Group I, Phase II
Development Document for
Effluent Limitations Guidelines and
New Source Performance Standards
for the
PRESSED AND BLOWN GLASS
Segment of the
GLASS MANUFACTURING
Point Source Category
*L PRO"
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
JANUARY 1975
-------
-------
DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES
and
NEW SOURCE PERFORMANCE STANDARDS
for the
PRESSED AND BLOWN GLASS
SEGMENT OF THE
GLASS MANUFACTURING POINT SOURCE CATEGORY
Russell E. Train
Administrator
James L. Agee
Assistant Administrator for Water and
Hazardous Materials
Allen Cywin
Director, Effluent Guidelines Division
Robert W, Dellinger
Project Officer
January, 1975
Effluent Guidelines Division
Office of Water and Hazardous Materials
U.S. Environmental Protection Agency
Washington, D.C. 20460
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 - Price $2.05
-------
-------
ABSTRACT
This document presents the findings of an extensive study of the
pressed and blown glass manufacturing industry by Sverdrup & Parcel
and Associates, Inc., for the Environmental Protection Agency for the
purpose of developing effluent limitations and guidelines. Federal
standards of performance, and pretreatment standards for the industry
for the purpose of implementing Sections 301, 304 (b) and (c) , 306(b)
and 307(b) and (c) of the Federal Water Pollution Control Act, as
amended (33 u.S.C. 1251, 1311 and 1314(b) and (c), 1316 (b) and
1317 (c); 86 Stat. 816 et seq.).
Effluent limitations and guidelines contained herein set fotth 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 are based on the degree of effluent reduction which is
achievable through the application of the best available demonstrated
control technology, processes, operating methods, or other
alternatives.
The development of data and recommendations in this document relate to
the pressed and blown glass segment of the glass manufacturing point
source category. This segment is further divided into six
subcategories on the basis of production processes and waste water
characteristics.
Separate effluent limitations are developed for each subcategory on
the basis of the raw waste loading and the degree of treatment
attainable by suggested model systems. This technology includes in-
plant modifications, recalculation, precipitation, coagulation,
sedimentation, flotation, stripping, filtration, and adsorption.
Supportive data and rationale for the development of the effluent
limitations guidelines and standards of performance are contained in
this document. A portion of the pressed and blown glass segment, the
machine pressed and blown glass industry and the remainder of the
glass tubing industry, is the subject of further analysis at the
present time. The results of this study will be presented as a
supplement to this document at a later date.
The remaining subcategories of the glass manufacturing point source
category not contained in this document comprise the flat glass
segment. The flat glass segment is the subject of a previous study
(Development Document for Effluent Limitations Guidelines and New
Source Performance Standards for the FLAT GLASS Segment of the Glass
iii
-------
Manufacturing Point Source Category, Effluent Guidelines Division,
U.S. Environmental Protection Agency, EPA-440/1-74-001-C, January,
1974). Regulations pertaining to the flat glass segment were set
forth in February of 1974 (Federal Register, Volume 39, Number 32,
page 5712, February 14, 1974) .
iv
-------
TABLE OF CONTENTS
SECTION PAGE.
I Conclusions 1
II Recommendations 3
III Introduction 21
Purpose and Authority 21
Summary of Methods 23
General Description of Industry 38
Production and Plant Location 39
General Process Description 41
IV Industry Categorization 51
V Water Use and Waste Characterization 57
Auxiliary Wastes 57
Glass Contaner Manufacturing 58
Machine Pressed and Blown Glass
Manufacturing 62
Glass Tubing (Danner) Manufacturing 68
Television Picture Tube Envelope
Manufacturing 72
Incandescent Lamp Envelope Manufacturing 77
Hand Pressed and Blown Glass
Manufacturing 81
VI Selection of Pollutant Parameters 89
VII Control and Treatment Technology 103
Applicable Treatment Technology 103
Suggested Treatment Technology 118
Glass Container Manufacturing 118
Machine Pressed and Blown Glass
Manufacturing 121
Glass Tubing (Danner) Manufacturing 122
Television Picture Tube Envelope
Manufacturing 124
Incandescent Lamp Envelope Manufacturing 127
Hand Pressed and Blown Glass
Manufacturing 131
v
-------
TABLE OF CONTENTS
SECTION PAGE.
VIII Cost, Energy, and Non-Water Quality Aspects 139
Cost and Reduction Benefits 139
Basis of Total Industry Cost Estimates 153
Energy Requirements 153
Non-water quality Aspects 157
IX Best Practicable Control Technology
Currently Available 159
Introduction 159
Identification of Technology 159
Effluent Reduction Attainable 162
Rationale for Selection - 164
X Best Available Technology Economically
Achievable 167
Introduction 167
Identification of Technology 168
Effluent Reduction Attainable 170
Rationale for selection 172
XI New Source Performance Standards 175
Introduction 175
New Source Standards 176
Pretreatment Considerations 177
XII Acknowledgements 179
XIII References 181
XIV Glossary 187
4
Conversion Table 190
vi
-------
FIGURES
NUMBER
1 ' Data Retrieval Form 25
2 Sample Computer Format 28
3 Location of Participating Glass Container
Manufacturing Plants 35
4 Location of Participating Pressed and
Blown Glass Manufacturing Plants 36
5 Glass Container Manufacturing 59
6 Machine Pressed and Blown Glass
Manufacturing 64
7 Glass Tubing (Danner) Manufacturing 69
8 Television Picture Tube Envelope
Manufacturing 73
9 Incandescent Lamp Envelope Manufacturing 78
10 Hand Pressed and Blown Glass Manufacturing 82
11 Waste Water Treatment -
Glass Container Manufacturing 119
12 Waste Water Treatment -
Glass Tubing (Danner) Manufacturing 123
13 Waste Water Treatment -
Television Picture Tube Envelope 125
Manufacturing t
14 Waste Water Treatment -
Incandescent Lamp Envelope Manufacturing 128
vii
-------
FIGURES
(Continued)
NUMBER PAGE
15 Waste Water Treatment -
Hand Pressed and Blown Glass
Manufacturing 133
16 Waste Water Treatment -
Hand Pressed and Blown Glass
Manufacturing 134
viii
-------
TABLES
NUMBER
1 Glass Container Plants
2 Pressed and Blown Glass Plants
3 Plants Visited
4 Pressed and Blown Glass Manufacturing
Production Data 40
5 Raw Waste Water, Glass Container
Manufacturing 61
6 Raw Waste Water, Machine Pressed and
Blown Glass Manufacturing 66
7 Raw Waste Water, Glass Tubing (Danner)
Manufacturing 71
8 Raw Waste Water, Television Picture Tube
Envelope Manufacturing 75
9 Raw Waste Water, Incandescent Lamp Envelope
Manufacturing 80
10 Raw Waste Water, Hand Pressed and Blown
Glass Manufacturing 86
11 Concentration of Waste Water Parameters
Pressed and Blown Glass Manufacturing 90
12 Concentration of Waste Water Parameters
Incandescent Lamp Envelope Manufacturing 91
13 Concentration of Waste Water Parameters
Hand Pressed and Blown Glass Manufacturing 92
1U Current Treatment Practices Within the Hand
Pressed and Blown Glass Manufacturing 135
Subcategory
ix
-------
TABLES
(Continued)
15 Current Operating Practices Within the Hand
Pressed and Blown Glass Manufacturing
Subcategory 135
16 Water Effluent Treatment Costs
Glass Container Manufacturing 141
17 Water Effluent Treatment Costs
Glass Tubing (Danner) Manufacturing 143
18 Water Effluent Treatment Costs
Television Picture Tube Envelope 145
Manufacturing
19 Water Effluent Treatment Costs
Incandescent Lamp Envelope
Manufacturing 147
20 Water Effluent Treatment Costs
Hand Pressed and Blown Glass
Manufacturing 150
21 Water Effluent Treatment Costs
Hand Pressed and Blown Glass Manufacturing
Suspended Solids Removal 151
22 Known Surface Dischargers
Glass Container Manufacturing
Subcategory 154
23 Known Surface Dischargers
Machine Pressed and Blown Glass
Manufacturing Subcategory 155
2U Known Surface Dischargers
Glass Tubing Manufacturing
Su bca t egory 155
-------
TABLES
(Continued)
NUMBER PAGE
25 Known Surface Dischargers
Television Picture Tube Envelope
Manufacturing Subcategory 155
26 Known Surface Dischargers
Incandescent Lamp Envelope
Manufacturing Subcategory 156
27 Known Surface Dischargers
Hand Pressed and Blown Glass
Manufacturing Subcategory 156
28 Recommended 30-Day Average Effluent
Limitations Using Best Practicable
Control Technology Currently Available 161
29 Recommended 30-Day Average Effluent
Limitations Using Best Available
Control Technology Economically
Achievable 169
xi
-------
-------
SECTION I
CONCLUSIONS
The pressed and blown glass segment of the glass manufacturing
category has been classified into six subcategories. The first
three subcategories include only the forming of products from molten
glass while the last three include both the forming and finishing of
glass products. The subcategorization is based on (a) production
process and (b) waste water characteristics. Factors such as raw
materials, age and size of production facilities, and applicable
treatment technology do not provide significant bases for
differentiation. The subcategories indicated are as follows:
1. Glass Container Manufacturing
2. Machine Pressed and Blown Glass Manufacturing
3. -Glass Tubing Manufacturing
a. Glass Tubing - Danner process
4. Television Picture Tube Envelope Manufacturing
5. Incandescent Lamp Envelope Manufacturing
a. Forming
b. Frosting
6. Hand Pressed and Blown Glass Manufacturing
a. Leaded and Hydrofluoric Acid Finishing
b. Non-Leaded and Hydrofluoric Acid Finishing
c, Non-Hydrofluoric Acid Finishing
Recommended effluent limitations to be achieved by July 1, 1977, and
July 1, 1983, are summarized in Section II for all of the above
subcategories except the machine pressed and blown glass
manufacturing subcategory. The machine pressed and blown glass
manufacturing subcategory and the remainder of the glass tubing
manufacturing subcategory are the subject of further study. The
results of this study will be presented in a supplement to this
document to be published at a later date.
-------
-------
SECTION II
RECOMMENDATIONS
It is recommended that the following effluent limitations be applied
as the best practicable control technology currently available
(BPCTCA) which must be achieved by existing point sources by July 1,
1977; the best available technology economically achievable (BATEA)
which must be achieved by existing point sources by July 1, 1983; and
the standards of performance for new sources (NSPS):
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE
BPCTCA - Glass Container Manufacturing Subcategory
Effluent Effluent
Characteri sti c Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
Oil 60.0 30.0
TSS 1UO.O 70.0
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil 0.06 0.03
TSS 0.14 0.07
pH Within the range 6.0 to 9.0.
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Glass Container Manufacturing Subcategory
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
Oil 1.6 0.8
TSS 1.6 0.8
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil 0.0016 0.0008
TSS 0.0016 0.0008
pH Within the range 6.0 to 9.0.
NSPS - Glass Container Manufacturing Subcategory
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
Oil 1.6 0.8
TSS 1.6 0.8
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil 0.0016 0.0008
TSS 0.0016 0.0008
pH Within the range 6.0 to 9.0.
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BPCTCA - Machine Pressed and Blown Glass
Manufacturing Subcategory
This subcategory is the subject of further study; the results of
this analysis will be presented at a later date.
BATEA - Machine Pressed and Blown Glass
Manufacturing Subcategory
This subcategory is the subject of further study; the results of
this analysis will be presented at a later date.
NSPS - Machine Pressed and Blown
Glass Manufacturing Suocategory
This subcategory is the subject of further study; the results of
this analysis will be presented at a later date.
BPCTCA - Glass Tubing (Danner)
Manufacturing Subcategory
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) g/kkq of furnace pull
TSS 460.0 230.0
pH Within the range 6.0 to 9.0.
(English units) lb/100Q U> o£ furnace pull
TSS 0.46 0.23
pH Within the range 6.0 to 9.0.
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Glass Tubing (Danner)
Manufacturing Subcategory
Effluent Ef fluent
Characteristic Limitations
Maximum for Average of daily
any one day - values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
TSS - 0.4 0.2
pH Within the range 6.0 to 9.0.
(English units) Ib/lOOQ Ib of furnace pull
TSS 0.0004 0.0002
pH Within the range 6.0 to 9.0.
NSPS - Glass Tubing (Danner)
Manufacturing Subcategory
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) cr/ldca of furnace pull
TSS 0.4 0.2
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
TSS 0.0004 0.0002
pH Within the range 6.0 to 9.0.
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BPCTCA - Television Picture Tube
Envelope Manufacturing Subcategory*
Effluent
Characteristic
Maximum for
any one day
Effluent
Limitations
Average of daily
values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
Oil
TSS
Fluoride
Lead
pH
260.0
300.0
140.0
9.0
130.0
150.0
70.0
4.5
Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil
TSS
Fluoride
Lead
PH
0.26
0.30
0.14
0.009
0.13
0.15
0.07
0.0045
Within the range 6.0 to 9.0,
*The fluoride and lead limitations are applicable to the abrasive
polishing and acid polishing waste water streams, while the TSS, oil,
and pH limitations are applicable to the entire process waste water
stream.
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Television Picture Tube
Envelope Manufacturing Subcategory*
Effluent
Character!stic
Maximum for
any one day
Effluent
Limitations
Average of daily
values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
Oil
TSS
Fluoride
Lead
PH
260.0
260.0
120.0
0.9
130.0
130.0
60.0
0.45
Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil
TSS
Fluoride
Lead
pH
0.26
0.26
0.12
0.0009
0.13
0.13
0.06
0.000*5
Within the range 6.0 to 9.0.
*The fluoride and lead limitations are applicable to the abrasive
polishing and acid polishing waste water streams, while the TSS, oil,
and pH limitations are applicable to the entire process waste water
stream.
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES ANP
STANDARDS OF PERFORMANCE (Continued)
NSPS - Television Picture Tube
Envelope Manutacturinq Subcategory*
Effluent
Characteristic
Maximum for
any one day
Effluent
Limitations
Average of daily
values tor thirty
consecutive days
shall not exceed
(Metric units) q/kkq ot furnace pull
Oil
TSS
Fluoride
Lead
pH
260.0
260.0
120.0
0.9
130.0
130.0
60.0
O.U5
Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil
TSS
Fluoride
Lead
pH
0.26
0.26
0.12
0.0009
0.13
0.13
0.06
0.00045
Within the range 6.0 to 9.0.
*The fluoride* and lead limitations are applicable to the abrasive
polishing and acid polishing waste water streams, while the TSS, oil,
and pH limitations are applicable to the entire process waste water
stream.
-------
PF.COMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BPCTCA - Incandescent Lamp Envelope
Manufacturing Subcategory
(a.) Any manufacturing plant which produces incandescent lamp
envelopes shall meet the following limitations with regard to the
forminq operations.
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of furnace pull
Oil 230.0 115.0
TSS 230.0 115.0
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil 0.23 0.115
TSS 0.23 0.115
pH Within the range 6.0 to 9.0.
10
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BPCTCA - Incandescent Lamp Envelope
Manufacturing Subcategory (Continued)
(b) Any manufacturing plant which frosts incandescent lamp
envelopes shall meet the following limitations with regard to the
finishing operations.
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of product frosted
Fluoride 230.0 115.0
Ammonia No limitation
TSS aeo.o 230.0
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of product frosted
Fluoride 0.23 0.115
Ammonia No limitation
TSS O.U6 0.23
pH Within the range 6.0 to 9.0.
11
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Incandescent Lamp Envelope
Manufacturing Subcategory
(a) Any manufacturing plant which produces incandescent lamp
envelopes shall meet the following limitations with regard to the
forming operation.
Effluent
Characteristic
Maximum for
any one day
Effluent
Limitations
Average of daily
values for thirty
consecutive days
shall_not exceed_
(Metric units) g/kkg of furnace pull
Oil 90.0 45.0
TSS 90.0 45.0
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
Oil 0.09 0.045
TSS 0.09 0.045
pH Within the range 6.0 to 9.0.
12
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Incandescent Lamp Envelope
Manufacturing Subcategory (Continued)
(b> Any manufacturing plant which frosts incandescent lamp
envelopes shall meet the following limitations with regard to the
finishing operations.
Effluent
Cha racteri stic
Maximum for
any one day
Effluent
Limitations
Average of daily
values for thirty
consecutive days
shall not exceed
(Metric units) g/kkg of product frosted
Fluoride 104.0 52.0
Ammonia 240.0 120.0
TSS 80.0 40.0
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of product_frosted
Fluoride 0.104 0.052
Ammonia 0.24 0,12
TSS 0.08 0.04
pH Within the range 6.0 to 9.0.
13
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
NSPS - Incandescent Lamp Envelope
Manufacturing Subcategory
(a) Any manufacturing plant which produces incandescent lamp
envelopes' shall meet the following limitations with regard to the
forming operations.
Effluent
Characteristic
Maximum for
any one day
Effluent
Limitations
Average of daily
values for thirty
consecutive days
shall not exceed
Oil
TSS
pH
Oil
TSS
pH
(Metric units) g/idcq of furnace pull
90.0 U5.0
90.0 U5.0
Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of furnace pull
0.09
0.09 0.045
Within the range 6.0 to 9.0.
14
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
NSPS - Incandescent Lamp Envelope
Manufacturing Subcategory (Continued)
(b) Any manufacturing plant which frosts incandescent lamp
envelopes shall meet the following limitations with regard to the
finishing operations.
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days '
shall not exceed
(Metric units) g/kkg of product frosted
Fluoride 104.0 52.0
Ammonia 240.0 120.0
TSS 80.0 40.0
pH Within the range 6.0 to 9.0.
(English units) lb/1000 Ib of product_frosted
Fluoride 0.104 0.052
Ammonia 0.24 0.12
TSS 0.08 0.04
pH Within the range 6.0 to 9.0.
15
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BPCTCA - Hand Pressed and Blown Glass
Manufacturing Subcategory
(a) Any plant which melts raw materials, produces hand pressed or
blown leaded glassware, employs hydrofluoric acid finishing
techniques, and discharges greater than 50 gallons per day of process
waste water, shall meet the following limitations.
Effluent Effluent
Characteristic Limitations
Lead No limitation
Fluoride No limitation
TSS No limitation
pH No limitation
(b) Any plant which melts raw materials, produces non-leaded hand
pressed or blown glassware, discharges greater than 50 gallons per day
of process waste water, and employs hydrofluoric acid finishing
techniques shall meet the following limitations.
Effluent Effluent
Characteristic Limitations
Fluoride No limitation
TSS No limitation
pH No limitation
(c) Any plant which melts raw materials, produces leaded or non-
leaded hand pressed or blown glassware, discharges greater than 50
gallons per day of process waste water, and does not employ
hydrofluoric acid finishing techniques shall meet the following
limitation s.
Effluent Effluent
Characteristic Limitations
TSS No limitation
pH No limitation
16
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Hand Pressed arid Blown Glass
Manufacturing Subcategory
(a) Any plant which melts raw materials, produces hand pressed or
blown leaded glassware, discharges greater than 50 gallons per day of
process waste water, and employs hydrofluoric acid finishing
techniques shall meet the following limitations.
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
_____ ____ shall not exceed^
mg/1
Lead 0.2 0.1
Fluoride 26.0 13.0
TSS 20.0 10.0
pH Within the range 6.0 to 9.0.
*f
(b) Any plant which melts raw materials, produces non-leaded hand
pressed or blown glassware, discharges greater than 50 gallons per day
of process waste water, and employs hydrofluoric acid finishing
techniques shall meet the following limitations.
Ef f luent Ef f luent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
Fluoride 26.0 13.0
TSS 20.0 10.0
pH Within the range 6.0 to 9.0.
17
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
BATEA - Hand Pressed and Blown Glass
Manufacturing Subcategory (Continued)
(c) Any plant which melts raw materials, produces leaded or non-
leaded hand pressed or blown glassware, discharges greater than 50
gallons per day of process waste water, and does not employ
hydrofluoric acid finishing techniques shall meet the following
limitations.
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
____ shall not exceed
nuj/1
TSS 20.0 10.0
pH Within the range 6.0 to 9.0.
NSPS - Hand Pressed and Blown Glass
Manufacturing Subcategory
(a) Any plant which melts raw materials, produces hand pressed or
blown leaded glassware, discharges greater than 50 gallons per day of
process waste water, and employs hydrofluoric acid finishing
techniques shall meet the following limitations.
Effluent Effluent
Character! st ic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
Lead 0.2 0.1
Fluoride 26.0 13.0
TSS 20.0 10,0
pH Within the range 6.0 to 9.0
18
-------
RECOMMENDED EFFLUENT LIMITATIONS GUIDELINES AND
STANDARDS OF PERFORMANCE (Continued)
NSPS - Hand Pressed and Blown Glass
Manufacturing Subcategory (Continued)
(b) Any plant which melts raw materials, produces non-leaded hand
pressed or blown glassware, discharges greater than 50 gallons per day
of process waste water, and employs hydrofluoric acid finishing
techniques shall meet the following limitations.
Effluent Effluent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
_ shall not exceed
mq/1
Fluoride 26.0 13.0
TSS 20.0 10.0
pH Within the range 6.0 to 9.0.
(c) Any plant which melts raw materials, produces leaded or non-
leaded hand pressed or blown glassware, discharges greater than 50
gallons per day of process waste water, and does not employ
hydrofluoric acid finishing techniques shall meet the following
limitations.
Ef f luent E f f luent
Characteristic Limitations
Maximum for Average of daily
any one day values for thirty
consecutive days
shall not exceed
TSS 20.0 10.0
pH Within the range 6.0 to 9.0.
19
-------
-------
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
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 set forth
effluent limitations guidelines pursuant to Section 304(b) of the Act
for certain subcategories of the glass and asbestos manufacturing
point source category. They include the glass container
manufacturing, glass tubing (Danner) manufacturing, television picture
tube envelope manufacturing, incandescent lamp envelope manufacturing,
and hand pressed and blown glass manufacturing subcategories. The
machine pressed and blown glass manufacturing industry and the
remainder of the glass tubing manufacturing industry are the subject
of further study; regulations pertaining to these industries will be
published at a later date.
21
-------
Section 306 of the Act requires the Administrator, within one year
after a category of sources is included in a list published pursuant
to Section 306 (b) (1) (A) of the Act, to propose regulations
establishing Federal standards of performance for new sources within
such categories. The Administrator published in the Federal Register
of January 16, 1973 (38 F.R. 162U), a list of 27 point 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 glass
manufacturing point source category which was included with the list
published on January 16, 1973. The pressed and blown glass industry,
which this document addresses, is a segment of the glass manufacturing
point source category as are the insulation fiberglass and flat glass
industries which have been previously studied.
Section 307(c) of the Act requires the Administrator to promulgate
pretreatment standards for new sources at the same time that standards
of performance for new sources are promulgated pursuant to Section
306. Section 307(b) of the Act requires the establishment of
pretreatment standards for pollutants introduced into publicly owned
treatment works. The regulations set forth pretreatment standards for
new sources and for existing sources pursuant to Sections 307 (b) and
(c) of the Act for the pressed and blown glass segment of the glass
manufacturing point source category.
The guidelines presented in this document identify (in terms of the
chemical, physical, and biological characteristics of pollutants) the
level of pollutant reductions attainable through the application of
the best practicable control technology currently available and the
best available technology economically achievable. The guidelines
also specify factors which must be considered in identifying the
technology levels and in determining the control measures and
practices which are to be applicable within given industrial
categories or classes.
In addition to technical factors, the Act requires that a number of
other factors be considered, such as the costs or cost-benefits and
the non-water quality environmental impacts (including energy
requirements) resulting from the application of such technologies.
22
-------
SUMMARY OF METHODS USED FOR DEVELOPMENT OF THE EFFLUENT LIMITATION'S
GUIDELINES AND STANDARDS OF PERFORMANCE • <-.
Methodology * •
The effluent limitations guidelines and standards of performance
freposed herein were developed in the following manner. The point
source category was first categorized for the purpose of determining
whether separate limitations and standards are appropriate for
different segments within the point source category. Such subcate-
aorization was based upon raw material used, product produced,
manufacturing process employed, and other factors. The raw waste
characteristics for each subcategory were then identified. This
included an analysis of (1) the source and volume of water used in
the process employed and the sources of waste and waste water 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 water or aquatic organisms. The
constituents of 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 subcategory was identified. This included an identification of
each distinct control and treatment technology, including both in-
plant and end-of-process technologies, which are existent or capable
of being designed for each subcategory. It also included an
identification in terms of the amount of constituents (including
thermal) and the chemical, physical, and biological characteristics
of pollutants, of 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 quality environmental impact, such as the
effects of the application of such technologies upon other pollution
problems, including air, solid waste, noise and radiation were also
identified. The energy requirements of each of the control and
treatment technologies were identified as well as the cost of the
application of such technologies.
The information, as outlined above, was then evaluated in order to
determine what levels of technology constituted the "best practic-
able control technology currently available", "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 applica-
tion of technology in relation to the effluent reduction benefits to
be achieved from such application, the age of equipment and
facilities involved, the process employed, the engineering aspects
of the application of various types of control techniques, process
23
-------
changes, non-water quality environmental impact (including energy
requirements)f and other factors.
Basis for Guideline Development
The data for identification and analyses were derived from a number
of sources. These sources included EPA and industry-supplied
information; published literature; and on-site visits, interviews,
and sampling at typical or exemplary plants throughout the United
States. References used in the guidelines for effluent limitations
and standards of performance on new sources reported herein are
included in Section XIII of this document.
Several types of waste water data were analyzed. These include:
RAPP data, information supplied by industry and State pollution
control agencies, and data derived from the sampling of typical or
exemplary plants. The data retrieval form illustrated in Figure 1
was developed to aid in the collection of data during interviews and
plant visits and was supplied to the industry to indicate the types
of information required for the study.
The data were analyzed with the aid of a computer program which
provided the capability for summing the data for each plant where
multiple discharges existed, averaging the data for each plant where
multiple data sets were available, and comparing and averaging the
data for all plants within each subcategory to determine values
characteristic of a typical plant. Input to the computer for each
plant consisted primarily of the plant production rate, the waste
water flow rate, the concentration of each constituent of the plant intake
water, the average and maximum concentrations of each constituent in
the waste water, and some descriptive information regarding existing
waste treatment methods, subcategory type, and sampling methods.
An example of the computer printout is the hypothetical summary of
effluent oil and grease concentration data for glass container
plants without treatment illustrated in Figure 2. The pounds,per day
increase, mg/1 increase, and pounds added per day per production
unit are calculated. Data from all of the plants listed are
summarized in terms of the average, standard deviation (SIGMA), and
minimum and maximum values for the data listed. The weighted
average listed on the final line was used when the data from a
single plant was summarized. Multi-sample data summaries, such as
weekly or monthly averages, were thereby averaged in proportion to
the number of individual samples included in the summary.
The name and location of the plants for which data were available
are listed in Tables 1 and 2, and their geographic location is
indicated on Figures 3 and 4. Seventy-eight plants supplied some
type of usable information or data for computer analysis. RAPP data
were available and used for 52 plants.
Thirteen plants covering various manufacturing processes were
visited. The subcategories are listed in Table 3 along with the
type of data collected, seven plants were sampled, including two
-------
Ui
EPA MASS INDUSTRY STUDY
Data Retrieval Form Ho. 3
November 1973
I GENERAL
A. Company Name
B. Plant Name and Location
C. Contact - Company Personnel
- Plant Personnel
D, Telephone No,
II MANUFACTURING PROCESS CHARACTERISATION (Separate sheet for each
process)
A. Products manufactured
B, Type of equipment and machirory used
C. General flow diagram of manufacturing process (See attachment)
D. Age
1. Age of Plant
2. Age of major manufacturing equipment
3. Estimated life of major manufacturing equipment
E. Production
1. Yearly average tons fill/day (total plant)
2, Approximate percent of yearly production requiring
fabrication where water is used
a. Grinding
b. Acid Polishing
c , Etching
d. Scrubbers
e. Other (Specify)
a. Tons Fill
b, Production for finishing steps requiring water
Piece B Pounds
l) Grinding
2) Acid Polishing
3) Etching
4) Scrubbers
5) Other (Specify)
F. Energy Requirements
(One of the requirements of the study is a statement of
the percentage increase in energy required for wastawater
treatmsnt as compared to the energy required for glass
production. Express energy requirements as horsepower,
BTU or other convenient units required to produce a unit
of glass. If possible, list melting tank fuel separate
from other energy requirements.)
G. Operating Schedule
1, Normal hr/day and day/week
2. Maximum hr/day
3. Maximum day/week
H. Approximate Number of Employees (by shift)
I. Water Requirements 4
1. Total irolume and source (city water, well water, etc.)
FIGURE 1
DATA RETRIEVAL FORM
-------
2. Uses
a. Process
b. Cooling
c. Plant Cleanup
d. Boiler
e. Scrubbers
f. Otiier (define use)
3, Attach any available information on Raw Water (jiality
(See III E.)
4. Pretreatment Requirements
a. Volume Treated
t>. Reason for Treatment
in PROCESS '.
A, Wastewater Source
For each setter that leaves company property, list manufac-
turing steps that contribute measurable ivastenater and give
the average, minimum and maximum flow from each source
expressed aa gal/day. Completely segregated sanltaiT1 sewers
maybe neglected. Estimated flow rates should be eo indicated.
c. Describe Treatment System and Operation
d. Type and Quantity of Chemicals Used
e. Attach any available information on Treated
Water Qiality (See III E.)
FIGURE 1 (CONTD.)
-------
Is wastewater discharged to a surface stream or storm sewer
or to a city sanitary sewer system!
Are wastewater characteristics appreciably different during
startup and shutdown as compared to normal operation?
Quantity and point of application of oil, cleaning agents
and other chemicals used which might enter the wastewater
stream.
Treatment Methods
1. Wastewater source and volune
2. Reason for Treatment
3. Describe treatment system and operation
quantity of chemicals used
F. Wastewater Quality
(Attach any available data on water quality, both before
and after treatment, such as pH, BOD, COD, solids, heavy
netals, temperature, etc. Identify with respect to tie
sources listed in part A of this section. Indicate the
type of sample (grab, _ hour composite, etc.) and give
the •production during the sampling period as outlined in
Part II E.
Q. Describe inplant methods of water conservation and/or waste
reduction presently in use or anticipated.
H. Identify any air pollution, noise or solid waste resulting
from treatment or other control methods. How is solid
waste disposed of?
I. Dascrlbe water pollution control methods being considered
for future application.
J. Cost information (related to water pollution control)
1, Treatirent plant and/or equipment cost
2. Operating Costs (personnel, maintenance, etc.)
3. fewer Costs
i,. Estimated Equipment Life
IV COOLING WATER
A. Process steps requiring cooling water
B. Heat rejection requirements (BTU/hour)
C. Type of cooling system (once-through or recycle)
D. Water temperatures and flow rate
1. Input
2. Output
3. Flow Hate
E. Cooling tower or spray pond (circle which)
1. Slowdown Rate
2. Slowdown Control Jtfethod
3. Type and quantity of water treatment chemicals used
4. Attach any available information on blowdown water
quality (See III E.)
F. Type and quantity of chemicals used for once-through
cooling water treatment
V BOILER
A. Capacity
B. Attach any available information on blowdown rate and
quality (See III E.)
FIGURE 1 (CONTD.)
-------
PART A AND 0 PARAMETERS OF INTAKE WATER AND DISCHARGE. BREAKDOWN BY PLANT
to
00
MGO
ITEM NO.
INF.
GPO/ CONO
P-UNIT MS/L
EFF.
AVE.
MG/L
CONC<
MAX
MG/L
NAME- PLANT A
0.36 1244*44 1.
550. OIL AND GREASE
17.
NAME- PLANT B
0.435 828.571 2.
6.
NAME- PLANT c
0.17 340.
NAME- PLANT 0
0*81 1350.
1.5
0*
7.1
11.
.LB/DAY INCREASE
AVE MAX
LBS ADDED PER
MG/L INCREASE UNIT/DAY PRODUCT UNIT
AV£ MAX
PRODUCTION- 450. TONS/DAY.NONE»GC
IB. 74.7264 79.3968 16. 17. 450.
PRODUCTION- 525. TONS/DAY.NONE»GC
7* 14.5116 18.1395 4. 5* 525*
PRODUCTION- 500. TONS/DAY*NONE»GC
8.4 7.93968 9.78281 5.6 6.9 500.
. PRODUCTION- 600. TONS/DAY.NONE.GC
14. 74.3094 94.5756 11. 14. 600.
AVE
MAX
SAMPLE TYPE
1 DATA POINTS
0,16605 0.17643COMPt24 HR, 6-18-72
1 DATA POINTS
0.02764 0.03455GRA8, 1-15-74
1 DATA POINTS
0.01587 0.01956COMP.24 HR» 1-25-74
1 DATA POINTS
0.12384 0.15762GRAB* 1-5-74
1.975 3763.01 4.5 41.1 47.4 171.487 201.895 36.6 42.9 2075.
0.49375 940.754 1.125 10.275 11.85 42.8717 50.^737 9.15 10.725 518.75
0.26625 459.42 0.85391 4.97016 5.09477 36.6405 42.7503 5.46107 5.7011 62i5
0.81 1350. 2. 17. 18. 74.7264 94.5756 16. 17. 600.
0.17 340. 0* 6. 7. 7.93968 9.78281 4. 5* 450.
0.33342 0.38818
0.08335 0.09704
0.07334 0«0814
0.16605 0.17643
0.01587 0.01956
0.49375 940.754 1.125 10.275 11.85 42.8717 50.4,737 9.15
10*725 518.75 0.08335 0.09704
TOTAL
AVER.
SIGMA
MAX.
M1N.
WT.AV.
FIGURE 2
SAMPLE COMPUTER FORMAT
-------
TABLE 1
GLASS CONTAINER PLANTS
COMPANY NAME
Anchor Hocking
Ball
Brockway Glass
Chattanooga Glass
Columbine Glass
Foster-Forbes Glass
Gayner Glass Works
Glass Containers
PLANT LOCATION
Jacksonville, Fla.
Houston, Texas
Gurnee, 111.
Connellsville, Pa.
Salem., N. J.
Winchester, Ind.
San Leandro, Calif.
Mundelein, 111.
El Monte, Calif.
Muskogee, Okla.
Clarks"burg, ¥. Va.
Lapel, Ind.
Ada, Okla.
Freehold, N. J.
Zanesville, Ohio
Chattanooga,- Term.
Corsicana, Texas
Gulfport, Miss.
Mt. Vernon9 Ohio
Keyser, ¥. Va.
Wheat Ridge, Colo.
Marion, Ind.
Salem, N. J.
Indianapolis, Ind.
Danville, Conn.
Jackson, Miss.
Parker, Pa-
Marienville, Pa.
Knox, Pa.
Forest Park, Ga.
Palestine, Texas
Antioch, Calif.
Gas City, Ind.
Hayward, Calif.
Vernon, Calif.
29
-------
TABLE 1 (Contd.)
GLASS CONTAINER PLANTS
COMPANY NAME
Glenshaw Glass
Kerr Glass Mfg.
Latchford Glass
Laurens Glass
Liberty Glass
Madera Glass
Maryland Glass
Metro Containers
Midland Glass
Northwestern Glass
Obear-Nestor
Pierce Glass
Owens-Illinois
PLANT LOCATION
Glenshaw, Pa.
Millville, N. J.
Plainfield, HI.
Dunkirk, Ind.
Santa Ana, Calif.
Sand Springs, Okla.
Los Angeles, Calif.
Henderson, N. C.
Laurens, S. C.
Ruston, La.
Sapulpa, Okla.
Madera, Calif.
Baltimore, Md.
Jersey- City, N. J.
Carteret, N. J.
Dolton, 111.
Washington, Pa.
Shakopee, Minn.
Seattle, Wash.
E. St. Louis, HI.
Lincoln, HI.
Port Allegany, Pa.
Huntington, V. Va.
Fairmont, W. Va.
Alton, 111.
Streator, 111.
Gas City, Ind.
Bridgeton, N. J.
Waco, Texas
Oakland, Calif.
30
-------
TABLE 1 (Contd.)
GLASS CONTAHIER PLANTS
COMPANY NAME PLANT LOCATION
Owens-Illinois (Contd.) Clarion, Pa.
Los Angeles, Calif.
Brockport, N. J.
Charlotte, Mich.
New Orleans, La.
Atlanta, Ga.
North Bergen, N. J,
Lakeland, Fla.
Portland, Ore.
Tracy, Calif.
Puerto Rico Glass San Jiian, P. R.
Thatcher Glass Mfg. Lawrencebtirg, Ind.
Saugus, Calif.
Ehnira, N. Y.
Whoaton, IT. J.
Tampa, Fla.
Streator, 111.
31
-------
TABLE 2
PRESSED AND BLOW GLASS PLANTS
COMPANY NAME
Anchor Hocking
Brockway Glass
Corning Glass Works
Federal Glass
General Electric
Owens-Illinois
Corning Glass Works
General Electric
GTE-Sylvania
Westinghouse Electric
Corning Glass Works
Owens-Illinois
Machine Pressed and Blown Glassware Plants
PLANT LOCATION
Lancaster, Ohio (Plant #l)
Lancaster, Ohio (Plant #2)
Clarksburg, W. Va.
Corning, N. Y.
Muskogee, Okla.
Greenville, Ohio
Danville, Va.
Harrodsburg, Ky.
Columbus, Ohio
Niles, Ohio
Somerset, Ky.
Toledo, Ohio
Walnut, Calif.
Tubing Plants
Blacksburg, Va.
Danville, Ky.
Bucyrus, Ohio
Logan, Ohio
Jackson, Miss.
Bridgeville, Pa.
Greenland, K. H.
Fairmont, W. Va.
Television Picture Tube Envelope Plants
Albion, Mich.
Bluffton, Ind.
State College, Pa.
Columbus9 Ohio
Pittston, Pa.
32
-------
TABLE 2 (Contd.)
PRESSED AND BLOWN GLASS PLANTS
COMPANY NAME
Corning Glass Works
General Electric
The Beaumont Co.
Blenko Glass
Canton Glass Division
Colonial Glass
Crescent Glass
Davis-Lynch Glass
Elite Co.
EMC Glass
Erie Glass
Erskine Glass
Fenton Art Glass
Fostoria Glass
Gillender Brothers
Glassworks, Inc.
Harvey Industries
Imperial Glass
Jeannette Shade & Novelty
Johnson Glass and Plastic
Kanawha Glass
Kessler, Inc.
Kopp Glass, Inc.
Lenox Crystal, Inc.
Lewis County Glass
Louie Glass
Minners Glass
Overmyer-Perram Glass
Pennsboro Glass
Pilgrim Glass
Raylite Glass
St. Clair Glassworks
Scandia Glassworks
Scott Depot Glass
Seneca Glass
Sinclair Glass
Sloan Glass, Inc.
Smith Glass
I ncandu.scent Lamp Enve Lope_PIantj>
PLANT LOCATION
Central Falls, R.I.
WeiIsboro, Pa.
Lexington, Ky.
Miles, Ohio
Cleveland, Ohio
l\ai\d Pressed & Blown Glassware Plants
Morgantown, W.Va.
Milton, W.Va.
Hartford City, Ind.
Deanville, W.Va.
Wellsburg, W.Va.
Star City, W.Va.
New York, N.Y.
Decatur, Texas
Parkridge, 111.
Wellsburg, W.Va.
Williamstown, W.Va.
Moundsvilie, W.Va.
Port Jervis, N.Y.
Huntington Beach, Ca.
Clarksburg, W.Va.
Bellaire, Ohio
Jeannette, Pa.
Chicago, 111.
Dunbar, W.Va.
Bethpage, L.I.
Pittsburgh, Pa.
Mt. Pleasant, Pa.
Jane Lew, W.Va.
Weston, W.Va.
Salem, W.Va.
Tulsa, Okla.
Pennsboro, W.Va.
Ceredo, W.Va.
Southgate, Ca.
Elwood, Ind.
Kenova, W.Va.
Fort Smith, Ark.
Morgantown, W.Va.
Hartford City, Ind.
Culloden, W.Va.
Mt. Pleasant, Pa.
33
-------
TABLE 2 (Contd.)
PRESSED AND BLOWN GLASS PLANTS
Company Name Hand Pressed & Blown Glassware Plants
Super Glass Brooklyn, N.Y.
Viking Glass New Martinsville, W.Va.
Viking Glass Huntington, W.Va.
Westmoreland Glass Grapeville, Pa.
Wheaton Industries Millville, N,J.
West Virginia Glass Specialty Weston, W.Va.
34
-------
w
FIGURE 3
LOCATION OF PARTICIPATING GLASS CONTAINER MANUFACTURING PLANTS
-------
u
ON
•& MACHINE PRESSED AND BLOWN GLASS PLANT
A GLASS TUBING PLANT
• TELEVISION PICTURE TUBE ENVELOPE PLANT
• INCANDESCENT LAMP GLASS PLANT
* HAND PRESSED AND BLOWN GLASS PLANT
FIGURE 4
LOCATION OF PARTICIPATING PRESSED AND BLOWN GLASS MANUFACTURING PLANTS
-------
TABLE 3
PLANTS VISITED
Plant Types Ho. of Plants Type of Data Obtained
Glass Container 3 CO (2)
Machine Pressed and Blown 2 Cl) (2)
Tubing 1 (2)
TV Picture Tube Envelope 2 Cl) (2)
Incandescent Lamp Envelope 1 (l) (2)
Hand Pressed and Blown k (l) (2)
(l) - Individual process or siib category.
(2) - End-of-pipe including all process and auxiliary wastes.
37
-------
glass container plants, one machine pressed and blown glass plant,
one television picture tube envelope plant, one incandescent lamp
envelope plant, and two hand pressed and blown glass plants. Plant
sampling provided significant data on raw and treated waste water
volumes and characteristics and verified the data obtained from the
industry.
GENERAL DESCRIPTION OF THE INDUSTRY
Production Classification
The U.S. Bureau of Census, Census of Manufacturers, classifies the
glass container manufacturing and pressed and blown glass
manufacturing industries as Standard Industrial Classifications
(SIC) group code numbers 3221 and 3229, respectively. Both group
numbers are under the more general category of Stone, Clay, Glass,
and concrete Products (Major Group 32) and,more specifically, under
Glass and Glassware, Pressed or Blown (Group Number 322). The four-
digit classification code (3221) covers industrial establishments
engaged in manufacturing glass containers for commercial packing and
bottling, and for home canning. The classification code (3229)
comprises all industrial establishments primarily engaged in
manufacturing glass and glassware, pressed, blown, or shaped from
glass produced in the same establishment. Establishments also
covered by code (3229) include those manufacturing textile glass
fibers and pressed lenses for vehicular lighting, beacons, and
lanterns. Effluent limitations guidelines and new source
performance standards for textile glass fiber manufacturing have
previously been promulgated by the EPA.
Origin and History
The origin and history of glass is thought to have begun with the
Egyptians in 4000 B.C. The first glass articles manufactured by the
Egyptians were small, decorative, glass-covered objects. The first
true glass vessels - small bottles, goblets, or vases - come from
the Egyptian royal graves of the period around 1555-1350 B.C. The
glass vessels were made by the sand core technique in which a sand
core is stuck to a metal rod, fired or fritted, and coated by a
thick layer of viscous glass. Further forming was accomplished by
reheating and using simple tools such as pinchers, but not by
blowing.
Glass blowing originated in the Eastern Mediterranean at the
beginning of the first century B.C. The glass blow-pipe was
introduced to the Western Mediterranean around 30 B.C. The blow-
pipe method of forming glass was used from this time on and has only
gradually been replaced by mechanical processes since the end of the
19th Century.
The glass pressing machine was introduced in America in 1827. In
this process the molten glass is pressed into a mold manually with a
plunger. Several other glass manufacturing innovations occurred in
the 19th Century. The first successful bottle-blowing machine was
38
-------
invented by Ashley of England in 1888. Several other bottle-making
machines were developed during the next years. In 1889 Michael J.
Owens conceived the first fully automatic bottle machine, which in
less than 20 years revolutionized glass container manufacturing.
Another major manufacturing breakthrough was the introduction of the
Corning ribbon machine in the early 1900's. The ribbon machine can
manufacture as many as 2200 bulbs per minute. The Hartford I.S.
(Individual Section) machine, developed in 1925, remains the most
popular method for manufacturing glass containers. Techniques for
forming glass containers and machine pressed products have
essentially remained the same since the 1920' s. Most recent
developments in the glass industry are in the application of glass
into new areas such as conductive coatings, electrical components,
and photosensitive glasses.
Description of Manufacturing Methods
There are four manufacturing steps that are common to the entire
pressed and blown glass industry. The four steps include weighing
and mixing of raw materials, melting of raw materials, forming of
molten glass, and annealing of formed glass products. Forming
methods vary substantially, depending on the product and
subcategory, and range from hand blowing to centrifugal casting of
picture tube funnels. Following forming and annealing, the glass
may be prepared for shipment or may be further processed in what is
referred to as finishing. There is little or no finishing involving
waste water in the glass container and machine pressed and blown
manufacturing, while extensive finishing is required in television
picture tube envelope, incandescent lamp envelope, and hand pressed
and blown glassware manufacturing. Finishing of glass tubing is not
covered by this study.
PRODUCTION AND PLANT LOCATION
There are approximately 30 firms with a total of 140 plants
presently manufacturing glass containers in the United States. The
eight largest firms in the industry produce about 78 percent of the
glass container shipments and operate two-thirds of the individual
plants. Plants are located throughout the United States to service
regional customers, but a large number are concentrated in the
northeastern United States. The industry originally located in the
Northeast because convenient sources of raw materials and fuel were
available.
The glass container industry employs over 70,000 persons and has a
daily processing capacity of 50,500 metric tons (55,500 tons) of
glass pulled. The average glass container plant capacity is 388
metric tons (U27 tons). Plants range in size from 122 metric tons
(13U tons) per day to 1320 metric tons (1U50 tons) per day (Table
<*)-
There are about 50 machine pressed and blown glass manufacturing
plants in the United States and the average capacity is 91 metric
tons (100 tons) pulled per day. Machine pressed and blown ware
39
-------
TABLE 1*
PRESSED AND BLOW GLASS MANUFACTURING
PRODUCTION DATA (a)
o
Number of Plants
GC
MPB
TB
TV
L
HPB
1UO
50
30
10
18
50
Average Plant Size Range
(metric tons/day) (metric tons/day)
388 122 - 1320
91
100
208
192
3.6
1*0
1*0
142
141
0.7
-3>*9
- 161*
- 255
- 245
- 6.5
Average Plant Size Range
(tons /day) (tons /day)
1*27
100
110
229
212
i*.o
13l*
1*1*
1*1*
156
155
0.8
- ll*50
- 381*
- 180
- 280
- 270
- 7.2
(a) All production figures except HPB based on weight of glass pulled from furnace in tons;
HPB "based on weight of finished product.
GC - Glass Containers
MPB - Machine Pressed and Blown
TB - Tubing
TV - Television Picture Tube Envelope
L - Incandescent Lamp Envelope
HPB - Hand Pressed and Blown
-------
plant capacities range from 40 metric tons (44 tons) to 349 metric
tons (384 tons).
About 30 plants manufacture glass tubing in the United States.
Production, expressed as furnace pull per day, ranges from 40 metric
tons (44 tons) per day to 164 metric tons (180 tons) per day and
averages 100 metric tons (110 tons).
Approximately 10 television picture tube envelope factories are
located in the United States. The average amount of glass pulled
per day is 208 metric tons (229 tons). Plant production varies from
142 metric tons (156 tons) pulled per day to 255 metric tons (280
tons) pulled per day.
Incandescent lamp envelopes are manufactured at 18 plants in the
United States. Plant production in terms of furnace pull ranges
from 141 metric tons (155 tons) per day to 245 metric tons (270
tons) per day. The average plant production is 193 metric tons (212
tons) per day.
Hand pressed and blown glass manufacturing plants are small and
primarily located in West Virginia, western Pennsylvania, and Ohio.
Approximately fifty handmade glassware plants are located in the
United States. A number of hand pressed and blown ware plants also
have facilities td manufacture machine-made glassware. The average
amount of finished product produced per day at a hand pressed and
blown ware plant is 3.6 metric tons (4.0 tons). The range of
production varies from 0.7 metric tons (0.8 tons) per day to 6.5
metric tons (7.2 tons) per day.
GENERAL PROCESS DESCRIPTION
Pressed and blown glass and glassware are covered in this study.
The pressed and blown glass industry has been characterized as glass
container, machine pressed and blown glass, glass tubing, television
picture tube envelope, incandescent lamp envelope, and hand pressed
and blown glass manufacturing. Pressed and blown glass
manufacturing consists of raw material mixing, melting, forming,
annealing, and, in some cases, finishing.
The basic unit of production for all subcategories, except hand
pressed and blown glass manufacturing, is the metric ton (or ton in
English units) and is based on the amount of glass drawn from the
melting tank. These units were chosen because they relate directly
to plant size and waste water production and will be readily
available to enforcement personnel. The number of metric tons
(tons) of finished product is a more convenient unit for hand
pressed and blown glass manufacturing because waste water
characteristics are related to finishing operations rather than
metric tons (tons) pulled from the furnace. The number or pieces
produced is also a common unit, but does not appear to correlate
with waste water production as well as the number of metric tons
(tons) of finished product.
41
-------
Raw Materials-
Soda-lime glass is used to some extent in all subcategories except
television picture tube envelope manufacturing. The basic composi-
tion of the batch mix remains the same; however, there may be minor
variations in raw material composition depending on the manufacturer
and the product. Sand (silica) is the major ingredient and accounts
for about 70 percent of the batch. Another major ingredient is soda
(sodium oxide) or soda ash which is about 13 to 16 percent of the
batch. Soda and sometimes small quantities of potash (potassium
oxide) are added as fluxing agents which reduce the viscosity of the
mixture greatly below that of the silica. This permits the use of
lower melting temperatures and thereby improves the process by which
undissolved gases are removed from the molten glass. Lime (calcium
oxide) and small amounts of alumina (aluminum oxide) and magnesia
(magnesium oxide) are added to improve the chemical durability of
the glass; iron or other materials may be added as coloring agents.
The usual batch also has between 10 and 50 percent cullet. The
quantity of cullet added depends on the availability and allowable
levels in the total batch.
Cullet is waste glass that is produced in the glass manufacturing
process. Principal sources are product rejects, breakage, or
intentional wasting of molten glass to produce cullet. The addition
of cullet improves the melting qualities of the batch because of its
tendency to melt faster than the other ingredients, thus providing
starting points from which the melting can proceed.
Other glass types used by pressed and blown glass manufacturers
include lead-alkali silicate glass and borosilicate glass. Lead
oxide replaces the lime of the soda-lime glass to form lead-alkali
silicate glasses. The lead oxide acts as a fluxing agent and lowers
the softening point below that of the soda-lime glass. The lead
oxide also improves the working qualities of the glass when the lead
oxide proportion is less than about 50 percent. Lead-alkali
silicate glass is used in the production of television picture tube
envelopes and lead crystal. Lead apparently limits radiation in the
television picture tube application.
Boric oxide acts as the fluxing agent for silica in borosilicate
glasses. Boric oxide has less effect than soda in lowering the
viscosity of silica and in raising the coefficient of expansion. A
higher melting temperature is required for borosilicate glasses than
for soda-lime and lead-alkali silicate glasses. The borosilicate
glass is also more difficult to fabricate than the other two glass
types. The primary advantages of borosilicate glass are its
coefficients of expansion and its greater resistance to the
corrosive effects of acids. The lower coefficient of expansion
allows the glass to be used at higher temperatures. Borosilicate
glass is used for machine pressed products such as lenses and
reflectors, for some incandescent lamp envelopes, and for tubing
that is to be fabricated into laboratory and scientific glassware.
-------
Raw Material Storage and Mixing-
Raw materials are shipped to the glass manufacturers in bulk
quantities. The raw materials are conveyed automatically to large
storage silos or holding bins. Gullet is transported from the
points where it is produced, and then sent to segregated storage
areas according to the type and color of the cullet.
Batch weighing and mixing is usually done according to formulas
which are based on either 454 kilograms (1000 pounds) of glass or on
454 kilograms (1000 pounds) of sand. The type of mixing systems
used at the pressed and blown glass manufacturing plants range from
hand batching at small hand pressed and blown glass plants to fully
automatic systems. Water is also added to the batch at some plants
to reduce segregation of the batch and to control dust emissions
during mixing. After mixing, the glass batch is charged into the
glass furnace manually or automatically. Furnace charging can be
either continuous or intermittent.
Melting-
Melting is done in three types of units, according to the amount of
glass required. Continuous furnaces are standard at the glass
container, machine pressed and blown, glass tubing, television
picture tube envelope, and incandescent lamp envelope plants, but
clay pots and day tanks are used in the manufacture of hand pressed
and blown ware.
Pots and day tanks are well suited for the variable composition and
small quantities of glass required in handmade glass plants. The
multi-pot furnace is the primary method of melting in these plants.
Eight or more pots may be grouped in a circular arrangement as part
of one furnace. Temperatures as high as 1400 degrees centigrade
(2550 degrees Fahrenheit) may be achieved. Pot capacities range
from 9 kilograms (20 pounds) to 1820 kilograms (two tons). A day
tank is a single furnace and is somewhat larger than a pot,
generally having a capacity of several metric tons (tons). Both
pots and day tanks are batch fed at the end of the working day and
allowed to melt overnight.
Continuous tanks range in holding capacity from 0.9 to 1270 metric
tons (one to 1400 tons), and outputs may be as high as 273 kkg/day
(300 tons/day). The continuous tank consists of two areas, a
melting chamber and a fining chamber. The chambers are separated by
an internally cooled wall built across the tank. The fining chamber
allows gas bubbles to leave the melt. Extensions from the fining
chamber called forehearths are used to condition the glass before
forming.
Forming-
Several methods are used to form pressed and blown glassware. These
include blowing, pressing, drawing, and casting.
-------
Blowing—The individual section (I.S.) forming machine is the most
widely used method for making glass containers. Forming of the
glass container involves several blowing steps. The molten glass is
cut into gobs by a set of shear cutters as the glass leaves the
forehearth of the melting tank. Chutes direct the gobs into blank
molds. The shear cutter and chutes are lubricated and cooled with a
spray of emulsified oil. The molten glass gob is settled with
compressed air and preformed with a counter blow. The preformed gob
(parison) is then inverted and transferred into a blow mold where
the glass container is finished by final blowing.
A pressing and blowing action is used to form wide-mouthed
containers. The molten glass gob is cut and delivered to the mold,
and the gob is then pressed and puffed. The preformed gob is in-
verted for final blowing to complete the forming of the container.
A few Owens machines are still in use but these are slowly being
replaced by I. S. machines, owing to the higher production and lower
operating expense associated with these units. The Owens machine
consists of a number of molds arranged around a central axis. The
entire machine rotates and glass is sucked by vacuum into the
parison mold. The parison is then transfered to the blow mold for
final blowing. Shear or chute sprays are not required for these
machines.
Incandescent lamp glass envelopes are formed using a ribbon machine.
The ribbon machine employs modified blowing techniques to form the
envelopes. The molten glass is discharged from the melting tank in
a continuous stream and passes between two water cooled rollers.
One roller is smooth while the other has a circular depression. The
ribbon produced by the rollers is then redirected horizontally on a
plate belt. The plate belt runs at the same speed as the forming
rollers. Each plate on the plate belt has an opening and the pill
shaped glass portion of the ribbon sags through the openings due to
gravity. The glass ribbon is met by a continuous belt of blow
heads; the blow heads aid the sag of the glass by properly timed
compressed air impulses. After the glass has been premolded, it is
enclosed by blow molds which are brought up under the premolded
glass on a continuous belt. The blow molds are pasted and rotate
about their own axis to obtain seamless smooth surfaces. Both the
blow heads and molds are lubricated with a spray of emulsified oil
(shear spray). The formed envelopes (bulbs) are separated from the
ribbon by scribing the neck of the bulb and tapping the bulb against
a metal bar. Residual glass is collected as cullet.
Hand blow glassware is made using a blowpipe. Molten glass is
gathered on the end of the blowpipe and, utilizing lung power or
compressed air, is blown into its final shape. After the main sec-
tion is formed, additional parts such as handles and stems can be
added. This is accomplished by gathering a piece of molten glass,
joining it to the molded piece,and then forming the joined pieces
with special glassworking tools.
44
-------
Pressing—Much glassware is manufactured using presses. A press
mold consists of three sections: the mold bottom, the plunger, and
an enclosing ring that seals the mold between the mold bottom and
the plunger. Pressing is done manually in the handmade subcategory
or by machine in the remainder of the industry.
In manual pressing of glassware, molten glass is collected on a
steel rod and allowed to drop into the mold bottom. When the proper
amount of glass is deposited in the mold, the glass remaining on the
rod is separated from that in the mold by cutting with a pair of
shears. The plunger is then forced into the mold with sufficient
pressure to fill the mold cavities. The glass is allowed to set-up
before the plunger is withdrawn and the pressed glass is removed
from the mold.
Machine pressing is done on a circular steel table. The glass is
fed to the presses in pulses from a refractory bowl following the
forehearth of the melting tank. The molten glass is cut into gobs
by oil-lubricated shear cutters beneath the orifice of the
refractory bowl. The motions of the shear cutters and the press
table are synchronized such that the gobs fall into successive molds
on the press table. After the gob is received in the mold, it moves
to the next station on the press table, where it is pressed by a
plunger. In the remaining stations, the pressed glass is allowed to
cool before it is removed from the press and conveyed to the
annealing lehr.
The mold bottoms are usually cooled by air jets and the plunger
sections are cooled with non-contact cooling water. The mold
temperature is critical; if the mold is too hot, the molded piece
will stick to the mold and if it is too cold, the piece may have an
uneven surface. In some cases, the mold is sprayed with water prior
to receiving the glass. The steam formed when the molten glass is
introduced helps prevent sticking. Machine pressed glass products
include tableware, lenses, reflectors, and television picture tube
faceplates.
Shear Spray—In the manufacture of most machine-made pressed or
blown glass products, blow heads, molds, and shearcutters are
lubricated and cooled with a spray of emulsified oil (shear spray) .
This may be made up of petroleum or synthetic oils of an animal of
vegetable nature. The trend in recent years has been to utilize
synthetic biodegradable shear spray oils.
Drawing—Glass tubing may be formed using three different processes.
In the Danner process, a regulated amount of glass falls upon the
surface of a rotating mandrel which is inclined to the horizontal.
Air is blown through the center of the mandrel continuously to
maintain the bore and the diameter of the tubing as it is drawn away
from the mandrel. The tubing is pulled away from the mandrel on
rollers by the gripping action of an endless chain. Tubing
dimensions are controlled by the drawing speed and the quantity of
air blown through the center of the mandrel. The tubing is scribed
by a cutting stone that is accelerated to the drawing speed and
45
-------
pressed vertically against the tubing and then cut by bending
against a spring controlled roller.
The Velio and Updraw processes can also be used to form tubing. In
the Velio process, the molten glass passes downward through the
annular space between a vertical mandrel and a refractory ring set
in the bottom of a special forehearth section of the melting tank.
The tubing is drawn away from the Velio machine and cut in a manner
similar to that used for the Danner Process.
The Updraw process is used to make large diameter tubing and glass
pipe. In the Updraw process, the tubing is drawn upward from a
refractory cone. Air is blown up through the cone to control
dimensions and cool the tubing. The tubing is cut into lengths at
the top of the draw.
Casting—Television picture tube envelope funnels are formed by
casting. Molten glass is cut into gobs by oil-lubricated shear
cutters. The glass gob is then dropped into the mold. The mold is
spun sufficiently fast that the centrifugal force causes the glass
to flow up the sides of the mold to form a wall of uniform
thickness. A sharp-edged wheel is used to trim the upper edge of
the funnel at the end of the spinning operation.
Gullet Ouenching-
Cullet is waste glass that is produced both intentionally and
inadvertently. Gullet results from breakage, wasting of molten and
formed glass during production interruptions or machine maintenance,
rejection of formed pieces because of imperfections, and intentional
wasting. Wasting of glass during production interruptions is
necessary to maintain a steady flow of glass through the melting
furnace. All portions of the pressed and blown glass segment except
for hand pressed and blown glass manufacturing are effected by this
requirement. Gullet is conveyed from the manufacturing operation by
chutes into carts or tanks located in the furnace basement.
A continuous stream of water is discharged through the chutes and
into the quench carts and tanks to cool or quench the hot glass.
Excess water overflows from the quench cart or tank and is
discharged into the sewer. When the cart or tank is filled with
glass, it is removed from the quench stream, allowed to drain, and
conveyed to a storage area where the cullet is dumped. In some
plants, quench carts have been replaced by water-filled vibrating
conveyors that automatically remove cullet to the storage area.
Cullet is segregated according to type and color.
Annealino-
After the glass is formed, annealing is required to relieve strains
that might weaken the glass or cause it to fail. The entire piece
of glassware is brought to a uniform temperature high enough3 to
permit the release of internal stresses and then cooled at a uniform
rate to prevent new strains from developing. Annealing is done in
46
-------
long continuous ovens called lehrs. The dimensions of the lehr
depend upon the type of glass to be annealed.
Finishing-
Following annealing, the pressed and blown glass is either finished
or inspected, packaged, and shipped. Glassware from all subcate-
gories may, in some cases, be finished but many finishing steps
require no water and produce no waste water. This study includes
the major waste water producing finishing steps that are normally
employed at the same location where the glass is produced. These
are television picture tube envelope finishing, incandescent lamp
envelope frosting, and hand pressed and blown glass finishing.
Television picture tube envelopes—Television picture tube envelopes
are manufactured in two pieces, referred to as the screen and
funnel. Both pieces require the addition of components prior to
annealing and several finishing steps which follow annealing. After
forming and prior to annealing, the seam on the screen is fire
polished and mounting pins are installed employing heat. The
mounting pins are required for proper alignment when the electronic
components are placed into the picture tube.
The stem portion and an anode to be used as a high voltage source
are added to the funnel prior to annealing. Both components are
fused onto the funnel using heat.
Following annealing, screens and funnels are visually inspected for
gross defects such as large stones, blisters and entrapped gas
bubbles. The screen dimensions and mounting pin locations are then
gaged to check for exactness of assembly. The funnel portion is not
gaged until all finishing steps are completed.
Screens and funnels are finished separately using different
equipment. The first finishing step applied to the television
screen section is abrasive polishing. Polishing is required to
assure a flawless and parallel surface alignment so that an un-
distorted picture will be produced when the tube is assembled. The
edge of both the screen and funnel must be perfectly smooth so that
a perfect seal will be formed when the two sections are glued
together. The seal must be sufficiently tight to hold a vacuum.
Abrasive polishing is accomplished in four steps using rough and
smooth garnet, pumice, and rouge or serium oxide. The abrasive
compounds are in a slurry form and are applied to the screen surface
by circular polishing wheels of varying texture. Between each
polishing step the screen is rinsed with water. The slurry
solutions are generally recycled through hydroclones or settling
tanks and only fine material too small to be useful for grinding or
polishing is wasted. Following abrasive polishing, the screen edge
is ground, beveled, and rinsed with water. This edge is then dipped
in a hydrofluoric acid solution to polish and remove surface
irregularities. This step may be referred to in the industry as
47
-------
fortification. Following rinsing, which removes residual acid, and
drying, the screen receives a final inspection.
The front edge of the funnel is polished with a diamond wheel
polisher. The polishing surface is bathed in oil and, therefore,
the funnel must be rinsed with water to remove the oily residue.
The edge of the funnel is then beveled and dipped in a combination
of hydrofluoric and sulfuric acids to polish or fortify. Following
the acid dip, the funnel is rinsed with water and dried before final
gaging and inspection.
Incandescent lamp envelopes—An incandescent lamp envelope may be
defined as the glass portion of a light bulb. Generally, envelopes
are not manufactured in the same plant where the bulbs are
assembled, and assembly is not covered by this study. Envelopes may
be clear, coated, or frosted, but either by habit or for esthetic
reasons, frosted bulbs are the most popular with consumers.
Frosting improves the light diffusing capabilities of the envelope.
Generally, lamp envelopes are frosted at the plant where the
envelope is produced and coatings are applied where the bulb is
assembled.
After annealing, the lamp envelopes are placed in racks for
processing through the frosting operation. The envelope interior is
sprayed successively with several frosting solutions. The specific
formulation of these solutions is proprietary, but primary
constituents include hydrofluoric acid and other fluoride compounds,
ammonia, water, and soda ash. Residual frosting solution is removed
in several rinse stages.
Hand pressed and blown—The manufacture of hand pressed and blown
glass involves several finishing steps including: crack-off,
washing, grinding and polishing, cutting, acid polishing, and acid
etching. The extent to which these methods are employed varies
substantially from plant to plant. Many plants use only a few of
the finishing methods. Washing and grinding and polishing are the
most prevalent.
Crack-off is required to remove excess glass that is left over from
the forming of hand blown glassware. Crack-off can be done manually
or by machine. When a machine is used for stemware, the stemware is
inserted into the crack-off machine in an inverted position. The
bowl of the stemware is scribed by a sharp edge, the scribed edge
passes by several gas flames and the excess glass is broken off.
The scribed surface is then beveled on a circular grinding medium
similar to sandpaper. Carborundum sheets are used in most cases.
The grinding surface is sprayed with water for lubrication and to
flush away glass and abrasive particles.
Hydrofluoric acid polishing of the beveled edge may follow crack-
off. This operation involves rinsing the glassware in dilute
hydrofluoric acid and city water, and in some cases, a final
deionized water rinse.
48
-------
Miscellaneous washing is employed throughout a handmade glass plant
and is associated with many finishing steps. Generally the
glassware receives a final washing before packaging and shipment.
In many cases this is done by hand in a small sink and the glassware
is hand-dried.
Mechanical washers are used in the larger plants. These units may
include several washes and rinses. In one such system, a
recirculating acid rinse is followed by a caustic rinse, a city
water rinse, and finally a steam spray to heat the glassware and
thus facilitate drying.
Abrasive grinding is used to remove sharp surfaces from the formed
glass products. Grinding is accomplished using a large circular
stone wheel. The glassware is placed in a rack and weights are
added to hold it against the rotating stone. The grinding surface
is lubricated with slowly dripping water.
Abrasive polishing is used to polish the glass surfaces and edges of
some types of handmade glassware. The glassware is placed in a bath
of abrasive slurry and brushed by circular mechanical brushes or
polishing belts. After polishing, the ware is rinsed with water in
a sink and dried,
Cutting as applied to handmade glassware manufacturing may be
defined as the grinding of designs onto the glassware or as the
removal of excess glass left over from forming. Designs may be
placed onto the glassware manually or by machine. In mechanical
design cutting, the ware is placed on a cutting machine and is
rotated in a circular motion. Designs are cut into the surface at
the desired points using a cutting edge. In the second form of
cutting, a saw may be used to remove excess glass from some handmade
products. Water is used in both machine design cutting and sawing
to lubricate the cutting surface and to remove cutting residue.
Acid polishing may be employed to improve the appearance or to
remove the rough edges from glassware. Automatic machines or
manually dipped racks may be employed. In the manual operation, the
glassware is placed in racks and treated with one or more
hydrofluoric acid dips followed by rinsing. The complexity and
number of steps is determined by the product. Many plants use a
one- or two-step acid treatment followed by two rinses. At least
one plant has a more complicated system using a series of
hydrofluoric acid, sulfuric acid, and water rinses.
Some of the larger plants employ automatic polishing techniques.
The glassware is loaded into acid-resistant plastic drums and placed
in the treatment vessel. Acid contact and rinsing is accomplished
automatically according to a preset cycle.
Complicated designs may be etched onto handmade stemware with
hydrofluoric acid. The design is first made on a metal template and
is transferred from the template to a piece of tissue paper by
placing a combination of beeswax and lampblack in the design and
49
-------
then pressing the tissue paper against the design. The tissue paper
is placed on the stemware and then removed leaving the pattern in
wax. All parts of the ware except for the pattern are then coated
with wax. The wax-coated stemware is placed in racks and immersed
in a tank of hydrofluoric acid where the exposed surfaces are
etched. Following a rinse to remove residual acid, the ware is
placed in a hot water tank where the wax melts and floats to the
surface for skimming and recycling. Several additional washes and
rinses are required to clean the ware and to remove salt deposits
from the etched surfaces. In some cases a nitric acid bath may be
used to dissolve these deposits. Deionized water may be used for
the final rinse to prevent spotting.
Miscellaneous finishing—Numerous finishing steps that do not
produce waste water are employed throughout the industry. These are
not of direct concern to this study and therefore are not covered in
detail. These finishing operations may be generally classified as
decorating or,in the container industry, as labeling. In most cases,
some form of paint or coating is applied and then baked onto the
glass surface. This procedure is referred to as glazing in the
handmade industry.
50
-------
SECTION IV
INDUSTRY CATEGORIZATION
The pressed and blown glass manufacturing industry, covered by this
study, includes a large and diverse group of products produced by
distinctly different manufacturing methods; these methods generate
waste waters with differing waste characteristics. Subcategorization
into smaller segments was necessary in order to develop meaningful and
workable effluent limitations and guidelines and new source
performance standards.
The following factors were given major consideration with respect to
subcategori zation:
1. Raw materials
2. Age and size of production facilities
3. Products and production processes
<*. Waste water characteristics
5. Applicable treatment methods
It is concluded that six subcategories are necessary to adequately
subdivide the industry and that, owing to variable finishing
requirements, several of these subcategories should be further
segmented. The subcategories and the identified further segmentation
are as follows:
1. Glass Container Manufacturing
2. Machine Pressed and Blown Glass Manufacturing
3. Glass Tubing Manufacturing
a. Glass Tubing - Banner process
4. Television Picture Tube Envelope Manufacturing
51
-------
5. Incandescent Lamp Envelope Manufacturing
a. Forming
b. Frosting
6. Hand Pressed and Blown Glass Manufacturing
a. Leaded and Hydrofluoric Acid Finishing
b. Non-Leaded and Hydrofluoric Acid Finishing
c. Non-Hydrofluoric Acid Finishing
Production methods and waste water characteristics are the primary
bases for subcategorization. Further segmentation within a
subcategory is necessary because of processing differences and/or
because of variable finishing requirements. For example, the forming
and frosting unit operations involved in the incandescent lamp
envelope manufacturing subcategory are vastly different both in terms
of water usage and waste characteristics. However, the basic
necessity for further segmentation is derived from the fact that not
all facilities which produce (form) incandescent lamp envelopes will
frost equal fractions of the formed envelopes. This necessitates the
use of separate limitations applicable to each of the two major unit
operations in order that any producer of incandescent lamp envelopes
may be properly characterized.
During the comment period following the proposal of regulations
pertaining to effluents discharged by plants which make up the pressed
and blown glass segment of the glass manufacturing point source
category, considerable additional data was submitted with regard to
the machine pressed and blown glass manufacturing subcategory. This
additional data and other information are being studied at the present
time. Also, more information is being gathered concerning the
manufacture of glass tubing. The results of these further analyses
wil1 be pres ented at a later date in a supplemental document.
Available data pertaining to the machine pressed and blown glass
manufacturing subcategory and the glass tubing (Banner) manufacturing
subcategory are presented in Section V of this document. However,
recommended effluent limitations pertaining to the machine pressed and
blown glass manufacturing and the glass tubing (other than by the
Danner process) manufacturing subcategories will be included in the
supplemental document.
52
-------
Raw Materials
Several types of glass are required in the pressed and blown glass
industry. soda-lime glass is used wherever possible, as it is the
least expensive to produce, Borosilicate glass is required where the
thermal coefficient of soda-lime glass is not satisfactory.
Borosilicate glass is used for some machine pressed and blown
products, tubing that is to be made into scientific glassware, and for
some incandescent lamp envelopes. Lead-alkali silicate glass is
required for television picture tube envelopes and for many types of
handmade glassware.
Available data do not show any relationship between raw materials and
waste water characteristics except where leaded glass is finished,
such as in a television picture tube or handmade glass plant. The
soluble and insoluble lead is discharged as a result of cutting,
grinding and polishing, or hydrofluoric acid treatment. Because lead
is discharged as a result of finishing operations and apparently is
not discharged as a result of forming, raw materials do not provide a
significant basis for subcategorization.
Age and Size of Production Facilities
Many pressed and blown glass manufacturing processes and techniques
have been used since the early part of this century. Improvements in
automation and water conservation have been made over the years but
because furnaces are rebuilt every three to six years, these
improvements have generally been applied to new and old plants alike.
Waste water volume and characteristics expressed per unit of
production do not vary significantly with respect to plant size.
Equipment of the same type and size is generally used throughout the
industry to manufacture a given product. Plant size or production
output is increased by operating more units in parallel. For these
reasons, the age or size of production facilities provides no basis
for subcategorization.
Products and Production Processes
The pressed and blown glass industry is readily categorized into
distinct products and production processes. Each product is unique to
a particular subcategory. These differences in production methods
provide a basis for subcategorization. Glass container manufacturing
is characterized by multi-blow forming techniques; machine pressed and
blown glass manufacturing by the automated press or multi-blow forming
techniques; tubing manufacturing by mandrel forming and drawing;
television picture tube envelope manufacturing by funnel casting and
53
-------
abrasive and acid polishing; incandescent lamp envelope manufacturing
by ribbon machine forming and frost finishing; and hand pressed and
blown glass manufacturing by hand blowing and hand pressing and by
numerous finishing steps applied to the glassware. The typical plant
production, expressed as metric tons per day, for these manufacturing
methods also varies significantly.
All of the manufacturing methods except those employed for handmade
glassware may be broadly classified as machine pressing or blowing,
but subcategorization is necessary because of the distinct variation
in manufacturing methods, typical production rates, and waste water
characteristics. The machine pressed and blown subcategory is
intended to cover the forming of products not covered under the other
subcategories. This portion of the industry is the subject of further
study at the present time. Results of this analysis and a further
analysis of the entire glass tubing industry will be published at a
later date.
Further categorization of the incandescent lamp envelope manfacturing
subcategory is necessary because not all of the products formed are
finished. The percentage of incandescent lamp envelopes frosted
varies from plant to plant. Forming waste water characteristics are
influenced by the metric tons pulled from the furnace, while frosting
waste water characteristics are governed by the metric tons of product
frosted.
Further categorization of the hand pressed and blown glass
manufacturing subcategory is necessary to take into account the
various finishing operations which are applied to the various types of
glass. Certain plants apply hydrofluoric acid finishing techniques to
either leaded or unleaded glass while other plants do not utilize
hydrofluoric acid. The further categorization is recommended in order
that effluent limitations guidelines be applied only to those
parameters which are consistent with the discharge from an individual
hand pressed and blown glass manufacturing plant.
Waste Water Characteristics
Waste water volumes and characteristics are directly related to the
manufacturing method and the quantity and quality of the product
produced. Forming waste waters may generally be characterized in
terms of oil and suspended solids. Finishing waste characteristics
are variable and depend upon the finishing technique employed. Some
finishing wastes contain only suspended solids, while others contain
suspended solids, fluoride, lead, or ammonia. The volume of waste
54
-------
water expressed in terms of production is substantially different
within each of the subcategories. Waste water characteristics form ,ai
basis for subcategorization.
Applicable Treatment Methods
Treatment methods are essentially the same throughout the pressed and
blown glass segment. Gravity separation methods are used to remove
oil from forming waste water; precipitation with lime addition,
followed by coagulation and sedimentation is employed to remove
fluoride, lead, and suspended solids from finishing wastes. Treatment
methods are not a basis for subcategorization because of similarities
of the treatment within the pressed and blown glass segment.
55
-------
-------
SECTION V
WATER USE AND WASTE CHARACTERIZATION
Water is used to some extent in all of the subcategories covered by
this study. Cooling water is required at all plants. Water is used
in the glass container manufacturing, machine-pressed and blown
glass manufacturing, and glass tubing manufacturing subcategories
for non-contact cooling and cullet quenching. The television
picture tube envelope manufacturing, incandescent lamp envelope
manufacturing, and hand pressed and blown glass manufacturing
subcategories use water for non-contact cooling, cullet quenching,
and also for product rinsing following the various finishing steps
specific to each subcategory.
Water used in-plant is obtained from various sources including the
city water supply, surface, or ground water. City water is used in
almost all cases, except where a plant-owned source is available.
AUXILIARY WASTES
For the purpose of this study, non-contact cooling, boiler, and
water treatment waste waters are considered auxiliary wastes as
distinguished from process waste waters. Process waste water is
defined as water that has come into direct contact with the glass,
and results from a number of sources involving both forming and
finishing.
Pretreatment requirements depend upon the raw water quality and the
intended water use. Cooling water pretreatment practices may range
from no treatment to coagulation - sedimentation, filtration,
softening, or deionization. Treatment is normally applied to
prevent fouling of the cooling system by clogging, corrosion, or
scaling. Boiler water treatment depends on boiler requirements.
Treatment normally involves the removal of suspended solids and at
least a portion of the dissolved solids. The waste waters developed
from pretreatment systems are highly variable and depend upon the
characteristics of the water being treated.
Auxiliary waste waters generated by the pressed and blown glass
industry are similar to those throughout industry using the same
cooling, boiler, and water pretreatment systems. Owing to highly
variable volumes and characteristics, auxiliary waste waters are not
included in the effluent limitations and standards of performance
developed for process wastes. Auxiliary wastes will be studied at a
later date and characterized separately for industry in general.
The values thus obtained will be added to the limitations for
process waste water to determine the effluent limitations and
standards of performance for the total plant.
It is general practice within the pressed and blown glass segment
that both auxiliary and process wastes are discharged together and
not segregated. The bulk of the data received pertaining to this
57
-------
industry segment applied to the combined process and auxiliary waste
water streams. For this reason, data presented in this section and
in other sections of this document are carefully referred to as
pertaining to combined non-segregated waste water streams or
segregated waste water streams, whichever is appropriate.
GLASS CONTAINER MANUFACTURING
Glass container manufacturing consists of melting raw materials and
then forming the molten glass using a blow-mold technique. The
major process steps and points of water usage are shown in Figure 5.
A detailed description of the manufacturing process is given in
Section III.
Process Water and Waste Water
Process water is used for cullet quenching and non-contact cooling
of the batch feeders, melting furnaces, forming machines, and other
auxiliary equipment. At some plants, a small amount of water is
also added to the batch to control dust. The volume discharged
depends on the quantity of once-through cooling water and on the
water conservation procedures employed at the glass container plant.
The typical flow is representative of a plant using some once-
through cooling water and practicing reasonable water conservation.
Batch Wetting-
Water is added to the batch for dust suppression at some plants in
all of the subcategories covered by this study, but the practice is
not considered typical for the industry. When water is added, it is
generally at a rate of about 11.5 I/metric ton (2.75 gal/ton).
Cooling-
Non-contact cooling water is used to cool batch feeders, melting
furnaces, forming machines, and other auxiliary equipment. The
typical flow of cooling water is 1380 I/metric ton (330 gal/ton).
This represents 47 percent of the total flow. Reported and
calculated heat rejection rates vary from 361,000 kg-cal/metric ton
(1,300,000 BTU/ton) to 13,900 Jcg-cal/metric ton (50,000 BTU/ton) .
Owing to the wide variation and absence of sufficient information to
explain the differences, it is not possible to define a typical heat
rejection value. The average value is 97,300 kg-cal/metric ton
(350,000 BTU/ton).
Cullet Quenching-
Cullet quench water is required to dissipate the heat of molten
glass that is intentionally wasted or discharged during production
interruptions, or to quench hot pieces which are imperfect. Some
plants use non-contact cooling water for the dual purposes of
furnace and equipment cooling and cullet quenching. The typical
cullet quench water flow is 1540 I/metric ton (370 gal/ton) or 53
percent of the total flow.
58
-------
COOLING
WATER
1380 L/METRIC TON
330 GAL/
47%
RAW MATERIAL STORAGE
MIXING
COOLING
WATER
I
MELTING
:OOL!NG
*ATCR I
FORMING
WASTE
WATER
1540 L/METRC TON
370 GAL/ TON
53%
ANNEALING
INSPECTION
PACKAGING
SHIPPING
CONSUMER
FIGURE 5
GLASS CONTAINER MANUFACTURING
59
-------
Miscellaneous Wastes-
Repair and maintenance departments are required in all glass con-
tainer plants. Waste water is produced in the maintenance depart-
ments from the cleaning of production machinery. The machinery is
inspected, cleaned, and repaired at specific intervals. The clean-
ing operation includes steam cleaning of large parts and caustic
batch cleaning of items such as molds. The waste water from the
maintenance department is of very low volume and is primarily
occasional rinse water from the cleaning operations.
Several glass container plants have corrugator facilities to manu-
facture boxes. Wastes developed from the corrugator facilities are
of low volume and include cleanup water from the gluing and ink
labeling equipment, lubricating oil, and steam condensate. The
wastes are usually contained at the plant site and treated or
discharged to a municipal sewer system. The corrugator box manu-
facturing operation is not covered in the SIC codes under study in
this report.
Waste Water Volume and Characteristics
Typical characteristics for the combined non-contact cooling and
cullet quench waste water streams for a glass container plant are
listed in Table 5. In all cases, except for pH, the values listed
are the quantities added to the water as a result of glass container
manufacturing; concentrations in the influent water have been
subtracted. The significant parameters are oil and suspended
solids. BOD and COD are a result of oil in the waste water; control
of oil therefore controls oxygen demand.
Flow-
The quantity of waste water produced in the manufacture of glass
containers is highly variable. Flows range from near zero to 6250
I/metric ton (1500 gal/ton) or from near zero to 2460 cu m/day (.65
mgd). Some plants have indicated no discharge, but are apparently
discharging an unknown quantity of blowdown. This blowdown may be
in the form of water carried with the cullet and fed to the furnace
during batching. The typical flow is 2920 I/metric ton (700
gal/ton). The amount of water usage depends, to a certain extent,
on the raw water source and age of the plant. Glass container
plants receive water from various sources including plant-owned
wells, surface water, and municipal water systems. The amount of
water conservation and recirculation is considerably greater at
plants that use water from a municipal system. Plant age is another
factor which may affect water usage. Newer plants may use somewhat
less water because of more attention to water conservation.
Biochemical Oxygen Demand-
A small amount of BOD is added to the waste water as shear spray or
lubricating oil. Shear spray is an oil-water emulsion used to cool
and lubricate the shears and the chutes that convey the glass to the
60
-------
TABLE 5
RAW WASTE WATER (a)
GLASS CONTAINER MANUFACTURING
Flow
Temperature
PH
BOD
COD
Suspended
Solids
Oil
2920
6°C
7.5
0.011*5
0.1H5
0.07
0.03
I/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
700
ll'F
0.029
0.29
O.lU
0.06
gal /ton
lb/ton
lb/ton
lb/ton
lb/ ton
5 mg/1
50 mg/1
2k mg/1
10 mg/1
(a) Representative of typical glass container manufacturing waste water.
Absolute value given for pH, increase over plant influent level given
for other parameters.
-------
Z.S. machine. Many plants now use a synthetic biodegradable shear
spray to reduce the effects of oil on the receiving stream. Excess
shear spray eventually finds its way into the cullet quench water.
Another potential source of BOD is leakage of lubricating oils into
the cooling water system. The typical raw waste water loading is
0.01U5 kg/metric ton (0.029 Ib/ton) of BOD5.
Chemical Oxygen Demand-
The COD is contributed by the same sources that contribute BOD,
namely shear spray oil and lubricating oil. The typical plant waste
water contains 0.1U5 kg/metric ton (0,29 Ib/ton) of COD.
Suspended Solids-
Suspended solids enter the plant waste water as the result of cullet
quenching and plant cleanup. The cullet quench water picks up fine
glass particles; additional suspended solids are added during
cleanup of the I.S. machine area. A typical plant generates 0.07
kg/metric ton (0.14 Ib/ton) of suspended solids.
Oil-
Oil is added to the plant waste water as shear spray oil and leaking
lubricants. The typical oil loading is 0.03 kg/metric ton (0.06
Ib/ton).
Other Parameters-
Some information is available on the temperature and pH of glass
container plant waste waters. The average rise in temperature over
the plant influent water is 6°C (11°F). The typical pH of the waste
water is 7.5 and reported values range from 6.5 to 8.6.
Discussion-
Glass container plant operation is continuous (2U hr/day, 7
day/week); and, therefore, waste water flows are relatively
constant. No significant variations in waste water volume or
characteristics occur during plant startup or shutdown, and there
are no known toxic materials in the waste water. The melting tanks
must be drained every three to five years for rebuilding and
excessive quantities of cullet quench water are produced for one or
two days during this period. in larger plants with several
furnaces, this discharge may occur several times a year. The very
limited data available indicate that temperature is the only
significant parameter and that receiving stream standards may
necessitate cooling of the quench water in some cases.
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
Machine pressed and blown glass manufacturing consists of melting
raw materials and then forming the molten glass using presses or
other techniques to manufacture tableware, lenses, reflectors,
62
-------
sealed headlamp glass parts, and other products not covered in the
other subcategories. The major process steps and points or water
usage are listed in Figure 6. The manufacturing of machine pressed
and blown products is more fully explained in Section III.
Process Water and Waste Water
Water is used in the manufacturing of machine pressed and blown
products primarily for non-contact cooling and cullet quenching.
Gullet quenching is the cooling of molten glass or hot rejects with
water. Some plants use a portion of the non-contact cooling water
for cullet quenching. Water may also be added to the batch for dust
suppression and an oil-water emulsion is used for shear spraying.
The following discussion of water usage is based upon a summary of
data gathered prior to proposal of regulations for the pressed and
blown glass segment of the glass manufacturing category. More
information has been received and is being gathered for further
analysis. The results of this study will be presented in a
supplemental document at a later date.
Cooling-
Non-contact cooling water is required to cool batch feeders, melting
furnaces, presses, and other auxiliary equipment. The typical flow
of non-contact cooling water, based on all data received prior to
publication of the proposed regulations for this subcategory, is
2710 I/metric ton (650 gal/ton). Non-contact cooling water amounts
to 48 percent of the combined flow from this subcategory. Although
no heat-rejection data is available for machine pressed and blown
glass plants, it is expected that heat rejection requirements are
similar to those of glass container plants,
Cullet Quenching-
Quench water is required at all machine pressed and blown glass
plants to cool intentionally wasted molten glass during production
interruptions and to quench hot pieces that are wasted or rejected
because of imperfections. The configuration of equipment is similar
to a glass container plant. Quench water and waste glass are
discharged into chutes and flow to a cart located in the furnace
basement. Excess quench water overflows the cart and is discharged
to the sewer. The typical quantity of water used for cullet quench-
ing, based on all data received prior to publication of the proposed
regulations for this subcategory, is 2920 I/metric ton (700
gal/ton). This accounts for 52 percent of the total flow.
63
-------
RAW MATERIAL STORAGE
MIXING
COOLING
WATER
COOLING
WATER
27W L/MCTMC TON
650 GAL/ TON
MELTING
GULLET
QUENCH
FORMING
T
.WASTE
WATER
2920 L/METRIC TON
700 GAL/ TON
52%
GULLET
ANNEALING
INSPECTION
DECORATION
ANNEALING
INSPECTION
PACKAGING
SHIPPING
CONSUMER
FIGURE 6
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
64
-------
Miscellaneous Waste Water Sources—
Some machine pressed and blown glass plants have small plating shops
where molds are periodically cleaned and chrome-plated. Low volumes
of rinse waters are periodically discharged, but no evidence of
chromium contamination was found in the data collected during this
study. Chromium discharges should be regulated by the effluent
limitations developed for plating wastes (17, 25) .
Finishing may be employed at some machine pressed and blown glass
plants, but most of the finishing techniques produce no waste water,
The great majority of the finishing steps can be classified as deco-
rating and involve painting or coating and re-annealing. Other
finishing steps may produce small quantities of waste water, but
these are not covered in this study. It is recommended that where
treatment is required, the technology developed for hand pressed and
blown glass finishing be applied.
Waste Water Volume and Characteristics
Typical characterisits of the combined non-contact cooling and
cullet quench waste water streams, based on all information received
prior to publication of the proposed regulations for this
subcategory, are listed in Table 6. In all cases, except for pH,
the values listed are the quantities added to the water as a result
of the manufacture of machine pressed and blown glass products.
Background concentrations in the influent water have been
subtracted. Oil and suspended solids are the significant
parameters. The COD is contributed by the oil.
Flow-
A variable volume of water is used during the manufacture of machine
pressed and blown glass products. Flows ranging from 2,210 to
27,500 I/metric ton (530 to 6,600 gal/ton) or 87 to 2,650 cu m/day
(0,023 to 0.7 mgd) were indicated. The typical combined flow of
non-contact cooling water and cullet quench water, based on all
information received prior to publication of the proposed
regulations for this subcategory, is 5,630 I/ metric ton (1,350
gal/ton). The variation in water usage depends on the amount of
once-through non-contact cooling used and also on the water
conservation practiced at the various machine pressed and blown
glass plants. Cullet quench water and non-contact cooling water are
generally combined prior to discharge.
65
-------
TABLE 6
RAW WASTE WATER (a)
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
Flow
Temperature
pH
BOD
COD
Suspended
Solids
Oil
5630
10°C
7.8
0.028
0.28
O.lU
0.056
1 /metric ton
kg/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
1350
18°F
0.056
0,56
0.28
0.11
gal /ton
It/ton
Ib/ton
It/ton
It/ton
5 mg/1
50 mg/1
25 mg/1
10 mg/1
(a) Representative of typical machine pressed and "blown glass manufacturing
waste water. Absolute value given for pH, increase over plant influent
level given for other parameters.
-------
COD-
The typical COD added to the waste water, based on all information
submitted prior to publication of the proposed regulations for this
subcategory, is 0.28 kg/metric ton (0.56 Ib/ton). The COD results
primarily from shear spray and lubricating oil leaks.
Suspended Solids-
The suspended solids are fine glass particles picked up by the
cullet quench water. The typical suspended solids loading, based on
all information submitted prior to publication of the proposed
regulations for this subcategory, is 0.1U kg/metric ton (0.28
Ib/ton).
Oil-
Oil is added to the waste water as shear spray and lubricating oil.
Water-soluble oil is used to lubricate the gob shear cutters and the
glass gob chute. The shear spray oil flows from the gob chute and
enters the cullet quench water. Lubricating oil leaks may also
contaminate the cooling water and cullet quench water. The typical
quantity of oil discharged, based on all information submitted prior
to publication of the proposed regulations for this subcategory, is
0.056 kg/metric ton (0.11 Ib/ton).
Other Parameters-
Some information is also available on BOD, pH, and temperature. The
typical pH is 7.8 and the typical temperature rise is 10°C (18°F).
The temperature increase resulting from cullet quenching alone is
not known. This data appears in Table 6.
Discussion-
Machine pressed and blown glassware plants are operated on various
schedules, some continuously, while others operate for an 8 hr/dayf
5 day/week. Continuous operation is desirable because furnace heat
must be maintained. Some glass must be wasted during the off
periods to maintain the flow of glass through the furnace;
therefore, cullet quench water is always required. No sifnificatn
variations in waste"volume or characteristics are experienced during
plant start-up or shutdown, and there are no known toxic materials
in process waste water resulting from the manufacture of machine
pressed and blown glassware. Excessive quench water volumes will be
produced when a tank is drained for rebuilding or for a change in
the composition in this waste water source.
67
-------
GLASS TUBING (DANNER) MANUFACTURING
The manufacture of glass tubing consists of melting raw materials
and forming the molten glass on a rotating mandrel or other forming
device. The partially formed tubing is then drawn into lengths and
cut by scribing or by themal shock. The major process steps and
points of water usage are illustrated in Figure 7. The glass tubing
manufacturing process is more fully explained in Section III. The
following discussion pertains to the manufacture of glass tubing by
the Banner process which involves the melting of raw materials in a
furnace and the mechanical drawing of the tubing from the furnace
horizontally. As defined in this document, the Danrier process
requires intermittent rather than continuous quenching of cullet.
The ramainder of the glass tubing industry is being studied at the
present time. Other processes such as the Velio and Updraw
processes and the production of tubing suitable for the manufacture
of scientific glassware are being studied in further detail. The
results of this analysis will be published in a supplemental
document at a later date.
Process Water and Waste Water
The only process water used in the manufacturing of glass tubing by
the Danner process is for cullet quenching. Cullet quenching is
infrequent compared with that amount common to the other pressed and
blown glass manufacturing subcategories and is done only when a
break or disruption occurs in the drawing process. During this
period, glass is wasted at the same rate that tubing is drawn so
that a constant flow through the furnace is maintained.
Cooling-
Cooling water is primarily used for non-contact cooling of furnace
walls and mandrel transmissions. The typical flow of non-contact
cooling water is 7920 I/metric ton (1900 gal/ton) and accounts for
about 95 percent of total plant water usage.
Cullet Quenching-
Cullet quenching is required only when there is a break or dis-
ruption in the drawing process. During a stoppage, molten glass
continues to run over the mandrel or forming device, but is formed
into a ribbon by two rollers that are cooled by a spray of water.
The cullet ribbon and quench water drop to a segregated storage area
in the melting tank basement. The quenching system is activated
only when required. The typical flow is *20 I/metric ton (100
gal/ton) and accounts for five percent of the total typical flow.
68
-------
COOLING
WATER
7920 L/METRIC" TON
1900 GAL/
RAW MATERIAL STORAGE
MIXING
COOLING
WATER
1
MELTING
COOLING
WATER
FORMING
WATER
GULLET
QUENCH
GULLET
WASTE
TEH
420 L/METRIC TON
100 GAL/ TON
1%
CUTTING
I
PACKAGING
i
SHIPPING
FINAL ASSEMBLY
FIGURE 7
GLASS TUBING MANUFACTURING
69
-------
Waste Hater Volume and Characteristics
Some typical characteristics of the combined non-contact cooling and
cullet quench waste waters resulting from glass tubing manufacturing
by the Danner process are listed in Table 7. In all cases, except
for pH, the values listed are the quantities added to the water as a
result of the manufacturing process. Background levels in the in-
fluent water have been subtracted. Oil and suspended solids are the
significant waste water parameters. COD is contributed by the oil.
Flow-
In most plants, non-contact cooling water and cullet quench water
streams are discharged as a combined waste stream. Flows range from
3,340 I/metric ton (800 gal/ton) to 9,910 I/metric ton (2,380
gal/ton). The typical flow is 8,340 I/metric ton (2,000 gal/ton).
The high flow is due to the use of once-through non-contact cooling
water.
COD-
Chemical oxygen demand results from oil contamination of the non-
contact cooling water. The typical COD is 0.08 kg/metric ton (0.16
Ib/ton). This corresponds to a concentration of 10 mg/1 at the
typical flow and is not considered significant.
Suspended Solids-
Suspended solids are added to the waste water during cullet
quenching. Fine glass and miscellaneous solid particles are picked
up in the quench tank and discharge trenches leading to the sewer.
The typical suspended solids loading is 0.225 kg/metric ton (0,45
Ib/ton),
Qil-
The typical oil loading is 0.085 kg/metric ton (0.17 Ib/ton). Oil
enters the waste stream from lubricating oil leaks in the non-
contact cooling water system. The manufacturing methods used to
form glass tubing do not require shears and, therefore, the oil
associated with shear spraying is not a factor in this system.
Other Parameters-
Some additional information is available on the temperature and pH
of glass tubing (Danner) manufacturing waste waters. The waste
water temperature increase due to the manufacture of glass tubing by
the Danner process is U.5°C.
70
-------
TABLE 7
RAW WASTE WATER (a)
GLASS TUBING (BANNER) MANUFACTURING
Flow
Temperature
pH
COD
Suspended
Solids
Oil
8340
4.5°C
7.9
0.08
0.225
0.085
I/metric ton
kg /me trie ton
kg/metric ton
kg/metric ton
2000
8°F
0.16
0.45
0.17
gal /ton
Ib/ton
Ib/ton
Ib/ton
10 mg/1
27 mg/1
10 mg/1
(a) Representative of typical glass tubing (Banner) manufacturing waste waters.
Absolute value given for pH; increase over plant influent level
given for other parameters.
-------
(8°F). The waste water pH is 7.9 and is in the acceptable range of
six to nine.
Discussion-
No significant variations in waste water volume or characteristics
are experienced during plant start-up or shutdown, and there are no
known toxic materials in the waste water resulting from glass tubing
manufacturing. As with all continuous furnaces, periodic furnace
drainage requires large volumes of cullet quench water; however,
temperature is the only significant pollutant parameter associated
with this waste water source.
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
Television picture tube envelope manufacturing consists of melting
the raw materials, forming the screen and funnel sections, adding
the components necessary for the final assembly of the picture tube,
and polishing the necessary screen and funnel surfaces. The major
process steps and points of water usage are illustrated in Figure 8.
A detailed description of the manufacturing process is given in
Section III.
Process Water and Haste Water
Water is used in television picture tube manufacturing for cooling,
quenching, abrasive polishing, edge grinding, and acid polishing.
Cooling Hater and Cullet Quenching-
Non-contact cooling water is required in the forming section of the
plant for the batch feeders, furnaces, presses, annealing lehrs, and
other auxiliary equipment such as compressors and pumps. Once-
through systems are used in all of the plants that submitted data.
In most cases, a portion of the water discharged from the above
sources is used as quench water to cool molten glass during
manufacturing interruptions or to quench defective pieces from the
forming operations. In at least one plant, cooling water is recir-
culated as rinse water later in the manufacturing process.
The typical flow for both the non-contact cooling and cullet quench
water streams is 4040 I/metric ton (970 gal/ton). Each of these
sources accounts for 32.5 percent of the total plant flow. Reported
flows for the combined forming waste water stream range from 7230
I/metric ton (1740 gal/ton) to 24,600 I/metric ton ( 5910 gal/ton) .
The typical flow for a plant practicing reasonable water
conservation is 8080 I/metric ton (1940 gal/short ton) and accounts
for approximately 65 percent of total water usage.
Abrasive Polishing-
The funnel portion of the picture tube is abrasively polished using
a diamond wheel machine with an oil lubricated grinding surface.
After grinding, the funnel is rinsed with water.
72
-------
RAW WATIRUL STORAGE
MIXING
COOUNQ
WATER
COOUNB1 COOLWG
HI 1 „
rratirm •> CUL<-^T \A
W QU*MCH f^
isCJEGtft CULLETT
PIN MOUNTING 4°4° L/METRIC TON
32.i%
1
i
^"1
CAM-MB •— i
fMlfL* X
»
STEM PLACEMENT
ANODE INSTALLATION
1
fc^ COOLINO
t 4040 L/METRC TON
970 GAL/ TQN
32.5%
ANNEALING
SCREENS
INSPECTION
POMMELS
WATER
w «*•«
AMASIVE POUMMG |—f>- WATER
20*) L/METRC TON
WATER I 500 GAL/ TON
WATER
OH. POLMH
EDOE
ACK) POUEMMG
2340 U/METWC TON
560 GAL/- TON
WATER
ACB POLISHING
INSPECTION
FINAL
FIGURE 8
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
73
-------
The outer face of the picture tube screen is also abrasively
polished. The screen face plate is polished in a step process using
garnet, pumice, and rouge; all of the grinding compounds are in the
form of a slurry. Between grindings with the various compounds,
each screen is rinsed with water. The grinding compound slurry is
recycled and only the blowdown from the slurry system is discharged.
After the face has been ground, the connecting edge is ground and
then beveled. The typical flow of abrasive waste water is 2080
I/metric ton (500 gal/ton) and is 17 percent of the total flow.
Edge Grinding and Acid Polishing-
Following abrasive polishing and beveling, the connecting edges of
both the funnel and screen are acid polished or fortified. The
funnel is dipped into a combination of sulfuric acid and
hydrofluoric acid. The two sections are then rinsed with water to
remove the residual acid. Constant overflow-type rinse tanks are
generally used. The acid polishing step removes irregularities from
the joining surfaces and allows a perfect seal when the screen and
funnel are joined. Fume scrubbers are required in the acid
polishing area and contribute significant amounts of fluoride to the
waste water. The combined typical waste water flow for funnel and
screen acid polishing is 2340 I/metric ton (560 gal/ton) or 18
percent of the total flow.
Waste Water Volume and Characteristics
Typical characteristics for the combined non-contact cooling, cullet
quenching, abrasive,and acid polishing waste waters resulting from
television picture tube envelope manufacturing are listed in Table
8. In all cases, except for pH, the values listed are the
quantities added to the water as a result of the process.
Background levels in the influent water have been subtracted. The
significant parameters are suspended solids, oil, dissolved solids,
fluoride, and lead.
Flow-
Total waste water flows, including non-contact cooling water, range
from 11,100 to 24,600 I/metric ton (2670 to 5910 gal/ton) or 1590 to
4620 cu in/day {0.42 to 1.22 mgd) . The typical flow is 12,500
I/metric ton (3000 gal/ton). The variation in flow rate depends
primarily upon the amount of water used for once-through cooling.
Suspended Solids-
Suspended solids are added to the waste water in the form of glass
particles and grinding slurry solids from edge grinding and abrasive
polishing. Typical plant waste water contains 4.2 kg/metric ton
(8.4 Ib/ton) of suspended solids.
74
-------
TABLE 8
RAW WASTE WATER (a)
TV PICTURE TUBE ENVELOPE MANUFACTURING
Temperature (b)
pH
COD
Suspended Solids
Dissolved Solids
Oil
Fluoride
Lead
12,500 I/metric ton
14°C
6-2
0.^35 kg/metric ton
*U 2 kg/metric ton
3,25 kg/metric ton
0.125 kg/metric ton
1.8 kg/metric ton
0.385 kg/metric ton
3000 gal/ ton
25°F
0.87 It /ton
8.1* It/ton
ton
0.25 IV ton
3.6 It/ton
0.77 It/ton
35 mg/1
335 mg/1
260 mg/1
10 mg/1
1^3 mg/1
30 mg/1
Ca) Represents typical TV picture tube envelope manufacturing process waste water
prior to treatment.. Absolute value given for pH; increase over plant influent
level given for otner parameters.
Cb) Indication of approximate level only; insufficient data are available to
define typical value.
-------
Dissolved Solids-
Dissolved solids are contributed to the waste water stream from acid
polishing and abrasive polishing. The typical loading is 3.25
kg/metric ton (6.5 Ib/ton) of dissolved solids.
Fluoride*
Fluoride is contributed by the rinse waters following acid polish-
ing, fume scrubbing, and the periodic dumping of the concentrated
acid. Hydrofluoric acid is used to polish the edges of both the
screen and funnel portions of the picture tube envelope. The
typical loading is 1.8 kg/metric ton (3.6 Ib/ton) of fluoride.
Lead-
Lead results from both abrasive and acid polishing. It is not clear
if the lead in the abrasive waste stream is truly dissolved or in
the form of colloidal particles, but standard analytical procedures
show a significant concentration. Lead in the acid waste is assumed
to result from the dissolution of the glass. The typical quantity
of lead added to the waste water is 0.385 kg/metric ton (0.77
Ib/ton).
Oil-
Oil is added to the waste water as shear spray drippage into the
quench water during forming operations, as lubrication leaks, and as
funnel rinse water. The typical oil loading is 0.125 kg/metric ton
(0.25 Ib/ton) .
Other Parameters-
Some information is also available on temperature, pH, and COD, The
typical increase in COD is 0.435 kg/metric ton (0.87 Ib/ton). The
low organic content indicated by the COD is not considered
significant. Owing to the segregation of the various waste streams,
a typical value for the pH of the combined waste streams from a
picture tube envelope plant is not available. Typical pH values for
the various process streams are acid polishing, 3.0; abrasive
polishing, 9.5; cooling and quenching, 7.6. The cooling and
quenching water contributes 65 percent of the combined plant flow.
Owing to this high flow, it is estimated that the raw waste water pH
should be in the range of six to nine.
Discussion-*-
Television picture tube envelope manufacturing plants generally
operate continuously and no significant variations in waste water
volume or characteristics are experienced during plant start-up or
shutdown. An • additional source of waste water from a picture tube
envelope plant may be chrome plating waste water resulting from mold
repair. This is a very low volume waste and is usually batch
treated at the plant or trucked from the plant for disposal.
Available data indicate no chromium is added to the waste water.
76
-------
Where Applicable, the effluent limitations developed for plating
wastes should be used (17, 25}.
INCANDESCENT LAMP ENVELOPE MANUFACTURING
Incandescent lamp envelope manufacturing consists of melting raw
materials and forming the molten glass with ribbon machines into
clear incandescent lamp envelopes. Many of the clear envelopes are
then frosted or etched with a hydrofluoric acid solution. The major
process steps and points of water usage are listed in Figure 9. The
incandescent lamp envelope manufacturing process is more fully
explained in Section III.
Process Water and Waste Water
Process water is used in the manufacturing of incandescent lamp
envelopes for cullet quenching and for rinsing frosted bulbs. The
frosting waste water stream is the major source of pollutants and
contains high concentrations of both fluoride and ammonia. Cullet
quench water is required to cool the wasted molten glass and to
quench imperfect lamp envelopes. Quenching practices are similar to
those of other pressed and blown glass plants.
Cullet Quenching-
Non-contact cooling water from batch feeders, melting furnaces,
ribbon machines, and other auxiliary equipment is used as a source
of quench water. Additional waste water is contributed by the
emulsified oil solution that is sprayed on the ribbon machine
blowpipes and bulb molds. The excess of this oil-water emulsion
flows to the cullet quenching area and is discharged with the quench
water, cullet quenching contributes approximately 53 percent of the
total waste water flow in the typical plant.
Frosting-
Frosting imparts an etched surface inside the lamp envelope that
improves the light diffusing capabilities of the light bulb. The
frosting solution contains hydrofluoric acid, fluoride compounds,
ammonia, and other constituents, but the exact formulation is pro-
prietary. The percentages of lamp envelopes frosted at a given
plant range from 40 to 100 percent..
In the frosting operations, the solution is sprayed on the inside of
the bulb and then removed by several countercurrent water rinses.
High fluoride and ammonia concentrations in the rinse water result
from frosting solution carry-over. Fume scrubbers are required in
the frosting area and contribute significant amounts of fluoride and
ammonia to the frosting waste water. Frosting waste water accounts
for approximately 47 percent of the total flow in a plant where 100
percent of the envelopes are frosted.
77
-------
RAW MATERIAL STORAGE
MIXING
COOLING
WATER
I
MELTING
COOLING
WATER
COOLING WATER
WATER
GULLET
QUENCH
BULB BLOWING
{RIBBON MACHINE)
i
GULLET
WASTE
'WATER
4500 L/METRIC TON
1080 GAL/ TON
53 %
ANNEALING
WATER
ETCHING PROCESS
(FROSTING)
WASTE
* WATER
_3960 L/METRIC TON
950 GAL' TON
47%
FINAL ASSEMBLY
FIGURE 9
INCANDESCENT LAMP GLASS MANUFACTURING
78
-------
Waste Hater Volume and Characteristics
Gullet quenching waste water and frosting waste water from an incan-
descent lamp envelope manufacturing plant must be classified and
characterized separately because the percentage of bulbs frosted
varies from plant to plant. The discharge from each of these
sources must be added to obtain the total plant discharge. Gullet
quenching waste water is characterized by low concentrations of oil,
suspended solids, and COD, while the frosting waste contains high
concentrations of fluoride and ammonia. Typical waste water volumes
and characteristics are summarized in Table 9.
Flow-
The typical cullet quenching waste water flow is 4500 I/metric ton
(1080 gal/ton) and the typical frosting waste water flow is 3960
I/metric ton frosted ( 950 gal/ton frosted). The flow is variable in
accordance with water conservation practices and the quantity of
once-through cooling water used. Reported combined quenching and
frosting waste water flows range from 5420 I/metric ton pulled (1300
gal/ton pulled) to 83UO I/metric ton pulled (2000 gal/ton pulled) or
570 to 1670 cu m/day (0.15 to 0.44 mgd) .
Suspended Solids-
Suspended solids are generated by cullet quenching and by frosting
of lamp envelopes. Fine glass particles are discharged with the
cullet quench water and a significant concentration of suspended
solids is contributed by the frosting rinse water. The typical
suspended solids produced by cullet quenching is 0.11 kg/metric ton
(0.23 Ib/ton) and by frosting is 0.40 kg/metric ton frosted (0.79
Ib/ton frosted).
Oil-
Oil is contained in significant concentrations only in the cullet
quench water and results from the residual emulsified oil used to
spray the ribbon machine blowtips and from lubricating oil leaks.
The typical loading is 0.11 kg/metric ton (0.23 Ib/ton).
Fluoride-
Fluoride is contributed to the waste water by the frosting solution
carry-over and the discharge of fume scrubbing equipment. Spent
frosting solution is usually regenerated and reused or disposed of
separately and is not discharged to the waste water stream. The
typical fluoride content of the frosting waste water is 11.1
kg/metric ton (22.2 Ib/ton) .
Ammonia-
Ammonia is added to the plant waste water as a result of frosting
solution carry-over and the discharge from fume scrubbing equipment.
79
-------
TABLE 9
RAW WASTE WATER (a)
INCANDESCENT LAMP ENVELOPE MANUFACTURING
Gullet Quenching
Flow
Temperature
PH
COD
Suspended
Solids
Oil
4500
8°C
8.6
0.11
0.11
0.11
I/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
1080 gal/ton
14°F
0.23 Ib/ton
0.23
0.23
Ib/ton
Ib/ton
25 mg/1
25 mg/1
25 mg/1
oo
o
Flow
Temperature
PH
COD
Suspended
Solids
Fluoride
Ammonia
3960
38°C
3.0
0.099
0.40
11.1
2.6
Frosting
I/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
950 gal/ton
100 °F
0.20 Ib/ton
0.79
22.2
5.1
Ib/ton
Ib/ton
Ib/ton
25 mg/1
100 mg/1
2800 mg/1
650 mg/1
(a) Representative of typical incandescent lamp envelope manufacturing waste water. Absolute
value given for pH and frosting temperature; increase over plant influent level given
for other parameters.
-------
Ammonia is one of the major constituents of the frosting solution
and is apparently necessary in order to get the desired frosted
effect. A considerable amount of ammonia vapors are picked up by
the frosting area fume scrubber and then discharged to the waste
water flow. The typical discharge is 2.6 kg/metric ton ( 5.1
Ib/ton).
Other Parameters-
Some information pertaining to COD, pH, and temperature is also
included in Table 9. The typical COD concentration in both the
cullet quench and frosting waste water streams is only 25 mg/1 and
is not considered significant. The temperature increase during
cullet quenching is similar to that obtained in the other subcate-
gories. Frosting rinse water is heated and the 38°c (100°F)
discharge temperature remains fairly constant.
Discussion-
Lamp glass envelope plants usually operate 24 hrs/day and 5
days/week. Clear bulb production is continuous throughout the week.
The frosting operation is intermittent and is related to consumer
demand. No significant variations in the waste water volume or
characteristics of cullet quench or frosting waste waters are
experienced during plant start-up or shutdown. Fluoride and ammonia
nitrogen discharged at the concentrations typical of the raw waste
water are toxic and should be reduced. The furnaces are drained every
3 to 5 years for rebuilding and require excessive cullet quench
water during the draining period.
HAND PRESSED AND BLOWN GLASS MANUFACTURING
Hand pressed and blown glass manufacturing consists of melting raw
materials and forming the molten glass with hand presses or by hand
blowing to make high quality stemware, tableware, and decorative
glass products. The major process steps and points of water usage
are listed in Figure 10. The hand pressed and blown glass manufac-
turing process is more fully explained in Section III of this
report.
Process Water and Haste Water
Process water and waste water are used almost entirely for finishing
in the hand pressed and blown glass industry. Negligible quantities
of water are used for forming; non-contact cooling water is not
required. There are at least eight finishing steps that may be
employed in the handmade industry. Some plants employ several
finishing steps while others use only one or two. Finishing steps
that require water and produce waste water include: crack-off and
polishing, grinding and polishing, machine cutting, alkali washing,
acid polishing and acid etching. Several handmade plants also have
machine presses. Waste waters resulting from machine forming are
covered in the machine pressed and blown subcategory. Some of the
81
-------
RAW MATERIAL STORAGE
MIXING
WATER
MELTING
FORMING
MUTE
WATER
(NEGLIGIBLE VOLUME)
ANNEALING
GLAZING
ANNEALING
WATER
DECORATMQ
WATER
WATER
CRACK-OFF
„ WATTE
WATER
9920 L/METRIC TON
2380 GALA. TQN
WASHING
GRINDING
POLISHING
WASTE
WATER
TON
TON
WASTE WATBI
4795 L/M TON
1150 Gf TON
WATER
CUTTING
WATBI
ACID
POLISH
WASTE
WATER <
10880 L/M TON
2610 G/ TON
ETCHING
WASTI
E WATER
5380 UM TON
1290G/ ~
WASTE
WATER
L/METRJC TON
INSPECTION
PACKAGING
SHIPPING
CONSUMER
FIGURE 10
HAND PRESSED AND BLOWN GLASS MANUFACTURING
82
-------
machine pressed products are finished using the methods covered
under this subcategory.
Data on waste water volumes and characteristics from the hand
pressed and blown glass industry are almost nonexistent. Almost all
of the data presented in this report were collected during the
sampling program.
Forming-
A negligible amount of water is required for quenching and for
partial cooling of the glass during some types of forming. Small
water-filled tanks are used at some plants to collect waste glass
and rejects. Wheelbarrows with no water may be used at other
plants. Some types of glassware are blown in a mold partially
submerged in water. Small tanks, approximately 19 liters (5
gallons) in size, are used. The quench tanks and forming tanks are
drained periodically.
Crack-Off-
Crack-off is required to remove excess glass left over from the hand
blowing of stemware. Crack-off can be done either manually or by
machine. The top portion of the stemware is scribed, the scribed
surface heated, the excess glass removed, and the cut edge ground on
a carborundum or other type abrasive surface. The grinding surface
is sprayed by a continuous stream of water for cooling and to remove
grinding residue. Grinding may be followed by acid polishing to
remove the scratches and is considered part of the crack-off
operation in this presentation. Polishing is accomplished by two
hydrofluoric acid rinses followed by two water rinses. The combined
cutoff and acid polishing waste water flow is 9920 I/metric ton
(2380 gal/ton).
Grinding and Polishing-
Abrasive grinding and polishing are common finishing stepsand may
be used to repair imperfect glassware. Water is required for cool-
ing and lubrication when grinding wheel stones and belt polishers
are used. Abrasive polishing may also be used and involves
mechanical brushing with an abrasive slurry. The residual slurry is
removed in a booth or wash sink. The grinding and polishing flow
rates observed were 3460 I/metric ton (830 gal/ton).
Cutting-
Designs may be cut into tableware or stemware. Water is required
for lubrication and cooling of the cutting surface and to flush away
glass particles. The observed flow from the machine cutting
operation was 10,880 I/metric ton (2610 gal/ton).
83
-------
Acid Polishing-
Acid polishing is another finishing operation that may be applied to
handmade glassware. This improves the appearance of the glassware
and removes rough edges. The glassware is dipped in hydrofluoric
acid and then rinsed with water. The type of equipment used for
acid polishing ranges from highly automated equipment to hand-dipped
tubs and, consequently, the required volume of water varies. The
observed acid polishing flow for a plant utilizing countercurrent
rinsing was 5380 I/metric ton (1290 gal/ton),
Acid Etchina-
Designs are etched onto some stemware. A pattern is stenciled on
tissue paper using a proprietary mixture. The tissue is placed on
the glass and then removed to leave the pattern. All parts of the
ware, except for the pattern, are then coated with a wax mixture.
At this point the glassware is ready for etching. Etching involves
a number of steps including dipping in the etching solutions,
rinsing, wax removal, additional rinsing, treatment with a cleaning
solution, rinsing, nitric acid treatment to remove spots from the
acid carry-over, and final rinsing. The waste waters result from
the various rinsing steps. The acid and cleaning solution tanks are
not drained. The observed flow from this type of system is 36,500
I/metric ton (8760 gal/ton).
Alkali Washing-
Final washing, prior to packing and shipment may be required for
some products. An acid-alkali cleaning system is used for this
purpose in at least one plant. The glassware first passes through
an acid wash and then an alkali rinse followed by several hot water
rinses. The flow from this unit is 4795 I/metric ton (1150
gal/ton).
Mi seellaneous Finishing-
Finishing steps that do not involve water or waste water are
employed at many handmade glass plants and are generally referred to
as glazing or decorating. Paint or some other coating is applied to
the glassware and in many cases is baked onto the glass surface by
reannealing.
Miscellaneous Waste Water Sources-
Abrasive mold cleaning is employed at some plants. An abrasive
slurry is sprayed on the molds at high pressure in a process similar
to sandblasting. A small but undefined volume of high-suspended
solids waste is produced. Following cleaning, the molds may be
dipped in a rust preventative solution. This tank is not drained to
the sewer.
Fume scrubbers are required in the acid treatment areas and con-
tribute significant fluoride to the acid polishing and etching waste
waters.
84
-------
Haste Water Volume and Characteristics
Observed waste water characteristics for the finishing steps
described above are listed in Table 10, In all cases, except for pH
and some of the temperatures, the values listed are the quantities
added to the water as a result of the manufacture of hand pressed
and blown glassware. Concentrations in the influent water have been
subtracted.
Flow-
Waste water flows from hand pressed and blown glass manufacturing
plants are highly variable and depend upon the quantity of glass
finished and the finishing method employed. Reported values range
from 0.15 cu m/day (40 gal/day) to 38 cu m/day (10,000 gal/day).
Owing to the variation in finishing methods and the percentage of
product finished, it is impossible to define a typical flow for the
industry.
Suspended Solids-
Grinding, polishing, and cutting are major sources of suspended
solids. Lesser quantities are generated by the other finishing
steps. Machine cutting and grinding and polishing contribute
approximately 28 kg/metric ton (56 Ib/ton) and 15 kg/metric ton (30
Ib/ton) to the waste waters respectively.
Fluoride-
Fluoride discharges result from crack-off and hydrofluoric acid
polishing, hydrofluoric acid polishing, and hydrofluoric acid
etching. Loadings expressed in terms of production vary
significantly from 1.93 kg/metric ton (3.85 Ib/ton) for crack-off
and polishing to 10.6 kg/metric ton (21.3 Ib/ton) for acid
polishing, and 17 kg/metric ton (34 Ib/ton) for acid etching. The
differences are caused, at least in part, by variations in acid
strength. The crack-off polishing solution is much less
concentrated than the acid polishing or acid etching solutions.
Lead-
Lead is contained in all leaded glass finishing waste waters. It is
not clear if the lead in the abrasive waste streams is truly
dissolved or is in the form of small glass particles, but standard
analytical procedures show a significant concentration. Lead in the
acid wastes is assumed to be in a soluble form.
Other Parameters-
Other parameters that may be of significance include pH, tempera-
ture, dissolved solids, and nitrate. Raw waste water pH values vary
significantly depending on the source. No pH value is available for
grinding and polishing but it is assumed the pH will be in the range
85
-------
TABLE 10
RAW WASTE WATER (a)
HAND PRESSED AND BLOWN GLASS MANUFACTURING
Crack-Off and Polishing
oo
Flov
Temperature
PH
Suspended Solids
Lead
Fluoride
Flow
Temperature
Suspended Solids
Lead
Flow
Temperature
pH
Suspended Solids
Lead
9920
2.8°C
3
0.35
0.010
1.93
31*60
2.8ec
15
0.086
10,880
l.6°c
10
28
1.1
I/metric ton
2380
kg/metric ton 0.71
kg/metric ton 0.019
kg/metric ton 3.85
Grinding and Polishing
I/metric ton
kg/metric ton
kg/metric ton
Machine
I/metric ton
kg/metric ton
kg/metric ton
830
5°F
30
0.17
Cutting
2610
3°F
56
2.2
gal /ton
Ib/ton
Ib/ton
Ib/ton
gal /ton
Ib/ton
Ib/ton
gal /ton
Ib/ton
Ib/ton
36 mg/1
0.96 mg/1
191* mg/1
1*350 mg/1
25 mg/1
2580 mg/1
100 mg/1
-------
TABLE 10 (Contd.)
Alkali Washing
oo
-4
57°C
11
0.08
5380
2
1.2
0.17
10.6
36,530
33° C
0.29
0.29
17
I/metric ton
kg/metric ton
Acid Polishing
I/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
Etching
I/metric ton
kg/metric ton
kg/metric ton
kg/metric ton
1150
0.16
1290
2.1;
0.33
21.3
8760
91° F
0.58
0.58
gal /ton
Ib/ton
gal /ton
Ib/ton
Ib/ton
Ib/ton
gal /ton
Ib/ton
Ib/ton
Ib/ton
17 mg/l
220 mg/l
31 mg/l
1980 mg/l
8 mg/l
8 mg/l
k60 mg/l
Flow
Temperature (b}
pH
Suspended Solids
Flow
Temperature (b)
pH
Suspended Solids
Lead
Fluoride
Flow
Temperature (b)
pH
Suspended Solids
Lead
Fluoride
(a) Representative of observed hand pressed and "blown glass manufacturing waste water.
Absolute value given for pH, increase over plant influent level for other parameters.
(b) Controlled temperature required for the process; therefore, absolute temperature given.
-------
of 8 to 10. Temperature increases are insignificant except where
heated rinse waters are used. Dissolved solids are not reported,
but significant concentrations may be anticipated in the acid
polishing and etching waste waters. Nitrates are discharged as a
result of the rinsing steps following etching. Insufficient data is
available to define the levels of discharge.
Discussion-
Hand pressed and blown glass manufacturing plants generally operate
only one or two shifts per day, five days per week, and finishing is
done only as necessary and varies with product demand. Rarely is
all the finishing equipment available at a given plant in use at the
same time. For these reasons, it is impossible to generalize the
hand pressed and blown industry in terms of a typical plant.
88
-------
SECTION VI
SELECTION OF POLLUTANT PARAMETERS
Subcategories with the most significant pollution problems in the
pressed and blown glass industry are television picture tube
envelope manufacturing, incandescent lamp envelope manufacturing,
and portions of the hand pressed and blown glass manufacturing
subcategory. The primary sources of the waste water constituents
are cullet quenching, rinsing following abrasive and acid polishing
of television picture tube envelopes, rinsing following frosting of
incandescent lamp envelopes, and rinsing of handmade glassware
following hydrofluoric acid polishing and etching.
The major parameters of pollutional significance for the combined
group of subcategories are:
1. Fluoride
2. Ammonia
3. Lead
4. Oil
5. COD
6. pH
7. Suspended Solids
8. Dissolved Solids
9. Temperature (Heat)
These parameters are not present in the waste water from every
subcategory, and may be of more significance in one subcategory than
in another. Tables 11, 12, and 13 list the concentrations of each
parameter by subcategory. Fluoride, lead, and ammonia discharged at
the levels present in certain waste water streams associated with
the manufacture of television picture tube envelopes, incandescent
lamp envelopes, and some hand pressed and blown ware are known to be
toxic to aquatic life.
FLUORIDE
As the most reactive non-metal, fluorine is never found free in
nature but as a constituent of fluorite or fluorspar, calcium
fluoride, in sedimentary rocks and also of cryolite, sodium aluminum
fluoride, in igneous rocks. Owing to their origin only in certain
types of rocks and only in a few regions, fluorides in high
concentrations are not a common constituent of natural surface
89
-------
TABLE 11
ID
O
CONCENTRATION OF WASTE WATER PARAMETERS
PRESSED AND BLOWN GLASS MANUFACTURING
TYPICAL RAW WASTE WATER CONCENTRATION (a)
Glass Container
6
7.5
5
50
2h
10
Machine Pressed Television Picture
and Blown Tubing Tube Envelope
8
7.8
5
50
25
10
U.5
7.9
10
27
10
8
35
335
10
260
Temperature °C
pH
BOD, mg/1
COD, mg/1
Suspended Solids, mg/1
Oil, mg/1
Dissolved Solids, mg/1
Fluoride, mg/1
Lead, mg/1
(a) Increase over background concentration for all parameters except for pH.
30
-------
TABLE 12
Temperature °C
pH
COD, mg/1
Suspended Solids, mg/1
Oil, mg/1
Fluoride, mg/1
Ammonia, mg/1
CONCENTRATION OF WASTE WATER PARAMETERS
INCANDESCENT LAMP GLASS MANUFACTURING
TYPICAL RAW WASTE WATER CONCENTRATION (a)
Gullet Quenching Frosting Rinse_Watejr
8 3800
8.6 3.0
25 25
25 100
25
2800
650
(a) Increase over "background concentration for all parameters except for pH.
(b) Controlled temperature required for the process; therefore, absolute
temperature given.
-------
TABLE 13
CONCENTRATION OF WASTE WATER PARAMETERS
HAND PRESSED AND BLOW GLASS MANUFACTURING
TYPICAL RAW WASTE WATER CONCENTRATION (a)
to
Crack-Off
and
Polishing
2.8
3.2
36
191*
• 96
Grinding
and
Polishing
2.8
1*350
.1*3
Machine
Cutting
1.6
10.0
2580
100
Alkali
Washer
57
11.2
17
Acid
Polishing
1*6
2.2
220
1980
31
Acid
Etching
33
i*.o
8
1*62
7.9
Temperature °C
PH
Suspended Solids, mg/1
Fluoride, mg/1
Lead, mg/1
(a) Representative of observed hand pressed and "blown glass manufacturing vaste water,
Increase over background concentration for all parameters except for pH.
-------
i waters, but they may occur in detrimental concentrations in ground
, waters.
4
Fluorides are used as insecticides, for disinfecting brewery
; apparatus, as a flux in the manufacture of steel, for preserving
wood and mucilages, for the manufacture of glass and enamels, in
', chemical industries, for water treatment, and for other uses.
, Fluorides in sufficient quantity are toxic to humans, with doses of
250 to U50 mg giving severe symptoms or causing death.
There are numerous articles describing the effects of fluoride-
bearing waters on dental enamel of children; these studies lead to
the generalization that water containing less than 0.9 to 1.0 mg/1
of fluoride will seldom cause mottled enamel in children, and for
adults, concentrations less than 3 or 4 mg/1 are not likely to cause
endemic cumulative fluorosis and skeletal effects. Abundant
literature is also available describing the advantages of
maintaining 0.8 to 1.5 mg/1 of fluoride ion in drinking water to aid
in the reduction of dental decay, especially among children.
Chronic fluoride poisoning of livestock has been observed in areas
where water contained 10 to 15 mg/1 fluoride. Concentrations of 30
- 50 mg/1 of fluoride in the total ration of dairy cows is
considered the upper safe limit. Fluoride from waters apparently
does not accumulate in soft tissue to a significant degree and it is
transferred to a very small extent into the milk and to a somewhat
greater degree into eggs. Data for fresh water indicate that
fluorides are toxic to fish at concentrations higher than 1.5 mg/1.
Fluoride is contained at various concentrations in the waste waters
of television picture tube envelope manufacturing, incandescent lamp
envelope manufacturing, and some hand pressed and blown glass
plants. Typical concentrations range from 143 mg/1 for the
television picture tube envelope manufacturing subcategory to 2800
mg/1 for the process waste water stream resulting from the frosting
of incandescent lamp envelopes.
AMMONIA
Ammonia is a common product o£ the decomposition of organic matter.
Dead and decaying animals and plants along with human and animal
body wastes account for much of the ammonia entering the aquatic
ecosystem. Ammonia exists in its non-ionized form only at higher pH
levels and is the most toxic in this state. The lower the pH, the
more ionized ammonia is formed and its toxicity decreases. Ammonia,
in the presence of dissolved oxygen, is converted to nitrate (NO3)
by nitrifying bacteria. Nitrite (NO2), which is an intermediate
product between ammonia and nitrate, sometimes occurs in quantity
when depressed oxygen conditions permit. Ammonia can exist in
several other chemical combinations including ammonium chloride and
other salts.
93
-------
Oil is a constituent of the waste water from all subcategories
except hand pressed and blown glass manufacturing. The typical oil
concentration ranges from 10 mg/1 for glass container manufacturing
to 25 mg/1 for cullet quenching during the manufacture of
incandescent lamp envelopes. The oil is added to waste water as
shear spra y oi1, by lubricating oil leaks, and by finishing
operations such as oil polishing of television picture tube
envelopes.
CHEMICAL OXYGEN DEMAND
COD is contributed by process waste waters from each subcategory.
The COD concentrations range from 10 mg/1 for glass tubing
manufacturing to 50 mg/1 for glass container and machine pressed and
blown glass manufacturing. In most cases the COD is a result of the
oil concentration and can be controlled by limiting the oil.
Because BOD concentrations are low, COD is a more accurate measure
of organic content for pressed and blown glass manufacturing,
pH
The term pH is a logarithmic expression of the concentration of
hydrogen ions. At a pH of 7, the hydrogen and hydroxyl ion
concentrations are essentially equal and the water is neutral.
Lower pH values indicate acidity while higher values indicate
alkalinity. The relationship between pH and acidity or alkalinity
is not necessarily linear or direct.
Waters with a pH below 6.0 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 aesthetic liabilities of any waterway. Even
moderate changes from "acceptable" criteria limits of pH are
deleterious to some species. The relative toxicity to aquatic life
of many materials is increased by changes in the water pH.
Metalocyanide complexes can increase a thousand-fold in toxicity
with a drop of 1.5 pH units. The availability of many nutrient
96
-------
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.
The pH of the waste water from cullet quenching is within the
acceptable range of 6-9. Waste waters produced by rinishing of acid
polished glass and the frosting of incandescent lamp envelopes is
acidic and in the pH range from 2-3. Most plants treat the acidic
waste waters to remove fluoride. Lime is added to a pH level of
about 11-12, Some plants discharge the treated effluent at this
alkaline pH, while other plants use acid to neutralize the treated
effluent back to an acceptable level of about 7.
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 obj ectionable 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 used in the textile, pulp and paper, beverage,
and dairy products industries and can cause difficulties at
laundries, for dyeing operations, for photographic processes, for
cooling systems, and at power plants. Suspended particles also
97
-------
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 aesthetically 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.
Suspended solids are contributed to the process waste waters from
all subcategories. Typical suspended solids concentrations range
from 25 mg/1 for machine pressed and blown glass manufacturing to
335 mg/1 for television picture tube envelope manufacturing.
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 States and in other countries use
water supplies containing 2000 to 4000 ing/1 of dissolved salts, when
no better water is available. Such waters are not palatable, may
not quench thirst, and may have a laxative action on new users.
Waters containing more than 4000 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 5000 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 fish are adapted to living in more saline
waters, and a few species of fresh-water forms have been found in
natural waters with a salt concentration of 15,000 to 20,000 mg/1.
Fish can slowly become acclimatized to higher salinities, but fish
in waters of low salinity cannot survive sudden exposure to high
salinities, such as those resulting from discharges of oil-well
98
-------
brines. Dissolved solids may influence the toxicity of heavy metals
and organic compounds to fish and other aquatic life, primarily
because of the antagonistic effect of hardness on metals.
Waters with total dissolved solids over 500 mg/1 have decreasing
utility as irrigation water. At 5,000 mg/1 water has little or no
value for irrigation.
Dissolved solids in industrial waters can cause foaming in boilers
and 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 concentration.
Acid polishing of television picture tube envelopes and handmade
glassware and frosting of incandescent lamp envelopes are the main
sources of the dissolved solids in the raw waste water from plants
within the pressed and blown glass segment. Dissolved solids are
also added to the waste water by the addition of lime for fluoride
removal and the addition of acid for pH control. Dissolved solids
concentrations range from 260 mg/1 for television picture tube
envelope manufacturing to several thousand milligrams per liter for
the process waste water stream from the frosting of incandescent
lamp envelopes. The control and treatment technologies presented in
Section VII of this document do not reduce the level of dissolved
solids discharged. Therefore, no effluent limitations guidelines
are established for this parameter.
TEMPERATURE
Temperature is one 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 or 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 or 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.
99
-------
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 food
supply is abundant.
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 food 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 decreases 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
benthic 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
esthetic value of a water course.
100
-------
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.
The significant increases in water temperatures result from cullet
quenching and the heating of rinse waters used in some finishing
steps. Typical temperature increases for cullet quenching are 5.6°C
(1C°F) to 8.4°C (15°F). The absolute temperatures of etching and
alkali washing waste waters range from 33°C (91°F) to 57°C (135°F).
The temperature measurements were taken directly from the process
and are much greater than at the end of the pipe before the
receiving stream. Natural cooling in the sewer and dilution with
non-contact cooling water tend to reduce temperatures to about 5.6°C
(10°F) over ambient. An acceptable temperature discharge limit must
be based upon the volume and the water quality criteria of the
receiving stream. For this reason, no attempt has been made to
propose standards to limit effluent temperatures.
101
-------
-------
SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
As concluded in Section VI, the primary pollutants from the pressed
and blown glass segment are oil, fluoride, ammonia, lead, and sus-
pended solids. Oil is contributed to the waste water from all
subcategories except hand pressed and blown glass manufacturing.
Fluoride and lead are added by the finishing steps for television
picture tube envelopes and hand pressed and blown glass. Fluoride
and ammonia are carried over into the waste water following frosting
of incandescent lamp envelopes. Suspended solids are a result of
grinding, acid treatment, and Gullet guenching.
The industry is currently treating its waste waters to reduce or
eliminate most of the pollutants. Oil is reduced by using gravity
separators such as belt skimmers and API separators. Treating for
fluoride and lead involves the addition of lime, rapid mixing,
flocculation, and sedimentation of the resulting reaction products.
Several glass container plants recycle non-contact cooling and
cullet quench water. Treatment for ammonia removal is presently not
oracticed in the industry segment.
This section is divided into two parts. The first part is a general
description of the applicable treatment technologies that will
reduce or eliminate the pollutants from pressed and blown glass
manufacturing waste waters. The next section gives a detailed
description cf treatment schemes that may be used to meet the
proposed effluent limitations and guidelines. The transfer of
treatment technologies from other industry categories is necessary
in some cases.
APPLICABLE TREATMENT TECHNOLOGY
Suspended Solids Removal
Two common methods of suspended solids removal are sedimentation and
filtration. Sedimentation can be accomplished with or without
chemical addition in a sump or catch basin arrangement, in a
settling tank or pond, or in a clarifier. Filtration can occur by
passage of a waste water stream through sand, mixed media, or
diatomaceous earth.
Sedimentation Methods-
Sumrj or Catch Basin. Solids removal can occur in a sump or catch
basin arrangement and can reduce the solids loading to another part
of the treatment system and allow for materials recovery. The basic
principle is that the velocity of the waste water stream is reduced
and forces resulting from density differences between the suspended
solids and the waste water come into affect and the solids settle
out.
103
-------
This in-plant method of waste control can be designed with a scraper
mechanism to remove the bottom sludge and with a skimmer to achieve
a removal of floating oil.
Settling Tank or Pond. The same principles as apply to sumps and
catch basins apply to settling tanks and ponds. However, when used
as end-of-pipe treatment, larger detention times may be employed
with chemical addition and sludge recycle to attain greater
efficiencies of suspended solids removal.
Clarifier. A substantial portion of suspended solids may be removed
by clarification. Settling involves the provision of a sufficiently
large tank in order that the velocity of the waste water discharge
stream be reduced sufficiently to allow for suspended solids to
settle out. Mild mechanical agitation is added to assist in the
settling process and in the removal of suspended solids. Chemical
addition and sludge recycle may also be employed to increase
treatment efficiency.
Settled solids from the bottom of the clarification unit in the form
of a sludge may be pumped to a rotary vacuum filter, where the
slurry is concentrated by removal of water which is returned to the
clarifier. The outside surface of the filter cylinder is covered
with a filter medium (screen or cloth). The lower portion of the
filter is suspended in the liquid slurry. As the drum rotates, the
vacuum which is maintained within the cylinder forces liquid into
the cylinder while leaving a solids layer on the outside of the
filter medium. As the drum rotates, a scraper mechanism removes
solids from the surface of the filter medium. This method of solids
thickening has been widely used in both industrial and municipal
waste water treatment.
Filtration Methods-
Sand and Mixed-Media Filtration. A variety of filters can be
employed to remove suspended solids from a treated waste water:
slow sand filters, rapid sand filters, and mixed media filters. The
effluent from a sand filter is of a high quality. A summary of
available information indicates that an effluent suspended solids
concentration of less than 10 mg/1 can be expected to occur from the
sand filtration of wastes similar in nature to those of the pressed
and blown glass industry segment.
A slow sand filter is a specially prepared bed of sand or other
mineral fines on which doses of waste water are applied and from
which effluent is removed by an under-drainage system. A rapid sand
filter may operate under pressure in a closed vessel or may be built
in open concrete tanks. It is primarily a water treatment device
and thus would be used for final treatment. Mixed media filters are
special versions of rapid sand filters that permit deeper bed
penetration by gradation of particle sizes in the bed.
104
-------
The slow sand filter removes solids primarily at the surface of the
filter. The rapid sand filter is operated to allow a deeper
penetration of suspended solids into the sand bed and thereby
achieve solids removal through a greater cross section of the bed.
The rate of filtration of the rapid filter is greater than that of
the slow sand filter. Thus, the rapid sand filter requires
substantially less area than the slow sand filter. The larger area
required for the latter means a higher initial investment cost. The
rapid sand filters operate essentially unattended with pressure loss
controls and piping installed for automatic backwashing. They are
contained in concrete structures or in steel tanks. Slow sand
filters require hand or machine labor to breakup the crust which
develops on the surface. The frequency of this operation varies
depending on the quality of pretreatment and the gradation of the
sand.
In a rapid sand filter, as much as 80 percent of the head loss can
occur in the upper few inches of the filter. One approach to
increase the effective filter depth is the use of more than one
media in the filter. Other filter media have included coarse coal,
heavy garnet or ilmenite media, and sand.
Diatpmacegus Earth Filtration. Diatomaceous earth filters have
found use as: (1) mobile units for water purification and (2)
stationary un its for swimming pools and general water supplies.
Skeletons of diatoms mined from deposits compose the diatomaceous
earth. The filter medium is a .layer of diatomaceous earth built
upon a porous septum. The resulting pre-coat is supported by the
septum, which serves also as a drainage system. Water is strained
through the pre-coat unless the applied water contains so much
turbidity that the unit will maintain itself only if additional
diatomaceous earth, called body feed, is introduced into the
incoming water to preserve the open texture of the layer.
Diatomaceous earth is generally of finer texture than sand and has
been reported to reduce suspended solids effluent concentrations to
5 mg/1 or less. Diatomaceous earth filtration is being used to
treat the effluent from at least one glass container manufacturing
facility. No long-term data have been generated but short term data
show a suspended solids effluent concentration of 7.1 mg/1
indicating that levels of less than 10 mg/1 should be readily
attainable.
Oil Removal
Oil is usually removed in two steps. In the primary treatment step,
floatable or free oils are removed by gravity separation. The
second step involves breaking any oil-water emulsions and separating
the remaining oil.
Primary Treatment-
Primary treatment makes use of the difference in specific gravity of
oil and water. The oily waste water is retained in a holding basin.
105
-------
the oil and water being allowed to separate; the separated oil is
skimmed from the waste water surface. The efficiency of the gravity
separator device depends upon both the proper holding basin
hydraulic design and the retention time in the basin. Typically, 60
to 90 percent of the influent free oil can be removed with gravity
separation units.
Secondary Treatment-
Oil emulsions can be broken by either chemical or physical methods.
Physical methods include high rate filtration through sand and
gravel filters, high rate filtration with coagulant, and diatoma-
ceous earth filtration. High rate filter pilot plant studies in the
oil industry using an influent emulsified oil concentration of 230
mg/1 indicated that an effluent concentration of 15 mg/1 can be
achieved with filtration, and a 10 mg/1 effluent level can be
achieved using coagulant-assisted filtration.
Oil-adsorptive diatomaceous earth filtration has been used to reduce
oil and suspended solids effluent concentrations to 5 mg/1. The
diatomaceous earth filtration system consists of the filter, precoat
tank, and a slurry tank for continuous feeding of the diatomaceous
earth. About 0.9 kg (2 Ib) of diatomaceous earth is required per
0.45 kg (1 Ib) of oil removed, and the filtration rates range from
20.4 to 40,7 1/min/sq m (0.5 to 1 gpm/sq ft). Dry discharge
diatomaceous earth filters require no backwashing, and the sludge
requires no dewatering. Diatomaceous earth filtration is being used
to treat the blowdown from at least one cullet quench recycle system
at a glass container plant. No long-term data have been generated
but short-term data show an oil effluent concentration of 7.6 mg/1
indicating that levels of less than 10 mg/1 should be readily
attainable.
Chemical treatment is a primary method used to break oil emulsions
by destabilizing the dispersed oil droplets or destroying the
emulsifying agents. The treatment may consist of chemical addition,
rapid mixing, flocculation and settling, or flotation.
Air flotation can be used to separate the oil and water and will
also result in the removal of suspended solids. It is a relatively
recent technology in the glass industry and, therefore, is not in
widespread use. However, air flotation is being used to treat
emulsified oil-water streams in the flat glass industry and it has
been indicated that at least one glass container plant will employ
this treatment technology in the near future.
The air flotation system operates by mixing the waste water with
compressed air in a pressurized tank. The waste water flows to the
flotation tank where the pressure is released, thereby generating
numerous, small air bubbles which effect the flotation of the
suspended material by one of three mechanisms: 1) adhesion of the
air bubbles to the particles of matter, 2) trapping of the air
bubbles in the floe structures of suspended material as the bubbles
rise, and 3) adsorption of the air bubbles as the floe structure is
106
-------
formed from the suspended matter.
removal facilities are also provided.
In most cases, bottom sludge
Improved performance of the air flotation system is achieved by
coagulation of the suspended matter prior to treatment. This is
done by pH adjustment or the addition of coagulant chemicals, or
both. Aluminum sulfate, iron sulfate, lime, and polyelectrolytes
are used as coagulants at varying concentrations up to 300 to 400
mg/1 in the raw waste. These chemicals are essentially totally
removed in the dissolved air flotation unit, thereby adding little
or no load to the waste water stream. Typical effluent oil
concentrations range from 10 to 15 mg/1.
Chemical coagulation and sedimentation can also be used to remove
the oil. In this process, the oil is adsorbed onto the coagulant
floe. Oil in television picture tube abrasive waste water is
removed in this manner. Removal efficiencies are similar to those
for chemical assisted air flotation; however less area is required
for the air flotation equipment.
Fluoride Removal
The waste waters from pressed and blown glass plants are con-
taminated with fluoride by carry-over into the rinse waters
following hydrofluoric acid treatment. The fluoride is either in
the form of hydrogen fluoride (HF) or fluoride ion (F-), depending
on the pH of the waste water. The high fluoride concentrations in
the waste waters from television picture tube envelope
manufacturing, incandescent lamp envelope frosting, and hydrofluoric
acid polishing and etching of hand pressed and blown glass should be
reduced to an acceptable level to prevent any toxic action of the
fluoride on aquatic life in the receiving body of water. There are
two methods to treat these waste waters, which may be classified as
the additive and the adsorptive methods.
Additive Methods-
In the additive methods, chemicals are added to the waste water and
the fluoride either forms a precipitate or is adsorbed onto a
precipitate. The fluoride removal efficiencies depend upon the
detention time in, as well as the effectiveness of, the
clarification unit used to separate the precipitate. The chemicals
used include lime and aluminum sulfate, but lime treatment is the
most practical method for treatment of waste waters with high
concentrations of fluoride. The lime is added to the waste water as
slurry, is rapidly mixed, and reacts with the fluoride during floc-
culation to form calcium fluoride. The calcium fluoride precipitate
is then settled out in a clarification unit. Suspended solids are
also removed by the lime treatment process.
Calcium fluoride has a maximum theoretical solubility of about 8
mg/1 as fluoride and concentrations above this theoretical
solubility limit form a precipitate. Therefore, . the effluent
concentrations can be lowered by adding calcium ion concentrations
107
-------
in excess of the stoichiometric requirements which results in
raising the pH during treatment to a value in the range of 9 to 11.
Typical treated effluent fluoride concentrations range from 10 mg/1
to 30 mg/1.
The calcium fluoride precipitate formed during reaction with lime
has a very small particle size, and the flocculation and clarifica-
tion steps must therefore be optimized to remove the maximum amount
of fluoride. Factors to be considered include the flocculation
time, clarifier type and detention time, and post-sedimentation
filtration. Longer flocculation periods allow greater agglomeration
of the precipitate particles. Improved separation of the calcium
fluoride precipitate from the water can be accomplished by increas-
ing the clarifier detention time, using a solids contact clarifier,
or recirculating sludge. In a solids contact clarifier, the treated
waste water flows down through a center skirt in the clarifier and
up through a sludge blanket formed at the bottom of the clarifier.
Filtering the clarifier effluent can reduce fluoride concentrations
to about 10 mg/1 by removing additional calcium fluoride particles.
Sand or graded media filters similar to those vised in water treat-
ment plants can be used.
High concentrations of aluminum sulfate have also been used to
reduce low fluoride concentrations in soft waters, but this method
is considered both technically and economically unfeasible for the
primary or secondary treatment of high fluoride wastes.
Adsorptive Methods-
Treatment of fluorides by the adsorptive methods involves passing
the waste water through a contact bed, the fluoride being removed by
general or specific ion-exchange or chemical reaction with a solid-
bed matrix. Adsorptive methods may be used for treating low level
fluoride wastes and polishing the effluent from the lime process.
The requirement for frequent bed regeneration makes the adsorptive
methods economically infeasible for treating high fluoride
concentration wastes. Activated alumina, hydroxylapatite, and ion
exchange resins have been used as the adsorptive media, but
activated alumina has been determined to be the least expensive and
the most suitable for the pressed and blown glass industry segment.
Activated alumina has been used since the 1950's in municipal water
treatment plants to reduce the fluoride content of ground waters
from 8 mg/1 to 1 mg/1. In laboratory studies, the effluent from a
lime precipitation system treating a high fluoride content waste
(1000-3000 mg/1) was reduced from 30 mg/1 to 2 mg/1 using activated
alumina adsorption. A pH in the alkaline range was found not to
affect the ion exchange operation. The influent waste water should
be filtered before activated alumina adsorption to prevent premature
fouling of the exchange resin and to prevent shortened periods
between regeneration cycles.
108
-------
An activated alumina filter can be either gravity or pressure oper-
ated. The gravity filter is similar to those used in municipal
water treatment plants, and consists of the activated alumina media,
underdrains, wash troughs, and a regenerant distributor. The pres-
surized column is similar to those used in conventional ion exchange
treatment systems.
Regenerating the activated alumina can be accomplished with a
caustic solution, sulfuric acid, hydrochloric acid, or alum.
Caustic regeneration is being practiced at most water treatment
plants. Water and dilute acid rinses are used to remove residual
caustic from the bed following regeneration. The residual spent
caustic regenerant can be bled into the lime precipitation system
and can be neutralized with the lime treatment effluent. If a
mineral acid such as hydrochloric acid is used as the column
regenerant, it may be necessary to include separate neutralization
facilities and sludge handling equipment to treat the spent
regenerant stream.
Ammonia Removal
Ammonia removal methods include air and steam stripping, biological
nitrification/denitrification, breakpoint chlorination, and selec-
tive ion exchange. Air and steam stripping appear to be the most
viable methods for the incandescent lamp envelope manufacturing sub-
category. A discussion of these treatment techniques follows.
Ammonia Stripping-
Ammonia exists in solution in two forms, as the ammonium ion, and as
dissolved ammonia gas. The equilibrium may be explained by the
following equation:
NH4+ = H+ + NH3(g)
The reaction is pH-dependent with only ammonium ions present at pH
7, while only dissolved ammonia exists at pH 12; as the temperature
rises the reaction proceeds toward the production of ammonia gas.
At a pH approaching 12, ammonia gas can be removed from solution by
heating the solution and using an inert gas such as air or steam as
a stripping medium.
Steam Stripping, Many oil refineries, petrochemical plants, and the
nitrogen fertilizer industry use steam stripping for ammonia
removal. There are many different stripping designs in existence,
but most involve the downward flow of waste water through a packed
or trayed column countercurrent to an ascending flow of steam.
Other stripping media such as flue or fuel gases are also employed.
109
-------
Steam stripping is used in the petroleum industry to remove ammonia
from sour water. In columns ranging in size from 1.07 to 1.52 m
(3.5 to 5 ft) in diameter and 5.18 to 9.14 m (17 to 30 ft) in
height, and at temperatures ranging from 110 to 127°C (230 to
260°F) , ammonia removal efficiencies range from 86 to 96.4 percent.
Various designs are used including trayed columns with from 6 to 13
plates or packed columns containing 3.66 vertical meters (12
vertical feet) of Raschig-rings. Ammonia concentrations in sour
water range from 1000 to 9800 mg/1 at a pH ranging from 8.0 to 9.25.
It should be noted that sour water strippers are designed for
removing hydrogen sulfide rather than ammonia. The optimum pH range
of ammonia removal is within the range of 10.8 to 11.5 which is
considerably higher than the ranges described above. The removal
efficiencies will greatly increase as the pH is adjusted to within
the optimum range.
Steam stripping in the nitrogen fertilizer manufacturing industry is
used to remove ammonia from process condensate. Packed columns have
yielded effluent ammonia concentrations in the 20 to 30 mg/1 range
at feed rates varying from 7.6 to 10.7 I/sec (120 to 170 gpm). A
typical column might be 0.914 m (3 ft) in diameter and 12.2 m (40
ft) high. Stainless steel Pall rings have been used as packing
material. Another system uses a trayed stripping column 1.37 m (4.5
ft) in diameter, and 12.2 m {40 ft) high. The unit will handle 44
I/sec (700 gpm) of feed and produces an ammonia effluent
concentration of less than 5 mg/1.
Air Stripping. The ammonia stripping (air) tower is an economical,
simple, and easy-to-control system. The process involves raising
the pH of the waste water stream to within the range of 10.8 to
11.5, the formation and reformation of water droplets in a packed
stripping tower, and providing maximum air-to-water contact by
circulating air through the tower. Two serious limitations have
been encountered with air strippers: operational problems can occur
at ambient air temperatures below 0°C (32°F), calcium carbonate
scaling has developed, which can cause a loss in treatment
efficiency due to a reduction in the amount of air circulated. The
temperature limitation is not a drawback in warm climates. The
scaling problem may be controlled or eliminated by installing water
sprays to wash them away.. Complete accessibility to the tower
packing will permit mechanically scraping the packing. A dilute
acid rinse can be used to remove calcium carbonate scale.
Most research and development of the various air stripping systems
has involved treating raw domestic waste waters. At air-to-liquid
loadings of 3.74 cu m/1 (500 cu ft/gal) and at a pH of 11, one study
reports ammonia removals of 92 percent (from domestic sewage) in a
2.13 m (7 ft) tower packed with 1.27 cm (0.5 in.) Raschig rings
loaded at a rate of 12.2 1/min/sg m (0.3 gpm/sq ft). In a 7.6 m (25
ft) high, 1.83 m (6 ft) wide, and 1.22 m (4 ft) deep tower packed
with redwood slats, ammonia removals of 95 percent (from domestic
sewage) were achieved at a pH of 11.5 and an air-to-liquid loading
of 3.0 cu m/1 (400 cu ft/gal).
110
-------
A full-scale ammonia stripping tower has been built at South Tahoe
to remove ammonia from domestic sewage. This tower is of cross-flow
design and is equipped with a two-speed reversible 7.32 m (24 ft)
diameter horizontal fan and packed with treated hemlock slats. Its
overall dimensions are 9.75 m (32 ft) by 19.5 m (64 ft) by 14.3 m
(U7 ft) high, and the tower is designed to treat 14,200 cu m/day
(3.75 mgd) of water. Treatment efficiencies have been reported to
closely parallel that of the pilot scale tower from which it was
designed, but problems have limited winter-time operation. Ammonia
removal efficiencies on the order of 90 to 95 percent are being
consistently achieved in warm weather operation.
A study of air stripping of ammonia from petroleum refinery waste
waters in the 100 mg/1 range reported ammonia removal efficiencies
of greater than 95 percent at all pH values above 9.0 in a closely
packed aeration tower with an air-to-liquid ratio of 3.59 cu m/1
(480 cu ft/gal) .
Ammonia treatment efficiencies have been reported as being
consistently good when the temperature of the waste water being
treated is maintained above 20°C (67°F). However, the colder air
and water temperatures in winter have been observed to have a
pronounced effect on the ammonia stripping efficiency. It was
determined that during winter operating conditions, at an air-to-
liquid ratio of 3.59 cu m/1 (480 cu ft/gal) and a loading rate of
81.5 1/min sq m (2.0 gpm/sq ft), temperature drops of from 8 to 10°C
(14-18°F) occurred when waste water influent was introduced at
temperatures in the 13 to 20°C (55-67°F) range.
All the reported cold air operational problems should be noted as
having been associated with the stripping of ammonia from the
effluent from a domestic sewage treatment plant. This effluent
would be relatively cold during winter operating conditions. The
effluent from an incandescent lamp envelope manufacturing plant,
however, is at an approximate • temperature of 38°C (100°F), even
during winter operating conditions.
It is unclear whether the conventional air stripping of ammonia is
practicable technology during winter operating conditions for the
incandescent lamp envelope manufacturing subcategory.
Theoretically, the rate at which ammonia strips is a function of the
difference in partial pressures of the ammonia dissolved in the
liquid phase and that of the gaseous phase. Therefore, at the high
ammonia concentrations experienced in the incandescent lamp envelope
manufacturing segment (approaching 650 mg/1) , it is not clear
whether the driving force for ammonia stripping will be sufficiently
hindered during cold weather to render this technology impractical.
Ill
-------
The ammonia concentrations experienced in the domestic treatment
field are in the range of 12 to 30 mg/1, and the driving force for
stripping is considerably lower at these concentrations. Whether
the 38°C (100°F) effluent temperatures will be sufficient to
overcome the low air temperatures experienced in northern climates
during winter operations is indeterminable at this time. There is
sufficient justification for further research of the application of
this technique to industrial waste waters.
The most recent advance in the area of ammonia stripping includes an
ammonia recovery step. Preliminary results indicate that most of
the problems usually associated with stripping towers have been
overcome. This process involves the air stripping of ammonia in a
closed cycle with the gas stream recycled rather than outside air
being used in a single pass manner. The stripped ammonia is then
absorbed in an absorbing liquid which is maintained at a low pH to
convert dissolved ammonia gas to ammonium ion. The absorbent liquid
initially is water with acid added to maintain a low pH. If
sulfuric acid is added, an ammonium sulfate salt solution is formed
which builds up in concentration; thus, ammonia is ultimately
discharged from the stripping unit as a liquid or solid blowdown.
Advantages of this system are that the usual scaling problems
associated with ammonia stripping will be eliminated because carbon
dioxide (which can react with calcium and hydroxide ions to form
calcium carbonate scale) is eliminated from the stripping air during
the first few passes as nearly all outside air is excluded. The
problem of tower freezing is also eliminated due to the exclusion of
outside air in significant quantities. The treatment system will
normally operate at a temperature approaching that of the waste
water itself. it is estimated that the cost of this method of
treatment is approximately 1.5 to 2.0 times as much as conventional
air stripping. However, this cost can be offset somewhat if the
concentrated ammonia is sold as a by-product, such as fertilizer.
It is predicted that process optimization and sale of the by-product
could yield a cost of approximately the same as that associated with
conventional air stripping, which is usually considerably less than
that associated with other nitrogen removal techniques.
It is apparent from the above discussion that while the air
stripping of ammonia is not currently demonstrated in the glass
manufacturing category, there is sufficient information available to
justify further study of the application of this ammonia removal
technique. This further study could lead to an economical and
easily operated procedure of ammonia removal and/or recovery.
Selective Ion Exchange-
In recent years, a considerable amount of experimental work has been
done with clinoptilolite, a naturally occurring zeolite that is
selective for the ammonium ion in the presence of calcium and
magnesium. The experimental work has been done primarily with
112
-------
domestic sewage where typical ammonia removals ranging from 93 to 97
percent were achieved for influent ammonia nitrogen concentrations
of 10 to 20 mg/1. The secondary treated sewage was filtered through
a multimedia filter before ammonia removal to prevent plugging of
the exchange media.
The clinoptilolite can be regenerated by a lime slurry or by an
electrolytic method. A mixture of NaCl and CaC12 in a solution
adjusted to a pH of about 11 with lime is used to regenerate the
clinoptilolite. The spent regenerant can then be air stripped to
remove the ammonia. Scaling can occur in the exchange columns with
the lime slurry regeneration method. The electrolytic method uses a
mixture of calcium, sodium, magnesium, and potassium chlorides for
eluting the ammonia from the beds. The regenerant is then
introduced into an electrolytic cell in which chlorine is produced
and reacts with the ammonia to produce nitrogen gas. The
electrolytic renovation of spent regenerant is economically
competitive with air stripping and does not require atmospheric
disposal of the ammonia.
A high frequency of regeneration and resultant disposal of
concentrated regenerant will be required at the high ammonia levels
present in the incandescent lamp envelope frosting waste waters.
Further research is required to determine if selective ion exchange
and regenerant recovery can be feasible as a secondary method for
treating frosting waste waters following primary removal by
stripping.
and Denitrif ication-
Nitrification. Nitrification is the biological conversion of
litrogen in organic or inorganic compounds from a more reduced to a
nore oxidized state. In the field of water pollution control,
nitrification usually is referred to as the process in which
ammonium ions (NH4.+) are oxidized to nitrite and nitrate
sequentially. In the nitrification step, aerobic bacteria convert
the ammonia nitrogen to nitrates. The nitrification step is carried
out in an aeration chamber with a longer retention time and lower
loading than a conventional activated sludge unit. The following
equations describe the reactions which occur during the
nitrification step:
2NH3 +
2NO2- +
302
02
2NO2
2NO3
2H+
2H2O
Factors that affect the nitrification process include concentration
of nitrifying organisms, temperature, pH, dissolved oxygen
concentration, and the concentration of any inhibiting compounds.
Adequate process design and operating control are necessary for
consistent results.
113
-------
The nitrifying organisms of significance in waste management are
autotrophic with Nitrosomonas being the major bacterial genera that
are involved. Nitrifying bacteria are ubiquitous in the soil
although they may not be part of untreated wastes. Nitrifying
organisms are aerobic and adequate dissolved oxygen (DO) in the
aeration system is necessary. DO concentrations should be above 1
to 2 mg/1 to assure consistent nitrification. Nitrification is
affected by the temperature of the system. Available information
provides conflicting data on the performance of nitrification
systems at low temperatures. Although detailed studies are lacking,
it should be possible to achieve nitrification at low temperatures
and compensate for slower nitrifying organism growth rates by
maintaining a longer solids detention time and hence a larger
nitrifying active mass in the system.
The optimum pH for nitrification of municipal sewage has been
indicated to be between 7.5 and 8.5. Nitrification can proceed at
low pH levels, but at less than optimum rates. During
nitrification, hydrogen ions are produced and the pH decreases, the
magnitude of the decrease being related to the buffer capacity of
the system. A decrease in pH is a practical measure of the onset of
nitrification.
High concentrations of un-ionized ammonia (NH3) and un-ionized
nitrous acid (HNO2_) can inhibit nitrification. These compounds can
be in the influent waste water or can be generated as part of the
nitrification process. The concentrations of un-ionized ammonia and
nitrous acid that are inhibitory and operational approaches to avoid
such inhibition have been documented. Using these approaches it
should be possible to operate nitrification systems that produce
consistent results even with waste waters having high nitrogen
concentrations.
While research on nitrification has been conducted for a number of
years, most pilot and full-scale studies have been initiated since
1970. Even though there has been a relatively short time frame of
evaluation, nitrification is already a very readily described
process for which treatment system designs can be implemented. Most
of the applications have been on municipal effluents, but
concentrations of ammonia in these effluents have ranged between 20
mg/1 and 800 mg/1. Like any other "tertiary11 level of treatment,
nitrification requires more operational attention than has generally
been given to simple biological treatment, but the applicability of
the process to many types of effluents appears very reasonable.
Nitrification/Denitrification.
This
denitrification is
two-step
of primary
process of
importance for
secondary
nitrification and
removal of the residual ammonia, nitrite, and nitrates in
treatment systems. Removal of the above soluble nitrogen forms can
be virtually complete, with nitrogen gas as the end product. This
process differs from ammonia stripping and nitrification in that the
latter processes convert or remove only the ammonia content of a
waste water.
114
-------
As described earlier, nitrification is carried out under controlled
process conditions by aerating the waste water sufficiently to
assure the conversion of the nitrogen in the waste water to the
nitrite-nitrate forms. The denitrification process reduces the
oxidized nitrogen compounds (nitrites and nitrates) to nitrogen gas
and nitrogen oxides thereby reducing the nitrogen content of the
waste water as the gases escape from the liquid.
Denitrification takes place in the absence of dissolved oxygen.
Additional important factors affecting denitrification include
carbon source and temperature. Denitrification is brought about by
heterotrophic facultative bacteria. Generally, high denitrification
rates require the addition of a biodegradable carbon source such as
sugar, ethyl alcohol, acetic acid, or methenol. Methanol is the
least expensive and performs satisfactorily in that it reacts
rapidly and provides for a minimal growth of new organisms.
Investigators working on this process have found that a 30-percent
excess of methanol over the stoichiometric amount is required, or
about 3 mg of methanol to 1 mg of nitrate. The following reaction
takes place if methanol is used as the carbon source and proper
conditions are maintained:
6N03-
5CH30H = 3N2
5C02
7H20 + 60H-
Denitrification does not take place until the dissolved oxygen
concentration of the waste water is near or at zero. The organisms
responsible for denitrification are ubiquitous and can adapt to pH
levels within the range of about 6.0 to 9.0. As with any
biochemical process, denitrification exhibits a temperature
dependency although within the range of 20°C to 30°C, little effect
has been observed. Denitrification activity decreased when the
temperature decreased to 10°C, Denitrification can be operated at
low temperatures by designing systems with long solids retention
times (SRT). For denitrification systems, an SRT of at least 3 to U
days at 20°C and 30°C and 8 days . at 10°C has been recommended.
Nitrate reduction efficiency in denitrification can be controlled by
adjusting the SRT of the process to assure adequate numbers of
denitrifying organisms and adequate denitrification rates . as
environmental conditions change.
In a sequential nitrification/denitrification process, the waste
water from the denitrification step may be sent to a second aeration
basin, following denitrification, where the nitrogen gases are
stripped from the waste stream. The sludge from each stage is
settled and recycled to preserve the organisms required for each
step in the process. The processes of nitrification and
denitrification can occur simultaneously in aeration systems in
which both aerobic and anaerobic portions occur.
Although nitrification/denitrification has not been applied to
pressed an blown glass manufacturing waste water as yet, the process
has been evaluated in a number of bench and pilot scale studies on a
variety of wastes. Anaerobic processes evaluated
115
-------
as part of the denitrif ication sequence have included anaerobic
ponds, an anaerobic activated sludge system, oxidation ditches, and
anaerobic filters. Efficient nitrogen removals from agricultural
subsurface drainage water were accomplished with an anaerobic
filter. In Germany, the successful elimination of nitrogen from
sewage and digester supernatant was achieved by first nitrifying the
wastes and then denitrifying in a separate vessel. Two- and three-
stage systems have been shown to be feasible for the
nitrification/denitrification process. A pilot model of a three-
stage system using this process was developed at the Cincinnati
Water Research Laboratory of the EPA and is being built at Manassas,
Virginia.
The nitrification and denitrif ication methods of nitrogen removal
have been used primarily to treat municipal waste waters. Pilot
plant work using frosting waste water must be conducted to determine
the feasibility of the method in treating the frosting wastes. Such
factors as the high ammonia levels (650 mg/1) , shock loads,
biological upsets, and supplemental chemical addition might preclude
the nitrification/denitrification method as a viable method for
treating frosting waste waters alone. However, it may prove
economical for a facility to treat its combined sanitary and
industrial waste waters in a nitrification or nitrification/
denitrif ication system as is being done in at least one facility
which handles wastes similar in nature to those characterisic of the
incandescent lamp envelope manufacturing subcategory.
Breakpoint Chlorination-
When chlorine is added to waste water containing ammonia nitrogen,
the ammonia reacts with the chlorine to produce chloramines. The
further addition of chlorine up to a "breakpoint" results in con-
verting the chloramines to nitrogen oxide which is released as a gas
to the atmosphere. Ammonia nitrogen in domestic sewage can be
reduced to a level of 0.1 mg/1 if adequate mixing, dosing, and pH
control are maintained. The following equations illustrate the
reactions:
NH3 + HOC1 =
NH3 + 2HOC1 =
NH2C1 + NHC12 +
NH2C1 (monochloramine) + H20
NHC12 (dichloramine) + 2H2O
HOC1 = N2O + UHC1
Breakpoint chlorination is a well understood and well documented
technology. Applications have centered on tertiary treatment of
secondary municipal wastes, although the concept has been found to
be useful as a "polishing" mode in conjunction with ammonia
stripping. It appears from the literature that the process offers a
possible alternative for ammonia control of ammonia concentrations
similar to those encountered in municipal secondary effluents.
116
-------
Approximately eight to ten parts of chlorine to one part of ammonia-
N are required to reach the chlorine breakpoint. The high chlorine
dosage results in excessive chemical costs at high ammonia levels in
the waste water. Additional adverse effects of breakpoint
chlorination include high chlorine residuals and mineralization in
the form of chlorides. The high chlorine residuals can be reduced
by carbon contactors before discharge to the receiving body of
water. Breakpoint chlorination, however, will probably not prove
viable for treating frosting waste because of excessive chemical
costs due to high concentrations of ammonia. However, as a
polishing step subsequent to air or steam .stripping, breakpoint
chlorination could prove to be a viable means of attaining water
quality-related limitations.
Lead Removal
Lead is contributed by the waste waters from the television picture
tube envelope and hand pressed and blown glass manufacturing
subcategories. The lead is primarily in the form of particulates
removed during grinding and polishing of lead crystal and the funnel
section of television picture tube envelopes, and soluble lead
resulting from hydrofluoric acid polishing of leaded glass. The
primary methods used to remove lead from waste waters include plain
sedimentation, lime precipitation and sedimentation, and filtration.
Suspended solids are also removed in the lead treatment processes.
Plain sedimentation is relatively effective in removing particulate
lead but not dissolved lead. Improved settling is obtained by pH
adjustment to a neutral pH and by lengthened detention time in the
clarification unit.
The lime precipitation process is the most common method used to
treat dissolved lead wastes. In the lead precipitation process,
lead is precipitated as the carbonate (PbCO^) or the hydroxide
(Pb (OH)2). Conflicting values are given for the optimum pH for
precipitating the lead hydroxide: the suggested pH values range
from 6.0 to 10.0. Improved removal efficiencies can be obtained by
adding ferrous sulfate to the lime precipitation process. Treatment
efficiencies exceeding 95 percent have been achieved with lime
precipitation plus sedimentation both in full scale and pilot plant
operations.
In pilot plant work and in full scale studies at a municipal water
treatment plant, filtering through a dual media filter was shown to
futher reduce the lead content following lime precipitation and
sedimentation. Effluent levels were reduced almost an order of
magnitude by sedimentation and filtration rather than by sedi-
mentation only. The additional removals are obtained by removing
poorly settling lead hydroxide particles that are carried over from
the clarification units.
The lead wastes from the pressed and blown glass segment are treated
in conjunction with the fluoride waste waters. The point of
117
-------
application of the lead waste varies; at one picture tube envelope
plant the lead wastes are treated by coagulation and then allowed to
settle with the lime treated wastes. At another picture tube plant,
the lime treated fluoride wastes are settled in a primary clarifier
and the lead abrasive wastes are added to the treated fluoride
wastes and settled again. The effluent from the two-stage system
contains about 1 mg/1 of lead. The lead wastes settle readily
because the lead is in the particulate form.
SUGGESTED TREATMENT TECHNOLOGY
As was indicated in the previous section, several treatment
technologies are usually available to reduce a given pollutant
parameter. This section discusses the application of specific
methods of treatment which may be employed for each subcategory to
achieve the effluent limitations and new source performance
standards recommended in Sections IX, X, and XI. These technologies
are not to be construed as the only means for achieving the stated
effluent levels, but are considered to be feasible methods of
treatment based on available information. The cost estimates
developed in Section VIII are based on these technologies.
Glass Container Manufacturing
As was stated in Section V, waste water results from forming and
cullet quenching in the manufacture of glass containers. In most
plants, these waste waters are combined with non-contact cooling
water prior to discharge; however, in some cases a portion of the
cooling water is used for cullet quenching. Oil and suspended
solids are the only significant parameters contained in this waste
water. The quantity of pollutants discharged may be reduced by
recycling the cullet quench water and treating the blowdown using
dissolved air flotation followed by diatomaceous earth filtration as
illustrated in Figure 11.
Existing Treatment and Control (Alternative A)-
Both in-plant techniques and end-of-pipe methods have been employed
to reduce pollutant discharge. Many plants have achieved low
effluent levels with only in-plant methods, and the presence of end-
of-pipe treatment systems has not necessarily assured a high quality
effluent. A number of plants without end-of-pipe treatment are
achieving low discharge levels while several plants with treatment
are discharging at rather high levels.
The typical combined cooling and cullet quench water flow for a
glass container plant is 2,920 I/metric ton (700 gal/ton) with 53
percent of the total flow being process water. Suspended solids
discharges of 70 g/metric ton (0.1U Ib/ton) and oil discharges of 30
g/metric ton (0.06 Ib/ton) are presently being achieved by 70
percent of the 40 plants for which data are available. These values
correspond to 2U mg/1 for suspended solids and 10 mg/1 for oil at
the typical flow.
118
-------
GULLET
WATER
RETURN TO
riiiin-niiCMrH
1
GULLET QUENCH
1
GRAVITY OIL SEPARATOR
>
GULLET
SLOWDOWN
DISSOLVED AIR FLOTATION
.
1
DIATOMACEOUS
EARTH FILTER
••SLUDGE TO
LAND DISPOSAL
TO
LAND DISPOSAL
SURFACE DISCHARGE
FIGURE 11
WASTE WATER TREATMENT
GLASS CONTAINER MANUFACTURING
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
119
-------
These effluent levels should be readily achievable by all plants
with a minimum of in-plant modification or end-of-pipe treatment.
In-plant modifications to reduce pollutant discharge include shear
spray collection of forming machine shop oil, or modified cleanup
procedures. Many plants collect and recycle shear spray. Pans are
placed around the shears to collect as much of the excess spray as
possible. The collected material is filtered and returned to the
shear spray make-up tank. Approximately 70 percent of the shear
spray can be recovered in this manner. In some plants, troughs are
built around the forming machines to collect the oily runoff
resulting from excess lubrication and leaks. The oily waste flows
by gravity to a storage tank and is periodically hauled away for
reclamation or disposal.
It is the practice of many plants to periodically hose down the area
around the forming machines. It may be possible to use a dry
removal method for at least part of the cleanup. One of the oil
adsorptive sweeping compounds might be used and disposed of as solid
waste, thereby eliminating some of the oil discharged into the waste
water system.
End-of-pipe treatment might involve some type of sedimentation
system with oil removal capability. This will serve to reduce
suspended solids and free oil but will not significantly reduce
emulsified oil. Although end-bf-pipe treatment systems are
presently being used by some plants, it would appear that in-plant
techniques will be more effective and less expensive to achieve the
suggested effluent levels.
Recycle with Dissolved Air Flotation of Slowdown (Alternative B)-
Effluent levels can be further reduced by segregating the cullet
quench water from the cooling water system, recycling the cullet
quench water through a gravity separator and treating the blowdown
using dissolved air flotation. Suspended solids and oil will build
up in the recirculation system, but the dissolved solids
concentration will probably be limiting. A conservative value of 5
percent blowdown is assumed, based on the operating dissolved solids
level of approximately 1700 mg/1 in an existing recycle system.
Dissolved solids levels of 4000-5000 mg/1 are probably acceptable,
but supportive data are not presently available. A cooling tower is
not considered necessary. Existing recycle systems use only a tank
that serves as the recycling pump wet well and from which oil is
removed using a belt skimmer.
Segregation of the non-contact cooling water and recycle with a 5
percent blowdown will reduce the typical contact water discharge
flow to 77 I/metric ton (18.5 gal/ton). Blowdown from the recycle
system can be treated to 2 g/metric ton (O.OOU Ib/ton) using
dissolved air flotation. COD is expected to be reduced in
proportion to the oil removed. The sludge production is
approximately 1900 I/day (500 gal/day) at 3 percent solids
concentration.
Z20
-------
Several glass container plants are presently recycling cullet quench
water to conserve water, but none are treating the blowdown using
dissolved air flotation. This technology is practiced in the flat
glass industry and should be readily transferable to the pressed and
blown glass industry. It has been reported that a new glass
container plant will employ this technology but at the present time
no operating data has been generated and no pilot or bench-scale
data has been submitted to the Agency.
At least one plant has recently begun treating a portion of the
recycling quench water using diatomaceous earth filtration. Long-
term operating data for this system are not available. It is
possible that diatomaceous earth filtration will not be effective
for the high oil concentrations in a recycling system or that
excessive diatomaceous earth usage will be required. For this
reason, the proposed model system includes dissolved air flotation,
prior to diatomaceous earth filtration, to lessen the oil loading to
the diatomaceous earth filter.
Diatomaceous Earth Filtration (Alternative C]_-
Diatomaceous earth filtration may be employed to further reduce the
oil and suspended solids in the dissolved air flotation discharge
stream to less than 10 mg/1 or 0.8 g/metric ton (0.0016 Ib/ton).
Approximately 50 I/day (13 gal/day) of 15 percent solids sludge is
produced. This technology has been commonly employed for steam
condensate treatment and should be readily transferable to the
pressed and blown glass industry. As stated above, at least one
plant is presently employing the diatomaceous earth filtration
technology.
Rather than treat to such a low effluent level, it may be feasible
for a plant to consider complete recycle or discharge of the
blowdown into the batch. Several container manufacturers are
investigating this possibility and a number of plants have achieved
nearly complete recycle. More data than was available for this
study will be necessary to evaluate the feasibility of zero
discharge through application of this technique.
Machine Pressed and Blown Glass Manuf acturing
Owing to similar manufacturing techniques, waste water resulting
from machine pressing and blowing of glass is similar to glass
container manufacturing waste water. Oil and suspended solids are
the significant pollutant parameters and their discharge may be
reduced by recycling the cullet quench water and then treating the
blowdown. The machine pressed and blown glass manufacturing
subcategory is the subject of further study at the present time.
The results of this study will be presented in a supplemental
document at a later date.
121
-------
Glass Tubing (Dannerj Manufacturing
Process waste water in the glass tubing (Danner) manufacturing
subcategory results from cullet quenching during periods when normal
production has been interrupted. In most plants, cullet quench
water is combined with non-contact cooling water prior to discharge.
Suspended solids is the only significant pollutant in the quench
water along with small quantities of tramp oil. Recycle with
treatment of the blowdown, as illustrated in Figure 12, is a
feasible method of treatment.
Existing Treatment and Control (Alternative AI-
Owing to the high quality and erratic discharge of cullet quench
water, no plants presently treat this source of waste water. All
four of the plants for which data are available presently achieve a
discharge of less than 225 g/metric ton (0.45 Ib/ton) of suspended
solids, and 85 g/metric ton (0.17 Ib/ton) of oil. This corresponds
to 27 mg/1 of suspended solids and 10 mg/1 of oil at the typical
combined cullet quench water and non-contact cooling water flow of
8,340 I/metric ton (2,000 gal/ton).
Recycle with Diatomaceous Earth Filtration of Slowdown (Alternative
BI-
Because cullet quench water accounts for only five percent of the
combined flow, it is possible to further reduce the oil and
suspended solids levels by segregating the cullet quench water from
the non-contact cooling water, recycling the quench water through a
cooling tower, and treating the blowdown using diatomaceous earth
filtration. A flow over the cooling tower of 12.6 I/second (200
gpm) for the typical plant is assumed. Assuming a five percent
blowdown, the discharge will be 21 I/metric ton (5 gal/ton). The
minimum allowable blowdown is unknown because this technology is not
presently employed in the glass tubing industry, but five percent is
considered a conservative estimate. Suspended solids will probably
be limiting because only negligible dissolved solids increases were
noted in the available data. It is anticipated that at least a
portion of the suspended solids can be removed in a glass trap
associated with the collection sump.
It may be possible to use a tank rather than a cooling tower
provided sufficient water can be stored to sufficiently dissipate
the heat in the glass to be quenched. Information to calculate the
required storage volume is not available and, therefore, a cooling
tower is assumed for the purpose of this analysis.
Blowdown from the recycling system can be treated at a constant rate
using diatomaceous earth filtration. Approximately 15 I/day (4
gal/day) of 15 percent solids sludge will be produced. Diatomaceous
earth filtration is used to treat boiler condensate and is readily
transferable to the glass tubing (Danner) manufacturing subcategory.
Refer to earlier portions of this section for more detailed
information.
122
-------
WATER.
GULLET
GULLET QUENCH
GULLET
A
RETURN TO
GULLET QUENCH
COOLMQ TOWER
SLOWDOWN
DIATOIMCEOUS
EARTH FILTER
TO
LAND DISPOSAL
fi
SURFACE DISCHARQE
FIGURE 12
WASTE WATER TREATMENT
GLASS TUBING MANUFACTURING
123
-------
Treatment of the blowdown from the cullet quench recirculation
system by sand filtration or disposal of the blowdown in the batch
are other alternatives; tne latter will allow for zero waste water
discharge. The typical blowdown is approximately 1.5 percent by
weight of the furnace fill, well within the range of the three
percent of water added when batch wetting is used-
Television Picture Tube Envelope Manufacturing
Waste waters are produced during both the forming and finishing of
television picture tube envelopes. Cullet quench water contains low
concentrations of oil and suspended solids and does not require
further treatment. Finishing waste water, produced by acid and
abrasive polishing of television picture tube screens and funnels,
contains high concentrations of suspended solids, fluoride, and
lead. The acid and abrasive wastes are presently treated using lime
precipitation, coagulation, and sedimentation but effluent levels
can be further reduced by sand filtration followed by activated
alumina adsorption. These treatment technologies are illustrated in
Figure 13.
Existing Treatment and control (Alternative AL~
Television picture tube envelope manufacturing plants employ in-
plant methods of water conservation and end-of-pipe treatment for
fluoride, lead, and suspended solids removal. Because many of the
plants have been built within the last 10 years and all within the
last 25 years, relatively good water conservation is practiced.
Abrasive grinding slurries are recycled to recover usable abrasive
material and only the particles too small to be of further value are
discharged. Rinse waters are recycled where possible by using
countercurrent or overflow type rinse tanks. Some final rinses are
once through because a high quality water is required to prevent
spotting. It may be possible to recycle this water for less
critical uses. Spent acid solutions are either bled into the
treatment system at a slow rate or returned to the manufacturer for
recovery and recycling.
All of the plants, for which information was available, treat
abrasive and acid polishing waste waters by lime precipitation
followed by combined coagulation and sedimentation of the calcium
fluoride precipitate and abrasive waste suspended solids. The pH is
reduced where necessary and sulfuric acid is generally used. Vacuum
filtration is the most common method of dewatering, and the sludge
is disposed of as landfill. One plant reports sludge production of
20.9 metric tons/day (23 tons/day). The cullet quench waters are
combined with non-contact cooling water prior to discharge and are
not treated. The typical combined non-contact cooling and cullet
quench water flow is 8,080 I/metric ton (1,940 gal/ton) and
suspended solids and oil concentrations are below 5 mg/1. When
combined with the treatment plant effluent, the total typical flow
is 12,500 I/metric ton (3,000 gal/ton).
124
-------
WATER
ACID
POLISHING
RETURN TO
PRECIPITATION
t
BACKWASH
WATER
~
SPENT
REGENERANT
WATER
ABRASIVE
POUSHIMQ
LJ
WATER
PRECIPITATION
COAGULATION
SEDIMENTATION
±
SLUDGE
pH ADJUSTMENT
DEWTER
LAND
DISPOSAL
; X"
SAND FLTRATON
CAUSTIC REGENERANT
±
ACTIVATED ALUMINA
FILTRATION
J
GULLET
GULLET
QUENCH
I
SURFACE DISCHARGE
FIGURE 13
WASTE WATER TREATMENT
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
GULLET
125
-------
Effluent levels of 150 g/metric ton (0.30 Ib/ton) for suspended
solids, 130 g/metric ton (0.26 Ib/ton) for oil, 70 g/metric ton
(0.1** Ib/ton) for fluoride, and 4.5 g/metric ton (0.0090 Ib/ton) for
lead can be achieved using existing treatment methods and equipment.
These values are equivalent to concentrations in the treatment plant
effluent of 15 mg/1 of fluoride and 1 mg/1 of lead and
concentrations in the combined treated and cullet quench water
streams of 10 mg/1 for oil and 12 mg/1 for suspended solids. The
fluoride and lead concentrations in the combined flow are 5.6 mg/1
and 0.36 mg/1, respectively. Of the four television picture tube
envelope manufacturing plants for which data were available, three
of the four presently achieve the above discharge level for
suspended solids, two of three for oil, three of four for fluoride,
and all meet the discharge level for lead. All plants can achieve
these levels by upgrading the operation of existing treatment
systems and by improving housekeeping to minimize pollutant
discharge from the forming area.
Sand Filtration (Alternative B)_-
Fluoride and lead precipitates that are not removed during
sedimentation may be further reduced by filtering the lime treated
effluent using sand or graded media. The filter backwash can be
returned to the head of the lime treatment system and, therefore, no
additional sludge handling equipment is required. Filtration will
reduce the fluoride to less than 13 mg/1, the lead to 0.1 mg/1, and
the suspended solids to less than 10 mg/1. The total plant
discharge, including the treated effluent and the cullet quench
water,' will be reduced to 130 g/metric ton (0.26 Ib/ton) for
suspended solids, 60 g/metric ton (0.12 Ib/ton) for fluoride, and
.45 g/metric ton (0.0009 Ib/ton) for lead. The concentration of
pollutants in the total typical plant discharge for this level of
treatment will be 10 mg/1 for suspended solids, 10 mg/1 for oil, 4.8
mg/1 for fluoride, and 0.036 mg/1 for lead.
Filtration of waste water is not presently practiced in the pressed
and blown glass industry, but is a commonly employed treatment
method used in the water treatment industry, usually following lime
softening.
Activated Alumina Filtration (Alternative C)-
Reduction of fluoride to less than 2.0 mg/1 can be accomplished by
passing the effluent from the sand filter through a bed of activated
alumina. The activated alumina may be regenerated with sodium
hydroxide (rinsing with sulfuric acid may be necessary to reduce
causticity) or mineral acid. If sodium hydroxide is used, the
regenerant may be returned to the head of the lime treatment system
for removal of the fluoride. If a mineral acid such as hydrochloric
acid is used, it may be necessary to include separate neutralization
and sludge handling facilities to treat the spent regenerant stream.
The costs presented in Section VIII of this document reflect the use
of hydrochloric acid as the regenerant and include separate
neutralization and sludge handling facilities. With this
126
-------
technology, the fluoride discharge will be reduced to 9 g/metric ton
(0.018 Ib/ton) and the concentration of fluoride in the total
typical plant discharge will be 0.72 mg/1.
Activated alumina is not presently used in the pressed and blown
glass segment, but has been successfully used for many years at
several potable water treatment plants in the United States.
Experiments have indicated that the higher pH associated with lime
treatment will not adversely affect the fluoride removal capability.
All plants should be able to reduce the average effluent of fluoride
waste waters to 2.0 mg/1 using this technology.
Incandescent Lamp Envelope Manuf acturing
Waste waters are produced during both forming and frosting in the
manufacture of incandescent lamp envelopes. Cullet quench waters
contain small quantities of oil and suspended solids, and frosting
waste waters contain moderate concentrations of suspended solids and
high* concentrations of fluoride and ammonia. Frosting wastes are
presently treated for fluoride removal, but ammonia removal
techniques are currently not employed. Treatment methods that may
be employed to reduce the level of pollutants discharged by the
incandescent lamp envelope manufacturing subcategory are illustrated
in Figure 14.
Existing Treatment and Control (Alternative AJ_-
Most of the treatment methods presently in use in the incandescent
lamp envelope manufacturing subcategory can be considered end-of-
pipe methods. Cullet quench waters are discharged untreated or at
some plants belt type oil skimmers are used to skim free oil from
pump or discharge sumps. Frosting waste waters are treated in all
cases using lime precipitation for fluoride and suspended solids
removal; however, this sytem is ineffective for ammonia removal.
Some ammonia discharge is eliminated by separate disposal of the
concentrated etching sblution. At least one plant recovers the
salts from this solution by evaporating most of the water and then
allowing the sludge to air dry. Other plants truck the spent
frosting solution to permanent storage.
The percentage of lamp envelopes frosted varies from plant to plant
and, therefore, the cullet quench and frosting waste waters from
this subcategory must be categorized separately. Pollutants
discharged in the cullet quench water as a result of forming will be
expressed in terms of metric tons (tons) pulled from the furnace
while the pollutant parameters contributed by frosting will be
expressed in terms of the metric tons (tons) pulled for the frosting
line. This value is 'calculated by multiplying the metric tons
(tons) pulled by the percentage of the plant output that is frosted.
A plant frosting 85 percent of its production has been assumed for
cost estimating purposes and is presented in Section VIII.
127
-------
CULLET
mam k
RETURN TO
BACKWASH
WATER
SPENT
BQENERANT
ETCHMO PROCESS
(FROSTING)
|
PRECIPITATION
COAOULATION
SHMMENTATION
1 !~.
* 1
*
RECARBOMATKM
|
HEAT EXCHANOER
±STEM
STEAM STMPPMQ
1 i r
t jr
ACTnwnEO ALUMMA
FCTRATION
IV
1
L
^ cut
WTCT p QU1|
aujo^
DEWKTBI '
I
onmu.
I* AMMONIA QAS
+•
\
1
1C REOENERANT
.
1
MATONU
EARTH
S ->—
r
t
tce°* .^ksOLDS TO
FILTER F'LAND DMPOSAL
FIGURE 14
WASTE WATER TREATMENT
INCANDESCENT LAMP GLASS MANUFACTURING
128
-------
Little information is available on the quality of quench water, but
it is apparent that all plants can achieve a level of 115 g/metric
ton (0.23 Ib/ton) suspended solids and oil. This is equivalent to
25 mg/1 at the typical cullet quench,water flow of 4,500 I/metric
ton (1,080 gal/ton) . Plants not presently achieving these levels
can apply many of the methods for improved housekeeping described
for the glass container manufacturing subcategory. Much of the oil
and suspended solids originates in the ribbon machine area. Careful
attention to coolant spray and lubrication techniques should
eliminate excessive oil discharges. It might be necessary, in some
cases, to collect the highly contaminated waste waters that occur
during clean-up for separate disposal or treatment in the lime
treatment system.
Frosting waste waters are treated using lime to precipitate calcium
fluoride, followed by flocculation and sedimentation. The effluent
pH is lowered to at least 9.0 at most plants and neutralization is
considered typical. It is possible, using existing equipment to
treat frosting waste waters to levels of 230 g/metric ton frosted
(0.46 Ib/ton frosted) for suspended solids and 115 g/metric ton
frosted (0.23 Ib/ton frosted) for fluoride. These levels are
equivalent to 58 mg/1, and 29 mg/1, respectively, at the typical
flow of 3,960 I/metric ton frosted (950 gal/ton frosted). The
typical fluoride concentration of 29 mg/1 is higher than can be
achieved with equivalent treatment technology in the television and
handmade subcategories because of apparent interference by one or
more constituents of the frosting solution. The data indicate
consistently higher effluents from incandescent lamp envelope plants
than are obtained in television picture tube envelope plants.
A typical plant that frosts 85 percent of its production would have
a total effluent concentration of 39 mg/1 for suspended solids, 15
mg/1 for oil, 12.4 mg/1 for fluoride, and 275 mg/1 for ammonia.
When the combined forming and frosting waste waters are considered,
two of the five plants for which data are available are presently
achieving the recommended level for suspended solids, three are
achieving the recommended level for oil, two are achieving the
recommended level for fluoride, and no plant significantly reduces
ammonia.
Plants that are not achieving these effluent levels can upgrade
their treatment systems using the methods discussed earlier in the
treatment technology section. It is likely that, in many cases,
excessive fluoride discharge is associated with poor suspended
solids removal. Improvements to optimize suspended solids removal
such as careful control of flocculation, addition of
polyelectrolytes or other coagulant aids, sludge recycle, and
reduced weir overflow rates may be employed in an existing waste
water treatment plant with a minimum of modification.
129
-------
Sand Filtration and Ammonia Removal (Alternative B)-
Fluoride in the frosting waste waters may be further reduced using
sand filtration. The filter backwash may be returned to the head of
the lime precipitation system for treatment and disposal. Suspended
solids can be reduced to 40 g/metric ton frosted (0.080 Ib/ton
frosted) and fluoride to no more than 52 g/metric ton frosted (0.104
Ib/ton frosted) using this technology. These loadings are
equivalent to 10 mg/1 and 13 mg/1, respectively, at the typical
frosting waste water flow rate. This technology is not presently
employed in the pressed and blown glass industry, but has been used
for many years for potable water treatment.
The ammonia in the frosting waste water can be reduced to a more
acceptable level by steam stripping. This and other ammonia removal
technologies are discussed in detail in the treatment technology
section. One possible configuration is recarbonation, followed by a
heat exchanger, and then the stripping column.
Recarbonation will stabilize the excess calcium in the lime
treatment discharge and control pH. Further experimentation will be
required to determine the optimum location of the recarbonation
step. Ammonia removal efficiency increases as the pH increases, but
the calcium may precipitate in the stripping column and the heat
exchanger and form calcium carbonate scale. It is probable that a
trade-off exists between ammonia removal efficiency and scaling. It
is possible that recarbonation will be more advantageous subsequent
to steam stripping. Purchased CO2 is assumed in the cost estimate,
but the melting furnace stack gas is rich in CO2_ and should be
considered as a possible source. The heat exchanger will preheat
the water entering the stripper while cooling the water being
discharged, thus minimizing fuel requirements.
A packed or tray type column can be used. It is estimated that one
pound of steam will be required for each gallon of water treated.
Additional plant boiler capacity to meet this requirement is assumed
to be a necessary expense. The waste heat discharged up the melting
tank stack may be a potential source of heat, but this possibility
can only be hypothesized pending further investigation by the
industry. The stripped ammonia vapor discharge may be above the
threshold of odor, in which case it should be vented to the
atmosphere through the melting tank stacks. Refer to Section VIII
for a more detailed discussion of this subject.
Frosting waste water ammonia levels can be reduced from 2.6
kg/metric ton frosted (5.2 Ib/ton frosted) to 0.12 kg/metric ton
frosted (0.24 Ib/ton frosted) using this technology. This
corresponds to an effluent concentration of 30 mg/1 at the typical
flow.
The alternative methods of ammonia removal discussed earlier in this
section should also be carefully investigated before an ammonia
removal system is chosen. Air stripping has been employed with some
success in several domestic sewage treatment plants and may have
130
-------
potential in the glass industry. Ion-exchange appears to have
potential as a polishing step following air or steam stripping, but
is still in the experimental stage and, therefore, has not been
recommended. Steam stripping is a demonstrated technology and is
presently being successfully used for ammonia removal in both the
petroleum and fertilizer industries.
Diatomaceous Earth Filtration {Alternative Cl-
The oil and suspended solids in the cullSt quench water can be
reduced using diatomaceous earth filtration. The cullet quench
water troughs can be intercepted and the water filtered through an
oil adsorptive diatomaceous earth media. A dry discharge type
filter will produce a sludge cake suitable for landfill.
Approximately 0.54 cu m/day (0.7 cu yd/day) of 15 percent solids
sludge will be produced. With this technology, the oil and
suspended solids concentrations can be reduced to less than 10 mg/1
or 23 g/metric ton (0.045 Ib/ton). A similar treatment technology
is presently practiced in at least one glass container plant.
Activated Alumina Filtration (Alternative gj_-
Fluoride in the frosting waste water may be further reduced using
activated alumina filtration. It may be possible for the activated
alumina to serve the dual function of filtering suspended solids and
adsorbing fluoride, but this is doubtful at the anticipated
suspended solids loading. The activated alumina regenerant can be
returned to the head of the lime precipitation system for treatment
and disposal if sodium hydroxide is used as the regenerant. If
hydrochloric acid is used, it may prove necessary to provide
separate facilities to neutralize the spent regenerant waste stream.
The costs presented in Section VIII reflect the use of hydrochloric
acid as the regenerant and include the costs associated with
separate neutralization and sludge handling facilities. Fluoride
can be reduced to 7.9 g/metric ton frosted (0.016 Ib/ton frosted)
using this technology. This loading is equivalent to 2 mg/1 of
fluoride at the typical frosting waste water flow rate.
This technology is not presently employed in the pressed and blown
glass industry, but has been used for many years for potable water
treatment.
Hand Pressed and Blown Glass Manufacturing
Significant sources of waste water in the hand pressed and blown
glass manufacturing subcategory result from finishing operations.
At least six waste water producing processes are presently used in
131
-------
the industry. These have been classified as crack-off and
hydrofluoric acid polishing, grinding and polishing, machine
cutting, alkali washing, hydrofluoric acid polishing, and
hydrofluoric acid etching. Some plants employ all of the finishing
steps, while others use only one or two, but grinding and polishing
is probably the most frequently used. Owing to the variation in
finishing steps, it is impossible to generalize the industry in
terms of a typical plant.
The waste water constituents requiring treatment are suspended
solids, fluoride, and lead, but all of these are not contained in
each type of waste water. High and low pH values have also been
observed, and neutralization may be required in some cases. Figure
15 illustrates the sequence of treatments that might be employed for
a waste water containing all of these constituents. This type of
treatment system would apply to those plants which employ
hydrofluoric acid finishing techniques to leaded or unleaded glass.
Figure 16 illustrates the sequence of treatments that might be
employed to a waste containing only suspended solids. This system
would be applicable to those plants which produce leaded or unleaded
glass and do not employ hydrofluoric acid finishing techniques.
Very limited data were available from the hand pressed and blown
industry; therefore, the information presented in this subsection is
almost entirely the result of plant visits and field sampling done
as part of this study. Owing to the small size of the companies
within the industry, the low waste water volumes, the lack of
significant quantities of cooling water that could be used for
dilution, and the very limited data available, achievable effluent
levels in the hand pressed and blown glass manufacturing subcategory
are expressed in terms of milligrams per liter (mg/1).
Tables 14 and 15 present a summary of the current operating
practices of the hand pressed and blown glass manufacturing
subcategory. Forty-two plants were contacted with regard to
treatment practices, type of glass produced, and finishing
techniques employed. It should be noted that the majority (69%) of
the plants either discharge to municipal systems or do not discharge
process waste water. Treatment practices for the remaining 31% of
the subcategory vary from no treatment to sedimentation to batch
lime precipitation.
Plants which employ hydrofluoric acid finishing techniques would
have potential problems with regard to fluoride, suspended solids,
and, in the case of leaded glass production, lead. Plants which do
not employ hydrofluoric acid finishing techniques would have
potential problems with regard to suspended solids. A treatment
system for the removal of lead and fluoride from waste water would
include batch lime precipitation, sand filtration, and ion exchange,
while for removal of suspended solids would include coagulation,
sedimentation, and sand filtration. For this reason, two treatment
schemes are discussed; the first is applicable to those plants which
employ acid finishing techniques to leaded or unleaded glass, while
132
-------
WATER
RETURN TO
PRECIPITATION
t
BACKWASH
WATER
t
SPENT
REOENERANT
FINISHING OPERATIONS
1
PRECIPITATION
COAGULATION
SEDIMENTATION
1
SLUDGE
DEWATER
RECARBONATION
LAND
DISPOSAL
.
WATER
SAND FILTRATION
CAUSTIC REQENERANT
ACTNATED M.UJMM
FILTRATION
SURFACE CHSCHAHGE
FIGURE 15
WASTE VM4TER TREATMENT
HAND PRESSED AND BLOWN GLASS MANUFACTURING
133
-------
WATER
FINISHING OPERATIONS
i
COAGULATION
SEDIMENTATION
B
SLUDGE
RETURN TO
COAGULATION
SEDIMENTATION
t
BACKWASH
WATER
LAND
DISPOSAL
WATER
SAND FILTRATION
FIGURE 16
WASTE WATER TREATMENT
HAND PRESSED AND BLOWN GLASS MANUFACTURING
134
-------
TABLE 14
Current Treatment Practices Within the Hand Pressed
and Blown Glass Manufacturing Subcategory
Treatment Practice
No Discharge
Treatment with Surface
Discharge
No Treatment with Surface
Discharge
Municipal Discharge
Total in Survey
No. of Plants
6
7
6
23
Percentage of Subcategory
14.3
16.7
14.3
54.7
42
100.0
TABLE 15
Current Operating Practices Within the Hand PresseM
and Blown Glass Manufacturing Subcategory
Type of Glass Produced
No. Percentage
Leaded Glass 4
Non-Leaded
Glass 38
9.5
90.5
TOOT
Finishing Techniques
No. Percentage
Employ HF 19
Do Not
Employ HF 23
45.3
54.7
TOO"
135
-------
the second is applicable to those plants which do not employ acid
finishing techniques.
Treatment System Applicable to Plants which Employ Hydrofluoric Acid
Finishing Techniques
Existing Treatment and Control (Alternative AJ_-
Very few hand pressed and blown glass plants are presently treating
waste waters; however, a few plants have lime precipitation systems
for fluoride and lead removal. In most cases, flows are low, less
than 38 cu m/day (10,000 gpd). Significant quantities of pollutants
may be discharged, however, and could have a detrimental effect on a
small receiving stream.
Batch Freeipitation and Recarbonation (Alternative BJ_-
Fluoride, lead, and suspended solids concentrations can be sig-
nificantly reduced using batch lime precipitation followed by
coagulation, sedimentation, and recarbonation for pH reduction and
calcium stabilization. Using this system, the daily flow of waste
water might be collected in a tank equipped with a stirring
mechanism. At the end of the day, lime and polyelectrolyte would be
added to precipitate fluoride or lead where removal of these
constituents was required. The tank would be slowly stirred for a
sufficient time to allow optimum flocculation and then allowed to
settle overnight. The following day the supernatant would be
transferred to a second tank for recarbonation and additional
sedimentation, and the sludge would be transferred to a holding tank
where additional thickening would take place before the sludge was
disposed of as landfill or to permanent storage. Acid could be used
in place of recarbonation for pH reduction, but dissolved solids
levels would be increased rather than decreased. The achievable
percent solids in the sludge would depend on the type of material
treated and coagulant used. It is estimated that 10 to 15 percent
solids can be achieved in a lime precipitation system. Effluent
levels of 25 mg/1 for suspended solids, 20 mg/1 for fluoride, and
1.0 mg/1 for lead are achievable using a batch system. At least one
handmade plant is presently using batch lime precipitation, but is
not neutralizing the effluent pH.
Sand Filtration (Alternative CI-
Precipitates and other particulates not removed by gravity
separation can be further reduced by sand or graded media fil-
tration. Additional suspended solids, fluoride, and lead can be
removed using this technology. Effluent levels can be reduced to less
than 13 mg/1 for fluoride, 10 mg/1 for suspended solids, and 0.1 mg/1 for
lead. Backwash waters can be returned to the batch treatment system
for further treatment. No hand pressed and blown plants presently
practice this technology, but filtration is widely used in the water
treatment industry.
136
-------
Activated Alumina Filtration (Alternative Dl-
Activated alumina filtration is an available technology for further
reducing fluoride concentrations. Following sand filtration, the
waste water may be passed through a bed of activated alumina to
reduce jthe fluoride concentration to 2 mg/1. Hydrochloric acid
may be_ used for regeneration; separate neutralization and sludge
handling facilities are provided for. This technology is not
presently employed in the hand pressed and blown glass industry, but
can be transferred from the water treatment industry.
Treatment System Applicable to Plants Which Do Not Employ
Hydrofluoric Acid Finishing Techniques
Existing Treatment and Control (Alternative A) -
Many plants, where grinding and abrasive polishing are done, collect
finishing waste water in trenches with small traps which catch the
gross solids. These are periodically cleaned and disposed of as a
solid waste. In most cases flows are low, less than 11.U cu m/day
(3000 gpd). The typical flow is 1.89 cu m/day (500 gpd).
Batch Coagulation and S ed iment at ion (Alternative B) -
Suspended solids concentrations can be significantly reduced using
batch coagulation and sedimentation. Using this sytem, the daily
flow of waste water might be collected in a tank equipped with a
stirring mechanism. Alum or some other coagulant would be added and
the tank stirred slowly for a sufficient time to allow solids to
settle. The following day the supernatant would be discharged and
the sludge transferred to a holding tank where additional thickening
would take place prior to sludge disposal. An effluent level of 25
mg/1 for suspended solids is achievable using a batch coagulation
and sedimentation system. Many handmade glass plants employ
sedimentation systems for solids control,
Sand Filtration (Alternative C) -
Particulates not removed by gravity separation can be further
reduced by sand or graded media filtration. Additional suspended
solids can be removed to an effluent level of 10 mg/1. Backwash
waters can be returned to the batch treatment system for further
treatment.
137
-------
-------
SECTION VIII
COST, ENERGY, AND NONWATER QUALITY ASPECTS
COST AND REDUCTION BENEFITS OF ALTERNATIVE TREATMENT AND CONTROL
TECHNOLOGIES
Investment and operating costs for the alternative waste water
treatment and control technologies described in Section VII are
presented here.
The cost data include the traditional expenditures for equipment
purchase, installation, and operation and where necessary, solid
waste disposal. No significant production losses due to the in-
stallation of water pollution control equipment are anticipated.
The costs are based on a typical plant for all subcategories except
for hand pressed and blown glass manufacturing, where two
hypothetical plants are presented. It is assumed that one is a
producer of leaded glass to which many finishing steps are applied
including hydrofluoric acid finishing; this represents a maximum raw
waste load discharge and the model treatment system is
representative of any hand pressed and blown glass plant which
employs hydrofluoric acid finishing techniques. The other
hypothetical plant is representative of any hand pressed and blown
glass plant which does not employ hydrofluoric acid finishing
techniques. Owing to wide variations in production methods and
waste water characteristics, it is impossible to define a typical
plant for the handmade industry.
Investment costs include all the equipment, excavations, founda-
tions, buildings, etc., necessary for the pollution control system.
Land costs are not included because the small additional area
required is readily available at existing plants.
Costs have been expressed as August, 1971, dollars and have been
adjusted using the national average Water Quality Office - Sewage
Treatment Plant Cost Index. The cost of capital was assumed to be 8
percent and is based on information collected from several sources
including the Federal Reserve Bank. Depreciation is assumed to be
20 year straight-line or 5 percent of the investment cost.
Operating costs include labor, material, maintenance, etc.,
exclusive of power costs. Energy and power costs are listed sepa-
rately. Six subcategories have been defined in the development
document and costs for a typical plant(s) in each subcategory will
be covered separately.
Glass Container Manufacturing
The typical glass container manufacturing plant may be located in
any part of the country and may be 50 or more years old. The daily
production is approximately 454 metric tons (500 tons). Gullet
quenching and non-contact cooling water are not segregated. Costs
139
-------
and effluent quality for the three treatment alternatives are
summarized in Table 16.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. These effluent
levels are readily achievable by all plants within this subcategory
through normal maintenance and clean-up operations within the plant
and represent the raw waste loadings expected from a glass container
plant. Improved housekeeping techniques may be required at some
plants to achieve the typical effluent levels, while others may
elect to provide end-of-pipe treatment in the form of some type of
sedimentation system with oil removal capabilities. It is felt
however, that in-plant techniques will be a more effective and a
less expensive means of achieving effluent levels.
Costs. No additional cost.
Reduction Benefits, Upgrading of all effluent discharges to
this level.
Alternative B - Recycle with Dissolved Air Flotation of Blowdown-
Alternative B involves segregation of non-contact cooling water from
cullet quench water. The cullet quench water is recycled back to
cullet quench process through a gravity oil separator, and blowdown
is treated using dissolved air flotation. The blowdown is 5 percent
of the total cullet quench water flow.
Costs, incremental investment costs are $285,000 and total
annual costs are $56,100 over Alternative A,
Reduction Benefits. The incremental reductions of oil and
suspended solids compared to Alternative A are 93 percent and 97
percent, respectively.
Alternative C - Diatomaceous Earth Filtration-
Alternative C provides further treatment of the effluent from
Alternative B by diatomaceous earth filtration.
Costs. Incremental investment costs are $27,000 and total
annual costs are $10,800 over Alternative B.
Reduction Benefits, The incremental reductions of oil and
suspended solids compared to Alternative B are 60 percent.
Total reductions of oil and suspended solids are 97.3 and 98.9
percent, respectively.
140
-------
TABLE 16
WATER EFFLUENT TREATMENT COSTS
GLASS CONTAINER MANUFACTURING
Alternative Treatment or Control
Investment
Annual Costs:
Capital Costs
Depreciation
Operating and Maintenance Costs
(excluding energy and power costs)
Energy and Power Costs
Total Annual Cost
Effluent Quality:
($1000)
B
285. 312.
0
0
0
0
0
22.8
1U.3
IT. 2
1.8
56.1
25.
15. T
23.
3.2
66.9
Effluent Constituents
Flow (l/metric ton)
Oil (g/metric ton)
Suspended Solids
(g/metric ton)
Flow (l/sec)
Oil Crag/1)
Suspended Solids (mg/l)
Raw
Waste
Load
2920
30
TO
15.3
10
2k
Resulting Effluent
2920
30
TO
15
10
2U
Levels
TT T7
2 0
2 0
.3 .*a
25 10
25 10
.8
.8
M
141
-------
Machine E£§§sed and Blown Glass Manufacturing
The machine pressed and blown glass manufacturing subcategory is the
subject of further study at the present time. The results of this
study including the cost, energy, and non-.water quality aspects of
selected pollution control technologies will be presented at a later
date.
G^ass Tubing (Danner) Manufacturing
The typical glass tubing (Danner) manufacturing plant may be located
in any part of the country and is at least 10 years old. The daily
production at the plant is approximately 90.9 metric tons (100
tons) . Costs and effluent quality for the two treatment
alternatives are summarized in Table 17.
The remainder of the glass tubing industry is the subject of further
study at the present time. The results of this study including the
cost, energy, and non-water quality aspects of selected pollution
control technologies will be presented at a later date.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. There are no plants
at present which treat cullet quench water and all plants for which
data are available achieve these effluent levels.
Costs. No additional costs.
Reduction Benefits. None.
Alternative B - Recycle with Diatomaceous Earth Filtration of
Blowdown-
Alternative B involves the recirculation of the cullet quench water
stream through a cooling tower. The cooling tower blowdown is
treated by diatomaceous earth filtration.
Costs. Incremental investment costs are $97,600 and total
annual costs are $22,700 over Alternative A.
Reduction Benefits. Almost complete oil and suspended solids
removal is obtained.
142
-------
TABLE 17 .
WATER EFFLUENT TREATMENT COSTS
GLASS TUBING (DANKER) MANUFACTURING
Alternative Treatment or Control
Technologies
Investment
Annual Costs:
Capital Costs
Depreciation
Operating & Maintenance Costs
(excluding energy and power costs)
Energy and Power Costs
TOTAL ANNUAL COST
Effluent Quality:
Raw
Waste
Effluent Constituents Load
Flow (I/metric ton) 8340
Oil (g/metric ton) 80
Suspended Solids
(g/metric ton) 230
Flow (I/sec) 8.8
Oil (mg/1) 10
Suspended Solids (mg/1) 27
($1000)
A B
0 97.6
0 7.8
0 4.9
0 9.7
0 0.3
0 22.7
Resulting Effluent
Levels
8340 21
80 0
230 0
8.8
10 10
27 10
.2
.2
.022
143
-------
Television Picture Tube Envelope Manufacturing
The typical television picture tube envelope manufacturing plant can
be located in any part of the country and is at least 10 years old.
The daily production of the plant is 227 metric tons (250 tons).
Costs and effluent quality for the three treatment alternatives are
summarized in Table 18. The effluent values are for the combined
cullet quench and finishing waste water streams.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. Lime addition,
precipitation, coagulation, sedimentation, and pH adjustment are
presently used throughout the industry for removal of fluoride,
lead, and suspended solids from finishing wastes. Cullet quench
water is not treated.
Costs. No additional cost.
Reduction Benefits. Total reductions of suspended solids,
fluoride, and lead are 96, 96, and 99 percent, respectively.
The waste water pH is adjusted to neutrality.
Alternative B - Sand Filtration-
Alternative B includes sand filtration of the effluent from the lime
precipitation system of Alternative A. Filter backwash water is
recycled back to the lime precipitation system.
Costs. Incremental investment costs are
annual costs are $18,400 over Alternative A.
$67,000 and total
Reduction Benefits. The incremental reductions of suspended
solids, fluoride, and lead over Alternative A are 13.3, 14.3,
and 90 percent, respectively. Total reductions of suspended
solids, fluoride, and lead are 96.9, 96.7, and 99.9 percent,
respectively.
Alternative C - Activated Alumina Filtration-
Alternative C involves the activated alumina filtration of the
effluent from Alternative B. Following sand filtration the
fluoride-bearing waste water stream is passed through a bed of
activated alumina to further reduce the remaining fluoride.
144
-------
TABLE 18
WATER EFFLUENT TREATMENT COSTS
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
Alternative Treatment or Control
Technologies :
Investment
Annual Cost:
Capital Costs
Depreciation
Operating & Maintenance Costs
(excluding energy & power costs)
Energy & Power Costs
TOTAL ANNUAL COSTS
Effluent Quality:
Effluent
Constituents
Flow (I/metric ton)
Oil (g/metric ton)
Suspended Solids
(g/metric ton)
Fluoride (g/metric ton)
Lead (g/metric ton)
Flow (I/sec)
Oil (mg/1)
Suspended Solids (mg/1)
Fluoride (mg/1)
Lead (mg/1)
Raw Waste
Load
12,500
130
4,200
1,800
390
33
10
335
143
30
A
0
0
0
0
0
0
($1000)
B
67.0
5.4
3.4
8.7
0,9
15.4
C
560
44.8
28.1
65.8
2.1
140.8
Resulting Effluent
Levels
12,500
130
150
70
4.5
33
10
12
5.6
0.36
12,500 12
130
130
60
0.45
33
10
10
4.8
.036
,500
130
130
9
0.45
33
10
10
0.72
.036
145
-------
Costs. Incremental investment costs are $493,000 and total
annual costs are $122,400 over Alternative B.
Reduction Benefits, The incremental reduction of fluoride over
Alternative B is 85 percent- Total reductions of suspended
solids, fluoride, and lead are 96.9, 99.5, and 99.9 percent,
respectively.
Incandescent Lamp Envelope Manufacturing
The typical incandescent lamp envelope manufacturing plant may be
located in any part of the country and is at least 50 years old.
Daily oroduction is 159 metric tons (175 tons). Frosted envelopes
account for eighty-five percent of the plant production, and clear
envelopes make up the remainder of the plant production. Cost and
effluent quality for the four treatment alternatives are summarized
in Table 19. Effluent characteristics are given for the combined
cullet quench and frosting waste water flows.
Alternative A - Existing Treatment and Control-
Alternative A involves . no additional treatment. Lime addition,
coagulation, precipitation, and sedimentation are presently used
throughout the industry for removal of fluoride and suspended solids
from frosting wastes. Oil skimmers are employed for oil removal
from cullet quench water. Some plants may have to improve
housekeeping techniques to meet these effluent levels.
Costs. No additional costs.
Reduction Benefits. Total reductions of suspended solids and
fluoride are 31 and 99 percent, respectively.
Alternative B - Sand Filtration and Ammonia Removal-
Alternative B involves the addition of sand filtration and of an
ammonia removal technique to reduce the fluoride and ammonia level
in the effluent from the Alternative A system. This alternative
includes steam stripping as the ammonia removal technique and also
includes recarbonation and a heat exchanger, Recarbonation may be
required for pH adjustment and also to prevent scaling in the
stripping unit. A heat exchanger is used in conjunction with the
steam stripping unit to maximize the efficiency of stripping and to
reduce the discharge temperature of the treated waste water.
146
-------
TABLE 19
WATER EFFLUENT TREATMENT COSTS
INCANDESCENT LAMP ENVELOPE MANUFACTURING
Alternative Treatment or Control
Technologies :
Investment
Annual Cost:
Capital Costs
Depreciation
Operating & Maintenance Costs
(excluding energy & power costs)
Energy & Power Costs
TOTAL ANNUAL COSTS
Effluent Quality:
Effluent
Constituents
Flow(l/metric ton formed)
(I/metric ton frosted)
Oil (g/metric ton formed)
Suspended Solids
(g/metric ton formed)
(g/metric ton frosted)
Fluoride (g/metric ton)
Ammonia (g /me trie ton)
Flow (I/sec)
Oil (mg/1)
Suspended Solids (mg/1)
Fluoride (mg/1)
Ammonia (mg/1)
Raw Waste
Load
4500
3960
115
115
400
11,100
2600
14.5
15
58
1200
281
A
0
0
0
0
0
0
($1000)
B C
547
43.8
27.4
76.4
134.3
282
620
49.6
31.0
85.7
136.2
302
D
963
77.0
48.2
125.1
136.8
387.1
Resulting Effluent
Levels
4500
3960
115
115
230
115
2600
14.5
15
39
12.4
281
4500
3960
115
115
40
52
120
14.5
15
19
5.6
13
4500
3960
23
23
40
52
120
14.5
3
7
5.6
13
4500
3960
23
23
40
8
120
14.5
3
7
0.9
13
147
-------
Costs. Incremental investment costs are $547,000 and total
annual costs are $282,000 over Alternative A.
Reduction Benefits. The incremental reduction of ammonia
compared to Alternative A is 95 percent. The treated waste
water pH is adjusted to 9.0, Total reductions of suspended
solids and fluoride are 66.7 and 99.5 percent, respectively.
Alternative C - Diatomaceous Earth Filtration-
Alternative C involves diatomaceous earth filtration of the cullet
quench water. The frosting waste waters are not treated above that
level represented as Alternative B.
Costs . Incremental investment costs are $73,000 and total
annual costs are $20,600 over Alternative C.
Reduction Benefits. Incremental reductions are 47. 3 percent for
suspended solids and 61 percent for oil. Total reductions of
oil, suspended solids, fluoride, and ammonia are 61, 82, 99.5,
and 95 percent, respectively.
Alternative D - Activated Alumina Filtration-
This alternative includes activated alumina filtration of the
frosting waste water effluent from Alternative B. Following sand
filtration, the waste water is passed through a bed of activated
alumina to reduce the remaining fluoride in the waste water.
Costs. Incremental investment costs are $343,000 and total
annual costs are $84,600 over Alternative B.
Reduction Benefits. An incremental reduction of 85 percent for
fluoride results. Total reductions of fluoride and suspended
solids are 99.9 and 82 percent, respectively.
and Blown Glass Manufacturing
No typical plant can be developed for the hand pressed and blown
glass manufacturing subcategory because of the wide variation in
finishing steps applied to the handmade glass. The hypothetical
plants assumed for cost estimating purposes may be located in any
part of the country and are at least 50 years old. The first plant
is one of the largest in the country and has a daily finished
product output of 5.9 metric tons (6.5 tons). The plant employs all
148
-------
the finishing steps available at handmade glass plants and is
representative of those plants which produce leaded or unleaded
glass and employ hydrofluoric acid finishing techniques. The second
hypothetical plant is representative of those handmade glass plants
which produce leaded or unleaded glass and do not employ
hydrofluoric acid finishing techniques. The cost and effluent
quality for the treatment alternatives applicable to each
hypothetical plant are listed in Tables 20 and 21 -
Treatment System Applicable to Plants Which Employ Hydrofluoric Acid
Finishing Techniques
Alternative A - Existing Treatment and Control-
Alternative A is no waste water treatment or control. Many plants
do not need waste water treatment or control because of the absence
of waste-producing finishing steps or because of the low volume of
discharge. Some plants have lime precipitation treatment facilities
for the reduction of fluoride from hydrofluoric acid polishing and
acid etching wastes. It is felt that for any plant discharging less
than 0.19 cu m/day (50 gallons/day) of waste water, treatment is
impractical as other means of disposal are considerably less
expensive (i.e., land retention or dust suppression).
Costs. None.
Reduction Benefits. None.
Alternative B - Batch Precipitation and Recarbonation- y
\
This alternative includes a batch lime precipitation system for
reduction of suspended solids, fluoride, and lead from finishing
waste waters. The lime precipitation system effluent is recar-
bonated with carbon dioxide gas to adjust the treated waste water to
a neutral pH from the alkaline pH of the lime treatment process.
Costs. Incremental investment costs are $284,000 and total
annual costs are $55,100 over Alternative A.
Reduction Benefits. Total reductions of suspended solids,
fluoride, and lead are 95, 95, and 91 percent, respectively.
The pH of the acidic waste, is raised to an alkaline pH of 11-12
during lime treatment and then is lowered to a pH of 9 by
recarbonation.
Alternative C - Sand Filtration-
Alternative C involves the sand filtration of the effluent from
Alternative B. The sand filtration system is similar to those
employed at municipal water treatment works.
Costs. Incremental investment costs are $41,000 and total
annual costs are $8400 over Alternative B.
149
-------
TABLE 20
WATER EFFLUENT TREATMENT COSTS
HAND PRESSED AND BLOWN GLASS MANUFACTURING
Alternative Treatment or Control
Technologies :
Investment
Annual Costs:
Capital Costs
Depreciation
($1000)
Operating & Maintenance Costs
(excluding energy & power costs)
Energy & Power Costs
TOTAL ANNUAL COST
Effluent Quality:
Effluent
Constituents
Flow (I/sec)
PH
Suspended Solids (mg/1)
Fluoride (mg/1)
Lead (mg/1)
Raw Waste
Load
0.61
2
544
422
11.4
A
0
0
0
0
0
0
B
284
22.7
14.2
15.6
2.6
55.1
C
325
26.0
16.2
18.6
2.7
63.5
D
410
32.8
20.4
21.6
2.8
77.6
Resulting Effluent
0.61
2
544
422
11.4
0.61
9
25
20
1
Levels
0.61
9
10
13
0.1
0.61
9
10
2
0.1
150
-------
TABLE 21
WATER EFFLUENT TREATMENT COSTS
HAND PRESSED AND BLOWN GLASS MANUFACTURING
SUSPENDED SOLIDS REMOVAL
Alternative Treatment or Control
Investment
Annual Costs:
Capital Costs
Depreciation
Operating & Maintenance Costs
(excluding energy & power costs)
Energy and Power Costs
TOTAL ANNUAL COST
Effluent Quality:
Effluent
Constituents
Flow — cu m/day
Suspended Solids(mg/l)
Raw Waste
Load
1.89
9600
($1000)
A B
0 48.7
0 3.9
0 2.4
0 5.3
0 0.3
0 11.9
Resulting Effluent
Levels
1.89 1.89
9600 25
C
54.3
4.3
2.7
8.0
0.3
15.3
1.89
10
151
-------
Reduction Benefits. Incremental reductions over Alternative B
for suspended solids, fluoride, and lead are 60 , 35., and 90
percent, respectively. Total reductions of suspended solids,
fluoride, and lead are 98.2, 96.9, and 99.1 percent, respectively.
The waste water pH is adjusted to 9.
Alternative D - Activated Alumina Filtration-
This alternative includes activated alumina filtration of the
effluent from Alternative C. Activated alumina filtration is
employed for further reduction of the effluent fluoride concen-
tration.
Costs. Incremental investment costs are $84,500
annual costs are $14,100 over Alternative C.
and total
Reduction Benefits. The incremental reduction of fluoride is 85
percent over Alternative c. Total reductions of suspended
solids, fluoride, and lead are 98.2, 99.5, and 99.1 percent,
respectively.
Treatment System Applicable to Plants Which Do Not Employ
Hydrofluoric Acid Finishing Techniques
Alternative A - Existing Treatment and Control -
Alternative A involves no waste water treatment or control. Many
plants do not need waste water treatment or control because of the
absence of waste-producing finishing steps or because of the low
volume of discharge. Many plants employ some type of sedimentation
system for solids control. It is felt that for any plant
discharging less than 0.19 cu m/day (50 gallons/day) of waste water,
treatment is impractical as other means of disposal are considerably
less expensive (i.e., land retention or dust suppression).
The raw waste water suspended solids expressed in terms of grams
(pounds) per production unit or concentration is impossible to
typify, owing to the wide range of production methods employed in
the subcategory. Approximately 9600 mg/1 was assumed for
calculating sludge production, but the influent suspended solids
concentration is not directly related to treatment costs. The
typical flow is 1.89 cu m/day (500 gpd).
Costs. None.
Reduction Benefits, None.
Alternative B * Batch Coagulation and Sedimentation -
The daily waste water discharge is collected in one of two mixing
tanks (one tank is treated and discharged while the other is
filling). At the end of the day coagulants are added, and the
mixture is flocculated. The treated waste water is discharged
152
-------
following overnight sedimentation. Sludge is collected in a holding
tank and eventually discharged as landfill.
Costs. Incremental investment costs are $48,700 and total
annual costs are $11,900 over Alternative A.
Reduction Benefits. Suspended solids reduced to 25 mg/1,
Alternative C - Sand Filtration -
Discharge from Alternative B is passed through sand filters for
additional suspended solids reduction. Filter backwash is returned
to the head of the system.
Costs. Incremental investment costs are $5600 and total annual
costs are $3400 over Alternative B.
Reduction Benefits. Suspended solids reduced to 10 mg/1.
BASIS OF TOTAL INDUSTRY COST ESTIMATES
The effluent limitations guidelines presented in this document
pertain to surface dischargers and therefore, only surface
dischargers are considered impacted by the recommended guidelines.
There are: (a) 55 known glass container, (b) 23 known machine
pressed and blown glass, (c) 9 known glass tubing, (d) 4 known
television picture tube envelope,
envelope, and (f) 13 known hand
manufacturing surface dischargers.
applications, industry supplied data, and a survey of the pressed
and blown glass segment. Tables 22 through 27 list the known
surface dischargers for each subcategory of the pressed and blown
glass segment of the glass manufacturing category.
(e) 3 known incandescent lamp
pressed and blown glass
This estimate is based on RAPP
ENERGY REQUIREMENTS OF TREATMENT AND CONTROL TECHNOLOGIES
Large quantities of energy are used in the pressed and blown glass
industry to produce the high temperatures required for glass melting
and annealing. Approximately 1,670,000 kilogram-calories/metric ton
(6,000,000 BTU/ton) are required to melt the raw materials for the
manufacture of glass containers. This energy requirement is
considered typical for the pressed and blown glass industry. The
additional energy required to implement the treatment technologies
is less than 1 percent of the process requirements for each of the
subcategories with the exception of the incandescent lamp envelope
manufacturing subcategory. The treatment alternatives requiring
relatively little additional energy include: cullet quench recycle
systems, the lime precipitation process, and sand or activated
alumina filtration. The energy requirements for these systems range
from 124,000 to 537,000 kilogram-calories/day (492,000 to 2,130,000
BTU/day).
153
-------
TABLE 22
KNOWN SURFACE DISCHARGERS
GLASS CONTAINER MANUFACTURING SUBCATEGORY
Company
Anchor Hocking Corporation
Ball Corporation
Brockway Glass Company, Inc.
Chattanooga Glass Company
Diamond Glass Company
Foster-Forbes Glass Company
Gayner Glass Works
Glass Containers Corporation
Glenshaw Glass Company
Indian Head, Inc.
Kerr Glass Manufacturing Corporation
Laurens Glass Company
Maryland Glass Corporation
Midland Glass Company
Obear-Nester Glass Company
Owens-Illinois
Puerto Rico Glass Corporation
Star City Glass Company
Thatcher Glass Manufacturing Company
Universal Glass Products Company
TOTAL
No. of Plants
7
1
11
3
1
1
1
7
2
2
2
1
1
1
1
8
1
1
2
1
55
154
-------
TABLE 23
KNOWN SURFACE DISCHARGERS
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
SUBCATEGORY
Company
Anchor Hocking Corporation
Corning Glass Works
Federal Glass Company
General Electric-Mahoning
Mid-Atlantic Glass Company
Owens-Illinois
L.E. Smith Glass Company
No. of Plants
3
14
1
1
1
2
1
TOTAL
23
TABLE 24
KNOWN SURFACE DISCHARGERS
GLASS TUBING MANUFACTURING SUBCATEGORY
Company
Corning Glass Works
General Electric Company
GTE - Sylvania, Inc.
RCA
Westinghouse Electric Corporation
TOTAL
No. of Plants
2
4
1
1
_J
9
TABLE 25
KNOWN SURFACE DISCHARGERS
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING SUBCATEGORY
Company
Corning Glass Works
Owens-Illinois
TOTAL
No. of Plants
2
2
4
155
-------
TABLE 26
KNOWN SURFACE DISCHARGERS
INCANDESCENT LAMP ENVELOPE MANUFACTURING
SUBCATEGORY
Company
Corning Glass Works
General Electric Company
No. of Plants
2
1
TOTAL
TABLE 27
KNOWN SURFACE DISCHARGERS
HAND PRESSED AND BLOWN GLASS MANUFACTURING
SUBCATEGORY
Company
Blenko Glass Company
Colonial Glass Company
Davis-Lynch Glass Company
Fenton Art Glass Company
Fostoria Glass Company
Gillender Brothers, Incorporated
Imperial Glass Corporation
Kanahwa Glass Company
Lewis County Glass Company
Pennsboro Glass Company
Pilgrim Glass Corporation
Wheaton Industries
West Virginia Glass Specialty Company
No. of Plants
1
1
1
1
1
1
1
1
1
1
1
1
1
TOTAL
13
156
-------
Steam stripping of incandescent lamp envelope frosting waste waters
for ammonia removal will require the greatest energy requirement of
the proposed treatment alternatives. Steam stripping of the typical
flow will require approximately 54,000,000 kilogram-calories/day
(214,000,000 BTU/day) and is equivalent to 9120 liters/day (2410
gallons/day) of No. 2 fuel oil. This energy requirement is about 8
percent of that required for the total manufacturing process.
Industry supplied data indicate that approximately 605,000,000
kilogram-calories/day (2,400,000,000 BTU/day} of energy per plant
are required in the total incandescent lamp- envelope manufacturing
process. The energy requirement for steam stripping is not
excessive, when compared to the total energy consumed in the
manufacturing process. It may be feasible to use melting tank stack
gas as a source of heat, thereby eliminating the necessity for
additional fuel, but further investigation is necessary to determine
the practicability of such a system.
NON-WATER QUALITY ASPECTS OF TREATMENT AND CONTROL TECHNOLOGIES
Air Pollution
The incandescent lamp envelope manufacturing subcategory is the only
subcategory that may pose an air pollution problem. Ammonia removal
by steam stripping is recommended for control of high ammonia
discharges from the frosting waste stream. It is possible that the
steam and ammonia gas from the stripping unit could be vented to the
atmosphere through the furnace exhaust stack. The ammonia
concentration of the combined stack discharge is not expected to
exceed 35 mg/cu m (46 ppmv), which is the threshold odor limit for
ammonia. Because the ammonia concentration will be below the
threshold odor level, steam stripping should not cause a significant
air pollution problem.
There are no significant air or noise pollution problems directly
associated with the treatment and control technologies of the other
sufccategories. The waste waters and sludges are odorless and no
nuisance conditions result from their treatment or handling.
Solid waste Disposal
Three types of waste solids are produced by the treatment systems
developed for the pressed and blown glass industry. These are: (1)
gravity oil separator and dissolved air flotation skimmings, (2)
spent diatomaceous earth, and (3) lime precipitation sludges
associated with fluoride waste water treatment.
The skimmings and spent diatomaceous earth result from the treatment
of cullet quench waste waters. The skimmings have a three percent
solids content and the production of skimmings ranges from 21.4 to
49.1 kg/day (47 to 108 Ib/day) or 720 to 1630 I/day (190 to 430
gal/day) . The oily skimmings can be disposed of by an oil
reclamation firm, used as road oil, or can be incinerated.
157
-------
Spent diatomaceous earth has an estimated moisture content of 85
percent, but does not flow. This material is stable and should be
suitable for landfill- Estimated production of diatomaceous earth
waste ranges from 0.042 to 0.53 cu m/day (1.5 to 19 cu ft/day). The
lower figure results from the treatment of the blowdown for the
cullet quench system and the higher figure is the result of treating
the entire cullet quench waste water stream at an incandescent lamp
envelope plant.
The lime precipitation process for fluoride removal produces the
largest volume and most difficult sludge to handle. Vacuum
filtration is used at almost all plants to reduce the sludge volume.
The volume of sludge production ranges from 277 kg/day (610 Ibs/day)
for a handmade glass plant to 20.9 metric ton/day (23 tons/day) at a
television picture tube envelope manufacturing plant. The
television picture tube envelope manufacturing plant is treating a
combination of abrasive grinding wastes and fluoride containing
rinse waters.
Most lime precipitation sludge is currently disposed of as landfill.
Several attempts have been made to convert the sludge into a salable
material, but no markets have been found for these products.
Currently, further research is being conducted to develop a saleable
by-product from the sludge.
158
-------
SECTION IX
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION
OF THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE EFFLUENT LIMITATIONS GUIDELINES
INTRODUCTION
The effluent limitations that must be achieved by July 1, 1977, are
to specify the degree of effluent reduction attainable through the
application of the best practicable control technology currently
available. Best practicable control technology currently available
is generally based upon the average of the best existing performance
by plants of various sizes, ages, and unit processes within the
industrial category or subcategory.
Consideration must also be given to:
a,
b.
c.
d.
e.
f.
The total cost of application of technology in relation to
the effluent reduction benefits to be achieved from such
application;
the size and age of equipment and facilities involved;
the processes employed;
the engineering aspects of the application of various types
of control techniques;
process changes;
non-water quality environmental impact
requirements).
(including energy
Also, best practicable control technology currently available
emphasizes treatment facilities at the end of a manufacturing
process, but also includes the control technologies within the
process itself when the latter are considered to be normal practice
within the industry.
A further consideration is the degree of economic and engineering
reliability that 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 of
confidence in the engineering and economic practicability of the
technology at the time of commencement of construction or
installation of the control facilities.
IDENTIFICATION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
AVAILABLE
CURRENTLY
Current treatment practices constitute the best practicable control
technology currently available. The best practicable control
159
-------
technology currently available for the subcategories of the pressed
and blown segment is summarized below. Recommended effluent
limitations are summarized in Table 28. These limitations are 30-
day averages based on any 30 consecutive calendar days. Maximum
daily averages are two times the monthly averages.
Glass Container Manufacturing
No additional control technology is proposed for the glass container
manufacturing subcategory. Oil skimmers are presently employed at
some plants, but many plants do not require treatment. Improved
housekeeping techniques may be required at some plants to meet the
limitations. Effluent limitations for suspended solids are 70
g/metric ton (0.14 Ib/ton); for oil, 30 g/metric ton (0.06 Ib/ton);
and pH, between 6.0 and 9.0.
Machine Pressed and Blown Glass Manufacturing
The machine pressed and blown glass manufacturing subcategory is the
subject of further study at the present time. The results of this
study, including recommended limitations representative of best
practicable control technology currently available, will be
published at a later date in a supplement to this document.
Glass Tubing (Dannerl Manufacturing
No additional control technology is proposed for the glass tubing
(Banner) subcategory. Most plants presently do not provide
treatment because the raw waste water pollutant concentrations are
already at low levels. Improved housekeeping may be required at
some plants to achieve the limitations. Effluent limitations for
suspended solids are 230 g/metric ton (0.46 Ib/ton) and for pH,
between 6.0 and 9.0.
The remainder of the glass tubing manufacturing subcategory,
including those plants which manufacture glass tubing by the Velio
and Updraw processes or those plants which manufacture glass tubing
suitable for the manufacture of scientific glassware, is the subject
of further study at the present time. The results of this study
will be published at a later date in a supplement to this document.
Television Picture Tube Envelope Manufacturing
The control technology on which the recommended limitations are
based involves lime addition, coagulation, sedimentation, and pH
adjustment. This technology is currently practiced throughout the
industry for the treatment of finishing waste waters. Effluent
limitations for suspended solids are 150 g/metric ton (0.30 Ib/ton);
for oil, 130 g/metric ton (0.26 Ib/ton); for fluoride, 70 g/metric
ton (0.14 Ib/ton); for lead, 4.5 g/metric ton (0.009 Ib/ton); and
pH, between 6.0 and 9.0,
160
-------
TABLE 28
RECOMMENDED 30-DAY AVERAGE EFFLUENT LIMITATIONS USING
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
Suspended
Solids Oil Fluoride Lead Ammonia pH
Glass Container
g/metric ton 70 30 - - 6-9
(Ib/ton) 0.14 0.06
Machine Pressed &
Blown Glass*
g/metric ton - - - _ _ _
(Ib/ton) - - -
Glass Tubing
(Danner)*
g/metric ton 230 - - - 6-9
(Ib/ton) 0.46 -
Television Picture
Tube Envelope
g/metric ton 150 130 70 4.5 - 6-9
(Ib/ton) 0.30 0.26 0.14 0.009
Incandescent Lamp
Envelopes
Forming
g/metric ton 115 115 - - 6-9
(Ib/ton) 0.23 0.23 - - -
Frosting
g/metric ton frosted 230 - 115 - - 6-9
(Ib/ton) 0.46 - 0.23
Hand Pressed &
Blown Glass
Leaded & Hy d ro--
Acid
^
Finishing
mg/1 - - -
Non-Leaded &
Hydrofluoric
Ac id Fjinish :ing_
mg/1 - - -
Non-Hydrofluoric
Acid Finishing^
mg/1 - - -
*The machine pressed and blown glass manufacturing subcategory and the
remainder of the glass tubing subcategory are the subject of further
study. Results of this study will be presented at a later date.
161
-------
Incandescent Lamp Envelope Manufacturing
The control technology on which the recommended limitations are
based involves a lime precipitation system for fluoride and
suspended solids removal. The lime precipitation -treatment is
practiced throughout the industry for frosting waste water
treatment. Recarbonation is also included in the control technology
for adjustment of the treated waste water pH to a range of 6 to 9.
Effluent limitations are listed separately for forming and frosting
because there is a wide variation in the percentage of envelopes
that are frosted. The forming limitations are based on furnace pull
production and the frosting limitations are based on the portion of
the furnace pull production that is frosted. Effluent limitations
for the waste waters resulting from forming are 115 g/metric ton
(0.23 Ib/ton) for both suspended solids and oil. Frosting waste
water effluent limitations for suspended solids are 230 g/metric ton
(0.46 Ib/ton); for fluoride, 115 g/metric ton (0.23 Ib/ton); and pH,
between 6.0 and 9.0.
S§U
-------
Lead
Lead is contributed to television picture tube envelope plant and
handmade glass plant waste waters by finishing steps applied to the
picture tube envelope and leaded handmade glassware. Application of
the best practicable control technology currently available will
reduce lead levels in television picture tube envelope manufacturing
waste waters by 99 percent.
Oil
Oil is a constituent of the waste waters from all subcategories
except the hand pressed and blown , glass manufacturing. Belt oil
skimmers and baffled skimming basins are employed at some plants,
but many plants do not provide treatment. Analysis of the data
indicates no discernible difference between the effluent oil
concentration of plants employing oil skimming and plants without
treatment. No additional waste water treatment or control is
proposed because of the low oil concentrations in the raw waste
water. Some plants may need to improve housekeeping techniques to
meet the proposed effluent levels.
P-XY3en Demanding Materials
Oxygen demand in the pressed and blown glass segment is related to
the oil content of the waste water. Since no additional waste water
treatment or control for oil removal is proposed, the BOD and COD
will not be reduced. The BOD and COD are already low by
conventiona1 standards.
BS
Waste waters resulting from acid treatment of glassware have a pH of
2 to 3. The acidic wastes are treated to remove fluoride and other
pollutants by lime addition, typically to a pH of 11-12. At some
waste water treatment plants, the alkaline treated waste waters are
adjusted to a neutral pH. This control technology will be applied
to the television picture tube envelope and incandescent lamp
envelope manufacturing subcategories to achieve an effluent pH of 6
to 9.
Suspended Solids
Suspended solids are contributed to the process waste waters from
all subcategories. Application of the best practicable control
technology currently available will reduce suspended solids levels
for television picture tube envelope manufacturing and incandescent
lamp envelope manufacturing by 96 and 31 percent, respectively. The
cullet quench water stream is not treated for the incandescent lamp
envelope subcategory and, therefore, lower removal percentages are
obtained. Suspended solids remain at the present levels for the
glass container manufacturing and the glass tubing (Danner)
manufacturing subcategories.
163
-------
Dissolved Solids
Dissolved solids are contributed to the waste waters from the
pressed and blown glass segment by acid treatment of glass and
frosting of incandescent lamp envelopes. The proposed control
technologies do not reduce dissolved solids.
Temperature
Process waste waters from all subcategories may show some
temperature increase because of cullet quenching, acid polishing,
and frosting of incandescent lamp envelopes. Application of the
best practicable control technology currently available will not
result in significant temperature reduction,
RATIONALE FOR THE SELECTION OF BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
Engineering Aspects of Application
In all cases, this control technology has been applied in the
pressed and blown glass segment or in another industry where the
characteristics of the water treated are sufficiently similar to
provide a high degree of confidence that the technology can be
transferred to the pressed and blown glass industry. The derivation
and rationale for selection of the control technologies are
described in detail in Sections V and VII, These may be briefly
summarized as follows:
Glass Container Manufacturing-
No additional waste water treatment or control will be required at
the majority of glass container plants to achieve this level. Some
plants presently employ oil skimmers, but many plants do not provide
treatment. In analysis of the data, no discernible difference could
be established between plants with oil skimming treatment and plants
without treatment. Collection of I.S. machine oil leakage, control
of shear spray oil drippage, and other housekeeping techniques may
be required at some plants to meet the effluent limitations.
tDanner) Manufacturing-
Most plants presently do not provide waste water treatment and are
meeting the effluent limitations. It might be necessary for some
plants to improve housekeeping techniques to achieve the effluent
limitations.
Television Picture Tube Envelope Manufactur ing-
Lime precipitation, coagulation, sedimentation, and pH adjustment
are currently practiced throughout the industry to treat waste
waters from the finishing of television picture tube envelopes. The
majority of plants meet the effluent limitations, but those that do
164
-------
not may be required to upgrade waste water treatment practices and
in-plant housekeeping controls to meet the effluent limitations.
Incandescent Lamp Envelope Manufacturing-
Lime precipitation, coagulation, and sedimentation are currently
practiced throughout the industry for removal of fluoride and
suspended solids from frosting waste waters. Gullet quench waste
waters are also treated at most plants. None of the plants provide
treatment for ammonia removal.
At least two plants are meeting the fluoride effluent limitations.
By implementation of improvements in the treatment facilities such
as increased flocculation, longer retention time in the
clarification unit, and improved clarifier design, the remaining
plants should be able to meet the fluoride and suspended solids
limitations levels.
Water pH adjustment by recarbonation has been practiced for many
years in conventional water treatment plants. This method can also
be applied for pH adjustment of treated frosting waste waters.
Hand Pressed and Blown Glass Manufacturing-
At least one hand pressed and blown glass plant is employing the
batch lime precipitation method to remove suspended solids,
fluoride, and lead from finishing waste waters. Most plants
presently do not provide treatment other than sedimentation basins;
those with waste water producing finishing steps may have to employ
treatment to meet water quality standards.
Total Cost of Application
Based on the information presented in Section VIII of this document,
the industry, as a whole, will not have to invest significant
amounts of money to achieve the effluent limitations prescribed
herein. Plants currently have the equipment necessary to attain the
effluent limitations and in all cases, it is expected that the
application of improved housekeeping techniques and operating
procedures will enable a»ll plants in the pressed and blown glass
industry segment to achieve the best practicable control technology
currently available effluent limitations guidelines.
Size and Age of Equipment
The size of plants within the same subcategory does not vary enough
to substantiate differences in control technology based on size.
Most pressed and blown glass plants have actively developed and
implemented new production methods so that the age of equipment and
facilities does not provide a basis for differentiation in the
application of this control technology.
165
-------
Processes Employed
All plants in a given subcategory use very similar manufacturing
processes and produce similar waste water discharges. The control
technology for a given subcategory is compatible with all of the
manufacturing processes presently used in that subcategory.
Process Changes
No process changes are required to implement this control
technology, and major changes in the production processes are not
anticipated. Therefore, the waste water volume and characteristics
should remain the same for the foreseeable future.
Non-Water Quality Environmental Impact
There is no evidence that application of the best practicable
control technology currently available will result in any unusual
air pollution or solid waste disposal problems. The control
technologies which represent the best practicable control technology
currently available are currently used in either the pressed and
blown glass industry or other industries without adverse
environmental effects. The pressed and blown glass industry
consumes enormous amounts of energy for melting raw materials and
annealing. The energy reguired to apply this control technology
represents only a small increment of the present total energy
requirements of the industry.
166
-------
SECTION X
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF
THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
EFFLUENT LIMITATIONS GUIDELINES
INTRODUCTION
The effluent limitations that must be achieved by July 1, 1983, are
to specify the degree of effluent reduction attainable through the
application of the best available technology economically
achievable. This control technology is not based upon an average of
the best performance within an industrial category, but is
determined by identifying the very best control and treatment
technology employed by a specific plant within the industrial
category or subcategory, or where it is readily transferrable .from
one industry process to another.
Consideration must also be given to:
a. The total cost of application of this control technology in
relation to the effluent reduction benefits to be achieved
from such application;
b. the size and age of equipment and facilities involved;
c. the processes employed;
d. the engineering aspects of the application of this control
technology;
e. process changes;
f. non-water quality environmental
requirements) .
impact (including energy
Best available technology economically achievable also considers the
availability of in-process controls as well as control or additional
end-of-pipe treatment techniques. This control technology is the
highest degree 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 the top-of-the-
line of current technology subject to limitations imposed by
economic and engineering feasibility. However, this control
technology may be characterized by some technical risk with respect
to performance and with respect to certainty of costs. Therefore,
this control technology may necessitate some industrially sponsored
development work prior to its application.
167
-------
IDENTIFICATION OF BEST
ACHIEVABLE
AVAILABLE CONTROL TECHNOLOGY ECONOMICALLY
In-plant control measures as well as end-of-pipe treatment
techniques contribute to the best available technology economically
achievable. Water recycle and reuse will tend to reduce the cost of
end-of-pipe treatment facilities.
The best available technology economically achievable for the
subcategories of the pressed and blown glass industry is summarized
in the following paragraphs. Recommended effluent limitations are
summarized in Table 29. These limitations are 30-day averages based
on any 30 consecutive days. The maximum daily average is two times
the monthly average.
Glass Container Manufacturing
The control technology includes segregation of non-contact cooling
water from the cullet quench water. The cullet quench water is
recycled back to the cullet quench process through a gravity oil
separator. Cullet quench system blowdown is treated by dissolved
air flotation followed by diatomaceous earth filtration. The
blowdown is 5 percent of the total cullet quench water flow,
Effluent limitations for suspended solids and oil are 0.8 g/metric
ton (0.0016 Ib/ton) .
Machine Pressed and Blown Glass Manufacturing
The machine pressed and blown glass manufacturing subcategory is the
subject of further study at the present time. The results of this
study, including the recommended best available technology
economically achievable effluent limitations, will be presented in a
supplement to this document at a later date.
ii^ss Tubing (Banner) Manufacturing
Che best available technology economically achievable involves the
recirculation of the cullet quench water through a cooling tower.
The cooling tower blowdown is treated by diatomaceous earth
filtration. The blowdown is estimated at 5 percent of the total
mullet quench water flow. Effluent limitations for suspended solids
are 0.2 g/metric ton (0.0004 Ib/ton) .
Television Picture Tube Envelope Manufacturing
The control technology specified includes lime precipitation,
sedimentation, and pH adjustment of all finishing waste waters, as
described in Section IX, followed by sand filtration. Cullet quench
water is not treated. Effluent limitations for suspended solids are
130 g/metric ton (0.26 Ib/ton); for oil, 130 g/metric ton (0.26
Ib/ton); for fluoride, 60 g/metric ton (0.12 Ib/ton); for lead, 0.45
g/metric ton (0.0009 Ib/ton) ; and pH, between 6.0 and 9.0.
168
-------
TABLE 29
RECOMMENDED 30-DAY AVERAGE EFFLUENT LIMITATIONS USING
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
Suspended
Solids
Oil
Fluoride
Lead
Ammonia
Glass Container
g/metric ton
(Ib/ton)
Machine Pressed &
Blown Glass*
g/metric ton
(Ib/ton)
Glass Tubing
(Danner)*
g/metric ton
(Ib/ton)
Television Picture
Tube Envelope
g/metric ton
(Ib/ton)
Incandescent Lamp
Envelopes
Forming
g/metric ton
(Ib/ton)
Frogting
g/metric ton
(Ib/ton)
Hand Pressed &
Blown Glass
Leaded & Hydro-
fluoric Acid
mg/1
Npn-L ead ed &
Hydrofluoric
Acid Finisjiing
mg/1
Non-Hydrofluoric
Ac id Finishing
mg/1
0.8
0.0016
0.8
0.0016
6-9
0.2
0,0004
130
0.26
45
0.09
40
0.08
0.2
0.0004
130
0.26
45
0.09
60
0.12
0.45
0,0009
6-9
6-9
52
0.104
120
0.24
6-9
6-9
10
10
10
13
13
0.1
6-9
6-9
6-9
*The machine pressed and blown glass manufacturing subcategory and the
remainder of the glass tubing subcategory are the subject of further
study. Results of this study will be presented at a later date.
169
-------
Incandescent Lamp Envelope Manufacturing
The best available technology economically achievable involves the
treatment of frosting waste waters by lime precipitation,
sedimentation and recarbonation, as described in Section IX,
followed by sand filtration and ammonia removal by steam stripping.
In addition to this control technology, diatomaceous earth
filtration is used to treat the cullet quench waste waters.
Effluent limitations for waste waters resulting from the forming of
incandescent lamp envelopes are 45 g/metric ton (0.09 Ib/ton) for
suspended solids and oil. Frosting waste water effluent limitations
for suspended solids are 40 g/metric ton (0.08 Ib/ton); for
fluoride, 52 g/metric ton (0.10** Ib/ton) ; for ammonia, 120 g/metric
ton (0.24 Ib/ton); and pH, between 6,0 and 9.0.
Hand Pressed and Blown Glass Manufacturing
The best available technology economically achievable includes batch
lime precipitation, sedimentation, and recarbonation, followed by
sand filtration. Effluent limitations for suspended solids,
fluoride, and lead are 10, 13, and 0.1 mg/1, respectively. The pH
of the effluent waste water must be adjusted to the range between
6.0 and 9.0.
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF BEST
AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
Based on the information contained in sections III through VIII of
this document, a determination has been made of the degree of
effluent reduction attainable through the application of the best
available technology economically achievable. Recycle of cullet
quench water is attainable for the glass container and glass tubing
(Danner) manufacturing subcategories. The effluent reductions
attainable through application of the specified control and
treatment technologies are summarized here.
Fluoride
The application of the best available technology economically
achievable will reduce fluoride discharges from television picture
tube envelope manufacturing by 96.7 percent and from incandescent
lamp envelope manufacturing by 99.5 percent. The effluent fluoride
concentration for handmade glass plants which employ hydrofluoric
acid finishing techniques is reduced to 13 mg/1 by application of
this technology. The incremental reduction over the levels achieved
using the best practicable control technology currently available
for television picture tube envelope manufacturing and incandescent
lamp envelope manufacturing are 14.3 and 55.1 percent, respectively.
Ammonia
A primary constituent of the raw waste water from the frosting of
incandescent lamp envelopes is ammonia. Ammonia levels will be
reduced by 95 percent in the incandescent lamp envelope
170
-------
manufacturing subcategory through the application of the best
available technology economically achievable. The incremental
increase over the application of the best practicable control
technology currently available (BPCTCA) is also 95 percent as no
limitations for ammonia were established for BPCTCA.
Lead
With the implementation of the best available technology
economically achievable effluent limitations, the lead discharged as
a result of television picture tube envelope manufacturing is
reduced by 99.9 percent and the incremental increase in removal over
the level achieved using the best practicable control technology
currently available is 90 percent. The lead concentration for
handmade glass plants which employ hydrofluoric acid finishing
techniques is reduced to a concentration of 0.1 mg/1 using this
technology.
Oil
With the implementation of the best available technology
economically achievable effluent limitations, oil in glass container
manufacturing waste waters is reduced by 97.3 percent and from
incandescent lamp envelope manufacturing waste waters by 61 percent.
The incremental reductions over the best practicable control
technology currently available are equal to the total reductions
listed above. The lower reduction achieved for the incandescent
lamp envelope manufacturing subcategory is due to a larger discharge
volume because the waste water is not recirculated as proposed in
the other three subcategories.
Oxygen Demanding Materials
Oxygen demand is related to the waste water oil concentration in the
pressed and blown glass industry and, therefore, the reductions in
oxygen demand will be in proportion to the oil removals listed
above.
EH
Waste waters resulting from glass container manufacturing and glass
tubing (Danner) manufacturing are presently in the pH range of 6-9.
This technology includes the adjustment of pH in the television
picture tube, incandescent lamp envelope, and hand pressed and blown
glass manufacturing subcategories to a range from 6-9.
Suspended Solids
The application of the best available technology economically
achievable will reduce suspended solids for glass container
manufacturing, glass tubing (Danner) manufacturing, television
picture tube envelope manufacturing, and incandescent lamp envelope
manufacturing by 98.9, 99.9, 96.9, and 82.U percent, respectively.
Incremental increases in removal over the level achieved using the
171
-------
best practicable control technology currently available are 13.3
percent for television picture tube envelope manufacturing and 74.6
percent for incandescent lamp envelope manufacturing. The lower
incremental reduction achieved for television picture tube envelope
manufacturing is due to the low suspended solids in the treated
waste water. Suspended solids are reduced to a concentration of 10
mg/1 in the hand pressed and blown glass manufacturing subcategory
by application of this technology.
Qther Pollutant Constituents
Temperature and dissolved solids are not significantly reduced by
application of the best available technology economically
achievable.
RATIONALE FOR THE SELECTION OF BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE
Total Cost of Application
Based upon the information contained in Section VIII of this
document, the industry as a whole is estimated to have to invest
approximately $22,500,000 to achieve the effluent limitations
prescribed herein. The increased annual costs to the industry are
estimated at approximately $5,304,000 -
Size and Age of Equipment and Facilities
As discussed in Section IX, differences in size and age of equipment
and facilities do not play a significant role in the application of
this control technology.
Process Employed
The manufacturing processes employed within each subcategory of the
industry are similar and will not influence the applicability of
this control technology.
Engineering Aspects of Application
This level of technology is presently being achieved by several
glass container plants and can be readily applied to the glass
tubing (Banner) manufacturing subcategory. The specified waste
water treatment and control systems are now employed in other
industries and this technology is readily transferrable to the
pressed and blown glass segment. The derivation and rationale for
selection of the control technology are described in detail in
Section VII. These may be briefly summarized as follows:
Glass Container Manufacturing-
Cullet quench water recycle systems are presently employed at a
number of glass container plants. The recycle systems have been in
operation for several years without major operational difficulties.
172
-------
The technologies for treating the blowdown are presently used by at
least one glass container plant and also used in the flat glass
industry. This technology is readily transferrable to the remainder
of the segment.
Glass Tubing jDannerl Manuf a ctur inq-
Recycle of cullet quench water is feasible because the pollutant
concentrations are at low levels in the quench water. Non-contact
cooling water is already recycled at a number of plants within the
industry.
Television Picture Tube Envelope Manufacturing-
Rapid sand filtration is a thoroughly proven technology that is used
extensively in the water treatment industry. This technology can be
applied in the television picture tube envelope, incandescent lamp
envelope, and hand pressed and blown glass manufacturing
subcategories to further reduce effluent suspended solids, fluoride,
and lead concentrations.
Ioc§lldescervt Lamp Envelope Manufacturing"-
Steam stripping is currently l>eing used in the petroleum refining,
petrochemical, and fertilizer industries. The ammonia waste water
stream concentrations and volumes are similar to those occurring in
the incandescent lamp envelope manufacturing subcategory. Effluent
concentrations equal to those necessary to achieve the effluent
limitations are being achieved in the fertilizer industry and,
therefore, can be anticipated when this technology is transferred to
the incandescent lamp envelope manufacturing subcategory.
Both diatomaceous earth filtration and recarbonation are proven
water treatment methods and can be readily applied to the treatment
of waste waters resulting from incandescent lamp envelope
manufacturing.
Process Changes
No process changes are required to implement this technology and
plant operations and production will not be significantly affected
during the installation of the treatment equipment.
Non-Water Quality Environmental Aspects
The application of this control technology is not expected to create
any new air or land pollution problems. The ammonia stripped from
incandescent lamp envelope manufacturing waste waters is expected to
be vented to the atmosphere, although methods are available to
recover ammonia as a salable product. Techniques are available to
reduce the concentration of ammonia in the air to below the
threshold of odor. Energy requirements will not increase
significantly above the levels of the best practicable control
technology currently available in most of the subcategories because
173
-------
the additional energy requirements are primarily for pumping within
the treatment system. The one exception is the incandescent lamp
envelope manufacturing subcategory where, if no excess steam or
other heat source to produce steam is available, an 8.2 percent
increase in energy requirements could result.
174
-------
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
INTRODUCTION
In addition to. guidelines reflecting the best practicable control
technology currently available and the best available technology
economically achievable, applicable to existing point source
discharges by July 1, 1977, and July 1, 1983r respectively, the Act
requires that performance standards be established for new sources.
The term "new source" is defined in the Act to mean "any source, the
construction of which is commenced after the publication of proposed
regulations prescribing a standard of performance". New source
technology shall 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 technology is to be based upon an analysis of
how the level of effluent may be reduced by changing the production
process itself. Alternative processes, operating methods or other
alternatives must be considered. However, the end result of the
analysis will be to identify effluent standards which 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 must be made for new source technology
is whether a standard permitting no discharge of pollutants is
practicable.
Specific Factors to be Taken into consideration
At least the following factors should be considered with respect to
production processes which are to be analyzed in assessing new
source technology:
a. the type of process employed and process changes;
b.
c.
d.
e.
operating methods;
batch as opposed to continuous operations;
use of alternative raw materials and mixes of
materials;
raw
use of dry rather than wet processes (including
substitution of recoverable solvents for water); and
recovery of pollutants as by-products.
175
-------
NEW SOURCE PERFORMANCE STANDARDS FOR THE PRESSED
SEGMENT OF THE GLASS MANUFACTURING CATEGORY
AND BLOWN GLASS
Because of the large number of specific improvements in management
practices, design of equipment, and process and systems that have
some potential of development, it is not possible to determine,
within reasonable accuracy, the potential waste reductions
achievable through their application in new sources. However, the
implementation of those in-plant and end-of-pipe controls described
in Section VTI, Control and Treatment Technology, would enable new
sources to achieve the effluent discharge levels defined in Section
X as the best available technology economically achievable.
The short lead time for application of new source performance
standards (less than a year versus approximately three and nine
years for other guidelines) affords little opportunity to engage in
extensive development and testing of new procedures. The single
justification for more restrictive limitations for new sources than
for existing sources would be one of relative economics of
installation in new plants versus modification of existing plants.
There is no data to indicate that the economics of the application
of in-plant and end-of-pipe technologies described in Section VII,
Control and Treatment Technology, would be significantly weighted in
favor of new sources. The only cost reductions for new plants would
be those savings resulting from not having to segregate existing
process waters from non-contact cooling waters, whereas in existing
plants, this may be necessary.
The attainment of zero discharge of process waste water pollutants
is feasible for some facilities within the pressed and blown glass
segment if process waste water is recirculated to a sufficient
degree to allow discharge of the blowdown to the batching operation.
Water is used in the batching operation to reduce segregation of the
batch and to control dust emissions during mixing. This water
evaporates during the melting operation and is not discharged.
Several plants in the industry are achieving zero discharge of
process waste water pollutants by this or similar means. However,
it is not apparent that all plants within the industry can attain
zero discharge of pollutants by this means; it has been reported
that during times in which soda ash is in short supply, liquid
caustic must be substituted. All the water needed in the batching
operation is supplied by the liquid caustic. Thus, the blowdown
from the process water recirculation system would have to be
discharged unless sufficient land was available to allow for
evaporation or seepage of this waste water stream.
In view of the aforegoing, it is recommended that the effluent
limitations for new sources be the same as those determined to be
best available control technology economically achievable, presented
in Section X.
176
-------
PRETREATMENT CONSIDERATIONS
Plants which make up the pressed and blown glass segment o£ the
glass manufacturing point source category discharge waste waters
containing both pollutants which will be adequately treated by a
publicly owned treatment works and pollutants which will pass
through inadequately treated. The following is a discussion of each
of the applicable pollutant parameters and recommendations as to
their adequate treatment by a publicly owned treatment works:
Fluoride results from the use of hydrofluoric acid to frost
incandescent lamp envelopes, to acid polish glass in the manufacture
of television picture tube envelopes, and to polish and etch
handmade glassware in the finishing operations associated with hand
pressed and blown glass manufacturing. It is expected that fluoride
will pass through a publicly owned treatment works untreated. It
is, therefore, recommended that pretreatment requirements for point
sources be established to ensure the treatment of fluoride bearing
waste waters. It is further recommended that pretreatment
requirements for existing sources be set at those levels established
as the best practicable control technology currently available and
for new sources at those levels established as new source
performance standards. These levels are readily attainable by the
proven methods of treatment discussed in Section VII.
Ammonia
Ammonia is contributed to waste water by the frosting of
incandescent bulbs. It is anticipated that ammonia discharged to a
publicly owned treatment works will be oxidized to nitrite and then
nitrate during the treatment process and, therefore, will not pass
through untreated.
Oil emulsions of a mineral or biodegradable animal or vegetable
nature are utilized as shear spray within the pressed and blown
glass segment of the glass manufacturing category. This shear spray
oil and leakage of machine lubricating oils contribute to the waste
loading in the glass container manufacturing/ television picture
tube envelope manufacturing and the incandescent lamp envelope
manufacturing subcategories. It has been determined that animal and
vegetable oils can be adequately removed in publicly owned treatment
works, whereas mineral oil may not be readily removed and may pass
through untreated. Therefore , it is appropriate that separate
pretreatment regulations be established for these categories of
oils.
It is recommended that mineral oil discharges from existing sources
be maintained at a level of less than 100 mg/1 to reflect the
capability of publicly owned treatment works. It has also been
determined that many existing sources are attaining the best
177
-------
practicable control technology currently available effluent
limitations through in-plant controls with no end-of-pipe treatment.
It is expected that new sources should be able to attain this same
level of in-plant control. Therefore, it is recommended that new
sources be required to maintain mineral oil discharges at levels
reflecting the best practicable control technology currently
available.
Lead
Lead is contributed to waste waters during the abrasive grinding and
polishing and hydrofluoric acid treatment of leaded glassware. Data
indicate that the greatest concentration of lead is that contained
in suspended solids. Control of suspended solids is expected to
control lead discharges from pressed and blown glass manufacturing
plants.
Suspended Solids and pH
Suspended solids and pH are expected to be adequately treated in a
publicly owned treatment works. There are no unusual suspended
solids loadings anticipated that would hinder the operation of a
publicly owned treatment works. Extreme variations in pH can exist
at those facilities which use hydrofluoric acid to etch or polish
glass. Facilities in the television picture tube envelope, the
incandescent lamp envelope, and the hand pressed and blown glass
manufacturing subcategories employ finishing techniques which
utilize hydrofluoric acid.
178
-------
SECTION XII
ACKNOWLEDGEMENTS
The Environmental Protection Agency wishes to acknowledge the
contributions to the project by Sverdrup & Parcel and Associates,
Inc., St. Louis, Missouri. Dr. H. G. Schwartz, Project Executive,
Mr. Richard C. Vedder, Project Manager, and Mr. John Lauth, Project
Engineer, directed the project, conducted the detailed technical
study, and 'drafted the initial report on which this document is
based.
Appreciation is extended to the many people and companies in the
pressed and blown glass industry who cooperated in providing
information and data and in making a number of their plants
available for inspection and sampling.
Acknowledgement is also given to Mr. John H. Abrahams, Jr., of the
Glass Container Manufacturers Institute, and Mr. Joseph V. Saliga,
of the Air Pollution Committee of the West Virginia Society of
Ceramic Engineers, who were helpful in providing input to this study
and in soliciting the cooperation of their member companies.
Acknowledgement is also given to Mr. John Schmidt and his staff at
the Commonwealth of Pennsylvania, Department of Environmental
Resources, for their efforts in gathering information and providing
data related to those portions of the pressed and blown glass
segment located in the State of Pennsylvania.
Appreciation is expressed to those in the Environmental Protection
Agency who assisted in the performance of the project. Especially
deserving recognition are: Ernst Hall, John Riley, Arthur Mallon,
Calvin Smith, Glenwood Sites, James Kamihachi, Ms. Jaye Swanson, and
Ms. Barbara Wortman.
179
-------
-------
SECTION XIII
REFERENCES
1.
2,
3.
4.
5.
6.
7.
American Water Works Association, Water Quality
McGraw-Hill Book Co,, New York, 1971.
and Treatment,
"Ammonia Removal from Agricultural Runoff and Secondary Effluent
by Selected Ion Exchange," U.S. Department of the Interior,
FWPCA, Cincinnati, Ohio, March 1969.
Ammonia Removal in a Physical-Chemical Wastewater Treatment
Process,11 U. S. Environmental Protection Agency, EPA-R2-72-123,
November 1972.
Anthonisen, A.C., et al. , "Inhibition of Nitrification by Un-
ionized Ammonia and Un-Ionized Nitrous Acid," presented at 47th
Annual Conference Water Pollution Control Federation, October
1974. -
Barnes, Robert A., Atkins, Peter F., Jr., and Scherger, Dale A.,
"Ammonia Removal in a Physical- Chemical Wastewater Treatment
Process," prepared for Office of Research and Monitoring, U.S.
Environmental Protection Agency, November 1972.
Battelle Memorial Institute, "Inorganic Fertilizer and Phosphate
Mining Industries - Water Pollution and Control," Environmental
Protection Agency Grant No. 12020FFD, September 1971.
Battelle - Northwest and South Tahoe Public Utility District,
"Wastewater Ammonia Removal by Ion Exchange," Water Pollution
Control Research Series No. 17010EEZ, Environmental Protection
Agency, February 1971.
8. Beychok, M. R., Aqueous Wastes from the Petroleum
Petrochemical Plants, John Wiley and Sons, 1967.
9.
10.
Child, Frank, S., "Aspects of Glassmaking, as an Engineer
It*" American Glass Review, December 1973, pp. 6-7.
and
Views
"Control of
Environmental
March 1974.
Nitrogen in Waste Water
Protection Agency, ORD (NERC)
Effluent," U.S.
Cincinnati, Ohio,
11. Gulp, Gordon L., "Physical Chemical Techniques for Nitrogen
Removal," Environmental Protection Agency, Technology Transfer
Seminar, Kansas City, Missouri, January 15^17, 1974.
12. Gulp, R, L- and Gulp, G. L., Advanced Wastewater Treatment,
Nostrand Reinhold Company, New York, 1971.
Van
181
-------
13.
15
16
17
18
19.
20.
21.
22
23.
Gulp, .R. L. and Gonzales, J. G. , "New Developments in Ammonia
Stripping," Public Works, May-June 1973.
Gulp, Russell L. and Stoltenberg, Howard A., "Fluoride Reduction
at Lacrosse, Kansas," Journal of the American Water works
Association, March 1958, pp. 423-431.
"Development and Demonstration of Nutrient Removal from Animal
Wastes," U.S. Environmental Protection Agency, EPA-R2-7 3-095,
January 1973,
"Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the BASIC FERTILIZER
CHEMICALS Segment of the Fertilizer Manufacturing Point Source
Category," Effluent Guidelines Division, U.S. Environmental
Protection Agency, EPA-440/l-74-011a, March 1974.
"Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the COPPER, NICKEL,
CHROMIUM, AND ZINC Segment of the Electroplating Point Source
Category," Effluent Guidelines Division, U.S. Environmental
Protection Agency, EPA-440/l-74-003a, March 1974.
"Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the FLAT GLASS Segment of
the Glass Manufacturing Point Source Category," Effluent
Guidelines Division, U.S. Environmental Protection Agency, EPA-
440/1-74-001-C, January 1974.
"Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the PETROLEUM REFINING
Point Source Category," Effluent Guidelines Division, U. S.
Environmental Protection Agency, EPA-440/l-74-014a, April 1974.
"Development Document for Effluent Limitations Guidelines and
New Source Performance Standards for the RENDERER Segment of the
Meat Products and Rendering Processing Point Source Category,"
Effluent Guidelines Division, U.S. Environmental Protection
Agency, EPA-440/l-74/031-d, January 1975,
Drews, R.J.L.C. and Greeff, A.M., "Nitrogen Elimination by Rapid
Alternation of Aerobic/"Anoxic" Conditions in "Orbal" Activated
Sludge Plants," Water Research, Vol. 7, 1973.
Duddles, Glenn A., "Plastic Medium Trickling Filters for
Biological Nitrogen Control," Journal Water Pollution Control
Federation. Vol. 46, No. 5, May 1974.
Eliassen, Rolf and Tchobanoglous, George, "Advanced
Processes," Chemical Engineering, October 14, 1968.
Treatment
Federal Register, Volume 39, Number 32, page 5712, February 14,
1974.
182
-------
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
Federal Register, Volume 40, Number 80, page 18130, April 24,
1975.
Giegerich, W. and Trier, W. , Glass Machines, Springer-Verlag
Inc., New York, 1969.
Haug, Roger T. and McCarty, Perry L., "Nitrification with
Submerged Filters," Journal Water Pollution Control Federation,
Vol. 44, No. 11, November 1972.
Hodkin, F. W. and Cousen, A., A Textbook of Glass Technology,
Constable & Company, Ltd., London, 1925.
Hutchins, J. R., III and Harrington, R. V., Corning Glass Works,
"Glass," Encyclopedia of Chemical Technology, 2nd Edition,
Volume 10, John Wiley 6 Sons, Inc.7*1966, pp. 533-604.
Johnson, Walter K., "Process Kinetics for Denitrification,11
Journal Sanitary Engineering Division, American. Society of Civil
Engineers, August 1972.
Jorgensen, Professor S. E,, "A New Method for the Treatment of
Municipal Wastewater," Paper No. 2, Water Pollution Control,
1972.
Kepple, Larry G., "Ammonia Removal and Recovery
Feasible," water and Sewage Works, April 1974.
Becomes
Ledbetter, Joe O., Air Pollution, Part A;_
Dekker, Inc., New York, 1972.
Analysis, Marcel
Loehr, Raymond C., Agricultural Waste Management, Academic
Press, New York, 1974. ""*
Lue-Hing, Cecil, et al., "Nitrification of a High Ammonia
Content Sludge Supernatant by Use of Rotating Discs," presented
at 29th Annual Purdue Industrial Waste Conference, May 1974.
McKee, J. E. and Wolf, H. W., "Water Quality Criteria," 2nd
Edition, Publication No. 3A, State Water Quality Control Board,
State of California, The Resources Agency, 1963.
McLaren, James R. and Farquhar, Grahame J., "Factors Affecting
Ammonia Removal by Clinoptilolite," Journal of the Environmenta1
Engineering Division, ASCE, Vol. 99, No. EE4, August 1973, pp.
429-446.
Maier, F. J., "Defluoridation of Municipal Water Supplies,"
Journal of the American Water works Association, August 1953,
pp. 879-887.
183
-------
39
40.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Mulbarger, M. C,, "Nitrification and Denitrification in
Activated Sludge Systems," Journal of the Water Pollution
Control Federation, Vol. 43, No. 10, October 1971, pp. 2059-
2070.
"Nitrification and Denitrification Facilities - Wastewater
Treatment," Environmental Protection Agency Technology Transfer
Seminar Publication, August 1973.
"Nitrogen Removal by Ammonia Stripping, w U. S. Environmental
Protection Agency, EPA-670/2-73-040, September 1973.
"Nitrogen Removal From Wastewater s," Federal Water Quality
Administration, Division of Research and Development, Advanced
Waste Treatment Research Laboratory, Cincinnati, Ohio, October
1970,
O'Farrell, T. P., Franson, F. P., Cassel, A. F. , and Bishop, D.
F., "Nitrogen Removal by Ammonia Stripping," Journal of the
Water Pollution Control Federation, August 1972, pp. 1527^1535,
Office of Management and Budget, Standard Industrial
Classification Manual, U.S. Government Printing Office,
Washington, D.C., 1972.
Patterson, J. W. , and Mi near, R. A., Wastewater Treatment
Technology. 2nd Edition, Illinois Institute for Environmental
Quality, National Technical Information Service, February 1973.
Prakasam, T.B.S., et al . , "Approaches for the Control of
Nitrogen with an Oxidation Ditch," Proceedings 1974 Agricultural
Waste Management Conference, Cornell University, Ithaca, New
York, March 1974.
"Public Health Service Drinking
Department of Health, Education,
Service, Washington, D.C,, 1962.
Water standards," U.S.
and Welfare, Public Health
"Pulling Effluents Into Line," Chemical Engineering. July 12,
1971, p. 40.
Reeves, T. G., "Nitrogen Removal: A Literature Review," Journal
of the Water Pollution Control Federation, Vol. 44, No. 10,
October 1972, pp. 1895-1905.
Roesler, Joseph F., Smith, Robert, and Eilers, Richard G.,
"Simulation of Ammonia Stripping from Wastewater,11 Journal of
the Sanitary Engineering Division. ASCE, Vol. 97, No. SA3, June
1971.
Sampayo, Felix F., "How to Get Low Ammonia Effluents," Water and
Sewage Works, August 1974.
184
-------
52, Sanitary Engineering Research Laboratory, University of
California, Berkeley, "Optimization of Ammonia Removal by Ion
Exchange Using Clinoptilolite," Report for the Environmental
Protection Agency, Project No. 17080 DAR, September 1971.
53. Savinelli, Emilio A. and Black, A. P., "Defluoridation of Water
with Activated Aluminarw Journal of the American Water Works
Association. January 1958, pp. 33-44.
54, Shand, E. B., Glass Engineering Handbook* McGraw-Hill Book
Company, New York, 1958.
55, Slechta, Alfred P. and Owen, William F., "ABF Nitrification
System, 1974 Pilot Plant Study," Interim Report, Neptune
Microfloc, Inc., September 1974.
56. Smith, Robert, and MeMichael, Walter F., "Cost and Performance
Estimates for Tertiary Wastewater Treating Processes," U.S,
Department of the Interior, June 1969.
57, Snow, R. H., and Wnek, W. J., "Design of Cross-Flow Cooling
Towers and Ammonia Stripping Towers," Industrial Engineering
Chemical Process Design Development, Vol. 11, No. 3, 1972, pp.
343-349.
58. Stenquist, Richard J., et al., "Carbon Oxidation-Nitrification
in Synthetic Media Trickling Filters," Journal Water Pollution
Control Federation, Vol. 46, October 1974.
59. Sutton, Paul M., et al., "Biological Nitrogen Removal - The
Efficacy of the Nitrification Step," presented at 47th Annual
Conference Water Pollution Control Federation, October 1974.
60. "Treatment and Recovery of Fluoride Industrial Wastes," U.S.
Environmental Protection Agency, EPA-660/2-73-024, March 1974.
61. "Water Quality Criteria - 1972," National Academy of Sciences
and National Academy of Engineering for the Environmental
Protection Agency, Washington, D. C., 1972 (U.S. Government
Printing Office Stock No. 5501-00520).
62. Zabban, Walter, and Jewett, H. W., "The Treatment of Fluoride
Wastes," Proceedings of the 22nd Industrial Waste Conference,
Purdue University, 1967, pp. 706-716.
185
-------
-------
SECTION XIV
GLOSSARY
Act
The Federal Water Pollution Control Act as amended.
Activated Alumina
An insoluble, granular media that adsorbs fluoride as the waste
water percolates through the media.
Annealing
Prevention or removal of objectionable stresses by controlled
cooling from a suitable temperature.
API Separator
A free oil separator based on the design recommendations of the
American Petroleum Institute.
Batch
The raw materials, properly proportioned and mixed, for delivery to
the furnace.
Slowdown
A discharge from a system, designed to prevent a buildup of some
material, as in a boiler to control dissolved solids.
Blowpipe
The pipe used by a glassmaker for gathering molten glass and blowing
the glass by mouth.
Casting
The forming method used to make television picture tube envelope
funnels. The funnel mold is spun and centrifugal force causes the
molten glass to form in the funnel shape.
Category and Subcategory
Divisions of a particular industry which possess different traits
which affect water quality and treatability.
Cooling Water
Water used primarily for dissipation of process heat. Can be both
contact or non-contact, and is usually the latter.
187
-------
Crack-off
The process of severing a
scratching and then heating.
Gullet
glass article by breaking, as by
Waste or broken glass, usually suitable as an addition to the raw
material batch.
Gullet Quench
The process of dissipating the heat from cullet by the addition of
water.
Diatomaceous Earth
The skeletal remains of tiny aquatic plants, commonly used as a
filter medium to remove suspended solids from fluids. Specially
treated diatomaceous earth can be obtained for the removal of
emulsified oil from water.
Envelope
The glass portion of a picture tube or light bulb that encloses the
electrical components of the assembled product.
Etching
The process of placing designs in high quality stemware by hydro-
fluoric acid attack of the glass.
Forehearth
A section of a melting tank, from which glass is taken for forming,
Frosting
The process used in the incandescent lamp envelope industry to give
the inside surface of an envelope a matted surface. This improves
the light diffusing property of the envelope.
Gob
A portion of hot glass delivered by a feeder, after being cut from
the molten glass stream by shear cutters.
I-S. Machine
The individual section machine is the machine most commonly used to
form glass containers.
188
-------
Lehr
A long tunnel-shaped oven for annealing glass by continuous passage.
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.
Process Water
Any water which comes into direct contact with the intermediate or
final product. Includes contact cooling, washing, grinding and
polishing, etc.
Ribbon Machine
The machine used to form incandescent lamp envelopes.
Surface Waters
Navigable waters.
territorial seas.
Tons Frosted
The waters of the United States including the
Calculated by multiplying the tons pulled by the percentage of plant
production frosted.
Tons Pulled
Tons of glass drawn from the melting furnace.
Washer
A process device used for water cleaning of the product.
Waste Water
Process water or contact cooling water which has become contaminated
with process waste and is considered no longer usable.
189
-------
TABLE 31
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
square feet sq ft
square inches sq in
ton (short) ton
yard yd
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)* atm
0.0929
6.452
0.907
0.9144
* Actual conversion, not a multiplier
ha hectares
cu m cubic meters
kg cal kilogram - calories
kg cal/kg kilogram calories/kilogram
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 ki 1 ograms
cu m/day cubic meters/day
km kilometer
atmospheres (absolute)
sq m square meters
sq cm square centimeters
kkg metric ton (1000 kilograms)
m meter
190
U.S. GOVERNMENT PRINTING OFFICE: 1975— 210-810/17
-------
-------
-------
-------
-------
-------
-------
-------
U.S. ENVIRONMENTAL PROTECTION AOENCY {A-107)
WASHINGTON, D.C. 20460
POSTAGE AND FEES PAID
ENVIRONMENTAL PROTECTION AGENCY
EPA-335
------- |