant G
XVI Investment Cost of Total Recycle Per Unit Production
XVII Annual Operating Costs of Total Recycle Per Unit Production
XVIII Energy Consumption of Total Recycle
8
9
10
19
24
30
48
53
56
57
59
62
63
65
67
77
78
82
VI
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TABLES
I Properties Related to Applications of Glass Fibers
II Chemical Compositions of Glasses Used To Form
Commercial Fibrous Glass
III Primary Fibrous Glass Wool Products
IV Fibrous Glass Mats-Basic Forms
V Fibrous Glass Packs-Basic Forms
VI U.S. Shipments and Value of Wool Glass Fiber
1964-1971
VII Insulation Fiberglass Plants
VIII Constituents of Insulation Fiberglass Plant Waste streams
IX Chain Wash Water Usage
X Raw Waste Loads for Insulation Fiberglass Plants
XI Annual Raw Waste Loads
XII Sieve Analysis on Waste Gullet Water
XIII Biological Treatment System at Plant A
XIV Water Pollution Abatement Status of Existing Primary
Insulation Fiberglass Plants
XV A Comparison between the Alternate Treatment and control
Technologies
XVI Water Pollution Abatement Costs for Total Recycle
XVII Estimated Cost of Waste Water Treatment for Insulation
Fiberglass Manufacture
XVIII Summary of capital and Operating Cost Effects;
Wool Glass Fiber
XIX Effects on Returns on Investment; Wool Glass Fiber
XX Metric Units Conversion Table
vii
page
12
13
15
16
17
21
23
31
32
33
34
36
49
51
72
73
75
76
79
102
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SECTION I
CONCLUSIONS
For the purpose of establishing effluent limitations guidelines and
standards of performance, the insulation fiberglass manufacturing
segment of the glass manufacturing category of point sources serves as a
single logical subcategory. Factors such as age, size of plant, process
employed, waste water constituents and waste control technologies do not
justify further segmentation of the industry.
Presently 7 of the 19 operating plants are employing or installing total
recirculation systems. It is concluded that the remainder of the
industry can achieve the requirement as set forth herein by July 1,
1977. The aggregate capital needed for achieving those limitations and
standards by all plants within the industry is estimated to be about $10
million assuming that there are presently no treatment facilities.
These costs could increase the capital investment in the industry 1.2 to
3.8 percent. As a result, the increased costs of insulation fiberglass
to compensate for pollution control requirements could range from 0.6 to
3.8 percent under present conditions. Achieving those limitations and
standards will result in complete elimination of all harmful substances
in the waste waters.
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SECTION II
RECOMMENDATIONS
No discharge of process waste water pollutants into navigable waters is
recommended as the effluent limitations guidelines and standards of
performance for the insulation fiberglass manufacturing segment of the
glass manufacturing category of point sources. This represents the
degree of effluent reduction obtainable by existing --'point sources
through the application of the best practicable control technology
currently available and the best available technology economically
achievable. This also represents, for new sources, a standard of
performance providing for the control of the discharge of pollutants
which reflects the greatest degree of effluent reduction achievable
through application of the best available demonstrated control tech-
nology, processes, operating methods, or other alternatives.
Because the addition of advanced air emission control systems may
increase the hydraulic and raw waste load to the point where these waste
waters cannot be evaporated on the product without process changes,
excess water used for these purposes must meet the following
requirements as best practicable control technology currently available:
Pollutant
characteristic
Phenols
COD
BOD5
TSS
Maximum for any
one day
kg/kkg (lb/1000 Ib)
of product
0.0006
0.33
0.024
0.03
Maximum average of
daily values for
any period of 30
consecutive days
kg/kkg (lb/1000 Ib)
of product
0.0003
0.165
0.012
0.015
pH
within the range 6.0 to 9.0
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SECTION III
INTRODUCTION
Purpose and Authority
Section 301 (b) of the Act requires the achievement by not later than
July 1, 1977, of effluent limitations for point sources, other than
publicly owned treatment works, which are based on the application of
the best practicable control technology currently available as defined
by the Administrator pursuant to Section 304 (b) of the Act. Section 301
(b) also requires the achievement by not later than July 1, 1983, of
effluent limitations for point sources, other than publicly owned
treatment works, which are based on the application of the best
available technology economically achievable which will result in
reasonable further progress toward the national goal of eliminating the
discharge of all pollutants, as determined in accordance with
regulations issued by the Administrator pursuant to Section 304 (b) of
the Act, section 306 of the Act requires the achievement by new sources
of a Federal standard of performance providing for the control of the
discharge of pollutants which reflects the greatest degree of effluent
reduction which the Administrator determines to be achievable through
the application of the best available demonstrated control technology,
processes, operating methods, or other alternatives, including where
practicable a standard permitting no discharge of pollutants*
Section 304 (b) of the Act requires the Administrator to publish within
one year of enactment of the Act regulations providing guidelines for
effluent limitations setting forth the degree of effluent reduction
attainable through the application of the best practicable control
technology currently available and the degree of effluent reduction
attainable through the application of the best control measures and
practices achievable including treatment techniques, process and
procedure innovations, operation methods and other alternatives. The
regulations proposed herein set forth effluent limitations guidelines
pursuant to section 304 (b) of the Act for the insulation fiberglass
subcategory of the glass manufacturing category of point sources.
Section 306 of the Act requires the Administrator, within one year after
a category of sources is included in a list published pursuant to
Section 306 (b) (1) (A) of the Act, to propose regulations establishing
Federal standards of performances for new sources within those
categories. The Administrator published in the Federal Register of
January 16, 1973 (38 F.R. 1624), a list of 27 source categories.
Publication of the list constituted announcement of the Administrator's
intention of establishing, under Section 306, standards of performance
applicable to new sources within the insulation fiberglass manufacturing
subcategory of the glass manufacturing category of point sources, which
was included in the list published January 16, 1973.
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Summary of Methods Used for Development of the Effluent, .timitatipns
Guidelines and Standards of Performance
The effluent limitations guidelines and standards of performance
proposed herein were developed in the following manner. The point
source category was first studied for the purpose of determining whether
separate limitations and standards are appropriate for different
segments within the category. This analysis included a determination of
whether differences in raw material used, product produced,
manufacturing process employed, age, size, waste water constituents and
other factors require development of separate limitations and standards
for different segments of the point source category. The raw waste
characteristics for each such segment were then identified. This
included an analysis of (1) the source, flow and volume of water used in
the process employed and the sources of waste and waste waters in the
plant and (2) the constituents (including thermal) of all waste waters,
including toxic constituents and other constituents which result in
taste, odor, and color in the water or aquatic organisms. The
constituents of the waste waters which should be subject to effluent
limitations guidelines and standards of performance were identified.
The full range of -control and treatment technologies existing within
each segment was identified. This included an identification of each
distinct control and treatment technology, including both in-plant and
end-of-process technologies, which is existent or capable of being
designed for each segment. It also included an identification of, in
terms of the amount of constituents (including thermal) and the
chemical, physical, and biological characteristics of pollutants, the
effluent level resulting from the application of each of the treatment
and control technologies. The problems, limitations and reliability of
each treatment and control technology and the required implementation
time were also identified. In addition, the non-water Duality
environmental impact, such as the effects of the application ec the
technologies upon other pollution problems, including air, solid v aste,
noise and radiation, was also identified. The energy require.:?nts of
each control and treatment technology were identified as well as the
cost of the application of such technologies.
The information outlined above was then evaluated in order to determine
what levels of technology constituted the "best practicable control
technology currently available," the "best available technology
economically achievable" and the "best available demonstrated control
technology, processes, operating methods, or other alternatives." In
identifying such technologies various factors were considered. These
included the total cost of application of technology in relation to the
effluent reduction benefits to be achieved from the application, the age
of equipment and facilities involved, the process employed, the
engineering aspects of the application of various types of control tech-
niques process changes, non-water quality environmental ir act
(including energy requirements) and other factors.
The data on which the above analysis was performed were derived from EPA
permit applications, EPA sampling and inspections, consultant reports
and industry submissions. Seven plants were inspected by the project
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officer. Three more were previously inspected by the EPA.
were discussed with the industry.
General Description of the Industry
All- plants
The industry covered by this document is the insulation fiberglass
manufacturing segment of the glass manufacturing source category. It
encompasses a part of Standard Industrial Classification 3296 in which
molten glass is either directly or indirectly made, continuously
fifcerized and chemically bonded into a wool-like insulating material.
The scope of this subcategory also includes those products, generally
referred to as insulation fiberglass by the industry, that are produced
by the same equipment and by the same techniques as thermal insulation.
These include, but are not limited to, noise insulation products, air
filters, and bulk wool products. This category will be referred to as a
primary process in contrast to a secondary operation in which waste
textile fiberglass is processed into an insulation product. Such
secondary operations are excluded because of their textile origin and
the difference in processing techniques. These secondary operations
usually do not use process water. Insulation fiberglass research and
development laboratories are also excluded in this report because the
range of such research includes textiles and a great diversity of
experimentation not necessarily related to insulation products. The
term insulation fiberglass is synonymous with the terms glass wool,
fibrous glass, and construction fiberglass.
The modern fiberglass industry was born in 1935 when the Owens Illinois
Glass Company and the Corning Glass Works combined their research
organizations, later forming Owens-Corning Fiberglas in 1938. The
original method of producing glass fibers is to allow molten glass to
fall through platinum bushings, forming continuous, relatively thick
threads of soft glass. The glass streams are then attenuated (drawn)
into thin fibers by high velocity gas burners or steam. This process,
generally referred to as flame attenuation, is pictured in Figure I.
In the 1950"s, Owens-Corning Fiberglas and the Cie de St. Gobain
perfected the centrifugal or rotary process, A single stream of molten
glass is fed into a rotating platinum basket which distributes the glass
on an outer rotating cylindrical spinner. The spinner contains a large
number of small holes arranged in rows in the wall. The molten glass is
forced through the holes forming fibers which are then attenuated 90°
from their forming direction by high velocity gas burners, air, or
steam, as depicted in Figure II. The output of a single spinner may
range from 0.23 to 0.45 metric tons per hour (500-1000 Ib/hr) and up to
5 or 6 spinners are used to feed fiber to one line.
Figure III depicts the basic insulation fiberglass processes. The flame
attenuation and rotary spinning processes have their own individual
merits. The flame attenuated product has greater longitudinal strength
because the fibers are attenuated in the same direction (away from the
gas or steam blower) and the lengths consequently align in one direction
to give added tensile strength in that direction. This property results
in decreased damage to the product upon installation. Rotary spun
fibers, on the other hand, are attenuated as they form on the
circumference of a rotating disk. The fiber lengths thus assume random
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FIGURE I
FLAME ATTENUATION PROCESS
FLAME OR STEAM
ATTENUATION
DOWNWARD DRAFT
OF AIR
MOLTEN GLASS
STREAM
HOLES
*"^ PLATINUM BUSHING
GLASS FIBERS
MAT
WIRE MESH CHAIN OR FLIGHT CONVEYOR
<•
o)
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FIGURE II
ROTARY SPINNING PROCESS
DOWNWARD DRAFT
OF AIR
MOLTEN GLASS
ATTENUATION
AIR
ASSEMBLY CAN SWING
BACK AND FORTH FOR
EVEN DISTRIBUTION
OF FIBERS
HOOD WALL
SPRAY NOZZLE
ROTATING SPINNER
HOLE ON
CYLINDRICAL WALL
HOOD WALL
OVERSPRAY RING
BINDER SPRAY RING
COATED FIBERS
FALL TO CHAIN
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FIGURE III
HOW INSULATION FIBERGLASS IS MADE
Li-
e-LAS S MELTING &
REFINING TANK
MARBLES
OOOOOOOGOOOOOOOOOOOOO&
MARBLE
REMELT
BINDER
JL>
GLASS MELTING
& REFINING TANK
GLASS MELTING
& REFINING TANK
GLASS MELTING
& REFINING TAN
STEAM BLOWER
STEAM BLOWER
FORMING
AIR BLOWER
FORMING
COMPRESS
AND CURE
COMPRESS
AND CURE
PACK OR
FABRICATE
(UNBONDED)
MARBLE
FORMING
ROLLS
PACK &
FABRICATE
CENTRIFUGE
FORMING
CURING
OVEN
PACK OR
FABRICATE
CURING
OVEN
PACK OR
FABRICATE
(UNBONDED)
PACK OR
FABRICATE
CURING OVEN
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directions as they fall. Standard building insulation produced by the
flame attenuated process generally uses less fiber (approximately 35% to
50%) to achieve the same thermal properties as rotary spun standard
insulation. Since insulation is priced in accordance with its thermal
properties, annual production ratings and plant capacities measured in
kilograms can be somewhat misrepresentative when comparing the economics
of the two processes. All small plants utilize the flame attentuation
process and are financially better off than an economic impact based on
overall industry plant capacity would indicate. Rotary forming
processes can produce more uniform and finer fibers. They are also
capable of producing huge tonnages of wool, and for these reasons the
rotary process now dominates the industry.
Borosilicate glasses and low alkali silicate glasses are generally used
in making glass fibers because of their chemical durability. The
surface area to weight ratio of the glass fibers in glass wool products
is so great that even atmospheric moisture could seriously weather
common silicate glass fibers. Table I is a compilation of the uses for
the various types of insulation fiberglass and Table II lists the glass
composition. These tables serve as examples of insulation fiberglass
products. Technological changes brought on by consumer demands have
already made some of these products obsolete. The low thermal
conductivity property of insulation fiberglass is not directly
attributable to the glass, but rather to the ability of the glass fibers
to establish stationary pockets of air. The fiberglass web in which
these pockets are held minimizes heat transfer by air convection
currents and limits it to conduction in air, which is a much slower
rate.
There are two methods of producing the molten glass (1260-1316°C) that
feeds the fiberizing machine in the forming area. The older method
involves first producing 2.5 cm. (one inch) glass marbles and then
feeding the marbles to a small remelt furnace which in turn feeds the
fiberizer with molten glass. There can be several remelt pots to each
production line. The marbles may either be produced at the plant site
or made at a centrally located plant with a large furnace and shipped to
other plants. The original purpose of this seemingly redundant
procedure is to insure glass uniformity before the fibers are made by
visually inspecting the glass marbles. The mechanical problems caused
by seeds and bubbles are more troublesome in fibers than massive glass
because of the small glass diameters involved. The assurance of better
quality control in the glass-making stage, however, has led to the
replacement of the intermediate glass marble process by direct feed
furnaces. Currently only one company operates marble-'feed processes for
insulation products. This company finds it less costly to ship marbles
than to build and maintain glass making furnaces at every small plant.
Rotary processes are always fed by direct melt furnaces because rotary
spinners have high volume production capabilities which can only be
matched by direct melt furnaces. Furthermore, the high cost of a glass
furnace usually necessitates that it be large, which in turn requires a
large plant capacity in order for the operation to be profitable. Both
marble feed and direct melt processes feed flame attenuation forming
processes.
11
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TABLE I
PROPERTIES RELATED TO APPLICATIONS
OF GLASS FIBERS
Glass Type
1. Low-alkali lime-
alumina borosilicate
Fibrous-glass
Forms
Textiles and
mats
Fiber Diameter
Range, mm
0.00585 - 0.00965
Fiber Diameter
Range, in.
0.0023 - 0.00038
Dominant
Characteristics
Excellent dielectric
and weathering pro-
perties
Principal Uses
Electrical textiles. General
textiles. Reinforcement for
plastics, rubber, gy spurn,
papers. General -purpose mats
2. Soda-lime borosilicate Mats
Textiles
3. Soda-lime borosilicate Wool (coarse)
4. Soda-lime
5. Lime-free soda
borosilicate
Packs (coarse
fibers)
Wool (fine)
(Ultrafine)
0.0101 - 0.0152
0.00585 - 0.00965
0.00760 - 0.0152
0.114 - 0.254
0.00040 - 0.00060
0.00023 - 0.00038
Acid resistance
0.000.30 - 0.00060 Good weathering
0.0045 - 0.010
Low cost
0.00076 - 0.00508 0.00003 - 0.00020 Excellent weathering
0.0000(est)-0.00076 6.0000 - 0.00003
Mats for storage - battery re-
tainers, for corrosion protec-
tion, water proofing, etc.
Chemical (acid) filter cloths.
anode bags
Thermal insulations.
products
Acoustical
Coarse fibers only, for air and
liquid filters, tower packing,
airwasher contact and elimi-
nator packs
Lightweight thermal insulations,
sound absorbers, and shock-
cushioning materials. All-glass
high-efficiency filter papers
and paper admixtures
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TABLE I!
CHEMICAL COMPOSITIONS OF GLASSES USED TO FORM
COMMERICAL FIBROUS GLASS (PERCENT) (4)
Si09 Al90o CaO MgO BJL NaJ) K 0 ZKL TiQ PbO Fe
c. £. j /- 3 2 2 2 ?
Type
1. Low-alkali, lime-
alumina borosilicate 54.5 14.5 22.0
2. Soda-lime boro-
silicate
3. Soda-lime boro-
silicate
4. Soda-lime
5. Lime-free soda
borosilicate
8.5 0.5
65.0 4.0 14.0 3.0 5.5 8.5 0.5
59.0 4.5 16.0 5.5 3.5 11.0 0.5
73.0 2.0 5.5 3.5 16.0
59.5 5.0
7.0 14.5
4.0 8.0
2.0
13
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When production changes occur in a direct melt process, the molten glass
flow is temporarily diverted from the fiberizers and quenched with
water. The glass immediately solidifies and fractures into fragments
resembling a mixture of sand and aggregate, which is termed cullet. A
major portion of the cullet is collected at the machine in hoppers for
reuse in the melting furnace. If the furnace is not bled by producing
cullet, the lighter components in the molten glass will volatilize and
the composition of the glass will be unpredictably altered. This is not
a problem in the marble-feed process because of the very small volume of
molten glass held in the remelt pots. This problem along with other
restrictions requires that direct melt processes be operated 24 hours a
day all year round.
The quality of water needed for cullet cooling is not critical in that
this water may be reused, with make-up water added to compensate for the
water vaporized by contact with the hot glass. It is not important that
the water be cooled, but sufficient suspended solids must be removed to
prevent damage to the pimps. Colloidal silica suspensions are
controlled by sufficient blowdown.
After the molten glass is divided into fibers and attenuated, the fibers
are sprayed in mid-air with a phenolic water-soluble binder (glue) and
are forced by a downward air draft onto a conveyor chain. This air flow
is considerable and can vary from 55.6 standard cu m/kg product (890
standard cu ft/lfc) for a rotary process to 215 standard cu m/kg product
(3450 standard cu ft/lb) for a flame attenuation process. In many
plants the newly formed fibers are oversprayed with water at the same
time that the binder is applied. This overspray serves to cool the
almost molten glass, minimizing both volatilization and early
polymerization of the binder.
The binder is a thermosetting resin composed of a dilute solution of
phenols (resin) and other chemical additives which provide terminal
cross-linking and stability of the finished product. The resin itself
is a complex mixture of methylophenols in both the monomer and polymer
states formed by reacting phenol and formaldehyde. For some products,
lubricants are applied to the newly formed fibers singly or in addition
to the binder. The lubricant, usually a mineral oil, is used to
minimize skin irritation (fiber abrasion) of persons handling the in^
sulation. Tables III, IV, and V list the binders and lubricants used
for the various insulation products. The properties and uses of each
product are also listed. These tables serve again as examples. Rapidly
changing technology has led to improved products since the lists were
compiled.
The binder is diluted with two to six times its volume in water before
it is applied to the product. The quality of the dilution water is
important in that it must not contain solids of such size as to plug the
spray nozzles and it must not contain sufficient concentrations of
chemicals to interfere with the curing properties of the binder. For
instance, magnesium and calcium found in hard water are incompatible
with the binder. The quantity of binder applied to the fiberglass is
governed by the type of product and process. It is measured as the
ignition loss of the product and will range from 4 to 15 percent.
Binder efficiency is defined as the percentage cf binder applied to the
fiberglass that remains in the product. Binder efficiencies typically
14
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TABLE III
PRIMARY FIBROUS-GLASS-WOOL PRODUCTS
Produce
Unbonded wool
("white")
Bonded wool
(molded)
Bonded wool
Bonded wool
Bonded wool
Bonded wool
(fine fiber)
Bonded wool
Bonded wool
(fine fiber)
Bonded wool
(fine fiber)
Basic fine
Fibers (bulk)
Nominal Fiber
Diameter, mm
0.013
0.0096
0.0086
0.013
0.016
0.016
0.0010
0.0020
0.0030
0.0030
0.0030
0.0043
0.00051
0.0030
0.0005-0.0030
Nominal Fiber
Diameter, In.
0.0005
0.00038
0.00034
0.0005
0.0006
0.0006
0.00004
0 . 00008
0.00012
0.00012
0.00012
0.00017
0.00002
0.00012
Density Range, Density Range, Maximum Tempera-
8/Cu. Cm. Ib/cu. ft. Binder ture Limit, C
0,024 up 1.5 up Oil only 538
3.0 std.
Phenolic 204
resin
0, 024-0. 060 1. 5-3. 75 Phenolic 204
resin
0.032-0.060 2.0-3.73 Phenolic 204
resin
0.096 6.0 Phenolic plus 316
high-temp resin
0 . 032-0 .19 2.0-12.0 Phenolic 204
resin
0.0096 0.6 Phenolic resin 316
high- temp resin
0.0080 0.5 phenolic resin
Sllicone oil
0.12-0.032 0.75-2.0 phenolic plus 316
high-temp resin
0.12-0.032 0.75-2.0 Phenolic 204
resin
0.0048-0.0080 0.3-0.5 Phenol reain
Silicons oil
0.012-0.032 0.75-2.0 Phenol 204
resin
Unbonded
Un lubricated
Ma^or Application
Heated equipment & appliances
Pipe insulation-low temperature
and low pressure heated pipe
Appliance Insulation
Appliance insulation
Duct insulation-fire barrier
insulation
General purpose and fabricated
forms, rolls, batts, blocks,
boards, (plain, faced, asphalt-
ed), metal-mesh blankets; duct
insulation, pouring wool
Aircraft insulation
Flotation application
Wrapped on pipe insulation
insulation "
General purpose insulation-aouid
control-shock cushing
Clothing inter liner
Seat cushioning
Railroad-car, truck-trailer,
and furnace insulation
Fibers for papermaklng
Maximum surface temperature in contact with Insulation under most favorable conditions, organic lubricants and binders begin to oxidize
from hot surface at 135°C. Actual losa of organic material depends on amount present, access to oxygen, and thickness and density of
insulation. There is no low-temperature limitation so far discovered down to -185°C.
15
-------
TABLE IV
FIBROUS-GLASS MATS—BASIC FORMS
Primary Mat Products
Product
Nominal Fiber
Diameter, mm
Nominal Fiber
Diameter, in.
Weight Range,
_g/sq. cm.
Thickness*
Range, mm,
Notes
Staple fiber mat 0.015 - 0.016
Reinforcing mat 0.058 - 0.096
Staple mat (ran-
dom-reinforced)
Base mat,
0.016
Staple mat (par- Base mat
allei-reinforced) 0.0.6
0.00060 - 0.00065
0.00023 - 0.00038 0.015 - 0.091
0.25 - 2.5
0.00065
0.5
0.00065
Resins, starch, gelatin
and sodium silicate
binder. Fibers in
random lay
Cut strands of continuous
filament bonded in jack-
straw (random) arrange-
ment. Resin-type binders
Base mat of staple fibers
intertwined with endless
continuous-filament
strand in a random ar-
rangement. Phenolic binder
Base mat of staple fibers
interlaid with parallel
strands of continuous
filament for undirec-
tional strength. Phenolic
binder
Thickness measured at 2.75 psi. That is 11 Ib. load on 1/4-in. diameter platen.
-------
TABLE V
FIBROUS GLASS PACKS—BASIC FORMS
Product
Fiber Diameter
mm, Nominal
Fiber Diameter,
in.. Nominal
Notes
Bonded packs
(coarse fibers)
Curly wool
0.11
0.15
0.20
2.5
0.029
0.0045
0.0060
0.0080
0.100
0.00115
Packs 1/2 and 1 in. thick
water-soluble or insoluble
binders. Used in air
filters, air washers and
as distillation column
packing
Bulk wool - usually lubri-
cated. Special uses in
process industries
17
-------
range from 60 to 70 percent. That percentage lost either goes off in
the forming air or curing oven air or remains on the chain.
The fibers fall to the chain where they collect in the desired mass and
depth required for the ultimate product. The density of the fiber mass
(mat) on the conveyor is controlled by the fiber production rate and the
speed of the conveyor chain. For a rotary forming process the chain
speed will range from 127 to 508 linear cm/sec (50-200 ft/min). This
mat then proceeds by conveyor through curing (200-260°C) and cooling
ovens. It is compressed, and an appropriate backing (asbetos, paper,
aluminium, etc.) may be applied as a vapor barrier. The product is then
sized and/or rolled and packaged. The cured mat may instead be shredded
to make blowing and pouring wool. This product is used where existing
structures require insulating material that can be blown or poured into
the walls. The thermal properties, however, are inferior to those of
backed insulation.
The cured phenolic resin imparts a yellow color to the glass wool, which
may not ^be appealing to the customer. Consequently, various dyes are
applied to the fiberglass in the binder spray.
Two types of chains are employed in the forming area. Flexible wire
mesh conveyor belts were originally used, but many have since been
replaced with flight conveyors. These are hinged steel plates that
contain numerous holes or slits. The air stream which transports the
glass fibers to the conveyor also contains droplets of resinous binder
which have not adhered to the glass fibers. Many of these droplets
deposit resin on the chain, and if not removed, the resin build-up will
eventually restrict passage of the air stream. When the deposit becomes
sufficiently great, insulation fiberglass formation is no longer
possible, necessitating replacement of the conveyor.
Historically, the wire mesh chain has been cleaned while in service by
routing the chain through a shallow pan containing a hot caustic water
solution (refer to Figure IV). Fresh caustic makeup to the pans created
caustic overflew containing phenolic resin and glass fiber.
Another method of chain cleaning uses either fixed position pressurized
water sprays or rotating water sprays. Unlike the caustic soda bath
processes, the waste waters from this method are amenable to treatment
and recirculation. Water spray chain cleaning has replaced caustic
chain cleaning at all but one plant which uses a combination of the two
methods. Although both methods have been used to clean wire mesh
chains, it is impractical to caustic clean flight conveyors. Unlike the
flexible wire mesh chains, the hinged plates of the flight conveyor
cannot be so easily routed through a pan. Furthermore a flight conveyor
is more expensive than a wire mesh chain, and corrosion caused by the
caustic is of greater concern. Spray cleaning has the added advantage
of cooling the forming chain, thereby decreasing both volatilization and
polymerization of the phenolic resin.
Pipe insulation is made in various ways. One principal method involves
wrapping uncured insulation about mandrels and curing the bundles
batchwise in ovens. The mandrel is a perforated pipe of the appropriate
dimensions. Caustic is still used by the industry to batch clean
18
-------
FIGURE IV
WIRE MESH CHAIN CLEANING (5)
POTS
BURNER
FIBER GLASS MAT
OD
feSip5i!5% CAUSTIC
5P*Wm WASH PAN
CHAIN CLEANING
WATER SPRAY
OVEN
CUT
PACKAGE
CAUSTIC WASTE WATER
TRENCH WITH GLASS
FIBERS AND PHENOLIC
WASTE
METHOD #1
CAUSTIC CHAIN
CLEANING
Iu [PHENOLIC WASTE WATER
HI TRENCH WITH GLASS FIBERS
METHOD #2
WATER SPRAY
CHAIN CLEANING
-------
mandrels. However, the volumes involved are much less than those
required for chain washing and are consequently much less of a problem.
Another source of water pollution is hood wash water* The hood is
either a stationary or a rotating wall used to maintain the air draft in
the forming area. It is necessary to wash the hood in order to keep any
wool that has agglomerated there from falling onto the chain and causing
non-uniformity of the product.
Insulation fiberglass plants experience both air particulate and odor
problems. Particulate emissions are found in the glass furnace, forming
area, and curing and cooling oven exhaust gases. The principal source
of odors is volatilized phenols in the curing and cooling ovens exhaust
gases. Several methods, involving both wet and dry processes, are being
investigated in an effort to reduce the air emissions. The industry
considers air pollution control to be a more serious problem than water
pollution control.
Sales and Growth
The insulation fiberglass industry is currently at 100 percent
production. Current annual glass wool production is estimated at 0.77
million metric tons (1700 million pounds) a year. Profits before tax on
sales range from about 9 percent to 20 percent with a median of 12
percent. Table VI summarizes recent sales. Supply and demand
projections estimate 8 percent growth a year for the next five years.
This picture may substantially change in light of the recent trend in
fuel conservation, a situation which will create even more demand for
insulation materials. In anticipation of this growth, new plants and
expansions are planned in high demand areas. In addition, the industry
is constantly revamping its plants, utilizing the latest technology to
obtain more and a better product. Major changes are made at times of
furnace rebuilding, normally about every five years. Although the
industry may operate old plants, it operates new processes.
The principal Federal government influence on demand is brought about
through changes or modifications in building code requirements. Such a
change took place recently when the Department of Housing and Urban
Development, Federal Housing Administration, revised the Minimum
Property standards for multi-family and single-family housing in order
to fulfill the Department's commitments to the national energy
conservation policy.
The revision, which took effect in July, 1971 for single-family
construction and in June, 1972, for multi-family construction, went into
effect immediately for all mortgage insurance projects for which a
letter of feasibility has not been issued and for low rent public
housing projects for which a program reservation has not been issued.
This implementation will definitely provide more economical operating
costs for the heating and cooling of residential units and will also
conserve the nation's energy resources.
The major uses for glass wool are wall insulation, roof decking,
acoustical tile, pipe insulation, ventilation ducts, and appliance and
equipment insulation. In the areas of residential insulation and
acoustical tile, fiberglass has largely replaced its competition (e.g..
20
-------
TABLE VI
U.S.SHIPMENTS AND VALUE OF WOOL GLASS FIBER 1964-1971 0-1)
Insulation Use
Structural Building 368
Industrial,Pipe &
Equipment
Total
Insulation Use
Structural Building 557
Industrial,Pipe &
Equipment
Total
MM Ib
368
570
938
MM Ib
557
567
1124
1964
$ MM
76
151
227
1968
$ MM
133
179
312
C/lb
20.7
26.5
24.2
C/lb
23.9
31.6
27.8
MM Ib
438
608
1046
MM Ib
627
675
1302
1965
$ MM
93
158
251
1969
$ MM
158
198
356
C/lb
21.1
26.0
24.0
C/lb
25.2
29.3
27.3
MM Ib
484
608
1092
MM Ib
644.8
541.5
1186.3
1966
$ MM
105
173
278
1970
$ MM
165.6
190.6
356.2
C/lb
22.6
28.5
25.9
C/lb
25.7
35.2
30.0
. 1967
MM Ib $ MM
484 109
554 170
1038 279
1971
MM Ib $ MM
—
— —
1518.7 426.9
C/lb
22.5
30.7
26.9
C/lb
—
28.2
Note: Values are average manufacturers1 net selling prices, f.o.b. plant, after discounts and allowances,
and excluding freight and excise taxes.
Source: Department of Commerce "Current Industrial Reports"
-------
mineral wool, perlite, urethane, wool fiberboard, Tectum, lightweight
concrete or gypsum, foam glass, and ceramic insulation) because of the
combined properties of low cost, light weight, low thermal conductivity,
and fire resistance. In the residential insulation sector, fiberglass
products have an estimated 90 percent of the market. The principal
competition for non-residential uses are urethane, styrene, and calcium
silicate. Due to the greater competition, fiberglass products have only
a relatively small share of this market.
An estimated breakdown of products for the year 1971 is given below. As
seen batt insulation (standard building insulation) is the principal
product, averaging 66 percent of total production.
ESTIMATE OF U.S. CONSUMPTION OF
WOOL GLASS FIBER, 1971
Batt Insulation
Acoustic Tiles
Board Insulation
Pipe, Appliance and Equipment
Miscellaneous
TOTAL
1000
90
175
165
89
Thousand
tons
metric
1519 Million
Ib
At present only three companies produce fiberglass insulation. The
nineteen existing plants and the estimated production by their parent
companies are listed in Table VII. Figure V is a production size
distribution graph of these plants. Because a high volume production
is necessary and the glass fiber operation is difficult to scale down,
there are no very small plants when compared to other industries. The
smallest plant produces 2270 metric tons (5 million pounds) of specialty
products a year.
22
-------
TABLE VII
INSULATION FIBERGLASS PLANTS
Company
Owens-Corning
Fiberglas Inc,
Approximate Percent of
Industry Production.
77
Johns-Manville
Corporation
10
Certain-Teed
Products Corporation
13
Plant Locations
Harrington, NJ
Fairburn, GA
Kansas City, KS
Newark, OH
Santa Clara, CA
Waxahachie, TX
Cleburne, TX
corona, CA
Defiance, OH (3)
Parkersburg, WVA
Penbyrn, NJ
Richmond, IN
Winder, GA
Berlin, NJ
Kansas City, KS
Mountaintop, PA
Shelbyville, IN
(recently purchased
from PPG Industries)
23
-------
FIGURE V
SIZE DISTRIBUTION OF INSULATION FIBERGLASS PLANTS
10
ro
U-
O 6
DC
LU
09
Z
n
n
(100) 50
(200) 100
(300) 150
(400)
ANNUAL CAPACITY
THOUSANDS OF METRIC TONS PER YEAR
(MILLION Ib/YR)
-------
SECTION IV
INDUSTRY CATEGORIZATION
Introduction
In developing effluent limitations guidelines and standards of
performance for new sources for a given industry, a judgment must be
made by EPA as to whether effluent limitations and standards are
appropriate for different segments (subcategories) within the industry.
The factors considered in determining whether such subcategories are
justified for the insulation fiberglass manufacturing segment of the
glass manufacturing category of point sources are:
1. Wastes Generated
2. Treatability of Waste Waters
3. Manufacturing Process
4. Chain Cleaning Process
5. Plant Size
6. Plant Age
7. Raw Materials
8. Product
9. Air Pollution Control Equipment
For the purposes of this report, the insulation fiberglass manufacturing
segment consists of primary plants in which molten glass is either
produced from the raw materials or from glass marbles, continuously
fiberized and chemically bonded with phenolic resins into a wool-like
insulating material. As the result of an intensive literature search,
plant inspections, and communications with the industry, it is the
judgment of this Agency that the primary insulation fiberglass industry
should be considered as a single subcategory. Not included are
secondary plants which process wasted textile fiberglass and research
and development facilities.
25
-------
Factors considered
1. Waste Generated
From evaluation of the available data it is concluded that the types of
wastes generated in producing insulation fiberglass, such as suspended
solids, dissolved solids, phenols, and oxygen demanding substances, are
common to all such plants. The only exceptions are dyes and water
treatment backwashes. The former parameter presents no problem insofar
as quality of recycled water is concerned. The quality of water
treatment backwashes varies considerably among the industry depending
upon the intake water quality. The principal factor of concern to the
industry is water hardness which will inhibit the bonding properties of
the phenolic resins. The generally similar nature of the wastes
generated in insulation fiberglass production indicates that the
industry should be considered as a single subcategory.
2. Treatability of Waste Waters
From discussions with the industry and from plant inspections it was
concluded that in a recycle system for an insulation fiberglass plant
only three basic parameters in the process water affect its
treatability: suspended solids, dissolved solids, and pH. The recycled
waters can be adequately treated for reuse by coarse filtration, pH
control (if necessary), and fine filtration or coagulation - settling.
Blowdown can be eliminated as overspray or binder dilution water thus
checking the buildup of dissolved solids. Through proper design of the
treatment system there should be no forseeable reason other than plant
expansion that these basic systems need to be altered in order to
accommodate varying waste load characteristics. Therefore treatability
of waste water factors indicates that all insulation fiberglass plants
fit into a single subcategory.
3. Manufacturing Process
As described in Section III of this document, there are two types of
glass fiber forming processes, flame attenuation and rotary. In the
forming stage both processes are dry, and since the products are the
same, water quality is not affected.
U. Chain Cleaning Process
As described in Section III, there are also two basic methods for
cleaning the forming chain of the glass fibers and phenolic resins. One
method consists of dragging the wire mesh chain, on its return path to
the forming area, through a hot caustic bath. The second method
consists of spraying the wire mesh chain or flight conveyor with high
velocity water.
The resultant wastes from caustic cleaning are extremely difficult to
treat and unless considerable dilution is provided the wastes are
incompatible with the phenolic resins and are not suitable for
recycling. The blowdown from spray washing is amenable to treatment and
recycle.
26
-------
Two subcategories, therefore, would seem appropriate. However, at the
present time only one plant employs caustic chain washing. The
remainder of the industry has switched to spray washing and has future
plans to employ only spray washing equipment. The one existing plant
that uses caustic baths does so in conjunction with spray washing
equipment and it is not necessary in this case to blowdown from the
caustic bath. The carryover caustic on the chain is so diluted by the
wash water volumes that no problems are anticipated in the recycle
system.
For these reasons the industry cannot be
according to chain cleaning techniques.
5. Plant Size
meaningfully subcategorized
It has been determined from the data (Tables X and XI) and from
inspections that despite the wide range in plant capacities plant size
has no effect upon the quality of waste waters. Plant size does affect
the costs of installing total recycle systems because of the effect of
plant size on the volume of water used. In the economic analysis of
Section VIII it is concluded that the cost of recycle per unit
production will increase as much as threefold for plants producing less
than 9000 metric tons per year. However, plants of this size usually
produce specialty products (e.g. pipe insulation) which command a higher
price per unit weight than standard residential insulation. This factor
will minimize the financial impact for the smaller plants. Therefore,
subcategorization according to plant size is not indicated.
6. Plant age
Glass wool plants span an age of from 2 years to more than 25 years
since plant start-up. About 30 percent of the plants are 10-15 years
old, while 25 percent are less than 10 years old. All plants that are
at least 5 years old have undergone considerable upgrading of the
production processes and in many cases facilities have been expanded
with installation of state of the art processes. Waste water
characteristics are therefore similar for plants despite any difference
in age. Except for old plants of large capacity, plant age should not
significantly affect costs of installing the facilities. In large old
plants space limitations and major pipe relocations will increase the
capital costs. However, the capital cost of recycled water is lowest
for large plants and this will help compensate for the increased
installation costs. Hence, plant age is not an appropriate basis for
subcategorization.
7. Paw Materials
The raw materials required for wool glass are much the same as for
standard massive glass, 55-73 percent silica and 27-45 percent fluxing
oxides (e.g., limestone and borates). The compositions of typical
glasses are listed in Table I. Once the glass is made either as fibers
or cullet it is for all practical purposes inert in water, and thus will
not chemically affect waste water quality.
The type of resin used, however, will exert some influence on both air
and water quality. The industry is continually formulating new binder
27
-------
mixtures in an effort to minimize manufacturing and environmental
problems. However, the industry can not be meaningfully subcategorized
according to type of binder used for the following reasons. Different
products can require different binder formulations, and these products
can be made at different times on the same line. Composition changes in
the binder can occur at any time, as the industry tries to improve the
product and decrease raw material costs. No matter what formulation of
resin is used, the general waste characteristics are the same and a
chemical - physical treatment system will not be affected.
8. Product
The type of product made will affect the chain wash water quality in
that different products may require different resin formulations.
However, for the same reasons given in the paragraph above, the industry
cannot be meaningfully subcategorized on this topic.
9. Air Pollution Control Equipment
The type of system used to control air pollution will definitely affect
the water treatment scheme. If water is used to scrub the forming air,
this volume of water will far surpass that volume used to clean the
chains. This occurs because of the large volumes of forming air used
and the small size of the particulates.
One company in order to avoid treating and disposing of these high
volumes of water has used high energy air filters using fiberglass
filters. This and another company have altered the binder composition
in order to reduce volatilization. The second company has also improved
the design of the initial drop out boxes in order to minimize the amount
of particulates going to the secondary emission control devices.
A third company buys its resin and is currently unable to operate a
closed process water system when additional water is used for advanced
air emission control devices such as electrostatic precipitators.
Additoinal process modifications and operating experience will be
necessary before a total recirculation system can be operated in
conjunction with advanced air emission control systems.
Rather than creating a separate subcategory this problem will be handled
as an exception to best practicable control technology currently
available. Best available technology and best demonstrated control
technology can include process changes. Such changes are currently
employed by 2 of 3 companies in the industry.
28
-------
SECTION V
WASTE CHARACTERIZATION
Waste Water Constituent Analysis
A general water flow diagram for an insulation fiberglass plant is
pictured in Figure VI. Non-process waters identified in this diagram
include boiler blowdown, noncontact cooling water and water treatment
backwashes. Those parameters that are likely to be found in significant
quantities in each of the waste streams are listed in Table VIII. A
more detailed analysis of each waste flow (i.e., concentration ranges)
is not possible since the combined waste stream only has been of
interest to the industry from whom most of the data were obtained. The
principal process waste streams within the process are the chain
cleaning water and forming air scrubber water.
The principal uses for steam are for building heating and steam
attenuation. In the latter case the industry has been converting to
compressed air attenuation. The accompanying boiler blowdown in this
case is replaced with non-contact cooling water for air compressors.
Flow Rate Analysis
The quantity of water used varies significantly between plants. Factors
such as design of furnace, method of chain cleaning and method of air
emissions control will affect quantities of water. For example, plants
at which marbles are remelted require very little furnace cooling water,
since the remelt furnaces are small melting pots. targe continuous
drawing furnaces, however, need large quantities of water to control
oven temperatures and to protect the furnace bricks. Table IX lists
chain wash water flows for plants of various sizes. Again there is no
correlation between plant size and water usage for chain washing,
because each of the three insulation fiberglass producers uses chain
wash water at different pressures and therefore at different flow rates.
Raw Waste Loads.
Table X summarizes the raw waste concentrations for several plants.
Although the numbers are not completely comparable because of treatment
differences and different blowdown percentages, the table nevertheless
shows a wide variance in waste water composition. Other factors
affecting the raw waste load include binder composition, chain
temperature, and other thermal and time factors affecting the rate of
resin polymerization. Annual raw waste loads in metric tons are
computed in Table XI. The values are based on an average of five
parameters at four plants.
29
-------
FIGURE VI
GENERAL WATER FLOW DIAGRAM FOR AN INSULATION FIBERGLASS PLANT
CO
o
RUST AND n*», ilATCBlAIC
FUNGUS INHIBITORS , RAW MATERIALS
STACK
COOLING WATER -4
HOOD SPRAY
FIBERIZER
OVERSPRAY -
RESIN, CHEMICALS, BINDER
DILUTION WATER
STACK
WATER SPRAYS
WASTE WATER
MELTING FwAPoRATION
FURNACE EVAPOKAMUIN
MOLTEN GLASS,
t
7\
WATER
WASTE
WATER
1
>-CULLET
CULLET
COOLING
WATER
HOOD
WATER
EVAPORATION
WASTE WATER
1
f
1
(0
CHAIN
1
+
(? 1 ^
T
SPRAY
r i
1 — * —
CAUSTIC
r BATH
CURING AND COOLING
OVEN
AIR POLLUTfON
CONTROL EQUIPMENT
AIR
PRODUCT
CAUSTIC
'MAKEUP
CARRYOVER
WASTE
WATER
WATER-
SUPPLY
TREATMENT
•>-TO PROCESS
FORMING
DROP AIR
OUT
BOXES
T
BACKWASH
AND
SLUDGES
SLOWDOWN
BOILER
NON PROCESS
-------
Waste Stream
Air
Scrubbing
Boiler
Blowdown
Caustic
Slowdown
Chain
Spray
Gullet
Cooling
Fresh Water
Treatment
Hood Spray
Noncontact
Cooling Water
TABLE VIII
CONSTITUFNTS OF INSULATION
FIBERGLASS PLANT WASTE STREAMS
Dissolved Suspended Oil R Specific
Phenols BOD5 COD Solids Solids Grease Ammonia pH Color Turbidity Temperature Conductance
-------
TABLE IX
CHAIN WASH WATEF USAGE
Plant_si.zei
Thousands of Million pounds
Metric Tons per year
Per Year
Water Usage
Chain sprays
liters/sec,
gpm
A
B
C
D
E
F
G
120
34
35
32
18
16
2
270
75
77
71
41
35
5
44
38
14
63
50
8
3
700
600
200
1000
800
120
48
All production figures are estimates.
32
-------
TABLE X
CO
CO
11-98
RAW WASTE LOADS
FOR INSULATION FIBERGLASS PLANTS
ant
H
F'
G
A
B1
Phenol
mg/1
363
2564
4.11
212
240
BODS
mg/1
156
7800
991
6200
COD
mg/1
2500-4000
43,603
6532
23,000
TSS
mg/1
116-561
360
76
769
200
TDS
mg/1
3000-5000
822
10,000-20,1
16,000
TURBIDITY
PH
900
3,290
690
302
40.0002
2,080
200
7.7-8.9
8.0
6.1-12.2
Percent .
Slowdown'
8.3
13.0
1.5
1.0
2.3
1 - Sample taken from water recirculation system
2 - Given by company with no backup data
3 - Defined as percent total process water used as overspray or binder dilution
-------
TAJiLtf XI
ANNUAL RAW WASTE LOADS
Plant Estimated Size
(1000 metric
tons per yr. )
Kilograms Pollutant Per Metric Ton Product
Suspended Dissolved
Phenol
Solids
BOD,
COD
Solids
A
E
H
I
Average
Annual Raw
120
18
16
131
Waste Load
0.36
0.06
0.90
0.33
0.41
316
1.29
4.45
0.40
5.60
2.90
2240
(Metric tons per yr.)
1.67 11.0
8.90 31.5
8.1
6.65 24.2
4.40 18.7
3390 14,400
18.0
14.1
16.0
12,300
Derived by multiplying kg/metric ton by 771,000 metric tons product
per year by 1/1000 metric ton per kg.
34
-------
One particular waste stream addressed by this report is cullet cooling
water. Suspended solids concentrations are extremely variable and
depend upon how many fiberizers are being bypassed. Concentrations in
the waste water can range from a few hundred to tens of thousands mg/1
even after settling. A size distribution study of the suspended solids
resulting from cullet cooling appears in Table XII,
As seen from this table 99.50 percent of the cullet should be amenable
to primary settling. However, especially at high cullet producing
times, an appreciable amount of minus 100 mesh glass particles can
remain suspended in the waste water. Visual inspections at some plants
noted cullet scattered about the river banks below discharges of cullet
cooling water.
Summary
In summary, the quantity of water used and raw waste loads are not
relatable in a practical manner to production levels or techniques. Of
the 19 existing plants, there are as many different formulas for
relating these factors. There are significant differences between
plants even within the same company. A compensating factor, however, is
the fact that all such wastes are amenable to the same general type of
chemical and/or physical treatment.
35
-------
TABLE XII
U.S. Sieve Number
50
100
140
200
325
400
Finer Passed
SIEVE ANALYSIS
ON WASTE GULLET WATER
urn Equivalent
297
149
105
74
44
37
% By Weight
Retained
98.30
1.20
0.30
0.05
0.01
0.05
0.09
100.00%
36
-------
SECTION VI
POLLUTANT PARAMETERS
Pollutants and Pollutant Parameters
Upon review of the corps of Engineers Permit Applications for discharge
of waste waters from insulation fiberglass plants, EPA data, industry
data, and observations made during EPA plant inspections, the following
chemical, physical, and biological properties or constitutents are found
within the process wastewater ef fluent .
Phenols
COD
Dissolved Solids
Total Suspended Nonf ilterable Solids
Oil and Grease
Ammonia
pH
Color
Turbidity
Temperature (Waste heat)
Specific Conductance
The basic constituents of the binder are phenol, formaldehyde, urea, and
ammonia, which react to form various mono-and-poly-methylol phenols.
Therefore, free phenols will occur in any water that has contact with
uncured resin. Phenol concentrations range from 4 mg/1 in once-through
process waters to several hundred mg/1 in recycled waters. The higher
concentrations consist of colloidal suspensions of resins in a partially
polymerized state. However, as some companies have found, a significant
portion of the total phenols also occur in a free state.
Because of the nature of the organic compounds used in the binder, a
BOD^S will exist. Values range from 156 mg/1 to 7,800 mg/1, with the
higher values again representing recycled waters.
For the same reasons given above, a sizeable chemical oxygen demand will
exist in the raw waste stream. Values range from 3,290 mg/1 to 43,603
mg/1, the higher values occurring in recycled waters.
Dissolved (filtrable) organics and super-fine colloidal organics, that
are classified as being filtrable according to Standard Methods (12) ,
will increase the background dissolved solids concentrations
significantly as a result of chain washing and wet air pollution
control. Net increases of 200 mg/1 to gross concentrations of 40,000
mg/1 are noted, A closed water cycle will significantly raise the level
of this parameter.
Conglomerated glass fibers and partially polymerized resins will appear
as suspended solids in the chain wash water. Values have been reported
to be as high as 770 mg/1 in untreated waste waters.
37
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Mineral oils are frequently added to the binder to alleviate abrasion
problems. The amounts of lubricant used are proprietary information but
relatively small. Slight oil sheens have been noted in the waste
streams of some plants during inspections. Values for final effluents
range from 7.5 mg/1 to 140 mg/1.
Ammonia is sometimes added to the binder for stabilization purposes.
The rate of binder polymerization is decreased by an increasing pH.
Ammonia can also be added to the chain wash water to inhibit
polymerization in order to minimize screen and filter plugging. Ammonia
concentrations in effluents range from 0.6 mg/1 to 4.83 mg/1.
As previously mentioned the binder polymerization reaction is pH
dependent. Unless neutralization is practiced, waste water from an
insulation fiberglass plant will be alkaline with a pH greater than 9.0.
Color will result from both the polymerized resin (yellow to brown) and
any dye that is added to the product in the binder spray, colored waste
streams have been seen at nearly all the plants inspected. It is
especially noticeable at plants with process water recirculation
systems.
Turbidity is a measure of the light absorbing properties of the
constitutents in water. For an insulation fiberglass plant these result
from colloidal suspensions and from dyes. Values range from 55 to 200
Jackson Turbidity Units for once-through waters.
Since high temperatures are required to make molten glass (2700°F.),
thermal increases in contact and non-contact waters will be noted.
Properties of the Pollutants and Pollutant Parameters
The following paragraphs describe the chemical, physical and biological
properties of the pollutants and pollutant parameters that exist for
this industry. The undesirable characteristics that these parameters
exhibit or indicate are stated, giving reason why these parameters were
selected.
Phenols
Phenols and phenolic wastes are derived from petroleum, coke, and
chemical industries; wood distillation; and domestic and animal wastes.
Many phenolic compounds are more toxic than pure phenol; their toxicity
varies with the combinations and general nature cf total wastes. The
effect of combinations of different phenolic compounds is cumulative.
Phenols and phenolic compounds are both acutely and chronically toxic to
fish and other aquatic animals. Also, chlorophenols produce an
unpleasant taste in fish flesh that destroys their recreational and
commercial value.
It is necessary to limit phenolic compounds in raw water used for
drinking water supplies, as conventional treatment methods used by water
supply facilities do not remove phenols. The ingestion of concentrated
solutions of phenols will result in severe pain, renal irritation, shock
and possibly death.
38
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Phenols also reduce the utility of water for certain industrial uses,
notably food and beverage processing, where they create unpleasant
tastes and odors in the product.
BiochemicalL Oxygen Demand (BOp]_
Biochemical oxygen demand (BOD) is a measure of the oxygen consuming
capabilities of organic matter. The BOD does not in itself cause direct
harm to a water system, but it does exert an indirect effect by
depressing the oxygen content of the water. Sewage and other organic
effluents during their processes of decomposition exert a BOD which can
have a catastrophic effect on the ecosystem by depleting the oxygen
supply. Conditions are reached frequently where all of the oxygen is
used and the continuing decay process causes the production of noxious
gases such as hydrogen sulfide and methane. Water with a high BOD
indicates the presence of decomposing organic matter and subsequent high
bacterial counts that degrade its quality and potential uses.
Dissolved oxygen (DO) is a water quality constituent that, in
appropriate concentrations, is essential not only to keep organisms
living but also to sustain species reproduction, vigor, and the
development of populations. Organisms undergo stress at reduced DO
concentrations that make them less competitive and less able to sustain
their species within the aquatic environment. For example, reduced DO
concentrations have been shown to interfere with fish population through
delayed hatching of eggs, reduced size and vigor of embryos, production
of deformities in young, interference with food digestion, acceleration
of blood clotting, decreased tolerance to certain toxicants, reduced
food efficiency and growth rate, and reduced maximum sustained swimming
speed. Fish food organisms are likewise affected adversely in
conditions with suppressed DO. Since all aerobic aquatic organisms need
a certain amount of oxygen, the consequences of total lack of dissolved
oxygen due to a high BOD can kill all inhabitants of the affected area.
If a high BOD is present, the quality of the water is usually visually
degraded by the presence of decomposing materials and algae blooms due
to the uptake of degraded materials that form the foodstuffs of the
algal populations.
Chemical _ Oxygen Demand^ (CQD}_
COD is a measure of the quantity of oxidizable materials present in
water. In some instances, a rough correlation between COD and BOD can
be established. Since an oxygen demand will exist, this parameter
exhibits the same adverse conditions that are indicated by BOD.
Dissolved Solids
In natural waters the dissolved solids consist mainly of carbonates,
chlorides, sulfates, phosphates, and possibly nitrates of calcium,
magnesium, sodium, and potassium, with traces of iron, manganese and
other substances.
Many communities in the United Stages and in other countries use water
supplies containing 2000 to 4000 mg/1 of dissolved salts, when no better
water is available. Such water is not palatable, may not quench thirst.
39
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and may have a laxative action on new users. Waters containing more
than 4,000 mg/1 of total salts are generally considered unfit for human
use, although in hot climates such higher salt concentrations can be
tolerated whereas they could not be in temperate climates. Waters
containing 5,000 mg/1 or more are reported to be bitter and act as
bladder and intestinal irritants. It is generally agreed that the salt
concentration of good, palatable water should not exceed 500 mg/1.
Limiting concentrations of dissolved solids for fresh-water fish may
range from 5,000 to 10,000 mg/1, according to species and prior
acclimatization. Some fisn are adapted to living in more saline waters,
and a few species of fresh-water forms have been found in natural waters
with a salt concentration of 15,000 to 20,000 mg/1. Fish can slowly
become acclimatized to higher salinities, but fish in waters of low
salinity cannot survive sudden exposure to high salinities, such as
those resulting from discharges of oil-well brines. Dissolved solids
may influence the toxicity of heavy metals and organic compounds to fish
and other aquatic life, primarily because of the antagonistic effect of
hardness on metals.
Water with total dissolved solids over 500 mg/1 has decreasing utility
as irrigation water. At 5,000 mg/1 water has little or no value for
irrigation.
Dissolved solids in industrial water can cause fcaming in boilers and
cause interference with cleaness, color, or taste of many finished
products. High contents of dissolved solids also tend to accelerate
corrosion.
Specific conductance is a measure of the capacity of water to convey an
electric current. This property is related to the total concentration
of ionized substances in water and water temperature. This property is
frequently used as a substitute method of quickly estimating the
dissolved solids concnetration.
Total suspended solids
Suspended solids include both organic and inorganic materials. The
inorganic components include sand, silt, and clay. The organic fraction
includes such materials as grease, oil, tar, animal and vegetable fats,
various fibers, sawdust, hair, and various materials from sewers. These
solids may settle out rapidly and bottom deposits are often a mixture of
both organic and inorganic solids. They adversely affect fisheries by
covering the bottom of the stream or lake with a blanket of material
that destroys the fish-food bottom fauna or the spawning ground of fish.
Deposits containing organic materials may deplete bottom oxygen supplies
and produce hydrogen sulfide, carbon dioxide, methane, and other noxious
gases.
In raw water sources for domestic use, state and regional agencies
generally specify that suspended solids in streams shall not be present
in sufficient concentration to be objectionable or to interfere with
normal treatment processes. Suspended solids in water may interfere
with many industrial processes and cause foaming in boilers or
encrustations on equipment exposed to water, especially as the
temperature rises. Suspended solids are undesirable in water for
40
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textile industries; paper and pulp; beverages; dairy products;
laundr ies; dye ing; photography; cooling systems, and power plant s.
Suspended particles also serve as a transport mechanism for pesticides
and other substances which are readily sorbed into or onto clay
particles.
Solids may be suspended in water for a time and then settle to the bed
of the stream or lake. These settleable solids discharged with man's
wastes may be inert, slowly biodegradable materials, or rapidly
decomposable substances. While in suspension, they increase the
turbidity of the water, reduce light penetration and impair the
photosynthetic activity of aquatic plants,
Solids in suspension are esthetically displeasing. When they settle to
form sludge deposits,on the stream or lake bed they are often much more
damaging to the life in water, and they retain the capacity to displease
the senses. Solids, when transformed to sludge deposits, may do a
variety of damaging things, including blanketing the stream or lake bed
and thereby destroying the living spaces for those benthic organisms
that would otherwise occupy the habitat. When of an organic and
therefore decomposable nature, solids use a portion or all of the
dissolved oxygen available in the area. Organic materials also serve as
a seemingly inexhaustible food source for sludgeworms and associated
organisms,
Turbidity is principally a measure of the light absorbing properties of
suspended solids. It is frequently used as a substitute method of
quickly estimating the total suspended solids when the concentration is
relatively low,
Gil and Grease
Oil and grease exhibit an oxygen demand. Oil emulsions may adhere to
the gills of fish or coat and destroy algae or other plankton.
Deposition of oil in the bottom sediments can inhibit normal benthic
growths, thus interrupting the aquatic food chain. Soluble and
emulsified material ingested by fish may taint the flavor of the fish
flesh. Water soluble components may exert toxic action on fish.
Floating oil may reduce the re-aeration of the water surface and in
conjunction with emulsified oil may interfere with photosynthesis.
Water insoluble components damage the plumage and coats of water animals
and fowls. Oil and grease in water can result in the formation of
objectionable surface slicks preventing the full aesthetic enjoyment of
the water.
Oil spills can damage the surface of boats and can destroy the esthetic
characteristics of beaches and shorelines.
Ammonia
Ammonia is a common product of the decompositicn of organic matter.
Dead and decaying animals and plants along with human and animal body
wastes account for much of the ammonia entering the aquatic ecosystem.
Ammonia exists in its non-ionized form only at higher pH levels and is
the most toxic in this state. The lower the pH, the more ionized
ammonia is formed and its toxicity decreases. Ammonia, in the presence
-------
of dissolved oxygen, is converted to nitrate (N03) by nitrifying
bacteria. Nitrite (NO^), which is an intermediate product between
ammonia and nitrate, sometimes occurs in quantity when depressed oxygen
conditions permit. Ammonia can exist in several other chemical
combinations including ammonium chloride and other salts.
Nitrates are considered to be among the poisonous ingredients of
mineralized waters, with potassium nitrate being more poisonous than
sodium nitrate. Excess nitrates cause irritation of the mucous linings
of the gastrointestinal tract and the bladder; the symptoms are diarrhea
and diuresis, and drinking one liter of water containing 500 mg/1 of
nitrate can cause such symptoms.
Infant methemoglobinemia, a disease characterized by certain specific
blood changes and cyanosis, may be caused by high nitrate concentrations
in the water used for preparing feeding formulae. While it is still
impossible to state precise concentration limits, it has been widely
recommended that water containing more than 10 mg/1 of nitrate nitrogen
(N03-N) should not be used for infants. Nitrates are also harmful in
fermentation processes and can cause disagreeable tastes in beer. In
most natural water the pH range is such that ammonium ions (NH*£+)
predominate. In alkaline waters, however, high concentrations of un-
ionized ammonia in undissociated ammonium hydroxide increase the
toxicity of ammonia solutions. In streams polluted with sewage, up to
one half of the nitrogen in the sewage may be in the form of free
ammonia, and sewage may carry up to 35 mg/1 of total nitrogen. It has
been shown that at a level of 1.0 mg/1 un-ionized ammonia the ability of
hemoglobin to combine with oxygen is impaired and fish may suffocate.
Evidence indicates that ammonia exerts a considerable toxic effect on
all aquatic life within a range of less than 1.0 mg/1 to 25 mg/1,
depending on the pH and dissolved oxygen level present.
Ammonia can add to the problem of eutrophicaticn by supplying nitrogen
through its breakdown products. Some lakes in warmer climates, and
others that are aging quickly, are sometimes limited by the nitrogen
available. Any increase will speed up the plant growth and decay
process.
pH, Acidity and Alkalinity
Acidity and alkalinity are reciprocal terms. Acidity is produced by
substances that yield hydrogen ions upon hydrolysis, and alkalinity is
produced by substances that yield hydroxyl ions. The terms "total
acidity" and "total alkalinity" are often used to express the buffering
capacity of a solution. Acidity in natural waters is caused by carbon
dioxide, mineral acids, weakly dissociated acids, and the salts of
strong acids and weak bases. Alkalinity is caused by strong bases and
the salts of strong alkalies and weak acids.
The term pH is a logarithmic expression of the concentration of hydrogen
ions. At a pH of 7, the hydrogen and hydroxyl ion concentrations are
essentially equal and the water is neutral. Lower pH values indicate
acidity while higher values indicate alkalinity. The relationship
between pH and acidity cr alkalinity is not necessarily linear or
direct.
42
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Waters with a pH below 6.0 are corrosive to water works structures,
distribution lines, and household plumbing fixtures and can thus add
such constituents to drinking water as iron, copper, zinc, cadmium and
lead. The hydrogen ion concentration can affect the taste of the water.
At a low pH water tastes sour. The bactericidal effect of chlorine is
weakened as the pH increases, and it is advantageous to keep the pH
close to 7. This is very significant for providing safe drinking water.
Extremes of pH or rapid pH changes can exert stress conditions or kill
aquatic life outright. Dead fish, associated algal blooms, and foul
stenches are esthetic liabilities of any waterway. Even moderate
changes from "acceptable" criteria limits of pH are deleterious to some
species. The relative toxicity to aquatic life of many materials is
increased by changes in the water pH. Metalocyanide complexes can
increase a thousand-fold in toxicity with a drop of 1.5 pH units. The
availability of many nutrient substances varies with the alkalinity and
acidity. Ammonia is more lethal with a higher pH,
The lacrimal fluid of the human eye has a pH of approximately 7.0, and a
deviation of 0.1 pH unit from the norm may result in eye irritation for
the swimmer. Appreciable irritation will cause severe pain.
Color
Color can impart aesthetically unpleasant characteristics to water.
Color can also filter light, reducing light penetration and impairing
the photosynthetic activity of aquatic plants.
Temperature is cne of the most important and influential water quality
characteristics. Temperature determines those species that may be
present; it activates the hatching of young, regulates their activity,
and stimulates cr suppresses their growth and development; it attracts,
and may kill when the water becomes too hot or becomes chilled too
suddenly. colder water generally suppresses development; warmer water
generally accelerates activity and may be a primary cause of aquatic
plant nuisances when other environmental factors are suitable.
Temperature is a prime regulator of natural processes within the water
environment. It governs physiological functions in organisms and,
acting directly cr indirectly in combination with other water quality
constituents, it affects aquatic life with each change. These effects
include chemical reaction rates, enzymatic functions, molecular
movements, and molecular exchanges between membranes within and between
the physiological systems and the organs of an animal.
Chemical reaction rates vary with temperature and generally increase as
the temperature is increased. The solubility of gases in water varies
with temperature. Dissolved oxygen is decreased by the decay or
decomposition of dissolved organic substances, and the decay rate
increases as the temperature of the water increases, reaching a maximum
at about 30°C (86°F). The temperature of stream water, even during
summer, is below the optimum for pollution-associated bacteria.
Increasing the water temperature increases the bacterial multiplication
rate when the environment is favorable and the fcod supply is abundant.
43
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Reproduction cycles may be changed significantly by increased
temperature because this function takes place under restricted
temperature ranges. Spawning may not occur at all because temperatures
are too high. Thus, a fish population may exist in a heated area only
by continued immigration. Disregarding the decreased reproductive
potential, water temperatures need not reach lethal levels to decimate a
species. Temperatures that favor competitors, predators, parasites, and
disease can destroy a species at levels far below those that are lethal.
Fish feed organisms are altered severely when temperatures approach or
exceed 90°F. Predominant algal species change, primary production is
decreased, and bottom associated organisms may be depleted or altered
drastically in numbers and distribution. Increased water temperatures
may cause aquatic plant nuisances when other environmental factors are
favorable.
Synergistic actions of pollutants are more severe at higher water
temperatures. Given amounts of domestic sewage, refinery wastes, oils,
tars, insecticides, detergents, and fertilizers more rapidly deplete
oxygen in water at higher temperatures, and the respective toxicities
are likewise increased.
When water temperatures increase, the predominant algal species may
change from diatoms to green algae, and finally at high temperatures to
blue-green algae, because of species temperature preferentials. Blue-
green algae can cause serious odor problems. The number and
distribution of benthic organisms decrease as water temperatures
increase above 90°F, which is close to the tolerance limit for the
population. This could seriously affect certain fish that depend on
benthinc organisms as a food source.
The cost of fish being attracted to heated water in winter months may be
considerable, due to fish mortalities that may result when the fish
return to the cooler water.
Rising temperatures stimulate the decomposition of sludge, formation of
sludge gas, multiplication of saprophytic bacteria and fungi
(particularly in the presence of organic wastes), and the consumption of
oxygen by putrefactive processes, thus affecting the an esthetic value
of a watercourse.
In general, marine water temperatures do not change as rapidly or range
as widely as those of freshwaters. Marine and estuarine fishes,
therefore, are less tolerant of temperature variation. Although this
limited tolerance is greater in estuarine than in open water marine
species, temperature changes are more important to those fishes in
estuaries and bays than to those in open marine areas because of the
nursery and replenishment functions of the estuary that can be adversely
affected by extreme temperature changes.
In establishing limits only certain primary parameters have been chosen:
Phenols
EOC5
COD"
Total suspended Nonfilterable Solids
PH
44
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The parameters turbidity and specific conductance were not chosen
because they represent alternate methods of estimating suspended solids
and dissolved solids respectively.
The parameters oil and grease and ammonia will receive adequate
treatment if the limitations for the primary parameters are met,
Color is not a primary pollutant, because the only company which has
stated a need to discharge does not use dyes in the manufacturing
process. color due only to the resin will be adequately removed in
conjunction with treatment of the primary parameters.
Insufficient data exist to establish limitations
and temperature.
for dissolved solids
The principal source of waste heat will be noncontact cooling water.
Regulations governing control of temperature in noncontact cooling water
will be promulgated at a future date.
45
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SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
Historical Treatment
In only one insulation fiberglass plant has secondary or more advanced
treatment been applied to an effluent. Historically plants have
discharged their waste streams to publicly owned treatment works. Use
of biological end-of*pipe treatment for phenolic waste waters was
attempted at Plant A. The treatment scheme (Figure VII) consisted of
equalization, alum coagulation, nutrient addition, temperature control,
extended aeration, post chlorination, aerobic sludge digestion, and
vacuum filtration. It is noteworthy that the recirculation of chain
wash waters was practiced thirteen years ago at this plant and that only
blowdown from this recycled water received biological treatment. Table
XIII summarizes the performance of the system. Despite the percent
removal efficiencies of the treatment system, objectionable
concentrations of phenol and COD were still discharged. In addition the
parameter of color caused by a dye received no treatment other than
dilution. The company researched use of activated carbon absorption in
an effort to remove the dye and the remaining phenol and COD in the
effluent. This approach, however, proved more costly than total recycle
of process waters.
Phenol and organic treatment is commonly practiced in other industrial
categories. One coke plant has a raw waste containing 410 mg/1 of
phenols at a flow rate of 1,820,000 I/day (480,000 gal/day). The
treatment system consists of a 980,000 1 (260,000 gal) activated sludge
unit employing surface aerators and a clarifier. Sludge from the
clarifier is returned to the activated sludge unit at a rate of
1,110,000 I/day (294,000 gal/day). This treatment plant was able to
obtain the following concentrations:
Effluent Concentration
mg/1
1.0
0.5
0.12
0.066
0.038
Percent of Time
Met
99.5
99
90
75
50
The only pollutant that may interfere with a biological publicly owned
treatment works is phenol. Only certain strains of microorganisms
effectively remove phenols from waste waters and their effectiveness is
confined to specific concentration ranges. Therefore, if sufficient
dilution water is not present, wide variations of phenol in the raw
waste load due to process changes may adversely affect the populations
of these organisms.
state of the Art Treatm€nt__TechnQlQgy
The industry has long realized that recirculation of chain wash water is
feasible and that a blowdown is necessary to control the buildup of
47
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FIGURE VII
BIOLOGICAL TREATMENT AT PLANT A
WAS
SLUC
A
RET
SLUI
TE *»
>GE
k
JRN
3GE
WA
SUF
TER
'PLY
-
?
PROCESS
i
r
EQUALIZATION
AND
MIXING
<
COAULy
AND
SEDIMEh
*
>^
^
r"
MION
JTATION
-
ACTIVATED
SLUDGE
BIOLOGICAL
TREATMENT
t
SUSPENDED
SOLIDS
REMOVAL
T
CHEMICAL
ADDITION
SLUDGE FILTRATE
^ TO SEDIMENTATION
^
*-
r
4 i
SEDIMENTATION
1,
^
r
AEROBIC
DIGESTION
DEWATERED
DRY
SLUDGE
SLUDGE
FILTRATION
SLUDGE
1
THICKENING
t AND
CONDITIONING
STREAM
48
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Parameter
Phenol
Suspended Solids
COD
BODS
Table XIII
Biological Treatment System
at
Plant A
Mean
Raw Waste
mg/1
199
761
6532
998
Mean
Final Effluent
mg/1
0.8
21.4
269
15.2
Mean
Percent
Removal
99.6
97,2
95.9
98.5
Standard
Deviation
mg/1
0.46
8.8
74.7
10.6
Flow was 0.57 million liters per day (0,15 trillion gallons per day)
EQUIPMENT
Unit
Equalization
Chemical Mixing
Flocculation
Clarification
Aeration
Secondary Clarification
Chlorine Contact
Aerobic Digestion
(Sludge Thickener)
Vacuum Filter
Drum Area 110 sq. ft.
Solids Loading Rate 1.25 Ibs/sq. ft./hr
No. of
-Units
3
1
1
1
2
>n 2
1
1
1
Design
Flew
GPSJ
104
104
104
104
2031
104
104
9
11.1
Capacity
era 1. /unit
48r500
540
2,870
42,250
113,500
7,450
3,000
113,500
28,500
Total
Detention
Time
ir.-n .- -i— mi — —,m ^
23.25 hr.
0.09 hr.
'0.46 hr.
6.76 hr.
18,20 hr.
2.40 hr.
0.48 hr.
17.4 days
—
Over Flow
qal/sq. ft
^
-
-
210
*
490
—
-
42.3
Rate
-/day
Aerators
Aeration
Cs
T
Conditions
0.85 H20 CL = 2.0 mg/1
30°C L = 0.5
Unit
Transfer Rate
125 Ibs 02/hr
Digestion
^includes 95 percent return sludge
Cs = 0.85 H20 CL = 1.0 mg/1 6.25 Ibs 02/hr
T = 30°C L = 0.5
49
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solids in the system. The industry also recognizes that suitable
treatment of the blowdown for reuse as overspray or binder dilution
water is less costly than performing advanced treatment to a final
effluent. in the total recirculation scheme the contaminants in the
blowdown essentially go onto the product as the binder, and overspray
waters evaporate from the hot fiberglass. There has been no noticeable
affect on product quality due to the small addition of these extra
solids on the fiberglass. As an alternate method of blowdown disposal,
some plants, because of favorable climatic conditions and space
availability, have employed evaporation ponds.
The amount of water necessary to effectively clean the chain can be
reduced by use of increased water pressures. However, sufficient
concentrations of suspended and dissolved solids can in turn limit this
pressure due to problems of increased pump maintenance and spray nozzle
clogging. Since the dissolved solids concentration in the chain wash
system is determined by the blowdown rate and degree of resin
polymerization, it is the more difficult of the two parameters to
control. The need to eliminate waste streams other than chain wash
water by use as overspray or binder dilution will limit the blowdown
rate of the recirculation chain wash system. This in turn will effect a
steady state concentration of solids in the system, which limits the
wash water pressure.
The above methods constitute the current "state of the art treatment
technology" employed by the industry. Table XIV lists the water
pollution abatement status of all existing primary plants. In summary,
the table shows that 3 plants completely recycle all process waters.
Another does the same except for cullet cooling water. Four plants
recycle with three blowing-down to evaporation ponds and the fourth to a
spray field. Four plants recycle and discharge blowdown to publicly
owned treatment works. Five discharge once-through waters to such
works. Six plants have plans for complete recirculation of process or
all wastes streams.
All three insulation fiberglass producers operate plants in which
process water is recirculated and in which blowdown is used as overspray
or binder dilution. Thus the entire industry has the technology to
apply the "state of the art treatment technology."
Detailed descriptions of those plants that are currently practicing this
technology follow. The plants described cover the entire range of types
of plants: new and old; small, medium and large; flame attenuation and
rotary spinning processes. The examples also illustrate how air
pollution abatement methods can affect the water system.
It should be noted that technology transfer of specific items between
plants is not always possible. This is especially true when comparing
rotary and flame attenuation processes, which have widely different
glass, binder, and air flow rates. This does not affect the conclusions
that total process water recycle is practicable for all plants.
50
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TABLE XIV
WATER POLLUTION ABATEMENT STATUS OF EXISTING
PRIMARY INSULATION FIEERGLASS PLANTS
Plant
A Complete recirculation of process waters. Seme indirect cooling
water from an experimental air emissions control device discharged
to stream
E Complete recirculation
C Discharge once-through waters to POTW.* Plans for recirculation
D Complete recirculation except for discharge of cullet cooling
water
E Complete recirculation of phenolic wastes by 5-1-73. other
wastes to POTW
F complete recirculation
G Completely recycle phenolic waters. Caustics and other waters to
POTW
H Recycle with blowdown to POTW, cooling waters to river. Plans for
complete recirculation
I Discharge once-through waters to POTW. Recycles cullet water. Plans
for complete recirculation
J Recycle on 1 line. Other lines discharge to river
K Recycle with blowdcwn to evaporation pond
L Evaporate wastes in pond
M Discharge once-through water to POTW. Plans for recirculation
N Wastes used for spray irrigation
O Discharge to POTW
P Recycle with blowdown to evaporation seepage ponds
Q Discharge once-through waters to POTW. Plans for recirculation
R Discharge one-through waters to POTW. Plans for recirculation
S Recycle with blowdown to POTW
i POTW - Publicly Owned Treatment Works
51
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Plant A
This plant was built in 1956 and currently has a production capacity of
120,000 metric tons (270 million pounds) per year. Four rotary lines
are fed by direct melt, gas fueled furnaces. Flight conveyors are used
in the forming area. The plant produces standard building insulation,
acoustical ceiling board, pipe insulation, and blowing wool.
Efforts to close the water system have been undertaken for the past
thirteen years. The plant has been operating a complete closed circuit
process water loop for the past three years, but is continuing to
research more effective and economic ways of internally treating the
waste waters for reuse. Figure VIII depicts the present system.
The company considers the crucial point in this water system to be the
huge amounts of heated air which when drawn through the forming area
become saturated with water from the chain wash and air scrubber system.
The plant has a 1.5 percent blowdown of dirty water, which stabilizes
the total solids concentration within the system to between one and two
percent. Phenol concentrations range between 200 and 500 mg/1 within
the system.
The plant is currently operating stationary chain sprays at 21 atm (294
psig) absolute pressure using recycled water. Clean water is used at
between 135 and 204 atm (2000 to 3000 psig) when the resin buildup is
particularly bad. This flow is estimated to average 0.6 I/sec (10 gpm)
and to occur over a period of 10 minutes each shift. The dirty water
sprays use 19 I/sec (300 gpm) per machine. This plant operates its
water systems at a higher total solids concentration than other plants
and must therefore us^ less powerful pumps in order to protect them from
severly erosive conditons.
As seen from Figure VIII, the system consists of directly recycling
screened chain wash water, periodic blowdown for binder dilution water,
and chemical treatment of additional blowdown before being returned to
the recycle water system. Since a very low percentage blowdown exists,
the plant must thoroughly treat a large portion of the process water
before recycling it. The company originally employed flocculation and
clarification to remove dissolved organics and suspended solids, but has
recently discontinued flocculation without harmful effects to the
manufacturing process. Sludge from the treatment systems is landfilled.
The company considers the use of recycle water as overspray to be
neither practicable nor desirable from an air emissions standpoint. The
probable reason is the relatively high concentration of contaminants in
the recycle water when compared to those plants that do recycle water as
overspray.
52
-------
FIGURE VIII
WATER FLOW DIAGRAM OF PLANT A
DEHUMIDIF1CATION
Ul
U)
FIBERGLASS
MANUFACTURE
1
WASH WATER
SCREENING
FILTRATION
EQUALIZATION
RAPID MIX
FLOCCALATION
(STOPPED)
CLARIFICATION
O
FRESH
WATER
MAKE-UP
HOLDING
•SLUDGE
-------
Like the rest of the industry this plant is dissatisfied with the
performance and maintenance requirements of diatcmaceous earth filters
and is investigating alternate treatment methods such as paper filters
and cyclones.
A considerable amount of cullet is produced. The cullet quench water
system is a separate recireolation system with blowdown to the
flocculaticn treatment system. The indirect furnace cooling water
system is also closed. Elowdown from this system goes to the
flocculation system. Chromates were used in the cooling waters for
corrosion control but are retained in the closed water system. The
company is changing to zinc organics.
Caustic mandrel cleaning for the pipe insulation manufacturing process
is performed at this plant. However, the volume of caustic blowdown is
small and they can be put into the wash water recirculation system
without causing noticeable problems.
Air has replaced steam in the forming process, thus reducing the demand
for softened waters. The only water required for air attenuation is for
indirect cooling of the air compressors.
The majority of water used in the plant is for particulate air pollution
control of the forming air. This water is also used as chain wash
water. The company is therefore concerned that future regulations which
may require changes in air pollution control equipment will affect the
wash water system.
A pilot dehumidification system is used on the forming air of one line
to control odor. Contact cooling water is recycled, with the blowdown
going to the chain wash water system. Blowdown of noncontact cooling
water from the dehumidification system is discharged to a small stream
behind the plant. At present this is the only plant in the industry
employing a dehumidification system.
One of the more effective techniques to curb odor problems at this plant
has been to change binder compositions to inhibit phenol volatilization
in the hot forming area. Whenever this is done the wash water quality
must be reevaluated to insure its compatability with the new binder.
The company expressed concern that future air pollution abatement
requirements will further complicate the wash water system, but at this
time they see no reasons why the system cannot remain a total recir-
culaticn system.
No treatment problems due to start-up or shutdown can be foreseen at
this plant. This does not preclude the possibility of temporary plant
shutdown due to process upsets or treatment system problems.
-------
Plant_B
This plant best represents how a new plant can avoid air and water
treatment problems through proper design before the plant is built. The
plant was completed in June of 1971 and with only two lines has a
capacity of 34,800 metric tons (75 million pounds) per year. The plant
employs rotary spinners that are fed by cold, top-feed electric melt
furnaces. This technique has the advantage of virtually eliminating the
air emissions encountered by conventional gas fired furnaces. The cost
of electricity is three times that of gas. The total costs, however,
are about the same since the electrodes are positioned at the bottom of
the furnace and require but one-third the energy to melt the same amount
of raw materials. Gas fired furnaces have their burners less
efficiently positioned in the furnace walls. Only standard building
insulation is produced at this plant.
Figure IX is a schematic diagram of the plant's operations, and Figure X
is a detailed water flow diagram. As it can be seen, the process is
virtually identical to that at Plant A. However flocculation, using
Benonite clay and a polymer, and diatomite filtration are still
employed, and since the air and water treatment systems operate both
efficiently and economically there are no plans to alter the system. As
long as the total solids concentration can be held below two percent,
the recycle system will function properly.
Sufficient land was acquired to build a retention pond which is used to
collect contaminated storm water. The pond can also be used to contain
furnace cooling water and cullet cooling water in the event of process
upsets and shutdowns.
55
-------
FIGURE IX
SCHEMATIC DIAGRAM OF PLANT B
MIXING CHAMBER
o>
FORMING
SCRUBBER SUMP
EOUIUZATION
GRIT BASINS
CONVEYOR
-------
>z
is
±5
Oq
Zm
si
— m
o;
i
TO WASH WATER SYSTEM
-------
Plant ...P
This plant is currently experiencing the most difficult problems within
the industry in maintaining a completely closed cycle water system, and
consequently serves as an example that with even minimal internal waste
water treatment a closed water loop can be operated. In 1965 the plant
was bought from a company which also produced fiberglass. The structure
was built in 1961. In September 1970 the company was given a cease and
desist order by the State Water Pollution Control Board and since that
time has operated the system shown in Figure XI. The plant is medium
sized (32,000 metric tons per year) and produces only standard building
insulation. There are two lines employing rotary spinners and direct
melt, gas fueled furnaces.
At the heart of the treatment system there are two 25,000 liter (6,500
gallcn) sumps, one for each line. The wash water passes through 40 mesh
screens and receives approximately five minutes retention in the sumps
before the water is again used to clean the flight conveyor. A pressure
of 7 atm (87 psig) is used to clean the flight conveyors.
A small amount of water is pumped from the sumps to two 38,000 liter
(10,000 gallon) tanks for additional settling. Sludge is then pumped to
a 19,000 liter (5,000 gallon) tank to hold until it is hauled away to a
landfill. The plant is able to keep the total solids in as little
control that exists by blowing down 98,000 and 57,000 liters (26,000 and
15,000 gallons) per day respectively as overspray and binder dilution
water respectively-
Because the preliminary screening is inadequate and the water in the
sump is constantly stirred up due to the short retention time, quite a
bit of foaming occurs. So much foaming occurs that a half resin, half
fiber, mass eventually floats and hardens to a depth of about two feet,
necessitating "digging out" the sumps once a week. While this is being
done, both lines must be shut down for 10 to 12 hours. In addition the
flight conveyors must also be blasted with crushed walnut shells to free
them of polymerized resin. Walnut shells are used to minimize chain
wear. Despite the lost time in production and high maintenance costs,
the plant is still able to make some profit.
By the autumn of 1973 automatic, chain driven scrappers will be
installed in both sumps and the existing screens will be repositioned
for easier access to the sumps. In addition a portion of the recycled
water will be treated by flocculation much like plants A and B. It is
not known at this time what percentage of the recycled water flow will
be so treated, and it is conceivable that this will be as high as 100
percent. The plant expects to profit from the installation of the
treatment facilities, since increased production will offset the cost of
the waste treatment.
58
-------
FIGtJRE XI
WATER FLOW DIAGRAM OF
PLANT D
CITY MAKEUP
95,000 1PD
(25,000 GPD)
SOFTENER BACKWASH,
MISCELLANEOUS WATERS 40 MESH
SCREENS
CITY WATER
CULLET
COOLING
RIVER
76,000 - 680,000 1PD
(20,000- 180,000 GPD)
SOLID WASTES
25,000 1
(6,500 GAL)
SUMP
SOLID
WASTE
(FOAM)
CHAIN + HOOD
WASHING
80 I/SEC
(1,200 GPM)
AIR POLLUTION
SUPERNATENT
SOLID WASTE 4
SLUDGE
38,000 1
(10, 000 GAL]
TANK
BINDER
DILUTION
EXPANSION
CHAMBER
SPRAYS
57,000 1PD
(15,000 GPD)
OVERSPRAY
SLUDGE (TREATMENT SYSTEM IDENTICAL 1 I/SEC
"" (18 GPM)
FOR OTHER LINE)
-------
Because the recycled water currently has a total solids concentration of
4 percent (90 percent of which is dissolved organics), the wet scrubbers
employing recycled water are ineffective. Like other plants, it is
estimated that the total solids should be less than two percent in order
to keep these water and air systems in control.
Except for cullet cooling water all waste waters are sent to the sumps.
The former is discharged to a stream without adequate treatment.
Since the plant has gone to total recycle, trout have reportedly
reappeared downstream. A successful fish farm reportedly is also
operating downstream of the plant.
60
-------
Plant E
This plant is medium sized having a capacity of 18,200 metric tons (41
million pounds) per year. There are four flame attenuated lines, one
rotary spun line, and one line which uses textile fiberglass wastes as a
raw material. Standard building insulation is produced by five primary
lines that are fed by gas fueled, direct melt furnaces. The plant was
purchased in 1952, but the original structure is considerably older.
The water flow diagram for this plant appears as Figure XII. As seen,
the recycle technique differs considerably from that employed at Plants
A and B. Except for the blowdown treatment system, the recirculation
system has been successfully in operation since May 1972.
Wire mesh chains are used in the forming area of the flame attenuated
lines. The plant employs a combination of both hot caustic washing and
spray washing of the wire mesh chains at 14 atm (190 psig) (refer to
Figure XIII) . The only blowdown from the caustic bath occurs as carry-
over water on the chain which is then washed by the spray wash water
system. Attempts to get away from using caustic have not succeeded so
far, but the amount of caustic entering the system does not interfere
with the binder because of the sizable dilution of wash water. The
rotary spinning line employs a flight conveyor cleaned only by a
rotating water spray. The waste textile line is a dry process.
Although drop out boxes are used with water sprays for the exiting
forming air, considerably less water is used than for plants A and B.
Sufficient suspended solids are removed by the Hydrasieves and
sufficient blowdcwn occurs so that this plant does not need to treat the
recycled water by flocculation and coagulation as do Plants A and B.
The blowdown treatment system consists of pH adjustment, coagulation,
settling and vacuum filtration. The treated water is then used as resin
dilution water. The company is presently having seme difficulties in
recycling this blcwdown since it is affecting the curing properties of
the resin. Two possible sources of this problem are the caustic and the
acid used in the coagulation step.
Sludge and backwash from lime softening, cooling tower blowdown and
boiler blowdown are directed to a lagoon for settling. Overflow is
neutralized with sulfuric acid and discharged to a municipal sanitary
sewer. Gullet cooling water is directed to the same lagoon and is
discharged to a sanitary sewer.
61
-------
FIGURE XII
WATER FLOW DIAGRAM OF
PLANT E
CITY
GULLET
COOLING
FURNACES
(COOLING)
RIVER
HEATING
BOILERS
CITY WATER
380,000 I/DAY
(100,000 GPD)
COLD
WELL
ll
I I
PRETREATMENT AND HVnpA<;iFVF
t u*c c/-\CTCMiKi/-I MYUKAilCVE
LIME SOFTENING! SCREENS
HOT
WELL
SLOWDOWN
38,000 I/DAY
(10,000 GPD)
COOLING
TOWER
SLUDGE
95,000 I/DAY
(25,000 GPD)
I
SOLID WASTES
HOLDING
TANK
-i-BACKWASH
LAGOON
CHAIN SPRAYING
CHAIN
CARRYOVER
, - 1
VER
POTASH
CAUSTIC
CHAIN WASH
SLOWDOWN
95, OOP I/DAY
Vi (25,000 GPD)
pH CONTROL
POLYMER
STORAGE
TREATMENT
TANKS
1 I/SEC
(20 gpm) DROP OUT
BOXES
RESIN DILUTION
VACUUM
FILTERS
FLIGHT
CLEANING
PH CONTROL
4 I/SEC
(60 gpm)
r] VIBRATING SCREEN
T 1 I/SEC
SUMP
PUBLICLY OWNED
TREATMENT WORKS
-------
FIGURE XIII
CHAIN CLEANING AT PLANT E
GLASS
THREADS^
FORCED GAS
FLAMES
TO OVEN
NIP ROLL
SPRAY
FIBERGLASS MAT
ALKALINE BATH
HIGH PRESSURE
SPRAY
SUMP ^
• o^
-------
This plant best illustrates how with minimization of water usage, most
problems of the general recirculation model can be avoided. The plant
was built in 1969 with two standard insulation lines employing marble
fed, flame attenuation processes. The addition of two similar lines in
1972 has boosted the plant from small to medium size. Current
production is 15,900 metric tons (35 million pounds) per year. Since
the plant was built, it has successfully maintained the total recycle
system depicted in Figure XIV.
The principal reason for the reliability of the system is that approxi-
mately 8 percent of the process water flow is continually blown down.
This condition is able to be attained by use of low volume, 69 atm (1000
psig), rotating, and chain (wire mesh) water sprays. The only other
water use within the system is to flush out the dirty water pit. The
blowdown, 2 I/sec (30 gpm), is consumed in the process as overspray.
In order to protect the pumps and spray nozzles, suspended solids are
removed from the recycled water by vibrating screens, diatomaceous earth
filters, and fiberglass filters operated in series. With the com-
bination of water treatment and high blcwdcwn rate, the total solids
concentration ranges between 0.3 and 0.5 percent. This then allows high
pressure pumps to be used, which in turn minimizes water use and makes
the system possible. The addition of anhydrous ammonia aids the filters
in that the ammonia inhibits polymerization of the phenols and thereby
keeps the filters free. Although this practice will raise the dissolved
solids concentration, this problem is adequately handled by the high
blowdown percentage. Even though it is used in the binder, additional
ammonia is automatically added to the recycled water to obtain an
optimum pH of about 9.0.
The plant also minimizes water use by using dry air pollution control
equipment. Drop out boxes (without water sprays) are used for the
exiting forming air. High energy fiberglass filters are used for the
curing oven gases.
Maintenance of the diatomaceous earth (Per) filters has proved to be a
major cost of the system, and the company is researching alternate
treatment schemes that need less attention. Flocculation is so far the
most promising technique.
Cooling tower blowdown is bled into the recycle system. No water
softening is required at this plant.
-------
FIGURE XIV
WATER FLOW DIAGRAM OF
PLANT F
CHAIN
WASH
SPRAYS
FINAL
FILTERED
TANK
FIBERGLAS
FILTERS
CLEAN
WATER
TANK
COOLING TOWER
SLOWDOWN
3 ml/SEC (.05 gpm)
8 I/SEC
(120 gpm)
2 I/SEC
(30 gpm)
>[ DIRTY WATER PIT t
OVERFLOW
8 I/SEC
020 gpm)
SLOWDOWN
TO
OVERSPRAYS
OVERFLOW
RETURN LINE
SLUICE WATER
VIBRATING
.SCREENS
SOLID
WASTE
DIATOMACEOUS EARTH
(PER) FILTERS
15 I/SEC
(240 gpm)
22 I/SEC
(360 gpm)
DIRTY WATER
SIDE
PER WATER
SIDE
STORAGE TANK
CITY WATER
MAKEUP
-------
Plant G
This plant was the recipient of government research funds in 1968 for
demonstrating the feasibility of complete recirculation of chain washing
waters. The project was based on three principles. First, the caustic
baths used to clean the forming chains could be replaced by high
pressure water at 69 atm (1000 psig). Secondary diatcmite filtration
would prevent spray nozzle plugging. Finally, the entire blowdown from
the system could be used as overspray. Figure XV illustrates the
process water system.
The plant is an old, small plant producing 2,300 metric tons (5 million
pounds) per year of pipe insulation. Consequently, a simpler binder
mixture is used than for standard building insulation, and fewer
problems are encountered in recyling the waters. The recycle system
operates at between 0.1 and 0.5 percent total solids concentration.
Several items have been changed since the research grant. The diatomite
filters have not proved to be as successful as they were originally
thought to be, since excessive maintenance is required. The company has
subsequently decided to replace these filters with a screening and
clarification system. The research report also included anticipated
resin savings in the systems costs, since the recycled phenols do
display some binding properties. These properties, are not as
significant as first assumed and no cost savings occurred.
Additional pipes discharging process waters have been discovered since
the research project was carried out, and have been subsequently
connected into the treatment system. The remaining discharges have been
diverted to a sanitary sewer. These wastes include caustics for mandrel
cleaning, cooling water, and other phenol-free waste streams.
66
-------
FIGURE XV
WATER FLOW DIAGRAM OF
PLANT G
92 GPM (61/SEC)
DUST COLLECTOR
15 GPMV (1 I/SEC)
0 I/SEC)
17 GPM
200 PSI
OVERSPRAY PUMPS
(1000CM. Hg)
1000 PS I
CHAIN CLEAN
PUMPS (5200 CM. Hg)
BINDER AND
OVERSPRAY
12 GPM EACH
TO EVAPORATION
(.81/SEC)
(4 I/SEC)
-60GPM
8 I/SEC)
12 GPM
(.8 I/SEC)
GPM
2GPM
HOSES
BINDER MIX. RM.
I
FIBER GLASS MACHINES
U
MANDREL WASH"!
BOILER BLOW
DOWN 1
DOMESTIC &STORM
SEWER
FLOOR TRENCH
r DOMESTIC
\ WASTE
SCRAP COLLECTION PIT
A SCRAP PUMP
B+B1 SLURRY PUMPS
C SUMP PUMP
D PRIMARY FILTER
E DIRTY WATER TANK
F DIATOMITE FILTER
G FILTERED WATER TANK
H CARTRIDGE FILTERS
J FILTERED WATER SUPPLY TANK
K HOLDING TANK WITH AERATOR
L SEPTIC TANK
M SOFTENERS
N TO PRESCOTT RUN
P PUMP
HVALVE, NORMALLY CLOSED
S CHAIN CLEANING STATION
67
-------
Air Pollution Control Effects on EecIrculatj.on Systeni
It was previously discussed in Section IV that the three companies use
different methods to control air emissions. It was also mentioned that
one company was unable to maintain a total recirculation system and
consume all the water used to flush the plates of an electrostatic
precipitator.
This company at one line uses a binder solution at a resin concentration
of 8 percent rather than the normal 15 to 20 percent. This in effect
eliminates the need for a separate overspray system. Since some of the
binder ingredients are already in solution the extra dilution comprises
70% of the binder. Using chain wash water as dilution water will
eliminate 670 kg/kkg product of water. Through experience the company
has found that the maximum organic solids content that can be tolerated
by the system due to plugging and binder compatability problems is 1
percent. This amounts to 6.7 kg/kkg product. The organic input into
the process from the binder is 27 kg/kkg, assuming a binder efficiency
of 67 percent before total recirculation. The assumption is then made
that 50 percent of this organic load is removed as suspended solids in
the chain wash water treatment system. It is further estimated that
two-thirds of the remaining 13.5 kg/kkg product of organics are
entrained in the wasted forming gas. In order to comply with state air
emission requirements an electrostatic precipitatcr was designed to
remove 85 percent of the particulates. This amounts to 1.3 kg/kkg
product loss as an air emission and 12.2 kg/kkg product of dissolved
organic solids still in the water system.
At the concentration of 1 percent, 6.7 kg/kkg product of organic solids
can be removed for binder dilution, necessitating the discharge of 5.5
kg/kkg product of organic solids.
Preliminary analysis of the effluent by the company shows concentrations
of parameters in the ranges given in Section IV,
Summary
In summary the preceding examples illustrate the following points.
1.
2.
The type of fiberizing process has no effect
treatability of the wastes in a recycle system.
upon the
High pressure sprays at 69 atm (1000 psig) can effectively
clean the forming chain if sufficient treatment of the recycled
water is provided to avoid damage to the pumps, pipes, and
spray nozzles.
Smaller volumes of water can be used at
order to effectively clean the chain.
The size of the plant has no effect upon
the wastes in a recycle system.
higher pressures in
the treatability of
The age of a plant does affect the efficiency of a recycle
system in that in the design of a new plant minor changes in
68
-------
the process will significantly improve the treatability of
waste waters.
the
6. Although recycled phenols do have some binding capabilities,
they are not such as to cause a significant reduction in the
amount of binder used.
7. The treatment systems described operate within a rather narrow
range of total solids concentrations. New binder formulations
and additional wet air pollution control equipment may
necessitate significant changes in the recycle system requiring
external blowdown as an interim measure. The reason for this
is that only a limited quantity of water can be eliminated as
binder dilution or overspray water.
8. Using properly treated blowdown for overspray or binder
dilution water will not affect the quality of the product.
9. The use of blowdown for either overspray or binder dilution
varies among the industry, depending upon the the particular
air emissions, water rate, and treatment problems encountered
by each company.
69
-------
-------
SECTION VIII
COST, ENERGY AND NONWATER QUALITY ASPECTS
Cost Reduction Benefits of Alternate Treatment and
Control Technologies
The three alternate treatment and control technologies considered are
biological treatment, biological treatment and carbon adsorption, and
complete recycle. All three treatment schemes consist of recycling
chain wash water and treatment of only the blowdcwn. Consideration of
treatment of once-through process water has long since been abandoned by
the industry because of the large volumes involved and the amenability
of chain wash water to treatment and recycle.
Table XV compares the costs and effluent qualities for the three
alternate treatment schemes as they are estimated for Plant A. The
table clearly indicates that total recycle is the best economic
alternative of the three treatment schemes for best practicable control
technology currently available, best available technology economically
achievable, and best available demonstrated control technology. It is
here assumed that the relationship between the costs of the three
alternatives will hold for different plant sizes. Even if this were not
true, it is quite significant that no discharge of pollutants can be
achieved at costs comparable to end-of-pipe treatment technology.
Furthermore, the best available technology economically achievable
specifies application of technology "which will result in reasonable
further progress toward the national goal of eliminating the discharge
of all pollutants." Total recycle of process waters is economically
achievable and meets the no discharge of pollutants goal. Total recycle
of process waters is currently practiced by a significant portion of the
industry.
Cost of TotalT_Recvcle of Process Waters
Table XVI summarizes the water pollution abatement costs for a few
insulation fiberglass plants. Investment costs have been interpolated
to August 1971 dollars by using EPA tables of sewage treatment plant
cost indexes. (14) Two depreciation periods are used in calculating
total annual cost. The first is the true depreciation period as deter-
mined by the company. For the second, a 10 year depreciation period is
used for the purpose of comparison.
An economic study by one consultant (11) concluded that zero discharge
is practical for the insulation fiberglass industry. The firm selected
two basic forms of recycle systems. Treatment A, coarse filtration,
fine filtration and water recycle, is practiced at Plant F.
71
-------
TABLE XV
A COMPARISON BETWEEN THE ALTERNATE TREATMENT
AND CONTROL TECHNOLOGIES*
Raw Waste
Load
Extended
Aeration
Extended
Aeration
+
Activated
carbon
Total
Recycle
Capital Costs ($1000)
Annual Operating Costs
($1000)2
Effluent Quality
($1000)
EOD5 (mg/1)
COD (mg/1)
Phenol (mg/1)
Suspended solids
(mg/1)
Color
yes
1160
540
yes
1320
556
no
785
508.5
998
6532
199
761
15.2
269
0.8
21.4
103
503
0.053
53
0+
0*
0*
0*
no
l. All cost data based upon a 123,000 metric tons (270 irlllion pounds)
per year plant.
Slowdown is 0.57 million liters per day (0.15 million gallons per
day).
2. Operating and maintenance costs and power costs for extended aeration
and activated carbon are assumed to be the same for the total recycle
system.
3. Estimated
*. No discharge, hence no pollutants.
72
-------
TABLE XVI
WATER POLLUTION ABATEMENT COSTS FOR TOTAL RECYCLE
Plant
Capacity (Thousand Metric Tons/Yr.)
(Million Pounds/yr.)
Investment1 ($1000)
Investment/metric tons/yr.
Annual Costs
Capital Costs ($1000)
Depreciation ($1000)
Years Amortization
Operating and Maintenance ($1000)
Energy and Power Costs ($1000)
Total Annual Cost ($1000)
Adjusted Annual Cost2 ($1000)
Adjusted annual cost/metric ton/yr.
Energy Consumption (100,000 kilowatt-hours/yr)4.0
1 Adjusted to August 1971 dollars using sewage treatment plant cost index (14).
2 Total Annual Cost using a 10 year amortization period.
3 After 1972 expansion to 4 lines, includes original oversized treatment system.
4 Estimated by company, not necessarily adjusted to August 1971 dollars.
A
123
270
7854
6.4
78.5
10
382
48
508.5
508.5
4.1
'r)4.0
B
34
75
6604
19.4
66
10
100
20
186
186
5.5
2.3
E
16.9
35
483
28.6
2
24
20
55
8
89
113
6.7
.551
F
9
20
325
36.2
23.7
14
36.5
1.7
62
71
7.9
.1658
F3
16
35
340.5
21.3
44.5
2.3
81
5.1
.212
G
2.3
20
245.4
100.6
17.5
14
13.8
4.6
36
43
18.7
.512
I
130
287
10604
8.2
106
10
200
66
372
372
2.9
6.9
L
33
73
31 64
9.6
31.6
10
50
19
100.6
100.6
3.1
2.3
0
71
157
12204
17.2
122
10
137
29
288
288
4.1
4.6
Q
200
444
. 27004
13.5
270
10
438
98
806
806
4.0
12.7
-------
Treatment B, coarse filtration, flocculation, settling and water
recycle, is practiced at Plant B. Table XVII lists the resultant fixed
capital investment and annual operating costs for the two treatment
schemes scaled to the four plant sizes considered by the consultant.
As a conservative estimate, 80 percent production was used to calculate
incremental capital and operating costs as shown in Table XVIII.
Assumed selling prices and estimated current fixed capital investments
were used. Figures XVI and XVII both clearly show that the investment
cost of total process water recycle per unit production and the annual
operating cost per unit production for the treatment systems are not
lineally related to plant size. Therefore, the smaller plants will
spend more per unit of product in order to maintain a closed water
system than larger plants.
Assuming no price increases, the relative effects on company and plant
pretax earnings as a result of the incremental operating costs will be
equal to the. proportion of selling price represented by these costs. If
incremental costs are passed on, the current rate of profitability will
be maintained. As current returns on investment are unknown for
individual plants, the relative effects on returns on investment can
only be obtained by assuming a certain level of profits on sales before
taxes, and measuring sensitivity at various levels of returns on
investment.
For this analysis, average pretax earnings are assumed to be 12 percent
on sales for wool glass fibers. The current returns on investments
tested are 5, 10, and 15 percent in Table XIX. Thus for wool glass, a 1
percent increase in operating costs will reduce returns on investments
by 8.3 percent of the current rate.
Plants of any size that currently have a return on investment no better
than 5 percent will become marginal and could possibly cease production.
However, no such facilities exist. Plants operating at over 5 percent
return on investment will continue to enjoy reasonable returns.
The capital that is needed for the industry to achieve nc discharge,
assuming that there are presently no treatment facilities, will range
from 6.0 to 13.5 million dollars depending upon the recycle alternative,
10 million dollars being the estimated mean. Operating costs of a
pollution control equipment are estimated to be 3.7 million dollars per
year for the industry. The consultant concluded that the insulation
fiberglass industry has the financial capability to install total
recycle facilities, and that this will have a minimal effect on the
selling price of its products.
The economic analysis of the consultant report was based upon treatment
systems employed at only two plants of different companies.
74
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TABLE XVII
ESTIMATED COST OF WASTE WATER TREATMENT FOR
INSULATION FIBERGLASS MANUFACTURE (11)
Plant
Capacity
Thousand Million
metric Ib/yr
tons/yr.
Type Treatment System
A B
200
41
440 Fixed Cap. Investment ($1000)
Fixed Cap. Investment/Metric
tons/yr.
Annual Operating Cost ($1000)
Annual Operating Cost/Metric
tons/yr.
90 Fixed Cap. Investment ($1000)
Fixed Cap. Investment/Metric
tons/yr.
Annual Operating Cost ($1000)
Annual Operating Cost/Metric
tons/yr.
20 Fixed Cap. Investment ($1000)
Fixed Cap. Investment/Metric
tons/yr.
Annual Operating Cost ($1000)
Annual Operating Cost/Metric
tons/yr.
5 Fixed Cap. Investment ($1000)
Fixed Cap. Investment/Metric
tons/yr.
Annual Operating Cost ($1000)
Annual Operating Cost/Metric
tons/yr.
2000
10.0
610
3.0
800
19.5
200
4.9
325-1-
36.1
80
8.9
150
65.2
46
20.0
1050
5.2
680
3.4
4001'2
9.8
2003
4.9
17.8
71
7.9
70
30.4
37
16.1
A. Coarse filtration, fine filtration and water recycle.
B. Coarse filtration, flocculation, settling and water recycle.
1. Based on costs reported by the Industry
2. Actual investment was closer to $600,000 but the existing system
has more capacity than required.
3. Reported cost was closer to 0.3
-------
TABLE XVIII
SUMMARY OF CAPITAL AND OPERATING COST
EFFECTS: WOOL GLASS FIBER
Water Pollution Control Costs
Incremental
Current Fixed Investment Incremental Incremental
Plant Plant Capital Incremental as % of Operating Operating Cost
Capacity Output Net Revenues Investment • Investment Current Cost as % of Selling
M -metric (MM IV) Tvne of Treatment Process (MM lb) ($MM) ($MM) C$MM> Investment (
-------
LL
INVESTMENT COST/METRIC TON/YEAR
oo
-P-
O
Ln
O
CT>
O
00
o
o
o
o
o
OJ
o
o
o
o
N
o
8 3
n
o
z
w
M
1-3
a
n
1-3
M
§
o
o
a*
H
§
-------
ANNUAL OPERATING COST ($)/METRIC TONS/YEAR
Ln
00
W
O
-P-
O
N
»
n
-<
O
CO
O
O
O
to
O
O
o
o
o
o
o
-------
TABLE XIX
EFFECTS ON RETURNS ON INVESTMENT
WOOL GLASS FIBER (11)
Plant size
Capacity
(M metric
tons/vr)
Waste Water
Operating Cost
as % of
Predicted effect on
return on investment
if currently at
596 ~ 10% 15%
200
A
B
.64
.68
4.7
4.7
9.5
9.5
14.2
14.2
41
A
B
1.04
1.11
4.6
4.5
9.2
9.1
13.7
13.6
A
B
1.79
1.57
4.3
4.4
8.5
8.7
12.8
13.0
A
B
3.83
3.10
3.4
3.7
6.8
7.4
10.2
11.1
79
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Figures XVI and XVir compare the costs of water treatment for different
sizes of plants as determined from actual industry calculations and the
estimates by the consultant previously mentioned. As seen, actual costs
lie within or below the limits estimated by the consultant report, and
it can be assumed that the conclusions of the consultant study generally
hold true for the entire insulation fiberglass industry-
Further analysis reveals that annual operating and investment of recycle
per annual production rating roughly double from the largest plant,
200,000 metric tons per year, to plants producing 9,000 metric tons per
year. Eighty-five percent of the insulation fiberglass plants operate
within this range, and the relatively small cost variance should not
give the large plants a particular advantage. In fact the largest
plants, which seemingly have the greatest cost advantage, are old plants
which require considerable plant modifications not accounted for in the
economic analysis. The costs of recycle systems increase at a much
faster rate for plants smaller than 9,000 metric tons per year.
However, plants in this size range produce specialty products that sell
for a higher price than the standard building insulation that is most
economically produced by medium and large plants. The average price of
industrial insulation is 40 percent more than for building insulation.
Pipe insulation, which is a speciality product, sells for $1.16 per
pound for one company compared to $0.305 per pound for building
insulation. This means that the percentage cost increase per product
weight relative to market price should vary less over the entire range
of plant sizes than Figures XVI and XVII indicate. In fact, the
smallest primary insulation plant has successfully recycled chain wash
water for 3 1/2 years.
Nonwater Pollution.Effects_o£ the Closed Treatment System
Subsurface disposal cf process waters by seepage ponds has caused ground
water contamination at one insulation fiberglass plant. Evaporation
ponds should therefore be lined or sealed. Insufficient information
regarding spray irrigation with process waste waters exists to judge
this disposal method.
In the progression from no treatment to recycle systems, the industry
has had to contend with increasing amounts of sludges consisting of
cullet, glass fiber - resin masses, particulates removed from stack
gases, and wasted product. Since these solids are in an unusable form,
they are hauled to sanitary landfills. Restrictions at some sites
prohibit burial of phenolic wastes because of the fear of ground water
contamination. One company proposes to autoclave its sludges to insure
complete polymerization of the phenols. It should be emphasized that
the amounts of solid wastes generated by total recirculation system are
no greater than if the industry were to employ alternate end-of-pipe
waste water treatment technologies.
Total process water recirculation systems have no adverse impact on air
emissions as long as the total organic content of the recycled water is
kept at or below 1 percent. Plant D illustrates this point. In this
case inadequately treated water is recycled as air scrubber water and
may actually transfer contaminants to the air. However, this plant will
80
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soon be installing additional water
correct the problem.
treatment equipment which should
High pressure spray water pumps can produce objectionable levels of
noise. However, a fiberglass plant is extremely noisy, especially in
the forming area. The small increment of additional noise introduced by
pumps and other miscellaneous recycle equipment will not affect the
hearing protection measures already practiced by the industry.
Insulation techniques can also minimize this problem.
This type of treatment system does affect land requirements. The
treatment systems employed at Plants A and B and proposed at Plant D re-
quire considerable space for flocculating and settling tanks, since low
pressure, high volume wash systems are used. Emergency holding ponds
are desirable but not practicable at many existing urban plants.
Estimated energy consumption for existing and proposed treatment systems
are given in Figure XVIII, As seen from the graph, power requirements
are nearly directly proportional to plant size. The total additional
energy required is estimated to be 38.6 million kilowatt-hours per year.
The industry considers this extra energy needed to operate water
treatment systems to be minor when compared to the energy requirements
of the fiberglass manufacturing equipment and furnaces.
81
-------
CO
ro
FIGURE XVIII
ENERGY CONSUMPTION OF
TOTAL RECYCLE
50 100
PLANT SIZE (1000 METRIC TONS/YEAR)
150
200
-------
SECTION IX
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION
OF THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE — EFFLUENT LIMITATIONS GUIDELINES
Introduction
The effluent limitations which must be achieved July 1, 1977, are to
specify the degree of effluent reduction attainable through the
application of the best practicable control technology currently avail-
able. This technology is generally based upon the average of the best
existing performance by plants of various sizes, ages and unit processes
within the industrial category and/or subcategory industry. This
average is not based on a bread range of plants within the insulation
fiberglass manufacturing industry, but based on performance levels
achieved by exemplary plants. Consideration must also be given to:
a. The total cost of application of technology in relation to
the effluent reduction benefits to be achieved from that
application;
b. the size and age of equipment and facilities involved;
c. the processes employed;
d, the engineering aspects of the application of various
control techniques;
e. process changes; and
f, non-water quality environmental impact (including energy require-
ments) .
Best practicable control technology currently available emphasizes
treatment facilities at the end of a manufacturing process but includes
the control technology within the process itself when this is considered
to be normal practice within an industry.
A further consideration is the degree of economic and engineering
reliability which must be established for the technology to be
"currently available," As a result of demonstration projects, pilot
plants and general use, there must exist a high degree cf confidence in
the engineering and economic practicability of the technology at the
time of commencement of construction or installation of the control
facilities.
Effluent Reduction Attainable Through The Application of Best
Practicable Control Technology Currently Available
On the basis of the information contained in Sections III through VIII
of this report, a determination has been made that the degree of
effluent reduction attainable through the application of the best
83
-------
practicable contrcl technology currently available is no discharge of
process waste water pollutants and noncontact cooling water pollutants
to navigable waters.
Identification_Qf^Eest Practicable Control Technology Currently Available
Best practicable control technology currently available for the
insulation fiberglass manufacturing subcategory consists of recycle and
reuse of process waters and noncontact cooling water within the
operation. To implement this will require:
1. Replacement of caustic taths with pressurized water sprays in
order to clean forming chains of glass fiber and resin. This
has already been accomplished by the industry.
2. The higher the pressures are, the better the cleaning results.
This results in minimizing the use of other cleaning methods
and in the design of smaller treatment systems, since less water
is used.
3. Reuse of chain wash water after suitable treatment.
4. Slowdown from the chain wash system to control dissolved solids
disposed of in the process as overspray and binder dilution water,
or extra - process by evaporation.
5. Incorporation of hood wash water in the chain wash system.
6. Incorporation of other miscellaneous process waters, .such as
mandrel cleaning caustic, in the chain wash system.
7. Recirculation of cullet cooling water with blcwdcwn to the chain
wash recirculation system.
This treatment technology is currently being implemented by the industry
with completion expected before the July 1, 1977, deadline.
Noncontact cooling water may be discharged.
Standards governing the discharge of noncontact cooling water will be
formulated in a later study and added to the effluent limitations for
this subcategory.
Waste water, used exclusively for advanced air emission control devices,
which cannot be totally recycled as binder dilution water or as
overspray may be discharged after suitable treatment. This discharge
-must meet the following limitations:
8/t
-------
Pollutant
characteristics
Phenols
COD
BOD 5
TSS
PH
Maximum for
any one day
kg/kkg (lb/1000 Ib)
of product
0.0006
0.33
0.024
0.03
Maximum average of
daily values for
any period of 30
consecutive days
kg/kkg (lb/1000 Ib)
of product
0.0003
0.165
0.012
0.015
within the range 6.0 to 9.0
Gullet water is determined to be compatible with publicly owned
treatment works.
Rationale for the
Currently Available
of Best Practicable Control Technology
Age and size of Equipment and Facilities
As set forth in this report, industry competition and general
improvements in production concepts have hastened modernisation of plant
facilities throughout the industry. This, coupled with the similarities
of waste water characteristics for plants of varying sizes substantiates
that total recycle is practicable.
Total Cost of Application in Relation to Effluent Reduction Benefits
According to the information in Section VIII of this report, the
industry as a whole would have to invest up to an estimated maximum of
$10,000,000 to achieve the effluent limitations prescribed herein. This
amounts to approximately a 1.2 to 3.8 percent increase in projected
total capital investment and an anticipated increase of 0.6 to 3.8
percent in the operating cost.
Table XI lists the annual raw waste loads for this industry. About
fifty percent is discharged to publicly owned treatment works. Another
thirty-two percent is retained by existing recycle operations. The
proposed standards would prevent direct discharge of the remaining
amounts of pollutants to navigable streams. In conjunction with the
Pretreatment standards for existing sources, the standards would
eliminate that portion of pollutants not receiving treatment at publicly
owned treatment works. In addition the proposed regulations would
prevent discharge of pollutants at future plants.
It is concluded that the benefit of the ultimate reduction to zero
discharge of pollutants outweighs the costs. Presently 32 percent of
plants are achieving no discharge of pollutants.
Processes Employed
All plants in the industry use the same or similar production methods,
the discharges from which are alsc similar. There is no evidence that
operation of any current process or subprocess will substantially affect
85
-------
capabilities to implement best practicable control technology
available-
Engineering Aspects of Control Technique Applications
currently
Seven plants have installed or are starting up phenolic waste water
total reciruclation systems. Four of these plants are totally recycling
other process waste waters, such as cullet cooling water and caustic
mandrel wash water. In addition other plants recycle certain waste
streams such as noncontact cooling and cullet cooling water or have
partial process waste water recirculation systems that are one step from
being total recirculation systems. The concepts are proved; they are
available for implementation; they enhance production; and waste
management methods may be readily adopted through adaptation or
modification of existing production units.
Process changes
This technology is an integral part of the whole waste management
program now being implemented within the industry. While it does
require inprocess changes, they are practiced by many plants in the
industry.
Air Emission Controls
As described in section VII a discharge of process waste water may be
necessary when advanced air emission control devices are employed.
Process changes will be required that may not qualify as best
practicable control technology currently available. It is judged that
discharge of the excess waste water will be permitted.
A biological treatment system operated on these specific wastes has
attained the concentration levels listed in Table XIII. Multiple stage
bio-'-oxidation systems can attain phenol concentrations below 0.1 mg/1.
The following concentrations are judged to be achievable after
biological treatment of these phenolic wastes given the raw waste loads
listed in Section IV:
COD
BOD5
SS
Phenol
275 mg/1
20 mg/1
25 mg/1
0.5 mg/1
The one company that is unable to recirculate all process waste water
must discharge 0.513 Ifc water/lb product. Allowing 0.60 Ib water/It
product and using the above concentrations the following pounds of
pollutant are calculated:
COD
BOD5
TSS
Phenols
This only applies to that
emission control systems.
0.165 lb/1000 Ib product
0.012 lb/1000 Ib product
0.015 lb/1000 Ib product
0.003 lb/1000 Ib product
water exclusively used for advanced air
86
-------
Insufficient data on the biological treatment system once operated at
Plant A exist for one to perform a thorough statistical analyses.
However, for this treatment system, if the maximum allowable discharge
where set at twice the maximum long term average this would
approximately equal three standard deviations for COD and TSS, two
standard deviations for BOD5,, and one standard deviation for phenol.
The activated sludge system operated at the coke plant discussed in
Section VII is able to keep the phenol concentration less than 1.0 mg/1,
which is twice the 0.5 mg/1 used to determine the effluent limitation
99.5 percent of the time. It therefore does not seem unreasonable in
requiring the maximum discharge of a parameter to be less than twice the
average,
Monwater Quality Environmental Impact
There is one essential impact upon major non-water elements of the
environment: a potential effect on soil systems due to strong reliance
upon the land for ultimate disposition of solid wastes. Subsurface
disposal of process waste waters from seepage, percolation, or
infiltration is not recommended due to possible contamination of ground
waters.
Pretreatment
Process waste waters may generally be divided into two categories.
Those that are exposed to the binder and those that are not. The only
waste water that qualifies for the latter category is that water used
ahead of the fiber forming process, that is, cullet water. Gullet waste
water accumulates only minor amounts of heat and suspended solids. Both
parameters are compatible with publicly owned treatment works. However,
those works are not normally designed to treat the pollutants associated
with the binder. These pollutants are therefore considered to be
incompatible with publicly owned treatment works.
87
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-------
SECTION X
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF THE BEST
AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE — EFFLUENT LIMITATIONS
GUIDELINES
Introduction
The effluent limitations which must be achieved by July 1, 1983, are
based on the degree of effluent reduction attainable through the
application of the best available technology economically achievable.
For the fertilizer manufacturing industry, this level of technology was
based on the very best control and treatment technology employed by
specific point sources within the industrial category or subcategory, or
where it is readily transferable from one industry process to another.
Best available technology economically achievable places as much
emphasis on in-process controls as on control or treatment techniques
employed at the end of a production process.
Those plant processes and control technologies which at the pilot plant,
semi-works, or other level have demonstrated both technological
performance and economic viability at a level sufficient to reasonably
justify investing in such facilities were also considered in assessing
best available technology economically achievable. This technology is
the highest degree of control technology that has been achieved or has
been demonstrated to be capable of being designed for plant scale
operation up to and including "no discharge" of pollutants. Although
economic factors are considered in this development, the costs for this
level of control are intended to be for the top-of-the-line of current
technology subject to limitations imposed by economic and engineering
feasibility. However, best available technology economically achievable
may be characterized by some technical risk with respect to performance
and with respect to certainty of costs. Therefore, this technology may
necessitate some industrially-sponsored development work prior to its
application,
The following factors were taken into consideration in determining best
available technology economically achievable:
a. The age of equipment and facilities involved;
b. The process employed;
c. The engineering aspects of the application of various types of
control techniques;
d. Process changes;
Process Water Guidelines
The effluents limitations reflecting this technology is no discharge of
process waste water pollutants into navigable waters as developed in
Section IX.
89
-------
Two of three companies manufacturing insulation fiberglass are achieving
no discharge of process waste water pollutants by methods that include
process changes such as binder formulations, it is within the scope of
best available technology to include process changes in determining
effluent limitations. The fact that this technology is being
demonstrated by two-thirds of the industry qualifies it as best
available.
90
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SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
AND PRETREATMENT STANDARDS
Introduction
This level of technology is to be achieved by new sources. The term
"new source" is defined in the Act to mean "any source, the construction
of which is commenced after publication of proposed regulations
prescribing a standard of performance." New source performance standards
are to be evaluated by adding to the consideration underlying the
identification of best available technology economically achievable a
determination of what higher levels of pollution control are available
through the use of improved production processes and/or treatment
techniques. Thus, in addition to considering the best in-plant and end-
of-process control technology identified in best available technology
economically achievable, new source performance standards are to be
based on an analysis of how the level of effluent may be reduced by
changing the production process itself. Alternative processes,
operating methods, or other alternatives were to be considered.
However, the end result of the analysis identifies effluent standards
which would reflect levels of control achievable through the use of
improved production processes (as well as control technology), rather
than prescribing a particular type of process or technology which must
be employed. A further determination which was to be made for new
source performance standards is whether a standard permitting no
discharge of pollutants is practicable.
Process Water Guidelines
The effluents limitations for new sources is no discharge of process
waste water pollutants into navigable waters, as developed in Section
IX.
Two-thirds of this industry is achieving no discharge of process waste
water pollutants by methods that include process changes such as binder
formulations. It is within the scope of best demonstrated technology to
include process changes in determining effluent limitations.
Pretreatment
As developed in Section IX, cullet water is determined to be compatible
with publicly cwned treatment works. All other process waste water
pollutants are determined to be incompatible with publicly owned
treatment works.
91
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-------
SECTION XII
ACKNOWLEDGMENTS
The author wishes to express his appreciation to various persons with
the insulation fiberglass industry for their willing cooperation in
providing analytical data, flow diagrams, related information, and
assistance with respect to on-site plant visits. In this regard those
persons so cited are: Mr. S.H. Thomas, Director of Environmental
Control, and Mr. George W. Fletcher, Environmental Control Specialist,
Owens-Corning Fiberglas, Inc.; Mr. E.M. Fenner, Director of Technical
Relations, and Mr. G.A. Ensign, Manager of Environmental Control
Engineering, Johns-Manville corporation; Mr. E.B. Norwicki and Mr. Peter
J. Rafferty, Managers of Environmental Control, Certain-Teed Products
Corporation; and Mr. L.T. Powell, Manager of Process Engineering,
Pittsburgh Plate Glass Industries. In addition to these men and their
immediate staff, the author also wishes to express his appreciation to
the plant managers and staff at those plants inspected by EPA for their
more than cooperative assistance,
Acknowledgment is given to the Office of Research and Monitoring for
providing contacts in the fiberglass industry through existing and past
Technology Research Projects. Previous Interim Guidance Documents by
the Office Permit Programs have formed a basis on which this document
was written.
Thanks are given to Ernst Hall, Walter Hunt and Ronald McSwiney of the
Effluent Guidelines Division who spent many extra hours revising the
document. The working group/steering committee members who reviewed
this document in order to coordinate intra-agency environmental efforts
are Ernst Hall, Effluent Guidelines Division; Taylor Miller, Office of
Enforcement and General Council; Arthur Mallon and Charles Ris III,
Office of Research and Monitoring; James Santroch, National
Environmental Research Center, Corvallis; John Savage, Office of
Planning and Evaluation; J. William Jordan and James Grafton. Office of
Permit Programs; and Robert Atherton, Office of Air Quality Planning and
Standards. Last but not least, appreciation is given to the secretarial
staff of the Effluent Guidelines Division, in particular Ms. Kay Starr,
in the typing of drafts and revisions and final preparation of the
effluent guidelines document.
93
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-------
Section XIII
BIBLIOGRAPHY
9.
10
"Glass Fibers," Encyclopedia Britannicaf Volume 10, William Benton,
Publisher, Chicago, pp. 475-476."
Phillips, C. J., "Fiber Glass," The Encyclopedia Americana, Volume
6, Americana Corporation, New York, pp. 170-17Ob.
Shreve, R. Morris, Chemical Process Industries» 3rd edition, McGraw-
Hill Book Company, New York, pp. 700-702, (1967).
Shand, E. B., Glass Engineering Handbook, 2nd
Ecck Corcpany, New York," pp. 375-410, (1958).
edition, McGraw-Hill
Phenolic Waste Reuse by Diatcrnite Filtration, Johns-Man ville
Products Corporation, Water Pollution Control Research Report,
federal grant number 12080 EZF (September, 1970) .
Balcga, J.M., Hutto, F.B., Jr., and Merrill, E.I., "A Solution To
The Phenolic Pollution Problem In Fiber Glass Plants: A Progress
Report," Chemical Engineering Progress Symposium Series, American
Institute of Chemical Engineers, Number 97, Volume 65, pp. 124-127,
(1968) .
Angelbeck, Donald L., Reed, Walter B., and Thomas, Samuel H.,
"Development and Operation of a closed Industrial Waste Water
System," Owens-Corning Fiberglas Corporation Paper Presented at the
Purdue Industrial Waste Conference, Purdue University, West
Laffayette, Indiana, (May 4, 1971).
Fletcher, George W., Thomas, Samuel H., and Cross, Donald E.,
"Development and Operation of a Closed Wastewater System For The
Fiberglas Industry," Owens-Corning Fiberglas Corporation, Paper
Presented at the 45th Annual conference. Water Pollution Control
Federation, Atlanta, Georgia, (October 9, 1972).
"Welcome to Owens-Corning Fiberglas.,.A citizen
Owens-Corning Fiberglas Corporation.
of Newark, Ohio,"
Helbring, Clarence H. , et al, "Plant Effluent - Recycle and Reuse,
PPG Industries, Works #50, Shelbyville, Indiana, "PPG Industries, A
Paper Presented at the Purdue Industrial Waste Conference, Purdue
University, West Laffayette, Indiana, (1971) .
11. "Initial Economic Impact Analysis of Water Pollution control Costs
Upon The Fiber Glass Industry," report to Environmental Protection
Agency by Arthur D. Little, Inc.., Cambridge, Massachusetts, Contract
No, 68-01*0767, (1973).
12. Standard Methods for the Examination of Water and Wastewater. 13th
edition, American Public Health Association, Washington, D. C,
(1971) .
95
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13. "Methods for Chemical Analysis of Water and Wastes," Environmental
Protection Agency, National Environmental Research Center,
Analytical Quality Control Laboratory, Cincinnati, Ohio (1971) .
14. "Sewage Treatment Plant and sewer Construction cost Indexes,"
Environmental Protection Agency, Office of Water Programs
Operations, Municipal Waste Water Systems Division, Evaluation and
Resource Centre! Branch.
for Background Information from Fibgr Glass
Manufacturing, Vulcan-Cincinnati, Inc,. Cincinnati, Ohio, prepared
for EPA, Contract number 68-02-0299, (December 4, 1972) .
1 5 .
16. Kater fiualitV; Criteria, 2nd edition. The Resources Agency of
California, State Water Quality Control Board, publication No. 3-A
(1963) .
96
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SECTION XIV
GLOSSARY
The Federal Water Pollution Control Act Amendments of 1972.
Advanced Air Emission Control Devices
Air pollution control equipment, such as electrostatic precipitators and
high energy scrubbers, that are used to treat an air discharge that has
had initial treatment by equipment such as knock out chambers and low
energy scrubbers.
Annual Operating Costs
Those annual costs attributed to the manufacture of a product or
operation of equipment. They include capital costs, depreciation,
operating and maintenance costs, and energy costs.
Atmosphere
Unit of pressure. One atmosphere is normal atmosphere pressure, 14.70
pounds per square inch.
Batt
Standard wool mat used for residential insulation.
Best Available Technology Economically Achievable (EATEA)^
Treatment required by July 1, 1983, for industrial discharges to surface
waters as defined by Section 301 (b) (2) (A) of the Act.
Best Practicable Control Technology.uCurrentlv Available (BPCTCA)
Treatment required by July 1, 1977, for industrial discharges to surface
waters as defined by Section 301 (b) (1) (A) of the Act.
Best Available Demonstrated Control Technology (EADCT)
Treatment required for new sources as defined by Section 306 of the Act.
Binder
Chemical substance sprayed on the glass fibers in order to bond them
together. Synonymous with the terms resin and phenolic resin.
Blowing Wool
Insulation that is either poured or blown into walls. It is produced by
shredding standard insulation mats and is also referred to as pouring
wool.
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Biochemical Oxygen Demand, 5 day, 20 °C.
Borosilicate
A glass containing approximately five percent boric oxide.
Cogts
Financial charges which are computed as the cost of capital times the
capital expenditures for pollution control. The cost of capital is
based on a weighted average of the separate costs of debt and equity.
Category anct Subcategogy
Divisions of a particular industry which possess different traits which
affect water quality and treatability.
Caustic
Any strongly alkaline material. Usually sodium hydroxide.
Chain
A revolving metal belt upon which the newly formed glass fibers fall to
form a thick mat. There are two general types of chains: wire mesh
chains and flight conveyors. The latter are hinged metal plates with
several holes to facilitate the passage of air.
COD
Chemical Oxygen Demand
Chunks of solid glass formed when molten glass bled from a furnace comes
into contact with water.
Curing
The act of thermally polymerizing the resin onto the glass fibers in a
controlled manner.
Depreciation
Accounting charges reflecting the deterioration of a capital asset over
its useful life,
Diatomaceous Earth
A filter medium used in this case to remove fine glass-resin particles.
The process of filtration is referred to as diatcmite filtration.
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Dry Air Pollution Control
The technique of air pollution abatement without the use of water.
Extremely fine fibers of corrosion resistant glass of diameters
typically less than 0.015 mm. Also fiber glass, fiberglas and glass
fibers.
Flame Attenuation
The glass fiber forming process in which thick threads of glass are
forced through perforated bushings and then reduced in diameter by
burning gases or steam.
Forming Area
The physical area in which glass fibers are formed, sprayed with
lubricant and/or binder, and fall to the chain. A downward forced air
draft is maintained to insure proper binder dispersal and to force the
fibers to the chain.
glas§ Vjgol
The cured fiberglass - resin product. Also referred to as insulation
fiberglass.
Ignition Loss
The percentage of product lost in combustion. It is a measure of the
amount of resin in the product.
Investment Costa
The capital expenditures required to bring the treatment or control
technology into operation. These include the traditional expenditures
such as design, purchase of land and materials, site preparation, con-
struction and installation, etc., plus any additional expenses required
to bring the technology into operation, including expenditures to
establish related necessary solid waste disposal.
Lubricant
Usually a mineral oil added to the binder to inhibit abrasion from the
fibers.
Mandrel
A metal pipe with numerous holes about which fiberglass is wrapped to
make pipe insulation.
The newly formed layer of fiberglass on the chain.
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mq/1
Milligrams per liter
concentration.
Nearly equivalent to parts per million
MM
Million (e.g. million pounds)
Navigable watgrg
All navigable waters of the United states; tributaries of navigable
waters of the United States; interstate waters; intrastate lakes,
rivers, and streams which are utilized by interstate travelers for
recreational or other purposes; intrastate lakes, rivers, and streams
from which fisii or shellfish are taken and sold in interstate commerce;
and intrastate lakes, rivers, and streams which are utilized for
industrial purposes by industries in interstate commerce.
New source
Any building, structure, facility, or installation from which there is
or may be a discharge of pollutants and whose construction is commenced
after the publication of the proposed regulations.
Operations and Maintenance
Costs required to operate and maintain pollution abatement equipment.
They include labor, material, insurance, taxes, solid waste disposal
etc.
Water spray applied to the newly formed glass fibers, the purpose of
which is both to cool the hot glass and to decrease the rate of resin
volatilization and polymerization.
A fiberglass product made from relatively thick fibers, as compared to
glass wool insulation, that is used for special application (e.g. air
filters and distillation column packing) .
A measure of the hydrogen ion concentration in water. A pH of 7.0
indicates a neutral condition. A greater pH indicates alkalinity and a
lower pH indicates acidity. A one unit change in pH indicates a tenfold
change in acidity and alkalinity.
Class of cyclic organic derivatives with the basic formula C6HJ5OH.
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Pretreatment
Treatment proved before discharge to a publicly owned treatment works.
Process Water
Any water which during the manufacturing process comes into contact with
any raw materials, intermediate product, by-product, waste product, or
finished product.
Synonymous with binder.
Rotary Spinning
The glass fiber forming process in which glass is forced out of holes in
the cylindrical wall of a spinner.
Sec
Second. Unit of time.
Secondary Treatment
Biological treatment provided beyond primary clarification.
Silicates
A chemical compound containing silicon, oxygen, and one or more metals,
staple Fiber
Glass fibers with short irregular lengths used for insulation products
in contrast to continuous filaments used for textile products.
Wet Air Pollution Control
The technique of air pollution abatement utilizing water as an
absorptive medium.
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TABLE XX
METRIC UNITS
CONVERSION TABLE
MULTIPLY (ENGLISH UNITS) by TO OBTAIN (METRIC UNITS)
ENGLISH UNIT ABBREVIATION CONVERSION ABBREVIATION METRIC UNIT
acre ac
acre - feet ac ft
British Thermal
Unit BTU
British Thermal
Unit/pound BTU/lb
cubic feet/minute cfm
cubic feet/second cfs
cubic feet cu ft
cubic feet cu ft
cubic inches cu in
degree Fahrenheit F°
feet ft
gallon gal
gallon/minute gpm
horsepower hp
inches in
inches of mercury in Hg
pounds Ib
million gallons/day mgd
mile mi
pound/square
inch (gauge) psig
sqrare feet sq ft
square inches sq in
tons (short) t
yard y
0.405
1233.5
0.252
0.555
0.028
1.7
0.028
28.32
16.39
0.555(°F-32)*
0.3048
3.785
0.0631
0.7457
2.54
0.03342
0.454
3,785
1.609
(0.06805 psig +1)*
0.0929
6.452
0.907
0.9144
ha hectares
cu m cubic meters
kg cal kilogram - calories
kg cal/kg kilogram calories/kilograi
cu m/min cubic meters/minute
cu m/min cubic meters/minute
cu m cubic meters
1 liters
cu cm cubic centimeters
°C degree Centigrade
m meters
1 liters
I/sec liters/second
kw killowatts
cm centimeters
atm atmospheres
kg kilograms
cu m/day cubic meters/day
km kilometer
atm atmospheres (absolute)
sq m square meters
sq cm square centimeters
kkg metric tons (1000 kilograi
m meters
* Actual conversion, not a multiplier
102
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