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440182022
United States
Environmental Protection
Agency
Effluent Guidelines Division
WH-552
Washington DC 20460
September 1982
Water and Waste Management
Development
Document for
Effluent Limitations
Guidelines and
Standards for the
Textile Mills
Point Source Category
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DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES AND STANDARDS
for the
TEXTILE MILLS POINT SOURCE CATEGORY
Anne M. Gorsuch
Administrator
\
Jeffery D. Denit
Director, Effluent Guidelines Division
Robert W. Dellinger
Actirtg Chief, Wood Products and Fibers Branch
Richard E. Williams
Project Officer
September, 1982
Effluent Guidelines Division
Office of Water
U.S. Environmental Protection Agency
Washington, D.C. 20460
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ABSTRACT
This document presents the findings of an extensive study of the
textile industry for the purpose of developing effluent
limitations for existing point sources, standards of performance
for new sources, and pretreatment standards for existing and new
sources to implement Sections 301, 304, 306, and 307 of the Clean
Water Act. The study covers approximately 6,000 textile
manufacturing facilities in SIC Major Group 22 of which
approximately 2,000 are specifically affected by the findings.
Effluent limitation guidelines are set forth for the degree of
effluent reduction attainable through the application of the best
practicable control technology currently available (BPT), and the
best available technology economically achievable (BAT) and the
best conventional pollutant control technology (BCT) which must
be achieved by existing point sources by July 1, 1984. Standards
of performance for new sources (NSPS) set forth the degree of
effluent reduction that is achievable through the application of
the best available demonstrated control technology, processes,
operating methods, or other alternatives. Pretreatment standards
for existing and new sources (PSES and PSNS) set forth the degree
of effluent reduction that must be achieved in order to prevent
the discharge of pollutants that pass through, interfere with, or
are otherwise incompatible with the operation of POTWs.
BPT regulations for new subcategories are established based on
biological treatment. The regulations for BAT are equal to
existing BPT for toxic and nonconventional pollutants. NSPS are
based on biological treatment as demonstrated by the best
performing mills in the industry. The regulations for PSES and
PSNS shall be the General Pretreatment Regulations at 40 CFR Part
403, 43 FR 27736 (June 26, 1978) and at 46 FR 9462 (January 28,
1981).
Supporting data, rationale, and methods for development of the
effluent limitation guidelines and standards are contained in
this document.
in
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TABLE OF CONTENTS
SECTION
I EXECUTIVE SUMMARY
SUBCATEGORIZATION
EFFLUENT LIMITATIONS
BPT
BAT
NSPS
PSES and PSNS
II INTRODUCTION
PURPOSE AND AUTHORITY
PRIOR EPA REGULATIONS
OVERVIEW OF THE INDUSTRY
SUMMARY OF METHODOLOGY
DATA AND INFORMATION GATHERING PROGRAM
Previous Data Collection Activities
308 Data Request
Mill Visits
Raw Materials Review
Screening and Verification Sampling
Processing of Data and Information
III DESCRIPTION OF THE INDUSTRY
GENERAL DESCRIPTION
Profile of Major Group 22
Industry Survey (308 Data Request)
UNIT MANUFACTURING (INDUSTRIAL) PROCESSES
Raw Materials
Major Dry or Low Water Use Processes
Other Fabric Manufacturing
Major Wet Processes
FINAL PRODUCTS
Wool Stock and Top (Wool Scouring subcategory)
Finished Wool Goods (Wool Finishing subcategory)
Greige Goods and Adhesive Products (Low Water Use
Processing subcategory)
Finished Woven Goods (Woven Fabric Finishing
subcategory)
Finished Knit Goods (Knit Fabric Finishing
subcategory)
Finished Carpet (Carpet Finishing subcategory)
Finished Stock and Yarn (Stock and Yarn Finishing
subcategory)
9
11
11
12
13
13
13
14
14
14
15
17
17
17
21
30
30
32
33
37
52
52
54
54
54
57
57
57
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Nonwovens (Nonwoven Manufacturing subcategory)
Felted Fabric (Felted Fabric Processing subcategory)
IV INDUSTRY SUBCATEGORIZATION
INTRODUCTION
RESULTS
BASIS OF FINAL SUBCATEGORIZATION SCHEME
Rationale for Selection of Final Subcategorization
Scheme
Additional Analyses
IMPACT OF TOXIC POLLUTANT DATA
SUBCATEGORY DESCRIPTIONS
Wool Scouring Subcategory
Wool Finishing Subcategory
Low Water Use Processing Subcategory
Woven Fabric Finishing Subcategory
Knit Fabric Finishing Subcategory
Carpet Finishing Subcategory
Stock and Yarn Finishing Subcategory
Nonwoven manufacturing Subcategory
Felted Fabric Processing Subcategory
V WASTE CHARACTERISTICS
INTRODUCTION
DISCUSSION OF UNTREATED WASTEWATER CHARACTERISTICS
Wool Scouring Subcategory
Wool Finishing Subcategory
Low Water Use Processing Subcategory
Woven Fabric Finishing Subcategory
Knit Fabric Finishing Subcategory
Carpet Finishing Subcategory
Stock and Yarn Finishing Subcategory
Nonwoven Manufacturing Subcategory
Felted Fabric Processing Subcategory
WATER USE
TOXIC POLLUTANTS
Industry Survey Information
Field Sampling Program
Field Sampling Results
Field Sampling Results
Field Sampling Results
Effluents
Field Sampling Results - Individual Subcategories
Water Supply
Untreated Wastewater
Biologically Treated
Other Sources of Information
57
62
65
66
66
66
69
74
74
74
75
75
76
77
78
78
79
79
81
81
82
82
83
85
86
90
92
94
95
95
96
99
99
101
106
106
119
125
155
VI
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TRADITIONALLY MONITORED POLLUTANTS
Characterization of Mill Water Supply
Characterization of Untreated Wastewaters
157
158
158
VI SELECTION OF POLLUTANT PARAMETERS
WASTEWATER PARAMETERS OF SIGNIFICANCE
Conventional Pollutants
Toxic Pollutants
Nonconventional Pollutants
Summary of Previous Regulations
SELECTION OF POLLUTANTS OF CONCERN
Toxic Pollutants
Nonconventional Pollutants
Conventional Pollutants
VII CONTROL AND TREATMENT TECHNOLOGY
IN-PLANT CONTROLS AND PROCESS CHANGES
Summary of In-Plant Controls Data
Water Reuse
Water Use Reduction
Chemical Substitution
Material Reclamation
Process Changes and New Process Technology
EFFLUENT TREATMENT TECHNOLOGIES
197
197
197
197
199
199
199
199
224
226
231
231
232
232
234
235
237
237
238
VIII EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION
OF BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE
GENERAL
REGULATED POLLUTANTS
IDENTIFICATION OF THE BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE
BPT EFFLUENT LIMITATIONS
RATIONAL FOR THE SELECTION OF BEST PRACTICABLE
CONTROL TECHNOLOGY CURRENTLY AVAILABLE
METHODOLOGY USED FOR DEVELOPMENT OF BPT LIMITATIONS
Water Jet Weaving Subdivision
Nonwoven Manufacturing and Felted Fabric
Processing
COST OF APPLICATION AND EFFLUENT REDUCTION BENEFITS
NON-WATER QUALITY ENVIRONMENTAL IMPACTS
Energy
Solid Waste
385
385
385
386
386
386
388
388
388
392
392
392
392
VII
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Air and Noise
IX EFFLUENT REDUCTION ATTAINABLE THROUGH THE
APPLICATION OF BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE EFFLUENT LIMITATIONS
GUIDELINES
GENERAL
PRIOR REGULATIONS
REGULATED POLLUTANTS
IDENTIFICATION OF THE BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE
BAT EFFLUENT LIMITATIONS
RATIONALE FOR THE SELECTION OF BEST AVAILABLE
TECHNOLOGY ECONOMICALLY ACHIEVABLE
NON WATER QUALITY IMPACTS
X NEW SOURCE PERFORMANCE STANDARDS
GENERAL
PRIOR REGULATION
REGULATED POLLUTANTS
IDENTIFICATION OF THE TECHNOLOGY BASIS OF NSPS
NSPS EFFLUENT LIMITATIONS
RATIONALE FOR THE SELECTION OF NSPS
METHODOLOGY USED FOR THE DEVELOPMENT OF NSPS
Data Base
Calculation of Subcategory Long Term Average
EFFLUENT VARIABILITY ANALYSIS
Effluent Limitations Guidelines
Data Base
Variability Factors
Daily Variability Factors
30-Day Variability Factor
COST OF APPLICATION AND EFFLUENT REDUCTION BENEFITS
NON-WATER QUALITY IMPACTS
XI PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
GENERAL
PRIOR REGULATION
REGULATED POLLUTANTS
IDENTIFICATION OF PRETREATMENT STANDARDS FOR
EXISTING AND NEW SOURCES
RATIONALE FOR THE SELECTION OF PRETREATMENT
STANDARDS FOR EXISTING AND NEW SOURCES
392
393
393
393
394
394
394
394
400
401
401
401
402
402
402
402
405
405
406
406
413
413
413
413
414
416
416
419
419
419
420
420
420
viii
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COST OF APPLICATION
NON-WATER QUALITY IMPACTS
XII ACKNOWLEDGEMENTS
XIII REFERENCES AND BIBLIOGRAPHY
XIV GLOSSARY
APPENDIX A - COSTS OF TREATMENT AND CONTROL SYSTEMS
421
421
423
425
445
451
IX
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SECTION I
1-1
1-2
1-3
1-4
LIST OF TABLES
TITLE
BPT Effluent Limitations
BAT Effluent Limitations
BAT Allowances
New Source Performance Standards
PAGE
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TITLE
SECTION III
III-l Geographical Distribution
Textile Mill Products Major Industrial Group
III-2 General Statistics
Textile Mill Products Major Industrial Group
III-3 Water Use and Wastewater Discharge Statistics
Textile Mill Products Major Industrial Group
III-4 Survey Status Summary-Mills on Master List
III-5 Geographical Distribution-Mills on Master List
III-6 Production Size-Mills on Master List
III-7 Wastewater Discharge-Mills on Master List
III-8 Discharge Type-Mills on Master List
PAGE
19
20
22
23
25
26
27
28
XI
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TITLE
SECTION IV
IV-1
IV-2
IV-3
Median Untreated Wastewater Characteristics
Comparison of Raw Wastewater Characteristics
of Selected Subcategories and Industry Segments
Comparison of Raw Wastewater Characteristics
of Selected Subcategory Segments
PAGE
68
71
73
xii
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TITLE
PAGE
SECTION V
V-l Water Discharge Rate-Summary of
Historical Data
V-2 Water Discharge-Summary of Historical Data
V-3 Water Discharge-Estimated Subcategory Totals
V-4 Industry Responses to Toxic Pollutants List
Summary of All Mills
V-5 Summary of Mill Characteristics and Sample
Collection Field Sampling Program
V-6 Summary of Analytical Results Toxic Pollutant
Sampling Program-Water Supply
V-7 Toxic Pollutants Detected in Textile Mill
Untreated Wastewaters
V-8 Summary of Analytical Results Toxic Pollutant
Sampling Program-Untreated Wastewater and
Biologically Treated Effluent
V-9a Summary of Analytical Results Toxic Pollutants
Sampling Program-Wool Scouring SUbcategory
V-9b Summary of Analytical Results Toxic Pollutant
Sampling Program-Wool Finishing Subcategory
V-9c Summary of Analytical Results Toxic Pollutant
Sampling Program-Low Water Use Processing
(General Processing) Subcategory
V-9d Summary of Analytical Results Toxic Pollutant
Sampling Program-Low Water Use Processing
(Water-Jet Weaving) Subcategory
V-9e Summary of Analytical Results Toxic Pollutant
Sampling Program-Woven Fabric Finishing
(Simple Processing) Subcategory
V-9f Summary of Analytical Results Toxic Pollutant
Sampling Program-Woven Finishing
(Complex Processing) Subcategory
97
98
100
102
107
113
115
120
126
129
131
132
133
135
XI11
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V-9g
V-9h
V-9i
V9-J
V-9k
V-91
V-9m
V-9n
V-10
V-ll
V-12
V-13
V-14
V-15
TITLE PAGE
Summary of Analytical Results Toxic Pollutant 137
Sampling Program-Woven Fabric Finishing
(Desizing) Subcategory
Summary of Analytical Results Toxic Pollutant 140
Sampling Program-Knit Fabric Finishing
(Simple Processing) Subcategory
Summary of Analytical Results Toxic Pollutant 142
Sampling Program-Knit Fabric Finishing
(Complex Processing) Subcategory
Summary of Analytical Results Toxic Pollutant 144
Sampling Program-Knit Fabric Finishing
(Hosiery Products) Subcategory
Summary of Analytical Results Toxic Pollutant 145
Sampling Program-Carpet Finishing Subcategory
Summary of Analytical Results Toxic Pollutant 147
Sampling Program-Stock and Yarn Finishing Subcategory
Summary of Analytical Results Toxic Pollutant 150
Sampling Program-Nonwoven Manufacturing Subcategory
Summary of Analytical Results Toxic Pollutant 151
Sampling Program-Felted Fabric Procesing Subcategory
Summary of Analytical Results Traditionally 159
Monitored Conventional and Nonconventional
Pollutants Field Sampling Program-Water Supply
Raw Waste Characteristics 160
Untreated Wastewater Concentrations Traditionally 184
Monitored Conventional and Nonconventional Pollutants
Historical Data-Median Values
Mass Discharge Rates for Untreated Wastewater 185
Traditionally Monitored Conventional and Nonconventional
Pollutants Historical Data-Median Values
Summary of Analytical Results-Raw Waste Concentrations 187
Traditionally Monitored Pollutants-Field Sampling Program
Untreated Wastewater Concentrations Traditionally 190
Monitored Conventional and Nonconventional Pollutants
xiv
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V-16
V-17
V-18
V-19
TITLE PAGE
Field Sampling Data-Median'Values
Raw Waste Mass Discharge Traditionally Monitored 191
Pollutants Filed Sampling Program
Mass Discharge Rates for Untreated Wastewater 194
Traditionally Monitored Conventional and Nonconventional
Pollutants Field Sampling Data-Median Values
Typical Untreated Wastewater Concentrations Traditionally 195
Monitored Conventional and Nonconventional Pollutants
Summary of Historical and Field Sampling Data
Typical Mass Discharge Rates for Untreated Wastewater 196
Traditionally Monitored Conventional and Nonconventional
Pollutants Summary of Historical and Field Sampling
Data-Median Values
xv
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SECTION VI
VI-1
VI-2
VI-3
VI-4
VI-5
VI-6
TITLE
Summary of Pollutants Controlled by Previous Effluent
Limitations Guidelines
Pollutants Initially Excluded from Regulation
Pollutants Initially Excluded From Regulation
Summary of Toxic Pollutants Potential Concern
Summary of Data Assessment-Pollutants of Potential
Concern
Toxic Pollutants Excluded
PAGE
200
202
204
205
206
211
xvi
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TITLE
PAGE
SECTION VII
VII-1 Mills Reporting In-plant Control Measures-Results 233
of Industry Survey
VI1-2 Wastewater Treatment Status-Wet Processing 239
Mills Surveyed
VII-3 Existing Treatment Technologies-Direct and Zero 241
Discharge Mills
VII-4 Existing Pretreatment Technologies-Indirect Dischargers 242
VII-5 Wastewater Screening By Textile Industry-Results 244
of Industry Survey
VII-6 Wastewater Neutralization By Textile Industry-Results 246
of Industry Survey
VII-7 Wastewater Equalization By Textile Industry-Results of 247
Industry Survey
VI1-8 Performance of Aerated Lagoons in the Treatment 249
of Traditionally Monitored Pollutants
VI1-9 Performance of Aerated Lagoons in the Treatment 251
of Toxic Pollutants Woven Fabric Finishing Mills (Simple)
VII-10 Performance of Aerated Lagoons in the Treatment for 252
Toxic Pollutants Woven Fabric Finishing Mills (Complex)
VII-11 Performance of Aerated Lagoons in the Treatment 253
of Toxic Pollutants Knit Fabric Finishing Mills (Simple)
VI1-12 Performance of Activated Sludge in the Treatment 258
of Traditionally Monitored Pollutants
VI1-13 Performance of Activited Sludge in the Treatment of 262
Toxic Pollutants Wool Scouring Mills
VII-14 Performance of Activated SLudge in the Treatment of 263
Toxic Pollutants Wool Finishing Mills
VI1-15 Performance of Activated Sludge in the Treatment of 265
Toxic Pollutants Low Water use Processing Mills (General)
VI1-16 Performance of Activated Sludge in the Treatment of 266
xvn
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TITLE
PAGE
Toxic Pollutants Woven Fabric Finishing Mills (Simple)
VI1-17 Performance of Activated Sludge in the Treatment of 267
Toxic Pollutants Woven Fabric Finishing Mills (Complex)
VI1-18 Performance of Activated Sludge in the Treatment of 268
Toxic Pollutants Woven Fabric Finishing Mills (Desizing)
VII-19 Performance of Activated Sludge in the Treatment of 272
Toxic Pollutants Knit Fabric Finishing Mills (Simple)
VI1-20 Performance of Activated SLudge in the Treatment of 273
Toxic Pollutants Knit Fabric Finishing Mills (Complex)
VII-21 Performance of Activated Sludge in the Treatment of 274
Toxic Pollutants Knit Fabric Finishing Mills (Hosiery)
VII-22 Performance of Activited Sludge in the Treatment of 275
Toxic Pollutants Carpet Finishing Mills
VII-23 Performance of Activated Sludge in the Treatment of 276
Toxic Pollutants Stock and Yarn Finishing Mills
VII-24 Performance of Activated Sludge in the Treatment of 278
Toxic Pollutants Felted Fabric Finishing Mills
VI1-25 Performance of Activated Sludge in the Removal 279
of Color
VII-26 Use of Stabilization Lagoons By Textile Industry- 283
Results of Industry SUrvey
VII-27 Performance of Stabilization Lagoons in the Treatment 285
of Traditionally Monitored Pollutants
VII-28 Performance of Chemical Coagulation in the Treatment 288
of Traditionally Monitored Pollutants
VI1-29 Case 1 - Laboratory Study of Chemical Coagulation on 289
Dyehouse Effluent
VI1-30 Case 2 - Laboratory Study of Chemical Coagulation on 289
a Printing Waste System
VII-31 Case 3 - Full Scale Coagulation at a Knit Fabric 291
Finishing Mill
XVlll
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TITLE PAGE
VII-32 Full Scale Chemical Coagulation at a Woven Fabric 293
Finishing (Desizing) Mill
VII-33 Full Scale Chemical Coagulation at a Stock and Yarn 294
Finishing Mill
VII-34 Summary of Results-EPA/Industry Field Studies Chemical 296
Coagulation at Wool Finishing Mills Traditionally
Monitored Pollutants
VI1-35 Summary of Results-EPA/Industry Field Studies Chemical 297
Coagulation at Wool Finishing Mills Toxic Pollutants
VII-36 Summary of Results-EPA/Industry Field Studies Chemical 298
Coagulation Traditionally Monitored Pollutants
VII-37 Summary of Results-EPA/Industry Field Studies Chemical 299
Coagulation Toxic Pollutants
VII-38 Effectiveness of Lime and Sulfide in the Precipitation of 301
Toxic Metals From the Untreated Wastewater of a Knit
Fabric Finishing Mill
VI1-39 Case 2 - Ozonation of Tufted Carpet Dye Wastewater 303
Summary of Results
VII-40 Summary of Results Ozonation of Textile Effluents 305
Traditionally Monitored Pollutants (Wool Scouring Mills)
VII-41 Summary of Results Ozonation of Textile Effluents 306
Toxic Pollutants (Wool Scouring Mills)
VII-42 Summary of Results Ozonation of Textile Effluents
Traditionally Monitored Pollutants (Other Mills)
VII-43 Summary of Results Ozonation of Textile Effluents
Toxic Pollutants (Other Mills)
VII-44 Effluent Concentrations from Textile Mills Using
Filtration as a Final Treatment Step
VII-45 Case 1 - Biosystem and Multimedia Filter Summary of
Analytical Results Conventional, Noncbnventional, and
Toxic Pollutants
307
308
311
312
VII-46 Case 2 - Biosystem and Reator/Clarifier-Dual Media Filter 314
xix
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VII-47
TITLE
Summary of Analytical Results Conventional, Nonconven-
tional, and Toxic Pollutants
Case 3 - Biosystem and Dual Media Filter Summary of
Analytical Results Conventional, Nonconventional, and
Toxic Pollutants
PAGE
315
VII-48 Case 4 - Multimedia Filter Summary of Analytical Results 317
Conventional, Nonconventional, and Toxic Pollutants
VII-49 Case 5 - Reactor/Clarifier and Multimedia Filter Summary 318
of Analytical Results Conventional, Nonconventional, and
Toxic Pollutants
VI1-50 Case 6 - Sand Filter Summary of Analytical Results 319
Conventional, Nonconventional, and Toxic Pollutants
VII-51 Summary of Analytical Results Multimedia Filtration 321
(After Clarification) Traditionally Monitored Pollutants
Wool Scouring Mills
VII-52 Summary of Analytical Results Multimedia Filtration 322
{After Clarification) Toxic Pollutants Wool Scouring Mills
VII-53 Summary of Analytical Results Multimedia Filtration 323
(First Treatment Step) Traditionally Monitored Pollutants
Wool Finishing Mills
VII-54 Summary of Analytical Results Multimedia Filtration 324
(First Treatment Step) Toxic Pollutants Wool
Finishing Mills
VII-55 Summary of Analytical Results Multimedia 325
Filtration (After Chemical Coagulation)
Traditionally Monitored Pollutants Wool
Finishing Mills
VII-56 Summary of Analytical Results Multimedia Filtration 326
(After Chemical Coagulation) Toxic Pollutants Wool
Finishing Mills
VII-57 Summary of Analytical Result Multimedia Filtration 327
(First Treatment Step) Traditionally Monitored
Pollutants Other Mills
xx
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TITLE
PAGE
VII-58 Summary of Analytical Results Multimedia Filtration 328
(First Treatment Step) Toxic Pollutants Other Mills
VII-59 Summary of Analytical Results Multimedia Filtration 329
(With Precoagulant) Traditionally Monitored Pollutants
other Mills
VII-60 Summary of Analytical Results Multimedia Filtration 330
(With Precoagulant) Toxic Pollutants Other Mills
VII-61 Summary of Analytical Results Multimedia Filtration 331
(After Chemical Coagulation) Traditionally Monitored
Pollutants Other Mills
VII-62 Summary of Analytical Results Multimedia Filtration 332
(After Chemical Coagulation) Toxic Pollutants Other
Mills
VII-63 Summary of Analytical Results Case 1 - Dissolved Air 337
Flotation Unit Conventional, Nonconventional, and Toxic
Pollutants
VII-64 Summary of Analytical Results Case 2 - Dissolved Air 339
Flotation Unit Conventional, Nonconventional, and Toxic
Pollutants
VII-65 Summary of Analytical Results Case 3 - Dissolved Air 340
Flotation Conventional, Nonconventional, and Toxic
Pollutants
VII-66 Summary of Analytical Results Granular Activated Carbon 345
Adsorption Traditionally Monitored Pollutants Wool
Scouring Mills
VII-67 Summary of Analytical Results Granular Activated Carbon 346
Adsorption Toxic Pollutants Wool Scouring Mills
VII-68 Summary of Analytical Results Granular Activated Carbon 347
Adsorption Traditionally Monitored Pollutants Wool
Finishing Mills
VII-69 Summary of Analytical Results Granular Activated Carbon 348
Adsorption Toxic Pollutants Wool Finishing Mills
VI1-70 Summary of Analytical Results Granular Activated Carbon 349
Adsorption Traditionally Monitored Pollutants Other Mills
xxi
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TITLE PAGE
VII-71 Summary of Analytical Results Granular Activated Carbon 351
Adsorption Toxic Pollutants Other Mills
VI1-72 Summary of Analytical Results Case 1 - Pact Process 353
Conventional, Nonconventional, and Toxic Pollutants
VI1-73 Summary of Analytical Results Case 2 - Pact Process 354
Toxic Pollutants
VI1-74 Summary of Analytical Results Case 3 - Pact Process 354
Traditionally Monitored Conventional and Nonconven-
tional Pollutants
VI1-75 Summary of Analytical Results Powdered Activated Carbon 356
Treatment Traditionally Monitored Conventional and
Nonconventional Pollutants Wool Scouring Mills
VII-76 Summary of Analytical Results Powdered Activated Carbon 358
Treatment Traditionally Monitored Conventional and
Nonconventional Pollutants Wool Finishing Mills
VI1-77 Summary of Analytical Results Powdered Activated Carbon 360
Treatment Traditionally Monitored Conventional and
Nonconventional Pollutants Other Mills
VI1-78 Long Term Effluent Concentrations 72 Selected 366
Treatment Facilities
VI1-79 Median Long Term Average Treated Effluent Concentrations 368
VI1-80 Biological Treatment Effluent Concentrations Average 369
of Field Sampling Data
VI1-81 Summary of Pollutant Removals for Add-on Components of 370
Control Options Wool Scouring Mills
VII-82 Summary of Pollutant Removals for Add-on Components 371
of Control Options Wool Finishing Mills
VII-83 'Summary of Pollutant Removals of Control Options 372
All Other Mills
VI1-84 Long Term Average Effluent Characteristics 374
Option 1 - Biological Treatment
VI1-85 Long Term Average Effluent Characteristics 376
Option 2 - Biological Treatment Plus Multimedia
xxii
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TITLE
Filtration
VI1-86 Long Term Average Effluent Characteristics
Option 3 - Biological Treatment Plus Chemical
Coagulation
VI1-87 Long Term Average Effluent Characteristics
Option 4 - Biological Treatment Plus Chemical
Coagulation Plus Multimedia Filtration
VII-88 PSES and PSNS-Option 2
Chemical Coagulation Precipitation
Effluent Characteristics
PAGE
379
381
384
xxiii
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TITLE
SECTION VIII
VIII-1 BPT Effluent Limitations
VIII-2 Calculation of BPT Limitations Water Jet
Weaving Subdivision
VI1-3 Comparison of Raw Waste Loads Felted Fabric
Processing and Nonwoven Manufacturing Subcategories
VIII-4 Calculation of BPT Limitations Felted Fabric
Processing and Nonwoven Manufacturing Subcategories
PAGE
387
389
390
391
xxiv
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TITLE
SECTION IX
IX-1
IX-2
BAT Effluent Limitations
BAT Allowances
PAGE
395
396
XXV
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SECTION X
X-l
X-2
X-3
X-4
X-5
TITLE
New Source Performance Standards
Long Term Average Effluent Discharge Biological
Treatment (72 Plant) Data Base
Calculation of NSPS Long Term Average
Maximum Day Variability Factors Lognormal Data
Distribution
Maximum 30-Day Average Variability Factors for
BOD5., TSS, and COD
PAGE
403
407
410
415
417
xxvi
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TITLE
APPENDIX
A-l Treatment and Control Options
A-2 Model Mill Cost Summary
A-3 Installed Equipment and Construction Investment
Costs for Component Technologies
A-4 Annual Operation and Maintenance Man-hours
A-5 Annual Maintenance Materials Costs
A-6 Estimated Annual Sludge Quantities for
Component Technologies
A-7 Estimated Annual Power Requirements for
Component Technologies
A-8 Estimated Annual Cnemical Costs for
Component Technologies
A-9 Model Plant Control Cost Summary
PAGE
452
453
477
481
483
484
485
489
493
XXVll
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LIST OF FIGURES
TITLE
SECTION III
III-l Wastewater Treatment Status-Wet Processing
Mills on Master List
III-2 Fibers Used in the Manufacture of Textiles
III-3 Subcategory 1: Typical Wool Scouring
Process Flow Diagram
III-4 Subcategory 2: Typical Wool Fi.nish.ing
Process Flow Diagram
III-5 Subcategory 3: Typical Low Water Use Processing
Process Flow Diagram
III-6 Subcategory 4: Typical Woven Fabric Finishing
Process Flow Diagram
III-7 Subcategory 5: Typical Knit Fabric Finishing
Process Flow Diagram
III-8 Subcategory 6: Typical Carpet Finishing
Process Flow Diagram
II1-9 Subcategory 7: Typical Stock and Yarn Finishing
Process Flow Diagram
IH-10 Subcategory 8: Typical Nonwoven Manufacturing
Process Flow Diagram
III-l1 Subcategory 9: Typical Felted Fabric Processing
Process flow Diagram
Section VII
VII-1 Detention time vs_ Aearation Horsepower Per Unit
Volume of Basin Plants with Activated Sludge Technology
APPENDIX A
A-l
A-2
A-3
Textile Industry BAT Review Treatment Cost
Computation Sheet
Screening - Installed Cost
Equalization - Installed Cost
PAGE
29
31
53
55
56
58
59
60
61
63
64
261
461
462
463
XXVlll
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A-4
A-5
A-6
A-7
A-8
A-9
TITLE
Activated Sludge - Installed Cost
Chemical Coagulation - Installed Cost
Vacuum Filtration - Installed Cost
Multimedia Filtration - Installed Cost
Dissolved Air Flotation - Installed Cost
Granular Activated Carbon - Installed Cost
PAGE
464
465
466
467
468
469
A-10
A-11
A-12
A-13
A-14
A-15
A-16
Powdered Activated Carbon-Installed Cost
Ozonation-Installed Cost
Estimated Engineering Compensation
Cost for Hauling and Disposing Dewatered Sludge
Alternative A: Screening and Extended Aeration
Activated Sludge Investment and Annual Costs
for Existing Mills
Alternative B: Chemical Coagulation/Sedimentation
Investment and Annual Costs for Existing Mills
Alternative C: Multimedia Filtration Investment
and Annual Costs for Existing Mills
470
471
479
488
494
495
496
A-17
A-18
A-19
A-20
A-21
Alternative D: Chemical Coagulation/Sedimentation
and Multimedia Filtration Investment and Annual
Costs for Existing Mills
Alternative E: Multimedia Filtration and Granular
Activated Carbon Investment and Annual Cost for
Existing Mills
Alternative F: Chemical Coaulgation/Sedimentation,
Multimedia Filtration, and Granular Activated Carbon
Investment and Annual Costs for Existing Mills
Alternative G: Ozonation Investment and Annual
Costs for Existing Mills
Alternative H: Chemical Coagulation/Sedimentation and
Ozonation Investment and Annual costs for Existing Mills
497
498
499
500
501
XXIX
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TITLE
SECTION VII
A-22
A-23
A-24
A-25
A-26
A-27
Alternative I: Powdered Activated Carbon Addition
To Biological Treatment Investment and Annual
Costs for Existing Mills
Alternative J: Multimedia Filtration and Ozonation
Investment and Annual Costs for Existing Mills
Alternative K: Chemical Coagulation/Sedimentation,
Multimedia Filtration and Ozonation Investment and
Annual Costs for Existing Mills
Alternative M: Chemical Coagulation and Dissolved
Air FLoatation Investment and Annual costs for
Existing Mills
Alternative N: chemical Coagulation, Dissolved Air
Floatation, Multimedia Filtration, and Granular
Activated Carbon Investment and Annual Costs for
Existing Mills
Alternative P: Chemical coagulation, Dissolved Air
Floatation and Ozonation Investment and Annual
Costs for Existing Mills
PAGE
502
503
504
505
506
507
XXX
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SECTION I
EXECUTIVE SUMMARY
SUBCATEGORIZATION
For the purpose of establishing effluent limitations guidelines
for existing sources, standards of performance for new sources
and pretreatment standards for new and existing sources, the
textile mills point source category has been subcategorized as
follows:
Wool Scouring
Wool Finishing
Low Water Use Processing (formerly Dry Processing)
Woven Fabric Finishing
Knit Fabric Finishing
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
The subcategorization scheme from previous rulemaking was
reviewed, taking into account all available information. Factors
such as age, size of plant, location, raw material, process
employed, products and waste treatability were considered in
reviewing the adequacy of the original subcategorization scheme.
This review resulted in the establishment of a new subdivision of
an existing subcategory (water jet weaving in the low water use
processing subcategory) and two new subcategories (nonwoven
manufacturing and felted fabric processing).
The water jet weaving subdivision of the low water use processing
subcategory (formerly the dry processing subcategory) has been
established to account for mills using this new process. The
nonwoven manufacturing and felted fabric processing subcategories
have been added to account for these distinct processing
operations.
In the woven fabric finishing subcategory, simple, complex and
desizing subdivisions have been developed for NSPS that reflect
those processing differences. For BAT, allowances for complexity
of processing, fiber type and commission finishing remain the
same as for BPT effluent limitations.
Also, the knit fabric finishing subcategory has been subdivided
into simple, complex, and hosiery products subdivisions for NSPS
to reflect these processing differences. For BAT, as in the
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woven fabric finishing subcategory, allowances for complexity of
processing, fiber type and commission finishing remain the same
as for BPT.
EFFLUENT LIMITATIONS
BPT
BPT effluent limitations are established for the nonwoven
manufacturing and the felted fabric finishing subcategories and
for the water jet weaving subdivision of the low water use
processing subcategory. These limitations control three
conventional pollutants (BOD£, TSS and pH), three nonconventional
pollutants (COD, sulfide and total phenols) and one toxic
pollutant (total chromium). BPT limitations are presented in
Table 1-1 in terms of kilograms of pollutant per 1000 kilograms
of product (lb/1000 Ibs). Product is defined as the final
material produced or processed at the mill.
BPT for the water jet weaving subdivision of the low water use
processing subcategory is based on the average performance of two
water jet weaving mills where biological treatment is employed.
BPT for the nonwoven manufacturing and felted fabric processing
subcategories is based on the transfer of technology from the
carpet finishing and wool finishing subcategories, respectively,
because those subcategories have similar waste characteristics.
BAT
BAT effluent limitations control toxic and nonconventional
pollutants and are equal to BPT effluent limitations. Therefore,
BAT effluent limitations have the same technology basis as BPT,
biological treatment. The toxic pollutant total chromium and the
nonconventional pollutants, COD, total phenols and sulfide (as
measured by the procedures listed in 40 CFR Part 136) are
regulated in all subcategories except low water use processing.
The nonconventional pollutant chemical oxygen demand (COD) is
regulated in all subcategories. BAT effluent limitations are
presented in Table 1-2. Additional discharge allowances for COD
in the woven fabric finishing, knit fabric finishing and carpet
finishing subcategories based on complexity of processing and
fiber type are presented in Table 1-3.
In all subcategories except wool scouring and wool finishing,
limitations for total chromium, total phenols, sulfide and COD
are presented on a mass basis in terms of kilograms of pollutant
per 1000 kilograms of product (lbs/1000 Ibs). Product is defined
as the final material produced or processed at the mill. In the
wool scouring subcategory, limitations are presented on a mass
basis in terms of kilograms of pollutant per 1000 kilograms
(lbs/1000 Ibs) of wool. Wool is defined as the dry raw wool as
it is received by the wool scouring mill. In the wool finishing
subcategory, limitations are presented on*a mass basis in terms
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Subcategory
Low Water Use Processing
Water Jet Weaving
Nonwoven Manufacturing
Felted Fabric Processing
CO
TABLE 1-1
BPT EFFLUENT LIMITATIONS*
Maximum
any one
BODS
8.9
4.4
15.2
Conventional
for
day
TSS
5.5
6.2
55.4
Pollutants
Average of daily values
for 30 consecutive days
BODS TSS
4.6 2.5
2.2 3.1
17.6 27.7
pH shall be within the range 6.0 to 9.0 at all times.
Toxic and Nonconventional Pollutants
Subcategory
Low Water Use Processing
Water Jet Weaving
Nonwoven Manufacturing
Felted Fabric Processing
Maximum for
any one day
Total
COD Sulfide Phenols Chromium
Average of daily values
for 30 consecutive days
COD
Sulfide Phenols
Total
Chromium
21.3 — — — 13.7
40.0 0.046 0.023 0.023 20.0 0.023
256.8 0.44 0.22 0.22 128.4 0.22
Expressed as kg pollutant/kkg of product (lb/1000 Ib)
0.011
0.11
0.011
0.11
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TABLE 1-2
BAT EFFLUENT LIMITATIONS*
Subcategory
Wool Scouring**
Wool Finishing**
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing**
Knit Fabric Finishing**
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Maximum for any one day
COD
138.0
163.0
2.8
21.3
60.0
60.0
70.2
84.6
40.0
256.0
Sulfide
0.20
0.28
-
0.20
0.20
0.08
0.24
0.046
0.44
Phenols
0.10
0.14
-
0.10
0.10
0.04
0.12
0.023
0.22
Total
Chromium
0.10
0.14
_
0.10
0.10
0.04
0.12
0.023
0.22
Average of daily values
for 30 consecutive days
COD
69.0
81.5
1.4
13.7
30.0
30.0
35.1
42.3
20.0
128.4
Sulfide
0.10
0.14
-
0.10
0.10
0.04
0.12
0.023
0.22
Phenols
0.05
0.07
-
0.05
0.05
0.02
0.06
0.011
0.11
Total
Chromium
0.05
0.07
-
0.05
0.05
0.02
0.06
0.011
0.11
* Expressed as kg pollutant/kkg of product (lb/1000 Ib) except for wool scouring, which is
expressed as kg pollutant/kkg of wool processed and wool finishing which is expressed as kg
pollutant/kkg of fiber processed.
** For commission finishers, an additional allocation of 100% of the limitations is allowed.
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TABLE 1-3
BAT ALLOWANCES*
CHEMICAL OXYGEN DEMAND (COD)
Simple Manufacturing Operations
employing a synthetic fiber or
complex manufacturing operations
employing a natural fiber.
Woven Fabric Finishing
Simple Manufacturing Operations
employing a natural and synthetic
fiber blend or complex manufacturing
operations employing a synthetic
fiber.
Woven Fabric Finishing
Knit Fabric Finishing
Complex manufacturing Operations
employing a natural and synthetic
fiber blend.
Woven Fabric Finishing
Knit Fabric Finishing
Complex Manufacturing Operations
Carpet Finishing
Maximum for
any one day
Average of daily values
for 30 consecutive days
20.0
40.0
20.0
60.0
40.0
20.0
10.0
20.0
10.0
30.0
20.0
10.0
* Ojiantities of pollutant which may be discharged by a point source in addition to
the BAT limitations in Table 1-1.
-------
of kilograms of pollutant per 1000 kilograms of fiber. Fiber is
defined as the dry wool and other fibers as received at the wool
mill for processing into wool and blended fibers.
NSPS
NSPS are based on the performance of the best performing
biological treatment systems currently in place at textile mills.
Three conventional pollutants (BOD5., TSS and pH) and one
nonconventional pollutant (COD) are regulated in all
subcategories. One toxic pollutant (total chromium) and the two
nonconventional pollutants (total phenols and sulfide) are
regulated in all but the low water use processing subcategory,
NSPS are presented in Table 1-4.
PSES and PSNS
Categorical pretreatment standards have not been promulgated for
existing and new indirect dischargers. The textile mills point
source category is subject only to General Pretreatment
Regulations (40 CFR Part 403).
-------
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing
Simple Operations
Complex Operations
Desizing
Knit Fabric Finishing
Simple Operations
Complex Operations
Hosiery Products
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
TABLE 1-4
NEW SOURCE PERFORMANCE STANDARDS*
CONVENTIONAL POLLUTANTS**
Maximum for any one day
BODS TSS
Average of daily values
for 30 consecutive days
3.6
10.7
1.4
8.9
3.3
3.7
5.5
3.6
4.8
2.3
4.6
3.6
2.6
16.9
30.3
32.3
1.4
5.5
8.8
14.4
15.6
13.2
12.2
8.4
8.6
9.8
4.9
50.9
BODS
TSS
1.9
5.5
0.7
4.6
1.7
1.9
2.8
1.9
2.5
1.2
2.4
1.9
1.4
8.7
13.5
14.4
0.7
2.5
3.9
6.4
6.9
5.9
5.4
3.7
3.8
4.4
2.2
22.7
* Expressed as kg pollutant/kkg of product (lb/1000 Ib) except for wool scouring which is
expressed as kg pollutant/kkg of wool processed and wool finishing which is expressed as
kg pollutant/kkg of fiber processed.
#* For all subcategories, pH within the range 6.0 to 9.0 at all times.
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TABLE 1-4 (coat'd)
NEW SOURCE PERFORMANCE STANDARDS*
TOXIC AND NUNCONVENTIONAL POLLUTANTS
Subcategory
Maximum for any one day
Average of daily
for 30
values
consecutive days
Total
Wool Scouring
Wool Finishing
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing
Simple Operations
Complex Operations
•Desizing
Knit Fabric Finishing
Simple Operations
Complex Operations
Hosiery Products
Carpet Finishing
Stock and Yarn finishing
No 11 wo ven Manufacturing
Felted Fabric Manufacturin
COD
52.4
113.8
2.8
21.3
41.7
68.7
59.5
48.1
51.0
30-7
26.6
33.9
15.2
g 179.3
SuUide
0.20
0.28
-
-
0.20
0.20
0.20
0.20
0.20
0.20
0.08
0.24
0.046
0.44
Phenols
0
0
0
0
0
0
0
0
.10
.14
-
-
.10
.10
.10
.10
.10
.10
0.04
0
0
0
.12
.023
.22
Total
ChroaiuB
0
0
0
0
0
0
0
0
0
0
0
0
.10
.14
-
-
.10
.10
.10
.10
.10
.10
.04
.12
.023
.22
COD
33
73
1
13
26
44
38
31
32
19
17
21
9
115
.7
.3
.4
.7
.9
.2
.3
.0
.9
.8
.1
.9
.8
.5
Sulfide
0.10
0.14
-
-
0.10
0.10
0.10
0.10
0.10
0.10
0.04
0.12
0.023
0.22
Total
Phenols
0.05
0.07
-
-
0.05
0.05
0.05
0.05
0.05
0.05
0.02
0.06
0.011
0.11
Total
Chromium
0.05
0.07
-
-
0.05
0.05
0.05
0.05
0.05
0.05
0.02
0.06
0.011
0.11
Expressed as kg pollutant/kkg of product (lb/1000 Ib) except for wool scouring which
is expressed as kg pollutant/kkg of wool processed and wool finishing which is
expressed as kg pollutant/kkg of fiber processed.
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SECTION II
INTRODUCTION
PURPOSE AND AUTHORITY
The Federal Water Pollution Control Act Amendments of 1972
established a comprehensive program to "restore and maintain the
chemical, physical, and biological integrity of the Nation's
waters " (Section 101(a)). By July 1, 1977, existing industrial
dischargers were required to achieve "effluent limitations
requiring the application of the best practicable control
technology currently available (BPT)," [Section 301(b)(1)(A)].
By July 1, 1983, these dischargers were required to achieve
"effluent limitations requiring the application of the best
available technology economically achievable (BAT), which will
result in reasonable further progress toward the national goal of
eliminating the discharge of pollutants," [Section 301(b)(2)(A)).
New industrial direct dischargers were required to comply with
Section 306, new source performance standards (NSPS), based on
best available demonstrated technology. New and existing
dischargers to publicly owned treatment works (POTWs) were
subject to pretreatment standards under Sections 307(b) and (c)
of the Act. While the requirements for direct dischargers were
to be incorporated into National Pollutant Discharge Elimination
System (NPDES) permits issued under Section 402 of the Act,
pretreatment standards were made enforceable directly against
dischargers to POTWs (indirect dischargers).
Although Section 402(a)(l) of the 1972 Act authorized the setting
of requirements for direct dischargers on a case-by-case basis in
the absence of regulations, Congress intended that, for the most
part, control requirements would be based on regulations
promulgated by the Administrator of EPA. Section 304(b) of the
Act required the Administrator to promulgate regulations
providing guidelines for effluent limitations setting forth the
degree of effluent reduction attainable through the application
of BPT and BAT. Moreover, Sections 304(c) and 306 of the Act
required promulgation of regulations for NSPS, and Sections
304(f), 307(b) and 307(c) required promulgation of regulations
for pretreatment standards. In addition to these regulations for
designated industry categories, Section 307(a) of the Act
required the Administrator to promulgate effluent standards
applicable to all dischargers of toxic pollutants. Finally,
Section 501(a) of the Act authorized the Administrator to
prescribe any additional regulations "necessary to carry out his
functions" under the Act.
The Agency was unable to promulgate many of these toxic pollutant
regulations and guidelines within the time periods stated in the
Act. In 1976, EPA was sued by several environmental groups and,
in settlement of this lawsuit, EPA and the plaintiffs executed a
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"Settlement Agreement," which was approved by the Court. This
Agreement required EPA to develop a program and adhere to a
schedule for promulgating, for 21 major industries, BAT effluent
limitations guidelines, pretreatment standards and new source
performance standards for 65 "priority" pollutants and classes of
pollutants. [See Natural Resources Defense Council, Inc. v.
Train, 8 ERC 2120 (D.D.C. 1976), modified, 12 ERC 1833 (D.D.C.
1979).] On December 27, 1977, the President signed into law the
Clean Water Act of 1977. Although this law makes several
important changes in the federal water pollution control program,
its most significant aspect is its incorporation into the Act of
many of the basic elements of the Settlement Agreement program
for toxic pollution control. Sections 301{b)(2)(A) and (b)(2)(C)
of the Act now require the achievement by July 1, 1984, of
effluent limitations requiring application of BAT for "toxic"
pollutants, including the 65 "priority" pollutants and classes of
pollutants which Congress declared "toxic" under Section 307(a)
of the Act. Likewise, EPA's programs for new source performance
standards and pretreatment standards are now aimed principally at
toxic pollutant control. Moreover, to strengthen the toxics
control program, Congress added a new Section 304(e) to the Act,
authorizing the Administrator to prescribe what have been termed
"best management practices" (BMPs) to prevent the release of
toxic pollutants from plant-site runoff, spillage or leaks,
sludge or waste disposal and drainage from raw material storage
associated with, or ancillary to, the manufacturing or treatment
process.
In keeping with its emphasis on toxic pollutants, the Clean Water
Act of 1977 also revises the control program for nontoxic
pollutants. Instead of BAT for "conventional" pollutants
identified under Section 304(a)(4) (including biological oxygen
demanding pollutants, suspended solids, fecal coliform and pH),
the new Section 301(b)(2)(E) requires achievement by July 1,
1984, of "effluent limitations requiring the application of the
best conventional pollutant control technology" (BCT). The
factors considered in assessing BCT include the reasonableness of
the relationship between the costs of attaining a reduction in
effluents and the effluent reduction benefits derived, and the
comparison of the cost and level of reduction for an industrial
discharge with the cost and level of reduction of similar
parameters for a typical POTW [Section 304(b)(4)(B)]. For
nontoxic nonconventional pollutants, Sections 301(b)(2)(A) and
301 (b)(2)(F) require achievement of BAT effluent limitations
within three years after their establishment, but not later than
July 1, 1987.
The purpose of this document is to describe the development of
effluent limitations guidelines for BPT, BAT, NSPS and
pretreatment standards for existing and new sources (PSES and
PSNS) under authority of Sections 301, 304, 306 and 307 of the
Clean Water Act.
10
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PRIOR EPA REGULATIONS
BPT, BAT, NSPS and PSNS were originally promulgated for the
textile mills category in 1974. Industry representatives
challenged these limitations in the Fourth Circuit Court of
Appeals. In response to a joint motion of petitioners and EPA to
hold the case in abeyance while EPA reconsidered the BAT
limitations, the Court remanded all the regulations except BPT to
EPA for reconsideration. In the joint motion, petitioners
withdrew their challenge to the BPT limitations and therefore,
those limitations are presently in effect. As a result of the
court order, the Agency and the American Textile Manufacturers
Institute (ATMI) began a joint study to collect information and
data necessary to reconsider the BAT, NSPS, PSES and PSNS
regulations. PSES were promulgated in 1977 (42 FR 26979; May 26,
1977) .
The regulations supported by this document include BPT for two
new subcategories and one new subdivision and revised BAT, NSPS,
PSNS and PSES for all subcategories and subdivisions.
OVERVIEW OF THE INDUSTRY
The United States textile industries are covered by two of the
twenty major groups of manufacturing industries in the Standard
Industrial Classification (SIC). They are Textile Mill Products,
Major Group 22, and Apparel and Other Textile Mill Products,
Major Group 23. According to the SIC, the Textile Mill Products
group includes 30 separate industries that manufacture
approximately 90 classes of products. The Apparel and Other
Textile Products group includes 33 separate industries that
manufacture some 70 classes of products.
The original Textile Mills Point Source Category Development
Document (1) published in 1974 covers those facilities classified
in Major Group 22. These facilities are principally engaged in
receiving and preparing fiber; transforming this material into
yarn, thread or webbing; converting the yarn and webbing into
fabric or related products; and finishing these materials at
various stages of the production. Many of the facilities produce
a final consumer product such as thread, yarn, bolt fabric,
hosiery, towels, • sheets and carpet. The balance of the
facilities produce a transitional products for use by other
establishments in Major Groups 22 and 23,
The facilities in Major Group 23, Apparel and Other Textile Mill
Products, are principally engaged in receiving woven or knitted
fabric for cutting, sewing and packaging. Some of the products
manufactured are dry cleaned and some undergo auxiliary
processing to prepare them for the consumer. In general, the
processing is dry and no process-related wastewater is generated.
11
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Exact figures for the number of wet-processing mills or the total
number of mills in the textile industry are difficult to
establish because of the relatively large numbers involved, the
dynamic state of the industry and differing classification
criteria. Published reports and surveys place the first figure
(wet processing) around 2,000 mills and the total mills between
5,000 and 7,500. Nearly 80 percent of the facilities are located
in the Mid-Atlantic and Southern regions of the U.S. The
remaining 20 percent are distributed nearly equally between the
New England region and the North Central and Western regions.
SUMMARY OF METHODOLOGY
The data and technical findings presented in this document were
developed by performing the following major tasks:
1. Collecting, reviewing and evaluating existing information
including: the administrative record from previous effluent
guidelines development studies; historical wastewater data
from EPA regional offices, state water pollution control
agencies and municipalities; the literature; current
research projects; and information available from textile
trade associations.
2. Profiling the industry with regard to age, production,
geographic location, type of discharge, raw materials,
production processes, final products, in-plant controls,
end-of-pipe treatment practices and wastewater data.
3. Reviewing the existing industry categorization and
developing a revised categorization, where appropriate, to
accommodate any previously unidentified segments of the
industry.
4. Conducting a screening sampling program to determine
qualitatively which of the 129 toxic pollutants appear in
textile industry raw wastewaters and treated effluents.
5. Developing, distributing and retrieving 308 data collection
portfolios (DCPs) to update the existing data base.
6. Conducting a verification wastewater sampling program to
confirm the presence of the toxic pollutants identified in
the screening sampling program and to establish the
effectiveness of in-place and pilot-scale advanced treatment
technologies in removing toxic pollutants.
7. Organizing, analyzing and interpreting the data collected in
each task area to establish an updated administrative
record.
12
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8. Establishing the alternative in-plant control measures and
end-of-pipe treatment technologies that will result in the
elimination or reduction of pollutant discharge from the
industry.
9. Estimating the capital and the annual costs and
effectiveness of the alternative control measures and
treatment technologies for representative mills in each
subcategory of the industry.
10. Identifying technologies, developing the methodology and
establishing the effluent limitations and standards that can
be achieved in each subcategory of the industry.
DATA AND INFORMATION GATHERING PROGRAM
Previous Data Collection Activities
The collection, review and evaluation of existing information was
the initial major task performed. This task provided the
starting point for subsequent activities and established the
extent of effort that was to be required in each of the other
tasks. The review of literature and evaluation of current
research projects continued throughout the project.
308 Data Request
The 308 data request (Data Collection Portfolio (DCP) - Industry
Survey) was performed to update the existing data base. The
survey involved the following activity: 1) developing a master
list of textile mills thought to have wet-manufacturing
operations; 2} contacting mills on the master list by letter to
outline the purpose and intent of the survey; 3) contacting mills
on the master list by telephone to assess the value of available
wastewater information and to gather basic facility information;
4) distributing detailed DCPs; and 5) retrieving and analyzing
the DCPs.
In developing the master list of wet-manufacturing facilities,
consideration was given to several sources of information. These
sources included the Standard Industrial Classification (SIC),
the Census of. Manufactures, data collected during previous
textile industry studies, information from trade associations,
and information in a commercial directory, "Davison's Textile
Blue Book" (8). Examination of the various sources and knowledge
gained from previous studies indicated that the directory
provided the most useful and most current information. It was
reviewed and each facility listed was tentatively classified as
either a wet- or dry-manufacturing facility. Of 5,500 mills
listed in the directory, approximately 2,900 were initially
classified as dry manufacturing and 2,600 were classified as wet
manufacturing. Wet-manufacturing facilities were further studied
13
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to determine if additional subcategorization based on product,
raw materials, production processes and type of processing
equipment would be appropriate. Information necessary to
identify and contact each wet-manufacturing facility was
computerized and used to develop the master list.
A telephone survey of those mills originally classified as having
wet-manufacturing reduced the number of mills on the master list
to 1,973 because many turned out to be dry-manufacturing
facilities or were no longer in the textile manufacturing
business. Information on selected low water use mills was
obtained by means of a separate general survey. General survey
information was replaced by detailed survey information obtained
from the DCPs for the wet-manufacturing facilities that noted the
availability of historical wastewater data. DCPs were received
from 538 wet-manufacturing mills and an additional 573 mills
provided general survey information. The information obtained
from both types of surveys was computerized. It provides the
best general representation of the textile industry developed to
date and serves as the basis for this document and the resulting
regulation.
Mill Visits
Visits to 25 mills were made during the initial data gathering
program to develop an understanding of the current operating
practices used in the textile industry. Raw materials,
production processes, final products, in-plant controls and
end-of-pipe treatment technologies were examined and the
information obtained was added to existing information about the
industry. Visits to 53 mills (including 15 of the 25 noted
above) were made in conjunction with the wastewater sampling
program. Information similar to that noted above was obtained
during these visits.
Raw Materials Review
The raw materials used to manufacture textile products include
various natural and manmade fibers and a wide variety of organic
and inorganic chemicals and chemical products. The types and
nature of these fibers and chemicals are discussed under "Profile
of Manufacturing" in Section III. Current information about the
raw materials was obtained from the literature, from industry
trade associations, from manufacturers of the materials and from
the mills surveyed and visited.
Screening and Verification Sampling
The wastewater sampling program conducted to characterize textile
industry wastewater with respect to the 129 toxic pollutants was
performed in two phases. The first phase (screening) was
conducted between February and October of 1977. During this
phase, 12,446 data points were obtained by collecting 98 samples
14
-------
from 40 mills. The second phase (verification) was conducted
between September 1977 and March 1980. During this phase, 38,227
data points were obtained by collecting 301 samples from 24
mills. A total of 53 individual mills was sampled during the
study, some in both phases of the sampling program.
During both phases, mill visits were made before the actual
sampling to obtain process information and make the necessary
arrangements for the sampling crews. The samples collected were
analyzed by either a private laboratory under contract to EPA or
by one of several EPA laboratories. The sampling and analytical
procedures employed in all phases followed recommended EPA
procedures. A detailed discussion of the sampling and analytical
methods is included in the record.
The screening phase of the wastewater sampling program was
designed to identify which of the toxic pollutants were present
in textile industry untreated wastewaters and treated effluents.
During this phase, the source water, untreated wastewater and
treated effluent at each mill were sampled to determine
qualitatively which pollutants were present.
The verification phase consisted of sampling waste streams and
treated effluents to determine the amount of the toxic pollutants
identified in the screening phase that are present in textile
industry wastewaters. In addition to this objective, sampling
was also conducted to determine the effectiveness of in-place
treatment technologies and pilot-scale advanced treatment
technologies in removing toxic, nonconventional and conventional
pollutants. The pilot-scale data were obtained on biologically
treated effluents at 19 of the mills sampled during the screening
phase by utilizing one of two mobile pilot plants. Each pilot
plant contained the following treatment systems: chemical
coagulation/clarification, multimedia filtration, activated
carbon adsorption and ozonation. Bench-scale dissolved air
flotation studies also were performed on the waste at some of
these mills.
Processing of Data and Information
The data collected as part of the evaluation of existing
information, the DCP requests and the wastewater sampling program
were processed and analyzed. Most of the data were processed
electronically. Information obtained from the DCPs provides the
basis for the industry profile presented in Section III and the
industry subcategorization presented in Section IV. Historical
and current wastewater monitoring data were used to establish the
typical raw waste and treated effluent characteristics for each
subcategory (See Section V). Subsequent to the October 1979
proposal, we found that additional data, especially daily
monitoring data, were needed in order to determine accurately the
performance of wastewater treatment systems. Therefore, EPA
requested and received from ten mills daily results of treatment
15
-------
technology performance for the most recent full year of
operation. The historical data and the full-scale and
pilot-scale field sampling results were used to determine the
effectiveness of the control and treatment technologies available
to the industry (Section VII) and to provide information related
to the design and costing of those technologies (Appendix A).
These data and information, along with the findings of separate
environmental and economic impact analyses, were evaluated to
develop the effluent limitations guidelines, new source
performance standards and pretreatment standards presented in
Sections VIII through XI.
16
-------
SECTION III
DESCRIPTION OF THE INDUSTRY
This section presents a detailed profile of the textile industry
and a discussion of the unit manufacturing processes used by the
industry.
GENERAL DESCRIPTION
The United States textile industries are covered by two of the
twenty major groups of manufacturing industries in the Executive
Office of the President - Bureau of the Budget's Standard
Industrial Classification (SIC). They are Textile Mill Products,
Major Group 22, and Apparel and Other Textile Mill Products,
Major Group 23. The Textile Mill Products group includes 30
separate industries that manufacture approximately 90 classes of
products. The Apparel and Other Textile Products group includes
33 separate industries that manufacture some 70 classes of
products.
The textile mills point source category effluent limitations
guidelines and standards (40 CFR Part 410) apply to facilities in
Major Group 22. The facilities are engaged principally in:
receiving and preparing fibers; transforming these materials into
yarn, thread or webbing; converting the yarn and webbing into
fabric or related products; and finishing these materials. Many
facilities produce a final consumer product such as thread, yarn,
bolt fabric, hosiery, towels, sheets and carpet, while the rest
produce a transitional product for use by other establishments in
Major Groups. 22 and 23.
The facilities in Major Group 23, Apparel and Other Textile Mill
Products, are involved principally in receiving woven or knitted
fabric for cutting, sewing and packaging. Some of the products
manufactured are dry cleaned and some undergo auxiliary
processing to prepare them for the consumer. In general, the
processing is dry and no process related wastewater is generated.
Profile of Major Group 22_
Exact figures for the number of wet processing mills or the total
number of mills in the textile industry are difficult to
establish because of their relatively large number, the dynamic
state of the industry and differing classification criteria.
Published reports (1, 3, 4, 5, 6) and surveys (7, 8) over the
past ten years estimate the number of wet processing mills at
approximately 2,000, and the total mills at between 5,000 and
7,500. A U.S. Department of Commerce Publication, Census of
Manufactures (Census) provided the most structured and inclusive
the
information. Reports from the 1977
developing the general profile (7).
Census were used
in
17
-------
A breakdown of the textile mill products group by SIC code (major
product class) and region (geographic location) is provided in
Table III-l. The information in this table was taken from
preliminary statistics developed for the 1977 Census.
Approximately 16 percent of the known facilities had not yet been
assigned to a specific region. Assignments for these facilities
were not specified to avoid disclosing operations of individual
companies and to avoid further verification of data for smaller
producing states. Nearly 77 percent of the facilities for which
the locations are specified are located in the Middle-and South-
Atlantic regions. Of the remaining 23 percent of the specified
facilities, approximately 10 percent are located in the New
England region, approximately six percent are located in the
Pacific region, approximately four percent are located in the
East South Central region and approximately one and one-half
percent each are located in the East North Central and West South
Central regions. Only a few facilities are in the West North
Central region. Many mills, particularly yarn manufacturing,
weaving and carpet manufacturing, are concentrated in a few
southeastern states.
The geographic distribution of mills is based in part on historic
considerations. The textile industry in this country began in
the northeast and spread south because of that region's cotton
production. Although synthetics have replaced cotton as the
primary raw material in recent years, the southeast continues to
be the center of the textile industry.
General statistics regarding number of establishments, number of
employees and economics of manufacture are presented in Table
III-2 for the textile mill products group. The Standard
Industrial Classification system (SIC) identifies nine major
product classes. Of these nine classes (three digit SIC Codes),
three have been subdivided to present information for the
industry segments that are of primary concern here and are most
likely to be affected by the development of effluent limitations
guidelines, new source performance standards and pretreatment
standards.
Knitting Mills (SIC 225) is the largest single major product
class in terms of number of establishments with 36 percent of the
industry total. These mills employ 25 percent of all textile
workers and the value of their shipments is 18 percent of the
industry total. Weaving mills (SIC 221), yarn and thread mills
(SIC 228), finishing mills (SIC 226) and floor covering mills
(SIC 227) follow knitting mills in terms of number of
establishments and number of employees. The number of facilities
manufacturing felt goods, nonwoven goods and scoured wool is
small relative to the rest of the industry. Combined, these
three subdivisions accounted for less than three percent of the
employees and three percent of the value of shipments, based on
data available for the period prior to 1977.
18
-------
TABLE III-l
GEOGRAPHICAL DISTRIBUTION
TEXTILE MILL PRODUCTS MAJOR INDUSTRIAL GROUP
Region
221 222 223
SIC Code
224 225 226
227 228 229
22
New England
Middle Atlantic
East North
West North
Central
Central
South Atlantic
East South
West South
Central
Central
5
36
3
-
163
31
10
50
74
-
-
230
16
12
60
36
2
3
14
1
8
91
112
6
-
87
12
-
38
1149
8
-
760
63
-
91
245
9
-
193
19
1
5
32
5
2
381
19
12
74
113
5
-
454
63
3
169
343
56
5
213
38
35
Mountain Division - - - - - - - - '-
Pacific
Unspecified
Total
*
20
46
314
26
41
449
7
34
165
11
16
335
73
498
2589
41
79
678
71
65
592
19
67
798
92
303
1254
583
2140
94
10
2495
262
81
0
360
1149
7174
Census incomplete at time distribution was prepared; not all facilities
have been assigned to a region to avoid disclosing operations of indi-
vidual companies and to permit further verification of data for smaller
producing states.
Notes: New England
Middle Atlantic
East North Central
West North Central
South Atlantic
East South Central
West South Central
Mountain Division
Pacific
- ME, NH, VT, MA, RI, CT
- NY, NJ, PA
- OH, IN, IL, MI, WI
* MN, IA, MO, ND, SD, NB, KS
- DE, MD, DC, VA, WV, NC, SC, GA, FL
- KT, TN, AL, MS
- AR, LA, OK, TX
- MT, ID, CO, NM, AZ, UT, NV
- WA, OR, CA, AK, HI
221 - Weaving Mills, Cotton 226
222 - Weaving Mills, Synthetic 227
223 - Weaving & Finishing Mills, Wool 228
224 - Narrow Fabrics Mills 229
225 - Knitting Mills (Incl, Finishing) 22
Source: 1977 Census of Manufacturers
19
Textile Finishing, Exc. Wool & Knits
Floor Covering Mills
Yarn & Thread Mills
Miscellaneous Textile Goods
Textile Mill Products
-------
ro
CD
TABLE III-2
GENERAL STATISTICS
TEXTILE MILL PRODUCTS MAJOR INDUSTRIAL GROUP
Industry Segment
SIC Code
Establishments Employees
Total 20+ Employees (1000's)
Value Added Value of
by Manufacture Shipments
(million dollars/year)
Weaving Mills, Cotton
Weaving Mills, Synthetics
Weaving & Finishing Mills,
Wool
Narrow Fabrics Mills
Knitting Mills (+ Finishing)
Hosiery Mills
All Other Knitting Mills
Finishing Mills (Except
Wool & Knits)
Broadwoven Fabric
Stock, Yarn, Narrow Fabric
Floor Covering Mills
Yarn & Thread Mills
Miscellaneous Textile Goods
Felt Goods
Nonwoven Goods
Wool Scouring & NEC Goods
Other Miscellaneous
Products
Total Industry-All Segments
All Group No.
All Group No.
All Group No.
All Group No.
All Group No.
2251, 2252
2253, 2254,
2258, 2259
All Group No.
2261, 2262
2269
All Group No.
All Group No.
All Group No.
2291
2297
2299
2292, 2293,
2295, 2296,
Major Group No
221
222
223
224
225
2257
226
227
228
229
2294"
2298
. 22
314
449
165
335
2589
613
1976
678
495
183
592
798
1254
46
100
436
672
7174
192
351
84
182
1491
375
1116
395
283
112
285
608
523
27
74
90
332
4048
117.2
151.0
14.6
20.8
230.7
58.7
172.0
72.1
58.0
14.1
55.8
140.4
67.8
4.3
13.0
6.7
43.8
914.2
1944
2791
313
351
3720
818
2902
1417
1143
274
1530
2261
1641
103
386
109
1043
17011
4431
6326
583
683
9222
1790
7431
3995
3164
831
4775
6114
4174
198
864
231
2881
52405
NEC = Not Elsewhere Classified
Source: 1977 Census of Manufacturers
-------
Water use and wastewater discharge statistics for the nine major
product classes and their subdivisions are provided in Table III-
3. Because this information has not yet been compiled from the
1977 Census data, the values were developed from the 1972 Census.
Because of this, and because the Census reports these statistics
only for establishments that discharge 75,700 cubic meters (20
million gallons) per year or more, the numbers of establishments
do not correspond between Tables III-2 and III-3. The value of
shipments, which are provided in each table, give a good
indication of the significance of the establishments covered in
Table III-3. The average value of shipments for the facilities
covered by Table III-3 constituted approximately 50 percent of
the industry total in 1972, while the average number of
establishments represented only about 10 percent of the total
mills in the industry at that time.
Based on the 1977 Census, the industries in Major Group 22 employ
over 900,000 persons and manufacture goods valued at over 52
billion dollars annually. According to the 1972 Census,
approximately 600 million cubic meters (160 billion gallons!of
process wastewater is discharged annually.
Industry Survey (308 Data Request)
The industry survey discussed in Section II provided specific
information about the facilities in Major Group 22. A primary
result of the survey was compilation of a master list of the wet
processing facilities in the industry. A breakdown of those
facilities is presented in Table III-4. The manufacturing
segments listed correspond to the recommended subcategorization
of the industry for purposes of effluent limitation guidelines,
new source performance standards and pretreatment standards.
There are 1,165 mills in the nine wet processing classifications
and 808 mills classified as low water use processing operations.
Detailed survey information was received for 537 of the wet
processing mills, with 574 mills providing general survey
information. Wet processing activities at the remaining 54
locations could not be confirmed.
Just over two-thirds of the wet processing facilities finish
either woven or knit fabrics (including hosiery). Stock and yarn
finishing mills comprise nearly one-fifth of the wet processing
facilities; wool goods processing, carpet manufacturing and
nonwoven manufacturing and felted fabric processing together each
comprise approximately five percent. Detailed surveys provide
information on more than one-third of the mills in each wet
processing segment.
Low water use processing operations were surveyed separately from
the wet processing mills; 315 detailed survey responses were
obtained from a random sample of approximately half of the mills
initially classified as low water use operations.
21
-------
ro
ro
Industry Segment
TABLE III-3
WATER USE AND WASTEWATER DISCHARGE STATISTICS
TEXTILE MILL PRODUCTS MAJOR INDUSTRIAL GROUP
Value of
Establish- Shipments Water Use#
,6
Wastewater Discharge
Indirect Direct
ments"
$/yr)
cu m/yr) (1Q cu m/yr) (10 cu m/yr)
Weaving Mills, Cotton
Weaving Mills, Synthetics
Weaving & Finishing Mills, Wool
Narrow Fabrics Mills
Knitting Mills (+ Finishing)
Hosiery Mills
All Other Knitting Mills
Finishing Mills (Except Wool & Knits)
Broadwoven Fabric
Stock, Yarn, Narrow Fabric
Floor Covering Mills
Yarn & Thread Mills
Miscellaneous Textile Goods
Felt Goods
Nonwoven Goods
Wool Scouring & Goods NEC
Other Miscellaneous Products
Total Industry - All Segments
96
113
32
10
162
47
115
139
93
46
65
101
70
7
10
13
40
788
2058
2179
277
87
2357
459
1898
1852
1463
389
1868
1907
1328
64
140
74
1050
13913
35.2
51.9
22,0
0.8
88.9
5.7
83.3
169.6
141.9
27.3
58.7
39.0
15.5
1.5
4.9
3.8
5.3
481.6
22.0
28.4
11.4
1.1
84.8
9.1
75.7
78.3
53.0
25.4
43.5
30.7
20.8
0.8
2.3
3.4
14.4
321.0
26.9
48.1
13.6
0.4
25.7
0.0
25.7
105.2
100.7
4.5
23.8
27.6
12.1
1.5
3.4
2.3
4.9
283.4
* Only includes locations with greater than 7.57 x 10 cu m/yr discharge.
# Process water not including recirculated flow.
NEC = Not Elsewhere Classified
Source: 1972 Census of Manufactures
-------
TABLE III-4
SURVEY STATUS SUMMARY - MILLS ON MASTER LIST
ro
CO
Manufacturing Segment
Wool Scouring
Wool Finishing
Low Water Use Processing
Woven Fabric Finishing
Knit Fabric Finishing
Hosiery Finishing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
SIC Codes
Covered
2299
223
221, 222, 224, 2295
2296, 2298
2261, 2262
2253, 2254, 2257
2258, 2259, 2292
2251, 2252
227
2269
2297
2291
Total Mills
Listed
17
37
808
336
280
162
58
217
38
20
1973
Survey Status*
Detailed General No Response
13
19
315
151
113
58
37
121
14
11
852
4
15
15
158
155
103
18
90
23
8
589
0
3
478#
27
12
1
3
6
1
1
532
* A "detailed" survey status signifies that a detailed survey questionnaire (308 portfolio), was ob-
tained. A "general" survey status signifies that a telephone survey questionnaire only was obtained,
A "no response" survey status signifies that while contact was attempted, and in some cases made,
no response was obtained.
# A random sample of approximately 50 percent of the low water use processing segment was surveyed,
so this value represents facilities that were not surveyed as well as facilities that did not
respond to the surveys.
Source: EPA Industry Surveys, 1977 & 1980.
-------
The geographic distribution of the industry survey responses is
shown in Table III-5. The distribution confirms observations
made previously regarding Major Group 22. Over half of the wet
processing facilities are located in the southeast (EPA Region
IV), principally in the Carolinas and Georgia. Another 25
percent are located in the northeast (EPA Regions I and II).
Less than 5 percent of the mills are located in the west (EPA
Regions VI through X).
Table III-6 illustrates the rang-e of plant sizes (in terms of
production exposed to wet processing). Wet production is
dependent on the weight of material in the final product.
Therefore, mills producing lightweight products such as hosiery
and other sheer knit goods occupy the smaller production ranges
while mills manufacturing heavyweight woven goods (upholstery,
drapery fabric and carpet) occupy the larger production ranges.
Variation in production is substantial even within individual
manufacturing segments as evidenced by the fact that all but two
segments have production ranges of two to three orders of
magnitude. The woven fabric finishing segment is the largest,
with almost twice as many facilities than any other segment,
processing greater than 22,000 kg/day (48,000 Ib/day).
Wastewater discharge quantities, discharge type (direct or
indirect) and general treatment status are illustrated in Tables
III-7 and III-8 and Figure III-l, respectively. Table III-7
illustrates the distribution of discharge volume for the mills in
each segment of manufacturing. Each segment shows variation in
discharge from two to four orders of magnitude. The largest
dischargers are in the woven fabric finishing manufacturing
segment, which has almost 50 percent of the mills discharging
greater than 3,785 cu in/day (1.0 mgd). The smallest discharges
are associated with hosiery finishing, nonwoven manufacturing and
felted fabric processing facilities with 87, 76 and 90 percent of
the facilities, respectively, discharging less than 1,890 cu
m/day (0.5 mgd).
Based on the results of the industry survey, it is estimated that
over three-fourths of the wet processing facilities in the
industry discharge process wastewater to POTWs. Table II1-8
illustrates the numbers of mills on the master list that are
known to be direct dischargers, indirect dischargers or zero
discharge facilities. At one extreme, 95 percent of the hosiery
mills discharge to POTWs (indirect discharge), while on the other
extreme, less than 30 percent of the wool scouring mills
discharge to POTWs.
Figure III-l illustrates the type of wastewater treatment
provided by direct and indirect dischargers. Over half of the
indirect dischargers provide no treatment of process wastewater,
while slightly less than 10 percent provide treatment processes
equivalent to, or better than biological treatment. Over two-
thirds of the direct dischargers provide biological treatment.
24
-------
TABLE III-5
GEOGRAPHICAL DISTRIBUTION - MILLS ON MASTER LIST
Manufacturing
Segment
EPA Region All
I II III IV V VI VII VIII IX X Regions
Wool Scouring
Wool Finishing
Low Water Use
Processing
Woven Fabric
Finishing
Knit Fabric
Finishing
Hosiery
Finishing
Carpet
Finishing
Stock & Yarn
Finishing
Nonwoven
Manufacturing
Felted Fabric
Processing
All Segments
6
20
86
69
27
2
0
33
10
7
260
1
2
108
54
57
2
1
19
3
2
249
3
4
125
34
45
9
4
31
4
3
262
3
3
463
155
133
141
39
120
11
3
1071
0
1
11
11
9
5
1
6
7
2
53
3
1
8
3
1
2
4
3
2
0
27
0
1
1
1
2
0
0
1
0
0
6
0
1
0
2
0
0
0
0
0
0
3
0
0
4
7
6
0
9
4
1
3
34
1
4
2
0
0
1
0
0
0
0
8
17
37
808
336
280
162
58
217
38
20
1973
Notes :
EPA Region I
EPA Region II
EPA Region III
EPA Region IV
EPA Region V
ME,NH,VT,MA,RI,CT EPA Region VI
NY,NJ EPA Region VII
PA,WV,VA,MD,DE EPA Region VIII
KY,TN,NC,SC,MS,AL,GA,FL EPA Region IX
MN,WI,MI,IL,IN,OH EPA Region X
NM,TX,OK,AR,LA
NE,KS,IA,MO
MT,ND,SD,WY,U!,CO
CA,NV,AZ,HI
AK,WA,OR,ID
Source: EPA Industry Surveys, 1977 & 1980.
25
-------
Manufacturing
Segment
0-2 2-4
TABLE III-6
PRODUCTION SIZE - MILLS ON MASTER LIST
Mills Within Given Production Range, kkg/day
4-9 9-13 13-22 22-34 34-45 45-68 68-91
Un- All
91+ known* Mills
Wool Scouring
Wool Finishing
Low Water Use
Processing
Woven Fabric
Finishing
Knit Fabric
ro -r,. . , .
01 Finishing
Hosiery Finishing
Carpet Finishing
Stock & Yarn
Finishing
Nonwoven
Manufacturing
Felted Fabric
Processing
All Segments
2
8
10
36
42
94
2
32
3
6
235
3
9
7
27
26
26
2
47
3
5
155
0
9
11
33
34
10
7
35
2
2
143
1
2
19
28
29
5
3
23
4
1
115
4
1
23
33
48
2
8
25
3
0
147
2
2
21
21
21
0
5
20
5
0
97
2
2
7
20
7
0
6
6
2
0
52
2
0
5
12
9
0
7
7
2
1
45
0
0
3
9
5
0
5
1
0
0
23
0
0
2
21
1
0
5
2
1
0
32
1
4
700
96
58
25
8
19
13
5
929
17
37
808
336
280
162
58
217
38
20
1973
* Reflects the fact that many of the facilities surveyed by telephone were reluctant to provide pro-
duction information.
Source: EPA Industry Surveys, 1977 & 1980.
-------
Manufacturing
Segment
TABLE III-7
WASTEWATER DISCHARGE - MILLS ON MASTER LIST
2
Mills Within Given Discharge Range, 10 cu m/day (mgd)
0-0.36 0.36-3.70 3.70-18.9 18.9-37.8 37.8-94.6 94.6-378
(0-0.009) (0.010-0.099)(0.10-0.49) (0.50-0.99) (1.0-2.4) (2.5-10.0)
Un- All
known* Mills
Wool Scouring
Wool Finishing
Low Water Use Processing
Woven Fabric Finishing
Knit Fabric Finishing
ro Hosiery Finishing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
All Segments
0
5
243
48
38
57
2
27
16
7
443
10
8
60
65
60
70
7
61
7
1
349
5
10
23
71
68
13
17
70
6
10
293
1
4
0
33
44
0
16
25
2
0
125
1
5
1
35
26
0
9
18
0
0
95
0
0
0
19
3
0
0
1
0
0
23
0
5
481
65
41
22
7
15
7
2
645
17
37
808
336
280
162
58
217
38
20
1973
* Reflects the fact that many of the facilities surveyed by telephone could not provide an estimate of
their rate of discharge.
Source: EPA Industry Surveys, 1977 & 1980.
-------
Co
Manufacturing
Segment
TABLE III-8
DISCHARGE TYPE - MILLS ON MASTER LIST
Total Mills Mills Reporting Direct Indirect Zero
Listed Discharge Type Dischargers Dischargers Discharge-
Wool Scouring
Wool Finishing
Low Water Use Processing
Woven Fabric Finishing
Knit Fabric Finishing
Hosiery Finishing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
17
37
808#
336
280
162
58
217
38
20
1,973
17
36
309
311
268
161
55
211
37
19
1,424
6
8
26
77
38
7
11
36
5
1
215
10
25
87
226
221
152
42
172
25
14
974
1
3
196
8
9
2
2
3
7
4
235
* Includes mills that recycle wastewater, dispose of wastewater on land (spray irrigation),
send waste to a landfill, use septic tanks, place wastewater into nondischarging
holding ponds, or have waste hauled from mill site by a private contractor.
# Only 408 of these mills were surveyed.
Source: EPA Industry Surveys, 1977 & 1980.
-------
FIGURE III-l
WASTEWATER TREATMENT STATUS - WET PROCESSING MILLS ON MASTER LIST*
NO
TREATMENT
PRELIMINARY
TREATMENT
NUMBER
OF MILLS
BIOLOGICAL OR
EQUIVALENT TREATMENT
ADVANCED
TREATMENT
504
ro
40
Includes neutraliza-
tion, screening,
equalization, heat
exchange, disinfec-
tion, preliminary
sedimentation,
and/or flotation.
289
15
-500-
400—
—300—
—200 —
— 100 —
Includes aerated and
unaerated lagoons,
biological filtra-
tion, activated
sludge, chemical
coagulation/floccu-
lation without
preceeding biologi-
cal treatment.
148
77
Includes activated
carbon, chemical
coagulation follow-
ing biological
treatment, ozona-
tion, filtration,
ion exchange, mem-
brane processes,
etc.
18
DIRECT INDIRECT DIRECT INDIRECT DIRECT INDIRECT DIRECT INDIRECT
*0f the 1,973 mills on the master list, the figure does not include 808 mills classified as "Low Water Use
Processing," 57 mills that could not be contacted, and 16 wet processing mills for which the treatment
could not be classified.
Source: EPA Industry Survey, 1977.
-------
Direct dischargers without treatment are predominantly mills
waiting to connect to POTWs presently in the design or
construction phases.
UNIT MANUFACTURING (INDUSTRIAL) PROCESSES
The textile industry (SIC Major Group 22) consists of an
estimated 6,000 manufacturing facilities. These facilities are
engaged in various processing operations which transform fiber,
the industry's basic raw material, into yarn, fabric or other
finished textile products. Approximately 70 percent of the
facilities perform manufacturing operations that require no
process water and an additional 10 percent use only small
quantities of process water. In contrast, the remaining 20
percent of the facilities that scour wool fibers, clean and
condition other natural and man-made fibers and dye or finish
various textile products generally require large quantities of
process water. The remainder of this section discusses the
principal raw materials utilized by the industry, final products
manufactured by the industry and the processing operations
required to manufacture those products. Emphasis is placed on
operations and products requiring large quantities of process
water.
Raw Materials
A variety of natural and man-made fibers are used in the
manufacture of textiles. Presently, wool, cotton and various
man-made fibers (e.g., nylon, polyesters and rayon) are the basic
fibers used.
The term "synthetic" often is used synonymously with the term
"man-made" when referring to fiber. There is, however, a
technical distinction. As shown in Figure III-2, man-made fibers
consist of two major groups: the synthetic fibers (noncellulosic)
and the natural polymers (regenerated) group. Synthetic fibers
are usually synthesized from simple monomers while natural
polymer fibers are manufactured from naturally occurring raw
materials. The major portion of the man-made fibers produced are
synthetic fibers, with a lesser amount of regenerated fibers
produced. Because the term "synthetic" commonly is used to refer
to all man-made fibers, this terminology has been adopted for
this document.
In 1977, wool consumption by the industry (computed on a scoured
basis) was approximately 0.05 billion kilograms (0.11 billion
pounds), cotton consumption was approximately 1.6 billion
kilograms (3.5 billion pounds) and synthetic fiber consumption
was approximately 4.0 billion kilograms (8.8 billion pounds) (9).
Other fibers such as animal hair, silk and glass also are used by
the industry, but consumption is insignificant in comparison to
wool, cotton or synthetic fiber.
30
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FIGURE III-2
FIBERS USED IN THE MANUFACTURE OF TEXTILES (9,10)
FIBERS
NATURAL FIBERS
MAN-MADE FIBERS
VEGETABLE
ORIGIN
COTTON
JUTE
ANIMAL
ORIGIN
WOOL
ANIMAL HAIR
SILK
MINERAL
ORIGIN
ASBESTOS
METALS
GLASS
1
NATURAL POLYMERS
(REGENERATED)
(CELLULOSIC)
1
I
RAYON
CELLULOSE
ACETATE
PROTEIN
SYNTHETICS
(NON-CELLULOSIC)
1
1
t
1
1
POLYAMIDES
(NYLON)
POLYESTERS
POLYACRYLONITRILES
POLYVINYL
DERIVATIVES
MISCELLANEOUS
OTHER
-------
Cotton and wool are supplied in staple (short fiber) form while
the synthetic fibers are supplied as either staple or continuous
filament. The steps required to prepare these fibers for
processing are dependent on fiber type.
Wool Raw wool, depending on the breed and habitat of the sheep
from which it is obtained/ may contain from 30 to 70 percent
natural and acquired impurities such as grease, soluble salts
(suint) and dirt (10). Thorough scouring of this fiber prior to
spinning and other processing is necessary, and there are a
number of mills in the industry that perform this function only.
Cotton Consumption of cotton exceeded that of any other single
fiber in 1977. Cotton is a much cleaner raw fiber than wool and
initial fiber preparation consists only of dry operations such as
opening, picking, carding, combing and drawing to mechanically
remove vegetable matter and other impurities and to align the
fibers for spinning.
Synthetics Total synthetic fiber consumption was two and one-half
times greater than cotton consumption in 1977. Noncellulosic
fibers, including nylon (polyamides), acrylics, modacrylics and
particularly polyester, are used more extensively than cellulosic
fibers. Major cellulosic fibers are rayon and cellulose acetate.
Synthetic fibers are much cleaner than cotton fibers, eliminating
the need for the extensive dry fiber preparation processes used
with cotton.
Manor Dry oj: Low Water Use Processes
Depending on the primary fiber type, a variety of production
processes are used to manufacture the various products of this
industry. In general, the dry or low water use processing
operations precede the wet processing operations in the
manufacturing sequence.
Spinning Spinning is the process by which fiber is converted
into yarn or thread. It is performed after initial fiber
preparation and consists of drawing out the fibers, twisting them
into yarn and winding the newly made yarn onto a bobbin, cone or
other suitable holder. This process is completely dry.
Texturizing (modification of physical and surface properties of
yarn by mechanical or chemical means) also may be performed
during yarn manufacture.
Some yarn is dyed and finished as a final consumer product;
however, most manufactured yarn is used within the industry for
tufting, knitting, weaving or other fabric manufacturing.
Tufting Mechanical tufting is the predominant method of
manufacturing carpet. It is performed on large, vertically
positioned needle punch machines (tufting machines) that have
hundreds of needles in a horizontal bank. Multiple ends of yarn
32
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are fed to the bank of needles and the needles pull or loop the
yarns through a woven or nonwoven' backing material, usually made
of polypropylene or jute. The backing moves relative to the
needles to anchor each stitch, and the result is loops that form
the carpet pile. If the loops are cut during the tufting
process, the construction is known as cut pile rather than loop
pile. Tufting is a completely dry operation.
Knitting Knitting is a major method for manufacturing fabrics.
Nearly all hosiery is knit, as well as large amounts of piece
goods, outerwear and underwear. Knitting is accomplished by
interlocking series of loops of one or more yarns using any of a
number of popular stitches and is performed with sophisticated,
high-speed machinery. Although knitting is a completely dry
process, oils usually are applied to the yarn to provide
lubrication during stitching. These oils are removed in
subsequent wet processing and enter the wastewater stream.
Weaving Weaving is the most common method of producing fabrics
in the textile industry, and woven fabrics are used in the
manufacture of numerous consumer and industrial products.
Weaving is performed on any of a number of types of looms which,
generally speaking, cause lengthwise yarns {warp yarns) to
interlace with yarns running at right angles (filling yarns) by
going over and under the filling yarns. A special type of
shuttleless loom, known as a water jet loom, uses a jet of water
to propel the filling yarn. Similarly, an air jet loom, which is
a new weaving technology, uses sequential pulses of air to propel
the filling yarn. With the exception of,water jet"looms, weaving
is a dry operation. However, to prevent warp yarn breakage
caused by friction during the weaving operation, a processing
step known as slashing usually is necessary and a small amount of
wastewater may be generated as a result.
Slashing Slashing consists of coating warp yarns with sizing
compounds to impart tensile strength and smoothness and thus
prevent yarn rupture. It is performed by dipping the yarns
through a box or trough containing the sizing agent. This size
is dried on the yarn and remains until removed in subsequent
operations at a finishing mill. As a result of slashing, the
woven fabric may contain add-ons (sizing compounds) equivalent to
as much as 15 percent of the weight of the fabric (11). The most
common sizing agents are starch, polyvinyl alcohol (PVA),
carboxymethyl cellulose (CMC) and polyacrylic acid (PAA). Starch
traditionally is associated with the sizing of cotton. Slashing
may generate occasional wastewater discharges, usually because of
spillage and the cleaning of slasher boxes, rolls and size makeup
tanks.
Other Fabric Manufacturing
Two other general fabric manufacturing methods, in addition to
the methods previously described, are felted fabric manufacturing
33
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and nonwoven fabric manufacturing. These manufacturing methods
do not involve the use of yarn. Instead, they involve the direct
use of fiber to form a web or continuous sheet of fibers. The
differences between felts and nonwovens are in the types of
fibers used and in the methods of bonding the fibers together
into a fabric.
Traditionally, felt has been made of wool, with manufacture based
on the ability of the scaly structured wool fibers to felt, or
adhere, together naturally. Although use of wool in felts is
still common, the use of synthetics (mostly rayon and polyester)
has increased in recent years. Felts are made by physically
interlocking the fibers through a combination of mechanical
action, chemical action, moisture and heat.
Nonwovens, or webbed textiles as they are sometimes called, are
used in numerous applications, with more uses being discovered as
the relatively new industry expands. They are made of fibers
held together by an applied bonding agent or by the fusing of
self-bonding thermoplastic fibers. This results in a fabric
structure built up from a web or continuous mat of fibers.
Although a number of methods are used to form the web and
accomplish bonding of the fibers, certain operations are basic to
all methods of nonwoven fabric manufacture. These include, in
sequence: (1) preparation of the fiber; (2) web formation; (3)
web bonding; (4) drying; and (5) finishing techniques.
Web formation usually is accomplished by overlaying several
layers of carded fiber or, in the .case of thermal processing,
randomly laying down filament. A less common method of web
formation, called "wet lay," uses water as a transport medium for
the fibers. The fibers, suspended in the water, are deposited
onto a screen, and a web that is carried from the screen by a
large moving belt is formed. Once a nonwoven web is formed, by
any method, bonding usually is achieved by roller padding,
dipping or spraying with adhesives such as acrylic or polyvinyl
acetate resins. A less common bonding method, applicable only to
low melting point fibers, is to fuse the fibers together
thermally.
Adhesive Products Processing Adhesive product processes include
operations such as bonding, laminating, coating and flocking.
These processes are similar in that an adhesive or other
continuous coating is applied to a fabric or carpet in order to
change the original properties. These processes are completely
dry or extremely low in water use, although discharge of the
bonding and adhesive chemicals (often latex compounds) or coating
materials (often polyvinyl chloride) may result from
overspraying, spillage, rinsing and equipment cleanup. Brief
descriptions of the most prevalent adhesive product processes
follow.
34
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Bonding joins two textile materials together permanently by
application of a thin adhesive layer. The process enables
different fabric constructions, colors and textures to be
combined so that performance, appearance and use are extended.
Fabric-to-fabric bonding frequently is performed using either a
wet adhesive {often a water based acrylic compound) or urethane
foam. In wet adhesive bonding, the underside of the first fabric
is coated with adhesive and the second fabric is joined by
passing both fabrics through rollers. The adhesive is cured with
heat to effect a permanent bond. In foam flame bonding, a layer
of urethane foam is passed over a gas flame to make it tacky on
one side. The foam and the first fabric then are joined as they
pass through rollers. The second fabric can be joined to the
other side of the foam layer by repeating the process.
Laminating is similar to bonding except that laminated goods
generally consist of foam or nontextile materials bonded to
fabrics, or thick layers of foam bonded to two fabrics. Carpet
backing, performed to secure the yarns and impart dimensional
stability, is a specialized laminating process. It is achieved
by bonding a foamed latex or jute backing to the underside of the
carpet. Latex adhesives typically are used in both cases. An
alternative to latex adhesives is the application of a hot melt
(thermoplastic) composition.
Fabric coating is an adhesive process that uses various chemicals
and synthetic resins to form a relatively distinct, continuous
film on a base fabric. Polyvinyl chloride (PVC) is the most
common coating for textile fabrics. The coatings may be applied
as a 100 percent "active solids" system either as plastisols
(dispersions of polymer particles in liquid plasticizers) or as
melts (flexible grade polymer plus plasticizer). The plastisols
generally are applied by knife over roll coaters; and the melts
are applied by calenders (rollers). Although coatings of PVC
plastisols and melts are the most common, other substances and
methods also may be used for various reasons. One important
process is the application of latex coating to tire cord fabric.
The loosely woven tire cord fabric is dipped and coated with
latex so that the fabric will bond securely with rubber during
the manufacture of tires.
Flocking is an adhesive process in which short chopped fibers
are applied to an adhesive pattern that has been "preprinted" on
a fabric. In this manner, design areas can be produced on any
type of fabric to resemble embroidery or woven clipped figures.
The process is achieved by spray or electrostatic techniques.
Functional Finishing Functional finishing refers to the
application of a large group of chemical treatments that extend
the function of a fabric by providing it with desirable
properties. Special finishes can be applied to make a fabric
wrinkle resistant, crease retentive, water repellent, flame
resistant, mothproof, mildew resistant, bacteriostatic and stain
35
-------
resistant. Although the range of chemicals used is broad, the
wastewater generated during application usually is relatively
small. The finishes often are applied to the fabric from a water
solution. It is possible to apply several finishes from a single
bath. Application is by means of calenders that transport the
finish from a trough to a roll to the surface of the fabric. The
finish then is dried and cured onto the fabric. The wastewater
sources are bath dumps and cleanup of applicator equipment and
mix tanks.
Wrinkle resistance and crease retention (permanent press) are
achieved by treating the fabric with synthetic resins. The
resins are adhesive in nature and are permanently cross-linked
with the fiber molecules. Durability is achieved by curing with
heat and a catalyst, resulting in a reaction called
polymerization. The actual physical structure of the fabric is
changed and the fabric is said to have obtained a "permanent
memory" of its flat, finished state.
Water repellency is achieved by treating the fabric with
silicones and other synthetic materials. Insoluble soaps and wax
emulsions have been used in the past, but these materials lack
permanency. If properly applied, the silicone treatments can
stand repeated washings or dry cleanings. In addition to water,
the silicones successfully repel oily fluids.
Flame resistant finishes are applied to cellulosic fabrics to
prevent them from supporting combustion. Phosphorus is a
component of most flame retardants, as it is theorized that
oxides of phosphorus combine with water formed at high
temperatures to restrict the production of combustible gases.
Tetrakis (hydroxymethyl) phosphonium chloride (THPC) is the
essential ingredient of many flame retardant formulations.
Mothproofing finishes typically are applied to wool and other
animal hair fibers. Fabric made from these fibers are
impregnated with chemicals that make the fabric unfit as food for
the moth larva. Chemicals such as silicofluoride and chromium
fluoride are used in the formulations.
The growth of mildew, mold, fungus and rot is inhibited by
application of biocides that destroy their growth. Commonly used
compounds contain chlorinated phenols or metallic salts of zinc,
copper or mercury. Hygienic additives also are used to inhibit
the growth of bacteria. These additives prevent odors, prolong
the life of the fabric and also combat mildew, mold and fungus.
Soil release finishes make it possible to remove stains from
fabrics by ordinary washing. Most of the finishes use
organosilicone compounds that are applied by the pad-dry-cure
process. Other soil release finishes in use contain
fluorocompounds or oxazoline derivatives. Soil release finishes
36
-------
produce a hydrophilic state in the fabric and thus make polyester
and polyester blend fabrics less conducive to static collection.
In addition to functional finishing processes, there are a number
of mechanical finishing operations such as calendering, embossing
and napping that change the surface effect of fabric by means of
rollers, pressure, heat or similar actions. These processes can
be performed before or after the chemical treatment but do not
result in wastewater.
Major Wet Processes
Most high water use textile manufacturing processes involve the
conventional finishing of fiber and fabric products. The most
significant processes are desizing, scouring, mercerizing,
bleaching, dyeing and printing. In the case of wool products,
the distinct nature of this fiber often makes additional wet
processing necessary prior to conventional finishing. Additional
specific processes for wool include raw wool scouring,
carbonizing and fulling.
Although the various wet processes are described separately, it
is not uncommon for two or more operations to occur sequentially
in a single batch unit or on a continuous range. For example, it
is common for desizing, scouring and mercerizing operations to be
placed in tandem with the continuous bleaching range to finish
cotton more efficiently. A variety of wet finishing situations
of this type may occur, depending upon factors such as processes
used, type and quality of materials and product and original mill
and equipment design.
Raw Wool Scouring Wool scouring is the first treatment performed
on wool and is employed to remove the impurities peculiar to wool
fibers. These impurities are present in great quantities and
variety in raw wool and include natural wool grease and sweat and
acquired impurities such as dirt, feces and vegetable matter.
Disinfectants and insecticides applied in sheep dips for
therapeutic purposes also may be present. Most of the natural
and acquired impurities in wool are removed in the scouring
process.
Two methods of wool scouring, solvent and detergent, are
practiced in the U. S., although detergent scouring is used
almost exclusively. In the detergent process, the wool is raked
through a series of 5,700 to 11,400 liter (1,500 to 3,000 gallon)
scouring bowls known as a "scouring train." Unless the first bowl
is used as a steeping or desuinting bowl, the first two bowls
contain varying concentrations of either soap and alkali, or
nonionic detergents of the ethylene oxide condensate class. The
soap-alkali scouring baths are generally at a temperature of 46°
to 54<>C (115° to 130°F> and a pH of 9.5 to 10.5; neutral
detergent baths normally have a pH -of 6.5 to 7.5 and a
temperature of 57° to 71°C (135° to 160°F). The last two bowls
37
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of the scouring train are for rinsing and a counterflow
arrangement usually is employed using the relatively clean waters
from these bowls in preceding bowls.
Scouring emulsifies the dirt and grease and produces a brown,
gritty, turbid waste that often is covered with a greasy scum.
It is estimated that for every pound of fibers obtained, one and
one-half pounds of waste impurities are produced. Because the
wool grease present in the scour liquor is not readily
biodegradable and is of commercial value, grease recovery usually
is practiced. In the most typical recovery process, the scour
liquor first is piped to a separation tank where settling of grit
and dirt occurs. The supernatant from the tank then is
centrifuged (one or more stages) into high density, medium
density and low density streams. The high density stream
consists mainly of dirt and grit, and is discharged as waste.
The medium density stream is recycled to the wool scouring train.
The low density stream contains concentrated grease that normally
is refined further to produce lanolin. Acid cracking, utilizing
sulfuric acid and heat, is an alternative method of grease
recovery, but it is not practiced widely at this time.
Carbonizing Carbonizing removes burrs and other vegetable matter
from loose wool or woven wool goods. These cellulosic impurities
may be degraded to hydrocellulose, without damaging the wool,
when acted on by acids. It is important to remove these
impurities from the wool to prevent unequal absorption of dyes.
The first operation in carbonization is acid impregnation.
Typically, this step consists of soaking the wool in a 4 to 7
percent solution of sulfuric acid for a period of 2 to 3 hours.
The excess acid is squeezed out and the wool is baked to oxidize
the cellulosic contaminants to gases and a solid carbon residue.
The charred material, primarily hydrocellulose, is crushed
between pressure rollers so that it may be shaken out by
mechanical agitation. Some solid waste is generated but, with
the exception of an occasional dump of contaminated acid bath, no
liquid waste results. However, after the residue has been shaken
out, the acid must be removed. This is achieved by preliminary
rinsing to remove most of the acid followed by neutralization
with sodium carbonate solution. A final rinse is used to remove
residual alkali. As a result, the overall water requirements for
the carbonization of wool are substantial.
Fulling Fulling gives woven woolen cloth a thick, compact and
substantial feel, finish and appearance. To accomplish it, the
cloth is mechanically worked in fulling machines in the presence
of heat, moisture and sometimes pressure. This allows the fibers
to felt together, which causes shrinkage, increases the weight
and obscures the woven threads of the cloth.
There are two common methods of fulling, alkali and acid. In
alkali fulling, soap or detergent provides the needed lubrication
38
-------
and moisture for proper felting action. The soap or detergent
usually is mixed with sodium carbonate and a sequestering agent
in a concentrated solution. In acid fulling, which can be used
to prevent bleeding of color, an aqueous solution of sulfuric
acid, hydrogen peroxide and a small amount of a metallic catalyst
(chromium, copper or cobalt) is used.
The first step in both methods is to impregnate the fabric in the
fulling machines with heated fulling solution. If acid fulling
is performed, it is followed by alkali fulling. No waste is
produced during this step because all of the solution is absorbed
by the cloth. At this point, 10 to 25 percent of the fabric
weight may be process chemicals such as soap, alkali,
sequesterant and carding oil. Fulling is followed by extensive
washing to remove process chemicals and prevent rancidity and
wool spoilage. The usual washing procedure is to subject the
fulled cloth to two soapings, two warm rinses and one cold rinse.
The first soaping usually is achieved by agitation of the fabric
in the soapy solution created by the fulling soap already on the
cloth. After a warm rinse, the cloth usually is soaped a second
time in a stationary bath with a two percent solution of soap or
synthetic detergent. This step is followed by a second warm
rinse at 40°C (105°F) and a cold rinse to cool the cloth.
Desizinq Desizing removes the sizing compounds applied to yarn
in the slashing operation and is usually the first wet finishing
operation performed on woven fabric. It consists of solubilizing
the size with mineral acid or enzymes (starch size only) and
thoroughly washing the fabric. Acid desizing uses a solution of
dilute sulfuric acid to hydrolyze the starch' and render it water
soluble. Enzyme desizing uses vegetable or animal enzymes to
decompose starches to a water soluble form. In either case, the
desizing agent normally is applied to the fabric by roller pad.
After the desizing solution has been applied, the goods are
soaked or steeped in storage bins, steamers or J-boxes. After
the size has been solubilized, the solution is discarded and the
fabric is washed and rinsed. For desizing of PVA and CMC, sizing
materials that are directly soluble in water, no decomposition is
required and the goods are washed only with water.
Scouring Scouring is employed to remove natural and acquired
impurities from fibers and fabric. The nature of the scouring
operation depends on the fiber type. Raw wool scouring has been
discussed separately because of its uniqueness among textile
processes. Synthetic fiber scouring is milder than scouring of
cotton fiber because of the smaller amount of impurities present.
Cotton fabric contains natural impurities such as wax, pectins
and alcohols, as well as processing impurities such as size, dirt
and oil. These substances are removed from the fabric by hot
alkaline detergents or soap solutions. Also, cotton scouring
makes the fibers whiter and more absorbent for subsequent
bleaching and dyeing. Scouring of cotton often is done in
39
-------
conjunction with desizing rather than as a totally separate
operation and usually is accomplished by either kier or open
width boiling.
In kier boiling, desized cotton fabric in rope form is loaded
into a large cylindrical pressure vessel. An aqueous solution of
sodium hydroxide, soap and sodium silicate, or a similar mixture,
is recirculated through the goods at temperatures up to 104°C
(220°F), pH values of 10 to 13, and pressures of 0.70 to 1.41
kg/sq cm (10 to 20 psig) for 6 to 12 hours. The fabric then is
cooled and rinsed in the kier. Goods processed in the open width
normally are scoured in open width boil-out machines, also known
as progressive jigs. The goods are fed continuously through the
scouring solution by the use of transfer rolls, and after the
required contact period, are unrolled through wash boxes.
Methods of scouring and dumping the scour waste vary from mill to
mill, but at all mills the cloth is rinsed completely to clean
the fibers and remove residual alkali. Either light or heavy
scouring of wool goods may be performed during wool finishing to
remove acquired impurities.
Special Scouring The manufacture of synthetic fibers is well
controlled and the fibers are relatively free of impurities.
Consequently, only light scouring and little or no bleaching is
required prior to dyeing. Sizes and lubricating oils applied to
synthetics usually are removed in a special scouring process
rather than in a separate desizing step. Scour baths usually
contain weak alkalis, antistatic agents, lubricants, soap or
detergents, and special scouring agents such as ethoxylated
phenols and other emulsifiers. Optical brighteners, which
function in a capacity similar to dyes, often are applied to a
fabric during the special scouring process. The optical
brighteners function to absorb ultraviolet rays and reflect
certain wavelengths of visible light, which in turn add
brightness to the color of the fabric.
Although acetate fibers may be scoured and dyed in one bath, most
synthetics are scoured independently of the dyeing operation.
Rope soapers, jig scours, beck scours, drum or paddle scours or
beam dyeing equipment may be used. After scouring, the goods are
rinsed to remove excess material in preparation for the dye bath.
Mercerizing Mercerization increases the tensile strength,
luster, sheen, dye affinity and abrasion resistance of cotton
goods. It may be performed on yarn or greige goods, but usually
is conducted after fabric scouring. It is accomplished by
impregnating the fabric with cold sodium hydroxide solution (15
to 30 percent by volume). The solution causes swelling of the
cotton (cellulose) fibers as the alkali is absorbed. Higher
concentrations, longer residence times and lower temperatures
favor greater swelling. When increased tensile strength is a
primary consideration, the fabric is mercerized on a tenter
frame. After the desired period of contact, the caustic is
40
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washed off thoroughly, sometimes with the aid of an intermediate
acid wash. In many mills, the sodium hydroxide is reclaimed in
caustic recovery units and concentrated for reuse in scouring or
mercerization. It is estimated that less than half of all cotton
fabrics are mercerized and, with the increasing use of cotton-
polyester blends, less mercerization is likely in the future.
Bleaching Bleaching is a common finishing process used to whiten
cotton, wool and some synthetic fibers. In addition to removing
color, bleaching can dissolve sizing, natural pectins, waxes and
small particles of foreign matter. It usually is performed
immediately after scouring or mercerizing and prior to dyeing or
printing. Bins, jigs or continuous equipment may be employed.
Bleaching is accomplished primarily with hydrogen peroxide,
although hypochlorite, peracetic acid, chlorine dioxide, sodium
perborate or even reducing agents may be used.
Most cotton fabrics are bleached on continuous bleaching ranges
directly after scouring. The fabric, fed in either rope or open
width form, first is washed with hot water to ensure removal of
all contaminants. As the goods leave the washer, excess water is
removed and sodium hydroxide is added. The saturated fabric
remains at about 80° to 82°C (175° to 180°F) for approximately 40
to 60 minutes, resulting in the conversion of fats and waxes to
soaps. The material then is rinsed with hot water and passed
through a peroxide solution containing hydrogen peroxide and
sodium silicate. At this point, the cotton is bleached out at a
temperature of 90°C (195°F) for approximately 40 to 60 minutes
before the final hot water rinse. A second stage of bleaching,
sometimes with sodium hypochlorite, may be used in some mills.
In sodium hypochlorite bleaching, whether batch or continuous,
the cloth is rinsed, scoured with a weak solution of sulfuric or
hydrochloric acid and rinsed again. The cloth then is passed
through a solution of sodium hypochlorite and allowed to bleach
out in bins (batch) or J-boxes (continuous) for a designated
period of time. A final rinse then is performed.
Bleaching methods for synthetic fabrics depend on fiber type.
Because there is less coloring matter to remove, cellulosic
fibers (rayon and acetate) are bleached using methods similar to,
but less extensive than, those used in bleaching cotton.
Noncellulosic fibers (polyesters, acrylics, nylons) usually are
not bleached unless blended with natural fibers (principally
cotton and wool). When bleaching is performed, various weak
acids may be used.
Wool top or fabric may be bleached if white or very light colored
fabric is required. Hydrogen or sodium peroxide, or optical
brighteners composed of various organic compounds may be used.
Control of pH is important in peroxide bleaching of wool and
usually is achieved by mixing hydrogen peroxide with sodium
silicate or sodium peroxide with acid. Optical brighteners are
41
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useful in combination with peroxide bleaching agents to help give
wool a good white base for subsequent dyeing. Solvent bleaching
systems and pressure steamers for reduction of residence time in
continuous bleaching are two developments that may change the
character of bleaching operations in the future.
Dyeing Dyeing is the most complex of all the wet processing
operations. It is performed essentially for aesthetic reasons in
that it does not contribute to the basic structural integrity,
wearability or durability of the final product. It does,
however, play a major role in the marketability of textile
products.
The function of dyeing is to anchor dyestuff molecules to textile
fibers. The color observed is a result of the light waves
absorbed and reflected by the dyestuffs. The methods of dyeing,
the types of dyestuffs and auxiliary chemicals used in dyeing and
the types of equipment available and in use for the application
of dyes are discussed below.
The mechanisms of dyeing textile fibers can be summarized as
follows (10):
1. Migration of the dye from the solution to the interface,
accompanied by adsorption on the surface of the fiber.
2. Diffusion of the dye from the surface towards the center
the fiber.
of
3. Anchoring of the dye molecules by covalent or hydrogen
bonds, or other physical forces.
Dye/fiber interfacing is a function of the type of equipment
utilized, while the specific dye formulas provide the chemical
conditions for bonding to take place. Dyeing can be performed
while the goods (fiber) are in the stock, top (wool or wool
blends), yarn or fabric state. Both single and multiple fiber
goods can be dyed, although multiple fiber dyeing may require
multiple steps.
Stock dyeing is
the top or yarn
placing stock
sufficient quant
allowing time
to produce fancy
fibers used for
performed before the fiber has been converted to
state. In simplest terms, the process involves
fiber in a vat or pressure kettle, applying a
ity of dye liquor, providing optimum conditions,
for the chemical reaction and rinsing. Wool used
goods and a small amount of cotton or synthetic
flocking are dyed in this manner.
Top dyeing is performed on sliver or slubbing that is wound into
a cylindrical shape approximately 46 cm (18 in.) in diameter.
The top has been carded and combed but not spun into yarn.
Dyeing is accomplished by placing the top int cans, placing the
cans in a dye .vat, circulating the dye liquor and allowing
-------
sufficient time for reaction. Fibers
usually are dyed in this manner.
used for worsted fabric
Yarn dyeing is performed on yarns that are used for woven goods,
knit goods and carpets. The traditional methods are skein
(hank), package and space dyeing. Skein dyeing is accomplished
by placing turns of yarn on a frame, placing the frame in a dye
bath in which either the frame or the dye liquor is circulated,
providing optimum conditions, allowing time for reaction and
rinsing. Package dyeing is the most common yarn dyeing process
and is accomplished by placing yarn wound onto perforated tubes
on a frame, placing the frame into a pressure vessel, circulating
dye liquor in and out of the cones and yarn under optimum
conditions and rinsing. Warp yarns wound on large perforated
beams also are dyed using the package method. The beams of dyed
yarn can be used directly in weaving.
Package dyeing is favored over skein dyeing because skein-reeling
is a comparatively expensive process, more working space is
required and the skein-dyed yarn must be wound onto a bobbin,
cone or spool at a later stage.
Space dyeing is a specialty yarn dyeing process. The technique
resembles the roller printing process discussed below, in that
the dye liquor is applied to warp yarns at a repeat or random
interval by a roller type dye pad. The dyed yarn then enters a
hot water steam box for development and fixation of the color and
finally is rinsed. Two or more dyes can be padded. The process
is especially important to the manufacture of tufted carpet.
Fabric dyeing is the most common dyeing method in use today. It
is preferred over yarn dyeing because it is a continuous or
semicontinuous process and because a mill does not have to
process large lots to be cost effective. The methods employed
include beck (winch), jet, jig and continuous range.
Beck dyeing is accomplished with the fabric in the rope form.
Both atmospheric and pressure machines are used. In either case,
the fabric, connected end to end, is rotated through dye liquor
by passing over a large rotating drum. Twelve or more loops of
fabric can be dyed side by side, being kept apart by dividing
fingers. The length of each loop is such that the fabric lies in
a heap at the bottom of the beck for a short time. The proper
conditions and residence time must be provided as in the other
previously described methods.
Jet dyeing also is accomplished with the fabric in rope form.
Jet machines are similar to the pressure becks except that each
loop of fabric passes through a venturi tube. A pump circulates
the dye liquor through the tubes and the suction at the venturi
causes the fabric to rotate. Jet machines have improved on
certain deficiencies of beck dyeing by allowing shorter liquor-
to-fabric ratios (less dye liquor per unit weight of fabric),
43
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reducing the risk of tangling, providing a more uniform
temperature, reducing elongation of the fabric caused by tension
and lessening the formation of creases in synthetic fabrics. Jet
dyeing is especially suitable to synthetic fibers.
Jig dyeing is performed with the fabric in the open width. Both
atmospheric and pressure equipment are available. Dyeing is
accomplished by slowly winding the fabric over rollers that stand
above a shallow trough containing the dye liquors. The rollers,
by rotating in clockwise and counterclockwise directions
alternately, move the cloth through the dye liquor, complete
immersion being insured by guide rollers at the bottom of the
trough. Because only a few meters of the fabric are immersed at
a time, it is possible to work with an exceedingly short liquor
ratio (low dye liquor volume per unit weight of fabric). Jig
dyeing is particularly attractive for cellulosic fibers because
the dyes used generally do not exhaust well and less dyestuff is
wasted.
Continuous dyeing also is performed with the fabric in the open
width. It is accomplished under atmospheric conditions on what
are termed "continuous dyeing ranges." These ranges generally
consist of a number of dip troughs through which the fabric is
dyed and oxidized, rinse boxes that remove excess dye liquor and
heated rotating drying cans.
Thermosol dyeing is a continuous process used for dyeing
polyester, and polyester/cotton blends. Dye is padded onto the
fabric in the pigment form from a pad box and dried, causing a
film containing the dye to adhere to the surface of the fibers.
The fabric then is heated to 180° to 220°C (355° to 430<>F) for a
period of 30 to 60 seconds to set the dye. The transfer of dye
from the surface deposit to the polyester is through the vapor
phase.
Dyes are classified according to their
on the basis of their dyeing properties,
between the two systems. Classification
is most relevant and is discussed
according to chemical constitution is
reader is referred to the Colour Index,
the Society of Dyers and Colourists and
of Textile Chemists and Colorists for a
subject.
chemical constitution or
with little correlation
according to application
below. Classification
not discussed, but the
Volume III, published by
the American Association
thorough coverage of this
The following tabulation provides the classification name and the
principal fiber types for which the dye classes are used, based
on the application classification.
44
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Dye Class
Applicable Fiber Types
Acid
Azoic (Naphthal)
Basic (Cationic)
Direct
Disperse
Mordant (Chrome)
Premetallized
Reactive
Sulfur
Vat
Protein, polyamide (nylon)
Cellulosic
Acrylic, silk, protein, cellulos.ic if mordanted
Cellulosic
Cellulosic, acetate, synthetics (man-made)
Protein, cellulosic
Protein
Cellulosic, protein, silk
Cellulosic
Cellulosic, protein, silk
Acid Dyes - These dyes are sodium salts, usually of
sulfonic acids, but in a few cases carboxylic acids. They
invariably are manufactured as sodium salts because free acid
dyes are more difficult to isolate and they are hygroscopic,
which makes them difficult to pack and store. Acid dyes have a
direct affinity for protein fibers and are the main class of dyes
used in wool dyeing. Most will not exhaust on cellulosic fiber
but, because acid dyes resemble the direct dyes in chemical
constitution, there are a number that dye cellulose quite well.
The dyes also have an affinity for polyamide fibers.
There are many ways in which the acid dyes are applied.
Primarily, the variations create conditions suitable to the type
of dye used. In addition to the dyes, the following auxiliary
chemicals may be required for satisfactory dyeing:
sodium sulfate (Glauber's salt)
sulfuric acid
formic acid
acetic acid
ammonium acetate
ammonium sulfate
ammonium phosphate
leveling agents
Azoic Dyes - These dyes are insoluble pigments anchored
within the fiber by padding with a soluble coupling compound and
then treating with a diazotized base or stabilized color salt.
Because naphthol is used as the coupling component, azoic dyes
are also referred to as naphthol dyes. They are used for dyeing
cellulosic fibers when comparatively
brightness of shade are required at a reasonable cost.
especially satisfactory in the yellow, orange and red
They have been applied to protein
fibers,
fastness and
They are
spectrum.
but equally good
results can be obtained with acid dyes by simpler methods.
Dyeing with azoic dyes is a two-stage process involving
impregnating the fiber with an azoic coupling component and
coupling with a diazonium salt. There are over 50 coupling
components listed in the Color Index (C.I.), and over 50 bases
that can be diazotized and coupled with the former (10). In
addition to the coupling component and base, common salt and
-------
surface-active compounds (sulfated fatty alcohol or ethylene
oxide condensate) are usually used to speed the reaction.
Basic Dyes - These dyes are usually hydrochlorides of
salts or organic bases. The chromophores are found in the
cation; therefore, these dyes often are referred to as cationic
dyes. Because of poor fastness to light, these dyes virtually
had been discontinued until it was discovered that they would dye
acrylic fibers and give bright, clear shades of color which
possess good light fastness. Cellulbsic fibers have, for all
practical purposes, no affinity for basic dyes. The dyes can be
applied to cellulose if the fibers are mordanted before dyeing;
however, these dyes are rarely applied to cotton in current
practice. In the case of protein fiber, there is substantial
evidence that the affinity is of a chemical nature.
There are several methods of applying basic dyes to acrylic
fibers and many dyes that are suitable. In addition to the dye,
the following auxiliary chemicals may be necessary for
satisfactory dyeing:
acetic acid
formic acid
oxalic acid
tannic acid
sodium sulfate
sodium acetate ,
ethylene carbonate
Direct Dyes - These dyes resemble acid dyes in that they
are sodium salts of sulfonic acids and are almost invariably azo
compounds. They have a direct affinity for cellulosic fibers.
These dyes frequently are referred to as substantiative dyes and,
in special circumstances, they are used to dye protein fibers.
The distinction between acid and direct dyes is often not well
defined. For example, C.I. Direct Dye 37 may be applied as a
direct dye to cellulose or as an acid dye to protein fibers. The
dyes offer a rather wide range of color; however, their water
fastness and light fastness vary depending on shade.
The direct dyes are divided into three classes; self-leveling
(Class A), salt controllable (Class B), and temperature
controllable (Class C). Depending on the class of the dye used,
one or more of the following auxiliary chemicals may be necessary
for satisfactory dyeing:
sodium chloride
sequestering agents
sodium sulfate
sodium nitrite
hydrochloric acid
aromatic amines
46
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Disperse Dyes - this class of dyes arose out of the need
to find an easy and satisfactory way to dye cellulose acetate.
These dyes are suspensions of finely divided organic compounds
with very slight aqueous solubility. Hydrophobic fibers, such as
secondary or tertiary cellulose acetate, and the synthetic fibers
often will dye better with insoluble dyes than those that are
dissolved in water.
There are numerous disperse dyes but no sharp dividing lines to
group them into separate classifications according to their
dyeing behavior. In addition to the dyes, one or more of the
following auxiliary chemicals may be necessary for satisfactory
dyeing:
acetic acid
dispersing agents
orthophenylphenol
butyl benzoate carriers
chlorobenzene
diethyl phthalate
other carriers
Mordant Dyes - This class of dyes includes many natural
and synthetic dyes, the latter usually being obtained from
anthracene. These dyes have no natural affinity for textile
fibers, but are applied to cellulosic or protein fibers that have
been mordanted with a metallic oxide. Because chromium is the
most commonly used mordant, these dyes often are referred to as
chrome dyes. At one time, there were a number of naturally
occurring mordant dyes in use, but acid mordant dyes have
replaced these. The acid mordant dyes are applied to wool or
polyamide fibers as if they were acid dyes and, by subsequent
mordanting, are given good water fastness.
The mordant dyes usually are applied in a boiling acid dye bath
and, when exhaustion is complete, an appropriate amount of
dichromate is added and the bath boiled for an additional 30
minutes. The following auxiliary chemicals are generally
necessary to achieve satisfactory results:
acetic acid
sodium sulfate (Glauber's salt)
penetrating agents
sulfuric or formic acid
potassium or sodium dichromate
ammonium sulfate
Premetallized Dyes - These dyes were developed so wool
could be dyed directly without the need for mordanting in an
after-treatment step. They are classified as 1:1 and 2:1 metal
complex dyes depending on the number of dye molecules present for
each metallic atom. Premetallized dyes are quicker to apply,
easier to match, and for some colors, brighter than mordant dyes.
47
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The premetallized dyes are applied like acid mordant dyes in a
boiling acid dye bath. In addition to the dyes, the following
auxiliary chemicals are necessary to achieve satisfactory
results:
sulfuric acid
sodium sulfate
leveling agent
Reactive Dyes - These are the latest dyestuff discovery
and, because they react chemically with cotton, viscose, linen,
wool and silk, they possess very good water fastness. They can
be dyed by many methods and adapt well to the requirements of
continuous dyeing. The whole spectrum of color can be applied
with these dyes.
There are several classes of reactive dyes that are specific to
the fibers being processed. In addition to the dyes, one or more
of the following auxiliary chemicals may be necessary for
satisfactory dyeing:
sodium chloride
urea
sodium carbonate
sodium hydroxide
trisodium phosphate
tetrasodium pyrophosphate
Sulfur Dyes
These
_____ ____ dyes are complex organic compounds
that contain sulfur linkages within the molecules. Sulfur dyes
usually are insoluble in water, but dissolve in a solution of
sodium sulfide to which sodium carbonate may be added. The
sodium sulfide acts as a reducing agent, severing the sulfide
linkage and breaking down the molecules into simpler components
that are soluble in water and have an affinity toward cellulose.
The soluble components then are oxidized in the fiber to the
original insoluble sulfur dyes. These dyes have excellent
resistance to washing, but poor resistance to sunlight. Sulfur
dyes will dye cotton, linen and rayon, but the colors are not
very bright.
In the reduced state, the dyeing properties of the sulfur dyes
resemble those of the direct dyes. These dyes exhaust better in
the presence of electrolytes and vary considerably with regard to
the temperatures at which maximum exhaustion takes place. Sulfur
dyes are decomposed by acids, usually with the liberation of
hydrogen sulfide, and when exposed to air or acted upon by mild
oxidizing agents, some of the sulfur is oxidized to sulfuric
acid. In addition to the dyes, one or more of the following
auxiliary chemicals may be necessary for satisfactory dyeing:
sodium sulfide
sodium carbonate
48
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sodium dichromate
acetic or alternative acids
hydrogen peroxide
sodium chloride
sodium sulfate
copper sulfate
Vat Dyes - These are the best known dyes in use today
because of all-around fastness to both washing and sunlight. Vat
dyes are among the oldest natural coloring matters used for
textiles. These dyes are insoluble in water and cannot be used
without modification. When treated with reducing agents, vat
dyes are converted into leuco (combining) compounds, all of which
are soluble in water in the presence of alkali. The leuco
compounds have an affinity for cellulose and reoxidize to the
insoluble colored pigment within the.fiber when exposed to air.
Vat dyes are made from indigo, anthraquinone and carbazol and are
successfully used on cotton, linen, rayon, wool, silk and
sometimes nylon. These dyes also are used in the continuous
piece goods dyeing process, sometimes called the pigment
application process. In this method, the dyes are reduced after
they have been introduced into the fabric.
Each vat dye has its own optimum temperature and specific
proportions of alkali and reducing agents for vatting. In
practice, however, it is practical to classify them into four
groups, based on method of application:
Method 1 - Dyes requiring relatively high alkali concentration
and high vatting and dyeing temperatures.
Method 2 - Dyes requiring moderate alkali concentrations, lower
temperatures for reducing and dyeing, and some
electrolyte to complete exhaustion.
Method 3 - Dyes requiring low alkali concentration, low vatting
and dyeing temperatures and large quantities of
electrolyte.
Method 4 - A special case for dyeing blacks requiring
exceptionally high alkali concentration and
temperature but no electrolyte.
In addition to the dyes, one or more of the following auxiliary
chemicals may be necessary for satisfactory dyeing:
sodium hydroxide
sodium hydrosulfite
dispersing agents
hydrogen peroxide
acetic acid
sodium perborate
sodium chloride
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Printing Printing, like dyeing, is a process for applying color
to fabric. However, the color application techniques are quite
different. Instead of coloring the whole cloth as in dyeing,
print color is applied only to specific areas of the cloth to
achieve a planned design. Consequently, printing often is
referred to as localized dyeing.
Most of the textiles wet-printed in the U.S. are printed by the
roller machine method and a smaller proportion by the screen
method. Highly advanced electronically-controlled spray printing
techniques are beginning to emerge, especially in the printing of
carpet.
Roller printing is accomplished by transferring the desired
design onto copper rollers; applying print paste from reservoirs
to rotating rollers that contact a main cylinder roller that
transports the fabric; transferring the design to the fabric by
contacting the rollers and fabric; and steaming, aging or
performing other after-printing operations.
The design can be transferred to the rollers by hand engraving,
photo engraving or chemical etching. The latter two methods are
used most today. The copper rollers, as many as 16 per print
machine, may have a circumference of from 35 to 91 cm (14 to 36
in.), and a length of from 117 to 152 cm (46 to 60 in.). They
are hollow, and steel mandrils are pressed into the hollows to
hold the rollers in position and to turn them at the desired
speed. The rollers generally are coated with a thin layer of
chromium to prevent damage to the engraving during handling.
Each roller imprints one repeat of the design with color supplied
from the color trough. As the roller spins, a doctor knife
continuously scrapes the extraneous color back to the color
trough. A different design and color can be transferred for each
roller. Generally, only one side of the fabric is printed.
Final washing of the fabric removes excess print paste and leaves
a uniformly smooth effect. This process, along with the cleanup
of print paste mixing tanks, applicator equipment (troughs and
rollers) and belts, contributes the pollutant loading associated
with the printing process.
Screen printing differs from roller printing in that the print
paste is transferred forceably to the fabric through the openings
in specially designed screens. The process can be manual,
semiautomatic or completely automatic. Automatic screen printing
can be either flat bed or rotary, while manual and semiautomatic
screen printing are flat bed processes only.
Screens are made by manually (sketching or tracing) or
photographically transferring the desired design. If the
transfer is performed manually, the area outside the design is
opaqued so that print paste will be retained. In the
photographic transfer technique, which is the method most widely
50
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used in current practice, the negative is used for the opaquing
process, using a specially sensitized coating. The screens,
which are largely made of synthetic materials today, are securely
stretched over a wooden frame so they can be correctly
positioned. A separate screen is made for each color in the
design.
In manual screen printing, the fabric is stretched out on long
tables, the screens representing the pattern laid on it according
to the repeat pattern, and the selected print paste forced
through the screen mesh onto the fabric by squeegee. The fabric
is dried by placing it on a rack above the table, steamed to set
the color, followed by other finishing treatments for fineness
and texture.
The semiautomatic process is similar to the manual process except
that the fabric travels and the screens representing the pattern
are stationary. The handling of the screens and the application
of the color still are performed manually.
Automatic flat bed screen printing is accomplished on a machine
that electronically performs and controls each step of the
operation. It is a continuous process in which the fabric moves
along a table, the screens representing the design are
automatically positioned and the color automatically is deposited
and squeegeed through the screen onto the fabric. The fabric
moves forward one frame between each application of color and as
it leaves the last frame, it passes into a drying box, from which
it emerges dry and ready for aging (curing).
Rotary screen printing combines some of the advantages of both
roller printing and screen printing. Instead of flat screens,
the color is transferred to the fabric through lightweight metal
foil screens that resemble the cylinder rollers of the roller
printing process. The desired design is transferred to the foil
screens in much the same way as for the flat screens. The fabric
moves continuously under the cylinder screens and print paste is
forced, under pressure, from the inside of the screens through
and onto the fabric. A separate screen is required for each
color in the design.
Rotary screen printing is faster than flat bed printing and
approaches the production speed of roller printing. The down
time (out of production time) during pattern changeover is
somewhat less than for roller printing. As with roller printing,
wastewater is generated primarily from the final cleaning of the
fabric, cleanup of applicator equipment and cleaning of belts.
Another type of printing that is in use today is sublistatic
(heat transfer) printing. This method employs a prepared pattern
paper from which a design can be transferred to nearly any fabric
by a simple hot transfer or calendering operation. The main
advantages of the sublistatic process are ease of application,
51
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clarity of reproduction, flexibility in design choice and a wide
range of design sizes. After printing, no subsequent treatment
such as washing or steaming is required and there is no print
paste to clean from equipment. Consequently, the process does
not generate wastewater.
The auxiliary chemicals used in printing each of the dye types
are included in the lists provided in the discussion of dyeing.
In addition, a thickener is used to give the print paste the
desired viscosity for the method employed and the pattern
desired. The thickeners commonly used are locust bean, guar,
alginate, starch and combinations of these gums. Urea, thiourea
and glycols also are used in many print formulations.
In printing with pigments, which do not react chemically with the
fiber as do some dyes, the same general formula is "used for all
fiber types. The formula includes the pigment, resin, binder,
latex, emulsifier, varsol (solvent), thickener and water.
FINAL PRODUCTS
It has been noted earlier in this section that the textile mill
products group (SIC Major Group 22) includes 30 separate
industries that manufacture approximately 90 classes of products.
Throughout the 90 product classes, there are hundreds of
individual products and the number is changing constantly as a
result of ongoing research, development and marketing. Many of
the industries and product classes do not include wet operations
in their manufacturing processes and, consequently, are not of
specific interest here. Nine major subcategories have been
established to represent the wet processing segment of the
industry in the development of effluent limitations guidelines
and standards for this industry. Two of the nine major classes
(woven fabric and knit fabric) have been further subdivided
resulting in thirteen separate subcategories or subdivisions.
(See Section IV for explanation of the subcategorization
developed for the textile industry). The
subcategories/subdivisions represent 13 processing classes in
which the products are composed of characteristic raw materials
and in which the production is the result of similar manu-
facturing operations. A description of each major class
(subcategory) follows.
Wool Stock and Top (Wool Scouring subcategory)
Raw wool is very dirty and must be cleaned and prepared before it
can be processed. A number of mills scour wool and make wool top
as a final product and ship it to other facilities for further
processing. A schematic of a typical wool scouring operation is
presented in Figure III-3. Raw wool is scoured after it has been
sorted and blended. The scouring process has been described
previously. Most mills in this segment practice countercurrent
flow of wash water and recover grease from the scour waste. The
52
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FIGURE III-3
SUBCATEGORY 1: TYPICAL WOOL SCOURING PROCESS FLOW DIAGRAM
Water,
Alkali and
Detergent
Water t
Water _
\
/
SORT AND
BLEND
\
t
SCOUR
Liquor _ GREASE Liquid Waste ^
* RECOVERY *
1 i r
J,
WASH
\
t
DRY
s\
\ /RTwN
"— ' ( Wool J
V Grease J
CREASE Liquid Waste
PURIFICATION
^,
TOP
MAKING
Lanolin
^^
53
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scoured wool must be dried thoroughly to prevent rancidity.
Dried wool may be shipped as a final product, combed to create
wool top or finished in another portion of the mill.
Finished Wool Goods (Wool Finishing subcateqorv)
Wool not only requires more preparation than other fibers, but
also requires unique finishing operations. As a result, there
are a number of mills in the industry devoted exclusively to
finishing wool goods. A schematic of the typical wool finishing
process is presented in Figure III-4. Finished wool products
include top, yarn, blankets and fabrics for apparel, upholstery,
outerwear and numerous other uses, A single mill may manufacture
any number of these products. Light scouring, dyeing and washing
are employed regardless of whether top, yarn or fabric is being
finished. In addition, carbonizing, bleaching, oiling, carding
and spinning may be performed when finishing wool top.
Carbonizing and bleaching also are performed at mills finishing
wool fabric, as is fulling (felting) and final finishing.
Knitting or slashing and weaving must be performed to produce
wool fabric from yarn. These steps can occur at a greige mill,
at a top finishing mill after spinning, at a yarn finishing mill
after dyeing and washing, or at a fabric finishing mill prior to
carbonizing or fulling.
Greiqe Goods and Adhesive Products (Low Water Use Processing
subcateqorv)
Greige goods are materials that are woven or knit, but not
finished. A large number of mills perform the mechanical
operations to produce greige goods and ship them to other mills
for dyeing and finishing. The manufacture of woven greige goods
is the only fabric construction process that results in the
generation of process wastewater. A typical woven greige mill
operation (Figure III-5) consists of opening and picking the
fiber, carding and spinning the fiber into yarn, applying size to
the yarn and weaving the yarn into fabric on a loom. Usually,
only a small quantity of wastewater is generated during slasher
cleanup, although at the few mills where water jet weaving is
employed, the wastewater discharge may be substantial.
Adhesive products are goods that have been created or modified
because of operations such as bonding, laminating, coating or
flocking. Backed carpet, tire cord fabric other coated fabrics,
laminated fabric, and flocked fabrics are the principal products.
A schematic of a typical adhesive operation is presented in
Figure III-5. Application of adhesive and setting or drying are
the main adhesive processes.
Finished Woven Goods (Woven Fabric Finishing subcateqorv)
Finished woven fabric is a primary textile product that is used
in countless applications. Sheeting, industrial fabrics,
54
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FIGURE III-4
SUBCATEGORY 2: TYPICAL WOOL FINISHING PROCESS FLOW DIAGRAM
Water
H2SO4and
Na2CO3
Detergent, Acid,
and/or Alkali-
H202
* —
Scouring
Agents ^
Dyestuffs
and
Auxiliary
Chem. ^
Detergents
Lubricants,
Sizing, and
Finishing Agents
/ Wool \
1 Stock 1
\&Top >/
\
/
CARBONIZE
AND
SCOUR
\
/
BLEACH
AND
RINSE
N,
/
LIGHT
SCOUR
\
i
DYE
V
f
WASH
\
/
OIL AND
CARD
\
/
SPIN
\
/
( Wool \
\ Yarn /
f We
V Ya
A
/•
A
A
^ .....
j
-»»
-*•
^
H»
\
)0l \
rn y
/-
/
LIGHT
SCOUR
\
/
DYE
N
f
WASH
"X
\
t
SIZE
(Warp Yarns)
\
/
KNIT OR
WEAVE
\
/
f Wool \
1 Fabric I
t
f-
/-
A
f-
*
j
^
^>
^
^
A Wool A
I Fabric y
\
f
CARBONIZE
AND
SCOUR
<
/
FELT
AND
RINSE
^
V
BLEACH
AND
RINSE
>
f
LIGHT
SCOUR
\
f
DYE
\
/
WASH
<
t
FINAL
FINISH
\
f
I Finished ]
V Fabric J
Liquid
Waste
Liquid
Waste
Liquid
Waste
Liquid
Waste ^
Liquid
Waste ^
Liquid
Waste
Liquid
Waste
{From Cleanup)
(TOP)
(YARN)
(FABRIC)
55
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SUBCATEGORY 3:
FIGURE III-5
TYPICAL LOW WATER USE PROCESSING PROCESS FLOW DIAGRAMS
Water,
Starch, PVA,
and/or CMC
Water
(Water-jet
only)
f Stock \
1 Fiber I
\
f
OPEN AND
PICK
N
f
CARD AND
SPIN
\
f
SIZE
(SLASHING)
\
f
WEAVE
\
L
f Woven A
\ Fabric /
Liquid Waste
(From
Cleanup)
Liquid Waste^
/YarnA
f Fabric, ]
V Carpety
Water, Resin, ^
/
Latex, Acrylic DIP/PAD/ Liquid Waste
* SATURATE (From *
1
Cleanup)
/
DRY
V
f Coated \
1 Goods I
f Bac
I Car
(ADHESIVE P
V,
/Lam-\
I inated ]
V Fabricy
kedA
pet J
RODUCTS)
(WOVEN QREIQE GOODS)
56
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upholstery, towels and materials for numerous types of apparel
are finished at the mills in this subcategory. A typical process
flow diagram is presented in Figure III-6. For cotton fabrics,
typical processing consists of desizing to remove size applied to
the yarn prior to weaving, scouring to remove natural and
acquired impurities from the fabric, mercerizing to increase the
luster, strength and dye affinity of cotton fabric, bleaching to
whiten cloth and remove stains, dyeing and/or printing to impart
desired colors and patterns to the fabric and final finishing to
add other desired qualities and properties to the fabric. For
synthetic fabrics, extensive desizing, mercerizing and bleaching
are less common.
Finished Knit Goods (Knit Fabric Finishing subcateqory)
Finished knit goods include fabrics and hosiery. Principal
fabric products -are underwear, numerous types of outerwear,
various types of household and industrial items, circular knits
and warp knits. Hosiery products include both conventional
footwear, ladies nylon hose and pantyhose. Typical process flow
diagrams for knit fabric processing and hosiery processing are
presented in Figure III-7. Knit fabric finishing is similar to
the finishing required for woven goods, except that desizing and
mercerizing are not necessary. Hosiery finishing usually is
simpler because the cleaning and dyeing processes often are
combined and can be less extensive.
Finished Carpet (Carpet Finishing subcateqory)
Carpet manufacturing is an important and distinct segment of the
textile industry. Most carpet mills are integrated operations
that tuft, finish and back carpet at the same location.
Finishing operations may include scouring, bleaching, dyeing,
printing and application of functional finishing agents. A
typical process flow diagram is presented in Figure II1-8.
Finished Stock and Yarn (Stock and Yarn Finishing subcateqory)
Many of the products previously noted often are manufactured from
finished yarn. Stock also is used in the manufacture of products
already noted. Bo.th yarn and thread are used outside the
industry and as such are sold as final products. A schematic of
typical yarn and stock finishing operations is provided in Figure
III-9. Yarn finishing and stock finishing basically involve the
same processes except that mercerizing is not performed on stock.
Nonwovens (Nonwoven Manufacturing subcateqory)
Nonwoven manufacturing is a relatively new and rapidly growing
segment of the textile industry. Typical products include filter
media, diapers, interliners, padding, surgical gowns, absorbent
wipes and other disposable products, as well as fabrics for other
uses. A schematic of a typical nonwoven manufacturing operation
57
-------
FIGURE III-6
SUBCATEGORY 4: TYPICAL WOVEN FABRIC FINISHING PROCESS FLOW DIAGRAM
Enzymes
or
H2SO4
Water
NaOH and
Auxiliary Chem.
Concentrated NaOH
H2O2orNaOCI
Dyestuffs
Auxiliary Chem.
Print Pastes
Auxiliary Chem.
Finishing Agents
Finished
Woven
Fabric
Liquid Waste
>• •••••••••••j
(From Cleanup)
58
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FIGURE III-7
SUBCATEGORY 5: TYPICAL KNIT FABRIC FINISHING PROCESS FLOW DIAGRAM
Knit
Greige
Goods
Water
Detergent and
Scouring Agents
*?.,.
fs
Bleaching
Agents 1 ^
Dyestuffs and
Auxiliary Chem.
Print Pastes v
and T
Auxiliary Chem._
Finishing Agents
\
f
WASH/
SCOUR
N
/
BLEACH
N
/
DYE
\
f
EXTRACT/
DRY
\
/
PRINT
N
/
FINAL
FINISH
^
L
^^
^^^^
^^
/
^^^m
/
\
f
WASH/ Liquid Waste _
SCOUR
\
BLE
\
D^
Liquid Waste ^
(From Extract)
Liquid Waste
(From Cleanup)
Liquid W
(From Clea
aste
• • «^^
nup)
\
^~*
f
Liquid Waste
/
Liquid Waste
t
^"^
Finished
Fabric
(FABRIC)
Finished
Hosiery
(HOSIERY)
59
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FIGURE III-8
SUBCATEGORY 6: TYPICAL CARPET FINISHING PROCESS FLOW DIAGRAM
Water
Bleach or
Scouring Agents
Dyestuff and
Auxiliary Chem.
Finishing Agents
Latex Compounds
Liquid Waste
Liquid Waste
Liquid Waste
(From Cleanup)
LATEX
SEGREGATION
J
L
Liquid
(From Cleanup)
I Latex J
60
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FIGURE III-9
SUBCATEGORY 7: TYPICAL STOCK AND YARN FINISHING PROCESS FLOW DIAGRAM
Water
Stock
Detergents
and
Scouring Agents
\
Concentrated
NaOH
H2O2or NaOCI
Dyestuff and
Auxiliary Chem.
s
\
f
WASH/
SCOUR
T
f
MERCERIZE
>j
f
BLEACH
Liquid Waste
\
/
WASH/
SCOUR
>
^
f
BLEACH
f \
DYE/
PRINT
\
/
[Finished\
1 Yarn I
^^^^^.
^^^^^^
/
DYE
\
L
/Finished \
1 Stock I
Liquid Waste
Liquid Waste
Liquid Waste
(YARN)
(STOCK)
61
-------
is presented in Figure 111-10. Web formation is a dry operation
unless the wet-lay process is employed. In the latter case, a
portion of the water used to transport the fibers and form the
web often is discharged.
Felted Fabric (Felted Fabric Processing subcateqorv)
Although felted fabrics comprise a relatively small segment of
the textile industry, they are used in a variety of applications.
In addition to woven papermakers1 felt, there are pressed felts
and punched or needleloom felts. Typical products include
polishing cloth, insulating fabric, lining, trimming, acoustical
fabric, automotive padding, felt mats and felt apparel fabric. A
typical felted fabric processing flow diagram is presented in
Figure III-ll. Rinsing following fulling and dyeing (if
employed) is responsible for the rather high water use of this
segment.
62
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SUBCATEGORY 8:
FIGURE 111-10
TYPICAL NONWOVEN MANUFACTURING PROCESS FLOW DIAGRAM
(Wet-Lay Only)
Water
Water
Re-use
l
Acrylic,
Latex, Resins,
and Pigments
Finishing
Agents
I Stock A
Fiber
OPEN AND
BLEND
WEB
FORMATION
WET OUT
BONDAND
COLOR
_w
FINAL
FINISH
Non-
woven
V Goodsy
Liquid Waste
Liquid Waste
»•••••••••••
(From Cleanup)
Liquid Waste
(From Cleanup)
63
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FIGURE III-ll
SUBCATEGORY 9 - TYPICAL FELTED FABRIC PROCESSING PROCESS FLOW DIAGRAM
( Stock A
I Fiber j
OPEN,
BLEND
AND CARD
(Harden)
Water
WEB
FORMATION
Detergent, Acid,
and/or Alkali
FELT
(FULLING)
Dyestuffs and
Auxiliary Chem.
Finishing Agents
RINSE
DYE
FINAL
FINISH
Finished
Liquid Waste
(Batch Dumps)
Liquid Waste
Liquid Waste
Liquid Waste
»*••*§•••••
(From Cleanup)
64
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SECTION IV
INDUSTRY SUBCATEGORIZATION
INTRODUCTION
The purpose of subcategorization is to group together mills of
similar characteristics to allow for development of effluent
limitations and standards representative of each group
(subcategory) of mills. This enables permits to be written on a
uniform basis. The following seven subcategories were
established when BPT, BAT, NSPS and PSNS were promulgated on July
5, 1974 (39 FR 24736; 40 CFR Part 410):
Wool Scouring
Wool Finishing
Dry Processing
Woven Fabric Finishing
Knit Fabric Finishing
Carpet Mills
Stock and Yarn Dyeing and Finishing
The factors considered in identifying these subcategories
included raw materials used, products manufactured, production
processes employed, mill size and age, waste treatability,
location, climate and treatment costs. Additional pollutant
allowances were provided in the wool scouring, wool finishing,
woven fabric finishing and knit fabric finishing subcategories
for "commission finishers" (those facilities where textile
materials, 50 percent or more of which are owned by others, are
finished). In the woven fabric finishing and knit fabric
finishing subcategories, additional allowances were provided for
COD to account for different combinations of specified simple and
complex processing operations and natural, synthetic or
natural/synthetic blend fiber types. In the carpet mills
subcategory, additional COD allowances were provided for
specified complex processing operations.
As part of the BAT review program, detailed information has been
collected on 538 mills in the textile industry. EPA reviewed
available data in light of the original subcategorization scheme
to determine the adequacy of the original subcategories in
representing current industry characteristics. Conventional
pollutant data have been reviewed to determine the relationship
of raw wastewater characteristics to the processes employed and
the products manufactured at mills in the textile industry. In
addition, toxic pollutant data have been gathered and the
subcategorization scheme has been reviewed for validity in
accounting for toxic pollutant generation. As discussed below,
this review led to the identification of two new subcategories
and one subdivision of an existing subcategory representative of
portions of the textile industry not recognized in the original
subcategorization scheme.
65
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RESULTS
With the following exceptions, the revised subcategorization
scheme that forms the basis of final regulations is identical to
the subcategorization scheme used in establishing BPT regulations
promulgated in 1974. Two new subcategories, the nonwoven
manufacturing subcategory and the felted fabric processing
subcategory, have been established. In addition, a new
subdivision of the low water use processing subcategory (formerly
dry processing) has been established to account for a new textile
manufacturing process, water jet weaving. Water jet weaving is
not technically a low water use process; it is included as a
subdivision of the low water use processing subcategory because
it is related to greige goods production.
In addition, the Agency has decided to change the names of three
existing subcategories: (a) the dry processing subcategory is now
called the low water use processing subcategory; (b) the carpet
mills subcategory is now called the carpet finishing subcategory;
and (c) the stock and yarn dyeing and finishing subcategory is
now called the stock and yarn finishing subcategory.
The following revised subcategorization scheme forms the basis of
final regulations for the textile mills point source category:
Wool Scouring
Wool Finishing
Low Water Use Processing
-General Processing
-Water Jet Weaving
Woven Fabric Finishing
Knit Fabric Finishing
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
In addition, separate NSPS are being established for subdivisions
of the woven fabric finishing subcategory (simple manufacturing
operations, complex manufacturing operations and desizing) and
the knit fabric finishing subcategory (simple manufacturing
operations, complex manufacturing operations and hosiery
products.
BASIS OF FINAL SUBCATEGORIZATION SCHEME
Rationale for Selection o£ Final Subcategorization Scheme
The original subcategorization scheme of the textile mills point
source category included seven subcategories. After reviewing
all available data on the textile industry, the Agency determined
that certain processing operations were not covered by the
existing subcategorization scheme: nonwoven manufacturing, felted
66
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fabric processing and water jet weaving. The Agency determined
that raw waste loadings at mills where these operations are
employed are significantly different than those at mills that
conform to the seven original subcategory definitions (see Table
IV-1). Therefore, EPA has revised the original subcategorization
scheme to account for these process differences.
Water jet weaving is a relatively new weaving technology.
Because it is used in the production of greige goods, the Agency
has included it as a new subdivision of the low water use
processing subcategory which includes mills where greige goods
are produced. EPA has established separate nonwoven
manufacturing and felted fabric processing subcategories to
account for these processing operations.
Also, as shown in Table IV-1, raw wastewater loadings of various
mills within the woven fabric finishing and the knit fabric
finishing subcategories differ significantly. In the woven
fabric finishing subcategory, at mills where complex processing
operations {printing, water-proofing and application of
functional finishes in addition to dyeing and fiber preparation)
are performed, wastewaters are discharged that are higher in
volume and have higher BOD5_, COD and TSS raw waste loads than at
mills where simple operations (dyeing and fiber preparation) are
performed. In addition, at mills where the desizing process is
employed, wastewaters are generated that are higher in volume and
raw waste loadings than at complex mills.
In the knit fabric finishing subcategory, wastewaters that are
higher in volume and raw waste loadings are generated at complex
mills (mills where printing, water-proofing and application of
functional finishes are performed in addition to dyeing and fiber
preparation) than at simple mills (mills where dyeing and fiber
preparation are performed). In addition, at mills where hosiery
products are manufactured, wastewater loadings are
distinguishable from those associated with both simple and
complex processing.
Accordingly, final NSPS include separate limitations for these
subdivisions of the woven fabric finishing and knit fabric
finishing subcategories; however, the promulgated BAT limitations
do not. As discussed in Sections I and IX, the Agency is
establishing BAT effluent limitations controlling toxic and
nonconventional pollutants equal to the previously promulgated
BPT limitations. BPT limitations were based on biological
treatment and apply to all of the different operations employed
in the woven fabric finishing and the knit fabric finishing
subcategories. BPT does include COD allowances to account for
the higher COD raw waste loads typical of more complex operations
in both subcategories. It is likely that costs would be incurred
at some mills if BAT limitations required attainment of specific
new limitations for the new subdivisions (simple, complex and
desizing or hosiery operations) different from those specified in
67
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TABLE IV-1
MEDIAN UNTREATED WASTEWATER CHARACTERISTICS
CD
Subcategory
Wastewater
Discharge Rate
(I/kg) (gal/lb)
Pollutant Mass Discharge Rate
BOD5 COD TSS
(kg/kkg) (kg/kkg) (kg/kkg)
1.
2.
3.
4.
5.
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
11.7
304.4
6.7
86.7
76.7
97.6
105.9
117.6
122.6
75.1
46.7
96.7
40.0
212.7
1.4
36.5
0.8
10.4
9.2
11.7
12.7
14.1
14.7
9.0
5.6
11.6
4.8
25.5
41.8
63.6
1.3
16.0
22.3
33.2
45.1
23.1
28.1
25.8
25.6
19.5
6.7
70.2
225.7
204.8
7.7
18.2
88.4
104.9
122.0
84.4
121.5
88.4
82.3
62.1
38.4
186.0
51.9
16.3
1.6
2.7
7.7
9.1
14.8
6.3
8.4
6.1
4.7
4.5
2.2
64.1
Source: Industry 308 Survey,
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existing permits based on the BPT regulation. The Agency does
not have sufficient information to determine the magnitude of
these costs and, therefore, cannot assess the economic impact of
establishing different limitations. Accordingly, other than
those allowances included in the existing BPT regulation,
separate BAT limitations are not established for simple, complex
and desizing operations in the woven fabric finishing subcategory
or for simple, complex and hosiery operations in the knit fabric
finishing subcategory.
Additional Analyses
Prior to proposal of regulations in October of 1979, EPA
conducted additional analyses to investigate the possibility that
certain of the subcategories could be combined to simplify the
subcategorization scheme. The subcategories tested were those
established in earlier effluent guidelines studies of the textile
industry (wool scouring, wool finishing, woven fabric finishing,
knit fabric finishing, carpet finishing and stock and yarn
finishing), plus segments not previously recognized (hosiery
products, nonwoven manufacturing and felted fabric processing).
Specific statistical tests were used to determine if any of the
subcategories or industry segments could be combined or to verify
that they are truly different. Wastewater discharge rates and
BOD5> COD and TSS raw waste loadings were used in this analysis.
Long-term averages (means) were calculated for these parameters
based on historical sampling data and available production
information. The medians of the long-term averages were
determined for each subcategory and new industry segment and
compared. Because extensive historical sampling data were not
available for all mills, it was necessary to use only those data
that are representative of the segments of the industry being
compared. Questionable data, such as single grab samples and
estimated production values, and old data suspected of being
nonrepresentative of current processing, were not used in the
comparisons.
While statistical methods are a powerful tool for comparing and
drawing conclusions about different populations (subcategories),
other factors also can influence these comparisons. For example,
wastewater characterization data can vary from mill to mill
because of reasons not related to subcategorization. These
reasons include such factors as operation of ancillary equipment
and differences in sampling or analytical techniques. In
addition, a degree of uncertainty is inherently involved in the
use of statistics because conclusions are drawn about entire
populations (subcategories) based on limited samples from those
populations. This study has attempted to minimize these
influences by using the 95 percent confidence level (level of
significance) in deciding whether the statistical tests indicate
a true difference between subcategories.
69
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To select the most appropriate statistical tests to use in
determining statistical validity, it is necessary to establish
the type of distribution (e.g., normal, lognormal or geometric)
that the data most closely represent. To accomplish this for the
textile industry, wastewater discharge rates (I/kg of product)
and raw waste loadings (kg/kkg of product) for BOD£, COD and TSS
were plotted for selected trial subcategories on linear and log
probability paper. However, the plots, along with graphs of
frequency distribution, were inconclusive in establishing a
typical distribution for the data. As a result, EPA decided that
distribution-free tests would be most appropriate for testing the
subcategorization. The tests chosen were the Wilcoxon Two-Sample
Test and Mann-Whitney U Test (12, 13, 14). The tests are
similar, with the Wilcoxon Two-Sample Test more applicable to
smaller samples (usually less than 20 values).
The Wilcoxon Two-Sample and Mann-Whitney U Tests examine the null
hypothesis that two samples come from identical continuous
populations (subcategories) against the alternative that the
populations have unequal means, i.e., that the subcategories are
statistically different. Under certain assumptions, they are an
alternative to the standard two-sample "t" test used for normally
distributed data. The tests employ ranking of observations as
the basis for statistical decision-making and take into account
the relative position of each data point within the groups of
data being tested. The results of the statistical tests are the
determination of levels of significance that represent the
probability that an error has been made in stating that compared
samples come from statistically different subcategories. A low
level of significance indicates a high probability that the two
samples (subcategories) are statistically different.
The results of this analysis indicated that each of the original
subcategories and new industry segments are unique and that
combining any of the subcategories was not justified. Some
comparisons of the knit fabric finishing, woven fabric finishing,
carpet finishing and stock and yarn finishing subcategories and
the hosiery and felted fabric segments are shown in Table IV-2.
Based on the results of this analysis, EPA used the revised
subcategorization scheme as the basis of proposed rules published
in October 1979.
Comments received on the October 1979 proposed regulation were
very supportive of the revised subcategorization scheme.
However, some comments were received suggesting the following
revisions to the proposed subcategorization scheme:
a. one commenter suggested that, in the wool finishing
subcategory, significant differences in wastewater
characteristics result from the processing of virgin
and reprocessed wool.
70
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TABLE IV-2
COMPARISON 07 RAW WASTEWATER CHARACTERISTICS
OF SELECTED SUBCATEGORIES AND INDUSTRY SEGMENTS
Wastewater
Pollutant Mass Discharge Rate
Products Compared
(Subcategories)
Woven Fabric vs Knit Fabric
Knit Fabric vs Carpet
Kait Fabric vs Stock & Yarn
Carpet vs Stock & Yarn
Nonwoven vs Felted Fabric
Hosiery vs Carpet
Hosiery vs Stock & Yarn
Knit Fabric vs Hosiery
Discharge Rate
Sample*
138/108
108/37
108/117
37/117
11/11
58/37
58/117
108/58
Level #
0.5
(0.1)
11
(0.1)
0.1
0.5
2
(0.1)
BODS
Sample*
94/54
54/10
54/61
10/61
4/4
42/10
42/61
54/42
Level #
5
[20]
19
[20]
3
[20]
[20]
[20]
COD
Sample*
70/41
41/14
41/45
14/45
3/4
30/14
30/45
41/30
Level #
[20]
5
1
[20]
6
17
11
[20]
TSS
Sample*
76/51
51/12
51/58
12/58
4/4
31/12
31/58
51/31
Level #
3
2
0.2
[20]
1
17
15
[20]
* Number of data points (mills) in comparison; slash separates subcategories compared.
# The level of significance represents the probability that an error has been made in stating that the samples
(subcategories) compared are different (come from different populations). A 0.1 percent level of significance
indicates that the probability is 0.1 percent that an error has been made. A 10 percent level of significance
indicates that the probability is 10 percent that an error has been made. Levels of significance of 5 percent
or less indicate that the samples compared are statistically different.
Notes: 1. ( ) Indicates Level of Significance is less than reported value.
2. [ ] Indicates Level of Significance is greater than reported value.
3. The Mann-Whitney U Test was used when one or both samples exceeded 20.
4. The Wilcoxon Two-Sample Test was used when both samples were less than 20.
-------
b. one commenter suggested that significant differences in
wastewater characteristics result from the production
of ladies' hosiery compared to anklets and socks.
c. one commenter suggested that COD limits should be
revised because of significant differences in process
water requirements for yarn dyeing mills processing
only polyester/cotton blends.
d. some commenters suggested that the commission finishing
allowances contained in the BPT regulations should be
retained in final BAT regulations and new source
performance standards.
In response to comments on the proposed subcategorization scheme,
the Agency performed statistical tests identical to those
described above (see Table IV-3). EPA found that, while raw
materials, processes and process machinery differ in the
production of ladies' hosiery and anklets/socks, differences in
wastewater discharge rate and pollutant mass discharge rates are
not statistically different. Therefore, further segmentation of
the hosiery products subdivision of the knit fabric finishing
subcategory cannot be justified. Further, based on the limited
data available on wastewater characteristics resulting from the
processing of virgin compared to reprocessed wool, further
segmentation of the wool finishing subcategory is not warranted.
The Agency does not have sufficient data available to determine
if there are differences in process water requirements or COD raw
waste loads because of the type of fiber processed at yarn dyeing
mills (i.e., natural fibers, synthetic fibers or
natural/synthetic fiber blends). The commenter did not submit
additional data on water usage, production or COD discharges to
support his contention that an additional COD allowance should be
provided when only polyester/cotton blends are processed. He
simply stated that his yarn dyeing mill requires three times the
median wastewater discharge rate reported by the Agency to be
typical of the stock and yarn finishing subcategory. In the
absence of data, the Agency cannot justify further subdivision of
the stock and yarn finishing subcategory.
The Agency also evaluated "commission finishing" to determine if
the special nature of the processing performed by commission
finishers (small lot sizes, short runs, variability in fabric
processed and variability in chemical use) warrants additional
discharge allowances. A limited amount of historical data were
available on commission finishers from the initial industry
survey; therefore, the Agency conducted a special industry survey
in which current data on commission finishing were solicited from
industry. The Agency expended considerable effort to collect
these data, but response by the industry was poor; only a limited
amount of new data was made available. The Agency analyzed the
available data and determined that the wastewater characteristics
72
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TABLE IV-3
COMPARISON OF RAW WASTEWATER CHARACTERISTICS OF
SELECTED SUBCATEGORY SEGMENTS
w
Wastewater
Discharge Rate
Subcategocy
Wool Finishing
Hosiery Finishing
Woven Fabric, Desizing
Knit Fabric, Complex
Subdivisions Compared
Virgin vs Reprocessed
Ladies vs Socks & Anklets
Commission vs Noncommissioo
Commission vs Noncomnission
Sample*
138/108
108/37
108/117
37/117
Level #
0.5
(0.1)
11
(0-1)
Pollutant Mass Discharge Rate
BODS
Sample*
94/54
54/20
54/61
10/61
Level #
5
(20)
19
[20]
COD
Sample*
70/41
41/14
41/45 '
14/45
Level #
[20]
5
1
[20]
TSS
Sample*
76/51
51/12
51/58
12/58
Level #
3
2
0.2
[201
* Number of data points (mills) in comparison; slash separates subcategories compared.
it The level of significance represents the probability that an error has been made in stating that the samples
(subdivisions) compared are different (come from different populations). A 0.1 percent level of significance
indicates that the probability is 0.1 percent that an error has been made. A 10 percent level of significance
indicates that the probability is 10 percent that an error has been made. Levels of significance of 5 percent
oc less indicate that tile samples compared are statistically different.
Notes: 1. [ ] Indicates Level .of Significance is greater than reported value; ( ) indicates less than.
2. NC Indicates that no comparison was made due to an insufficient sample size to perform the statistical test.
3. The Mann-Whitney U Test was used when one or both samples exceeded 20.
4. The Wilcoxon Two-Sample Test was used when both samples were less than 20.
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of commission finishers are not significantly different than for
other mills (see Table IV-3), In fact, in some subcategories,
raw waste loadings for commission finishers are lower than for
other mills where commission finishing is not employed.
Accordingly, final NSPS do not provide an allowance for
commission finishing. Current BPT limitations allow an
additional discharge allowance for commission finishing. The
Agency has not investigated the economic impact on existing mills
of the elimination of the commission finishing allowance.
Because, as discussed in Sections I and IX, the Agency is
establishing BAT limitations equal to BPT limitations for the
textile industry, the Agency has decided that existing
dischargers shall still be entitled to this allowance.
IMPACT OF TOXIC POLLUTANT DATA
As part of technical study undertaken to review and revise, if
necessary, the effluent guidelines and standards previously
published, the Agency conducted a comprehensive sampling and
analytical program. The program was designed to determine the
frequency and amounts of toxic pollutants discharged from mills
in the textile industry. EPA reviewed the analytical data
generated through this sampling program. The Agency concluded
that, although certain toxic pollutants (e.g., napthalene,
acrylonitrile, arsenic, cadmium and silver) occurred more
frequently than did other toxic pollutants, no relationship
exists between the frequency of occurrence or quantity of toxic
pollutants discharged from mills characteristic of a specific
subcategory or subcategories. Therefore, toxic pollutant
generation is not a factor affecting subcategorization of the
textile mills point source category.
SUBCATEGORY DESCRIPTIONS
Wool Scouring Subcateqory
This subcategory includes facilities where natural impurities are
scoured from raw wool and other animal hair fibers. Before they
can be converted into textile products, raw wool and other animal
hair fibers must be thoroughly cleaned. This results in the
generation of wastewaters that contain considerably higher
pollutant concentrations than those of other subcategories (see
Section V). A complete description of the wool scouring process
is presented in Section III.
At integrated mills where both wool scouring and other finishing
operations are employed, discharge allowances should be
determined by applying wool scouring effluent limitations to the
wool scouring production and by applying limitations associated
with other finishing operations to the production associated with
each finishing operation.
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Wool Finishing Subcateqory
This subcategory includes facilities where fabric is finished,
the majority of which is wool, other animal hair fiber, or blends
containing primarily wool or other animal hair fibers. The
following processing operations are employed: carbonizing,
fulling, bleaching, scouring {not including raw wool scouring),
dyeing and application of functional finish chemicals. A
description of typical wool finishing operations is presented in
Section III.
Mills where stock or yarn consisting primarily of wool, other
animal hair fibers, or blends containing primarily wool or other
animal hair fibers are finished and where carbonizing is
performed are included in this subcategory; however, those mills
where carbonizing is not performed are included in the stock and
yarn finishing subcategory.
At integrated mills where both wool finishing and other textile
operations are performed, discharge allowances should be
determined by applying wool finishing effluent limitations to the
wool finishing production and by applying limitations associated
with other operations to the production associated with each
operation.
Low Water Use Processing Subcateqorv
Low water use processing operations include the manufacture of
greige goods (yarn, woven fabric and knit fabric), laminating or
coating fabrics, texturizing yarn, tufting and backing carpet,
producing tire cord fabric, and similar manufacturing processes
in which either cleanup is the primary source of wastewater or
process water requirements per unit of production are small, or
both.
As discussed previously, water jet weaving is not technically a
low water use process. It is included as a subdivision of this
subcategory because it is related to greige goods production.
The wastewater discharge rate is significantly higher for water
jet weaving than for other low water use processes; however, the
low strength of the wastewater results in low pollutant mass
discharge rates.
The low water use processing subcategory consists of two
subdivisions:
General Processing This low water use processing subdivision
includes all low water use processes except water jet weaving.
Water Jet Weaving This low water use processing subdivision
covers the manufacture of woven greige goods using the water jet
weaving process.
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Woven Fabric Finishing Subcategorv
This subcategory includes facilities where primarily woven fabric
is finished using the following processing operations: desizing,
scouring, bleaching, mercerizing, dyeing, printing and
application of functional finish chemicals. These processes are
described in Section III.
Integrated mills where primarily woven fabric is finished along
with greige manufacturing or other finishing operations such as
yarn dyeing and denim finishing are included in this subcategory.
At many finishing facilities, weaving is also done but the added
hydraulic and pollutant loadings from slasher equipment cleanup
are insignificant compared to the finishing wastes. Woven fabric
composed primarily of wool, other animal hair fiber, or blends
containing primarily wool or other animal hair fibers are
included in the wool finishing subcategory.
At integrated mills where both woven fabric finishing and other
textile operations are performed, discharge allowances should be
determined by applying woven fabric finishing effluent
limitations to the woven fabric finishing production and by
applying limitations associated with other operations to the
production associated with each operation.
The desizing process is a major contributor to the oxygen demand
in woven fabric finishing wastewater. When synthetic compounds
such as PVA, CMC and PAA are the primary sizing agents removed,
the COD load is noticeably increased. In addition, the number of
processes performed at a particular mill may vary from only
scouring or only bleaching to all of those listed above. As
explained previously, BPT effluent limitations provided
additional allowances for COD to account for the higher COD raw
waste loads typical of more complex operations in this
subcategory. In addition, in developing new source performance
standards, the following subdivisions were identified to account
for higher raw waste loads associated with more complex
operations and desizing:
Simple Manufacturing Operations This woven fabric finishing
subdivision includes facilities where desizing, dyeing or other
fiber preparation processes are performed.
Complex Manufacturing Operations This woven fabric finishing
subdivision includes facilities where the simple unit processes
{desizing, dyeing and fiber preparation) are employed in addition
to other manufacturing operations such as printing,
water-proofing or application of stain resistance or other
functional fabric finishes,
Desizinq This woven fabric finishing subdivision includes
facilities where, more than 50 percent of total production is
desized. At these facilities, other processes are employed such
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as fiber preparation, scouring, mercerizing, functional
finishing, bleaching, dyeing and printing.
Knit Fabric Finishing Subcateqory
This subcategory includes facilities where primarily knit fabrics
of cotton and/or synthetic fibers are finished. The following
processing operations are employed: scouring, bleaching, dyeing,
printing and application of lubricants, antistatic agents and
functional finish chemicals. Basic knit fabric finishing
operations are similar to those in the woven fabric finishing
subcategory. Knitting is performed in conjunction with finishing
at most of these facilities. Desizing is not required in knit
fabric finishing and mercerizing is uncommon. The generally
lower wastewater loads of this subcategory compared to the woven
fabric finishing subcategory can be attributed to the absence of
these processes.
Integrated mills where primarily knit fabrics or hosiery are
finished and greige manufacturing or other finishing operations
such as yarn dyeing are employed are included in this
subcategory. At integrated mills where both knit fabric
finishing and other textile operations are performed, discharge
allowances should be determined by applying knit fabric finishing
effluent limitations to the knit fabric finishing production and
by applying limitations associated with other operations to the
production associated with each operation.
As with woven fabric finishing, the number of processes performed
at a mill may vary considerably. In addition, hosiery
manufacture is distinct in terms of manufacturing and raw
wastewater. characteristics (see Tables V-29 and V-30). As
explained previously, BPT effluent limitations provided
additional allowances for COD to account for the higher COD raw
waste loads typical of more complex operations in this
subcategory. In addition, in developing NSPS, the following
subdivisions were identified to account for higher raw waste
loads associated with more complex operations and to account for
hosiery production.
i
Simple Manufacturing Operations This knit fabric finishing
subdivision includes facilities where fiber preparation and
dyeing are performed.
Complex Manufacturing Operations This knit fabric finishing
subdivision includes facilities where simple unit processes
(dyeing and fiber preparation) are employed in addition to
manufacturing operations such as printing, water-proofing or
application of stain resistance or other functional fabric
finishes.
Hosiery Products This knit fabric finishing subdivision
includes facilities where hosiery of any type is dyed or
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finished. Compared to other knit fabric finishing facilities,
hosiery finishing mills are generally much smaller in terms of
wet production {an average of 2,950 kg/day for hosiery mills
compared to 18,400 kg/day for other knit fabric finishing mills),
more frequently employ batch processing and more often perform
only one major wet-processing operation (dyeing). All of these
factors contribute to the lower raw waste loadings associated
with hosiery production (see Tables V-l and V-2).
Carpet Finishing Subcateqory
This subcategory includes facilities where textile-based floor
covering products, of which carpet is the primary element, are
finished by employing any of the following processing operations:
scouring, carbonizing, fulling, bleaching, dyeing, printing and
application of functional finish chemicals. These processes are
described in Section III.
Integrated mills where primarily carpet is finished along with
tufting or backing operations or other finishing operations (such
as yarn dyeing) are included in this subcategory. Mills where
only carpet tufting and/or backing are performed are included in
the low water use processing (general processing subdivision)
subcategory.
At integrated mills where both carpet finishing and other textile
operations are performed, discharge allowances should be
determined by applying carpet finishing effluent limitations to
the carpet finishing production and by applying limitations
associated with other operations to the production associated
with each operation. Carpet manufactured by woven or nonwoven
processes are included in this subcategory if the wet-finishing
operations are consistent with those presented above.
Stock and Yarn Finishing Subcateqory
This subcategory includes facilities where stock, yarn or cotton
and/or synthetic fiber thread is finished by employing any of the
following processing operations: scouring, bleaching,
mercerizing, dyeing or application of functional finish
chemicals. Thread processing (including bonding, heat setting,
lubrication and dressing) is basically dry and does not generate
much wastewater. Stock and yarn finishing processes are
described in Section III. The concentrations and mass discharge
rates of the commonly measured conventional and nonconventional
wastewater pollutants (BOD, COD and TSS) are typically lower than
in the other major wet-processing subcategories (see Tables V-29
and V-30).
Facilities where stock or yarn consisting principally of wool,
other animal hair fiber (or blends containing primarily wool or
other animal hair fibers) is finished are also included in this
subcategory if carbonizing is not performed. At integrated mills
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where both stock and yarn finishing and other textile operations
are performed, discharge allowances should be determined by
applying stock and yarn finishing effluent limitations to the
stock and yarn finishing production and by applying limitations
associated with other operations to production associated with
each operation.
Nonwoven Manufacturing Subcateqory
This subcategory includes facilities where nonwoven textile
products of wool, cotton or synthetics, singly or as blends, are
manufactured by mechanical, thermal and/or adhesive bonding
procedures. Nonwoven products manufactured by fulling and
felting processes are covered in the felted fabric processing
subcategory.
The nonwoven manufacturing subcategory includes a variety of
products and processing methods. The processing is dry
(mechanical and thermal bonding) or low water use (adhesive
bonding) with the major influence on process-related waste
characteristics resulting from the cleanup of bonding mix tanks
and application equipment. Typical processing operations are
described in Section III and include carding, web formation,
wetting, bonding (padding or dipping with latex acrylic or
polyvinyl acetate resins) and application of functional finish
chemicals. Pigments for coloring the goods are sometimes added
to the bonding materials. As discussed in Section IX,
wastewaters generated in this subcategory are similar to those
discharged from mills in the carpet finishing subcategory.
At integrated mills where both nonwoven manufacturing and other
textile operations are performed, discharge allowances should be
determined by applying nonwoven manufacturing effluent
limitations to the nonwoven manufacturing production and by
applying limitations associated with other operations to the
production associated with each operation.
Felted Fabric Processing Subcategory
This subcategory includes facilities where primarily nonwoven
products are manufactured by employing fulling and felting
operations as a means of achieving fiber bonding. Wool, rayon
and blends of wool, rayon and polyester are typically used to
produce felts. Felting is accomplished by subjecting the web or
mat to moisture, chemicals (detergents) and mechanical action.
Wastewater is generated during rinsing steps that are required to
prevent rancidity and spoilage of the fibers. Typical felted
fabric processing operations are discussed in Section III. As
discussed in Section IX, wastewaters generated in this
subcategory are similar to those discharged from mills in the
wool finishing subcategory.
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At integrated mills where both felted fabric processing and other
textile operations are performed, discharge allowances should be
determined by applying felted fabric processing effluent
limitations to the felted fabric processing production and by
applying limitations associated with other operations to the
production associated with each operation.
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SECTION V
WASTE CHARACTERISTICS
INTRODUCTION
Section IV provides the rationale for the subcategorization
scheme developed by EPA in establishing effluent limitations
guidelines, new source performance standards and pretreatment
standards for existing and new sources in the textile industry.
The information presented in this section includes: a detailed
discusssion of the untreated wastewater characteristics relative
to the typical processing in each subcategory; total wastewater
discharge (cu m/day) and rate of wastewater discharge per unit of
production (liter of wastewater/kg of production) for each
subcategory; pollutant concentrations (ug/1 or mg/1) and mass
discharge rates (kg of pollutant/kkg of production) for each
subcategory. Pollutant characteristics are presented separately
for toxic pollutants and for the traditionally monitored
nonconventional and conventional pollutants in the textile
industry.
The discussion of untreated wastewater characteristics was
developed from textbooks, technical periodicals, mill visits,
survey information and general discussion with knowledgeable
industry personnel.
Wastewater volume and traditionally monitored nonconventional and
conventional pollutant data were, for the most part, acquired
from the records of textile industry wastewater treatment plants,
Federal and state discharge monitoring reports, records of
publicly owned treatment works (POTWs) and field sampling. Toxic
pollutant data were not readily available and acquisition
required a detailed field sampling program. (See Section II for
a discussion of the sampling and analysis program.)
Besides characterizing untreated wastewater, the field sampling
program included the acquisition of toxic, nonconventional and
conventional pollutant data for the water supply at various
mills. These data.were collected to determine the relationship
between water supply and untreated process wastewater. In
addition, data were acquired for biological and physical/chemical
treatment systems. These data are presented in detail in Section
VII to document the effectiveness of treatment technologies. The
data showing the presence and concentrations of toxic pollutants
after biological treatment are presented in this section to
identify the toxic pollutants of significance in the industry.
The methods used to aggregate individual mill data, the data for
the mills represented by each subcategory and the data for the
industry as a whole are presented and discussed below.
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DISCUSSION OF UNTREATED WASTEWATER CHARACTERISTICS
The untreated wastewater characteristics for the textile industry
generally reflect the products produced and the methods employed
to produce them. Because there is such a diversity in products,
processing raw materials and process control, there is a wide
range in wastewater characteristics. This variation exists
within subcategories as well as between the subcategories.
Nonprocess variables such as intake water quality and discharge
of nonprocess wastes (e.g., sanitary wastewater, boiler blowdown,
cooling water) contribute to this lack of uniformity.
In Section III, the typical wet processing operations
contributing to wastewater discharge are presented and discussed.
In Section IV, the selected subcategories are presented and the
basis for their selection explained. The discussions that follow
relate the processing and untreated wastewater characteristics
for each subcategory and explain the source(s) of the pollutants
specific to each.
Wool Scouring Subcategory
Wool scouring wastewater contains significant quantities of
natural oils, fats, suint and adventitious dirt that, even after
in-process grease recovery steps, result in wastewater
characteristics that are distinctly different from other
subcategories. These materials are collectively responsible for
high concentrations and quantities of BOD5., COD, TSS and oil and
grease. Because the natural fat is technically a wax, it is not
readily biodegradable and must be removed by physical or chemical
treatment.
According to Trotman (10), a typical dirty wool might consist of
33 percent keratin (wool protein), 26 percent dirt, 28 percent
suint, 12 percent fat and 1 percent mineral matter. The
constituents are different for the wool from different breeds of
sheep, and it is stated that raw wool may contain between 30 and
70 percent impurities.
Sulfur, phenolics and other organic compounds are brought in with
the wool. Phenolics are derived from sheep urine, feces, blood,
tars, branding fluids and insecticides used in sheep dips.
Sulfur makes up approximately 3 to 4 percent of clean keratin and
enters the waste stream as fiber (10).
Wool scouring is generally performed in a series of scouring
bowls using a counterflow process. The total concentration of
soap or detergents and alkali (generally sodium carbonate) is
about 1 percent. The contribution of pollutants from these
scouring materials is insignificant compared to the residual
materials scoured from the stock fiber. Complete purification of
the wool is not practical, and it is usually accepted that the
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scouring has been satisfactory if the wool contains less than 0.5
percent oil and grease (10).
Wastewater from the wool scouring process is usually brown,
thickly turbid and noticeably greasy. It is strongly alkaline
and very putrescibe.
Wool Finishing Subcateqory
Wool finishing wastewaters are typically low in concentration of
BOD5_, COD, TSS and oil and grease, but because of the large
volumes generated, contribute large quantities of these
pollutants per unit of production relative to the other
subcategories. The other traditionally monitored pollutants
(total phenols, chromium, sulfide and color) are high in both
concentration and mass discharge rate, relative to the other
subcategories. These conditions can be attributed to the
numerous steps required in processing and finishing wool yarn and
wool fabric and to the wide variety of chemicals used. The
contributions of pollutants from each of the major wool finishing
steps are detailed below.
Heavy Scour Even after effective raw grease wool scouring, wool
fiber contains a small amount of grease and foreign material.
Also, oil (2 to 5 percent by weight) is often added prior to
spinning to provide lubrication. All of these materials must be
removed before finishing can be performed and to prevent future
degradation of the wool fiber by bacteriological action.
The heavy scour process consists of washing the fabric with
detergents, wetting agents, emulsifiers, alkali, ammonia or
various other agents to remove the foreign and applied materials.
Fibers used to manufacture fancy goods are dyed in the stock
state and undergo heavy scour prior to the stock dyeing step.
Piece-dyed goods are scoured in the fabric state before the
dyeing step; the weight, foreign material content and degree of
felting of the fabric all have a direct bearing on the degree of
scouring required.
Heavyweight, closely-woven fabrics with a high percentage of
recycled wool require very heavy detergents, long wash times and
extensive rinsing periods. Relative to lighter weight fabric
with no or a low percentage of recycled wool, high organic and
hydraulic discharge rates are associated with the scouring of
these types of fabric. Light, open goods with a low percentage
of recycled wool generally scour more easily with lighter
detergents, shorter wash times and less rinsing, resulting in
lower organic and hydraulic discharges than the heavy scour
process.
Because some woolen mills produce only heavyweight fabric, some
produce only lightweight fabric, and some produce both, it is
apparent that considerable hydraulic and organic fluctuations can
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exist from the heavy scour process. Typically, these
fluctuations alone do not significantly influence the variability
of the total discharge among wool finishing mills because of the
large amount of flow associated with the other major wool
finishing processes.
Carbonizing Carbonizing does not contribute greatly to the
pollutant concentration of wool finishing wastewater but, because
of the rinsing steps used to neutralize the acid taken up by the
fabric, does add significantly to the hydraulic load. As
discussed in Section III, carbonized vegetable matter is removed
as a solid waste and only the residual sulfuric acid and
neutralizing agents {generally sodium carbonate) enter the
wastewater. The acid bath must be dumped when it becomes too
contaminated for efficient carbonization and the acid taken up by
the fabric must be neutralized to prevent damage to the wool
fibers. The wastewaters from the carbonizing process are
typically acidic, low in organic content and high in total
solids.
Fulling Fulling, like carbonizing, does not contribute greatly
to the pollutant concentration of wool finishing wastewater but
does add to the hydraulic load. Wastewater is generated during
the washing and rinsing steps, which are required to prevent
rancidity and wool spoilage, when the water bath (wet fulling
only) is dumped. If alkali fulling is used, the rinse streams
will contain soap or detergent, sodium carbonate and sequestering
agents (phosphate compounds). If acid fulling is used, sulfuric
acid, hydrogen peroxide and small amounts of metallic catalysts
(chromium, copper or cobalt) also are present.
Bleaching Bleaching is performed on woolens, but to a lesser
degree than on cotton goods. Only 40 percent of the woolen mills
that returned detailed surveys practice bleaching. Those mills
that perform bleaching do so on 20 percent or less of their
production. Hydrogen peroxide is generally used because sodium
hydrochloride and calcium hydrochloride discolor and damage wool
fibers. The discharge rate of wastewater from hydrogen peroxide
bleaching of wool is generally in the range of 8.3 to 25.0 I/kg
(1 to 3 gal/lb) of product and the BOD contribution is usually
less than 1 percent of the total for the typical wool finishing
process. The mass discharge rates for other conventional
parameters are generally very small relative to the discharge
rates from other processes.
Dyeing The typical dyeing processes for the industry are
discussed in Section III. As noted in that discussion, some of
the dyes and dye chemicals used for wool goods are specific to
the wool fiber. The acid and metalized dyes are commonly used
while mordant and fiber reactive dyes are used to a lesser
extent. Because of the recognized hazards of chromium entering
the waste streams, the use of mordant dyes has greatly diminished
-------
and they presently are used only if exceptional wash fastness
required.
is
In sensitive dyeing, a prescour step is often used. Detergents
and wetting agents are added, the scouring performed and the
fabric thoroughly rinsed. The wastewater generated contributes
to the hydraulic load but adds little to the pollutant
concentration.
For acid dyes, control of pH to a value suitable to the type of
dye in use is necessary. The ingredients, in addition to the
dyes, include Glauber's salt (sodium sulfate), sulfuric acid and
formic acid.
The metalized dyes have very good wash fastness and a very high
affinity for wool even under mildly acidic conditions and at low
temperatures (below no°C). These dyes often are used on 100
percent wool fabric. Metalized dyes are almost completely
exhausted so only a small quantity of metallic ions (chromium)
enter the wastewater.
Blends of wool and synthetic fibers are dyed in a single bath or
in two separate baths. When two baths are used, dyes specific to
each fabric type are used and the hydraulic load can increase by
50 percent. In each type of dyeing, the fabric is cooled with
fresh water and thoroughly rinsed; both steps add greatly to the
hydraulic load.
Low Water Use Processing Subcateqory
Low water use processing refers, almost exclusively, to weaving
or adhesive products processing. Weaving facilities include the
conventional weavers and water jet weavers. The conventional
weavers and adhesive products processors (general processing
subdivision of the subcategory) have very low wastewater
discharge rates relative to the other subcategories, while the
water jet weavers have wastewater discharge rates comparable to
many of the other subcategories (see Table V-l). The only mills
with relatively large discharges are those engaged in water jet
weaving and those discharging large volumes of cooling or other
nonprocess wastwater. Process wastewater characteristics are
determined primarily by the slashing process (conventional
weaving), the weaving process (water jet weaving mills) or the
dipping, padding or saturating process (adhesive products
processing mills). The contributions of pollutants from these
processes are discussed below.
Slashing The slashing operation (see Section III) consists of
coating yarn with sizing compounds prior to weaving. At
conventional weaving mills, slashing is generally the only source
of process wastewater. Wastewater results from spillage in the
size mixing area, dumps of excess sizing and cleanup of the
slasher and mixing equipment. Among the components that are used
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in sizing formulations and that may enter the wastewater are the
sizing compounds (e. g., starch, PVA, CMC or PAA), wax or tallow,
wetting agents, softeners, penetrants, plasticizers, fungicides,
bacteriostats and other preservatives. Sizing formulations
typically exert a high COD and, when starch is the primary sizing
agent, high BODj> also is exerted. In general, the wastes from
the slashing operation are diluted by nonprocess wastewater, such
as sanitary wastewater, boiler blowdown and noncontact cooling
water generated at these mills.
Water Jet Weaving Water jet looms are a special type of
shuttleless loom that use a jet of water to propel the filling
yarns during the weaving operation. Although not widely
practiced during 1976 to 1979, water jet weaving is becoming more
popular. Each type of water jet loom has different water
requirements and discharges from the different machines were
reported to range less than 3,785 I/day (100 gpd) up to 37,850
I/day (1000 gpd). The water drains from beneath the machines and
may contain sizing chemicals and contaminants collected from the
fiber. Chemical sizing requirements are less with water jet
looms than with conventional looms because the water serves as
the lubricant. Most of the wastewater from greige mills that use
water jet weaving comes from this process.
Adhesive Products Processing Adhesive products processing (see
Section III) includes operations such as .bonding, laminating,
coating and flocking. In all of these operations, a continuous
adhesive or coating is applied to the material by padding,
dipping, saturating or similar means. Wastewater occurs as a
result of equipment cleanup, rinsing, overspraying or spillage.
PVC from coating or latex compounds from bonding, laminating or
flocking are likely to be the chief constituents of these
wastewaters. Latex wastes may be high in COD and suspended
solids. Depending on the plant operations, other contaminants
such as oil and grease and solids also may find their way into
adhesive products processing wastewaters.
Woven Fabric Finishing Subcategory
The wastewater generated from the finishing of woven fabric is
represented by a broad range of concentration and mass discharge
rates for BOD!>, COD, TSS and oil and grease. Three internal
subdivisions of this subcategory (simple manufacturing, complex
manufacturing and desizing) have been identified. The bases for
these subdivisions are discussed in Section IV. A schematic
displaying the typical processes employed is presented in Section
III. The differences between the three subdivisions are a
function of the complexity of the wet processing. Mills
classified in the complex manufacturing subdivision perform
simple manufacturing plus one or more additional major wet
processing steps. Mills classified in the desizing subdivision
perform desizing on the majority of their production. The
typical wastewater discharge and pollutant mass discharge rates
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are progressively greater for each subsequent subdivision and
generally reflect an increase- in the same basic pollutant
parameters.
The wet processing used by a woven fabric finishing mill could
include desizing, scouring, bleaching, mercerizing, dyeing,
printing and functional finishing. The contributions of
pollutants from these processing operations are discussed below.
Desizinq Desizing contributes to the organic load, adds some oil
and grease, and is responsible for most of the suspended material
found in woven fabric finishing wastewater. Natural starch size
is high in BODS^ while the synthetic sizing agents, which tend to
be less biodegradable unless exposed to an acclimated biological
environment, result in constant BOD5_ but result in increased COD.
Over an extended period (such as the 20 days required for the
BOD2£ test), however, the synthetic sizing agents can exert a
substantial biochemical oxygen demand. Depending on the fabric
type, desizing can contribute 50 percent or more of the total
solids resulting from the finishing of woven fabrics (1). For an
average woven fabric finishing mill processing 100 percent cotton
goods and using starch as the sizing agents, the desizing waste
generally will constitute about 16 percent of the total
wastewater volume, 45 percent of the BOD^>, 36 percent of the
total solids and 6 percent of the alkalinity (11).
Synthetic sizing agents such as PVA, CMC and PAA are soluble in
water and are removed from woven fabric without difficulty.
Starch is not readily soluble and must be hydrolyzed into a
soluble from by the action of special enzymes or acid solutions
before removal. Enzymatic removal generates starch solids, fat,
wax, enzymes, sodium chloride and wetting agents. The waste
contains organic and inorganic dissolved solids, suspended solids
and some oil and grease. It has a pH of 6 to 8 and is light in
color. Sulfuric acid removal generates starch solids, fat, wax
and sulfuric acid. The waste also contains organic and inorganic
dissolved solids, suspended solids and some oil and grease. It
has a pH of 1 to 2 and is relatively light in color. The
desizing subdivision of the woven fabric finishing subcategory
was established principally because of the additional
contribution of pollutants from the desizing operation.
Scouring Scouring of cotton and cotton-synthetic fiber blends
generates wastewater that is strongly alkaline (pH greater than
12), dark in color from cotton impurities and high in dissolved
solids relative to other processes. The wastewater contains oil
and grease and suspended solids that ate removed as impurities in
the cotton fiber. Besides sodium hydroxide, of which a 2 percent
solution typically is used; phosphate, chelating agents and
wetting agents may be used as auxiliary scouring chemicals. For
the typical finishing mill processing 100 percent cotton goods,
the scouring waste generally constitutes about 19 percent of the
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total wastewater volume, 16 percent of the BOD5., 43 percent of
the total solids and 60 percent of the alkalinity (11).
Synthetic fibers are relatively free of natural impurities so
they require less vigorous scouring. These fibers absorb very
little moisture, so static electricity can be a problem during
processing. To minimize this problem, antistatic materials are
applied to the yarns; these materials also serve as lubricants in
sizing compounds. Commonly used compounds are styrene-based
resins, polyalkylene glycols, gelatin, PAA and polyvinyl acetate.
These compounds become a source of water pollution when they are
removed from the fabrics during scouring. In general, a milder
sodium carbonate solution and a surfactant will suffice in
scouring synthetics,
Bleaching Cotton bleaching is accomplished with hypochlorite,
hydrogen peroxide, chlorine dioxide, sodium perborate, peracidic
acid or other oxidizing agents. Reducing agents also may be
used, although the oxidizing agents usually give a more permanent
white color. Today, most cotton bleaching uses hydrogen peroxide
or hypochlorite, either in kiers or on a continuous range;
hydrogen peroxide is the preferred oxidizing agent and the
continuous range the most efficient bleaching method.
Bleaching of cellulosic regenerated fibers is accomplished using
the same methods as for cotton; however, there is less coloring
matter to remove so the strength of the oxidizer can be
decreased. Polyester and polyacrylonitrile fibers are not often
bleached unless part of a cotton-synthetic fiber blend.
Hydrogen peroxide bleaching contributes very small waste loads
relative to other processes, most of which are inorganic
dissolved solids (sodium silicate, sodium hydroxide and sodium
phosphate) and organic dissolved solids (surfactants and
chelating agents). A relatively low level of suspended solids
(fibers and natural impurities) will be present when goods
containing cotton are bleached.
Mercerization Mercerization is practiced to increase the tensile
strength of the cotton fiber and to increase its affinity for
dyes (see Section III). Essentially, the process amounts to
saturating the fabric with sodium hydroxide (usually a 25 to 30
percent solution), allowing sufficient residence time for
interaction and washing the fabric to remove the excess caustic.
Mercerization wastewater is predominantly the sodium hydroxide
solution used in the process, diluted as a result of the washing
step. The wastewater contains high levels of dissolved solids
and may have a pH of 12 to 13. Depending on whether
mercerization is practiced before or after bleaching, small
amounts of foreign material and wax may be removed from the fiber
and will appear as suspended solids and oil and grease. In
total, mercerization has been found to contribute about 1 percent
-------
of the BOD5_ load generated during the processing of 100 percent
cotton woven fabric (15). Today, with synthetics and
cotton-synthetic blends replacing 100 percent cotton fabric,
mercerization is practiced less often. Most of the mills that do
utilize the process have found it economically attractive to
recover sodium hydroxide for reuse. Consequently, the wastewater
contribution from the process has decreased at many mills.
Dyeing Dyeing is without question the most complex of all the wet
finishing operations in the textile industry. There are 9 basic
classifications of dyes according to application and
approximately 17 types according to use by the textile industry
(10). There are thousands of individual dyes. In addition to
the dyestuff itself, various other chemicals are added to help
deposit the dye or to develop the color. Chemicals that are used
include acids, bases, salts, wetting agents, retardants,
accelerators, detergents, oxidizing agents, reducing agents,
developers and stripping agents. A detailed discussion of the
various dyes and dyeing methods is provided in Section III.
Woven fabric usually is dyed as piece goods with batch or
continuous dye equipment. The batch equipment is either
atmospheric type or pressure type; continuous dye equipment is
operated under atmospheric pressure conditions. Atmospheric
dyeing generally requires greater amounts of auxiliary chemicals
to achieve the desired results. Because most of these chemicals
are not retained in the final product but are discarded after
they have served their purpose, atmospheric dyeing customarily
results in increased pollutant mass discharge rates.
Depending on the type of fabric, dye, equipment used and the
efficiency of the processes, the wastewater from the dyeing of
woven fabric may contain many combinations of the dyes and
auxiliary chemicals. The process contributes substantially to
the total pollutant mass discharge rate and is responsible for
most of the wastewater flow. The wastewater from the process may
contain organic and metallic toxic pollutants and is high in
dissolved solids relative to other processes. It is, however,
low in suspended solids relative to other processes. The
wastewater typically is colored and, if the color is not reduced,
can be aesthetically undersireable for discharge into receiving
waters.
For woven fabric finishing mills that process 100 percent cotton,
the BODI3 contribution resulting from the dyeing process was found
to vary from 1.5 to 30 percent of the total (15). Carriers,
which are essential for dyeing polyester, can result in an even
greater BODI3 contribution when cotton/polyester blends and pure
polyesters are being processed.
Printing Printing generally occurs at the same stage in woven
fabric finishing as dyeing. The fabric goes through the
89
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preliminary cleaning and conditioning steps and is printed using
one of several methods. When woven fabric is both dyed and
printed, printing is performed last. A complete discussion of
the types of printing and equipment used is provided in Section
III. Printing often is referred to as "localized dyeing," and
the same basic dyestuffs are used. Dyes are applied as liquid,
while a paste is used in printing. In addition to the dyestuff
and auxiliary chemicals discussed under "Dyeing," a thickener is
used to give the print paste the desired viscosity. Gums serve
as thickeners and those commonly used include locust bean, guar,
alginate, starch and combinations of these. Urea, thiourea and
glycols also are used in many print formulations.
Printing wastes are comparable in constituents to dye wastes,
although the volumes are much lower and the concentrations
greater. The thickeners contribute to the biochemical oxygen
demand and solvents used to prepare pigments and clean pigment
application equipment often are present. Printing pigments will
contribute suspended solids when the fabric is rinsed, although
much of the wastewater from printing comes from the cleaning of
make-up tanks and process equipment.
Functional Finishing The functional finishes represent a large
group of chemical treatments that improve the function of a
fabric by making it resist creasing, water, stains, rot, mildew,
moths, bacteria and other undesirable items. They are more often
applied to the natural fibers (cotton and wool) and are quite
prevalent in the finishing of woven fabrics. As would be
expected from processes that provide such diverse effects, the
range of chemicals used is very broad. For resin treatment, a
urea-formaldehyde-glyoxal compound (DMDHEU), a fatty softener and
a catalyst (zinc nitrate, magnesium chloride) are used together.
Water repellents include silicones, fluorochemicals and fatty
materials, each generally applied with a catalyst. Soil release
treatments include special acrylic polymers and fluorochemicals.
These finishes generally are applied by impregnation of the
fabric followed by squeezing to retain the desired amount of
chemical in the fabric. The moist material is dried and then
heat cured. The cured fabric is frequently packed for shipment
without rinsing. Most resin treated goods are precured (fixed by
the application of heat) during the finishing process. Some
fabrics are postcured (fixed after a garment has been cut, sewn
and pressed). Wastewater from resin treatment, water proofing,
flame proofing and soil release are small in volume relative to
other finishing processes because the chemicals are applied by
padding, followed by drying and curing. Only small quantities of
these chemicals enter the mill's wastewater. Some finishes do
require rinsing after application, which increases the volume of
wastewater and quantity of chemicals discharged.
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Knit Fabric Finishing Subcategory
The wastewater generated from the finishing of knit fabric is,
like that from the finishing of woven fabric, represented by a
broad range in concentration and mass discharge rates for BODI3,
COD, TSS and oil and grease. The concentrations of these
pollutants are lower than those of the woven fabric finishing
subcategory (see Table V-15) and the variability from mill to
mill also is somewhat less. Three internal subdivisions of this
subcategory (simple manufacturing, complex manufacturing and
hosiery products) have been identified. As with woven fabric
finishing, the subdivisions are based on complexity of the
operations. Hosiery production requires less water and a less
variable quantity and variety of process chemicals than simple
and complex manufacturing. The justification for the
subdivisions is discussed fully in Section IV, and a schematic
representing the typical processing sequence for each
subdivision, as well as a description of processes, is presented
in Section III.
The wet processing used by a knit fabric finishing mill (simple
manufacturing and complex manufacturing subdivisions) includes
various combinations of the following operations: scouring,
bleaching, dyeing and printing. Hosiery production typically
uses scouring, bleaching and dyeing. Mills in each subdivision
might apply chemical coatings during the final finishing step,
but only a small amount, if any, of these chemicals enters the
wastewater. The impact of these processes on wastewater
discharged by knit fabric finishing mills is discussed below.
Sizing, as such, is not applied to knitted goods because the
knitting process does not stress the yarn to the same degree as
does weaving. Lubricants (generally mineral oils, vegetable
oils, synthetic esters or waxes) are added during the knitting
process and are effectively removed during scouring.
Scouring Washing or scouring is frequently the first process at
knit fabric finishing mills. Knit goods are washed or scoured
with detergents, soaps or solvents to remove natural or
artificial waxes, oil and other impurities. The discharge from
the process is high in dissolved solids and color (because of
cotton impurities) and may contain a significant amount of the
lubricants noted above. The scouring or washing of 100 percent
synthetic fabrics results in a waste contaminated with greater
concentrations of lubricating oil and and special scouring agents
such as ethoxylated phenols and other emulsifiers.
Bleaching Bleaching of knit fabrics is similar to bleaching of
woven fabrics. The bleaching agents used are generally sodium
hypochlorite or hydrogen peroxide. The previous discussion in
this section on wastewater characteristics associated with
bleaching woven fabrics is applicable to this subcategory.
Bleaching is generally associated with cotton fabric and blends
and is not applied to 100 percent synthetic fabrics.
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Dyeing The dyeing operation is a major source of wastewater in
knit fabric finishing. Beck, beam and jet dyeing are all
commonly employed using either atmospheric or pressure operating
modes. Paddle, rotary or tub dyeing also may be used, especially
for hosiery. Jig dyeing and continuous dyeing are less common.
The types of dyestuff, auxiliary chemicals and conditions
employed for dyeing knit goods are essentially the same as for
woven goods of comparable fiber composition. The discussion
previously presented in this section concerning wastewater
characteristics associated with dyeing woven fabrics also is
applicable to knit fabric dyeing and is not repeated here. In
knit fabric finishing, rinse solutions are often mechanically
extracted. In this step, a centrifugal extractor is used to draw
water out of the fabric.
Printing Printing methods used in finishing knit fabrics are
similar to the methods used on woven fabrics. Sources and
characteristics of the wastes are similar to those previously
discussed for the woven fabric finishing subcategory.
Functional Finishing The functional finishes applied to knit
fabrics are essentially the same as those previously noted for
woven fabrics. The methods of application are also similar and
the same variety of constituents is likely to appear in the
waste.
Carpet Finishing Subcateqory
The total volume of wastewater discharged from a carpet mill is
typically quite large but, when the discharge is normalized for
production, the discharge rate (I/kg of production) is low
relative to other subcategories (see Table V-l). This is because
of the specialized nature of carpet manufacturing. Factors that
contribute to low discharge rates per unit of production are:
limited preliminary wet processing such as scouring and bleaching
is required; dyeing that is performed is usually directed at less
then the total weight of the material placed in the dye machine
(the primary backing is not dyed and often part of the yarn has
been predyed); there is less redyeing to try to match shade;
printing of carpet results in small wastewater flows; and carpet
is heavier per square yard than any of the other textile
products.
The wet processing at a carpet mill includes various combinations
of the following operations: scouring, bleaching, dyeing,
printing, functional finishing and backing. Wastewater from
dyeing and printing are the major contributors to the flows at
these mills, but these processes result in only moderate levels
of the traditionally monitored conventional and nonconventional
pollutants, relative to other subcategories. Functional
finishing and carpet backing make relatively small contributions
to the total flow; the latter often results in a latex waste that
can be segregated from the rest of the wastewater discharge for
92
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separate treatment. The contributions of pollutants from these
processes are discussed below.'
Scouring/Bleaching Carpets may be scoured with soaps or
detergents to remove processing oils, waxes and other impurities
and prepare them for dyeing or printing. If bleaching is
requiring, the bleaching agents are added after scouring (5).
Less than 15 percent of the mills that returned detailed surveys
perform scouring, and at all of these the percentage of total
production scoured is small (1 to 40 percent with an average of
16 percent). Only three mills that returned detailed surveys
perform bleaching; the amount of production on reported bleached
was 1, 2 and 10 percent, respectively. Thus, scouring and
bleaching have only a minor effect on the characteristics of
carpet mill wastewaters.
Dyeing Nearly all carpet finishing mills perform piece dyeing,
and the wastewaters are greatly influenced by the dyes and dye
machines employed. Nylon is the major fiber type used in the
manufacture of carpet, although the use of polyester fiber is
substantial. Other fibers are used by only five mills that
returned detailed surveys. Dyeing is typically accomplished
using atmospheric dye becks or, to a lesser extent, continuous
dye ranges. Only four dye classifications were identified as
being used by carpet finishing mills. Acid dyes, dispersed dyes
and cationic dyes are most frequently used; relatively small
quantities of direct dyes are used.
In addition to the dyestuffs themselves, numerous auxiliary
chemicals such as leveling agents, inorganic compounds, acids,
sequestering agents, organic compounds, dispersing agents and
various carriers may be employed {see Section III). Because most
of these auxiliary chemicals are used to improve the quality of
the dyeing operation, they do not remain with the carpet. As a
result, they are found in the wastewater along with excess dyes
and contribute to BODS., COD, dissolved solids, organics and
color.
Printing Carpet is generally printed by rotary, flat bed, warp
yarn or tuft dyeing equipment. Flat bed printing is the most
common method, although even this mode of printing occurs at less
than 10 percent of the carpet mills returning detailed surveys.
Spray printing techniques, using highly advanced
electronically-controlled machinery, may play an important role
in carpet printing in the future but, at the present time,
wastewater from carpet printing should not differ substantially
from woven fabric printing wastewater.
Functional Finishing Chemical agents may be applied to carpets
after dyeing or printing to impart certain desirable qualities.
Chemicals that increase the water repellency, flame or mildew
resistance and soil retardance sometimes are used, as are
antistatic agents and softeners. Because these agents are not
93
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applied as frequently and are not as numerous as those which
might be used in finishing woven fabric, their effect on the raw
waste load should be less.
Carpet Backing The carpet backing process laminates a secondary
backing (normally jute or propylene) to the dyed or printed
carpet. The adhesive is normally a latex compound, although a
form backing of urethane or latex sometimes is used. The latex
used in both foamed and unfoamed backing is not soluble in water
but is used in a highly dispersed form. Wastewater from this
process will contain suspended solids and COD.
Stock and Yarn Finishing Subcategory
The volume of wastewater discharged by stock and yarn finishing
facilities is comparable to that from mills in other finishing
subcategories. The wastes generated generally are not as
concentrated as those found in the other subcategories and the
components of the wastes depend substantially on whether natural
fibers, blends or synthetic fibers alone are processed.
The wet processing employed by a stock and yarn finishing mill
includes various combinations of the following operations:
scouring, bleaching, mercerizing, dyeing and printing. Bleaching
and dyeing are the processes that generate most of the wastewater
in this subcategory. Scouring, mercerizing and "printing" (space
or knit-deknit dyeing) are performed less frequently, A
description of stock and yarn processing, as well as schematics
of typical finishing operations, is presented in Section III.
The contributions of pollutants from the wet processing
operations are discussed below.
Mercerization Concentrated caustic solution is used to mercerize
cotton yarns at some of the mills in this subcategory. The
resulting wastewater will contain dissolved solids and have a pH
of 12 to 13.
Bleaching/Scouring Bleaching is performed on either raw stock or
yarn to whiten the fibers and remove any natural colors. Sodium
hypochlorite or hydrogen peroxide are typically used for this
purpose. The contribution of bleaching to wastewater
characteristics has been discussed previously for woven fabric
finishing. Scouring is employed less frequently at stock and
yarn finishing mills and also has been discussed previously.
Dyeing/Printing Stock dyeing usually is performed in a vat or
pressure kettle. Yarn dyeing usually is performed by skein or
package dyeing methods. A specialty yarn dyeing process, similar
to and sometimes referred to as printing, is known as space
dyeing. All these methods have been discussed previously in
Section III; a discussion of dyes and auxiliary chemicals
associated with coloring various fibers also is presented there.
The effect of dyeing on wastewater characteristics is presented
94
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earlier in this section under woven fabric finishing. Virtually
all dye classes are used in stock and yarn dyeing, and the waste
generated will be similar to those generated in dyeing fabric or
carpet of the same fiber type.
Nonwoven Manufacturing Subcateqorv
The nature of nonwoven manufacturing is such that a typical
facility has a small hydraulic loading and small pollutant mass
discharge rates relative to other subcategories. The wastewater
may contain latex and numerous other contaminants such as
acrylic, pigments and dirt. At a few facilities, manufacturing
operations common to the other subcategories (bleaching, dyeing
or printing of fabric) are performed with resultant higher
wastewater discharges. However, performing these operations are
the exception rather than the rule. The wastewater generated
during the typical nonwoven manufacturing processes are discussed
below.
Web Formation Web formation is a dry operation unless the "wet
lay" process is used (see Section III). Because water is used as
a transport medium for the fibers in this method, some wastewater
results from this process. This waste is generally low in BOD5.,
COD and TSS, has a pH of 6 to 7 and is slightly milky in color.
Bonding and Coloring Bonding is used to impart structural
integrity to the nonwoven fabric. Adhesives such as acrylics,
polyvinyl acetate resins or other latex compounds are usually
used. Cleanup of applicator equipment and mixing tanks results
in wastewater contaminated with adhesives. The function of
nonwoven fabrics (e.g., commercial applications and disposable
items such as diapers) may not require adding color. When color
is required, it is generally applied in the form of pigments
added to the bonding agents.
Functional Finishing Chemical treatments to impact flame
resistance, water repellency or mildew resistance also are
applied to nonwovens. The methods of application and effects on
wastewater characteristics are similar to those previously
described for other subcategories.
Felted Fabric Processing Subcategory
Felted fabric processing typically results in a high wastewater
volume, relative to other subcategories, and low pollutant
concentrations. The wet processing operations include felting,
dyeing and functional finishing. The rinses that follow felting
(fulling) and dyeing, if used, result in high wastewater
discharge volumes and contribute most of the pollutants.
Functional finishing also may make a contribution to the
wastewater. The contribution of pollutants from the typical wet
processing steps is discussed below.
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Felting (Fulling) Fulling of felted fabric is similar to the
fulling used in wool finishing. Detergents, alkalis or acids may
be used. These constituents, along with auxiliary chemicals, are
discharged when the baths are dumped. In some cases,
neutralization of the acid absorbed by the fabric is necessary.
The major hydraulic loading comes from the washes or rinses that
follow fulling. Hardening is a mechanical pressure process used
by some mills prior to fulling to cause the wool to felt. The
only waste resulting from this step is from steam or mist
condensate that collects on the heavy vibrating metal plates.
Dyeing Dyeing of felts is like dyeing other fabrics. Dyes
appropriate to the fiber content of the felt are used, along with
appropriate amounts of auxiliary chemicals. Together, these
materials contribute to BOD5., COD and dissolved solids loadings
in the wastewater.
Functional Finishing A wide variety of functional finishes and
chemical treatments are applied to felts. These chemicals and
the methods of application have been previously described.
Although functional finishing has only a minor impact on
hydraulic loading, a wide variety of chemicals may be introduced
into the wastewater.
WATER USE
Although there is some loss of water by evaporation during
textile processing and textile wastewater treatment, wastewater
discharge is generally taken to represent water usage in the
industry. A summary of the wastewater discharge rates in I/kg
(gal/lb) for each subcategory is presented in Table V-l. The
values presented include minimum, median and maximum annual
average values for the plants in each subcategory. As noted
these data are from the industry surveys.
With the exception of low water use processing (general
processing), wool scouring requires the least water per unit of
production. In comparing the values shown, however, it should be
noted that raw wool contains between 30 to 70 percent by weight
of nonwool materials such as dirt and grease.
In contrast, wool finishing requires the greatest amount of
water, principally because of the numerous low temperature
rinsing steps that are required to remove natural contaminants of
the wool and residual process chemicals from the carbonizing,
scouring and bleaching operations and soaps from the fulling
process. Detailed descriptions of the process water requirement
are provided in Section III.
Minimum, median and maximum wastewater discharge flows for each
subcategory are presented in Table V-2. The minimum flows are
reported by mills in the low water use processing (general
processing) subcategory and the hosiery products subdivision of
96
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TABLE V-l
WASTEWATER DISCHARGE RATE - SUMMARY OF HISTORICAL DATA
1.
2.
3.
4.
5.
6.
7.
8.
9.
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Wastewater Discharge Rate, I/kg (gal/lb) of Product*
Minimum Median Maximum
4
124
0.
19
12
10
5
8
12
5
8
3
2
33
.2
.3
08
.2
.5
.8
.0
.3
.5
.8
.3
.3
.5
.4
(0.5)
(14.9)
(0.01)
(2-3)
(1.5)
(1.3)
(0.6)
(1-0)
(1.5)
(0.7)
(1.0)
(0.4)
(0.3)
(4.0)
11
304
6
86
76
97
105
117
122
75
46
96
40
212
.7
.4
.3
.7
.7
.6
.9
.6
.6
.1
.7
.7
.0
.7
(1.4)
(36.5)
(0.75)
(10.4)
(9.2)
(11-7)
(12.7)
(14.1)
(14.7)
(9.0)
(5.6)
(11.6)
(4.8)
(25.5)
38.
879.
76.
194.
275.
276.
507.
387.
392.
289.
162.
538.
82.
930.
4
0
7
3
2
9
9
8
8
4
6
7
6
7
(4.6)
(105.4)
(9.2)
(23.3)
(33.0)
(33.2)
(60.9)
(46.5)
(47.1)
(34.7)
(19.5)
(64.6)
(9-9)
(111.6)
No. of
Mills
11
15
86
6
40
39
59
57
51
58
37
117
11
11
* Wool scouring flows are per unit of raw wool.
Wool finishing flows are per unit of product, although effluent limitations are per unit of fiber.
Source: EPA Industry Surveys, 1977 & 1980.
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TABLE V-2
WASTEWATER DISCHARGE - SUMMARY OF HISTORICAL DATA
00
1.
2.
3.
4.
5-
6.
7.
8.
9.
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Wastewater Discharge, cu m/day (MGD)
Minimum Median Maximum
38
189
4
299
42
170
38
15
11
4
76
45
53
11
(0
(0
(0
(0
(0
(0
.010)
.050)
.001)
.079)
.011)
.045)
(0.010)
(0
(0
(0
(0
(0
(0
(0
.004)
.003)
.001)
.020)
.012)
.014)
.003)
193
1,207
95
640
678
1,703
3,217
1,438
2,029
182
1,590
946
379
564
(0.
(0-
(0.
(0.
(0.
(0.
(0.
(0.
(0.
(0.
051)
319)
025)
169)
179)
450)
850)
380)
536)
048)
(0.420)
(0.
(0.
(0.
250)
100)
149)
1,919
4,621
1,575
1,158
8,327
28,955
29,845
10,560
13,248
1,537
6,923
9,637
1,893
1,514
(0
(1
(0
(0
(2
(7
(7
(2
(3
(0
(1
(2
(0
(0
.507)
.221)
.416)
.306)
.200)
.650)
.885)
.790)
.500)
.406)
.829)
.546)
.500)
.400)
No. of
Mills
11
15
86
6
40
39
59
57
51
58
37
117
11
11
Source: EPA Industry Surveys, 1977 & 1980.
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the knit fabric finishing subcategory. This is expected because
process water requirements are lower in the low water use
processing subcategory, and the mill production is lower in the
hosiery products subdivision than in any of the other
subcategories. Maximum discharges are reported at mills in the
woven fabric finishing subcategory where complex processing and
desizing operations are employed. This also is predictable
because of the high water usage and large production capacity of
these mills. The median discharges tend to increase with
increase in complexity of the processing.
Estimates of the total flow of wastewater discharged by the
industry are presented in Table V-3. Values are presented for
direct dischargers, indirect dischargers and the total mills in
each subcategory. These estimates were developed by adding the
known average discharges from the historical data base and
estimated average discharges for mills not reporting flow. The
greatest amount of flow discharged by direct dischargers is in
the woven fabric finishing (desizing) subcategory. For indirect
dischargers, the greatest flow is discharged by the knit fabric
finishing (simple processing) subcategory. Considering all
dischargers, the greatest flow is discharged by the woven fabric
finishing (desizing) subcategory, which accounts for over 20
percent of the total wastewater flow discharged by the industry.
Four industry segments (wool scouring, low water use processing
(water jet weaving), nonwoven manufacturing and felted fabric
processing) each account for less than one percent of the total
wastewater flow discharged by the industry. The total industry
discharges an estimated wastewater flow of 1.85 million cu m/day
(490 MGD).
TOXIC POLLUTANTS
Industry Survey Information
Most of the organic toxic pollutants are specific compounds and
more sophisticated laboratory analytical techniques are required
to quantify them than are required for nonspecific parameters
such as solids, COD and alkalinity. Because the concentrations
of the organic toxics are considerably lower than for most of the
conventional and nonconventional pollutants, more elaborate
sample collection and handling methods are necessary to insure
that meaningful and reproducible results are obtained. Because
of this, and the fact that control of the toxic pollutants, with
the exception of total chromium, generally was not included in
previous permits requirements, there is relatively little
historical information about the presence or concentrations of
most of the toxic pollutants (especially the nonmetals) in
textile mill wastewaters.
One source of information utilized in developing information
about the toxic pollutants in textile wastes was the industry
survey. The questionnaire used in the survey has been described
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TABLE V-3
WASTEWATER DISCHARGE - ESTIMATED SUBCATEGORY TOTALS
Subcategory
Estimated Wastewater Discharge, cu m/day (MGD)
Direct Dischargers* Indirect Dischargers Total Subcategory
1. Wool Scouring
2. Wool Finishing
3. Low Water Use Processing
3,849 (1.017)
41,120 (10.864)
8,679 (2.293)
30,836 (8.147)
12,528 (3.310)
71,956 (19.011)
4.
5.
6.
7.
8.
9.
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Total Industry
16,775
4,527
65,870
96,650
225,034
66,722
45,216
753
20,378
82,350
2,490
791
672,525
(4
(1
(17
(25
(59
(17
(H
(0
(5
(21
(0
(0
(177
.432)
.196)
.403)
.535)
.454)
.628)
.946)
.199)
.384)
.757)
.658)
.209)
.682)
62
4
131
145
151
238
105
22
87
169
14
7
1,181
,044
,527
,752
,950
,491
,251
,651
,824
,559
,477
,500
,831
,372
(16.
(1-
392)
196)
(34.809)
(38.560)
(40.024)
(62.
(27.
(6.
(23.
(44.
(3.
(2.
(312.
946)
913)
030)
133)
768)
831)
069)
111)
78
9
197
242
376
304
150
23
107
251
16
8
1,853
,819
,054
,622
,600
,525
,973
,867
,577
,937
,827
,990
,622
,897
(20.824)
(2.392)
(52.212)
(64.095)
(99.478)
(80.574)
(39.859)
(6.229)
(28.517)
(66.525)
(4.489)
(2.278)
(489.793)
* Includes wastewater generated and disposed of by zero discharge mills (see Table III-8).
Note: The estimates were developed by adding the known average discharge values for the mills in each sub-
category reporting flow data plus estimates of the average discharge for the mills not reporting flow,
The estimates for mills not reporting values were based on the mill's assignment to a specific model.
Model assignments were made on the basis of survey information and information about products and
production equipment published in the 1978 edition of the Davison's Textile Blue Book.
Source: EPA Industry Surveys, 1977 & 1980 and Contractor estimates.
-------
previously. In the questionnaire, respondents were asked to
identify whether each of 123 toxic pollutants* was"known present,"
"suspected absent"or"known absent"in the untreated wastewater or
treated effluent. The agency rated the responses to Section VI
as "good," "poor" and "no response." A "good" rating was assigned
if an effort was made by the survey responder to consider each of
the toxic pollutants listed. A "poor" rating was assigned if the
only response was a single statement such as "known absent,"
"none used," "none present," or an "X" through the entire list.
A "no response" rating was assigned when the question was not
addressed. In summary, 418 responses were rated as "good," 65 as
"poor" and 131 as "no response." The responses for each pollutant
were tallied for the mills that provided "good" responses. A
summary of the "good" responses is presented in Table V-4 and
shows that 53 pollutants are know to be present and an additional
47 are suspected to be present by at least one mill. A total of
69 pollutants are reported known or suspected present by more
than two mills; 29 of these are known to be present by more than
two mills.
Field Sampling Program
Because of the absence of historical data for the toxic
pollutants noted above, it was necessary to perform a field
sampling program. The program was conducted in five phases and
involved a total to 51 textiles mills. The first phase was
conducted in connection with the joint ATMI/EPA mobile pilot
plant project. Untreated wastewater, biologically treated
effluent and, in some cases, physical/chemical treated effluent
samples were collected at 23 mills during March, April and May of
1977. In the second phase, during May, June and July of 1977,
untreated wastewater and biologically-treated effluent samples
were collected at eight additional mills and from the various
physical/chemical treatment modes of the mobile pilot plant at
one previously sampled mill. In the third phase, during
September, October and November of 1977, water supply, untreated
wastewater, biologically-treated effluent and/or
physical/chemical-treated effluent samples were collected at 13
additional mills and from the various treatment modes of the
mobile pilot at one previously sampled mill. An additional five
mills and six previously sampled mills were sampled in the fourth
phase from April to September 1978. This phase investigated the
day-to-day fluctuations in untreated wastewater and treated
effluents and the efficiencies of various full-scale
*At the time of the survey (March, 1977), the toxic pollutant
list contained only 123 compounds; shortly thereafter, the list
was increased to 129 with the addition of di-n-octyl phthalate,
PCB-1221, PCB-1232, PCB-1248, PCB-1260 and PCB-1016.
101
-------
Toxic Pollutant
TABLE V-4
INDUSTRY RESPONSES TO TOXIC POLLUTANTS LIST
SUMMARY OF ALL MILLS
Known Suspected
Present Present
Known Suspected
Absent Absent
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
acenaphthene
acrolein
acrylonitrile
benzene
benzidine
carbon tetrachloride
(tetrachlorome thane)
chlorobenzene
1,2, 4-trichlorobenzene
hexa chlorobenzene
1,2-dichloroethane
1,1, 1-trichloroethane
hexachloroethane
1 , 1-dichloroethane
1,1, 2-trichloroethane
1,1,2 , 2-tetrachloroethane
chloroethane
bis(chloromethyl) ether
bis(2-chloroethyl) ether
2-chloroethyl vinyl ether (mixed)
2-chloronaphthalene
2,4, 6-trichlorophenol
parachlorometa cresol
chloroform (trichloromethane)
2-chlorophenol
1 , 2-dichlorobenzene
1 , 3-dichlorobenzene
1 , 4-dichlorobenzene
3 , 3-dichlorobenzidine
1 , 1-dichloroethylene
1 , 2-trans-dichloroethylene
2 , 4-dichlorophenol
1,2-dichloropropane
1,3-dichloropropylene
2,4-dimethylphenol
2,4-dinitrotoluene
2 , 6-dinitrotoluene
1,2-diphenylhydrazine
ethylbenzene
fluoranthene
4-chlorophenyl phenyl ether
6
5
6
1
4
33
1
1
5
1
1
3
2
1
2
2
2
1
2
7
3
26
27
42
9
28
53
5
6
34
1
1
9
2
8
5
3
1
2
7
3
5
8
16
9
8
10
2
2
2
3
3
5
7
1
4
262
264
243
254
236
244
235
182
256
245
233
260
258
254
258
256
246
255
256
263
260
259
249
257
252
259
259
260
267
265
263
263
263
260
261
262
263
256
263
264
43
46
38
40
43
61
44
38
48
50
46
51
53
52
52
48
60
53
54
42
44
47
55
43
40
40
40
41
41
41
43
45
45
45
45
44
39
41
42
41
102
-------
TABLE V-4 (Cont.)
Toxic Pollutant
Known Suspected
Present Present
Known Suspected
Absent Absent
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
4-bromophenyl phenyl ether
bis (2-chloroisopropyl) ether
bis (2-chloroethoxy) methane
methylene chloride
(dichloromethane)
methyl chloride (chloromethane)
methyl bromide (bromomethane)
bromoform (tribromomethane)
dichlo rob romome thane
trichlorofluorome thane
dichlorodifluorome thane
chlorodibromomethane
hexachlorobutadiene
hexachlorocyclopentadiene
isophorone
naphthalene
nitrobenzene
2-nitrophenol
4-nitrophenol
2,4-dinitrophenol
4,6-dinitro-o-cresol
N-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
pentachlorophenol
phenol
bis(2-ethylhexyl) phthalate
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate*
diethyl phthalate
dimethyl phthalate
1,2 benzanthracene
3 , 4-benzopyrene
3 , 4-benzof luoranthene
1 1 , 12-benzof luoranthene
chrysene
acenaphthylene
anthracene
1 , 12-benzoperylene
fluorene
1
1
3 17
1 2
4
1
5
2
1
7 48
7
2
2
4
2
5
4
2 15
81 48
4
3 2
1 6
7
8 17
5
2
1
1
1
3 2
2 8
2
1 4
266
263
265
242
264
265
266
265
264
263
261
260
265
262
232
260
262
260
257
259
260
261
265
248
161
263
261
261
261
243
260
261
263
262
262
262
256
259
256
43
46
45
41
43
43
44
46
45
45
49
44
43
45
33
42
43
43
43
45
42
42
42
45
38
41
43
42
41
40
41
43
44
45
44
41
41
45
45
103
-------
TABLE V-4 (Cont.)
Toxic
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
Pollutant
phenanthrene
1,2,5 , 6-dibenz anthracene
indeno(l,2,3-cd) pyrene
pyrene
tetrachloroethylene
toluene
trichloroethylene
vinyl chloride (chloroethylene)
aldrin
dieldrin
chlordane (technical mixture
and metabolites)
4,4'-DDT
4, 4 '-DDE (p,p'-DDX)
4,4'-DDD (p,p'-TDE)
alpha-endosulfan
beta-endosulfan
endosulfan sulfate
endrin
endrin aldehyde
heptachlor
heptachlor epoxide
alpha-BHC
beta-BHC
gamma-BHC (lindane)
delta-BHC
PCB-1242 (Arochlor 1242)
PCB-1254 (Arochlor 1254)
PCB-1221 (Arochlor 1221)*
PCB-1232 (Arochlor 1232)*
PCB-1248 (Arochlor 1248)*
PCB-1260 (Arochlor 1260)*
PCB-1016 (Arochlor 1016)*
Toxaphene
Antimony (Total)
Arsenic (Total)
Asbestos (Fibrous)
Beryllium (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Known
Present
10
8
4
2
1
1
1
1
16
10
3
2
24
117
87
Suspected
Present
3
6
2
19
40
17
5
1
1
1
1
36
6
3
5
17
55
79
Known
Absent
260
258
261
261
242
223
251
253
242
241
242
239
240
240
243
243
244
246
246
246
246
244
245
245
245
244
244
243
208
246
257
257
219
117
146
Suspected
Absent
43
42
46
45
43
43
40
47
78
78
78
82
82
82
77
77
77
77
77
77
77
77
77
77
77
79
79
77
56
70
65
65
57
38
27
104
-------
TABLE V-4 (Cont.)
Toxic Pollutant
121.
122.
123.
124.
125.
126.
127.
128.
129.
Cyanide (Total)
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Thallium (Total)
Zinc (Total)
2,3,7 , 8-tetrachlorodibenzo-p-dioxin
(TCDD)
Known
Present
10
34
19
28
7
12
2
100
Suspected
Present
6
27
15
28
3
4
1
64
1
Known
Absent
240
204
212
208
242
244
251
140
260
Suspected
Absent
72
59
68
53
59
56
59
30
44
Pollutant not included on original list of 123
Known Present
- The compound has been detected by reasonable analytical
procedures in the discharge or by reference is known to
be present in the raw waste load.
Suspected Present- The compound is a raw material in the processes employed,
a product, a by-product, catalyst, etc. Its presence
in the raw waste load and discharge is a reasonable
technical judgment.
Suspected Absent - No known reason to predict that the compound is present
in the discharge.
Known Absent
- The application of reasonable analytical procedures
designed to detect the material have yielded negative
results.
Source: EPA Industry Survey, 1976-1977.
105
-------
physical/chemical treatment technologies. In the last phase, two
additional mills and six previously sampled mills were sampled
from December 1977 to October 1979, and one previously sampled
mill was sampled in March 1980.
A special sampling program was conducted during October and
November 1979 to measure asbestos levels, which had not been
investigated during previous sampling. Water supply, untreated
wastewater and treated effluent samples were collected at 13
previously sampled mills. The asbestos analyses were
subsequently conducted on these samples.
The scope of the field sampling program is presented in Table
V-5. The 51 mills sampled represent all subcategories, with
greater emphasis placed on the major subcategories. Most of the
direct discharging mills provided biological treatment, with a
few providing physical/chemical treatment. The sample collection
and handling procedures and the analytical procedures conformed
to protocols developed by EPA.
The field sampling program was designed to insure that the number
of mills sampled in each subcategory would closely fit the
distribution of mills in the industry. Because of the wide
diversity within the manufacturing processes used by the textile
industry, it was recognized that the screening phase should
include more than one mill in each subcategory.
Field Sampling Results - Water Supply
A summary of the analytical results showing the minimum, maximum,
average and median concentrations of all water supply samples for
each pollutant detected, the number of times each pollutant was
analyzed for and the number of times detected, is presented in
Table V-6. Samples were collected for 34 mills, with two pairs
of mills using the same water supply source. Thus, 32 separate
water supply samples were collected and analyzed. Seven toxic
organic pollutants, 9 toxic metals, asbestos and cyanide were
detected at concentrations greater than 10 ug/1. Chloroform and
copper, detected at concentrations of 1,360 and 781 ug/1
respectively, were the maximum toxic organic and maximum toxic
metal detected in the water supplies. Zinc, toluene and copper
were the most frequently detected pollutants. Bis(2-ethylhexyl)
phthalate, a compound present in a high percentage of the samples
analyzed across the industries being studied, may be an anomaly,
its presence explained by the fact that it is used as a
plasticizer in the plastic tubing used for sample collection.
Field Sampling Results - Untreated Wastewater
The overall qualitative results of the field sampling program of
textile mill untreated wastewaters are presented by subcategory
in Table V-7. Two toxic pollutants: copper and zinc were
detected in all nine subcategories. An additional eight
106
-------
o
-J
TABLE V-5
SUMMARY OF MILL CHARACTERISTICS AND SAMPLE COLLECTION
FIELD SAMPLING PROGRAM
Report
Number Mill Type
Typical Processing
Products
Samples Collected
Water Raw Biolog- Physico-
Supply Waste ical chemical
10006
10013
10015
20011
20021
(04935)
(01304)
(90200)
Wool Scouring
Wool Scouring
Wool Scouring
Wool Finishing
Wool Finishing
General
Processing
Water Jet
Weaving
Other
Raw wool scouring, spinning
Raw wool scouring, heavy
scour, carbonizing, bleaching
Raw wool scouring
Heavy scouring, bleaching,
stock & yarn dyeing
Heavy scouring, stock & yarn
dyeing
Low Water Use
Spinning, slashing, weaving
Water jet weaving
Fiberglass extrusion
Wool top & carpet X
yarn
Wool top & wool/ X
polyester fabric
Wool top X
Apparel & X
upholstery fabric
Woven fabric X
Processing
Woven greige goods
Woven greige goods X
Fiberglass yarns X
X X
XXX
XXX*
XXX*
XXX*
X X
X
XXX**
* Collected from mobile pilot plant.
( ) Represents mill sequence number instead of report number.
# Nontextile processing so data, with the exception of water supply, not included in results of
field sampling program.
** Collected from in-place treatment technology.
-------
TABLE V-5 (Cont.)
Report
Number Mill Type
Typical Processing
Products
Samples Collected
Water Raw Biolog- Physico-
Supply Waste ical chemical
o
00
Woven Fabric Finishing
40023 Simple Processing Piece dyeing
40144 Simple Processing Printing
40077 Complex Processing Scouring, bleaching,
printing, piece dyeing
40135 Complex Processing Slashing, weaving,
desizing, bleaching,
printing, yarn & piece
dyeing
40160 Complex Processing Desizing, scouring,
bleaching, mercerizing,
printing, piece dyeing
Upholstery fabric
Sheets, blankets,
towels
Finished fabric
Sheets & towels
(04742) Desizing
40034 Desizing
Desizing, scouring,
bleaching, mercerizing,
piece dyeing
Desizing, scouring,
bleaching, mercer-
izing, printing, piece
dyeing
Finished fabric
Finished fabric
& yarn
Sheeting
X
X
X X
X X
X X
X
X*
X
X X*
X
* Collected from mobile pilot plant.
** Collected from in-place treatment technology.
( ) Represents mill sequence number instead of report number.
-------
TABLE V-5 (Cont.)
Report
Number Mill Type
Typical Processing Products
Samples Collected
Water Raw Biolog- Physico-
Supply Waste ical chemical
40059 Desizing
40072 Desizing
40081 Desizing
40097 Desizing
40099 Desizing
40103 Desizing
40120 Desizing
Desizing, scouring, Finished fabric
bleaching, mercerizing,
piece dyeing
Desizing, scouring, Sheeting & shirting
bleaching, mercerizing,
piece dyeing
Desizing, scouring, Finished fabric
bleaching, mercerizing,
printing, piece dyeing
Desizing, scouring, Finished fabric
bleaching, piece dyeing
Desizing, scouring, Finished fabric
bleaching, mercerizing,
piece dyeing
Desizing, scouring, Finished fabric
bleaching, mercerizing,
printing, piece dyeing
Desizing, scouring, Sheeting & apparel
bleaching, mercerizing,
printing, piece dyeing
X
X
X
X
X
X
X
X
X
X
X
X
XJ.
"
X
X
x**
* Collected from mobile pilot plant.
* Collected from in-place treatment technology.
-------
TABLE V-5 (Cont.)
Report
Number Mill Type
Typical Processing
Products
Samples Collected
Water Raw Biolog- Physico-
Supply Waste ical chemical
40145
40146
40150
40156
50030
50104
50108
50112
50116
Desizing
Desizing
Desizing
Desizing
Simple Processing
Simple Processing
Simple Processing
Simple Processing
Simple Processing
Desizing, scouring,
bleaching , mercerizing ,
yarn & piece dyeing
Slashing , weaving ,
desizing , s couring ,
bleaching, yarn dyeing
Weaving, desizing,
scouring, bleaching,
printing, piece dyeing
Slashing, desizing,
scouring , bleaching ,
yarn & piece dyeing
Knit Fabric
Scouring, piece dyeing
Scouring, printing
piece dyeing
Piece dyeing
Piece dyeing
Scouring, bleaching,
piece dyeing
Finished fabric X
Denim fabric X X
Sheets X
Finished fabric X X
Finishing
Flat goods X X
Finished fabric X X#
Outerwear fabric X
Apparel & auto X X
upholstery fabric
Finished fabric X
X
X
X
X
X
X
X
X
X
XJ.
"
X*
"
XJL
"
XJl_X.
""
* Collected from in-place technology.
# Pretreatment effluent.
** Collected from in-place technology and mobile pilot plant.
-------
TABLE V-5 (Coat.)
Samples Collected
Report
Number
50013
50035
50099
5H012
5H027
5H034
60008
60031
60034
60037
(06443)
Mill Type Typical Processing
Complex Processing
Complex Processing
Complex Processing
Hosiery Products
Hosiery Products
Hosiery Products
Carpet Finishing
Carpet Finishing
Carpet Finishing
Carpet Finishing
Stock & Yarn
Finishing
Scouring,
piece dyeing
Water Raw Biolog-
Products Supply Waste ical
Finished fabric XXX
Scouring, bleaching, Apparel fabric XXX
printing, piece dyeing
Scouring, piece
dyeing
Piece dyeing
Scouring, bleaching,
piece dyeing
Piece dyeing
Tufting, printing,
piece dyeing,
latex backing
Tufting, piece
dyeing latex backing
Tufting, piece
dyeing, latex backing
Tufting, piece dyeing
latex backing
Yarn dyeing
Apparel fabric XX X
Ladies' hosiery X X
Men's hosiery X X
Men's hosiery XXX
Finished carpet X XX
Finished carpet X X
Finished carpet X X
Finished carpet X X
Finished yarn X X
Physico-
chemical
X*
XiAuJL.
«"
x**
X*
X*
"
* Collected from in-place technology.
** Collected from mobile pilot plant.
( ) Represents mill sequence number instead of report number.
-------
TABLE V-5 (Cont.)
Report
Number
Mill Type
Typical Processing
Products
Samples Collected
Water Raw Biolog- Physico-
Supply Waste ical chemical
PO
70009 Stock & Yarn Finishing
70072 Stock & Yarn Finishing
70081 Stock & Yarn Finishing
70087 Stock & Yarn Finishing
70096 Stock & Yarn Finishing
70120 Stock & Yarn Finishing
80008 Nonwoven Manufacturing
80011 Nonwoven Manufacturing
80019 Nonwoven Manufacturing
80025 Felted Fabric
Processing
Bleaching, mercerizing,
yarn dyeing
Yarn dyeing
Yarn dyeing
Yarn dyeing
Desizing, scouring,
bleaching
Wool scouring, stock
dyeing, yarn dyeing
Carding, adhesive
bonding, viscose
regeneration
Fiber preparation, wet
lay, adhesive bonding
Carding, adhesive
bonding
Weaving, scouring,
felting
Sewing thread & yarn
Finished yarn
Finished yarn X
Greige & finished
yarn
Surgical gauze &
cotton
Carpet yarn X
Finished fabric X
Finished fabric
Disposable wiping
towels
Papermaker's felt X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X.-'-
"
XJUJL,
ft rt
X
* Collected from in-place treatment technology.
** Collected from polishing pond.
# Asbestos analysis only.
-------
TABLE V-6
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - WATER SUPPLY
Toxic Pollutant
Minimum
Concentration Observed, ug/1
Water Supply
Maximum Average Median Analyzed*
Detected*
4.
7.
8.
9.
11.
13.
23.
24.
29.
38.
39.
44.
45.
48.
49.
51.
55.
65.
66.
67.
68.
69.
70.
72.
73.
benzene
chlorobenzene
1 ,2,4-trichlorobenzene
hexachlorobenzene
1,1, 1-trichloroethane
1 , 1-dichloroethane
chloroform
2-chlorophenol
1 , 1-dichloroethylene
ethylbenzene
fluoranthene
methylene chloride
methyl chloride
dichlorobromome thane
trichlorofluorome thane
chlorodibromome thane
naphthalene
phenol (GC/MS)
bis (2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
1 ,2-benzoanthracene
3 , 4-benzopyrene
1
1
2
1
1
1
3
1
4
1
1
4
2
3
6
2
1
1
1
1
1
2
1
1
1
8
2
5
1
2
1
1,360
1
4
6
1
47
9
7
6
2
1
36
140
5
15
2
8
1
1
4
2
4
1
1
1
179
1
4
2
1
16
6
5
6
2
1
10
19
2
3
2
3
1
1
4
2
4
1
30
1
1
14
6
5
6
7
1
2
2
34
34
32
32
34
33
34
31
33
34
29
34
33
33
34
31
32
32
32
32
32
29
32
29
29
10
2
2
1
3
1
11
1
1
8
3
14
2
2
1
1
1
8
25
6
13
1
8
1
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
113
-------
Toxic Pollutant
Minimum
TABLE V-6 (Cont.)
Concentration Observed, ug/1
Water Supply
Maximum Average Median Analyzed* Detected//
74.
78.
80.
84.
85.
86.
87.
102.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
128.
3 , 4-benzof luoranthene
anthracene
fluorene
pyrene
tetrachloroethylene
toluene
trichloroethylene
alpba-BHC
antimony (total)
arsenic (total)
asbestos (MFL)
beryllium (total)
cadmium (total)
chromium (total)
copper (total)
cyanide
lead (total)
mercury (total)
nickel (total)
selenium (total)
silver (total)
zinc (total)
1
1
1
1
1
1
1
5
1
1
1
1
2
6
6
22
8
1
18
1
1
14
1
1
1
1
7
13
6
5
36
72
68
1
29
30
781
22
75
1
150
6
129
418
1
1
1
1
3
3
2
5
23
12
13
1
11
15
86
22
44
1
74
2
32
109
1
1
1
2
2
2
25
4
2
7
13
47
46
1
61
1
19
64
31
32
31
32
34
34
34
23
33
33
7
31
33
33
33
32
33
31
33
31
33
33
1
8
3
3
5
20
8
1
10
9
6
1
5
7
17
1
8
3
10
5
11
24
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Kote: Concentrations shown represent detected values only.
Source: EPA Field Sampling Program.
114
-------
TABLE V-7
TOXIC POLLUTANTS DETECTED IN TEXTILE MILL UNTREATED WASTEWATERS
Toxic Pollutant
3a 3b 4a 4b
Subcategory
4c 5a 5b
5c
1.
2.
3.
4.
7.
8.
9.
10.
11.
13.
15.
17.
21.
22.
23.
24.
25-
26.
27.
29.
30.
31.
32.
33.
34.
acenaphthene
acrolein
acrylonitrile
benzene
chlorobenzene
1,2, 4-trichlorobenzene
hexa chlorobenzene
1 , 2-dichloroethane
1,1, 1-trichloroethane
1 , 1-dichloroethane
1,1,2, 2-tetrachloroethane
bis(chloromethyl) ether
2,4,6-trichlorophenol
parachlorometa cresol
chloroform
2-chlorophenol
1 , 2-dichlorobenzene
1 , 3-dichlorobenzene
1,4-dichlorobenzene
1 , 1-dichloroethylene
1, 2-trans-dichloroethylene
2,4-dichlorophenol
1,2-dichloropropane
1 , 3-dichloropropylene
2,4-dimethylphenol
X X
X X
X
X
X X
X
XXX
X
X
X
X
X
X X
XXX
X X
X X
X
X X
X X
X
X X
X
XXX
X
X
X
X
X
X
X
X
X
X X
XXX
X
X X
X X
X
X
X
XXX
X
X
X
X
X
X
X
X X
X X
X X
X
X
X
X
X
X
XXX
X
X
X
X
X
X
-------
TABLE V-7 (Cont.)
Toxic Pollutant
3a 3b 4a 4b
Subcategory
4c 5a 5b
5c
CT»
36.
37.
38.
44.
48.
49.
54.
55.
57.
58.
62.
64.
65.
66.
67.
68.
69.
70.
71.
77.
78.
80.
81.
83.
84.
2 , 6 -dinitro toluene
1 , 2-diphenylhydrazine
ethylbenzene X
methylene chloride X
d i chl o r ob r omome thane
trichlorofluoromethane
isophorone X
naphthalene
2-nitrophenol
4-nitrophenol
N-nitrosodiphenylamine
pentachlorophenol X
phenol (GC/MS) X
bis (2-ethylhexyl) phthalate X
butyl benzyl phthalate
di-n-butyl phthalate X
di-n-butyl phthalate X
diethyl phthalate X
dimethyl phthalate
acenaphthylene
anthracene
fluorene
phenanthrene
indeno(l,2,3-cd)pyrene
pyrene
X
X
X
X
X
X X
X X
X X
X
X
X
X
XXX
X X
X
X X
X
X
X X
XXX
XX X
X X X X
X
XXX
X
X X
X X
X
X
X
X
XX XXX
XX X
X
X
X X X X X X
X
X
X X
X X X X X X
X X X X X X X
X X
X X
XX X
X X
X
X
X XX
X
X
-------
TABLE V-7 (Coat.)
Toxic Pollutant
3a 3b 4a 4b
Subcategory
4c 5a 5b
5c
85.
86.
87.
88.
90.
94.
95.
96.
100.
101.
102.
103.
104.
105.
106.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
tetrachloroethylene
toluene
trichloroethylene
vinyl chloride
dieldrin
4,4'-DDD(p,p'-TDE)
alpha-endosulfan
beta-endosulfan
heptachlor
heptachlor epoxide
alpha-BHC
beta-BHC
gamma-BHC (lindane)
delta-BHC
PCB-1242 (Arochlor 1242)
antimony (total)
arsenic (total)
asbestos
beryllium (total)
cadmium (total)
chromium (total)
copper (total)
cyanide
lead (total)
mercury (total)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X
X
X
X
X
X X
X X
X X
X X
X
X X
X
X
X X
X
X
X
X
X X
XXX
XXX
X X
XXX
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X X
X
X
X X
X X
X
X X
X X
X X
X
X
X
X
X X
X
X X
X X
X X
X X
X X
X X
X
X X
X
X
X X
X
X
X X
X
X
-------
TABLE V-7 (Cont.)
Subcategory
124.
125.
126.
127.
128.
Toxic Pollutant
nickel (total)
selenium (total)
silver (total)
thallium (total)
zinc (total)
1
X
X
X
X
X
2
X
X
X
X
3a
X
X
X
3b
X
X
X
4a
X
X
X
X
4b
X
X
X
4c
X
X
X
X
X
5a
X
X
X
X
5b
X
X
X
5c
X
X
X
6
X
X
X
7
X
X
X
X
8
X
X
X
9
X
X
Source: EPA Field Sampling Program.
CO
-------
pollutants were detected in eight of the nine subcategories.
However, 24 toxic pollutants were detected in only a single
subcategory. This reflects the wide variety of manufacturing
methods and process machinery in the textile industry, and
perhaps, the fluctuating character of textile wastewaters caused
by batch operations and frequent changes in product line. The
quantitative results of the field sampling program are summarized
in Table V-8. Results are shown for both the untreated
wastewater and the biologically-treated effluent to illustrate
the pollutants of most significance in the industry. The results
from biological and physical/chemical treatment units are
included in Section VII to describe the performance of the
different technologies.
Table V-7 shows that 80 of the 129 toxic pollutants were detected
in textile industry untreated wastewaters. Sixty-five were
organic pollutants, 13 were metals, one was asbestos and one was
cyanide. Seventeen of the pollutants were detected only once.
The results of the field sampling program are summarized by
subcategory in Table V-9a through V-9n. The table is similar in
format to Table V-8 and serves to identify the toxic pollutants
of most significance in each subcategory.
The greatest variety of toxic pollutants detected in the
untreated wastewater at concentrations greater than 10 ug/1 was
found at mills in the woven fabric finishing subcategory where
desizing operations are employed. (Table V-9g); 27 organics, 9
metals and cyanide were detected. The next greatest number was
in the stock and yarn finishing subcategory {Table v-91) with 20
organics, 9 metals and cyanide detected. Ten toxic metals were
detected in the wool finishing subcategory (Table V-9b). These
three subcategories perform the most complex and variable
processing steps with a large variety of associated chemicals, as
noted in the general discussion earlier in this section.
The smallest variety of toxic pollutants detected in the
untreated wastewater at concentrations greater than 10 ug/1
occurred in the water wet weaving subdivision of the low water
use processing subcategory (Table V-9d), with no organic and five
metals detected; felted fabric processing subcategory (Table
V-9n), with four organics and three metals detected; at mills in
the knit fabric finishing subcategory where hosiery products are
manufactured (Table V-9j), with seven organics and three metals
detected. These results reflect the fact the these subcategories
perform the fewest complex processing steps and generally do not
use a great number of processing chemicals.
Field Sampling Results - Biologically-Treated Effluents
The quantitative results of the field sampling program for
biologically-treated effluents have been previously introduced as
part of Table V-8 for the industry as a whole, and Table V-9a
119
-------
ro
o
Toxic Pollutant
TABLE V-8
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - UNTREATED WASTEWATER AND BIOLOGICALLY TREATED EFFLUENT
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected//
1.
2.
3.
4.
7.
8.
9.
10.
11.
13.
15.
17.
21.
22.
23.
24.
25.
26.
27.
29.
acenaphthene
acrolein
acrylonitrile
benzene
chlorobenzene
1,2, 4-trichlorobenzene
hexa chlo r obenzene
1 , 2-dichloroethane
1,1, 1-trichloroethane
1 , 1-dichloroethane
1,1,2 , 2-tetrachloroethane
bis(chloromethyl) ether
2 , 4 , 6-trichlorophenol
parachlorometa cresol
chloroform
2-chlorophenol
1 , 2-dichlorobenzene
1,3-dichlorobenzene
1 ,4-dichlorobenzene
1 , 1-dichloroethylene
2
199
90
1
1
28
1
4
2
1
1
6
1
5
1
10
1
10
1
10
273
199
1600
200
296
14000
2
6
1200
14
21
6
94
29
642
131
460
1700
760
84
52
199
845
30
30
2212
2
5
89
7
11
6
29
14
77
71
85
705
188
41
20
845
10
10
315
2
5
16
6
11
20
9
15
71
10
555
11
34
69
66
78
78
73
76
71
70
73
70
68
58
76
76
78
68
76
68
71
72
8
1
2
22
16
15
2
2
21
5
2
1
7
3
34
2
15
4
8
4
1
87
400
1
2
1
1
1
2
5
2
1
2
10
1
13
1
1
2
87
400
64
26
1900
1
130
2
5
21
32
1020
10
20
33
16
44
2
87
400
11
8
407
1
37
2
5
12
8
78
10
4
23
6
15
2
5
4
29
1
10
12
4
7
1
23
5
7
64
62
80
96
69
92
66
67
64
62
94
94
95
65
94
63
66
64
3
1
1
15
5
15
3
6
1
1
2
7
19
1
18
2
6
4
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
ro
Toxic Pollutant
Min.
TABLE V-8 (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed» tected#
30.
31.
32.
33.
34.
36.
37.
38.
39.
44.
45.
48.
49.
51.
54.
55.
57.
58.
62.
63.
1,2-trans-dichloroethylene
2,4-dichlorophenol
1,2-dichloropropane
1 , 3-dichloropropylene
2,4-dimethylphenol
2 , 6-dinitrotoluene
1,2-diphenylhydrazine
ethylbenzene
fluoranthene
methylene chloride
methyl chloride
dichlorob r omome tha ne
trichlorofluorome thane
chlo rod ibromome thane
isophorone
naphthalene
2-nitrophenol
4-nitrophenol
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
2
20
2
2
2
54
22
1
3
7
27
111
1
60
65
11
360
41
100
2
190
54
22
19000
2600
7
45
111
2079
60
240
130
66
31
49
2
65
54
22
917
145
7
36
111
222
60
138
69
10
31
46
2
43
10
36
27
110
72
68
71
70
68
68
68
68
78
75
70
76
66
76
68
68
71 l
6
2
4
1
3
1
1
47
22
1
2
1
44
1
3
5
7
1
1
1
1
1
20
2
2
1
1
4
2
7
10
9
3018
1
58
20
10
2138
1
255
4
19
7
6
6
157
1
17
20
6
328
1
25
4
8
6
8
3
1
10
6
10
3
3
62
62
62
95
61
67
64
64
67
62
94
63
94
1
2
3
23
2
16
1
2
7
1
15
1
3
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
TABLE V-8 (Cont.)
ro
ro
Toxic Pollutant
Min.
Untreated Wastewater
Max. Avg. Med.
Concentration Observed, ug/1
Biologically Treated Effluent
Ana- De- Ana- De-
lyzed"" tected# Min. Max. Avg. Med. lyzed* tected#
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
77.
78.
80.
81.
83.
84.
85.
86.
87.
pentachlorophenol
phenol (GC/MS)
bis(2-ethylhexyl) phthalate
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
dimethyl phthalate
benzo(a)anthracene
benzo (a )pyrene
3 , 4-benzof luoranthene
1
1
1
1
1
1
1
3
acenaphthylene 4400
anthracene
fluorene
phenanthrene
indeno (1,2,3-cd) pyrene
pyrene
tetrachloroethylene
toluene
trichloroethylene
1
1
1
2
1
1
1
1
310
4930
1449
160
67
10
150
111
4400
12
15
12
2
1
1126
3200
5600
56
165
149
52
17
6
22
26
4400
4
7
7
2
1
178
199
303
31
" 20
32
38
12
6
7
13
1
5
7
11
12
16
76
77
76
71
71
66
71
71
68
71
68
68
66
71
78
78
78
20
57
57
6
20
2
20
7
1
4
3
2
1
1
24
54
24
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
66
103
760
5
58
1
12
1
2
1
1
4
1
1
370
140
130
21
16
56
2
7
1
4
1
2
1
1
1
1
1
59
13
33
14
10
19
2
4
2
1
1
1
10
4
15
94
95
94
66
66
61
66
66
61
61
63
66
63
65
96
96
94
10
24
75
5
18
1
14
4
1
1
1
9
1
7
19
51
16
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
ro
to
Toxic Pollutant
Min.
TABLE V-8 (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min, Max. Avg. Med. lyzed* tected#
88.
90.
94.
95.
96.
100.
101.
102.
103.
104.
105.
106.
114.
115.
116.
117.
118.
119.
120.
121.
vinyl chloride
dieldrin
4 ,4' -DDK
alpha-endosulfan
beta-endosulfan
heptachlor
heptachlor epoxide
alpha-BHC
beta-BHC
gamma -BHC
delta-BHC
PCB-1242
antimony (total)
arsenic (total)
asbestos (MFL)
beryllium (total)
cadmium (total)
chromium (total)
copper (total)
cyanide
11
2
5
1
5
5
1
2
1
5
3
1
1
1
1
2
1
1
3
4
11
5
5
1
5
6
1
5
1
5
5
1
515
225
197
3
46
4930
3120
242
11
4
5
1
5
5
1
4
1
5
4
1
41
41
31
3
7
334
292
37
5
5
5
1
5
4
10
11
5
3
5
27
49
10
70
50
50
50
50
50
50
50
50
50
50
50
65
70
15
58
76
76
76
65
1
3
1
1
1
3
1
5
2
3
2
1
47
35
7
3
25
61
69
24
1
2
1
1
1
1
1
1
1
1
1
2
3
5
2
1
1
5
867
160
391
1
130
1800
323
980
3
2
1
1
3
172
24
139
1
8
97
54
83
3
3
32
6
24
4
35
30
18
50
50
50
50
50
83
64
11
78
96
96
96
91
2
1
1
1
2
65
33
3
1
31
65
82
34
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
Toxic Pollutant
Min.
TABLE V-8 (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
122. lead (total)
123. mercury (total)
124. nickel (total)
125. selenium (total)
126. silver (total)
127. thallium (total)
128. zinc (total)
6
1
6
1
1
1
14
752
4
304
736
130
9
7900
105
1
84
58
31
4
664
55
1
73
8
19
2
224
76
64
75
60
75
64
75
38
12
44
19
33
3
73
1
1
4
1
1
8
25
3500
2
2000
97
500
18
38400
133
1
119
24
42
13
996
44
1
80
10
22
13
185
96
57
94
57
94
57
94
42
7
54
10
44
2
90
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Notes: Concentrations shown represent detected values only. Toxic pollutants not listed were not detected in the
untreated wastewater or biologically treated effluent.
Source: EPA Field Sampling Program.
-------
through V-9n for individual subcategories. On an industry-wide
basis, 68 of 129 toxic pollutants were detected. Fifty-three
were organic pollutants, 13 were metals, 1 was asbestos and 1 was
cyanide. Eighteen of the pollutants were detected only once.
The maximum concentrations of any organic or metal pollutant were
ethylbenzene at 3,018 ug/1 and zinc at 38,400 ug/1.
On an individual subcategory basis, the greatest variety of
organic pollutants detected in the effluent at greater than 10
ug/1 was in the woven fabric finishing subcategory where Resizing
operations are employed, with 15 pollutants detected (Table
V-9g). The greatest variety of metals detected at greater than
10 ug/1 was in the wool scouring (Table V-9a) and wool finishing
(Table V-9b) subcategories and in the knit fabric finishing
subcategory where simple operations are employed, each with nine
pollutants detected (Table V-9h).
The smallest variety of organics detected was one pollutant in
the general processing subdivision of the low water use
processing subcategory (Table V-9c) and two pollutants in the
felted fabric processing subcategory (Table V-9n). The smallest
variety of metals detected was three pollutants in the felted
fabric processing subcategory (Table V-9n), and four pollutants
at mills where hosiery products are manufactured, (Table V-9j).
The data indicates that many of the toxic organic pollutants are
reduced or removed through biological treatment, while many of
the metals are not affected.
Field Sampling Results - Individual Subcateqories
Wool Scouring Three mills in this subcategory were sampled for
toxic pollutants and the results are shown in Table V-9a.
Thirteen organics, eight metals and cyanide were detected in the
untreated wastewater at greater than 10 ug/1, with 4,930 ug/1
phenol (GC/MS) the maximum organic concentration and 1, 969 ug/1
zinc the maximum metal concentration. These results seem to
reflect the presence of phenol in the raw grease wool resulting
from the treatment of the wool with branding compounds and
insecticides. The metals may be present in mineral impurities in
the wool.
Five organics, nine metals and cyanide were detected in the
treated effluent at greater than 10 ug/1, with 87 ug/1
trichloroethylene the maximum organic concentration and 3,500
ug/1 lead the maximum metal concentration.
Wool Finishing Two mills in this subcategory plus the wool
finishing waste stream from an integrated wool scouring and wool
finishing mill were sampled for toxic pollutants and the results
of the sampling are shown in Table V-9b. Seventeen organics and
ten metals were detected in the untreated wastewater at greater
than 10 ug/1, with 14,000 ug/1 1,2,4-trichlorobenzene the maximum
organic concentration and 7,500 ug/1 zinc the maximum metal
125
-------
ro
Toxic Pollutant
TABLE V-9a
SUMMARY OE ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - WOOL SCOURING SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
4.
7.
8.
9.
11.
13.
23.
29.
38.
39.
44.
48.
54.
64.
65.
66.
68.
69.
70.
72.
benzene
chlorobenzene
1,2, 4-trichlorobenzene
hexa chlorobenzene
1 ,1,1-trichloroethane
1 , 1-dichloroethane
chloroform
1 , 1-dichloroethylene
ethylbenzene
fluoranthene
methylene chloride
dichlorobromome thane
isophorone
pentachlorophenol
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
benzo (a ) anthr a cene
10
10
1
7
12
10
1
10
111
24
10
18
10
10
86
19
20
1
52
14
10
23
10
111
24
4930
330
67
10
86
13
16
1
19
13
10
12
10
111
24
1222
123
39
10
86
10
18
10
13
10
12
10
211
20
39
6
6
5
6
6
6
6
6
5
5
6
5
5
5
5
3
3
1
5
2
3
2
3
1
1
6
3
2
1
1
10
32
10
10
10
1
10
10
8
10
10
2
10
32
10
18
10
1
10
10
16
42
10
2
10
32
10
•
14
10
1
10
10
11
20
10
2
8
7
10 8
14 8
8
7
10 8
8
10 8
15 7
10 7
7
1
1
2
2
1
1
3
1
4
4
2
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
ro
Toxic Pollutant
Win.
TABLE V-9a (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
73.
74.
78.
84.
85.
86.
87.
90.
94.
95.
96.
101.
102.
103.
104.
105.
106.
114.
115.
117.
benzo(a)pyrene
3,4-benzofluoranthene
anthracene
pyrene
tetrachloroethylene
toluene
trichloroethylene
dieldrin
4,4'-DDD (p,p'-TDE)
alpha-endosulfan
beta-endosulfan
heptachlor epoxide
alpha-BHC
beta-BHC
gamma -BHC
delta-BHC
PCB-1242 (Arochlor 1242)
antimony
arsenic
beryllium
10
10
13
2
5
1
5
1
5
1
5
3
1
2
162
2
10
62
13
5
5
1
5
1
5
1
5
5
1
4
225
3
10
31 27
13
4 5
5
1
5
1
5 5
1
5
4 4
1
3 4
193 192
3 3
6
6
6
5
5
5
5
5
5
5
5
5
, 5
5
4
5
1
4
1
3
1
1
1
1
2
1
1
2
1
3
3
3
1
1
2
1
10
1
87
1
1
5
21
4
1
1
2
1
10
10
87
5
1
5
540
160
1
1
2
1
10
7
87
3
1
5
153
37
7
7
7
7
10 8
10 8
8
3 6
6
6
26 6
6 6
1
1
1
1
3
5
1
2
1
1
4
6
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
Toxic Pollutant
ro
CO
Min,
TABLE V-9a (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
thallium
zinc
9
12
23
10
18
1
54
6
1
1
190
13
269
430
39
752
1
304
8
65
1
1969
11
199
131
21
435
1
134
7
17
1
832
11
240
66
15
477
99
7
2
665
5
5
5
3
5
5
5
4
5
5
5
4
5
5
3
5
1
5
2
4
1
5
3
3
2
20
57
1
28
2
1
25
130
80
320
980
3500
1
2000
4
500
1500
26
42
75
313
929
1
452
3
130
299
5
48
16
200
79
60
3
49
72
7
7
7
5
7
5
7
4
7
7
6
6
5
5
4
1
5
2
5
7
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 10006, 10013, and 10015.
-------
ro
10
Toxic Pollutant
TABLE V-9b
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - WOOL FINISHING SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected//
4.
7.
8.
11.
22.
23.
25.
26.
27.
29.
30.
34.
38.
39.
44.
49.
55.
62.
64.
65.
.66.
68.
70.
71.
78.
benzene
chlorobenzene
1,2, 4-trichlorobenzene
1 ,1 ,1-trichloroethane
parachlorometa cresol
chloroform
1,2-dichlorobenzene
1 , 3-dichlorobenzene
1 ,4-dichlorobenzene
1 , 1-dichloroethylene
1,2-trans-dichloroethylene
2 , 4-dimethylphenol
ethylbenzene
fluoranthene
methylene chloride
trichlorofluorome thane
naphthalene
N-nitrosodiphenylamine
pentachlorophenol
phenol (GC/MS)
bis(2-ethylhexyl)phthalate
di-n-butyl phthalate
diethyl phthalate
dimethyl phthalate
anthracene
5
8
90
9
10
10
10
10
10
10
6
4
1
110
29
1
1
10
1
3
12
10
10
14000
80
11
460
1700
760
10
10
1770
10
35
130
71
47
160
10
10
3
12
8
9
4195
26
10
160
705
299
10
10
267
8
17
120
50
18
51
10
7
3
12
8
10
960
10
10
11
555
215
10
10
10
17
120
50
11
10
10
8
8
8
8
8
8
8
8
8
6
8
8
8
8
8
8
8
8
8
8
8
4
4
7
5
5
7
4
5
1
3
7
5
7
2
2
7
5
1
5
1
1
4
2
46
1
4
2
1
13
1
8
1
1
6
3
1
1
6
1
1
1
1
5
2
1900
1
5
3
20
33
16
8
75
1
46
3
1
2
760
1
9
1
1
5
2
1257
1
5
3
7
23
7
8
21
1
21
3
1
2
204
1
5
1
1
5
1541
5
3
6
23
5
4
12
1
2
56
5
1
8
6
8
6
8
8
8
6
6
5
7
4
6
6
8
8
8
6
6
6
6
2
1
4
1
2
2
7
2
4
1
4
1
3
1
2
2
8
1
2
1
2
* Values represent the number of samples analyzed.
// Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
Toxic Pollutant
Min.
TABLE V-9b (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
81.
84.
85.
86.
87.
100.
102.
104.
114.
115-
116.
118.
119.
120.
121.
122.
123.
124.
125.
126.
128.
phenanthrene
pyrene
tetrachloroethylene
toluene
trichloroethylene
heptachlor
alpha -BHC
gamma-BHC (lindane)
antimony
arsenic
asbestos (MFL)
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
12
2
6
2
5
2
5
1
2
3
4
63
3
5
84
1
9
4
1
51
12
1126
44
187
6
5
5
43
200
3
46
880
70
5
133
4
100
18
47
7500
12
193
15
39
5
4
5
28
37
3
13
310
28
5
109
2
50
9
24
1307
10
10
10
5
5
5
34
5
5
175
21
109
1
41
5
24
385
8
8
8
8
5
5
5
7
8
1
8
8
8
5
8
7
8
7
8
8
1
6
6
6
3
3
2
6
6
1
5
8
8
1
2
4
3
3
2
8
1
1
1
1
2
2
2
2
24
6
116
8
15
30
30
2
6
320
1
1
5
31
4
2
32
60
24
6
1800
30
15
200
140
15
140
38400
1
1
3
11
3
2
22
17
24
6
363
20
15
115
72
9
73
6833
3
7
3
23
3
164
23
115
58
9
73
1073
6
6
8
8
8
4
8
6
1
8
8
8
8
8
8
8
8
8
1
1
2
6
2
1
7
4
1
1
8
7
1
2
4
2
2
8
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 20011, 20021, and 10013 (Finishing Waste).
-------
Toxic Pollutant
TABLE V-9c
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - LOW WATER USE PROCESSING (GENERAL PROCESSING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
23.
65.
66.
68.
86.
87.
116.
118.
119.
120.
122.
124.
126.
128.
chloroform
phenol (GC/MS)
bis (2-ethylhexyl)
phthalate
di-n-butyl phthalate
toluene
trichloroethylene
asbestos (MFL)
cadmium
chromium
copper
lead
nickel
silver
zinc
48
23
26
61
42
1
4
11
39
43
110
46
120
48
23
26
61
42
1
4
11
39
43
110
46
120
48
23
26
61
42
1 1
4
11
39
43
110
46
120
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
10
3
3
5
12
37
84
120
50
2300
10
3
3
5
12
37
84
120
50
2300
10
3
3
5
12
37
84
120
50
2300
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 04935 (sequence number) and 40023 (Weave Mill Waste).
-------
Toxic Pollutant
TABLE V-9d
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - LOW WATER USE PROCESSING (WATER-JET WEAVING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
65.
66.
114.
119.
120.
121.
122.
125.
126.
128.
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
antimony
chromium
copper
cyanide
lead
selenium
silver
zinc
1
10
38
4
10
10
22
50
14
63
1
10
38
4
10
10
22
50
14
63
1
10
38
4
10
10
22
50
14
63
1
1
1
1
1
1
1
1
1
1
1
1
1 Not Sampled
1
1
1
1
1
1
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plant 01304 (sequence number).
-------
CO
CJ
Toxic Pollutant
TABLE V-9e
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - WOVEN FABRIC FINISHING (SIMPLE PROCESSING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
1.
4.
8.
9.
10.
11.
23.
25.
38.
. 44.
55.
64.
65.
66.
68.
71.
78.
86.
87.
114.
acenaphthene
benzene
1,2, 4-trichlorobenzene
hexa chlo r obenz ene
1,2-dichloroethane
1,1, 1-trichloroe thane
chloroform
1,2-dichlorobenzene
ethylbenzene
methylene chloride
naphthalene
peritachlorophenol
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
di-n-butyl phthalate
dimethyl phthalate
anthracene
toluene
trichloroethylene
antimony
9
32
28
2
6
17
11
5
47
87
32
40
5
13
13
8
9
32
28
2
6
17
11
460
47
410
42
147
860
13
13
620
9
32
28
2
6
17
11
233
47
249
37
94
382
13
13
216
233
249
37
94
280
13
20
3
3
3
3
3
3
3
3
3
3
3
3
3
^3
3
3
1
1
1
1
1
1
1
2
1
2
2
2
3
2
1
3
1
24
15
12
10
6
1
1
1
4
1
24
66
24
10
6
1
140
76
28
1
24
41
18
10
6
1
48
39
18
41
18
10
2
39
21
6
4
6
6
6
4
4
6
6
4
1
1
2
2
2
1
1
3
2
3
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
CO
-p*
Toxic Pollutant
Min. Max.
TABLE V-9e (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Avg. Med. lyzed« tected# Min. Max. Avg. Med. lyzed* tected#
115.
118.
119.
120.
121.
122.
123.
124.
126.
127.
128.
arsenic
cadmium
chromium
copper
cyanide
lead
mercury
nickel
silver
thallium
zinc
5
4
230
6
13
1
54
6
9
48
5
12
329
6
15
1
54
6
9
460
5
8 8
292 317
6
14 14
1
54
6
9
254 254
3
3
3
2
3
2
2
2
2
2
1
2
3
1
2
1
1
1
1
2
4
3
48
3
25
1
11
7
8
195
4
6
170
23
38
1
54
12
18
340
4
4
87
14
32
1
37
10
13
248
4
82
18
32
46
10
13
229
2
6
6
6
6
4
6
6
4
6
1
4
6
5
2
1
3
2
2
4
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent statistics of detected values only.
Source: Compilation of field sampling data for plants 40023 and 40144.
-------
to
CJ1
TABLE V-9f
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - WOVEN FABRIC FINISHING (COMPLEX PROCESSING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana-
4.
7.
21.
22.
23.
24.
25.
29.
38.
45.
55.
62.
64.
65.
66.
67.
-68.
70.
71.
84.
Toxic Pollutant
benzene
chlorobenzene
2,4,6-trichlorophenol
p-chloro-m-cresol
chloroform
2-chlorophenol
1,2-dichlorobenzene
1,1-dichloroethylene
ethylbenzene
methyl chloride
naphthalene
N-nitrosodiphenylamine
pentachlorophenol
phenol (GC/MS)
bis (2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
diethyl phthalate
dimethyl phthalate
pyrene
Min.
31
42
20
33
131
18
11
20
9
7
3
12
1
Max.
31
296
20
33
131
2835
11
20
138
7
3
12
1
Avg . Med .
31
169 169
20
33
131
960 26
11
20
90 123
7
3
12
1
lyzed*
3
3
3
3
3
3
3
3
3
3
3
3
3
tected#
1
2
1
1
1
3
1
1
3
1
1
1
1
Min.
6
2
21
32
18
10
1
4
1
20
1
56
1
1
5
4
2
1
Max.
64
26
21
32
18
10
1
4
29
20
5
56
103
24
5
4
2
1
Avg . Med .
28 13
11 4
21
32
18
10
1
4
11 7
20
3 3
56
38 10
15 18
5
4
2
1
lyzed"
6
6
6
6
6
4
6
4
6
4
6
6
6
6
4
4
4
4
De-
tected#
3
3
1
1
1
1
1
1
4
1
2
1
6
6
1
1
1
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
GO
Toxic Pollutant
Min.
TABLE V-9f (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
85.
86.
87.
103.
114.
115.
116.
118.
119.
120.
121.
122.
123.
124.
125.
126.
128.
tetrachloroethylene
toluene
trichloroethylene
beta-BHC
antimony
arsenic
asbestos (MFL)
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
6
28
52
120
197
2
16
86
25
1
50
22
240
15
303
52
120
197
2
67
510
49
1
77
22
1080
11 11
204 281
52
120
197
2
42 42
239 120
37 37
1
64 64
22
537 290
3
3
3
3
1
3
3
3
3
2
3
3
3
2
3
1
1
1
1
2
3
2
1
2
1
3
3
1
1
1
50
3
391
2
13
37
6
22
4
2
23
80
3
33
1
1
54
3
391
4
140
290
11
44
110
2
44
390
3
15
1
1
52
3
391
3
92
120
9
33
75
2
29
188
13
53
3
102
111
10
33
86
25
167
6
6
6
3
5
4
1
6
6
6
6
6
6
3
6
6
1
4
1
1
3
1
1
2
5
6
3
2
5
1
4
6
* Values represent the number of samples analyzed.
// Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 40077, 40135, and 40160.
-------
TABLE V-9g
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - WOVEN FABRIC FINISHING (DESIZING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana-
Toxic Pollutant Min.
1.
4.
7.
8.
10.
11.
13.
21.
22.
23.
25.
27.
29.
30.
31.
32.
33.
38.
44.
48.
acenaphthene
benzene
chlorobenzene
1,2, 4-trichlorobenzene
1,2-dichloroethane
1,1, 1-trichloroethane
1 , 1-dichloroethane
2,4,6-trichlorophenol
parachlorometa cresol
chloroform
1,2-dichlorobenzene
1 , 4-dichlorobenzene
1 , 1-dichloroethylene
1 , 2-trans-dichloroethylene
2,4-dichlorophenol
1 , 2-dichloropropane
1,3-dichloropropylene
ethylbenzene
methylene chloride
d ichlo rob romome thane
2
1
1
45
4
16
4
1
5
3
1
2
39
2
41
36
1
3
Max.
27
170
1
156
4
306
4
94
9
32
62
2
84
360
41
100
19000
120
Avg.
15
49
1
101
4
79
4
44
7
18
17
2
62
181
41
68
1692
53
Med.
15
30
1
101
24
37
7
20
2
62
181
68
112
42
lyzed*
21
28
23
26
20
23
20
26
26
28
26
21
22
20
21
20
28
25
tected#
2
6
2
2
1
5
1
3
2
9
4
1
2
2
1
2
19
8
Min.
1
1
4
2
4
1
2
1
1
44
1
1
5
2
Max.
1
33
4
10
4
1
58
1
9
44
1
3018
58
2
Avg.
1
17
4
6
4
1
21
1
5
44
1
440
22
2
Med. lyzed*
21
17 23
21
6 23
21
23
12 23
1 23
5 21
18
18
2 23
7 21
18
De-
tec ted#
1
2
1
2
1
1
4
2
2
1
1
7
5
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
C*>
CD
Toxic Pollutant
Min.
TABLE V-9g (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
49.
51.
55.
57.
58.
62.
64.
65.
66.
67.
68.
69.
70.
71.
78.
84.
85.
86.
87.
104.
trichlorofluorome thane
chlorodlbromome thane
naphthalene
2-nitrophenol
4-nitrophenol
N-nitrosodiphenylamine
pentachlorophenol
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
dimethyl phthalate
anthracene
pyrene
tetrachloroethylene
toluene
trichloroethylene
gamma-BBC (lindane)
27
1
60
65
72
2
1
5
1
1
1
1
1
1
2
1
27
2079
60
110
72
310
295
1449
66
28
1
69
1
26
3200
5600
27
468
60
88
72
75
58
210
24
13
1
15
1
15
490
812
80
88
46
26
63
4
14
6
1
16
34
18
26
26
18
18
21
26
26
26
21
21
18
21
21
28
28
28
1
17
1
2
1
12
21
22
3
9
1
7
2
4
18
7
89
1
1
7
1
2
1
1
1
1
1
1
1
1
1
1
1
2138
1
22
16
31
231
2
58
1
3
1
4
1
51
111
130
1
1114
1
12
'10
15
44
2
10
1
2
1
2
1
14
16
42
1
1114
12
7
12
14
2
4
2
1
1
1
3
7
5
21
18
23
23
23
23
21
21
18
21
21
21
21
23
23
23
16
2
1
2
3
6
16
3
8
1
6
2
3
2
4
14
5
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
CO
IO
Toxic Pollutant
Min.
TABLE V-9g (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
114.
115.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.
antimony
arsenic
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
thallium
zinc
1
1
3
4
8
4
8
1
6
1
6
2
56
180
77
6
4930
3120
242
120
1
280
80
130
2
7900
17
22
5
787
656
71
57
1
70
17
33
2
999
7
15
5
35
98
8
55
1
40
1
17
274
25
24
26
26
26
22
26
22
26
20
26
22
26
23
16
4
19
24
7
12
2
17
5
10
1
24
1
1
1
5
5
11
1
40
1
11
27
96
71
6
100
212
120
1
140
1
80
5100
21
31
2
32
75
50
1
79
1
28
502
12
23
2
29
27
43
81
16
210
19
21
23
23
20
23
18
23
16
23
23
17
13
6
21
10
8
1
10
1
7
23
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 04742 (sequence number), 40034, 40059, 40072, 40081, 40097, 40099,
40103, 40120, 40145, 40146, 40150, and 40156.
-------
Toxic Pollutant
TABLE V-9h
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - KNIT FABRIC FINISHING (SIMPLE PROCESSING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
1.
2.
3.
4.
8.
11.
13.
23.
25.
27.
29.
32.
33.
34.
38.
44.
49.
55.
57.
64.
acenaphthene
acrolein
acrylonitrile
benzene
1,2, 4-trichlorobenzene
1,1, 1-trichloroethane
1 , 1-dichloroethane
chloroform
1 ,2-dichlorobenzene
1 ,4-dichlorobenzene
1,1-dichloroethylene
1 , 2-dichloropropane
1 , 3-dichloropropylene
2 , 4-dimethylphenol
ethylbenzene
methylene chloride
trichlorofluorome thane
naphthalene
2-nitrophenol
penta chlo ropheno 1
12
199
90
20
120
8
1
22
1
7
29
2
2
2
30
45
1
2
53
199
90
20
2700
1200
6
498
35
7
29
2
2
2600
2600
45
51
2
33
199
90
20
1045
406
4
260
18
7
29
2
2
711
1315
45
32
2
33
315
11
4
260
18
369
1315
45
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
2
1
1
1
3
3
2
2
2
1
1
1
1
5
2
1
3
1
87
6
69
2
2
1
10
9
3
28
2
4
87
6
130
2
2
1
10
9
4
28
2
4
87
6
100 100
2
2 2
1
10
9
4 4
28
2
4
7
8
6
6
8
6
6
6
8
6
6
6
1
1
2
1
2
1
1
1
2
1
1
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represents detected values only.
-------
Toxic Pollutant
Mia.
TABLE V-9h (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max . Avg. Med. lyzed* tected// Min. Max. Avg. Med. lyzed* tected#
65.
66.
70.
71.
80.
85.
86.
87.
114.
115.
118.
119.
120.
121.
122.
123.
124.
125.
126.
128.
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
diethyl phthalate
dimethyl phthalate
fluorene
tetrachloroethylene
toluene
trichloroethylene
antimony
arsenic
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
1
1
34
15
9
4
5
1
1
4
6
17
8
32
36
3
12
34
55
430
34
15
1108
140
840
186
100
10
210
590
10
99
130
15
100
343
17
157
34
15
438
45
322
59
35
6
53
156
9
61
89
9
41
163
8
41
317
12
121
13
4
5
14
64
8
60
100
9
19
144
6
6
6
6
6
6
6
5
6
6
6
6
6
6
6
5
6
6
5
3
1
1
4
5
3
5
3
4
5
6
3
5
5
2
5
6
5
1
8
1
37
1
3
2
4
7
6
1
1
54
20
13
47
50
1
27
1
41
684
70
10
150
130
17
48
1
150
62
80
570
20
1
17
1
39
230
27
5
63
65
11
36
1
79
41
33
154
17
17
1
39
83
7
4
32
70
9
42
64
41
17
68
8
6
8
8
8
7
6
9
9
9
9
9
6
9
5
9
9
6
1
3
2
2
7
3
3
6
9
3
6
1
5
2
6
9
* Values represent the number of samples analyzed,
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represents detected values only.
Source: Compilation of field sampling data for plants 50030, 50104, 50108, 50112, and 50116.
-------
-F*
ro
Toxic Pollutant
TABLE V-9i
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - KNIT FABRIC FINISHING (COMPLEX PROCESSING) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
1.
4.
7.
8.
11.
15.
23.
25.
30.
34.
38.
44.
55.
63.
65.
66.
67.
68.
70.
71.
acenaphthene
benzene
chlorobenzene
1,2, 4-trichlorobenzene
1,1,1-trichloroethane
1,1,2 , 2-tetrachloroethane
chloroform
1 ,2-dichlorobenzene
1,2-trans-dichloro-
ethylene
2,4-dimethylphenol
ethylbenzene
methylene chloride
naphthalene
N-nitrosodi-n-
propylamine
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
diethyl phthalate
dimethyl phthalate
1
14
190
3
21
17
5
2
852
8
2
2
30
160
3
2
12
1
25
190
3
21
71
5
2
1209
8
210
7
135
160
10
150
12
1
20 20
190
3
21
44 44
5
2
1031 1031
8
118 143
5 5
83 83
160
7 7
76 76
12
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
2
1
1
1
2
1
1
2
1
3
2
2
1
2
2
1
2
1
1
5
3
1
7
1
1
1
2
3
1
6
2
1
2
15
916
5
1020
1
7
1
278
6
255
19
1
109
4
1
2
6
237
5
221
1
7
1
78
4
87
11
1
34
3
1
5
15
44
1
2
4
3
11
1
27
3
5
22
21
5
21
21
5
5
22
5
21
21
21
21
5
5
1
5
4
1
6
4
1
1
5
2
3
2
3
18
3
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
OJ
Toxic Pollutant
Min. Max.
TABLE V-9i (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Avg. Med. lyzed" tected# Min. Max. Avg. Med. lyzed* tected#
77.
78.
85.
86.
87.
103.
114.
115.
118.
119.
120.
121.
122.
123.
124.
126.
128.
acenaphthylene
anthracene
tetrachloroethylene
toluene
trichloroethylene
beta-BHC
antimony
arsenic
cadmium
chromium
copper
cyanide
lead
mercury
nickel
silver
zinc
4400
39
3
3
1
57
4
1
40
7
13
100
11
75
4400
890
61
3
1
515
5
4
44
190
62
126
30
200
4400
465
33
3
1
286
5
3
42
70
38
113
21
132
465
36
286
5
3
42
12
38
113
21
120
3
3
3
3
1
3
3
3
3
3
3
3
3
3
1
2
3
1
1
2
2
3
2
3
2
2
2
3
1
1
1
3
31
2
2
4
7
3
11
1
40
8
42
1
370
22
47
867
2
6
98
323
140
82
2
187
73
5160
1
194
6
25
452
2
4
28
42
72
42
2
107
26
614
270
3
24
478
4
9
22
72
45
2
104
21
115
5
22
22
22
22
5
22
22
22
22
22
5
22
22
22
1
5
11
3
17
1
9
9
17
2
13
2
17
14
20
" Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 50013, 50035, and 50099.
-------
Toxic Pollutant
TABLE V-9j
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - KNIT FABRIC FINISHING (HOSIERY PRODUCTS) SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected//
3.
4.
21.
23.
55.
62.
65.
66.
85.
86.
114.
115.
116.
119.
120.
121.
125.
126.
128.
acrylonitrile 1600
benzene 1
2,4,6-trichlorophenol 27
chloroform
naphthalene
N-nitrosodiphenylamine
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
tetrachloroethylene
toluene
antimony
arsenic
asbestos (MFL)
chromium
copper
cyanide
selenium
silver
zinc
* Values represent the number of
# Values represent the number of
Note
140
7
20
3
22
2
1
6
2
6
8
5
10
38
10
40
1600 1600
3 2
27 27
642
9
20
59
22
16
3
10
2
6
656
5
10
736
10
1420
391
8
20
39
22
9
2
8
2
6
226
5
10
275
10
611
2
391
8
54
9
2
8
14
50
491
4
4
4
4
4
4
4
4
4
4
4
4
2
4
4
4
4
4
4
1 400 400 400
2
1
2
2 111
1
3 14 14 14
1 172 172 172
2
3 222
2
1
1
3 199 199 199
1 14 14 14
1
3 97 97 97
1
4 112 112 112
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
1 1
samples analyzed.
times
: Concentrations shown represent
pollutant was
detected
values
detected
only.
•
Source: Compilation of field sampling data for plants 5H012, 5H027, and 5H034.
-------
Toxic Pollutant
TABLE V-9k
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - CARPET FINISHING SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected//
1.
7.
9.
11.
23.
37.
38.
48.
55.
65.
66.
70.
80.
86.
114.
118.
119.
120.
121.
122.
acenaphthene
chlorobenzene
hexachlorobenzene
1,1, 1-trichloroethane
chloroform
1 , 2-diphenylhydrazine
ethylbenzene
dichlo rob romome thane
naphthalene
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
diethyl phthalate
fluorene
toluene
antimony
cadmium
chromium
copper
cyanide
lead
273
7
2
5
22
43
7
95
1
19
5
52
2
4
3
6
6
273
7
2
280
22
43
7
260
68
400
5
52
2
75
63
40
33
273
7
2
143 143
22
43
7
198 240
40 54
121 33
5
52
2
35 30
28 16
23 23
20 20
5
4
4
4
5
4
4
5
5
5
5
2
5
5
5
4
5
1
1
1
2
1
1
1
3
5
4
1
1
1
4
5
2
2
2
1
2
10
11
1
11
4
3
28
3
25
2
1
50
27
11
1
105
4
411
46
12
25
2
1
30 39
18 18
11
1
58 58
4
221 235
37 37
7 6
25
4
4
4
4
4
4
2
4
4
4
4
4
1
1
3
4
1
1
2
1
4
2
3
1
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
Toxic .Pollutant
Min.
TABLE V-9k (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max. Avg. Med. lyzed" tected# Min. Max. Avg. Med. lyzed* tected//
123. mercury
124. nickel
126. silver
128. zinc
1
28
9
17
1
98
42
450
1
63
.26
121
1
63
26
36
4
5
5
5
2
2
2
5
13
33
130
79
33
260
46
33
195
46
195
2
2
2
2
1
2
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 60008, 60031, 60034, and 60037
-------
Toxic Pollutant
TABLE V-91
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - STOCK & YARN FINISHING SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed" tected# Min. Max. Avg. Med. lyzed» tected#
1.
4.
7.
8.
9.
15.
17.
21.
22.
23.
24.
25.
27.
31.
32.
34.
36.
38.
44.
49.
acenaphthene
benzene
chlorobenzene
1,2, 4-trichlorobenzene
hexachlorobenzene
1,1,2,2-tetrachloroethane
bis (chloromethyl)ether
2,4, 6-trichlorophenol
p-chloro-m-cresol
chloroform
2-chlorophenol
1,2-dichlorobenzene
1 , 4-dichlorobenzene
2,4-dichlorophenol
1 , 2-dichloropropane
2,4-dimethylphenol
2 , 6-dinitrotoluene
ethylbenzene
methylene chloride
trichlorofluorome thane
13
1
1
270
1
6
9
29
1
10
1
1
20
56
2
54
1
4
30
1
2
270
1
6
16
29
410
10
56
. 1
20
56
190
54
6
9
22 22
1
2 2
270
1
6
13 13
29
86 3
10
29 29
1
20
56
96 96
54
3 2
7 7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
2
1
2
1
1
1
2
1
5
1
2
1
1
1
2
1
5
2
1
19
1
2
2
5
1
3
9
3
1
43
1
2
7
5
5
3
9
48
1
27
1
2
4
5
3
3
9
20
1 8
19 8
1 6
8
4 8
8
2 8
8
6
10 6
2
3
2
1
3
1
3
1
1
3
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
45*
CO
Toxic Pollutant
TABLE V-91 (Cont.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
55.
58.
63.
64.
65.
66.
67.
68.
70.
71.
78.
80.
81.
83.
84.
85.
86.
87.
114.
115.
naphthalene
4-nitrophenol
N-nitrosodi-n-propylamine
pentachlorophenol
phenol (GC/MS)
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
diethyl phthalate
dimethyl phthalate
anthracene
fluorene
phenanthrene
indeno (l,2,3-c,d) pyrene
pyrene
tetrachloroethylene
toluene
trichloroethylene
antimony
arsenic
1
240
2
3
3
3
14
1
1
1
2
1
2
1
5
3
41
240
19
490
24
15
111
1
1
1
2
310
12
229
200
19
14
240
10
90
14
8
48
1
1
1
2
156
5
80
94
9
6
10
22
14
5
18
156
4
10
86
6
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
5
1
3
7
2
3
3
1
1
1
1
2
6
3
4
3
1
2
13
3
2
1
5
3
1
1
3
1
3
2
13
2
23
3
340
1
7
12
1
1
3
38
177
9
6
2
18
3
89
1
7
7
1
1
3
18
95
6
6
18
58
7
7
1
15
141
6
8
8
8
8
8
6
6
6
6
6
8
8
8
8
4
1
2
1
8
1
2
3
1
2
1
3
5
4
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
-------
Toxic Pollutant
Min.
TABLE V-91 (Coat.)
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
128.
beryllium
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
1
3
36
17
36
1
12
3
51
130
6
650
300
17
160
1
200
32
68
1000
4
125
91
17
86
1
103
18
60
418
4
25
49
63
100
18
60
300
7
7
7
7
7
6
7
6
7
7
3
6
7
1
3
1
4
2
2
7
1
3
1
10
29
35
1
35
6
91
1
7
290
132
172
160
1
160
57
865
1
5
70
86
101
77
1
98
32
337
5
49
110
101
36
98
32
233
6
8
8
8
8
8
5
8
8
8
1
2
8
7
2
3
1
2
2
8
* Values represent the number of samples analyzed.
if Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 06443 (sequence number), 70009, 70072, 70081, 70087, 70096, and
70120.
-------
Toxic Pollutant
TABLE V-9m
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - NONWOVEN MANUFACTURING SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected# Min. Max. Avg. Med. lyzed* tected#
4.
23.
38.
55.
64.
benzene
chloroform
ethylbenzene
naphthalene
pentachlorophenol
65a. phenol (4-AAP)
66.
67.
86.
116.
118.
119.
120.
121.
122.
124.
126.
128.
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
toluene
asbestos (MFL)
cadmium
chromium
copper
cyanide
lead
nickel
silver
zinc
5
160
42
29
1
8
14
10
3
8
5
4
11
4
78
37
48
14
200
160
42
44
1
44
14
73
83
8
5
10
41
4
78
120
48
116
103
160
42
37
1
28
14
42
43
8
5
7
26
4
78
79
48
68
103
37
33
42
43
7
26
79
73
3
3
3
3
3
3
3
3
3
2
3
3
3
3
3
3
3
3
2
1
1
2
1
3
1
2 Not Sampled
2
1
1
2
2
1
1
2
1
3
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Concentrations shown represent detected values only.
Source: Compilation of field sampling data for plants 80008, 80011, and 80019.
-------
Toxic Pollutant
TABLE V-9n
SUMMARY OF ANALYTICAL RESULTS
TOXIC POLLUTANT SAMPLING PROGRAM - FELTED FABRIC PROCESSING SUBCATEGORY
Concentration Observed, ug/1
Untreated Wastewater Biologically Treated Effluent
Ana- De- Ana- De-
Min. Max. Avg. Med. lyzed* tected// Min. Max. Avg. Med. lyzed* tected#
55. naphthalene
65. phenol (GC/MS)
66. bis(2-ethylhexyl)
phthalate
85 . tetrachloroethylene
86. toluene
87 . trichloroethylene
88. vinyl chloride
116. asbestos (MFL)
119. chromium
120. copper
125. selenium
128. zinc
* Values represent the number
# Values represent the number
85
26
5
2
32
11
5
12
57
31
85 85
26 26
5 5
2 2
32 32
11 11
5 5
12 12
57 57
31 31
1
1
1
1
1
1
1
1
1
1
56 56 56
1 222
1 18 18 18
1
1
1
1
1 111
35 35 35
1
1 32 32 32
1 45 45 45
1 1
1 1
1 1
1 1
1 1
1 1
1 1
of samples analyzed.
of times pollutant was detected.
Note: Concentrations shown represent
Source: Compilation of field
sampling
detected values only.
data for plant 80025.
-------
concentration. The results seem to reflect the use of metallic
catalysts in fulling and the presence of a variety of organics in
the wool stock and processing agents.
Eight organics, nine metals, asbestos and cyanide were detected
in the treated effluent at greater than 10 ug/1, with 1,900 ug/1
1,2,4-trichlorobenzene the maximum organic concentration and
38,400 ug/1 zinc the maximum metal concentration. The high zinc
concentration does not appear to be representative of normal
treatment in the wool finishing subcategory because no other
treated effluent sample exceeded 6,402 ug/1. In fact, the
maximum zinc concentration in the untreated wastewaters of this
subcategory was only 7,500 ug/1, as noted above.
Low Water Use Processing Two mills in this subcategory were
sampled, one each in the general processing and water jet weaving
subdivisions. Five organics and eight metals were detected above
10 ug/1 in untreated wastewater.
Low Water Use Processing (General Processing) - One mill in
this subdivision was sampled for toxic pollutants and the results
are shown in Table V-9c. Five organic and six metals were
detected in the untreated wastewater, with 61 ug/1
di-n-butylphthalate the maximum organic concentration and 120
ug/1 zinc the maximum metal concentration.
No organics and six metals were detected in the treated effluent,
with 2,300 ug/1 zinc the maximum metal concentration. The low
concentrations of toxic pollutants detected in this subcategory
reflect the fact that few chemicals are used.
Low Water Use Processing (Water Jet Weaving) - One mill in
this subdivision was sampled for toxic pollutants and the results
are shown in Table V-9d. Five metals detected in the untreated
wastewater, with 63 ug/1 zinc the maximum concentration. The
mill is an indirect discharger, so no treated effluent samples
were collected. As with the general processing subdivision the
low concentrations of toxic pollutants detected reflect the fact
that usually, few chemicals are used.
Woven Fabric Finishing Eighteen mills in this subcategory were
sampled. Thirty organics, nine metals, asbestos and cyanide were
detected above 10 ug/1 in untreated wastewater. A summary of the
analytical results, by subdivision (simple, complex and
desizing), is presented below.
Woven Fabric Finishing (Simple Manufacturing Operations) -
Two mills in this subdivision were sampled for toxic pollutants
and the results are shown in Table V-9e. Thirteen organics and
five metals were detected in the untreated wastewater, with 620
ug/1 toluene the maximum organic concentration and 460 ug/1 zinc
the maximum metal concentration.
152
-------
Five organics, seven metals and cyanide were detected in the
treated effluent, with 140 ug/1 toluene the maximum organic
concentration and 340 ug/1 zinc the maximum metal concentration.
Woven Fabric Finishing (Complex Manufacturing Operations) -
Three mills in this subdivision were sampled for toxic pollutants
and the results are shown in Table V-9f. Thirteen organics,
seven metals and asbestos were detected in the untreated
wastewater, with 2,835 ug/1 ethylbenzene the maximum organic
concentration and 1,080 ug/1 zinc the maximum metal
concentration.
Eleven organics, seven metals, asbestos and cyanide were detected
in the treated effluent, with 103 ug/1 phenol the maximum organic
concentration and 390 ug/1 zinc the maximum metal concentration.
Asbestos was detected in the untreated wastewater at 197 MFL
(million fibers per liter) and in the treated effluent at 391
MFL; however, the results are based on data from a single plant
only.
Woven Fabric Finishing (Desizinq) - Thirteen mills in this
subdivision were sampled for toxic pollutants and the results are
shown in Table V-9g. As stated earlier, 27 organics, 9 metals
and cyanide were detected in the untreated wastewater. It should
be noted that more woven fabric finishing mills where desizing is
employed were sampled than any other, which may partly account
for why more pollutants were detected. Ethylbenzene detected at
19,000 ug/1 was the maximum organic concentration and zinc
detected at 7,900 ug/1 the maximum metal concentration.
Fourteen organics, eight metals and cyanide were detected in the
treated effluent, with 3,018 ug/1 ethylbenzene the maximum
organic concentration and 5,100 ug/1 zinc the maximum metal
concentration.
The results for the woven fabric finishing subcategory reflect
the overall trends for toxics in the industry and demonstrate the
effect of increasing the complexity of processing on both the
variety and the concentrations of the pollutants found.
Knit Fabric Finishing Eleven mills in this subcategory were
sampled. 29 organics, 9 metals and cyanide were detected above
10 ug/1 in untreated wastewaters. A summary of the analytical
results, by subdivision (simple, complex and hosiery), is
presented below.
Knit Fabric Finishing (Simple Manufacturing Operations) -
Five mills in this subdivision were sampled for toxic pollutants
and the results are shown in Table V-9h. Twenty organics and
nine metals were detected in the untreated wastewater, with 2,700
ug/1 1,2,4-trichlorobenzene the maximum organic concentration and
590 ug/1 copper the maximum metal concentration.
153
-------
Six organics, nine metals, and cyanide were detected in the
treated effluent, with 130 ug/1 1, V,1-trichloroethane the maximum
organic concentration and 684 ug/1 antimony the maximum metal
concentration.
Knit Fabric Finishing (Complex Manufacturing Operations) -
Three mills in this subdivision were sampled for toxic pollutants
and the results are shown in Table V-9i. Thirteen organics, six
metals and cyanide were detected in the untreated wastewater,
with 4,400 ug/1 acenaphthylene the maximum organic concentration
and 515 ug/1 antimony the maximum metal concentration.
Ten organics, seven metals and cyanide were detected in the
treated effluent, with 1,020 ug/1 chloroform the maximum organic
concentration and 5,160 ug/1 zinc the maximum metal
concentration,
Knit Fabric Finishing (Hosiery Products) - Three mills in
this subdivision were sampled for toxic pollutants and the
results are shown in Table V-9j. Seven organics and three metals
were detected in the untreated wastewater, with 1,600 ug/1
acrylonitrile the maximum organic concentration and 1,420 ug/1
zinc the maximum toxic metal concentration.
Three organics and four metals were detected in the treated
effluent, with 400 ug/1 acrylonitrile the maximum organic
concentration and 199 ug/1 chromium the maximum metal
concentration.
The results for the knit fabric finishing subcategory are less
clear then the results for the woven fabric finishing subcategory
with regard to a relationship between complexity of processing
and variety and concentration of pollutants found. The number of
pollutants is greater where simple processing is employed but the
concentrations are higher where complex processing is employed.
Carpet Finishing Four mills in this subcategory were sampled for
toxic pollutants and the results are shown in Table V-9k. Seven
organics, seven metals and cyanide were detected in the untreated
wastewater, with 280 ug/1 chloroform the maximum organic
concentration and 450 ug/1 zinc the maximum metal concentration.
Three organics, seven metals and cyanide were detected in the
treated effluent, with the maximum organic concentration and 411
ug/1 chromium the maximum metal concentration.
The variety and concentrations of toxic pollutants detected in
this subcategory are reflective of the less complex processing
involved, particularly the relative absence of scouring,
bleaching and functional finishing.
Stock and Yarn Finishing Seven mills in this subcategory were
sampled for toxic pollutants and the results are shown in Table
154
-------
V-91. Twenty organics, nine metals and cyanide were detected in
the untreated wastewater, with 410 ug/1 chloroform the maximum
organic concentration and 1,000 ug/1 zinc the maximum metal
concentration.
Seven organics, seven metals and cyanide were detected in the
treated effluent, with 50 ug/1 phenol the maximum organic
concentration and 865 ug/1 zinc the maximum metal concentration.
The variety of toxic pollutants detected in this subcategory is
extensive, although the concentrations are somewhat lower than
those found in the woven and the knit fabric finishing
subcategories.
Nonwoven Manufacturing Three mills in this subcategory were
sampled for toxic pollutants and the results are shown in Table
V-9m. Seven organics and five metals were detected in the
untreated wastewater, with 200 ug/1 benzene the maximum organic
concentration and 120 ug/1 nickel the maximum metal
concentration. Because these mills were all indirect
dischargers, treated effluent samples could not be obtained.
These results reflect the less complex processing involved in
this subcategory, most particularly the absence of dyeing and
printing.
Felted Fabric Processing One mill in this subcategory was sampled
for toxic pollutants, and the results are shown in Table V-9n.
Four organics and three metals were detected in the untreated
wastewater, with 85 ug/1 phenol the maximum organic concentration
and 57 ug/1 selenium the maximum metal concentration.
Two organics and three metals were detected in the treated
effluent, with 56 ug/1 naphthalene the maximum organic
concentration and 45 ug/1 zinc the maximum metal concentration.
Other Sources of Information
Various chemical and textile industry publications were reviewed
to obtain general information about the use of the 129 toxic
pollutants in the textile industry. These sources are included
in the bibliography. The most useful sources included the
Condensed Chemical Dictionary, the Merck Index and the Color
Index. Background information on the use of the toxic pollutants
also was compiled for all industrial segments from groups such as
the National Institute of Occupational Safety and Health and the
EPA Environmental Research Laboratory. In addition, specialists
within the textile industry were asked to provide information
about certain toxic pollutants. In some cases, the results were
opinions from chemists, engineers and others and were based on
the individual's experience. In other cases, special study
committees were established by trade associations to gather
information about certain toxic pollutants. Except for some of
the metals, the findings of these committees were qualitative
155
-------
because of the absence of quantitative historical information.
Two committees, one from the American Textile Manufacturers
Institute (ATMI) and one from the Dyes Environmental and
Toxicology Organization (DETO), were particularly helpful in
providing useful information.
ATMI organized a special Task Group on Priority (Toxic)
Pollutants that reviewed in detail a list of 52 toxic pollutants
that were neither clearly present nor clearly absent in textile
mill wastewaters. This list was based on the literature and some
early results of the field sampling program. Information was
requested about the likelihood of each pollutant being present
and, if so, information about potential sources. The Task Group
classified each pollutant as "probable," "possible," or "not
likely."
A pollutant was classified as "probable" if it was established as
present in a product or process. A pollutant was classified as
"possible" if it was known or suspected to be an intermediate or
contaminant of products and processes being used. Many of the
pollutants in this category could be entering the waste in an
auxiliary manner such as a component of maintenance products and
as agricultural contaminants in process water. A pollutant was
classified as "not likely*' if the task group was unable to find
data to support its probable presence.
For each "probable" or "potential" pollutant, possible sources
were suggested. This information is incorporated in the
discussions of the sources of the individual toxic pollutants in
Section VI.
The other industry-related group was the Ecology Committe of the
Dyes Environmental and Toxicology Organization, Inc. (DETO).
DETO comprises 18 member companies that, in aggregate, produce
over 90 percent of the dyes manufactured in the United States.
The committee carried out a survey of the DETO membership to
determine which of the toxic pollutants in textile wastewater
might originate in dyes. The list of pollutants was narrowed to
40 that the committee believed could possibly be present in
commercial dye products. The committe focused on dye products
for which domestic sales (1976) exceeded 90,000 kg (approximately
200,000 pounds) per year and for which there are more than two
producers. The list of dyes numbered 70. Questionnaires were
sent to all 18 member companies and, in addition to the 70 listed
dyes, responses were received for an additional 81 dyes, for a
total of 151 dye products representing 55.3 percent of the
113,380 metric tons (approximately 250 million pounds) sold in
1976. Six toxic pollutants (chromium, copper, pentachlorophenol,
parachlorometacresol, phenol and zinc) were classified as
"believed present in (some) commercial dyes at greater than 0.1%"
and 19 additional pollutants were classified as "believed present
in (some) commerical dyes at less than 0.1%." The results of the
156
-------
DETO survey are presented in more detail in the discussion of the
sources of the individual pollutant parameters in Section VI.
TRADITIONALLY-MONITORED POLLUTANTS
As a result of past regulatory efforts and studies certain toxic,
nonconventional and conventional pollutants have traditionally
been monitored in the textile industry. These pollutants
include:
Conventional
Biochemical Oxygen Demand (BODJ5)
Total Suspended Solids (TSS)
Oil & Grease
pH
Nonconventional
Chemical Oxygen Demand (COD)
Total Phenols
Sulfide
Color
Toxic
Total Chromium
Even though the above parameters are recognized as significant in
textile mill wastewater, monitoring practices across the industry
differ significantly. National Pollutant Discharge Elimination
System (NPDES) permits specify the parameters to be monitored by
these facilities. Im many cases, permit requirements were
developed prior to promulgation of BPT and the monitoring
requirements at the time of the survey did not include all of the
regulated pollutants. For mills discharging wastewater to POTWs,
monitoring requirements range from none, which is the typical
case, to very extensive requirements. The majority of the
indirect dischargers pay for wastewater disposal based on a local
surcharge factor per unit of water consumption; monitoring of
wastewater constituents is not regularly conducted.
In order to obtain the best possible characterization of the
wastewater from each subcategory of the industry, mills believed
to be potential dischargers of wastewater were contacted
regarding the availability of historical data. Based on the
contacts, 637 mills were sent a detailed questionnaire in 1977
that requested that the mills provide representative monitoring
results or information about where such data could be obtained.
The Agency specifically requested data for 1976 in order to
obtain a consistent and up-to-date data base.
157
-------
Data considered useful in developing untreated wastewater
characteristics were received for 506 wet processing mills and 92
low water use processing mills. In addition, field sampling data
were collected on the traditionally-monitored nonconventional and
conventional pollutants in textile mill water supplies and
untreated wastewater and are presented to confirm, and in some
cases, supplement the historical data.
Characterization of_ Mill Water Supply
The field sampling results for water supply for the traditionally
monitored conventional and nonconventional pollutants are
summarized in Table V-10.
The concentrations of these pollutants in the water supply are
shown to be generally at insignificant levels across the
industry. Thus, the levels that are present in textile untreated
wastewaters primarily are caused by the raw materials used and
the manufacturing processes.
Characterization of_ Untreated Wastewaters
The raw wastewater concentrations and mass discharge rates
reported in the mill surveys for the traditionally-monitored
nonconventional pollutant parameters are presented by mill and
subcategory in Table V-l1. The summaries provide the minimum,
maximum, average, median and standard deviation of the values as
well as the number of mills represented for each parameter in
each subcategory. The values represent averages for mills for
which historical data were obtained. The range in* these data
demonstrates the degree of variability that is inherent in the
industry. Untreated wastewater concentrations for the
traditionally-monitored nonconventional and conventional
pollutant parameters are summarized for each subcategory in Table
V-l2. Values are included for each parameter for which three or
more mills are available. The values are the medians of the
reported values.
Wastewater concentrations are of primary importance in predicting
the treatability of a particular waste stream and are used to
design, monitor and control the operation of treatment systems.
But concentration alone does not provide a complete picture of
the relative pollutant contributions of each subcategory. Mass
discharge rates, which relate pollutant concentrations and
wastewater discharge to production levels, provide a more
suitable means of regulating wastewater discharges by preventing
dilution of wastewater to meet concentration limits. Median mass
discharge rates for the appropriate pollutant parameters are
presented in Table V-l3. Again, values are reported for each
parameter for which three or more mills are available.
The nonconventional and conventional pollutant data collected in
conjunction with the field sampling program helped develop a more
158
-------
TABLE V-10
SUMMARY OF ANALYTICAL RESULTS
TRADITIONALLY MONITORED CONVENTIONAL AND
NONCONVENTIONAL POLLUTANTS
FIELD SAMPLING PROGRAM - WATER SUPPLY
Pollutant
Parameter Minimum
BOD (mg/1) 1
COD (mg/1) 2
TSS (mg/1) 1
Oil & Grease (mg/1) 1
Total Phenols (ug/1) 1
Sulfide (ug/1) 3
Color (APHA Units) 15
Color (ADMI pH 7.6) 5
Maximum
1
95
38
38
1020
100
15
276
Average
1
25
7
16
51
64
15
40
Median
1
20
5
15
10
100
16
Analyzed*
10
28
28
15
26
23
2
22
Detected*
10
22
18
11
26
9
1
17
* Values represent the number of samples analyzed.
# Values represent the number of times pollutant was detected.
Note: Statistical values based on detected values only.
Source: EPA Field Sampling Program.
159
-------
TABLB V-ll
RAW WASTE CHARACTERISTICS
WOOL SCOURING SDBCATEGORY
Report
10014
10012
100O4
10005
10011
10008
10015
10006
10002
10001
10013
Dis-*
Charge
I
D
D
D
I
X
D
D
1
D
D
VASTEWATER
DISCHARGE
RATE BOO-5 COD TSS
(gal/lb) («g/l) (kg/kk«) («g/l) (ka/kkg) («g/l) (kg/kka)
1.4
1.3
1.3
1.2
.7
2.2
4.6
1.5
1.9
.5
4.6
2270
4000
364
6678
313
1825
4578
413
—
1606
28.41
44.32
3.80
41.79
6.01
67.22
57.93
6.58
—
61.71
—
—
1136
7692
17831
2020
•
6895
—
—
20.10
334.44
225-66
32.21
—
263.92
2742
4800
480
13190
217
2655
82.17
120
—
2958
34.32
51.89
5.01
82.55
4.18
114.48
103.99
1.91
—
113.69
0
<•*/!)
2825
308
158
5000
580
942
—
80
—
—
TOTAL
& G pffiNOLS TOT-CR SOLFIDE
(kg/kkg) (iig/l) (a/kk*) (ug/l) (g/kkg) (ug/l) (g/kkg)
35.35
3.59
1.64
31.29
10.26
29.70
—
1-27
—
—
COLOR**
UNITS
—
—
—
—
—
—
__
—
Minimi* .5 313 3.80 1136 20.10 120 1-91 80 1.27
Maxima 4.6 6676 67.22 17831 334.44 13190 114.48 5000 35-35
Average 1.9 2449 35-30 7114 175.26 3931 56.89 1413 16.15
Median 1.4 1825 41.79 6895 225 -66 2742 51.89 580 10.26
Standard Deviation 1.4 2208 25.18 6650 141-66 4316 48.01 1841 15.30
Nunber 11 9 95 59 977
Source: EPA Industry 308 Survey.
** - Color units are APRA color units.
*I - indicates indirect discharger.
0 - indicates direct discharger.
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
FELTED FABRIC PROCESSING SUBCATEGORY
WASTEWATER
A DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS O & G PHENOLS TOT-CR SULFIDE COLOR**
No. Charge (gal/Ib) (mg/1) (kg/kkg) (mg/l) (kg/kkg) (•*/!) (kg/kkg) Qpg/l) (kg/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) (ug/1) (g/fckg) UNITS
60027
80013
80024
80021
80006
80023
80017
80010
80020
80025
80018
Minimum
Max! mum
Average
Medi an
Standard
Number
D
I
I
D
I
I
1
I
I
D
I
Deviation
28.1
15.1
24.8
4.0
25.5
16.6
33.3
49.7
9.8
111.6
31.8
4.0
111.6
31.8
25.5
29.2
11
136
—
—
—
—
—
55
271
—
376
—
55
376
209
203
142
4
31.89
—
—
—
—
—
15.43
108.57
—
309.97
—
15.43
309.97
116.46
70.23
135.23
4
521
—
—
—
—
—
230
586
—
2091
--
230
2091
857
553
837
4
122.19
—
—
—
—
—
63.97
249 . 77
—
2379-96
—
63.97
2379.96
703.97
185.98
1120.02
4
68
—
—
—
—
—
149
285
—
66
—
68
285
147
117
98
4
15,94
—
—
—
—
—
41.44
119.72
—
86.79
—
15,94
119.72
65.97
64,11
46.28
4
_„
—
—
—
—
—
8
28
—
156
—
8
156
64
28
80
3
—
—
—
—
—
2.36
11.15
—
126.40
—
2.36
126.40
46.63
11.15
69.21
3
70
—
—
—
—
—
—
575
—
1097
--
70
1097
580
575
513
3
16,41
—
—
—
—
—
—
247.35
—
1497.56
—
16.41
1497.56
587.11
247 . 35
796.89
3
50
—
—
—
—
—
500
—
—
—
—
50
500
275
275
318
2
11.72
—
—
—
—
—
139.07
—
—
~
—
11.72
139.07
75.39
75.39
90.04
2
500
—
—
—
—
—
—
—
—
_.
—
500
500
500
500
—
1
117.27
—
—
—
—
—
—
—
—
—
—
117.27
117.27
117.27
117.27
—
1
300
—
—
—
—
—
—
__
—
—
—
300
300
300
300
—
1
Source; EPA Industry 308 Survey.
£* - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
WOOL FINISHING SUBCATEGORY
Report
No.
20015
20005
20020
20021
20012
20017
20008
20009
20011
20007
20010
20006
20004
20018
20022
Minimum
!_, Maximum
Ch Average
1X3 Median
Standard
Number
WASTEWATER
^ DISCHARGE
Dis- RATE BOD-5 COD
Charae (gal/lb) (mg/1) (kg/kkR) (»g/l) (kR/kkE)
I
D
D
I
I
0
I
D
D
I
1
I
I
I
I
Deviation
78,8
61.4
32.1
42.6
33.9
105.4
34.0
27.2
36.5
40.0
41.6
27-9
18.6
50.0
14.9
14.9
105-4
42.9
36.5
23-5
15
66
89
466
—
94
—
150
247
—
183
—
150
232
—
66
466
186
150
122
9
43.41
22.36
160.47
—
83.47
—
34.13
85.76
—
63.62
—
24.80
96.79
—
22.36
J60.47
68.31
63.62
44.23
9
—
592
1336
—
341
—
900
653
—
280
—
—
—
1328
280
1336
775
653
431
7
—
148.84
448.27
—
3O0.60
—
204.81
212.35
—
97.35
—
—
—
166.22
97.35
448.27
225.49
204.81
116.67
7
TSS
(mg/1) (kg/kkg)
17
66
128
—
32
175
51
—
51
—
59
24
—
17
175
67
51
51
9
11.18
14.97
43.57
—
28.68
—
39.82
16.26
17.73
—
9.53
10.01
—
9.53
43.57
21.30
16.26
12.94
9
0
(mg/1)
—
—
70
—
~
—
—
—
—
—
—
—
—
—
70
70
70
70
—
1
& G
(kg/kkg)
—
9.16
—
—
—
—
—
—
—
—
—
—
—
9.16
9.16
9.16
9.16
—
1
TOTAL
PHENOLS
(ug/D (g/kkg)
—
8
—
—
—
50
187
—
—
—
—
—
—
8
187
81
50
93
3
—
—
2-90
—
--
—
11.37
82.74
—
—
—
—
—
—
2.90
82.74
32.33
11.37
43-85
3
TOT-CR
(ug/D (g/kkg)
100
—
107
—
—
—
—
456
—
—
—
—
—
—
100
456
221
107
203
3
65.77
—
38.89
—
—
—
—
194.14
—
—
—
—
—
—
38.89
194.14
99.60
65.77
82.96
3
SULFIDE
(ug/1) (g/kkR)
—
73
—
—
—
—
—
—
—
—
—
—
—
73
73
73
73
—
1
—
—
26.05
—
—
—
—
—
—
—
—
—
—
—
26.05
26.05
26.05
26.05
—
1
COLOR**
UNITS
—
—
—
—
—
—
1550
—
—
—
—
—
—
1500
1500
1500
1500
—
1
Source: EPA Industry 308 Survey.
£* - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABU V-ll (continued)
RAW WASTE CHARACTERISTICS
LOW WATER USE PROCESSING (GENERAL) SUBCATEGORY
Report
No.
G3034
G3055
G3035
G3111
G3075
G3076
G3077
G3027
G3033
G3061
G3031
G3048
G3060
G3067
63001
G3003
G3017
G3107
G3054
G3065
G3078
G3116
G3118
G3106
G3040
38001
G3025
G3079
G3016
G3080
G3058
G3092
G3004
G3011
G3036
G3086
G3084
G3081
G3062
G3082
*
Dis-.
Charge
I
D
I
I
D
I
I
I
I
I
I
I
I
D
I
I
I
D
I
D
D
D
D
D
I
I
I
I
I
I
D
D
I
I
D
I
D
I
I
I
WASTEWATER
DISCHARGE TOTAL
RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SULFIDE
(sal/lb) (mg/1) (kg/kkg) (»«/!) (ka/kkg) (»g/l) (ks/kkji) (BUE/I) (kg/kkg) (ug/1) (g/kkg) (ug/1) (g/kkn) (ug/1) (g/kkg)
2.0
4.4
.07
.05 — — — — — -- — . --
2.8 37 .87 — — 70 1.60 -- -- 91 2.34 97 3.42 180 3.78
.7 ~ — — -- — -- — — -
5.7 — -- — — -- -- -- ~
1.2
9.2
.1
.3
2.3
.9
.1
.8
i.o
.2
.01
.3 450 1.37 -- -- 372 1.13
.6
1.1
.1
.1
.07 — — — « -- — ~ --
.4 -- — — — — ~ ~ —
.06 450 .21
2.5
1.3
1.0 795 6.98 2955 25.95 216 1.90
.3
4.2 — -- — — ~ -- — --
8__ __ __ __ __ _ __ __ __ _ __ __ __
8—-. _** __ _. -.— __ __ _— _ __ __ __
5O -. .. _ _ __ __ " — — __ _.. __ — __ __ «_
• J
• 1 """ """ ™~ ^"* '"'*" *** ™~ ~~ ~~ "*"" "" ~~ "^ **"*
2 A «« «^ __ __ ^-« «_ __ _« __ ^_ __ ~~
. y
43
1-3 *** *™ ~™ ""* *~* ™~ ™~ ™~ "* ** ~™ ~~ "*~ ™*
1^0
1 " " ' "
COLOR**
UNITS
„_
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
— '
—
—
—
—
—~
Source: EPA Industry 308 Survey,
£* ~ Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
LOW WATER USE PROCESSING (GENERAL) SUBCATEGORY
WASTEWATER
^ DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SULFIDE COLOR**
No. Charge (gal/lb) (mg/1) (kg/kkg) (mg/i) (kg/kkg) (ag/1) (kg/kkg) («g/l) (kg/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) UNITS
G3066
G3013
G3010
G3009
34007
G3005
G3085
G3030
38004
G3059
G3039
G3090
G3028
G3026
G3049
G3023
G3072
G3045
G3029
G3022
G3050
G3064
G3083
G3073
G3057
G3108
G3021
G3019
G3070
G3056
G3071
G3041
G3042
G3046
G3020
G3024
G3053
G3113
G3015
G3119
G3063
G3052
G3032
G3069
G3007
D
I
I
I
D
I
I
I
I
I
D
I
I
I
I
I
I
I
I
I
I
D
I
D
D
I
I
I
D
I
J
I
I
I
I
1
I
D
I
D
D
I
I
D
I
.8
1.0
.4
.5
.0
.4
3.4
.6
-4
1.3
1.0
1.1
.9
.2
.7
.09
.1
3.0
2.0
.4
.7
2.5
.3
.6
.8
.5
.5
.4
2.7
.2
1.3
.5
.4
4.0
.9
.6
.4
.2
1.2
.8
.2
.04
1.0
1.4
2.4
—
—
650
—
497
—
—
—
—
—
—
275
—
__
—
—
209
—
—
—
-"-
—
—
293
—
317
—
--
—
—
—
~
—
.77
—
8.65 788
—
—
—
—
—
—
1.32
—
__
—
—
2.41 595
—
—
__
—
—
—
.70 1063
—
2.31 1069
—
__
—
—
— —
__
—
235
—
13.70 92
—
—
—
—
—
—
220
—
_-
—
—
6.87 187
—
—
__
—
—
—
2.74 183
—
7.72 532
—
._
—
—
— —
--
—
.33
—
1.59
—
—
—
—
—
—
1-05
—
__
—
—
2.16
—
—
„
—
—
—
,44
—
4.02
—
„
—
—
__ — — — — _*- — — .»*. — — — — — —
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
"
I - indicates indirect discharger
D - indicates direct discharger
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
LOW WATER USE PROCESSING (GENERAL) SUBCATECORY
WASTEWATER
A DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SULTIDE COLOR**
No. Charge (gal/lb) (rog/l) (kg/kkg) (mg/1) (kg/kkg) (mg/l) (kg/kkg) (ng/1) (kg/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) UNITS
G3018 D
G3068 D
Hinimum
Maximum
Average
Median
Standard Deviation
Number
.2
1.1
.01
9.2
1.22
.75
1.54
86
„_
—
37
795
397
383
219
10
__
—
.21
8.65
2.55
1.34
2.88
10
„
—
595
2955
1294
1063
949
5
._
—
2.74
25.95
11.39
7.72
9.02
5
„
—
70
532
234
216
141
9
•*
—
.33
4.02
1.58
1.59
1.10
9
__ __ __
—
91
91
91
91
__
— 0 1
_—
—
2.34
2.34
2.34
2.34
—
1
__
—
97
97
97
97
--
1
„
—
3.42
3.42
3.42
3.42
—
1
_—
—
180
180
180
180
—
1
—
3.78
3.78
3.78
3.78
—
1
**
—
—
—
--
—
—
~~
Source: EPA Industry 308 Survey.
£* - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
LOW WATER USE PROCESSING (WATER JET WEAVING) SUBCATEGORY
WASTEWATER
4 DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SOLFIDE COLOR**
No. Charge (gal/Ib) («g/l) (ke/kkg) («g/l) (kg/kkg) (,K/1) (kg/kkg) (•g/1) (kg/kkg) (ug/1) (g/kkg) (ug/1) (g/tfcg) (ug/1) (g/kkg) UNITS
G3117
G3012
G3014
C3115
G3114
G3038
Minima
HaxinuQ
Average
Median
Standard
Nunber
D
I
I
I
D
D
Deviation
15.3
6.5
2.3
9.0
11.8
23.3
2.3
23.3
11.3
10.4
7.3
6
119
—
—
55
204
—
55
204
126
119
74
3
15.95
—
—
4.33
20.41
—
4.33
20.41
13.56
15-95
8.30
3
137
—
—
247
183
—
137
247
189
183
55
3
18.19
—
—
19.20
17.57
—
17.57
19.20
18.32
18.19
.82
3
26
—
—
26
28
—
26
28
26
26
1
3
3.40
—
—
2.05
2.69
—
2.05
3.40
2.71
2.69
.67
3
5
—
—
15
8
—
5
15
9
8
5
0 « 0 3
.50
—
—
1.46
.63
—
.50
1.46
.86
.63
.52
3 — 0
__.
—
—
—
—
—
—
—
—
—
— -*
Source: EPA Industry 308 Survey.
^* - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
CTi
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
WOVEN FABRIC FINISHING (SIMPLE) SUBCATEG08Y
Report
No.
40147
40001
40063
40045
40086
40108
40138
40019
40152
40013
40116
40123
40021
40101
40124
40055
40029
40127
40143
40035
40113
40057
40110
40088
40144
40009
40005
40080
40027
40098
40071
40036
40023
40100
40076
40050
40070
40128
40066
40109
*
Dis-
charge
I
I
I
D
I
I
I
I
I
I
I
D
I
I
I
I
I
I
D
D
I
I
I
I
D
I
I
I
I
D
I
I
D
D
D
D
I
D
D
D
WASTEWATER
DISCHARGE
RATE BOD-5 COD
(Kal/lb) (.ng/l) (kg/kkjt) OoR/l) (ks/kkg)
6.1
3.2
10.0
1.5
3-3
24.0
9-5
5.2
22-1
4.0
26.3
33-0
8-5
9-4
8.5
12.1
5.1
2-7
14.4
28.0
.0
7.5
28.2
18.4
2.3
15.7
2.7
30.5
24.9
28.8
4.2
3.8
23.8
9.0
3.2
14.5
21.3
4-7
3-1
17.1
213
747
383
2048
212
611
30
305
877
322
188
133
66
915
69
298
300
660
89
143
136
—
616
19
232
—
142
—
—
—
486
10.89
62.88
29.06
90.42
38.70
20.85
6.69
22.13
69.52
23.00
22.29
30.49
4.16
215.35
10.80
5.73
39.33
15.42
23.76
29.93
28.84
—
19.96
3.77
18.02
—
17.21
—
—
—
69.56
1801
5020
1266
1396
218
862
2277
1985
659
472
203
1856
644
1230
1400
317
472
384
—
940
218
567
—
767
—
—
—
999
92.11
221.64
239.82
47.65
47.92
60.51
180.54
141.81
52.06
114.04
12.70
436.82
99.46
161.39
32.71
84.64
98.51
78.90
—
30.43
43.31
43.02
—
92.70
—
—
—
143.00
TSS
(rag/I) (kg/kkg)
16
590
258
53
345
29
31
289
460
28
34
24
54
64
262
75
60
28
—
192
890
36
—
35
—
—
—
— —
.81
49.66
11.39
9.55
11.77
6.41
2.16
22.93
32.86
3.28
7.73
5.64
8.19
8.49
6.12
20.02
12.67
6.73
.
6.22
176.82
2.75
—
4.28
—
—
—
~~
TOTAL
O S G PHENOLS
(fflg/D (kg/kkR) (UR/I) (8/kkR)
153 6.75 40
67 12.54
50
286 21.69 600
782 61.99
154 11.00
29
6 .86
350
—
32 .74 410
36 9.08 205
9 1.87 47
—
—
—
10
48
—
—
—
—
—
— — — — •"—
1.76
11.01
45.51
1.84
6.73
—
9.57
51.21
9.85
—
—
—
1.98
3.50
—
—
—
—
—
~™
TOT-CR SULFIDE
(ug/D (R/kkn) (ug/1) (R/kkg)
100
530
30
1
40
40
24
150
10
50
37
—
—
37
22
—
—
—
—
—
_._
5.11
18.09
6.55 580 128.21
.07
2.50 55 3.44
.77
3.14
3.50 25 .58
2.31 90 22.07
10.43 50 10.43
9.93
—
—
7.35
1.66
—
—
—
—
—
—- — —
COLOR**
UNITS
10000
3795
800
800
—
5000
1283
503
—
—
—
424
—
—
—
—
—
—
—
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
WOVEN FABRIC FINISHING (SIMPLE) SUBCATEGORY
WASTEWATER
DISCHARGE
TOTAL
Report Dis- RATE BOD-5 COD
No. Charge (gal/lb) (ng/1) (kg/kkR) («K/1) (kg/kkR)
40032 0
Minima
Maximum
Average
Median
Standard Deviation
Number
2.4
1.5
33.0
12.5
9.2
9.7
40
313
19
Z048
390
298
418
27
6.05
3.77
215.35
34.62
22.29
42.29
27
1411
203
5020
1140
901
1022
24
28.31
12.70
436.82
107.66
88.37
93.04
24
TSS
(«g/l) (kg/kkR)
135
16
890'
173
60
221
23
2.50
.81
176.82
18.21
7.73
36.34
23
0
C-8/1)
6
782
169
67
247
9
& G
(kg/kkg)
—
.74
61.99
14.05
9.08
19.18
9
PHENOLS
(ug/1) (g/kkg)
—
10
600
178
49
206
10
—
1.76
51.21
14.29
8.15
18.34
10
TOT-CR
(uR/1) (g/kkg)
--
1
530
82
37
140
13
--
-07
18.09
5.49
3.50
5.02
13
SULFIDE
(ug/1) (g/kkg)
—
25
5&0
160
55
235
5
—
.58
12&.21
32.94
10.43
53.89
5
COLOR**
UNITS
—
424
10000
2825
1041
3357
&
Source: EPA Industry 308 Survey.
** - Color units are APHA color units,
I - indicates indirect discharger
D - indicates direct discharger
CO
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS *
WOVEN FABRIC FINISHING (COMPLEX) SUBCATEGORY
ID
Report
No.
40046
40008
40106
40078
40020
40102
40122
40011
40119
40132
40094
40036
40134
40082
40139
40091
40067
40135
40115
40154
40131
40133
40163
40041
40i48
40022
40040
40090
40077
40125
40160
40024
40033
40111
40026
40025
40117
40114
40126
Minimum
Maximum
Average
Median
Standard
dumber
WASTEWATER
* DISCHARGE
Dis- RATE BOD-5 COD
Charge (gal/Ib) (mg/1) (kg/kkg) (ing/l) (fcg/fckg)
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
D
D
D
I
D
I
I
I
I
D
D
I
I
D
I
D
I
I
D
I
I
I
D
D
Deviation
20.4
1.3
9.8
14.9
11.9
4.9
8.7
12.6
2.9
7.1
29.4
6.2
4.4
16.6
6.6
9.3
8.6
9.7
3.9
23.5
10.4
8.2
22.0
25.0
11.9
33.2
2.4
3.5
12.7
24.9
11.7
27.0
19.8
17.7
15.7
29.6
5.9
18.4
3.9
1.3
33.2
13.2
11.7
8.6
39
106
—
853
450
780
—
—
—
630
201
—
—
97
144
—
356
106
399
350
337
471
—
—
—
328
83
2164
281
389
119
461
—
219
288
—
—
1125
565
—
83
2164
452
350
439
25
18.79
—
70.31
56.32
78.10
—
—
—
15.77
12.03
—
—
3.59
20.15
—
27.92
9.19
33.15
11.67
62.24
41.28
—
—
—
32.74
23.11
44.08
8.44
41.27
24.99
53.34
—
36.28
42.71
—
—
57.09 •
87.03
—
3.59
87.03
36.46
33.15
22.89
25
__
1850
—
3100
—
244
—
—
--
864
—
—
~
—
—
—
—
—
—
1076
—
—
—
1168
308
5138
1886
—
—
1442
—
726
934
—
—
—
1174
—
244
5136
1531
1168
1316
13
„
21.30
—
388.01
—
10. IS
—
—
_.
51.72
—
—
—
—
—
.
—
—
—
—
94.23
—
—
—
116.37
85.68
104.88
56.66
—
—
142.64
—
119.29
138.51
—
—
—
180.84
—
10.18
388.01
116.17
104.88
95.20
13
TSS
(mg/1) (kft/kke)
55
425
—
136
616
—
—
—
78
74
—
—
—
136
—
56
40
—
61
47
55
—
—
—
220
43
866
185
41
48
165
—
182
—
—
—
155
—
—
40
866
175
78
212
21
9.14
4.89
—
17.02
61.68
—
—
—
1.95
4.43
—
—
—
19.01
—
4.35
3.18
—
2.05
9.29
4.84
—
—
—
21.97
12.05
17.75
5.55
4.39
10.13
16.73
—
30.15
—
-
—
7.87
—
—
1.95
61.68
12.78
9.14
13.49
21
O
— —
5
—
48
—
—
—
—
—
—
—
—
—
—
—
—
_-
—
—
—
34
—
—
—
44
—
158
—
—
—
—
—
86
—
—
—
44
—
—
5
158
59
44
49
7
& G
(kg/kkg)
.05
—
6.00
—
—
—
—
--
—
—
—
—
__
—
—
~
—
—
—
2.97
—
—
—
4.45
—
3.24
—
—
—
—
—
14.24
—
—
—
2.24
—
—
.05
14.24
4.74
3.24
4.57
7
TOTAL
PHENOLS TOT-CR SULFIDE
(iiR/1) 6*/kkg) (ug/lj (s/kkg) (uK/1) (8/kks)
1500
—
62
—
600
—
—
—
—
—
—
—
—
—
—
„
—
—
—
10
—
—
—
—
—
—
—
298
—
—
—
46
—
—
—
—
—
—
10
1500
419
180
574
6
17.32
—
7.76
—
25,03
—
—
—
—
—
—
—
--
—
—
—
—
—
—
.91
—
—
—
—
—
—
—
31.63
—
—
—
7.62
—
—
—
--
—
—
.91
31.63
15.04
12.54
11.72
6
„
100
—
19
—
1180
—
—
100
—
—
—
—
—
—
—
—
—
—
30
—
—
—
—
157
125
110
133
—
—
—
—
—
—
—
—
—
—
19
1180
217
110
363
9
1.15
—
2.37
—
49.23
—
—
2.50
—
—
—
—
--
—
—
—
—
—
—
2.62
—
—
—
—
44.68
2.54
3.30
14.13
—
—
—
__
—
—
—
—
—
—
1.15
49.23
13.61
2.62
19.32
9
„
100
—
100
—
—
—
—
—
—
—
—
—
—
—
100
~
—
—
—
.-
—
—
—
—
—
—
—
5840
—
—
—
120
—
—
—
—
—
—
100
5840
1252
100
2564
5
„
1.15
—
12.51
—
—
—
—
--
—
—
—
—
—
—
7.84
__
—
—
—
~
—
'
—
—
—
—
—
619.21
—
—
—
19.88
—
—
—
—
—
—
1.15
619.21
132.11
12.51
272.37
5
COLOR**
UNITS
500
—
700
—
—
—
—
—
—
—
—
317
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
..
—
—
—
~
—
—
317
700
505
500
191
3
I - indicates indirect discharger
D - indicates direct discharger
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
-------
TABtE V-ll (continued)
RAW WASTE CHARACTERISTICS
WOVEN FABRIC FINISHING (DESIZING) SUBCATEGORY
WASTEWATER
DISCHARGE
TOTAL
Report
No.
40075
40120
40146
40031
40121
40089
40083
40010
40018
40093
40141
40047
40104
40060
40130
40064
40012
40118
40072
40028
40053
40015
40043
40049
40052
40073
40054
40056
40081
40065
40097
40058
40037
40042
40007
40004
40068
40155
40016
40074
Dis-
charge
I
D
D
D
I
I
I
D
I
I
I
D
I
I
D
D
D
D
D
I
I
I
I
D
I
D
D
I
I
D
D
D
D
I
D
I
I
I
I
D
RATE BOD-5 COD TSS
(gal/lb) (rag/1) (kg/kkR) (rag/1) (kg/kkR) (»g/l) (kg/kkE)
32.4
9.5
11-7
10.7
17.8
.0
15.8
25.0
13.2
60.9
23.0
16.5
4.3
16.8
15.7
8.6
6.8
25.2
10.3
10.8
3.3
2.5
30.5
20.0
7.9
3.1
6.6
4.3
21.5
.6
7.0
17.1
14.0
32.1
13,9
9,8
12,1
7.5
14.5
23,4
222
908
523
295
—
—
164
422
281
506
311
195
204
200
640
494
125
366
231
2604
—
435
193
712
242
1011
395
—
—
195
311
—
—
690
1110
—
240
668
972
60.20
72.67
46.97
44.04
—
34.21
46.76
142-97
97.24
42.93
7-16
28.75
26.33
45-50
28.27
26.30
31.64
20.98
63.68
—
109.02
33-16
47.52
5-90
56.71
14.42
—
—
11.56
44.48
—
—
80.63
98.30
—
15.15
81.28
188.51
2355
1708
997
—
—
372
883
1569
—
834
836
716
845
—
—
574
—
746
—
—
—
800
1837
—
2778
1316
—
—
1845
--
—
—
—
2120
—
1580
2488
—
181.59
153.13
148.94
—
—
77.60
97.88
798.32
"
114.85
30.62
100.68
111.25
—
—
120.80
—
67.42
—
—
—
130.55
122.63
—
153.04
48.04
—
—
107.24
~
—
—
—
194,95
—
99.80
302 . 74
—
309
—
86
—
—
1
56
147
246
—
33
64
82
—
—
213
78
131
1260
—
121
162
239
97
434
~
—
—
—
135
—
—
904
2442
—
155
311
186
24,01
—
12,90
—
—
.20
6,25
74,79
47.27
—
1.20
9.07
10.79
—
—
44.82
6.80
11.82
34.76
—
31.31
23.31
15.95
2.43
24.38
—
—
—
—
19.31
—
—
105.69
222.11
—
9.79
37.84
40.06
0
—
—
100
—
—
—
—
—
—
—
18
—
31
—
—
—
—
—
84
—
—
—
68
—
—
—
—
—
—
—
—
—
—
1444
—
—
—
—
& G
(kg/kkR)
~
—
14.93
—
—
—
—
—
—
—
.65
—
4.08
—
—
—
—
—
2.22
—
—
—
4.53
—
—
—
—
—
—
—
—
—
—
151.25
—
—
—
—
PHENOLS TOT-CR SULFIDE
(ug/l) (g/kkK) (uR/1) (g/kks) (uR/n (g/kkg)
—
—
1000 149.32 100
—
—
100
1215 134.71
—
—
317
4
260
151 19.88 30
—
—
-_
—
—
_-
—
1851
—
14 .93 7070
—
—
__
—
—
—
35 5.00 555
—
—
—
—
—
250
— 1250O
—
__
—
14.93
—
—
20.86
—
—
—
43.76
-14 130 4.76
36.57
3.95
—
—
__
—
—
—
—
480.56
—
471.96 4400 293.72
—
—
__
—
—
—
79.39 110 15.73
—
—
—
—
—
15.79
1521.01
—
COLOR**
UHITS
—
—
—
—
—
—
—
—
—
—
20
—
—
—
—
~
—
—
—
—
—
—
™
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
-------
TABLE V-II (continued)
RAW WASTE CHARACTERISTICS
WOVEN FABRIC FINISHING CDESIZING) SUBCATEGORY
WASTEWATER
... DISCHARGE TOTAL
Report Dis-" RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SULFIDE COLOR**
No. Charge (gal/lb) (mg/1) (kg/kk«) (mfi/I) (kg/kkg) (mg/1) (kg/kkg) (mg/1) (kg/kke) (ug/1) (g/kkg) (ug/I) (g/kkg) (ug/l) (g/kkg) UNITS
40092 I
40140 D
40079 D
40002 I
40014 D
40069 D
40017 D
40151 D
40145 D
40099 D
40153 D
40150 D
40103 D
40034 I
40059 D
4006 1 D
4008 7 D
40003 D
40142 D
40030 D
Minimum
Maximum
Average
Median
Standard Deviation
Number
4.0
5.2
1.8
5.5
51.3
4.9
4.0
8.7
21.8
15.8
17.5
9.6
10.5
14.2
14.5
12.7
7.6
18.3
14.7
20.9
.6
60.9
14.4
12.7
10.9
59
640
441
713
355
533
897
411
273
788
366
178
125
2604
510
403
421
42
28.33
17.86
51.89
46.96
77.97
79.12
49.13
33.14
119.96
44.74
30.52
5.90
188.51
53.16
45.12
37.80
42
1240
1562
2408
846
918
1026
1400
1899
1527
853
1763
835
1092
372
2778
1350
1240
617
33
54.15
61.30
175.14
154.11
121.99
151.47
113.10
167.51
181,57
103.56
266.85
103.22
185.01
30.62
798.32
151.54
121.97
129.65
33
173
310
60
78
168
127
196
548
--
1
2442
298
158
467
32
7.63
12.26
7.88
11.44
13.57
11.20
23.27
83.50
—
.20
222.11
30.86
14.76
42.63
32
5
--
5
1444
250
68
527
7
.36
—
.36
151.25
25.43
4.08
55.69
7
142
—
14
1215
426
146
534
6
6-33
—
.93
149.32
52-69
13.10
69.63
5
14
40
20
—
4
12500
1650
175
3638
14
.57
2.90
2.63
—
.14
1521.01
192.50
18.32
416.84
14
—
—
110
4400
1546
130
2471
3
—
—
4.76
293.72
104.73
15.73
163.75
3
—
--
20
20
20
20
—
1
Source: EPA Industry 308 Survey.
•£* - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V--11 (continued)
RAW WASTE CHARACTERISTICS
KNIT FABRIC FINISHING (SIMPLE) SUBCATEGOBY
Report
No.
50008
50001
50025
50038
50088
50120
50081
50117
50020
50005
50043
50017
50073
50110
50022
50067
50044
50042
50010
50077
50118
50028
50002
50087
50080
50121
50103
50102
50104
50070
50014
50122
50057
50108
50116
50093
50040
50119
50112
54060
*
Dis-
charge
D
I
I
I
I
I
D
D
I
I
D
I
I
I
D
I
I
I
I
I
I
I
I
I
I
I
I
I
D
I
I
D
D
D
D
I
I
I
D
I
WASTEWATER
DISCHARGE
RATE BOD-5 COD TSS
(gal/lb) (-8/1) (kg/kkg) (•«/!) (kg/kkg) (as/l) (kg/kk«)
20.4
17.4
28.4
2.6
2.1
20.0
6.0
5.8
12.4
20.0
27.9
11.0
1.0
31.5
16.6
19.0
46.5
31.1
3.2
16.3
4.8
24.3
14.8
14.7
13.5
12.9
9.4
13.8
4.8
20.6
14.0
10.8
12.4
16.1
8.8
19.9
20.0
6.4
18.2
39.2
__
303
—
—
550
—
181
91
130
—
318
—
1860
—
—
—
—
164
—
—
—
338
304
161
—
—
—
157
327
—
—
—
380
115
181
209
—
—
279
158
— ^
44.27
—
—
9.86
—
8.97
4.44
13.46
—
77.47
16.33
—
—
—
—
42.57
—
—
—
69,51
36.61
19.78
—
—
—
17.83
13.18
—
—
—
40.48
15.47
13.34
34.87
—
—
42.75
51.79
__
—
727
—
4000
—
369
—
452
—
1522
522
194000
—
—
—
—
529
—
728
—
1762
1300
535
—
—
—
—
1261
—
—
—
—
429
—
947
—
—
934
—
*•
—
172.54
—
71.76
—
17.90
—
46.81
—
372.39
48.06
170.40
—
—
—
137.41
—
99.22
—
306.98
159.40
65.73
—
—
—
—
50.80
—
—
—
—
57.53
—
158.04
—
—
143.96
—
__
—
83
—
355
—
95
—
77
—
42
122
216O
—
—
—
—
57
—
—
—
—
58
30
—
—
—
38
119
—
—
—
31
21
18
25
—
—
41
61
«—
—
19.91
—
6.36
—
5.46
—
7.97
—
9.96
11.23
18.97
—
—
—
—
14.90
—
—
—
—
7.17
3.68
—
—
—
4.69
4.88
__
—
— •
3.22
2.91
1.32
4.17
—
—
6.33
20.16
0
(•8/1)
—
195
—
30
—
—
—
—
—
14
204
455
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
93
& G
(kg/kkg)
—
46.43
—
.53
—
—
—
—
—
3.52
18.78
3.99
—
—
—
—
~
.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
'
—
—
30.48
TOTAL
PHENOLS
(us/1) (a/kkg)
—
1675 397.35
—
—
—
—
—
1 .10
—
22 5.35
10 .92
__
—
—
—
—
—
—
—
—
—
—
—
--_
—
—
126 4.18
—
. —
—
—
—
—
—
—
—
—
106 34.74
TOT-CR SULFIDE
(ug/1) (g/kka) (us/1) (a/kka)
—
15
—
—
—
13
—
—
—
26
—
—
—
—
—
—
--
—
—
—
—
600
80
—
—
—
171
58
—
—
—
—
—
—
—
—
—
- —
78
„
—
3.55 55 13.04
—
—
—
.64
—
—
—
6.21
—
—
—
—
—
—
—
—
—
—
—
85.25
9.82
—
—
—
25.90
2.35
—
—
—
—
—
—
—
—
—
—
25.56
COLOR**
UNITS
—
380
—
—
—
—
—
170
—
366
—
—
—
—
—
—
718
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
454
~
-------
TABLE V-11 (continued)
RAW WASTE CHARACTERISTICS
KMT FABRIC FINISHING (SIMPLE) SUBCATEGORY
h- •
-•J
CO
Report
No.
50030
50059
50011
50046
50037
50101
50007
50047
50054
50082
50015
50094
50048
50098
50106
50113
50026
Minimum
Maximum
Average
Median
Standard
Number
WASTEWATER
A DISCHARGE
Dis- RATE BOD-5 COD TSS
Charge (gal/lb) (n.R/1) (kg/kkg) (mg/1) (kg/kk*) (ag/1) (kg/kkR)
D
I
D
I
D
I
I
D
I
D
D
I
I
D
I
D
D
Deviation
8.2
4.0
6.5
29.4
17.2
8.8
1.8
16.6
18.7
13.5
27.6
19.7
12.9
8.2
35.4
12.2
14.1
1.0
46.5
15.6
14.1
9.7
57
334
505
196
158
139
60
205
—
209
256
412
119
198
—
60
1860
290
205
313
31
23.13
17.19
28.76
13.74
20.34
9.38
23.39
—
34.68
27.74
29.76
35.30
20.35
—
4.44
77.47
27.57
23.13
17.36
31
1265
982
664
344
536
—
873
1087
790
342
745
—
342
19400
1655
767
3691
26
87.60
33.44
81.11
53.82
60.49
—
144.33
117.79
55.66
101.29
76.75
—
17.90
372.39
111.20
84.35
81.51
26
168
70
93
60
32
31
--_
37
383
163
42
49
—
18
2160
157
58
395
29
5.72
10.43
6.95
5.89
5.00
3.42
—
6.14
41.50
11.40
12.59
5.08
—
1.32
41.50
9.22
6.33
8.02
29
O
—
—
17
--
—
—
—
—
—
—
—
14
455
144
93
158
7
& G
(kg/kka)
--
' —
2.65
__
—
—
—
—
—
—
—
.53
46.43
15.19
3.99
17.58
7
TOTAL
PHENOLS
(«8/l) (g/kkg)
_-
—
110 17.21
_-
—
—
1000 108.36
—
—
—
—
1 .10
1675 397.35
381 71.02
108 11.28
619 136.70
8 8
TOT-CR
(UR/I) (R/kkR)
—
—
50
103
—
—
30
—
—
--
—
13
600
111
58
168
11
—
—
7.82
11.33
—
—
3.25
—
—
—
.64
85.25
16.51
7.82
24.38
11
SULFIDE
i (UK/!) (g/kk«)
—
—
20
—
—
—
7100
—
—
—
—
20
7100
2391
55
4077
3
—
—
3.12
_-
—
—
769.42
—
—
—
—
3.12
769.42
261.86
13.04
439.58
3
COLOR**
UNITS
1462
198
—
400
__
—
—
—
—
—
—
—
170
1462
518
390
416
8
Source: EPA Industry 308 Survey.
*/*•" - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (cootimied)
RAW WASTE CHARACTERISTICS
KNIT FABRIC FINISHING (COMPLEX) SUBCATEGORY
Report
No.
50065
50107
50090
50062
50086
50024
50032
50035
50021
50072
50034
50074
50066
50111
50006
50029
50065
50009
50061
50031
50039
50079
50100
50069
50099
50071
50105
50056
50109
50123
50068
50097
50027
50016
50012
50063
50018
50115
50076
50092
A-
Dis-
Charge
I
I
D
I
I
D
I
D
I
I
D
I
I
D
I
I
D
I
I
I
I
I
I
I
D
I
I
D
I
0
I
I
I
I
D
I
I
D
I
I
WASTEWATER
DISCHARGE
RATE BOD-5 COD
(gal/lb) (mg/1) (kjt/kkg) («R/1) (kg/kkR)
21.4
10.0
19.9
27.7
30.0
26.6
45.3
17.7
18.5
8.9
4.6
8.1
5.1
8.9
1.5
5.7
14.1
19.1
11.7
11.6
11.7
27.9
19.6
34.2
14.7
20.2
10.0
24.2
16.6
2.8
6.3
21.7
16.9
25.7
9.1
26.7
6.8
47.1
11.1
4.3
._
—
—
167
550
123
—
150
151
266
—
275
187
261
—
—
264
500
—
—
—
—
519
—
—
—
—
272
—
869
166
229
—
—
250
200
503
173
—
277
—
—
36.70
137.69
27.36
—
22.10
23.31
20.59
—
18.69
8.04
19.60
—
—
31.25
79.86
—
—
—
—
85.06
«
—
—
—
53,56
—
20,67
8.33
38.61
—
—
19.12
44.57
26.82
67-91
—
10.15
—
760
—
—
—
—
614
514
791
—
—
—
1905
—
—
1057
3149
—
—
—
—
2311
—
—
—
—
694
—
—
—
1114
—
—
976
545
—
—
—
1348
—
126.83
—
—
—
—
88.56
79.34
60.34
—
—
—
143.06
—
—
124.76
503.01
—
—
—
—
378.79
—
—
—
—
135.93
—
—
—
199.07
—
—
74.65
121.46
—
—
—
49.43
TSS
(»g/D (kg/kkg)
—
127
—
430
38
—
742
35
31
—
32
53
164
—
—
46
46
—
—
—
—
35
—
—
—
—
28
—
656
133
48
—
—
108
50
—
45
—
88
__
—
21.19
—
107.65
8.45
—
110.04
.5.40
2.38
—
2.17
2.28
12.31
—
—
5.52
7.34
—
—
—
—
5.73
—
—
—
—
5,72
—
15.69
6.65
9.16
—
—
8.26
11.14
—
18.07
—
3-22
0
(•8/D
..
—
107
—
—
—
—
—
—
38
—
—
23
6
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
20
—
—
83
—
—
—
—
113
& G
(kg/kkg)
—
17.85
—
—
~
—
—
—
2.94
—
—
.98
.45
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
3.63
—
—
6.34
—
—
—
—
4.14
PHENOL
(ug/1) (R/kkg)
—
72 12.01
—
—
—
—
—
—
—
—
—
80 3.42
160 12.01
—
—
—
230 36.73
—
—
—
—
—
—
—
—
—
100 19.10
—
—
—
—
—
—
114 8.71
—
—
—
—
__ __
10T-CR SULFIDE
(ug/1) (g/kkg) (ug/1) (g/kkg)
—
10
—
100
__
—
—
230
—
—
20
80
80
—
—
65
10
—
—
—
—
—
—
—
—
—
100
—
—
—
—
—
—
100
—
—
—
—
~~
—
1.66 50 8.34
—
25.03
__
—
—
35.50
—
—
1.35
3.42 210 8.98
6.00 1470 110.39
— -
—
7.66
1.59
—
—
—
—
—
—
—
-^
—
19.10 100 19.10
—
—
—
—
—
—
7.64
—
—
—
—
__ -_ —
COLOR**
UNITS
—
—
—
—
750
—
—
—
—
—
829
937
37
—
—
—
777
—
—
—
—
781
—
—
—
—
—
—
—
—
—
—
—
—
640
—
—
—
417
Source: EPA Industry 308 Survey.
i* - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
KNIT FABRIC FINISHING (COMPLEX) SUBCATEGORY
WASTEHATER
A DISCHARGE
Report Dis- RATE BOD-5 COD
No. Charge (gal/lb) (mg/1) (kg/kkg) (*g/l) (kR/kk«)
50019 D
50051 I
50H4 I
50083 I
50023 I
50052 D
50078 I
50084 I
50045 I
50013 0
50091 I
Minimum
Maximum
Average
Median
Standard Deviation
Number
"""•* • 4* - Color units are
12.9
8.5
7.7
16.2
7.6
20.4
15.2
11.8
32.2
8.0
23.3
1.5
47.1
16.4
14.7
10.1
51
280
223
123
869
298
261
176
23
28.11
43.51
8.04
137.69
38.07
28.11
30.26
23
834
593
514
3149
1147
834
753
15
79.86
115.45
49.43
503.01
152.03
121.46
125.42
15
TSS
(rag/1) (kjj/kkjt)
108
60
28
742
141
51
200
22
10.69
11.66
2.17
110.04
17-76
8.35
29.90
22
0
66
—
6
113
57
52
41
8
f f*
(kg/kkR)
6.73
—
.45
17.85
5-38
3.88
5.50
8
TOTAL
PHENOLS
(ug/D (g/kkg)
—
—
72
230
126
107
59
6
—
—
3.42
36.73
15.33
12.01
11.66
6
TOT-CR SUtFIDE
(ug/1) (g/kkg) (ug/1) (g/kkg)
180
10
230
88
80
68
11
—
35.04
1.35
35-50
13.09
7.64
13.29
11
—
—
50
1470
457
155
678
4
—
—
8.34
110.39
36.70
14.04
49.37
4
COLOR**
UNITS
~
—
37
937
646
763
289
8
APHA color units
CJl • *
! I - indicates indirect
discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
KHIT FABRIC FINISHING (HOSIERY) SUBCATEGORY
WASTEWATER
DISCHARGE
Report
No.
5H044
5H012
5H059
5H043
5H038
5H001
5H023
SHOOS
5H056
5H052
5H009
5H018
5H032
5H045
5H051
5H034
5H054
5H002
5H020
5H008
511014
5H050
5H031
5H026
5H040
5H021
5H039
5HQ24
5H025
5H029
5H028
5H027
5H049
5H030
5H058
5HOS7
5H055
5H048
5H007
5H013
Dis-
charge
I
I
I
I
I
I
D
D
I
T
I
1
I
I
I
I
I
I
ft
I
I
I
I
I
I
I
I
I
I
D
D
I
I
I
I
I
I
I
I
I
RATE
(gal/lb)
2-Q
3.4
10.8
7.6
4.0
4.9
15.1
31.1
14.8
12.5
22.6
6.9
1.1
11. 1
26.4
8.3
4.0
1.3
5.9
.8
15.0
24.5
5.9
11.2
5.4
10.7
3.7
6.6
9.7
7.5
4.7
5.6
8.3
12.6
7.0
11.1
13.7
.7
13.4
8.0
BOD-5
fmg/I)
..
176
—
202
--
—
—
235
792
533
351
323
280
190
166
—
540
—
503
740
221
675
557
487
390
803
506
477
283
195
57
—
—
—
—
174
176
—
320
""-
(kg/kks)
„
5.01
—
12.92
—
—
—
60.83
98.39
55.92
65.31
18.91
2.73
17,66
36,65
—
18,04
—
25.20
5.48
27.81
138.33
27.48
45.78
17.70
74.50
14.35
26.56
23-55
12.20
2.27
—
—
—
—
16.50
21.00
—
36.04
—
(mg/1
._^_
1371
—
1015
—
—
—
—
1568
1397
3302
—
—
—
—
—
—
—
705
4980
694
1699
1770
2254
1225
1671
1846
1083
802
503
—
—
—
—
—
—
—
—
950
—
COD
.) (kg/kkg)
^___
38.91
—
64.93
—
—
—
—
194.80
146.59
625.76
—
—
—
—
—
—
—
35-33
36.93
67-33
34S.Q2
87.27
211-64
55.92
155.10
50.21
60.27
63.13
31.50
—
—
—
—
—
—
—
—
107.01
—
TSS
Jss/il
„
—
—
24
—
—
—
66
61
57
94
—
—
—
—
—
—
—
134
182
—
115
82
113
63
45
118
125
22
—
119
—
—
—
—
110
78
—
34
—
_UE&A*E>J
—
—
1.53
—
—
—
16. 84
7.57
5.98
18.43
—
—
—
—
—
—
—
6.73
1.34
—
23.59
4.08
10.65
2.92
3.95
3.41
6.98
1.86
—
4.78
—
—
—
—
9.74
9.03
—
3-83
-~
TOTAI.
0 & G PHENOLS TOT-CR SULFIDE
[•*/!) (kg/kkg) (ug/1) (g/kkR) (ug/1)
—
—
79 5,05
—
—
—
583 151.59 983
49 6.08 -- ~ &0
250
144 27.74
—
—
—
—
—
—
—
55 2.75 45
195 J.44 — — 50
—
145
205
—
144
191
—
210
38
—
__
—
—
—
—
—
—
—
69 7.77 30
— — — -- —
(8/kkg) (UB/1) (s/kkg)
— .
—
_-
—
—
—
265.63 675 1B0.10
9.93
26,23
—
—
—
—
—
—
—
—
2.25
.37
—
29.69
10.10
—
6.61
16.67
—
11.68
2.75
—
—
—
—
—
—
—
—
—
3.37
*** ~~ — **
COLOR**
UNITS
—
—
—
—
—
—
—
—
--
—
1062
407
533
241
—
—
—
40
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
™~
Source: EPA Industry 308 Survey. -
** - Color units are APHA color units.
I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
KNIT FABRIC FINISHING (HOSIERY) SUBCATEGORY
WASTEWATER
^ DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS O & G PHENOLS TOT-CR SULFIDE COLOR**
No- Charge (gal/lb) (mg/1) (kg/kkg) (mg/1) (kg/kkg) (mg/1) (kg/kkg) (mg/1) (kg/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) UNITS
5H046
5H003
5H042
5H010
5H035
5H015
5H016
5H036
5H041
5H037
5H053
5H047
5H006
5H013
5H022
5H019
5H017
5H004
Minimum
Maximum
Average
Median
Standard
Number
1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Deviation
8.3
9.9
10.2
6.3
9.9
24.1
6.0
34.7
17.7
14.3
33.3
4.2
11.2
3.1
12.2
5.0
10.0
23.7
.7
34.7
10.7
9.0
8.0
58
385
527
253
312
486
324
—
444
233
225
95
220
400
523
—
490
—
117
57
803
366
323
188
42
26.77
44.01
21.54
16.52
40.61
65.25
—
125.78
34.27
27.06
26.42
7.85
37.55
13.96
—
20.65
—
23.20
2.27
138.33
34.25
25.81
30.16
42
1702
2125
1049
1107
2167
659
—
—
1114
—
450
730
990
1507
—
1542
—
—
450
4980
1465
1298
905
30
118.38
177.31
89.38
58.52
180.84
132.84
—
—
161.99
—
125.16
26.05
92.93
40.25
—
59.25
—
—
26.05
625 . 76
122.11
88.35
118.38
30
87
124
72
58
—
—
—
55
93
89
14
9
54
—
—
179
—
44
9
182
81
78
43.
31
6.04
10.34
6.13
3.08
—
—
—
16.06
12.85
10.78
3.89
32
5.06
—
—
7.09
—
8.72
.32
23.59
7.53
6.13
5.44
31
142
79
297
43
—
—
—
—
136
—
27
99
—
—
—
275
—
15
15
275
113
99
76
13
9.90
6.63
16.81
2.27
—
—
—
—
19.60
—
7.51
3.53
—
—
—
9.54
—
2.97
1.44
27.74
9.15
6.63
7.77
13
26
41
—
47
—
—
—
—
—
—
90
82
—
—
—
160
—
30
26
583
118
62
167
10
1.84
3.46
—
2.51
—
—
—
—
—
—
25.03
2.92
—
—
—
5.00
—
5.95
1.84
151.59
20.88
4.23
46.43
10
170
1200
—
21
—
—
—
—
—
—
21
10
—
—
—
142
—
30
10
1200
208
142
322
19
11.82
100.13
—
1.10
—
—
—
—
—
—
5.84
.35
—
—
—
6.38
—
5.95
.35
265.63
27.20
6.61
61.92
19
—
—
450
—
—
—
—
—
—
—
—
—
—
—
—
—
10
10
675
378
450
338
3
—
—
23.78
—
—
—
—
—
—
—
—
—
—
—
—
—
1.98
1.98
180.10
68,62
23.78
97.16
3
—
—
312
—
—
—
—
—
—
—
—
500
—
—
940
—
—
40
1062
504
453
344
8
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
*I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
CARPET FINISHING SUBCATEGORY
00
Report
No.
60008
60021
60018
60010
60024
60028
60027
60023
60035
60QH
60005
60006
60036
60025
60026
60032
60013
60016
60029
60022
60007
60037
60012
60014
60015
60030
60004
60001
6001?
60020
60031
60034
60009
60002
60038
60003
60039
*
Dis-
charge
I
D
D
I
I
1
I
I
I
I
D
1
I
I
I
I
D
I
D
I
I
D
I
I
I
I
D
D
I
I
D
D
I
I
I
I
D
WASTEWATER
DISCHARGE
RATE BOD- 5 COD
(gal/lb) (rag/1) (kg/kkg) (mR/l) (kg/kkg)
2.3
8.0
4.6
4.7
11.7
5.4
9.3
4.1
11.5
11.2
4.0
5.9
6.0
5.0
5.4
6.1
3.8
3.3
6.3
3.3
6.5
5.6
8.5
8.2
6.6
4.0
2.1
5.7
17.4
2.0
4.4
7.5
5.3
4.4
1.0
19.5
14.6
—
—
—
—
—
—
421
—
—
342
—
561
—
569
—
506
—
—
—
—
458
411
—
—
—
—
188
—
—
217
483
—
—
-.-
—
—
—
—
—
—
—
40.78
—
—
17.03
—
23.52
—
29.23
—
14.20
—
—
—
—
32.75
28.11
~-
—
—
—
27.63
—
—
13.73
21.66
—
—
—
~~
—
2117
905
745
281
—
1390
—
—
869
—
1997
—
1564
—
986
—
—
—
—
1886
1402
—
—
—
—
621
—
—
474
1646
—
—
—
— -
—
84.15
B7.27
33.74
21.88
—
134.62
—
—
42.48
—
83.73
—
80.92
—
27.67
—
—
—
—
134.89
95.94
—
—
—
—
91.00
—
—
41.39
73.84
—
—
—
""•
TSS
(mg/1) (kg/kkg)
—
208
96
75
44
—
55
—
—
95
—
37
—
42
—
59
—
—
—
—
—
—
—
—
—
—
58
—
—
101
102
—
—
—
"""
—
8.26
9.27
3.39
3.49
—
5.35
—
—
4.76
—
1.55
—
2.17
—
1.65
—
—
—
—
—
—
—
—
—
—
8.37
—
—
6.40
4.57
—
—
—
~~
0 & G
(mg/1) (kg/kkR)
,-
27 1.08
93 9.37
18 .81
3 .23
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
-'_
—
—
—
10 1.58
—
—
—
—
—
—
—
__ ^—
TOTAL
PHENOLS
(Ug/1) (R/kkg)
—
115
40O
10
—
—
—
—
1
—
—
—
1138
—
—
—
—
—
—
—
—
—
—
—
—
314
—
—
130
—
—
—
—
~~
—
—
11.34
18.11
.77
—
—
—
—
.04
—
—
—
58.91
—
—
—
--
—
—
—
—
—
—
_-
—
45.86
—
—
8.05
—
—
—
—
""
TOT-CR SULFIDE
(uR/D (8/kkg) (ug/1) (g/kkg)
—
300
30
250
30
—
—
—
44
—
—
—
20
—
—
—
—
—
—
—
—
—
—
—
40
—
—
—
--
—
—
—
"
—
11.92
3.44 50 5.27
11.32 300 13.58
2.33 10 .77
—
—
—
—
.22 450 22.00
—
- —
—
1.07
—
— -
—
—
—
—
—
—
—
—
—
—
6.35
—
—
—
—
—
—
—
_. ..
COLOR**
UNITS
—
190O
590
—
-65
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
— -
—
—
—
—
—
383
—
—
—
—
—
—
—
"
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
*I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V~ll (continued)
RAW WASTE CHARACTERISTICS
CARPET FINISHING SUBCATEGORY
WASTEWATER
^ DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SULFIDE COLOR**
No. Charge (gal/lb) (mg/1) (kg/kkg) (mg/1) (kg/kkg) (ag/1) (kg/kkg) (mg/1) (kg/kkg) (ng/1) (g/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) UNITS
Minimum
Maximum
Average
Median
Standard Deviation
Number
1.0
19.5
6.6
5.6
4.0
37
188
565
415
439
131
10
13.73
40.78
24.86
25.57
8.58
10
281
2117
1205
1188
589
14
21.88
134.89
73.82
82.32
36.28
14
37
208
81
67
46
12
1.55
9.27
4.93
4.66
2.67
12
3
93
30
18
36
5
.23
9.37
2.61
1.08
3.80
5
1 .04
1138 58.91
301 20.44
130 11.34
397 22.98
7 7
4
300
96
30
123
7
.22
11.92
5.23
3.44
4.78
7
10
450
202
175
209
4
.77
22.00
10.40
9.42
9.37
' 4
65
1900
734
486
806
4
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
STOCK AND YARN FINISHING SUBCATEGORY
Report
No.
70045
70026
70042
70010
70043
70005
70108
70037
70092
70039
70057
70041
70072
70118
70087
70121
70067
_ 70120
00 70077
0 70035
70106
70113
70102
70095
70107
70109
70119
70038
70029
70069
70125
70096
70016
70079
70061
70027
70011
70012
70052
70054
i
Dis-
charge
I
I
D
I
I
I
I
I
I
I
D
D
D
D
D
I
I
D
I
D
D
I
D
I
I
I
I
D
I
I
I
D
D
I
I
I
D
I
I
I
WASTEWATER
DISCHARGE
RATE BOD-5 COD
(gal/Ib) (mK/D (kg/kkg) (mg/1) (kg/kkg)
19.9
5.5
2,3
19.0
5.9
1.3
10.0
24.6
12.0
6.2
6.2
4.1
6.6
6.1
6.7
5.7
1.0
7.5
13.4
53.7
3.9
33.8
4.0
7.3
7.1
39.9
13.6
51.9
16.6
5.9
16.6
6.7
6.2
3.0
10.3
8.3
37.1
5.4
10.0
1.8
450
—
210
—
286
—
116
150
—
252
—
327
—
296
306
—
—
—
180
924
102
—
—
633
48
—
108
—
77
180
—
167
—
46
235
154
484
—
1631
76.18
—
33.37
—
3.18
—
23.95
15.08
—
13.14
—
18.13
—
16.85
14.79
—
—
—
80.91
31.00
28.97
—
37.60
16.11
—
47.30
—
3.90
25.03
—
8.74
—
3.19
16.37
46.75
22.02
—
24.95
554
—
485
—
1147
—
282
880
—
556
—
1572
—
386
945
—
—
190
845
2431
250
—
—
1217
224
—
—
—
887
390
—
—
—
—
805
—
—
—
4756
25.69
—
77-08
—
12.77
—
58.08
88.47
—
29.00
—
86.98
—
21.59
45.60
—
—
21-40
380.40
109.97
70.68
—
—
72.30
74.86
—
—
—
43.27
54.23
—
__
—
—
56.03
—
—
—
72.76
TSS
(mK/l) (kg/kkR)
104
80
—
27
—
192
—
44
58
—
—
—
26
—
33
163
—
—
35
56
309
10
—
—
64
24
—
21
—
138
30
—
47
—
18
27
38
2
—
136
15.00
3.70
—
4.37
—
2.13
—
9.06
5.83
—
—
—
1.44
—
1.89
7.88
—
—
3.94
25.88
10.09
2.82
—
—
3.80
8.05
—
9.12
—
6.85
4.17
—
2.46
—
1.28
1.93
11.72
.09
—
2.09
TOTAL
0 & G PHENOLS TOT-CR SULFIDE
Gng/1) Ckg/kkg) (ug/1) (g/kkg) (us/1) (g/kkg) (UR/I) (g/kk«)
35 1 . 62
—
200
—
—
—
9 1.99 180
—
—
—
—
1 .05
—
—
52 2.53 519
—
—
5
—
—
—
—
—
144 8.55 40
8 2.81 175
—
—
—
__
600
—
__
—
—
—
—
—
—
— — —
—
—
31.86
—
—
—
37.07
—
—
—
—
--
—
—
25.05
—
—
.56
—
—
—
—
—
2.37
58.45
—
—
—
—
83.44
—
--
—
—
—
—
—
—
—
223
—
100
—
—
—
860
60
—
—
—
—
—
16
36
—
—
100
—
—
—
—
—
1400
1087
—
—
—
60
600
—
--
—
—
34
—
—
—
-~
10.35
—
15.97
—
—
—
177.12 293 60.41
6.03
—
—
—
—
—
.86
1.76
—
—
11.26
—
—
—
—
—
83.17
362.86
—
—
—
2.97
83.44 200 27.81
—
__
—
—
2.36
— -
—
—
— — —
COLOR**
UNITS
57
—
—
—
—
--
—
2300
—
—
—
—
—
—
566
—
—
—
—
—
—
—
—
—
—
--
—
—
—
—
—
—
228
—
—
—
—
—
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
*I - indicates iodirect discharger
D - indicates direct discharger
-------
TABLE V-ll (contiaued)
00
Report
No.
70066
70071
70065
70028
70006
70101
70082
70098
70073
70046
70058
70070
70112
70062
70030
70021
70086
70114
70115
70117
70104
70008
70056
70124
70048
70116
70032
70015
70033
70004
70023
70111
70064
70009
.70080
70089
70014
70123
70047
70094
70127
70003
70018
70002
70074
*
Dis-
charge
I
D
D
D
I
I
I
I
I
D
I
I
I
I
I
I
1
I
I
I
D
I
I
I
I
I
I
I
I
I
I
I
J
D
I
I
I
I
I
I
I
I
I
I
I
RAW WASTE CHARACTERISTICS
STOCK AND YARN FINISHING SUBCATEGORY
WASTEWATER
DISCHARGE TOTAL
RATE BOD-5 COD TSS 0 & G PHENOLS TOT-CR SULFIDE! COLOR**
(gal/lb) (mg/1) (kg/kkg) (mg/1) (kR/kkg) (rag/1) (kg/kkg) (rag/1) (kg/kkg) (ug/1) fg/kkg) (ug/1) (g/kkg) (og/1) (g/fcfcjt) UNITS
10.7
18.5
11.3
2.3
1.0
7.8
13.6
9.9
3.5
17.0
13.3
8.0
32.8
9.9
10.1
12.5
11.4
15.2
42.5
11.0
25.8
64.6
36.3
5.3
10.1
14.5
13.3
15.3
24.9
7.3
15.3
23.8
12.6
19.3
20.5
41.7
7.2
8.2
12.5
51.4
.4
22.5
21.3
17.6
6.0
171
156
375
1120
. —
990
199
—
—
102
190
105
464
180
302
285
—
—
—
90
67
—
—
200
—
—
890
283
258
—
—
—
83
229
141
—
—
—
—
180
—
368
—
—
26.53
15.08
7.23
9.75
—
112.77
16.65
—
—
10.89
12.77
29.00
38.75
15.27
31.75
27.22
—
—
—
19.32
36.15
—
—
16.93
—
—
113.00
59.19
15.93
—
—
—
13.51
39.29
49.30
—
—
—
—
.75
—
65.70
—
—
—
—
3809
—
1400
3669
—
—
420
923
—
—
—
792
619
—
--
—
333
406
—
—
—
—
—
1994
686
980
—
—
—
366
852
—
—
—
—
—
591
—
—
—
—
—
—
33-16
—
159.48
306.22
—
—
45.21
62.12
—
—
—
83.30
59.03
—
—
—
71-75
219.07
—
—
—
—
—
25A.65
143.26
60.51
—
—
—
59.34
146.08
—
—
—
—
—
2.46
—
—
—
~-
223
24
985 -
140
—
4200
58
—
—
11
11
—
77
—
17
118
—
—
—
32
42
—
—
25
—
—
52
8
—
—
—
—
38
49
47
—
—
—
—
31
—
12
—
—
34.53
2.17
18.87
1.21
—
478.45
4.87
—
—
1.11
-75
—
6.48
—
1.78
11.33
—
—
—
6.91
22.66
—
—
2.11
—
—
6.48
1.66
_.
—
—
—
6.20
8.50
16.40
—
—
—
—
.13
—
2.22
—
--..
—
—
30
—
—
~
—
—
57
24
—
8
8
15
—
—
--
—
—
—
—
—
—
—
—
—
—
24
—
—
—
—
38
_.
—
—
—
—
—
—
—
—
~—
—
—
.26
—
—
—
—
—
6.11
1.64
—
.74
.67
1.65
—
—
~
—
—
—
—
—
—
—
—
—
—
1.48
—
—
—
__
6.54
~
—
—
—
'
—
—
--
—
"
129 19.97
120 12.14 250 19.75 700 66.68
4437 85.37 1835
—
—
—
66
—
—
—
—
583
—
—
__
—
—
--
—
—
3000
—
—
2000 169.30
—
—
—
57 11.99
50 3.08 30 1.S5 80 4.93
—
—
—
__
228
__
—
—
—
—
621 2.59 200 .83
—
—
—
__ __ __ __ __ __ — _
Source.1 EPA Industry 308 Survey.
** - Color units are APHA color units.
*I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
STOCK AND YARN FINISHING SUBCATEGORY
ro
Report
No.
70075
70022
70025
70031
70034
70019
70100
70020
70110
70007
70053
70090
70063
70036
70078
70076
70088
70024
70085
70122
70097
70084
70081
70059
70093
70017
70105
70103
70044
70099
70126
70013
Minimum
Maximum
Average
Median
Standard
Number
WASTEWATER
^ DISCHARGE
Dis- RATE BOD-5 COD TSS
Charge (gal/lb) (ms/1) (kg/kkg) (mg/1) (kg/kkji) (fflg/1) (kg/kkg)
D
I
I
D
D
I
I
I
I
I
I
I
I
D
D
I
D
I
I
I
I
D
D
I
I
I
D
D
D
I
D
I
Deviation
8.2
22.2
12.0
10.6
10.7
2.2
13.4
2.2
13-3
60.6
18.7
21.4
5-8
25.0
48.9
30.6
22.8
14.9
14.3
11.6
4.5
10.3
22.9
12.6
2.1
45.0
17-6
28.8
33.6
.6
11.6
5.0
.4
64.6
15-6
11.6
13.4
117
151
196
160
148
160
101
—
160
—
—
127
—
—
105
346
—
—
285
21 B
300
—
—
60
—
—
—
—
~
46
1631
283
190
285
61
10.22
19.46
14.45
12.32
18.04
11.36
—
28.62
—
—
57.44
—
—
13.24
41.44
—
—
24.72
41.72
31.65
—
—
8.86
—
--
—
—
—
.75
113.00
28.25
19.46
23.43
61
546
505
683
201
—
1460
—
—
—
—
—
313
1349
—
—
716
800
600
—
—
331
—
—
—
—
—
190
4756
981
686
968
45
31.25
45.24
76.74
22.54
—
261.24
—
—
—
—
—
39.29
161.42
—
—
61.55
151.75
63.31
—
—
48.88
—
—
—
—
—
2.46
380.40
90.44
62.12
81.08
45
68
36
16
24
41
—
25
—
—
31
—
—
32
70
—
—
55
12
45
—
—
31
—
—
—
—
—
2
4200
144
38
558
58
5.04
3.20
1.47
2.76
4.65
—
4.47
—
—
12.90
—
—
4.00
8.39
—
—
5.22
2.43
4.74
—
—
4.57
—
—
—
—
—
.09
478.45
14.55
4.52
62.32
58
0
Cng/l)
—
—
18
—
—
—
—
—
—
180
—
—
—
—
3
—
—
—
—
~
—
—
—
1
180
38
24
49
17
& G
(kg/kkg)
—
3-22
—
—
—
—
—
—
21.52
—
—
—
—
.31
—
—
—
—
—
—
—
—
.05
21.52
3-62
1.65
5.19
17
TOTAL
PHENOLS TOT-CR SULFIDE
(ug/1) (g/kk«) (ug/1) (g/kkg) (ug/1) (g/kkg)
—
—
3
—
—
—
—
—
—
—
—
—
—
—
170
—
—
~
—
—
—
—
—
3
621
223
172
226
12
—
—
.53
—
—
—
—
-^
—
—
—
—
—
—
17.93
—
—
--
—
—
—
—
—
.53
83.44
22.92
15.03
26.25
12
68
650
—
1600
—
—
32
—
—
—
—
—
—
679
26
310
—
—
—
—
—
—
—
—
16
1600
358
114
461
24
7.63
72.68
—
286.29
—
—
14.15
—
—
—
—
—
—
56.91
4.89
32.71
—
—
—
—
—
—
—
—
.83
362.86
53.65
13.07
93.51
24
—
—
10
—
—
—
—
—
—
—
—
—
—
100
—
—
—
—
—
—
—
—
—
10
4437
977
246
1543
8
—
—
1.78
—
—
—
—
—
—
—
—
—
—
19.11
—
—
—
—
—
—
—
—
—
1.78
169.30
54.42
44.11
55.44
8
COLOR**
UNITS
--
—
760
—
—
—
—
—
—
—
—
—
—
—
500
—
—
—
—
—
—
—
—
57
3000
989
574
1022
10
Source: EPA Industry 308 Survey.
** - Color units are APHA color units.
*I - indicates indirect discharger
D - indicates direct discharger
-------
TABLE V-ll (continued)
RAW WASTE CHARACTERISTICS
NONWOVEN MANUFACTURING SUBCATEGORV
00
WASTEWATER
A DISCHARGE TOTAL
Report Dis- RATE BOD-5 COD TSS 0 & G PHEHOLS TOT-CR SUUIDE COLOR**
No. Charge Cgal/lb) (mg/ij (kg/kkg) frag/l) (kg/kkg) (mg/1? Qcg/kkg) (mg/1) (kg/itkg) (u»/l) (g/kkg) (ug/1) (g/kkg) (ug/1) (g/kkg) UNITS
80008 I
80012 I
80016 D
80014 I
80026 I
80011 I
80015 D
80005 I
80019 I
80009 I
80002 I
Minimum
Maximum
Average
Median
Standard Deviation
Number
5.6
.3
4.8
.6
.5
6.0
9.9
1.3
1.6
6.4
5.0
.3
9.9
3.8
4.8
3.1
11
64
195
633
158
64
633
262
176
253
4
3.27
16.14
6.73
6.65
3.27
16.14
8.19
6.69
5.53
4
205
3945
2360
205
3945
2170
2360
1877
3
10.38
38.39
99.44
10.38
99.44
49.40
38.39
45.53
3
83
74
179
59
—
59
179
98
78
54
4
.24
3.75
14.81
.63
—
.24
14.81
4.85
2.19
6.81
4
—
81
81
81
81
ei
—
1
—
3.41
3.41
3.41
3.41
3.41
—
1
21
—
21
21
21
21
—
1
.19
—
.19
.19
.19
.19
—
1
10
50
370
10
370
143
50
197
3
.50
.43
15.59
.43
15.59
5.50
.50
8.73
3
10
—
10
10
10
10
—
1
.50
—
.50
.50
.50
.50
—
1
—
28
28
28
28
28
—
1
** - Color units are APHA color units
*I - indicates indirect discharger
D - indicates direct discharger
-------
CO
-fh
TABLE V-12
UNTREATED WASTEWATER CONCENTRATIONS
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
HISTORICAL DATA - MEDIAN VALUES
1.
2.
3.
4.
5.
6.
7.
8.
9.
Sub category
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. De sizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BODS
(mg/1)
1830
150
380
120
300
350
405
205
260
325
440
190
175
205
COD
(mg/D
6900
650
1060
180
900
1170
1240
765
835
1300
1190
685
2360
555
TSS
(mg/1)
2740
50
220
25
60
80
160
60
50
80
65
40
80
115
0 & G
(mg/D
580
//
#
#
65
45
70
95
50
100
20
25
#
30
Sulfide
(ug/D
#
#
#
#
55
100
130
55
155
560
175
245
#
#
Total Phenols
(ug/1)
#
50
#
#
49
180
146
108
107
62
130
172
#
575
Color
(APHA Units)
#
#
#
$
1000
500
#
390
760
450
490
570
#
#
# Insufficient data to report value.
Source: 308 Survey Data, Table V-ll.
-------
00
TABLE V-13
MASS DISCHARGE RATES FOR UNTREATED WASTEWATER
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
HISTORICAL DATA - MEDIAN VALUES
1.
2.
3-
4.
5.
6.
7.
8.
9-
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. De sizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BOD5
41.8
63.6
1.3
16.0
22.3
33.2
45.1
23.1
28.1
25.8
25.6
19.5
6.7
70.2
COD
225.7
204.8
7.7
18.2
88.4
104.9
122.0
84.4
121.5
88.4
82.3
62.1
38.4
186.0
TSS
(kg/kkg)
51.9
16.3
1.6
2.7
7.7
9.1
14.8
6.3
8.4
6.1
4.7
4.5
2.2
64.1
0 & G
10.3
#
#
#
9.1
3.2
4.1
4.0
3.9
6.6
1.1
1.7
#
11.2
Sulfide
(g/kkg)
#
#
#
#
10.4
12.5
15.7
13.0
14.0
23.8
9.4
44.1
#
#
Total Phenols
(g/kkg)
#
11.4
#
#
8.2
12.5
13.1
11.3
7.6
6.6
11.3
15.0
#
247.4
# Insufficient data to report value.
Source: 308 Survey Data, Table V-ll.
-------
complete characterization of the typical wastewater from each
subcategory. Average data for each mill sampled is presented by
mill in Table v-14. These results are summarized by subcategory
in Table V-15, which presents the median values of the individual
mill averages. With the exception of oil and grease, the data
are for composite samples. The samples were collected with
automatic sampling equipment over either 8 or 24 hour periods or
by combining individual grab samples collected at representative
intervals over 8 or 24 hour periods. Although somewhat limited
in scope compared to the historical data base, the field sampling
data are useful to confirm or supplement the historical data
base.
Mass discharge rates for the traditionally-monitored pollutant
data from the field sampling program are presented by mill in
Table V-16. The wastewater discharge rates shown are calculated
on the basis of average discharges and productions, and the mass
discharge rates are calculated on the basis of the average of the
daily concentrations, as presented in Table V-15. The results
are summarized by subcategory in Table V-17, which presents the
median values from the individual mill averages. Again, the
values are useful to confirm or supplement the historical data
base.
Typical untreated wastewater concentrations for the
traditionally-monitored pollutant parameters, based on both the
historical data and the field sampling results, are presented in
Table V-18. The values are representative of the typical mill in
each subcategory and are those used in developing the treatment
options and costs in subsequent sections. For several
subcategory and parameter combinations, typical values could not
be established with sufficient confidence and are not presented.
Typical mass discharge rates for the traditionally-monitored
pollutants, based on both the historical data and field sampling
results, are presented in Table V-19. The values are
representative of the typical mill in each subcategory.
186
-------
TABLE V-14
SUMMARY OF ANALYTICAL RESULTS - RAW WASTE CONCENTRATIONS
TRADITIONALLY MONITORED POLLUTANTS - FIELD SAMPLING PROGRAM
Report
Number
10006
10013
10015
20011
20021
10013*
_ (04935)
S3 (01304)
40023
40144
40077
40135
40160
(04742)
40034
40059
40072
40081
40097
40099
Note:
Mill Type
Wool Scouring
Wool Scouring
Wool Scouring
Wool Finishing
Wool Finishing
Wool Finishing
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing
Simple Processing
Simple Processing
Complex Processing
Complex Processing
Complex Processing
Desizing
Desizing
Desizing
Desizing
Desizing
Desizing
Desizing
A dash indicates that analyses
BOD5
(mg/1)
5000
6300
1900
330
480
360
-
-
53
400
500
-
450
71
210
450
560
-
470
290
were not
COD
(mg/1)
24000
14000
6100
1100
2400
860
1900
720
-
1100
500
2000
1700
220
810
800
1700
2100
2100
320
performed
TSS
(mg/1)
87000
4900
2300
68
370
24
-
14
54
200
28
-
87
16
1
49
69
400
100
39
0 & G Sulfide
(mg/1) (ug/1)
1100
1300
500
1100
500 1600
68 ND
ND
83 ND
ND
ND
7600
ND
ND
ND
1800
5200
ND
ND
52 2800
ND
Total
Phenols
(ug/1)
_
2800
670
160
82
120
82
23
18
92
73
150
280
24
63
74
67
190
50
47
Color
APHA ADMI
(Units) (Units, pH 7.6)
_ _
110
2200
1000
2000 390
110 320
-
12
500
— -
1300
-
1500
1900
1900
2600
40000
210
3200 250
1300
ND Indicates "Not Detected."
* Represents finishing stream from Report 10013.
( ) Indicates sequence number instead of report number.
-------
TABLE V-14 (Cont.)
CO
CO
Report
Number
40103
40120
40145
40146
40150
40156
50030
50108
50112
50116
50104*
50013
50035
50099
5H012
5H027
5H034
60008
60031
60034
60037
Note:
Mill Type
Desizing
Desizing
Desizing
Desizing
Desizing
Desizing
Knit Fabric Finishing
Simple Processing
Simple Processing
Simple Processing
Simple Processing
Simple Processing
Complex Processing
Complex Processing
Complex Processing
Hosiery Products
Hosiery Products
Hosiery Products
Carpet Finishing
Carpet Finishing
Carpet Finishing
Carpet Finishing
A dash indicates that analyses
BODS
(mg/1)
830
1500
350
420
18
-
360
190
240
-
-
-
220
680
-
-
-
180
-
-
200
were not
COD
(mg/1)
2300
-
810
990
2700
770
700
580
780
730
1700
2400
560
170
2900
820
880
740
-
940
1300
performed.
TSS
(mg/1)
210
500
20
90
52
1
150
23
20
-
200
100
25
6
95
24
17
21
-
-
37
0 & G
(rag/1)
_
21
-
-
-
-
72
-
320
-
-
-
-
-
630
340
190
-
-
-
™
Sulfide
(ug/1)
ND
-
2500
-
ND
1000
270
2100
380
ND
50
ND
9200
6200
ND
ND
1800
-
-
ND
ND
Total
Phenols
(ug/1)
37
-
560
-
69
42
180
740
520
1
-
48
110
230
110
170
190
-
5
10
28
Color
APHA
(Units)
1000
-
500
-
250
-
750
150
1200
-
-
-
250
300
-
-
—
-
-
-
300
ADMI
(Units, pH 7.6)
_
-
-
-
-
380
-
-
280
-
160
120
-
-
270
220
820
-
-
-
"
ND Indicates "Not Detected".
* Represents pretreatment effluent.
( ) Indicates sequence number instead of report number.
-------
TABLE V-14 (Cont.)
CO
Report
Number
(06443)
70009
70072
70081
70087
70096
70120
80008
80011
80019
80025
Note:
Mill Type
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Nonwoven Manufacturing
Nonwoven Manufacturing
Felted Fabric Processing
A dash indicates that analyses
BODS
(fflg/D
_
120
-
-
380
1100
-
-
-
-
-
were not
COB
(mg/D
740
460
-
230
1100
1300
640
220
480
340
1100
performed.
TSS
(mg/D
58
33
-
25
19
32
130
36
16
-
40
0 & G
(mg/1)
_
-
-
-
-
-
210
26
97
-
260
Sulfide
(ug/1)
420
ND
-
44
4500
1400
ND
ND
ND
ND
1200
Total
Phenols
(ug/1)
_
64
-
810
38
42
—
33
8
44
160
Color
APHA
(Units)
_
10000
-
-
1300
1400
—
•
-
—
-
ADMI
(Units, pH 7.6)
110
-
-
130 v
-
-
310
140
34
-
190
ND Indicates "Not Detected".
( ) Indicates sequence number instead of report number.
-------
TABLE V-15
UNTREATED WASTEWATER CONCENTRATIONS
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
FIELD SAMPLING DATA - MEDIAN VALUES
Total
Color
1.
2.
3.
4.
5.
6.
7.
8.
9.
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BOD5
(mg/1)
5000
360
#
#
230
480
420
240
450
#
190
380
//
#
COD
(mg/1)
14000
1100
1900
720
1100
1700
900
730
560
880
940
690
340
1100
TSS
(mg/D
4900
68
#
14
130
58
52
87
25
24
29
33
26
40
0 & G
(mg/1)
1200
280
#
83
#
#
37
200
#
340
#
210
62
260
Sulfide
(ug/1)
500
1100
ND
ND
ND
3800
ND
270
6200
900
ND
230
ND
1200
Phenols
(ug/1)
1740
120
82
23
55
150
67
350
110
170
10
40
33
160
APHA
(units)
1200
1000
#
#
500
1400
1900
750
280
#
300
1400
#
#
ADMI
(units pH 7.6)
#
360
#
12
#
#
250
220
120
270
#
130
87
190
# No data.
ND Indicates "Not Detected."
Source: Field Sampling Program, Table V-14.
-------
TABLE V-16
RAW WASTE MASS DISCHARGE
TRADITIONALLY MONITORED POLLUTANTS
FIELD SAMPLING PROGRAM
Report
Number
10006
10013
10015
20011
20021
Mill
Wool
Wool
Wool
Wool
Wool
Type
Scouring
Scouring
Scouring
Finishing
Finishing
Wastewater
Discharge
Rate BODS
(gal/lb)
1
4
4
36
42
.5
.6
.6
.5
.6
62.6
241.7
72.9
100.5
170.4
COD TSS
(fcg/kkg)
300.2
537.1
234.0
334.8
852.5
1088.4
188.0
88.3
20.7
131.4
0 & G
13.8
49.9
-
-
177.8
Sulfide
(g/kkg)
_
-
19
334
568
.2
.8
.5
Total
Phenols
g/kkg
_
108.0
25.7
48.8
29.2
10013* Wool Finishing
Low Water Use Processing
(04935)
(01304)
40023
40144
40077
40135
40160
(04742)
40034
40059
40072
40081
40097
40099
Note:
General Processing
Water- Jet Weaving
Woven Fabric Finishing
Simple Processing
Simple Processing
Complex Processing
Complex Processing
Complex Processing
Desizing
Desizing
Desizing
Desizing
Desizing
Desizing
Desizing
A dash indicates that analyses
0.03
23.8
2.3
12.7
9.7
11.7
50.5
14.2
14.5
10.3
21.5
7.0
15.8
were
-
10.5
7.7
53.0
-
43.9
29.9
24.9
54.4
48.1
-
27.4
38.2
0.48
-
21.1
53-0
161.8
165.9
92.7
95.9
96.7
146.0
376.6
122.6
42.2
not performed, or
-
10.7
3.8
3.0
-
8.5
6.7
0.1
5.9
5.9
71.7
5-8
5.1
that loads
ND
ND
ND
805.0
ND
ND
ND
213.2
628.8
ND
ND
3.0 163.5
ND
0.02
3.6
0.44
7.7
12.2
27.3
10.1
7.5
9.0
5.8
34.4
2.9
6.2
were not calculable
(no water use data).
( ) Indicates sequence number instead of report number.
ND Indicates "Not Detected."
* Represents finishing stream from Report 10013-
-------
TABLE V-16 (Cont.)
ro
Report
Number
40103
40120
40145
40146
4015Q
40156
50030
50108
50112
50116
50104*
50013
50035
50099
5H012
5H027
5H034
60008
60031
60034
60037
Note:
Wastewater
Discharge
Rate BODS
Mill Type (gal/lb)
Desizing
De sizing
Desizing
Desizing
Desizing
Desizing
Knit Fabric Finishing
Simple Processing
SijHple Processing
Simple Processing
Simple Processing
Simple Processing
Complex Processing
Complex Processing
Complex Processing
Hosiery Products
Hosiery Products
Hosiery Products
Carpet Finishing
Carpet Finishing
Carpet Finishing
Carpet Finishing
A dash indicates that analyses
10.5
9.5
21.8
11.7
9.6
-
8.2
16.1
18.2
8.8
4.8
8.0
17.7
14.7
3.4
5.6
8.3
2.3
4.4
7.5
5.6
were
72.7
118.8
63.6
41.0
1.4
-
24.6
25.5
36.4
-
-
-
32.5
83.4
-
-
-
3.4
-
-
9-3
COD TSS 0 & G
(kg/kkg)
201.4
-
147.3
96.6
216.2
-
47.9
77.9
118.4
53.6
68.1
160.1
82.7
20.8
82.2
38.3
60.9
14.2
-
58.8
60.7
not performed, or
18.4
39.6 1.66
3.6
8.8
4.2
-
10.3 4.9
3.1
3.0 48.6
-
8.0
6.7
3.7
0.7
2.7 17.9
1.1 15.9
1.2 13.2
0.4
-
-
1.7
that loads were
Sulfide
(g/kkg)
ND
-
454.5
-
ND
-
18.5
282.0
57.7
ND
2.0
ND
1358.0
760.1
ND
ND
124.6
-
-
ND
ND
Total
Phenols
g/kkg
3.2
-
102.0
-
5.5
-
12.3
99.6
78.8
0.007
-
3.2
16.2
28.2
3-1
8.0
13.2
-
0.18
0.62
1.3
not calculable
(no water use data).
( ) Indicates sequence number instead of report number.
ND Indicates "Not Detected."
* Represents pretreatment effluent.
-------
TABLE V-16 (Cont.)
Wastewater
Report
Number
(06443)
70009
70072
70081
70087
70096
70120
80008
80011
80019
80025
Note:
Mill Type
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Nonwoven Manufacturing
Nonwoven Manufacturing
Felted Fabric Processing
Discharge
Rate
(gal/lb)
0.8
19.3
6.6
22.9
6.7
6.7
7.5
5.6
6.0
1.6
111.6
A dash indicates that analyses were
BOD5 COD
TSS 0 & G
(kg/kkg)
4.9
19.3 74.0
-
43.9
21.2 61.5
61.5 72.6
40.0
10.3
24.0
4.5
1023.8
not performed.
0.4
5.3
-
4.8
1.1
1.8
8.1 13.1
1.7 1.2
0.8 4.8
- -
37.2 242.0
Sulfide
(g/kkg)
2.8
ND
-
8.4
251.5
78.2
ND
ND
ND
ND
1116.9
Total
Phenols
g/kkg
_
10.3
-
155.0
2.1
2.4
-
1.5
0.40
0.59
149.0
( ) Indicates sequence number instead of report number.
ND Indicates "Not Detected."
-------
10
TABLE V-17
MASS DISCHARGE RATES FOR UNTREATED WASTEWATER
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
FIELD SAMPLING DATA - MEDIAN VALUES
1.
2.
3.
4.
5.
6.
7.
8.
9.
Subcategory
Wool Scouring
Wool Finishing
low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BOD5
72.9
135.5
i
9.1
48.5
41.0
25.5
58.0
6.4
21.2
#
*
COD TSS
(kg/kkg)
300.2
593.7
0.5
21.1
161.8
122.6
68.1
82.7
60.9
58.8
52.7
10.3
1023.8
188.0
76.1
I
7.3
5.7
5.9
5.6
3.7
1.2
1.1
3.3
1.2
37.2
0 & G
31.9
177.8
i
#
2.4
26.8
#
15.9
#
13.1
3.0
242.0
Sulfide
(g/kkg)
19.2
451.7
ND
#
ND
402.5
ND
18.5
760.1
62.3
ND
5.6
ND
1116.9
Total Phenols
g/kkg
66.9
39.0
0.02
#
2.0
12.2
6.8
45.6
16.2
8.0
0.62
6.3
0.59
149.0
# No data.
ND Indicates "Not Detected."
Source: Field Sampling Program, Table V-16.
-------
TABLE V-18
TYPICAL UNTREATED WASTEWATER CONCENTRATIONS
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
SUMMARY OF HISTORICAL AND FIELD SAMPLING DATA
10
en
1.
2.
3.
4.
5.
6.
7.
8.
9.
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BODS
(mg/1)
1800
150
380
120
300
350
400
210
260
320
440
190
180
200
COD
(mg/1)
6900
650
1100
180
900
1200
1200
770
830
1300
1200
690
2400
550
TSS
(mg/1)
2700
50
220
30
60
80
160
60
50
80
70
40
80
120
O&G
(mg/1)
580
(280)
(80)
70
50
70
90
50
100
20
20
(60)
30
Sulfide
(ug/1)
(500)
(1100)
(ND)
60
100
130
60
160
560
180
250
(ND)
(1200)
Phenols
ug/1
(1700)
(120)
(80)
(20)
50
180
150
110
110
60
130
170
(30)
580
APHA
(units)
(1200)
(1000)
i
1000
500
(1900)
390
760
450
490
570
#
*
ADMI
(units pH 7.6)
*
(360)
(10)
(250)
(220)
(120)
(270)
#
(130)
(90)
(190)
# Insufficient data to report value.
( ) Median of field sampling results.
ND Indicates "Not Detected."
Source: Tables V-12 and V-15.
-------
TABLE V-19
TYPICAL MASS DISCHARGE RATES FOR UNTREATED WASTEWATER
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENIONAL POLLUTANTS
SUMMARY OF HISTORICAL AND FIELD SAMPLING DATA - MEDIAN VALUES
10
1.
2.
3.
4.
5-
6.
7.
8.
9.
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BOD5
41.8
63.6
1.3
16.0
22.3
33.2
45.1
23.1
28.1
25.8
25.6
19.5
6.7
70.2
COD TSS
(kg/kkg)
225.7
204.8
7.7
18.2
88.4
104.9
122.0
84.4
121.5
88.4
82.3
62.1
38.4
186.0
51.9
16.3
1.6
2.7
7.7
9.1
14.8
6.3
8.4
6.1
4.7
4.5
2.2
64.1
0 & G
10.3
(177.8)
#
#
9.1
3.2
4.1
4.0
3.9
6.6
1.1
1.7
(3.0)
11.2
Sulfide
(g/kkg)
(19.2)
(451.7)
(ND)
#
10.4
12.5
15.7
13.0
14.0
23.8
9.4
44.1
(ND)
(1116.9)
Total Phenols
g/kkg
(66.9)
11.4
(0.02)
#
8.2
12.5
13.1
11.3
7.6
6.6
11.3
15.0
(0.59)
247.4
( ) Median of field sampling results.
# Insufficient data to report value.
ND Indicates "Not Detected."
Source: Tables V-13 and V-17.
-------
SECTION VI
SELECTION OF POLLUTANT PARAMETERS
WASTEWATER PARAMETERS OF SIGNIFICANCE
The Agency has conducted a thorough study of the textile
industry, the purpose of which is to establish effluent
limitations reflecting the best practicable control technology
currently available (BPT), the best available technology
economically achievable (BAT), new source performance standards
(NSPS) and pretreatment standards for new and for existing
sources (PSNS and PSES). After completion of a review of
existing regulations, a review of available literature and an
evaluation of data obtained during sampling at 51 mills, the
following pollutants or pollutant parameters have been identified
as present in textile wastewaters and should be subject to
limitation under BPT, BAT and NSPS as appropriate.
Conventional Pollutants:
Toxic Pollutants:
BOD5, TSS and pH.
Total Chromium.
Nonconventional Pollutants: COD, Phenols and Sulfide.
In plant specific situations the amounts and concentrations of
individual pollutants, either the pollutants discussed in this
section or other pollutants, may not be insignificant and should
be regulated. Permit-issuing authorities may find it necessary
to collect information, analyze for, or conduct bioassay testing
prior to issuing a NPDES permit. Specific pollutants may be
limited on a case-by-case basis when limitations are necessary to
carry out the purposes of the Act.
Presented below are the reasons that pollutants present in
textile wastewater have been excluded from national regulations.
Conventional Pollutants
1.
2.
The pollutant is indirectly measured
another parameter.
by measurement for
The pollutant is indirectly controlled when a
parameter is controlled.
selected
Toxic Pollutants
Paragraph 8 of the Settlement Agreement in Natural Resources
Defense Council, Inc. v. Train, 8 ERC 2120 (D.D.C~1976),
modified, 12 ERC 1833 (D.D.C. 1979), provides guidance to the
Agency on exclusions of specific toxic pollutants, subcategories
197
-------
or categories from regulation under the effluent limitations
guidelines, standards of performance and pretreatment standards:
"8(a) The Administrator may exclude from regulation under
the effluent limitations and guidelines, standards of
performance, and/or pretreatment standards contemplated by
this Agreement a specific pollutant or category or
subcategory of point sources for any of the following
reasons, based upon information available to him:
(i) For a specific pollutant or a subcategory or category,
equally or more stringent protection is already provided by
an effluent, new source performance, or pretreatment
standard or by an effluent limitation and guideline
promulgated pursuant to Section(s) 301, 304, 306, 307(a),
307(b) or 307(c) of the Act;
(ii) For a specific pollutant, except for pretreatment
standards, the specific pollutant is present in the effluent
discharge solely as a result of its presence in intake
waters taken from the same body of water into which it is
discharged and, for pretreatment standards, the specific
pollutant is present in the effluent which is introduced
into treatment works {as defined in Section 212 of the Act)
which are publicly owned solely as a result of its presence
in the point source's intake waters, provided however, that
such point source may be subject to an appropriate effluent
limitation for such pollutant pursuant to the requirements
of Section 307;
(iii) For a specific pollutant, the pollutant is not
detectable (with the use of analytical methods approved
pursuant to 304(h) of the Act, or in instances where
approved methods do not exist, with the use of analytical
methods which represent state-of-the-art capability) in the
direct discharges or in the effluents which are introduced
into publicly-owned treatment works from sources within the
subcategory or category; or is detectable in the effluent
from only a small number of sources within the subcategory
and the pollutant is uniquely related to only those sources;
or the pollutant is present only in trace amounts and is
neither causing nor likely to cause toxic effects; or is
present in amounts too small to be effectively reduced by
technologies known to the Administrator; or the pollutant
will be effectively controlled by the technologies upon
which are based other effluent limitations and guidelines,
standards of performance, or pretreatment standards; or
(iv) For a category or subcategory, the amount and the
toxicity of each pollutant in the discharge does not justify
developing national regulations in accordance with the
schedule contained in Paragraph 7(b).
198
-------
(b) The Administrator may exclude from regulation under the
pretreatment standards contemplated by this Agreement all
point sources within a point source category or point source
subcategory:
(i) if 95 percent or more of all point sources in the point
source category or subcategory introduce into treatment
works (as defined in Section 212 of the Act) which are
publicly owned, only pollutants which are susceptible to
treatment by such treatment works and which do not interfere
with, do not pass through, or are not otherwise incompatible
with such treatment works; or
(ii) if the toxicity and amount of the incompatible
pollutants (taken together) introduced by such point sources
into treatment works (as defined in Section 212 of the Act)
that are publicly owned is so insiginficant as not to
justify developing a pretreatment regulation..."
Nonconventional Pollutants
1. The pollutant is indirectly measured by measurement for
another parameter.
2.
3.
The pollutant is indirectly controlled when
parameter is controlled.
selected
The pollutant is not of uniform national concern (i.e., the
pollutant is present at only a small number of sources and
is uniquely related to those sources) and should be
regulated on a case-by-case basis, as appropriate.
4.
The pollutant is present but cannot be effectively
by technologies known to the Administrator.
reduced
Summary of Previous Regulations
Toxic nonconventional and conventional pollutants have been
limited under promulgated effluent limitations guidelines and
standards applicable to wastewater discharges from the textile
mills point source category. Table VI-1 presents a summary of
the pollutants that have been regulated in previous Agency
rulemaking for each of the subcategories of the industry.
SELECTION OF POLLUTANTS OF CONCERN
Toxic Pollutants
In addition to the pollutants controlled by existing regulations,
the Agency has investigated the potential for discharge of other
toxic pollutants as a part of EPA's ongoing studies. A total of
129 specific toxic pollutants have been the subject of extensive
study (see Section II). A sampling program has been conducted
199
-------
TABLE VI-I
SUMMARY OF POLLUTANTS CONTROLLED BY
PREVIOUS EFFLUENT LIMITATIONS GUIDELINES
O
O
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
Woven Fabric Finishing
Knit Fabric Finishing
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Finishing
Conventional Pollutants
BODS TSS pH Oil and Grease
(New subcategory, no previous regulation.)
(New subcategory, no previous regulation.)
Toxic Pollutant
Total Chreunion
Nonconventional Pollutants
COD Sulfide Phenols Color*
* Color was regulated only under previously promulgated BAT.
-------
that has led to the exclusion of many specific toxic pollutants
from regulation based on the guidance provided in Paragraph 8 of
the Settlement Agreement.
A summary of toxic pollutants detected in textile mill untreated
wastewaters is presented in Table V-7. A summary of analytical
results for the individual pollutants detected in untreated
wastewater and biologically treated effluents is presented in
Table V-8. Table V-9 (a through n) presents a summary of toxic
pollutant analyses by subcategory.
On December 18, 1980, EPA submitted an affidavit to the court
explaining that the Agency decided not to regulate 102 of the 129
toxic pollutants under the authority of Paragraph 8(a)(iii) of
the modified Settlement Agreement. The Agency excluded 65 of the
toxic pollutants from regulation because "they are not detectable
by Section 304(h) analytical methods or other state-of-the-art
methods;" 22 pollutants because "they are detected at only a
small number of sources within a subcategory and are uniquely
related to those sources;" and 15 because "they are present only
in trace amounts and neither cause nor are likely to cause toxic
effects." These 102 pollutants are listed in Table VI-2.
The remaining 27 toxic pollutants have been assessed to identify
those pollutants of potential concern and to determine if any
should be subject to limitation through the implementation of
uniform national standards. Table VI-3 presents projected
treatability levels for the 27 compounds not previously excluded
from regulation. Analytical results for each compound were
compared to the treatability levels to determine the frequency
and extent that these compounds were found in excess of
anticipated treatability.
A summary of pollutants that were found in excess of treatability
in either raw or biologically treated effluent in each
subcategory is presented in Table VI-4. A summary of the data
assessment including number of samples analyzed, number of
samples in excess of treatability, concentration range, and
average concentrations is presented in Table VI-5.
Based on the results of the analysis of toxic pollutant data
presented in Table VI-5, EPA decided to exclude 17 toxic
pollutants from regulation because "they are present in trace
amounts too small to be effectively reduced by technologies known
to the Administrator." The data in Table VI-5 show that these
pollutants have been found in excess of treatability in raw and
treated effluents in only a few subcategories and in only a small
percentage of samples. Two pollutants have been found at "only a
small number of sources within a subcategory and are uniquely
related to those sources." Six pollutants are "effectively
controlled by the technologies on which other effluent
limitations and standards are based." (see Table VI-6) Although
these pollutants were found above treatability in raw wastewaters
201
-------
TABLE VI-2
POLLUTANTS INITIALLY EXCLUDED FROM REGULATION*
Pursuant to Paragraph 8{a)(11i) of the Settlement Agreement, the
following 65 toxic pollutants are excluded from regulation in all
subcategories because they were not detected 1n treated effluents
by Section 304(h) analytical methods or other state-of-the-art methods:
benzidine
3,3-d1chlorobenz1dine
methyl bromide
2,4-d1n1tropheno1
N-ni trosod imethylami ne
phenanthrene
carbon tetrachloride
1,1,2-trichloroethane
chloroethane
4-chlorophenyl phenyl ether
dichlorodifluoromethane
isophorone
nitrobenzene
4,6-dinitro-o-cresol
acenaphthylene
aldrin
chlordane
4,4' -DDE
4,4' -ODD
alpha-endosulfan
beta-endosulfan
endosulfan sulfate
endrin
endrin aldehyde
heptachlor
heptachlor epoxlde
alpha-BHC
beta-BHC
gamma-BHC (lindane)
delta-BHC
toxaphene
acroleln
hexachloroethane
1,1,2,2-tetrachloroethane
bis (chloromethyl) ether
bis (2-chloroethyl) ether
2-chloroethyl vinyl ether
1,3-dlchlorobenzene
1,2-trans-dichloroethyl ene
1,3-dichloropropylene
2,4-dinitrotoluene
fluoranthene
4-bromophenyl phenyl ether
bis (2-chloroisopropyl) ether
bis (2-chloroethoxy) methane
bromoform
chlorodibromomethane
hexachlorobutadiene
hexachlorocyclopentadiene
di-n-octyl phthalate
1,2-benzanthracene
benzo(a)pyrene
chrysene
1,12-benzoperylene
1,2,5,6-dibenzanthracene
indeno (l,2,3-cd)pyrene
PCB 1242
PCB 1254
PCB 1221
PCB 1232
PCB 1248
PCB 1260
PCB 1016
asbestos
2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)
* By affadavtt dated December 18, 1980 to parties to the Settlement
Agreement.
202
-------
TABLE VI-2 (cont.)
Pursuant to Paragraph 8(a)(111) of the Settlement Agreement, the following
22 toxic pollutants are excluded from regulation in all subcategories
because they were detected in treated effluents by Section 304(h) analytical
methods or other state-of-the-art methods at only a small number of
sources and were uniquely related to those sources. The following 20
pollutants were found at only one plant at concentrations less than the
nominal detection limit in the treated effluent:
1,2-dichloroethane
1,1-dichloroethane
2-chloronaphthalene
2-chlorophenol
1,1-dichloroethylene
1,2-dichloropropane
2,4-dimethylphenol
2,6-dinitrotoluene
1,2-diphenylhydrazine
methyl chloride
dichlorobromomethane
2-nitrophenol
4-nitrophenol
3,4-benzofluoranthene
11,12-benzofluoranthene
fluorene
vinyl chloride
dieldrin
4,4' -DDT
beryllium
The following two pollutants were detected only in the treated effluents
and not in the raw effluents.
trichlorofluoromethane
N-nitrosodi-n-propylamine
Pursuant to Paragraph 8{a)(iii) of the Settlement Agreement, the following
15 toxic pollutants are excluded from regulation in all subcategories
because they were detected in treated effluents by Section 304(h) analytical
methods or other state-of-the-art methods at only trace amounts not likely
to cause toxic effects:
acenaphthene
chlorobenzene
hexachlorobenzene
1,1,1-trichloroethane
1,4-dichlorobenzene
2,4-dichlorophenol
methylene chloride
N-nitrosodiphenylamine
butyl benzyl phthalate
di-n-butyl phthalate
diethyl phthalate
dimethyl phthalate
anthracene
pyrene
tha11i urn
203
-------
TABLE VI-3
PROJECTED TREATABILITY FOR TOXIC POLLUTANTS
Toxic Pollutants
Compound Concentration Source for
Used for Comparison Concentration Used
3.
4.
8.
21.
22.
23.
25.
38.
55.
64.
65.
66.
85.
86.
87.
114.
115.
118.
119
120.
121.
122.
123.
124,
125.
126.
128.
acrylonitrile
benzene
1,2, 4- trichlorobenzene
2,4,6-trichlorophenol
parachlorometacresol
chloroform
1,2-dichlorobenzene
ethylbenzene
naphthalene
penta chlo ropheno 1
phenol
bis (2-ethylhexyl)phthalate
tetrachloroethylene
toluene
trichloroethylene
antimony
arsenic
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
100
50
10
25
50
100
50
50
50
10
50
10
50
50
100
80
830
270
2500
1800
280
230
100
1260
20
130
1800
*
*
*
*
*
•ft
*
*
*
*
*
*
*
*
*
*
-P—I^L.
WW7T
***
*#
**
**
*#
*#*
**
***#
-t^i — .L.
Wrnr
**
***
Murray P. Strier, "Treatability of Organic Priority Pollutants - Part C -
Their Estimated (30 Day Average) Treated Effluent Concentration - A Molec-
ular Engineering Approach, "Table I, 1978.
Treatability levels as specified in the Pretreatment Regulations for the v
Electroplating Industry point source category.
Development Document for Proposed Effluent Limitations Guidelines and
Standards for the Metal Finishing Point Source Category, EPA 440/l-82/091b,
August 1982.
Memorandum from Ben Honaker, Project Officer, Metals and Machinery
Branch, Effluent Guidelines Division, August 1982.
204
-------
TABLE VI-4
SUMMARY OF TOXIC POLLUTANTS OF POTENTIAL CONCERN
Toxic Pollutants
PO
3 4 8 21 22 23 25 38 55 64 65 66 85 86 87 114 115 118 119 120 121 122 123 124 125 126
Subcategory
Wool Scouring
Wool Finishing
Low Water Use (General)
Woven Fabric Finishing
Simple
Complex
Desizing
Knit Fabric Finishing
Simple
Complex
Hosiery x
Carpet Finishing
Stock and Yarn Finishing
Noowoven Manufacturing
Felted Fabric Processing
128
x
X
X X
X
X
X
X X
X
X X
X X
X X
X X X X
XXX
X X
X X
X X
X X
X
X X
x indicates detected above anticipated treatability levels in raw or treated effluent.
Toxic Pollutants are as Follows:
3. acrylonitrile
4. benzene
8. 1,2,4-trichlorobenzene
21. 2,4,6-trichlorophenol
22. parachlorometa cresol
23. chloroform
25. 1,2-dichlorobenzene
38. ethylbenzene
55. napthalene 115. arsenic
64. pentachlorophenol 118. cadimua
65. phenol 119. chromium
66. bis(2-ethylbexyl)pthalate 120. copper
85. tetrachloroethylene 121. cyanide
86. toluene 122. lead
87. trichlorethylene 123. mercury
114. antimony 124. nickel
125. silenium
126. silver
128 . zinc
-------
TABLE VI-5
SUMMARY OF DATA ASSESSMENT - POLLUTANTS OF POTENTIAL CONCERN
Niwber of Samples Analyzed
Influent Effluent
Conceotration Range
Pg/1
Influent Effluent
Average
Concentrations (Jg/1
Influent Effluent
Nuaber of Saatples
in Excess of
Treatability Levels
Influent Effluent
3. Acrylonitrile
Knit Fabric Finishing
(Hosiery Products)
ro
O ' 4. Benzene
°* : Woven Fabric Finishing (Complex)
Woven Fabric Finishing (Desizing)
Nonwoven Manufacturing
8. 1,2,4 Trichlorobezene
Wool Scouring
Wool Finishing
Woven Fabric Finishing (Simple)
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Stock and Yarn Finishing
21. 2,4,6-Trichlorophenol
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Hosiery)
23. Chloroform
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Knit Fabric Finishing (Hosiery)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
4
3
28
3
0
6
3
26
6
3
7
26
4
6
3
4
4
7
3
1
6
23
0
1
4
—
0
0
2
3
—
—
0
2
—
—
0
--
0-1600
31
1-170
5-200
—
90-14,000
28
45-156
120-2700
190
270
1-94
27
22-498
17-71
140-642
5-280
1-410
160
400
6-64
1-33
—
0-32
46-1900
—
2-10
6
1-916
19-43
—
—
2-2
3-1020
—
—
5
--
1600
31
49
103
— -
4195
28
101
1045
190
270
44
27
260
44
391
143
86
160
400
28
17
—
7
8
0
23
8
21
6
0
0
8
21
0
0
8
0
1
0
4
1
0
2
1
2
3
1
1
2
1
1
0
2
1
1
1
1
1
0
-
32
1257
—
6
6
237
27
—
—
2
221
—
—
5
—
-------
TABLE VI-5 (Continued)
no
o
Number of Samples Analyzed
Influent Effluent
Concentration Range
Pg/1
Influent Effluent
Average
Concentrations H8/1
Influent Effluent
Number of Samples
in Excess of
Treatability Levels
Influent Effluent
25.
38.
55.
64.
1 ,2-JJichlorobeozene
Wool Finishing
Woven Fabric Finishing (Desizing)
Stock and Yarn Finishing
Ethylbenzene
Wool Finishing
Woven Fabric Finishing (Simple)
Woven Fabric Finishing (Complex)
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Kait Fabric Finishing (Complex)
Kapthalene
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Carpet Finishing
Felted Fabric Processing
Pentachlorophenol
Wool Scouring
Wool Finishing
Woven Fabric Finishing (Simple)
Woven Fabric Finishing (Complex)
Woven Fabric Finishing (Desizing)
Stock and Yarn Finishing
8
26
7
8
3
3
28
6
3
26
6
3
5
0
5
8
3
3
26
0
a
23
8
7
0
6
23
8
22
23
0
21
0
1
—
8
6
6
23
8
10-460
1-62
1-56
6-1770
5-460
18-2835
1-19,000
2-2600
852-1209
1-2079
1-51
2-210
95-260
—
0-24
29-71
32-42
20
2-310
—
1-20
1-1
1-5
1-75
—
1-29
1-3018
3-4
1-278
1-22
—
2-255
—
56
—
1-2
15-66
56
7-16
13-23
160
17
29
267
233
960
1692
713
1031
468
32
118
198
—
24
50
37
20
75
—
7
1
3
21
—
11
440
4
78
12
—
87
—
56
—
2
41
56
10
18
3
1
1
1
1
1
15
4
2
9
1
2
3
--
1
2
2
1
9
—
0
0
0
1
—
0
2
0
2
0
~"
1
—
1
—
0
2
1
1
2
-------
TABLE VI-5 (Continued)
no
Nuober of Samples Analyzed
Influent Effluent
Concentration Range
Mg/1
Influent Effluent
Average
Concentrations pg/1
Influent Effluent
Number of Sanples
in Ezcess of
Treatability Levels
Influent Effluent
65. Phenol
Wool Scouring
Woven Fabric Finishing (Simple)
Woven Fabric Finishing (Complex)
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Hosiery)
Carpet Finishing
Felted Fabric Processing
Low Water Use Processing (General)
66. Bis (2-ethylhexyl)pthalate
Wool Finishing
Woven Fabric Finishing (Simple)
Woven Fabric Finishing (Complex)
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Knit Fabric Finishing (Hosiery)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Low Water Use (General Processing)
85 . Tetrachloroethylene
Wool Finishing
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Stock and Yarn Finishing
6
3
0
26
6
4
5
1
1
a
3
3
26
6
3
4
5
7
3
1
1
8
28
6
3
7
8
6
6
23
0
1
4
1
1
e
6
6
23
8
21
1
4
8
0
1
1
8
23
8
22
8
10-4930
40-147
—
1-295
1-55
3-59
1-68
85
82
1-160
5-860
9-138
5-1449
1-430
30-135
22
19-400
3-490
14
26
26
2-1126
1-26
9-1108
39-890
1-310
8-16
12-24
10-103
1-31
--
14
2-50
2
10
6-760
10-10
1-24
2-231
5-50
6-109
172
10-27
2-230
—
18
3
1-5
1-51
8-27
1-370
3
1222
94
—
58
17
39
40
85
82
51
382
90
210
157
83
22
121
90
14
26
26
193
15
438
465
156
11
18
38
15
—
14
30
2
10
204
10
15
44
20
34
172
18
89
—
16
3
3
14
17
194
3
5
1
—
6
1
2
3
1
1
2
2
2
20
2
3
1
4
3
1
1
1
I
0
3
2
1
0
0
1
0
—
0
0
0
0
7
0
4
9
2
14
1
3
7
—
1
0
0
1
0
3
0
-------
TABLE VI-5 (Continued)
ro
O
Number of Samples Analyzed
Influent Effluent
Concentration Range
Mg/1
Influent Effluent
Average
Concentrations
Influent Effluent
Number of Samples
in Excess of
Treatability Levels
Influent Effluent
86.
87.
114.
115.
Toluene
Wood Scouring
Woven Fabric Finishing (Simple)
Woven Fabric Finishing (Complex)
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Noncover Manufacturing
Trichloroethylene
Wool Finishing
Woven Fabric Finishing (Desiziag)
Knit Fabric Finishing (Simple)
Stock Yarn Finishing
Antimony
Wool Scouring
Woven Fabric Finishing (Desizing)
Knit Fabric Finishing (Simple)
Knit Fabric Finishing (Complex)
Carpet Finishing
Stock and Yarn Finishing
Arsenic
Wool Scouring
Wool Finishing
Woven Fabric Finishing (Complex)
6
3
3
28
6
3
3
8
28
6
7
S
25
5
3
2
7
4
8
3
8
6
6
23
8
22
0
8
23
8
0
6
19
7
22
2
8
6
6
4
10-62
8-620
28-303
2-3200
4-140
3-61
3-83
2-187
1-5600
5-840
1-229
2-4
1-180
1-186
57-515
52
5-200
162-225
2-200
120
1-10
1-140
1-33
1-111
1-1
1-22
—
2-4
1-130
37-41
—
21-540
1-96
1-684
31-867
11-105
3-177
4-160
2-60
3-
31
216
204
490
45
33
43
•39
812
322
80
3
n
59
286
52
94
193
37
120
7
48
15
16
1
6
—
3
42
39
—
153
21
230
452
58
95
37
17
3
1
1
2
7
2
I
1
1
1
2
1
0
3
1
1
0
1
3
1
1
0
1
0
1
0
0
—
0
1
0
—
1
1
5
11
J
4
0
0
0
118. Cadmium
Wool Scouring
9-13
3-130
11
26
-------
TABLE VI-5 (Continued)
ro
»-»
CD
Number of Samples Analyzed
Influent Effluent
Concentration Range
W/l
Influent Effluent
Average
Concentrations
Influent Effluent
Number of Samples
in Excess of
Treatability Levels
Influent Effluent
119.
120.
122.
124.
225-
126.
128.
Chromium
Woven Fabric Finishing (Desiziag)
Copper
Woven Fabric Finishing (Desiziag)
Lead
Wool Scouting
Nickel
Wool Scouring
Selenium
Kait Fabric Finishing (Hosiery)
Felted Fabric Processing
Silver
Wool Scouring
Wool Finishing
Ziuc
Wool Scouring
Wool Finishing
Woven Fabric Finishing (Desizing)
Kait Fabric Finishing (Complex)
Low Water Use Processing (General)
26
26
5
5
4
2
5
8
5
8
26
3
1
0
23
7
7
1
2
7
8
7
8
23
22
1
4-4930
8-3120
18-752
54-304
38-736
57
1-65
1-47
190-1969
51-7500
56-7900
75-200
120
—
5-100
57-3500
28-2000
97
32
1-500
6-140
25-1500
320-38400
27-5100
42-5160
2300
787
656
435
134
275
57
17
24
832
1307
999
132
120
—
32
929
452
97
32
130
73
299
6833
502
614
2300
7
5
4
0
1
1
0
0
1
1
4
0
0
__
0
1
1
0
1
1
1
0
3
1
2
1
-------
TABLE VI-6
TOXIC POLLUTANTS EXCLUDED
(1) Toxic pollutants present in trace amounts too small to be effectively
reduced by the technologies known to the Administrator:
2,4,6-trichlorophenol
chloroform
1,2,4-trichlorobenzene
1,2-dichlorobenzene
pentachlorophenol
parachlorometacresol
tetrachloroethylene
arsenic
cadmium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
(2) Toxic pollutants detected at only a small number of sources within a sub-
category and uniquely related to those sources:
acrylonitrile
antimony
(3) Toxic pollutants effectively controlled by the technologies on which
other effluent limitations and standards are based:
benzene
trichloroethylene
ethylbenzene
naphthalene
phenol
toluene
(4) Toxic pollutant not detectable with the use of analytical methods
approved pursuant to section 304(h) of the Act:
bis(2-ethylhexyl)phthalate
211
-------
they were consistently removed in biological treatment and
anticipated treatability levels were exceeded in only a few
instances.
Pollutants Found ir\ Trace Amounts For each of the pollutant found
in trace amounts too small to be effectively reduced by
technologies known to the administrator, possible sources and
analytical results are discussed below.
2,4,6-Trichlorophenol - The compound 2,4,6-trichlorophenol
belongs to the chemical class known as chlorinated phenols. This
class represents a group of commercially produced, substituted
phenols and cresols referred to as chlorophenols and
chlorocresols. Chlorinated phenols are used as intermediates in
the synthesis of dyes, pigments, phenolic resins, pesticides and
herbicides. Certain chlorophenols also are used directly as flea
repellents, fungicides, wood preservatives, mold inhibitors,
antiseptics, disinfectants, and antigumming agents for gasoline.
Sources of trichlorophenol in the textile industry include
possible usage as a preservative and as a constituent or impurity
in carrier systems for dyeing polyester. Out of 418
questionnaire returns, 7 indicated "suspected presence" in mill
wastewaters. Trichlorophenol was detected in the wastes at only
five textile mills during the field sampling program. It was not
detected above treatability levels in any biologically treated
effluent samples.
Chloroform - The major uses of chloroform are as a solvent
and as an intermediate in the production of refrigerants,
plastics and Pharmaceuticals. Chloroform seems to be ubiquitous
in the environment in trace amounts; discharges into the
environment result largely from chlorination treatment of water
and wastewater.
Sources of chloroform reported by the textile industry include
its use in dyeing operations and in the laboratory. Only 7 out
of 418 questionnaire returns indicated "known or suspected
presence" of chloroform. Although chloroform was occasionally
found above treatability levels in raw wastes it was found above
treatability levels only twice in biologically treated effluents.
1,2,4-Trichlorobenzene - The
is a chlorinated benzene and
organic compounds characterized by
to six chlorine atoms on
trichlorobenzene isomers are
1,3,5-trichlorobenzene but these
quantities. The compound has seen
textile industry, a herbicide
medium, a dielectric fluid in
lubricant, and as a potential
During the period 1973-1974,
compound 1,2,4-trichlorobenzene
is one of the class of aromatic
the substitution of from one
the benzene nucleus. Other
1,2,3-trichlorobenzene, and
are not used in significant
use as a dye carrier in the
intermediate, a heat transfer
transformers, a degreaser, a
insecticide against termites.
production and use of
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trichlorobenzenes resulted in approximately
(7,421 tons) entering the aquatic environment.
8,182 metric tons
Sources of trichlorobenzene reported by the textile industry
include usage as a dye carrier in dyeing polyester fiber,
laboratory operations, scouring in the dyeing process, and as a
raw material. Out of 418 questionnaire returns, 86 indicated
"known or suspected presence" in mill wastewaters.
1,2,4-Trichlorobenzene was found above treatability in only one
effluent sample in the wool scouring subcategory. It was found
at high levels in one plant in the wool scouring subcategory and
not detected at the other wool scouring plant. Only two of 21
effluent samples at one plant were above treatability in the knit
fabric finishing subcategory, while only one raw waste sample was
found above treatability level. Although three final effluent
samples were found above treatability levels in the stock and
yarn finishing subcategory, they were at one.plant. Only one raw
waste sample was detected above treatability.
1,2-Dichlorobenzene - The compound 1,2-dichlorobenzene
belongs to the chemical class known as dichlorobenzenes. This
class of compounds is represented by three isomers:
1,2-dichloro-, 1,3-dichloro- and 1,4-dichlorobenzene. Both
1,2-dichloro- and 1,4-dichlorobenzene are produced almost
entirely as byproducts from the production of monochlorobenzene.
The major uses of 1,2-dichlorobenzene are as a process solvent in
the manufacture of toluene di-isocyanate,and as an intermediate
in the synthesis of dyestuffs, herbicides and degreasers.
In the survey carried out by DETO, 1,2-dichlorobenzene was judged
to be present in some commerical dyes, but at levels less than
0.1 percent. This is the only reported source of this compound
in textile mill wastewaters. Out of 418 questionnaire returns,
18 indicated "known or suspected presence" in the wastewaters.
1,2-dichlorobenzene was not found above treatability levels in
textile mills biological effluent samples.
Pentachlorophenol - Pentachlorophenol (PCP) is a
commercially produced bactericide, fungicide and slimicide used
primarily for the preservation of wood, wood products and other
materials. As a chlorinated hydrocarbon, its biological
properties have also resulted in its use as a herbicide,
insecticide and molluscicide.
Pentachlorophenol is used in the textile industry as a
preservative in dyes. In the DETO survey results, this was one
of six toxic pollutants that could be expected in some commerical
dyes at levels greater than 0.1 percent, resulting in possible
raw textile wastewater concentrations in the 100 to 1,000 ug/1
range. Out of 418 questionnaire returns, 17 indicated "known or
suspected presence" in mill wastewaters. Pentachlorophenol was
detected above treatability in only 4 of 35 effluent samples in
the woven fabric finishing and in 2 of 8 effluent samples in the
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stock and yarn finishing subcategory. It was not found above
treatability in either raw waste or treated effluent samples in
any of the other textiles subcategories.
Parachlorometacresol - Parachlorometacresol belongs to the
chemical class known as chlorinated phenols. This class
represents a group of commercially produced substituted phenols
and cresols referred to as chlorophenols and chlorocresols.
Chlorinated phenols are used as intermediates in the synthesis of
dyes, pigments, phenolic resins, pesticides, and herbicides.
Certain chlorophenols also are used directly as flea repellents,
fungicides, wood preservatives, mold inhibitors, antiseptics,
disinfectants, and antigumming agents for gasoline.
Sources of Parachlorometacresol reported by the industry include
its possible use as a biocide or disinfectant in dyestuffs, dye
carrier systems, and in industrial cleaning compounds. The
survey of the dye manufacturing industry conducted by DETO
indicated that this compound was one of six toxic pollutants that
could be present at levels greater than 0.1 percent in some
commerical dyes, resulting in possible raw waste loadings from
100 to 1,000 ug/1. Of 418 questionnaire returns, only 3
indicated "suspected presence" in the mill wastewater.
Parachlorometacresol was not found above treatability levels in
either raw waste or treated effluent.
Tetrachloroethvlene - (Tetrachloroethylene, (1,1,2,2-
tetrachloroethylene, perchloroethylene, PCE) is a colorless,
nonflammable liquid used primarily as a solvent in dry cleaning
industries. It is used to a lesser extent as a degreasing
solvent in metal industries. Tetrachloroethylene is widespread
in the environment, and is found in water, aquatic organisms,
air, foodstuffs and human tissues, in micrograms per liter
quantities. The highest environmental levels of PCE are found in
commercial dry cleaning and metal degreasing industries.
Although PCE is released into water via aqueous effluents from
production plants, consumer industries, and househould sewage,
its level in ambient water is reported to be minimal because of
its high volatility.
Tetrachloroethylene is used in the textile industry as a dry
cleaning solvent and in some dyeing operations as part of the
carrier systems or scouring formulations. Out of 418
questionnaire returns, 29 indicated "known or suspected presence"
in mill wastes. Tetrachloroethylene was detected slightly above
treatability only once in the wool finishing subcategory
effluent. It was detected above treatability in only 3 of 22
effluent samples in the knit fabric finishing (complex)
subcategory. All three were at the same facility.
Arsenic - Arsenic
referred to as a metal,
is a naturally occurring element often
although chemically classified as a
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metalloid. Environmental concentrations of arsenic have been
reported at 0.0005 percent in the earth's crust and 3 u/gl in sea
water. Analysis of 1577 surface waters samples in the U.S.
showed arsenic present in 87 samples, with concentrations ranging
forom 5 to 336 ug/1, and a mean level of 64 ug/1 (16). Arsenic
and its compounds are used in the manufacturing of glass, cloth,
and electrical semiconductors, as fungicides and wood
preservatives, as growth stimulants for plants and animals, and
in veterinary applications.
Individual textile mills reported likely sources of arsenic in
their wastewaters as dyes and "raw materials." Out of 418
questionnaire responses, 16 indicated "known or suspected
presence" in mill wastes. The survey carried out by DETO
confirmed that some commerical dyes contain arsenic; likely
levels are less than 0.1 percent. Other possible uses include
its presence in fungicides and specialty chemicals. Arsenic was
not detected at appreciable levels in any mill water supplies
sampled. Arsenic was not detected above treatability in any
biologically treated effluent samples.
Cadmium - Cadmium is a soft, white metal that dissolves
readily in mineral acids. Biologically, it is a non-essential
element of high toxic potential. It occurs in nature chiefly as
a sulfide salt, frequently in association with zinc and lead
ores. Accumulations of cadmium in soils in the vicinity of mines
and smelters may result in high local conentrations in nearby
waters. The salts of the metal also may occur in wastes from
electroplating plants, pigment works, and textile and chemical
industries. Seepage of cadmium from electroplating plants has
resulted in groundwater cadmium concentrations of 0.01 to 3.2
mg/1.
Dissolved cadmium was found in less than 3 percent of 1,577 U.S.
surface water samples with a mean concentration of slightly under
10 ug/1. Most fresh waters contain less than 1 ug/1 cadmium and
most analyses of seawater indicate an average concentration of
about 0.15 ug/1 (16).
Sources of cadmium reported by individual textile mills include
pigments, dyes, nylon carpet processing, and "raw materials",
including dirt in raw wool. Cadmium was one of the toxic
pollutants in the DETO survey that could be present in dyes at
levels less than 0.1 percent. Of 418 questionnaire returns, 24
indicated "known presence" and 17 indicated "suspected presence"
in mill wastes. In the field sampling program cadmium was
measured above detectability in only 1 of the 12 water supplies
sampled. It was not found above treatability levels in any final
effluent samples.
Copper - Copper is a soft heavy metal that is ubiquitous in
its distribution in rocks and minerals of the earth's crust. In
nature, copper occurs usually as sulfide and . oxide salts and
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occasionally as metallic copper. Weathering and solution of
these natural copper minerals result in background levels of
copper in natural surface waters at concentrations generally well
below 20 ug/1. Higher concentrations of copper are usually from
anthropogenic sources. These sources include corrosion of brass
and copper pipe by acidic waters, industrial effluents and
fallout, sewage treatment plant effluents and the use of copper
compounds as aquatic algicides.
A five year study of natural surface waters in the U.S. revealed
copper concentrations ranging from less than 10 ug/1 (the limit
of detection) to 280 ug/1, with a mean value for U.S. waters of
15 ug/1. Values from 0.6 ug/1 to 4.3 ug/1 have been reported in
seawater (16).
Sources of copper reported by individual textile mills include
pigments, dyestuffs, and the mill plumbing system. The DETO
survey results indicated that copper may be present in some
commerical dyes at levels of 3 to 4 percent. Because the copper
is an integral part of the dye molecule, most of it should be
exhausted from the dye bath onto the fiber being dyed. Of 418
questionnaire returns, 87 indicated "known presence" and 79
indicated "suspected presence" in the mill wastewaters. In the
field sampling program, copper was not detected in nine of the
twelve water supply samples. Only one sample had more than 11
ug/1. Copper was found above treatability levels in only 5 of 26
raw waste samples, all in the woven fabric finishing subcategory
and was not found above treatability levels in samples of treated
effluent from any mill.
Cyanide - Cyanide compounds are almost universally present
where life and industry are found. Besides being very important
in a number of manufacturing processes, they are found in many
plants and animals as metabolic intermediates that generally are
not stored for long periods of time.
Possible sources of cyanide reported by individual textile mills
include dyestuffs and "raw materials." The ATMI Task Group
suggested that cyanide is probable in some waste streams,
originating in laboratory and specialty chemicals. Cyanide was
not among the 25 toxic pollutants identified in the DETO survey
as possibly present in commerical dyes. Of 418 questionnaire
returns, 16 indicated either "known or suspected presence" in
mill wastewaters. In the field sampling program, cyanide was at
less than 2 ug/1 in 9 of the 12 water supply samples with the
maximum level at 22 ug/1. Cyanide was not detected above
treatability levels in any raw waste or final effluent samples.
Lead - Lead is a naturally occurring metal that makes up
0.002 percent of the earth's crust. The reported concentration
of lead in seawater of 35 parts per thousand salinity is 0.03
ug/1, while available data indicate that the mean natural lead
content of the world's lakes and rivers ranges from 1 to 10 ug/1.
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Analyses of over 1500 stream samples from 1962 to 1967 found lead
in 19.3 percent of the samples, with concentrations ranging from
2 to 140 ug/1, and a mean value of 23 ug/1 (16).
Lead is used in the metallurgy of steel and other metals; in
ceramics, plastics and electronic devices; in construction
materials and in x-ray and atomic radiation protection devices.
Sources of lead reported by individual textile mills include
pigments, process chemicals, "raw materials," and tramp
impurities in dyes. The DETO survey results indicated that lead
may be present in some commerical dyes at levels less than 0.1
percent. Of 418 questionnaire returns, 34 indicated "known
presence" and 27 indicated "suspected presence" in mill
wastewaters. In the field sampling program, lead was either not
detected or detected at less than 5 ug/1 in 10 of the 12 water
supply samples measured. Two samples had lead levels of 37 and
45 ug/1, respectively. Lead was only detected above treatability
in the wool scouring subcategory in four raw waste samples and
one treated effluent sample.
Mercury - Mercury, a silver-white metal that is a liquid at
room temperature, can exist in three oxidation states: elemental,
mercurous and mercuric; it can be part of both inorganic and
organic compounds.
Sources of mercury reported by individual textile mills include
pigments, dyes and "raw materials", including impurities in
caustic soda. The ATMI Task Group suggested that mercury is
probably present in some textile mill wastewaters, originating in
dyes and specialty chemicals.
The DETO survey results included mercury among the toxic
pollutants possibly present in some commerical dyes at levels
less than 0.1 percent. Of 418 questionnaire returns, 19
indicated "known presence" and 15 indicated "suspected presence"
in mill wastewaters. In the field sampling program, mercury was
detected above minimum detectable levels in only 1 of the 12
water supply samples tested, at 0.79 ug/1. Mercury was not
detected above treatability levels in either raw wastes or
treated effluent.
Nickel - Nickel is a silver-white ductile metal commonly
occurring in natural waters in the +2 valence state in
concentrations ranging from a few micrograms per liter, to more
than 100 ug/1. Nickel seldom is found in groundwater, and if
present, probably exists in colloidol form.
Sources of nickel reported by individual textile mills include
pigments, dyes, processing chemicals, and "raw materials." The
DETO survey confirmed that nickel may be present in some
commercial dyes at levels less than 0.1 percent. Nickel may also
originate from plating operations in resurfacing of printing
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rolls. Of 418 questionnaire survey returns, 28 indicated "known
presence" and 23 indicated "suspected presence" in the mill
wastewaters. In the field sampling program, nickel was measured
at greater than 5 ug/1 in 2 of the 12 water supplies sampled; one
at 41 ug/1 and the other at 47 ug/1. Nickel was not found above
treatability levels in any raw waste samples and was found only
once in a wool scouring subcategory final effluent samples.
Selenium - Selenium is a naturally occurring element and is
an essential nutrient. In ground waters, selenium levels are low
(less than 1 ug/1) but in areas with seleniferous soils, water
levels up to 300 ug/1 have been reported (16).
No widely recognized sources of selenium in textile mill
wastewaters were reported in this study. The ATMI Task Group
suggested that selenium might be present in some dyes and
specialty chemicals. This was not confirmed by the DETO survey
of dye manufacturers. Of 418 questionnaire responses, seven
indicated "known presence" and three indicated "suspected
presence" in the mill wastewaters, although no specific sources
were mentioned. In the field sampling program, it was detected
above treatability in only one raw waste sample in the knit
fabric finishing subcategory and it was not found in any treated
effluent samples. In the felted fabric processing subcategory it
was found above treatability in one raw waste sample and one
final effluent sample.
Silver - Silver is a white ductile metal occurring naturally
in the pure form and in ores. Principal uses of silver are in
photographic materials, as a conductor, in dental alloys, solder
and braying alloys, paints, jewelry, silverware, and mirror
production.
Of 418 questionnaire returns, 12 indicated "known presence" and 4
indicated "suspected presence" in textile mill wastewaters,
although no specific sources were given. The ATMI Task Group
suggested that silver was a probable constituent of some textile
mill wastewaters, originating in dyes and/or specialty chemicals.
The DETO survey did not confirm commerical dyes as a likely
source of silver. In the field sampling program, silver was
measured at greater than 5 ug/1 in 2 of the 12 water supplies
sampled, both at 17 ug/1. Silver was not detected above
treatability levels in raw wastes and only twice in final
effluent samples.
Zinc - Zinc is a naturally occurring element that makes up
approximately 0.02 percent of the earth's crust. It is used in
various alloys, as a protective coating for other metals, in
galvanizing sheet iron, and as a reducing agent. Zinc was
detected in 1,207 of 1,577 surface water samples collected at 130
sampling locations throughout the U.S. between 1962 and 1967.
The maximum observed concentration was 1,183 ug/1 and the mean
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value was 64 ug/1.
approximate 5 ug/1 (16).
Levels of zinc in natural seawater
Zinc originates from many sources in textile mill wastewaters,
including pigements, dyes, dye stripping, coating materials,
catalysts, latex curing, and in many specialty chemicals both as
an added component and as an impurity. The DETO survey pointed
out that some dyes are prepared as double salts of zinc and may
contain up to 3 percent of this metal. Unlike chromium and
copper, the zinc is not exhausted onto the fiber in dyeing. Zinc
can also be contributed by water conditioning chemicals, alloys
used in pumps and valves, galvanized metals, painted surfaces,
and several other sources in industrial facilities. Of 418
questionnaire returns, 100 indicated "known presence" and 64
indicated "suspected presence" in the mill wastewaters. In the
field sampling program, zinc concentrations in the 12 water
supply samples ranged from 10 to 4500 ug/1. Four samples had
levels above 100 and two were above 1000. Zinc was found above
treatability in seven final effluent samples from four
subcategories. It was only found above treatability levels in
six raw waste samples from three subcategories.
Pollutants Unique to Source. For pollutants detected at only a
small number of sources within a subcategory and uniquely related
to those sources, the traditional uses, possible sources and
analytical results are discussed below.
Acrvlonitrile - Acrylonitrile is an unsaturated synthetic
organic compound primarily used in the production of acrylic and
modacrylic fibers, nitrile rubber, and plastics. Annual
production totals approximately 0.7 billion kilograms (1.5
billion pounds).
Sources of acrylonitrile reported by textile industry include
fibers and other raw materials, laboratory operations, dyes, and
latex compounds. Out of 418 questionnaire returns, 32 indicated
"known or suspected presence" in mill wastewaters. Despite this
indication of rather common usage, acrylonitrile was detected at
only 1 mill of 44 in the field sampling program.
Antimony - Environmental concentrations of antimony are
reported at 0.33 ug/1 in seawater of 35 parts per thousand
salinity and at 1.1 ug/1 in freshwater streams. Antimony and its
compounds are used in the manufacturing of alloys, as flame
retardants, pigments and catalysts, as well as for medicinal and
veterinary uses.
Individual mills reported possible sources of antimony in textile
wastewaters as finishing agents, dyestuffs and raw materials.
The DETO survey results did not list antimony as one of the 25
toxic pollutants likely to be present in the bulk of commerical
dyes produced. Various antimony compounds have been used as
mordants in dyeing, in printing pastes and as pigments in dye
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manufacture. Antimony trioxide is used as a flame retarding
agent. Out of 418 questionnaire returns, 52 indicated "known or
suspected presence" in mill wastes. Antimony was detected above
treatability in only one raw waste sample in each of four
subcategories although it was found above treatability levels
in 16 final effluent samples in the knit fabric finishing
subcategory.
Three of the 16 samples were at one facility and 7 at a second
facility. It is believed that these high levels are related to
the use of antimony trioxide fire retardants which are not in
common use in the industry. As antimony was either not detected
or detected at low levels throughout the industry EPA concluded
that antimony discharge is uniquely related to these two
facilities.
Standards
For pollutants
Pollutants Controlled by Other
effectively controlled by the technologies on which other
effluent limitations and standards are based, the traditional
uses, possible sources and analytical results are discussed
below:
Benzene - Benzene is produced principally from coal for tar
distillation and from petroleum by.catalytic reforming of light
naphthas from which it is isolated by distillation or solvent
extraction. The broad utility spectrum of benzene (commercially
sometimes called "Benzol") includes: extraction and
rectification; as an intermediate for synthesis in the chemical
and pharmaceutical industries; the preparation and use of inks in
the graphic arts industries; as a thinner for lacquers; as a
degreasing and cleaning agent; as a solvent in the rubber
industry; as an antiknock fuel additive and as a general solvent
in laboratories. Industrial processes involving the production
of benzene and chemical synthesis usually are performed in sealed
and protected systems. Currently, benzene is used by the
chemical industry at the rate of 5.3 billion liters (1.4 billion
gallons) annually. Sources of benzene reported by the textile
industry include raw materials, use as a solvent and dyes,
although it was not one of 25 priority pollutants suggested by
DETO as likely to be present in the 151 dye products that
represent the bulk of the dye industry's commercial volume by
weight. Out of 418 questionnaire returns, 32 indicated "known or
suspected presence" in mill wastewaters. Benzene was detected
above treatability levels in only one final effluent sample.
Benzene is effectively removed in biological treatment systems;
removal is reflected by the lower final effluent concentrations
reported for benzene.
Trlchloroethvlene - Trichloroethylene
(\t 1,2-trichloroethylene, TCE), a volatile nonflammable liquid,
is used mostly in the metal industries as a degreasing solvent.
It had minor applications as a dry cleaning solvent and as an
extractive solvent for decaffeinating coffee, but was replaced in
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both these capacities by perchloroethylene and methylene
chloride, respectively.
Its volatilization during production and use is the major source
of environmental levels of this compound. TCE has been detected
in ambient air, in food and in human tissue in ug/1 (ppb)
quantities. Its detection in rivers, municipal water supplies,
the sea and aquatic organisms indicates that TCE is widely
distributed in the aquatic environment at the microgram/kg level
or lower. Trichloroethylene is not expected to persist in the
environment. This is in part because of its short half-life in
air and its evaporation from water.
Sources of trichloroethylene in textile mill wastewaters reported
by the industry include its use as a solvent in dyeing and
cleaning, and also in some raw materials. Out of 418
questionnaire returns, 21 indicated "known or suspected presence"
in mill wastes. Trichloroethylene is effectively reduced in
biological treatment systems as is reflected by the fact that it
was found above treatability in only one biologically treated
final effluent sample.
Ethylbenzene - Ethylbenzene is an alkyl substituted aromatic
compound employed as an antiknock compound for airplane engine
fuel, as a lacquer diluent, in the synthesis of styrols for
resins, as a solvent for paraffin waxes, and in the production of
cellulose acetate silks. It is only slightly soluble in water,
but will dissolve in organic solvents.
Ethylbenzene was one of 25 toxic pollutants that may be present
in some commerical dyes, at less than 0.1 percent, according to
the survey carried out by DETO. Its presence in dyestuffs and as
a solvent in print pastes was also reported by individual mills.
While only 9 out of 418 questionnaire returns indicated "known or
suspected presence" in mill wastewaters. Ethylbenzene was only
detected above treatability in a few final effluent samples at
levels well below raw wastewater concentrations. It is
effectively removed in biological treatment which forms the basis
for BPT regulations.
Naphthalene - Naphthalene, a bicyclic aromatic compound, is
the most abundant single constituent of coal tar. It is also
found in cigarette smoke. This compound is used as an
intermediate in the production of dye compounds and in the
formation of solvents, lubricants, and motor fuels. The largest
use of napthalene in 1975 (58 percent of total use) was for the
synthesis of phthalic anhydride. It has also been used as a moth
repellent and insecticide.
Sources of naphthalene in textile mill wastewaters reported by
the industry are dyes and possibly laboratory operations. The
direct dyes were cited as specific sources of this compound. The
DETO survey results indicated that this toxic pollutant was
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likely to be present in some dyes at levels less than 0.1
percent. Out of 418 questionnaire returns, 55 indicated "known
or suspected presence" in mill wastewaters. Although napthalene
was detected above treatability levels in 15 raw waste samples it
was only detected above treatability 2 times in final effluent
samples. It was effectively reduced by biological treatment
which is the basis for BPT effluent limitations.
Phenol - Phenol is an aromatic compound that has a hydroxyl
group attached directly to the benzene ring. It is a liquid and
is somewhat soluble in water. Phenol is used in large quantities
as an industrial chemical. It is produced almost entirely as an
intermediate for the preparation of other chemicals. These
include synthetic polymers such as phenolic resins, bis-phenol
and caprolactam plastics intermediates, and chlorinated and
alkylated phenols.
Phenol is used in the textile industry as a preservative in dyes
and could be present in textile mill raw wastes in the 100 to
1,000 ug/1 range according to the results of the DETO survey.
Out of 418 questionnaire returns, 81 reported "known presence"
and an additional 47 reported "suspected presence" in mill
wastewaters. Reported sources cover a wide spectrum including
the water supply; raw materials, including various fibers; dyes
and dye carriers; finishing resins; nylon carpet processing;
laboratory operations; and general cleaners and distinfectants
used in the mill. Phenol was detected above treatability levels
in 20 raw waste samples but only 1 final effluent
sample. It is effectively controlled by biological treatment.
Toluene - Toluene is a clear, colorless, noncorrosive liquid
with a sweet, pungent odor. The production of toluene in the
U.S. has'increased steadily since 1940 when approximately 117
million liters (31 million gallons) were produced; in 1970,
production was 2.62 bill ion 1iters (694 mill ion galIons).
Approximately 70 percent of the toluene produced is converted to
benzene, another 15 percent is used to produce chemicals, and the
remainder is used as a solvent for paints and as a gasoline
additive.
Toluene is a volatile compound and is readily transferred from
water surfaces to the atmosphere. In the atmosphere, it is
subject to photochemical degradation. It degrades to
benzaldehyde and traces of peroxybenzoyl nitrate. Toluene can
also re-enter the hydrosphere in rain.
Sources of toluene reported by the textile industry include dyes
and dye carriers, raw materials, and use as a cleaning solvent.
Toluene is one of 25 toxic pollutants that may be present in
commerical dyes at levels less than 0.1 percent according to the
survey carried out by DETO. Out of 418 questionnaire responses,
48 indicated "known or suspected presence" in mill wastewaters.
Toluene was detected above treatability in 15 raw waste samples
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and in only 2 final effluent samples.
by biological treatment.
It is effectively removed
Toxic Pollutant Not Detectable - For the following pollutant,
which is not detectable with the use of analytical methods
approved pursuant to Section 304(h) of the Act, the traditional
uses, possible sources and analytical results are discussed
below.
Bis (2-ethylhexyl) Phthalate - Bis(2-ethylhexyl) phthalate
belongs to the group of compounds known as phthalate esters. The
phthalic acid esters (PAE) are a large group of substances widely
used in the U.S. and the rest of the world as plasticizers. In
the plastics industry, they are used to impart flexibility to
plastic polymers, to improve workability during fabrication, and
to extend or modify properties not present in the original
plastic resins.
PAE are extensively used in polyvinylchloride plastics, which
have a wide variety or applications. They are contained in
building and construction materials (flooring, weatherstripping,
wire, and cable), home furnishings (garden hoses, wall covering
and upholstery), transportation materials (seat covers, auto
mats), apparel (footwear, outerwear and baby pants), and food
surfaces and medical products (food wrap film, medical tubing and
intravenous bags). Dioctylphthalate (DOP) and its isomer
di-2-ethylhexyl phthalate (DEPH) are probably the most widely
used plasticizers today. PAE also have minor non-plastic uses as
pesticide carriers, in cosmetics, fragrances, industrial oils,
and insect repellents.
The PAE plasticizers, which can be present in concentrations up
to 60 percent of the total weight of the plastic, are only
loosely linked to the plastic polymers and are easily extracted.
PAE are known to be widely distributed in the environment. They
have been found in soil, water, air, fish tissue, and human
tissue. As shown in Table VI-5, bis(2-ethylhexyl) phthalate was
apparently detected in excess of treatability in raw waste and
treated effluents in nearly every subcategory. It was also
detected frequently in raw water samples and even tubing blanks
EPA concluded that its presence in nearly every subcategory
indicates sample contamination. This compound also iwas"" reported
to be a laboratory contaminant in other analytical programs. The
results for this pollutant, therefore, cannot be considered
valid.
Pollutant Controlled by. Existing Regulation The remaining toxic
pollutant, total chromium, is controlled by existing BPT effluent
limitations; during the Agency sampling programs, total chromium
was found above anticipated treatability levels infrequently.
BPT limitations established in -1974 have resulted in a
significant reduction in the total mass discharge, as well as the
concentration of chromium in treated textile industry wastewater
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effluents. Because the effectiveness of the control of chromium
is well demonstrated by BPT; that level of control should be
continued.
Nonconventional Pollutants
The nonconventional pollutants of potential concern that are
present in textile mills wastewaters are:
Chemical Oxygen Demand (COD)
Phenols
Sulfide
Color
Chemical Oxygen Demand (COD) Chemical oxygen demand (COD) is an
alternative to the BOD test for estimating the oxygen demanding
potential of a wastewater. This test procedure relies on the
principle that many organic compounds can be oxidized by strong
chemical agents under acidic conditions with the assistance of
inorganic catalysts. When an industrial wastewater contains
substances which tend to inhibit biological degradation of the
carbonaceous substrate, COD is a more reliable indicator of the
organic pollutant content of a water sample than is BOD. The COD
test measures the oxygen demand of both compounds that are
biologically degradable and of compounds that are not.
Pollutants that are measured by the BOD5. test as well as
pollutants which are more resistant to biological oxidation are
measured as COD. Because of this fact, COD yields higher oxygen
demand values than the BODS, test.
Compounds that are more resistant to biological oxidation are of
interest not only because they can exert a long-term oxygen
demand on surface waters but also because a potential exists that
these compounds can affect human health and aquatic life. Some
of the compounds that exert a COD have carcinogenic, mutagenic or
similar adverse effects, either alone or in combination with
other chemicals. An additional source of concern is that the
relatively long life of high COD, low BOD chemicals in surface
waters may result in contamination of downstream water intakes.
The standard water purification technologies are not always
effective in removing these chemicals. If disinfection with
chlorine during water treatment is practiced/ the presence of
organic compounds in the water may result in the creation of
hazardous chlorinated organic chemicals.
COD is present in the wastewater from all types, of textile
operations. In most cases the concentrations of COD are two to
three times the BOD concentration. COD concentrations in raw
textile wastewater are contributed by organic materials, such as
fats and dirt present in raw wool, sizing materials (slashing)
and desizing, the application of functional finishes and in some
cases dyeing operations.
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The continuation of controls on the discharge of COD will prevent
the discharge, on a national scale, of materials that can have an
adverse effect on receiving water quality. Likewise, it is
appropriate that limitations and standards controlling the
discharge of COD be continued.
Sulfide Sulfides discharged to neutral receiving waters can be
reduced to hydrogen sulfide. Hydrogen sulfide is an extremely
toxic and corrosive gas. It is very soluble and, exists as a
dissolved gas in surface waters. Minute concentrations {less
than 2 ^g/1) of hydrogen sulfide impart an objectionable odor and
taste to water, making it unfit for municipal consumption. The
proven toxicity of sulfides to aquatic life makes them
objectionable components of the discharge stream.
Sulfide corrosion of metal and cement structures is an additional
problem. In addition to corrosion, discoloration of structures
as a result of sulfide oxidation is a cause for concern.
Organic sulfur and sulfides can be present in the wastewater
discharges from textile industry dyeing operations. They can
also be discharged as a result of the use of organic sulfur
compounds in other textile processes. The BPT control
established in 1974 has adequately controlled the discharge of
sulfide and should be continued.
Phenols Phenols and phenolic wastes (as measured by the 4-AAP
method) are derived from textile processing chemicals; petroleum,
coke and chemical industries; wood distillation; and domestic and
animal wastes. Many phenolic compounds are more toxic than pure
phenol; their toxicity varying with the combinations and general
nature of total wastes. The effect of combinations of different
phenolic compounds is cumulative. Phenols and phenolic compounds
are both acutely and chronically toxic to fish and other aquatic
animals. Also, chorinated phenols produce an unpleasant taste in
fish flesh that can destroy their commercial value.
It is necessary to limit phenolic compounds in raw water used for
drinking water supplies, because conventional treatment methods
used at water supply facilities do not remove phenols. The
ingestion of concentrated solutions of phenols will result in
severe pain, renal irritation, shock and possibly death. Phenols
also reduce the utility of water for certain industrial uses,
particularly food and beverage processing, where they create
unpleasant tastes and odors in the product.
Phenolic compounds are used in the textile industry as
preservatives in dyes. In addition, sources include raw
materials, dye carriers; finishing resins, laboratory operations
and cleaners and disinfectants. Phenols should continue to be
regulated in those subcategories for which total phenols
limitations now exist.
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Color Color is defined as either "true" or "apparent." In
Standard Methods for the Examination of_ Water and Wastewater (2),
the true color of water is defined as "the color of water from
which the turbidity has been removed." Apparent color includes
"not only the color due to substances in solution, but also due
to suspended matter."
Foreign color bodies interfere with the transmission of light
within the visible spectrum which is used in the photosynthetic
process of microflora. Color can affect the aquarian ecosystem
by changing the amount of light transmitted and may cause species
turnover. Color discharges can alter natural stream color and
become an aesthetic pollutant affecting both the visual appeal
and the recreational value of the waterways.
Color discharged to surface waters may have a detrimental effect
on downstream municipal and industrial water users. Color is not
treated in conventional water treatment systems and, when passed
to users, may result in consumer discontent or interfere with
industrial processes requiring clear water.
Color, which is present in textile wastewater, results from
equipment washup, textile washwater and dyes not exhausted in the
dyeing process. Some colors are water soluble and some are not
(dispersed and vat dyes). Biodegradability of many of the dyes
responsible for the color is highly variable, and the toxicity
and effects of many of these dyes on aquatic life has not been
studied to any great extent. Because many different hues are
used in the dyeing process, they may appear in the wastewater.
However, the combination of hues in many waste streams frequently
results in a dominant gray or black color.
The Agency has decided not to establish either BAT limitations or
NSPS for color. The decision is based on an evaluation of color
discharged by the textile industry in terms of its national
significance. Color, in many instances, is simply an aesthetic
pollutant. In the textile industry, color is a mill-specific
problem related to the combination of dyes and finishing
chemicals used. For this reason, EPA feels that color should be
controlled on a case-by-case basis by local authorities as
dictated by water quality considerations.
Conventional Pollutants
The conventional pollutants of concern in textile mill discharges
aret
Biochemical Oxygen Demand (BOD)
Total Suspended Solids (TSS)
pH
Biochemical Oxygen Demand Biochemical oxygen demand (BOD) is the
quantity of oxygen required for the biological and chemical
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oxidation of waterborne substances under controlled test
conditions. Materials that may contribute to the BOD include:
carbonaceous organic materials usable as a food source by aerobic
organisms; oxidizable nitrogen derived from nitrates, ammonia and
organic nitrogen compounds which serve as food for specific
bacteria; and certain chemically oxidizable materials such as
ferrous iron, suIfides and sulfite, which will react with
dissolved oxygen or are metabolized by bacteria. In most
industrial and municipal wastewaters, the sources of BOD are
principally organic materials and ammonia (which is itself
derived from animal or vegetable matter).
The BOD of a waste can exert an adverse effect on the dissolved
oxygen resources of a body of water by reducing the oxygen
available to fish, plant life and other aquatic species.
Conditions can be reached where all of the dissolved oxygen in
the water is utilized, resulting in anaerobic conditions and the
production of undesirable gases such as hydrogen sulfide and
methane. The reduction of dissolved oxygen levels can be
detrimental to fish populations, fish growth rate and organisms
used as fish food. A total lack of oxygen can result in the
death of all aerobic aquatic inhabitants in the affected area.
Water with a high BOD indicates the presence of decomposing
organic matter and associated increased bacterial concentrations
that degrade the water's quality and its potential uses. A
by-product of high BOD concentrations can be increased algal
concentrations and blooms that result from decomposition of the
organic matter.
The BOD5. (five-day BOD) test is used widely to estimate the
oxygen demand of domestic and industrial wastewaters. The test
also is used to determine the amount of aeration required in
biological treatment and to measure the oxygen demand created by
organic pollutants in surface waters. Complete biochemical
oxidation of a given wastewater may require a period of
incubation too long for practical analytical test purposes. For
this reason, the five-day period is used, and the test results
are expressed as BOD!>. The biochemical reactions involved in the
oxidation of carbon compounds are related to the period of
incubation. The five-day BOD usually measures only 60 to 80
percent of the carbonaceous biochemical oxygen demand of the
sample; for many purposes, this represents a reasonable measure
of the oxygen demanding potential of wastewater.
Because the BODjj test is a measure of biological activity in
surface waters, standard conditions of time, temperature,
microbial seed and dilution water for the test are included in
the analytical procedure. The environmental conditions of the
BOD test must be suitable for uninhibited microorganism activity.
Therefore, toxic substances must be absent and nutrients, such as
nitrogen, phosphorus and trace elements, must be present.
Through the use of this procedure, the oxygen demand of diverse
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wastes can be evaluated and compared, and the treatability in
biological treatment systems estimated,
BODS is present in wastewaters from textile processing operations
in varying concentrations and amounts. The processes with the
highest concentrations are wool scouring, carpet finishing and
felted fabric processing.
BODj> should continue to be regulated in all subcategories of the
textile industry.
Total Suspended Solids (TSS) Suspended solids include both
organic and inorganic materials. The inorganic compounds include
sand, silt and clay. The organic fraction includes materials
such as grease, oil, tar and animal and vegetable waste products.
These solids may settle out rapidly and often leaving bottom
deposits composed of a mixture of both organic and inorganic
solids. Solids may be suspended in water for a time, and then
settle to the bed of the stream or lake. These solids may be
inert, slowly biodegradable materials or rapidly biodegradable
substances. While in suspension, solids increase the turbidity
of the water, reduce light penetration and retard the
photosynthetic activity of aquatic plants.
Suspended solids in water can interfere with many industrial
processes, and cause foaming in boilers and incrustations on
equipment exposed to such water, especially at elevated
temperatures. Suspended solids are undesirable in process water
used in most industries.
Solids in suspension are aesthetically displeasing. In addition,
suspended solids which settle to form sludge deposits on a stream
or lake bed often damage aquatic life. Solids that are
transformed to sludge deposits also may cause other damage such
as blanketing a stream or lake bed, destroying the living spaces
for the benthic organisms normally present in that habitat.
Organic solids use a portion of all of the dissolved oxygen
available in the area. Organic materials also serve as a food
source for sludgeworms and associated organisms.
Disregarding any toxic effects of these solids in water,
suspended solids may kill fish and shellfish by causing abrasive
injuries and by clogging the gills and respiratory passages of
various aquatic fauna. Suspended solids indirectly may harm
aquatic life by screening out light and by depleting the
available oxygen. This results in the killing of fish and fish
food organisms. Suspended solids can also reduce the
recreational value of the water.
Sources of solids in textile industry wastewater include the
following operations: wool scouring, low water use processing,
desizing, scouring, bleaching, printing and backing of carpet and
solids generated by biological activity in wastewater .treatment
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systems. TSS should continue to
subcategories of the textile industry.
be regulated in all
pH pH is related to the acidity or alkalinity of water, or
wastewater. It is not a linear or direct measure of either;
however, it may properly be used as a surrogate to control both
excess acidity and excess alkalinity in water. The term pH is
used to describe the hydrogen ion - hydroxyl ion balance in
water. Technically, pH is the negative logarithm of the hydrogen
ion concentrations. A pH of 7 indicates neutrality or a balance
between free hydrogen and free hydroxyl ions. Solutions with a
pH above 7 indicate that the solution is alkaline, while a pH
below 7 indicates that the solution is acidic.
The pH value of water or wastewater is useful in determining
necessary measures for corrosion control, pollution control and
disinfection. Waters with a pH below 6.0 are corrosive to water
system distribution lines and household plumbing fixtures. Such
corrosion can add constituents to drinking water such as iron,
copper, zinc, cadmium and lead. Low pH waters not only dissolve
metals from structures and fixtures, but also redissolve or leach
metals from sludges and bottom sediments. The hydrogen ion
concentrations can affect the taste of the water; at a low pH,
water tastes sour.
Extremes of pH or rapid pH changes can cause stress conditions or
kill aquatic life outright. Even moderate changes from
acceptable criteria limits of pH are deleterious to some species.
The harmful effect on aquatic life of many materials is increased
by changes in pH. For example, metalocyanide complexes can
increase a thousand-fold in toxicity with a drop of 1.5 pH units.
Similarly, the toxicity of ammonia is a function of pH. The
bacteriocidal effect of chlorine in most cases is less as the pH
increases, and it is economically advantageous to keep the pH
close to 7. Extremes of pH can occur in the textile industry as
a result of run changes, process adjustments and other
variabilities in process operations, therefore, pH should
continue to be regulated in all subcategories of the textile
industry.
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SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
This section describes the control and treatment technologies
that are in use and available to reduce the discharge of
pollutants from textile mills. There are two major technology
approaches available: 1) in-plant controls and process changes
and 2) effluent treatment technology. Programs combining
elements of both approaches are applicable to many mills in the
industry. Both approaches should be considered to determine
which specific combination is best suited to a particular
facility.
In-plant controls and process changes reduce hydraulic and
pollutant loadings originating from mill operations. Although
their use for pollutant reduction has been limited, greater
attention is now being given to them because of economic and
energy considerations.
Considerable research has taken place on the various effluent
treatment technologies applicable to textile mills. Over 80
percent of the direct discharging mills in the industry provide
wastewater treatment. Similarly, over 40 percent of the indirect
discharging mills provide wastewater treatment before discharging
to POTWs. Preliminary treatment, biological treatment, chemical
treatment, physical separation and sorption systems applicable to
textile industry wastewater are described following the
discussion of in-plant controls. In addition to the description
of each treatment method, detailed information on application of
the method in the textile industry and its effectiveness is
presented.
IN-PLANT CONTROLS AND PROCESS CHANGES
It is often more efficient to control pollution at its source,
i.e., to prevent the generation of waste, rather than to depend
on treatment to reduce or remove it. For this reason, an
investigation of in-plant controls and process changes that might
be instituted to reduce the strength or volume of wastewaters is
a logical first step in any pollution control program.
Conscientious implementation of in-plant controls and process
changes can be effective in reducing water use and pollutant
discharges.
For discussion purposes, in-plant measures have been divided into
five types: 1) water reuse, 2) water use reduction, 3) chemical
substitution, 4} material reclamation and 5) process changes and
new process technology. Water reuse and water use reduction
modifications result in a lower hydraulic loading on existing
treatment facilities that in turn yield an improved effluent
quality because of increased detention time. For new facilities,
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smaller treatment units may be used, involving less capital and
lower operating costs. Chemical substitution and material
reclamation can be used to reduce toxic, nonconventional and
conventional pollutant loadings on treatment facilities. Process
changes and new process technology can result in water and
pollutant reductions through improved process control and
operating efficiency.
Summary ol_ In-Plant Controls Data
The Agency received surveys from 541 textile mills during the
initial phase of this study. Of these, 152 provided relevant
information about the use of in-plant process control. In some
instances, this information was supplemented by telephone
discussions with knowledgeable mill personnel. A summary of the
responses, reported by subcategory, is provided in Table VII-1.
The number of controls cited by the 152 mills totaled 195, or 1.3
controls per mill. Approximately 47 percent are water reuse
measures, 23 percent are process water reduction measures, 19
percent involve substitution of process chemicals and 11 percent
involve reclamation of process chemicals.
Water Reuse
Water reuse measures reduce hydraulic loadings to treatment
systems by using the same water in more than one process. Water
reuse resulting from advanced wastewater treatment (recycle) is
not considered an in-plant control, because it does not reduce
hydraulic or pollutant loadings on the treatment plant. The two
major water reuse measures available to textile mills are: 1)
reuse of uncontaminated cooling water in operations requiring hot
water, and 2) reuse of process water from one operation in a
second, unrelated operation.
Cooling water that does not come in contact with fabric or
process chemicals can be collected and reused directly. Examples
include condenser cooling water, water from water-cooled
bearings, heat-exchanger water, and water recovered from cooling
rolls, yarn dryers, pressure dyeing machines, and air
compressors. This water can be pumped to hot water storage tanks
for reuse in operations such as dyeing, bleaching, rinsing and
cleaning where heated water is required. Energy and water
savings can be substantial.
Reuse of certain process water elsewhere in mill operations also
results in significant wastewater discharge reductions. Examples
of process water reuse include: reuse of wash water from
bleaching operations in caustic washing and scouring; reuse of
scouring rinses for desizing or for cleaning printing equipment;
and reuse of mercerizing wash water to prepare baths for
scouring, bleaching, and wetting fabric.
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TABLE VII-1
MILLS REPORTING IN-PLANT CONTROL MEASURES - RESULTS OF INDUSTRY SURVEY
Number of Mills Reporting Measure
Sub category
1.
2.
4.
5.
ro
CO
to
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
All Subcategories
Water
Reuse
2
2
28
24
1
10
21
2
2
92
Water Use
Reduction
1
4
20
8
0
2
9
1
0
45
Chemical
Substitution
0
1
17
9
1
3
3
1
1
36
Material
Reclamation
1
0
16
1
0
3
1
0
0
22
Total
4
7
81
42
2
18
34
4
3
195
Source: EPA Industry Survey, 1977.
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Ninety-two mills of the 541 mills in the survey reported some
form of water reuse. The mast common item is the reuse of
cooling water to heat process water. Temperature increases as
great as 33°C (91°F) were reported. Most mills in the survey
that reported the reuse of cooling water began the practice in
the mid-seventies to conserve energy. At some mills, both energy
and water savings were major considerations in instituting reuse.
Energy savings were reported ranging from 252 million to 25.2
billion kilogram-calories (1 billion to 100 billion Btu/yr),
while water savings varied from 9.5 to 380 cu m/d (2,500 to
100,000 gpd) or more. Costs to institute water reuse measures
ranged from less than $5,000 to more than $50,000 at some
facilities. The principal cost items were pumps, piping
modifications and hot water storage tanks.
As the costs of energy and wastewater treatment increase, reuse
of cooling water is expected to become more widespread in the
industry. This is supported by the fact that many mills have
reported current engineering studies in this area. The reuse of
water from various textile processing operations also is
practiced at a few mills and is being investigated at a number of
others. Savings similar to those noted for cooling water reuse
were reported and it is expected that more reuse of this nature
also will become common.
Water Use Reduction
While water reuse is the use of the same water more than once,
water use reduction is the elimination of unnecessary water
consumption. Three in-plant control measures that are considered
forms of water use reduction are: 1) countercurrent flow washing
or rinsing, 2) conservation, and 3) process modification.
The countercurrent flow system is based on the principle that
wash water is not used effectively if it is cleaner than the
fabric when the water leaves the washbox. In countercurrent flow
applied to operations such as wash boxes on a continuous range,
the water flows through the process in the direction opposite to
that of the material. As the water passes into each box, it
contacts material containing increasing amounts of impurities and
other undesirable matter. This system is considered standard
procedure in wool scouring and is not an uncommon practice at
finishing mills that scour, mercerize, bleach, or dye on
continuous ranges. At some of these mills, countercurrent flow
wash boxes have been used for a long time. However, many mills
still do not use countercurrent flow, especially where water is
inexpensive. This practice is expected to change as water and
wastewater treatment become more costly (17).
Conservation measures include a variety of steps that can be
taken to reduce water use in textile mills. They consist
primarily of maintaining close control over mill operations to
avoid accidental loss of process chemical baths and avoiding the
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preparation of larger batches than required. Supervision to
insure efficient operation of in-plant controls, such as the
countercurrent flow systems discussed above, is an important
conservation technique. Reduction of dirt, grease and rust in
production areas to avoid unnecessary washing and processing of
soiled material also contributes to conservation. Other measures
that are used are the construction of retaining walls,
splashboards and sills, and proper maintenance of machinery and
plumbing to minimize process fluid losses through spillage and
leaks. Use of liquid level controls, flow indicators and meters
and automatic shut-off devices also reduce water requirements at
textile mills.
Simply implemented process modifications that reduce water use
include longer process runs between dumps and modulation of water
supply to match the speed of the textile products being handled.
Carefully supervised trials should be run to determine minimum
water requirements possible without reducing product quality.
Instrumentation and automation can be incorporated into processes
to assist in uniformity of application, reduction of rework,
control of operating parameters, e.g., pH and temperature, or
similar functions may be used to achieve reductions in water and
chemical use.
Based on questionnaire and telephone surveys, 45 mills have
instituted water use reduction control measures. The most common
water use reduction measure identified was countercurrent flow of
water during wet processing operations. Countercurrent flow in
scouring and desizing, and the use of rinse water in bleaching,
dyeing and mercerizing have been instituted at various mills.
Energy and water savings can be substantial, but installation
costs can vary considerably.
A few mills have reported that they can use chemicals in
operations such as scouring and dyeing (continuous type) for
longer periods without dumping. For example, one mill has
recently extended the time between scour dumps from once every 2
hours to once every 24 hours without affecting quality. More
extensive modifications that result in lower water use generally
require process changes and are discussed later in this section.
Chemical Substitution
The objective of chemical substitution is to replace process
chemicals having high pollutant strength or toxic properties with
others that have less impact on water quality or that are more
amenable to wastewater treatment. A number of process chemical
substitutions have been suggested or developed for the textile
industry, and it is expected that this area will play a more
important role in the future. The cost to substitute other
chemicals and products for those containing toxic pollutants is
usually much less than the cost to remove the pollutants from a
mill's discharge via end-of-pipe treatment. For any
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substitution, however, a careful evaluation should be made to
assure that one pollution problem is not being substituted for
another.
Foaming problems in treatment facilities and receiving streams
have been solved by substituting biodegradable, low-foaming
detergents for the so-called "hard" detergents. Potentially
toxic pollutants have been reduced or eliminated by substitution.
For example, switching from chromate oxidizers to hydrogen
peroxide or iodates eliminates chromium in dyeing processes. The
replacement of soap with sulfuric acid in wool fulling operations
is a substitution that results in lower BOD loadings. Mineral
acids are substituted for high BOD acetic acid in dyeing
processes, offering an advantage in terms of wastewater treat-
ability. The substitution of mineral oils with nonionic
emulsifiers for the more traditional olive oil in carding wool
also results in lower pollutant levels.
Starch wastes from desizing are the single greatest source of BOD
at many mills. Consequently, substitutes with low BOD, such as
CMC, PVA and PAA, have become useful to reduce BOD loadings on
wastewater treatment systems. However, another consideration is
the net effect on the environment. These low BOD, high COD sizes
contribute substantially to the ultimate oxygen demand of the
wastewater. In view of this, the following from a report
prepared for the American Textile Manufacturers Institute (18) is
pertinent.
"Substitution should assume the direction of easily
treatable materials in terms of waste control
technology and recoverabi1i ty. Chemists and
environmental engineers must work together in
considering which process chemical is best handled by
the means or unit process most efficiently suited to
its recovery or removal. Certainly, in terms of
conventional biological systems, low BOD chemicals will
not lose their significance. However, as physical-
chemical treatment methods are adopted, other
characteristics (COD, ultimate BOD, solids, toxic
pollutants, etc.) will likely become increasingly
important. Additional research is necessary to
determine the viability of COD versus BOD substitutions
and the economic and treatability impact of such
cursory changes."
Thirty-six mills reported that they had instituted chemical
substitution as an in-plant control measure. Substitution for
dyes requiring chromium mordants and chromate oxidizers are the
most commonly cited. One wool finishing mill reported that
savings in labor and other processing costs more than offset the
higher cost of the dyes substituted for the traditional chrome
dyes. BOD reductions were achieved at some mills by substituting
synthetic warp sizes for starch, using low BOD detergents for
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those with high BOD, and eliminating the use of acetic acid as a
pH adjuster.
Material Reclamation
Material reclamation measures often are implemented to reduce
processing costs, the reduction of pollutant loadings being a
secondary benefit. As noted previously, caustic recovery after
mercerizing is quite common, especially in large finishing
operations. Recovery of various warp sizes has been investigated
at length and shows promise. Size recovery was identified at
three facilities; two mills reclaim PVA and one reclaims WP-50.
While many carpet finishing mills segregate latex waste streams
for treatment, only two segregate for recycle. Some mills
reclaim scouring detergent or dye liquor for future batches.
Reclamation of print solvent is practiced at one mill. In all,
some form of material reclamation was noted at 22 mills. It is
anticipated that chemical and wastewater treatment costs will
make material conservation and recovery a more viable alternative
in the future.
Process Changes and New Process Technology
Process changes and the implementation of new process technology
are modifications to the basic manufacturing operations of a
mill. Some reduce water use and eliminate or minimize the
discharge of high strength or toxic chemicals. Others provide
for material and energy reclamation. One new technology, water
jet weaving, requires additional water, although the wastewater
generated is relatively low in pollutant concentration.
Adoption of process changes and new process technology offers the
greatest opportunity for reducing hydraulic and pollutant loads
from textile mills. Technological advances in fibers, process
chemicals, other raw materials and processing equipment are
constantly occurring and, in general, these changes are resulting
in lower hydraulic and conventional pollutant loadings (3).
Solvent processing is an example of a new process technology. It
involves the use of a nonaqueous solvent such as
perchloroethylene to scour and dye fabric. Because the solvent
has a high vapor pressure (compared to water), it is possible to
vaporize it more easily and recover it for reuse. It has not,
however, achieved the original expectations of performance,
except for specialized processing and small batch operations.
Effective applications include solvent scouring of wool fabric
and some synthetic knit fabrics and solvent finishing of
upholstery, drapery, synthetic knits, and fabrics that are
sensitive to water.
There are a number of reasons for the limited application of
solvent processing to date. The most troublesome problem is that
the value of the recovered solvent is often less than is
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necessary to make the process economically feasible. In
addition, only a limited number of the thousands of different
dyestuffs and chemicals now used in commercial textile processing
can be transferred directly to solvent use. Another problem is
the emission of unrecovered solvent to the work place or the
atmosphere.
A more common method of reducing hydraulic and pollutant loadings
in the industry is changing process and material flow procedures.
It has been noted (19) that continuous operations generally
require less space, water and process chemicals than do batch
operations. Circulating baths and rinses also require less
water. Rope washers are reportedly more effective than open-
width washers in reducing water use. Significant water use
reductions also are achieved by combining separate operations,
such as scouring and dyeing in the finishing of synthetic fibers
and the desizing and scouring of cotton fibers.
Some of the newer textile processing equipment results in lower
water and chemical usage. For example, pressure dye machines use
dyestuff more efficiently, reduce water requirements and reduce
the level of toxic dye carriers required in atmospheric dyeing.
It is reasonable to expect that the textile processing equipment
of the future will be even more efficient in the use of water,
chemicals and energy.
EFFLUENT TREATMENT TECHNOLOGIES
Treatment of the total waste stream is the primary method used by
the textile industry to remove or reduce the pollutants present
in the wastewater from wet processing operations. This approach
is used because of the difficulty and expense of segregating
waste streams at existing facilities. New facilities, however,
have the opportunity to segregate more concentrated or more
troublesome wastes and treat them independently.
A summary of current wastewater treatment practices by the wet
processing mills surveyed is presented in Table VII-2. Not all
of the mills surveyed provided information on their treatment
systems so the table only includes 1,085 of the 1,169 mills in
the major wet processing subcategories. Eighteen percent of the
direct dischargers provide no wastewater treatment (discharge
directly to surface waters or have wastewater transported from
the site),"19 percent provide only preliminary treatment (i.e.,
screening, equalization, heat exchange, primary sedimentation,
flotation, filtration, neutralization, chemical coagulation and
oxidation), 56 percent provide biological treatment (i.e.,
aerated or unaerated lagoons, biological filtration and activated
sludge), and 7 percent provide an advanced level of treatment
(i.e., chemical coagulation/precipitation, filtration, activated
carbon adsorption, ozonation, ion exchange and membrane
processes).
238
-------
TABLE VII-2
WASTEWATER TREATMENT STATUS - WET PROCESSING MILLS SURVEYED
ro
CO
Mills
Reporting
Treatment
Status
Subcategory
1.
2.
4.
5.
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
All Subcategories
D
6
6
78
37
7
11
36
5
_!
187
I
10
24
210
218
149
42
168
25
13
859
Z
1
3
8
9
2
2
3
7
4
39
D
1
0
14
6
4
0
6
3
0
34
None
I
5
9
125
135
99
6
104
11
1
495
Z
0
2
4
5
2
1
0
7
1
22
Level of Treatment
Preliminary
Physical Chemical Biological
D
2
0
3
25
0
0
2
0
0
32
I
3
8
54
48
38
33
36
9
8
237
Z
1
1
1
0
0
0
0
0
1
4
D
0
0
2
0
0
0
1
0
0
3
I
0
3
17
11
7
1
17
2
4
62
Z
0
0
0
0
0
0
0
0
0
0
D
3
6
54
2
3
10
25
1
1
105
I
2
4
13
24
4
2
11
3
0
63
Z
0
0
3
1
0
1
1
0
2
8
Advanced
0
0
0
5
4
0
1
2
1
0
13
I
0
0
1
0
1
0
0
0
0
2
Z
0
0
0
3
0
0
2
0
0
5
Notes_: D refers to direct dischargers, I to indirect dischargers, and Z to zero discharge mills.
None - direct discharge to POTWs, surface waters, land, or wastewater hauled from site.
Preliminary, Physical - screening, equalization, heat exchange, sedimentation, flotation, filtration.
Preliminary, Chemical - neutralization, chemical coagulation, oxidation.
Biological - unaerated and aerated lagoons, biological filtration, activated sludge.
Advanced - chemical coagulation/precipitation, filtration, activated carbon adsorption, ozonation,
ion exchange, membrane processes.
Source: EPA Industry Survey, 1977.
-------
Effluent treatment technologies applicable to textile wastewaters
can be categorized as follows; 1) preliminary treatment
(screening, neutralization and equalization), 2) biological
treatment (aerated lagoons, activated sludge, biological beds and
stabilization lagoons), 3) chemical treatment (coagulation,
precipitation and oxidation), 4) physical separation (filtration,
hyperfiltration/ultrafiltration, dissolved air flotation,
stripping and electrodialysis), and 5) sorption systems
(activated carbon and powdered activated carbon). Each of these
categories is discussed in detail below.
Fifty-eight percent of the indirect dischargers provide no
treatment, 35 percent provide preliminary treatment, 7 percent
provide biological treatment and 0.2 percent (2 mills) provide an
advanced level of treatment.
Fifty-six percent of the zero discharge mills provide no
treatment, 10 percent provide preliminary treatment, 21 percent
provide biological treatment and 13 percent provide an advanced
level of treatment.
Approximately 18 percent of the mills that furnished data (63
percent of the direct dischargers, 8 percent of the indirect
dischargers and 33 percent of the zero discharge mills) provide a
minimum of biological treatment.
The specific treatment technologies employed by the mills
surveyed are presented in Table VII-3 for mills that discharge
directly to surface waters and zero discharge mills, and in Table
VII-4 for mills that discharge to a POTW.
Of the direct and zero discharge mills that treat their
wastewater, 65 percent provide screening, 36 percent provide
equalization and 23 percent provide neutralization. Similarly,
57, 46 and 19 percent of the indirect discharge mills that treat
their wastewater provide screening, equalization .and
neutralization. Approximately 68 percent of the direct and zero
discharge mills have activated sludge treatment systems.
Preliminary Treatment
Screening Screening is a physical unit operation and is usually
the first operation used in wastewater treatment. Based on size
of openings, less than or greater than 0.63 cm (0.25 in.),
screens may be classified as coarse or fine. Coarse screens
consist of parallel bars, rods or wires, grating, wire mesh or
perforated plate. The openings can be any shape, with circular
or rectangular slots the most common. Screens are hand cleaned
by plant personnel or mechanically cleaned and have the primary
function of removing rags, sticks and similar coarse solids that
may clog or damage the pipes, pumps, valves or other mechanical
equipment of the treatment system. Fine screens include inclined
disks or drums, static plates and mesh units and vibratory mesh
240
-------
TABLE VII-3
EXISTING TREATMENT TECHNOLOGIES - DIRECT AMD ZERO DISCHARGE MILLS
ro
Treatment
Physical Biological
Chemical Sorption
Sub category
1.
2.
4.
5.
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
No. of
Mills
6
5
56
29
2
11
29
1
3
Sc
3
4
39
20
1
8
17
1
Eq
1
2
21
10
4
13
1
1°
2
4
2
4
1
2° Sk Fl
3 1
3
41 1
23 1
2 2
6
18
1
Fi
2
5
1
3
AS
3
3
40
23
2
6
18
1
Al
2
13
6
4
8
1
A2 An TF Ne
1
2
16
9
5
9
2
3
2 13
6
3
7
CC
1
8
3
2
1
Ox AC PC
2
19 1
20
5 3,
12
2
Total
142
93 52 13 97
4 11 96 34 44 0 2 32 15 60 1
Note: Sc = Screening
Eq = Equalization
Fl = Flotation
Fi = Filtration
1° = Primary Sedimentation AS = Activated Sludge
2° = Secondary Sedimentation Al = Aerated Lagoon
TF = Trickling Filter
Ne = Neutralization
CC = Chemical Coagulation
Ox = Oxidation, incl. Disinfection
Sk = Skimming
A2 = Facultative or Tertiary Lagoon AC - Activated Carbon
An = Anaerobic Lagoon
PC = Powdered Activated Carbon
Source: EPA Industry Survey, 1977.
-------
TABLE VII-4
EXISTING PRETREATMENT TECHNOLOGIES - INDIRECT DISCHARGERS
ro
-t*
ro
Treatment
Physical Biological
Chemical Sorption
Sul
1.
2.
4.
5.
6.
7.
8.
9.
3 category
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Total
No. of
Mills
2
10
46
42
20
24
43
6
7
200
Sc
1
8
25
17
12
23
21
2
5
114
Eq
4
23
18
7
9
26
4
2
93
1°
1
2
1
2
7
1
14
2°
2
3
2
1
1
4
13
Sk Fl Fi AS
2
311
2
1 1
1 1
1 4
1 3 3 11
Al
2
6
11
2
2
23
A2
2
3
5
2
3
1
16
An TF Ne
3
8
3
2
1 2
13
2
5
1 0 38
CC
1
4.
1
2
2
10
Ox AC PC
1
1
3
2
4
11 0 0
Note: Sc = Screening Fl = Flotation
Eq = Equalization Fi = Filtration
1° = Primary Sedimentation AS = Activated Sludge
2° = Secondary Sedimentation Al = Aerated Lagoon
TF = Trickling Filter
Ne = Neutralization
CC = Chemical Coagulation
Ox = Oxidation, incl. Disinfection
Sk = Skimming
A2 = Facultative or Tertiary Lagoon AC = Activated Carbon
An = Anaerobic Lagoon
PC = Powdered Activated Carbon
Source: EPA Industry Survey, 1977.
-------
units. These are cleaned by continuous water spray, by
mechanically driven brushes, or, in the case of vibratory
screens, automatically by the vibration. Fine screens remove
floe, strings, short fibers, vegetable matter or other small
solids that clog or damage equipment or form a mat or scum layer
over aeration basins.
Industry Application - Both coarse and fine screening are
practiced in the textile industry. The number of direct
(including zero discharge mills) and indirect dischargers in each
subcategory using screening is provided in Table VII-5. The data
is from the mills that returned detailed questionnaires and is
the same data base previously noted. Only the most extensive
type of screening at each plant is noted in the tabulation.
Approximately 40 percent of the direct and zero discharge mills
and nearly 25 percent of the indirect discharge mills reported
static coarse screening as the only screening in their treatment
systems. Fine screening (static, mechanical, hydrosieve or
vibrating) is practiced by 34 percent of the direct and zero
discharge mills, and 31 percent of the indirect discharge mills
that provided detailed survey information.
Nearly all of the mills in the wool finishing and carpet
finishing subcategories provide some type of screening. This is
because of the high fiber content of the untreated wastewater in
both subcategories.
Neutralization Neutralization is the process of adjusting the pH
to within acceptable -limits for discharge to surface waters or
subsequent treatment operations. Generally, a pH range of 6.0 to
9.0 is acceptable for discharge to surface waters while
additional treatment operations usually require more specific pH
tolerances. Neutralization of acidic waste is accomplished by:
1) mixing with an on-site alkaline waste stream; 2) passing
through beds of limestone; 3) mixing with lime slurries; or 4)
adding a solution of caustic soda (NaOH) or soda ash (Na2C03.).
Alkaline waste may be neutralized by: 1) mixing with an on-site
acidic waste stream; 2) blowing waste boiler flue gas through
the waste; 3) adding compressed C0£; or 4) adding sulfuric acid
(H2S04). Mixing of various wastewater streams is usually
insufficient to meet the pH requirements of biological treatment.
Therefore, chemical addition frequently is required for proper pH
control. Limestone is the least expensive reagent for
neutralizing acidic wastewater but is not satisfactory for
sulfate-bearing wastewater because it becomes coated and
inactive. If the wastewater is deficient in either nitrogen or
phosphorus, ammonia or trisodium phosphate addition serves the
dual purpose of providing both alkalinity and the deficient
nutrient.
Industry Application - Current wastewater neutralization
practices reported by the textile mills surveyed are summarized
243
-------
TABLE VII-5
WASTEWATER SCREENING BY TEXTILE INDUSTRY - RESULTS OF INDUSTRY SURVEY
Mills Employing Screens
Coarse Fine
Mills
Sub category
1. Wool Scouring
2. Wool Finishing
4. Woven Fabric Finishing
5. Knit Fabric Finishing
4* Fabric Processing
Hosiery Processing
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
All Subcategories
Note: D represents direct and
Static Mechanical
D I D I
2
3
24
13
1
2
10
0
0
55
zero
1
2
14
9
6
3
8
1
1
45
1
0
2
0
0
0
1
0
0
4
discharge
0
3
1
0
0
1
0
0
0
5
mills.
Static
D I
0
0
7
4
0
3
3
0
1
18
0
0
5
5
4
12
10
0
0
36
Mechanical
D I
0
0
1
2
0
2
0
0
0
5
0
0
0
1
1
5
1
1
1
10
Hydro si eve
D I
0
1
2
0
0
1
2
0
0
6
0
0
2
0
0
2
1
0
0
5
Vibrating In Survey
D I D I
0
1
3
0
0
0
1
0
0
5
0
3
3
2
0
0
1
0
3
12
6
5
56
29
2
11
29
1
3
142
2
10
46
42
20
24
43
6
7
200
I represents indirect discharge mills.
Source: EPA Industry Survey, 1977.
-------
in Table VII-6. Approximately 21 percent of the direct and zero
discharge mills and 19 percent of the indirect discharge mills
surveyed practice neutralization. Neutralization of acidic waste
by indirect dischargers represents the greatest total. Only a
small percentage of both direct and indirect dischargers find it
necessary to provide both acidic and alkaline neutralizing
capability.
Equalization Industrial discharges that result from a variety of
processes in the mill often are treated more effectively when
equalization is practiced as an initial treatment step.
Subsequent physical, chemical and biological treatment steps are
more efficient if operated at uniform hydraulic, organic and
solids loading rates.
Equalization of discharges with fluctuating pollutant loads is
accomplished by holding the untreated wastewater for the period
of time that corresponds to the repetitive manufacturing
operations. For example, facilities that discharge a variable
waste over an eight hour work shift need to provide up to eight
hours of storage. Similar facilities that operate on two or
three shifts may need to provide storage for 16 to 24 hours of
wastewater flow. Equalization basins may be earthen or
fabricated and may be mixed or unmixed. Mixing is typically
accomplished by aeration to provide for a uniform influent to the
treatment processes.
Industry Application - Current equalization practices
reported by the textile mills surveyed are summarized in Table
VII-7. A higher percentage of indirect dischargers (46 percent)
than direct dischargers (37 percent) provide equalization. This
is a result of two factors. First, many of the direct discharge
mills have extended aeration activated sludge treatment systems
with several days detention time and do not require equalization.
Secondly, many of the indirect dischargers are required by the
municipalities to equalize their flow.
Biological Treatment
Biological treatment of industrial wastewater has been practiced
for decades, but most activated sludge processes have been
constructed in the last 10 to 15 years. Biological treatment is
based on the ability of microorganisms to consume organic carbon
as a food source. Biological treatment is classified aerobic or
anaerobic depending on the presence of free dissolved oxygen in
the wastewater. Aerobic biological treatment is accomplished by
aerobic bacteria that utilize free dissolved oxygen in breaking
down (oxidizing) organic compounds. Anaerobic biological
treatment is accomplished by anaerobic bacteria that utilize
chemically bound oxygen in oxidizing organic compounds. A third
class of bacteria, facultative, also is active. These bacteria
245
-------
TABLE VII-6
WASTEWATER NEUTRALIZATION BY TEXTILE INDUSTRY - RESULTS OF INDUSTRY SURVEY
Subcategory
Mills Practicing Neutralization
Addition of Acid Addition of Base Addition of Both Mills in Survey
Direct* Indirect Direct* Indirect Direct* Indirect Direct* Indirect
1.
2.
4.
5.
ro
-P*
a*
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
All Subcategories
0
0
10
0
0
0
3
0
0
13
0
0
4
1
1
0
5
1
1
13
0
2
2
5
0
3
2
0
0
14
0
3
4
1
1
2
7
0
2
20
0
1
1
0
0
0
1
0
0
3
0
0
0
1
0
0
1
1
2
5
6
5
56
29
2
11
29
1
3
142
2
10
46
42
20
24
43
6
7
200
* Includes zero discharge mills.
Source: EPA Industry Survey, 1977.
-------
TABLE VII-7
WASTEWATER EQUALIZATION BY TEXTILE INDUSTRY - RESULTS OF INDUSTRY SURVEY
Unmixed
Mixed
Subcategory
Mills in
Direct & Zero Indirect Direct & Zero Indirect Survey
LT 24* ETGT 24* LT 24 ETGT 24 LT 24 ETGT 24 LT 24 ETGT 24 Direct^ Indirect
1.
2.
4.
5.
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
All Subcategories
0
1
4
4
0
2
3
0
0
14
0
0
8
3
0
1
4
1
0
17
0
1
19
10
3
7
21
2
0
63
0
3
3
4
4
2
5
2
0
23
0
1
4
2
0
0
3
0
0
10
1
0
5
1
0
1
3
0
0
11
0
0
1
2
0
0
1
2
0
6
0
0
0
1
0
0
0
0
0
1
6
5
56
29
2
11
29
1
3
142
2
10
46
42
20
24
43
6
7
200
* LT 24 = Less than 24 hours; ETGT 24 = Equal to or greater than 24 hours.
# Includes zero discharge mills.
Note: For four direct discharge mills (two Subcategory 4 and two Subcategory 7) and seven indirect discharge
mills (two Subcategory 2, two Subcategory 5 - Fabric Processing, one Subcategory 5 - Hosiery Processing,
one Subcategory 6, and one Subcategory 7) the equalization detention times could not be calculated so 24
hours was assumed.
Source: EPA Industry Survey, 1977.
-------
can act as aerobes or anaerobes depending on the availability of
free oxygen in the wastewater.
Unlike municipal wastewater, industrial wastes frequently lack
nutrients to sustain microbial growth. This deficiency often is
eliminated by mixing sanitary wastewater from the plant site with
the process wastewater, or by addition of chemicals (usually
nitrogen or phosphorus). A description and discussion of each
biological process relevant to the treatment of textile mill
wastewaters follows (20).
Aerated lagoons An aerated lagoon is a basin to which air is
added through mechanical agitation or diffusion. The air
provides the oxygen required for aerobic biodegradation of
organic waste. If properly designed, the aeration provides
sufficient mixing to maintain the biological solids in suspension
so that they can be removed efficiently in a secondary
sedimentation tank. After settling, sludge may be recycled to
the head of the lagoon to insure the presence of a properly
acclimated seed. When operated in this manner, the aerated
lagoon is analogous to the activated sludge process, which is
discussed later in this section. The viable biological solids
concentration in an aerated lagoon is low when compared to that
of an activated sludge unit. The aerated lagoon relies primarily
on detention time for the breakdown and removal of organic matter
and aeration periods of 3 to 8 days are common.
Industry Application - Thirty-four direct dischargers and 23
indirect dischargers report using aerated lagoons as part of
their treatment systems. Of the direct dischargers, 12 employ
aerated lagoons as their primary means of treatment; 14 employ
aerated lagoons followed by unaerated aerobic lagoons as their
primary means of treatment; 2 employ aerated lagoons as polishing
ponds following activated sludge biological treatment; and 6
employ aerated lagoons in combination with advanced treatment (2
chemical coagulation, 2 filtration, 1 chemical coagulation plus
filtration and 1 activated carbon). Of the indirect dischargers,
21 employ aerated lagoons as their primary pretreatment step, 1
employs an aerated lagoon followed by an unaerated aerobic lagoon
and 1 provides multimedia filtration following an aerated lagoon.
Historical Data - The performance of aerated lagoons in the
treatment of textile wastewater is demonstrated in Table VI1-8
for those mills that provided wastewater monitoring data. The
values reported are averages for each mill and generally
represent data for the year 1976.
Field Sampling - Sampling was conducted at two woven fabric
finishing mills and one knit fabric finishing mill to determine
the effectiveness of aerated lagoons in the treatment of toxic
pollutants. Summaries of the data obtained from this program are
presented in Tables VII-9 through VII-ll.
248
-------
TABLE VI I -8
PERFORMANCE OF AERATED LAGOONS IN THE TREATMENT
OF TRADITIONALLY MONITORED POLLUTANTS
DESIGN DATA EFFLUENT CONCENTRATIONS (% REMOVAL)
Subcategory/Mill
Wool Scouring
10002
Wool Finishing
20017
20020
Woven Fabric
Finishing (Simple)
40066
40128
Woven Fabric
Finishing (Complex)
40067
40077
Woven Fabric
Finishing (Desizing)
40047
40142
Knit Fabric
Finishing (Simple)
50037
50117
Knit Fabric
Finishing (Complex)
50019
50034
50065
Carpet Finishing
60001
60021
60029
Direct/
Indirect
I
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
Detention
(hrs)
240
120
999
624
48
288
168
60
336
267
72
576
288
252
210
24
Aer. /Mixing
(Hp/mil.gal)
16
34
4.8
4.7
64
15
26
45
12
0.7
43
38
46
11
6.8
100
Settling
Pond
Yes
Yes
Yes
Yes
Yes
No
Yes
No
No
No
Yes
Yes
No
No
Yes
Yes
No
BODS
(mg/D
80(-)
53(44)
11(88)
95(-)
28(-)
36(66)
52(87)
147(53)
94(74)
45(77)
56(-)
87(-)
13(-)
63(76)
20(-)
78(-)
23(-)
COD
(rag/1)
1096(-)
190(44)
183(69)
2804(-)
177(~)
20(-)
676(19)
814(3)
84(-)
491(54)
133(-)
376(-)
330(~)
TSS O&G
(mg/1) (mg/1)
64(-) 67(-)
17(47)
23(65) —
208(-)
40(-)
27(33)
55(0) 25(-)
99(-)
89(-)
28(60)
54(-)
107(-) 46(-)
31(-)
52(0)
25(-)
85(-)
44(-)
Total Total
Phenols Chromium
(Mg/D (M8/D
76(-) 31(-)
70(77) 131(2)
27(91)
2K-)
32(-)
15(-) 113(0)
84(->
285(-) 15(-)
60(-) 25(-)
Total
Sulfide Color
(Mg/1) (APHA Units)
280(-)
169(97)
—
306(-)
16(-)
266(-)
287(-)
-------
TABLE VI1-8 (continued)
PERFORMANCE OF AERATED LAGOONS IN THE TREATMENT
OF TRADITIONALLY MONITORED POLLUTANTS
DESIGN DATA
EFFLUENT CONCENTRATIONS (% REMOVAL)
Subcategory/Mi 1 1
Stock and Yarn
Finishing
70035
70038
70044
70088
70103
Direct/
Indirect
D
D
D
D
D
Detention
(hrs)
240
75
264
240
240
Aer ./Mixing
(Hp/mil.gal)
23
25
10
26
3,0
Settling
Pond
Yes
No
Yes
Yes
No
BODS
(rag/1)
9(95)
14(87)
1U-)
15(-)
48(-)
COD
(mg/1)
218(74)
130(-)
189(-)
239(-)
TSS OSG
(mg/1) (mg/1)
16(71) —
12(43)
IS(-) 5(-)
24(-)
I9(-)
Total
Phenols
(M8/D
12(-)
52(-)
40(-)
Total
Chromium
(Mg/D
25(-)
21(-)
70(-)
Total
Sulfide
(M8/D
55(-)
236(-) ...
79(-)
Color
(APHA Units)
67(-)
Source: EPA/Industry 308 Study
ro
01
o
-------
TABLE VII-9
PERFORMANCE OF AERATED LAGOONS
IN THE TREATMENT OF TOXIC POLLUTANTS
WOVEN FABRIC FINISHING MILLS (SIMPLE)
Parameter
Mill
40144
Discharge type D
Detention, hrs 168
Mixing, hp/mil gal 18
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal, %) ug/1 %
Benzene
1 , 2-Dichloroethane
1 , 1 , 1-Trichloroethane
Chloroform
Ethylbenzene
Methylene Chloride
Naphthalene
Pentachlorophenol
Phenol
Bis(2-ethylhexyl) Phthalate
Di-n-butyl Phthalate
Toluene
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Silver (Total)
Thallium (Total)
Zinc (Total)
ND
ND
ND
ND
ND
ND
ND
TA
18
ND
ND
ND
ND
52
TA
32
TA
33
TA
13
ND
(100)
(100)
(100)
(100)
(100)
(100)
(100)
(77)
(66)
(100)
(100)
(100)
(100)
(84)
(NC)
(NR)
(NC)
(80)
(100)
(NR)
(100)
ND
ND
ND
ND
ND
ND
ND
TA
18
ND
ND
ND
ND
52
TA
32
TA
33
TA
13
ND
100
100
100
100
100
100
100
77
66
100
100
100
100
84
NC
NR
NC
80
100
NR
100
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
-------
TABLE VII-10
PERFORMANCE OF AERATED LAGOONS
IN THE TREATMENT OF TOXIC POLLUTANTS
WOVEN FABRIC FINISHING MILLS (COMPLEX)
Parameter
Discharge type
Detention, hrs
Mixing, hp/mil gal
Average Effluent
Benzene
Chlorobenzene
Chloroform
1,2-Dichlorobenzene
1 , 1-Dichloroethylene
Ethylbenzene
Methyl Chloride
Naphthalene
N-nitrosodiphenylamine
Phenol
Bis(2-ethylhexyl) Phthalate
Butyl Benzyl Phthalate
Di-n-butyl Phthalate
Tetrachloroethylene
Toluene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Asbestos (MFL)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Zinc (Total)
Mill
40077
D
288
15
Concentration, ug/1 (Removal, %)
TA (NC)
TA (NC)
TA (NC)
TA (NC)
TA (NC)
TA (100)
10 (NC)
TA (NC)
ND (100)
29 (NC)
18 (83)
TA (NC)
TA (NC)
TA (NC)
11 (89)
TA (NC)
39 (NC)
TA (NC)
391 (MR)
TA (NC)
77 (NC)
98 (50)
TA (NC)
TA (100)
ND (100)
66 (80)
TA (NC)
18 (NC)
132 (72)
Subcategory
Average
ug/1 %
TA NC
TA NC
TA NC
TA NC
TA NC
TA 100
10 NC
TA NC
ND 100
29 NC
18 83
TA NC
TA NC
TA NC
11 89
TA NC
39 NC
TA NC
391 m
TA NC
77 NC
98 50
TA NC
TA 100
ND 100
66 80
TA NC
18 NC
132 72
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program 252
-------
TABLE VII-11
PERFORMANCE OF AERATED LAGOONS
IN THE TREATMENT OF TOXIC POLLUTANTS
KNIT FABRIC FINISHING MILLS (SIMPLE)
Parameter
Mill
50030
Discharge type
Detention, hrs
Mixing, hp/mil gal
D
6
750
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal ,%) ug/1 %
Benzene
1,1, 1-Trichloroethane
1 , 1-Dichloroethane
Chloroform
1, 1-Dichloroethylene
Ethylbenzene
Methylene Chloride
Tetrachloroethylene
Toluene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Zinc (Total)
ND
100
TA
TA
TA
TA
ND
18
ND
10
TA
TA
145
68
13
240
(100)
(94)
(NC)
(55)
(66)
(100)
(100)
(95)
(100)
(23)
(NC)
(NR)
(29)
(56)
(NC)
(NR)
ND
100
TA
TA
TA
TA
ND
18
ND
10
TA
TA
145
68
13
240
100
94
NC
55
66
100
100
95
100
23
NC
NR
29
56
NC
NR
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
253
-------
Activated Sludge The activated sludge process is an aerobic
biological process. The basic components consist of an aerated
biological reactor, a clarifier for separation of biomass and a
piping arrangement to return separated biomass to the biological
reactor. Aeration provides the oxygen for aerobic biodegradation
and the mixing to maintain the biological solids in suspension.
The aeration requirements for activated sludge are similar to
those of the aerated lagoon.
The activated sludge process is flexible and adaptable to many
wastewater treatment situations. Factors that are considered in
design include: 1) loading criteria, 2) reactor type, 3) sludge
production, 4) oxygen requirements and transfer efficiency, 5)
nutrient requirements, 6) temperature, 7) solid-liquid
separation, and 8) desired effluent characteristics. Depending
on these factors, the conventional activated sludge process or a
commonly used modification of the conventional process is
selected. The processes that can be used to treat textile
wastewaters include: 1) conventional, 2) complete-mix, 3)
tapered-aeration, 4) step-aeration, 5) modified-aeration, 6)
contact-stabilization, 7) extended-aeration, 8) oxidation ditch,
and 9) pure oxygen.
In the conventional activated sludge process, influent wastewater
and recycled sludge enter the head of the reactor and are aerated
for a period of about 4 to 8 hours. Aeration is by either
diffusion or mechanical agitation and is constant as the mixed
liquor moves through the tank in a plug-flow fashion. Oxygen
demand decreases as the mixed liquor travels the tank length.
The mixed liquor is settled in a conventional clarifier, and the
activated sludge is returned at a rate of approximately 25 to 50
percent of the influent flow rate.
In the complete-mix activated sludge process, influent wastewater
arid recycled sludge enter the reactor from several points along a
central channel running the length of the reactor. The mixed
liquor is aerated at a constant rate as it passes from the
central channel to effluent channels at both sides of the
reactor. The contents of the reactor are completely mixed and
the oxygen demand remains uniform throughout. The aeration
period is from 3 to 5 hours, and the activated sludge is returned
at a rate of 25 to 100 percent of influent flow rate.
The tapered aeration process is a modification of the
conventional process, with the arrangement of the aerators and
the amount of air supplied the primary differences. At the head
of the reactor, where wastewater and returned activated sludge
are mixed, more oxygen is required so the aerators are spaced
close together. As the mixed liquor traverses the aeration tank,
the oxygen demand decreases so aeration is decreased by spacing
the aerators further apart. Because the decreased oxygen supply
is matched to the decreased oxygen demand, less total aeration is
required in the tapered-aeration process.
254
-------
The step aeration process also is a modification of the
conventional activated sludge process. The wastewater is
introduced to each segment of a compartmentalized reactor while
the return activated sludge is introduced at the head of the
reactor. The compartments of the reactor are linked together in
series. Aeration is either diffused or mechanical and is
constant as the mixed liquor moves through the tank in a plug-
flow fashion. Because wastewater is added in each compartment,
the oxygen demand is more uniformly spread over the length of the
reactor than in the conventional activated sludge process. This
results in better utilization of the oxygen supply and reduces
the aeration time. The aeration period is typically between 3
and 5 hours, and the activated sludge is returned at a rate of 25
to 75 percent of influent flow rate.
The modified-aeration activated sludge process is similar to the
conventional or tapered-aeration processes, except that the
aeration period is shorter (usually 1.5 to 3 hours) and the food-
to-microorganism ratio is higher. Activated sludge is returned
at a rate of only 5 to 15 percent of the influent flow rate.
BOD5. removal is approximately 70 percent (for typical sanitary
wastewater).
The contact stabilization process takes advantage of the
absorptive properties of activated sludge by operating the
process in two stages. In the first stage, most of the
colloidal, finely suspended and dissolved organics are absorbed
in the activated sludge in a contact tank. The wastewater and
return stabilized sludge enter at the head of the contact tank,
are aerated for a period of 20 to 40 minutes, and settled in a
conventional clarifier. In the second stage, the absorbed
organics are metabolically consumed providing energy and
producing new cells. In this stage the settled sludge from the
absorptive stage is aerated for a period of from 3 to 6 hours in
a stabilization tank, A portion of the sludge is wasted to
maintain a constant mixed liquor volatile suspended solids
(MLVSS) concentration in the stabilization tank. Total aeration
requirements are approximately 50 percent of those of the
conventional or tapered-aeration plants. However, the. process
usually is not effective in treating industrial waste in which
the organic matter is predominantly soluble.
The extended-aeration process is a complete-mix activated sludge
process in which the aeration period is relatively long (24 to 48
hours) and the organic loading relatively low (16 to 40 kg
BOD5/100 m' or 10 to 25 Ib BOD5/1000 cu ft). Because of these
conditions, the process is very stable and can accept
intermittent loads without upset. In smaller applications, the
reactor and clarifier are generally a single-fabricated unit and
all sludge is returned to the reactor. The mixed liquor solids
concentration is allowed to increase over a period of several
months and then is removed directly from the aeration basin. The
reactor and clarifier are separate in larger applications, and
255
-------
some means of wasting and treating sludge is usually necessary.
Reactors can be concrete with diffused aeration or a lined
earthen basin with mechanical aerators. The extended-aeration
activated sludge process is used by the majority of direct
dischargers in the textile industry.
The oxidation ditch activated sludge process is an extended-
aeration process in which aeration and circulation are provided
by brush rotors placed across a basin shaped like a race track.
The waste enters the ditch at one end, is aerated by the rotors,
and circulates at about 1 to 0.6 m/sec (2 fps). When the
operation is intermittent, the ditch is similar to a lagoon.
During continuous operation, a separate clarifier and piping for
recycling settled sludge are provided and treatment is similar to
activated sludge.
The pure oxygen activated sludge process is a modification of the
complete-mix process in which high purity oxygen, instead of air,
is introduced into the wastewater. Wastewater, returned
activated sludge and oxygen gas under a slight pressure are
introduced at the head of an aeration tank that is divided into
stages by baffles and covered with a gas-tight enclosure. Oxygen
is reintroduced to the mixed liquor by circulation through a
hollow shaft with a rotating sparger device or by surface
mechanical aerators. The mixed liquor passes from compartment to
compartment and is discharged from the last compartment to a
clarifier. Waste gas, which is a mixture of carbon dioxide,
nitrogen and 10 to 20 percent of the oxygen applied, is exhausted
in the last compartment. Reported advantages of the pure oxygen
process are improved oxygen transfer 'efficiency, decreased sludge
volume, reduced aeration tank volume, and improved sludge
settleability.
Industry Application - Ninety-four direct dischargers and 11
indirect dischargers report using activated sludge as part of
their wastewater treatment systems. Fifty-five direct
dischargers rely on activated sludge treatment alone; 24 use
activated sludge followed by unaerated lagoons; 3 use activated
sludge followed by chemical coagulation; 4 use activated sludge
with chemical addition to the activated sludge effluent to aid in
settling; 4 use activated sludge followed by filtration; 2 use
activated sludge followed by aerated lagoons; 1 uses activated
sludge followed by filtration and aeration lagoons; and 1 uses
activated sludge followed by a trickling filter. Nine indirect
dischargers rely on activated sludge alone for pretreatment,
while 2 other mills use activated sludge followed by chemical
coagulation.
Historical Data - The performance of the activated sludge
process in treating textile wastewater is demonstrated in Table
VII-12 for those mills that reported applicable historical
monitoring data. The values reported are averages for each mill
and generally represent data for the year 1976.
256
-------
Seventy-nine of the 82 mills listed are operating their activated
sludge systems with aeration detention times of 24 hours or more,
and all but one use surface aerators for mixing and oxygenation.
The detention periods noted are calculated based on reported
average flow conditions and full basin volumes.
The Agency conducted a detailed study of the effectiveness of
biological treatment in the textile industry using responses to
the EPA industry survey and monitoring data reports. The
extended-aeration mode of operating activated sludge systems is
commonly used by direct discharging mills. An analysis of the
available data indicated that the two principal design variables
affecting the quality of an aeration basin effluent are detention
time (hours) and aeration horsepower per unit volume of the basin
(hp/1000 cu ft). EPA conducted an analysis of treatment plants
with activated sludge biological treatment to determine the
minimum horsepower and detention time which would result in an
effluent meeting the BPT limitations. A total of 69 treatment
plants in subcategories 4, 5, 6 and 7 used activated sludge
biological treatment. The Agency found that 40 of 42 (95
percent) of the plants maintaining a minimum detention time of 40
hours, a minimum of 5.3 kw/1000 cu m (0.2 hp 1,000 cu ft) of
basin hours, and a minimum of 680 kg cal/cu m (0.2 hp per 1,000
cu ft) of basin volume, met the BPT limitations. Figure VII-1
presents this analysis.
Figure VII-1 shows that increasing detention time will compensate
for inadequate aeration horsepower but that the reverse is not
true. This emphasizes the importance of designing aeration
basins with sufficient detention time. Selecting and spacing
aerators for proper mixing and adequate recycle of activated
sludge also are important factors in achieving optimum
performance.
Field Sampling - Sampling was conducted at 32 mills (2 wool
scouring, 1 low water use processing, 15 woven fabric finishing,
4 knit fabric finishing, 3 carpet finishing, 6 stock and yarn
finishing and 1 nonwoven manufacturing) to determine the
effectiveness of activated sludge in the treatment of toxic
pollutants. DetaiIs of the overal1 sampling program are
discussed in Section V. Summaries of the data obtained for these
mills can be found in Tables VII-13 through VII-24.
In addition to the analysis of toxic pollutants, color (ADMI
method) was measured at 11 mills using the activated sludge
process. All measurements were performed at pH 7.6 to allow
comparisons between mills. Table VII-25 shows the effectiveness
of the activated sludge process in removing color.
Biological Beds Biological beds are fixed-growth biological
systems that contact wastewater with organisms attached to the
surfaces of supporting media. Systems that are in common use
include trickling filters, packed towers, and rotating biological
257
-------
TABLE VII-12
PERFORMANCE OF ACTIVATED SLUDGE IN THE TREATMENT
OF TRADITIONALLY MONITORED POLLUTANTS
DESIGN DATA
EFFLUENT CONCENTRATIONS (% REMOVAL)
CO
Direct/
Subcategory/Mill Indirect
Wool Scouring
10006
10015
Wool Finishing
20005
20009
20011
20021
Woven Fabric
Finishing (Simple)
40O23
40035
40050
40098
401OO
40109
40143
Woven Fabric
Finishing (Conplex)
40022
40091
40111
40114
40148
40154
40160
Woven Fabric
Finishing (Desiziog)
40003
40007
40012
40017
40031
40034
40037
40059
40064
40072
D
D
D
D
D
I
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
I
D
D
D
D
Detention
(hrs)
48
77
120
48
36
24
120
24
40
42
320
24
53
24
96
120
36
24
24
240
7
24
96
236
222
86
36
72
120
Aer . /Mixing
(HP/Mil.**!)
343
160
60
100
67
145
38
59
129
71
30
70
60
59
111
50
52
90
80
20
789
500
122
29
10
45
60
41
57
Settling BOD5
Pond (ntft/1)
No
No
No
No
No
No
No
No
Yes
No
No
Yes
No
No
No
Yes
Yes
No
No
Yes
Yes
Yes
No
No
No
No
Yes
No
No
No
60(99)
42(98)
24(-)
25(83)
25(90)
153(67)
5(74)
22(83)
15(89)
12(91)
45(81)
124(74)
9(95)
14(83)
69(81)
24(-)
101(82)
5(98)
3(99)
43(91)
53(-)
73(-)
19(96)
27(-)
15U-)
14(97)
27(-)
24 (~)
42(93)
8(98)
COD TSS
(•R/D («*/!) (
1443(92)
810(89)
212(68)
800(40)
139(36)
307(35)
384(50)
177(54)
409(28)
159(76)
152(51)
301C-)
426 (-)
714(39)
86(-)
452(69)
244(-)
155 (-)
166(98)
297(89)
49(-)
64(63)
61(0)
80(38)
19(98)
38(0)
36(0)
56(0)
49(0)
55(-)
18(36)
35(19)
95(0)
24(-)
5H-)
48(78)
18(62)
105(36)
67(-)
23H-)
9K-)
2K-)
Total
O&G Phenols
BR/1) (Mg/D
.
48(95) 37(-)
— iii(o)
45(76)
20(71) —
— 114(0)
24(-) 56(-)
• 13(-)
17(-)
35(27)
87(-)
20(-)
250(-)
25(-)
112(-)
30(-)
15(-)
Total Total
Chroaium Sulfide
(M8/D (M8/D
«(-)
24(-)
120(74)
20(46)
182(-)
20(-)
31(16)
16(27)
14(-)
17(-)
118(25)
27(-)
9(-)
8(-)
169(-)
22(-)
912(-) 123(-) — 103(-)*11637(-)
254(83)
214(-)
336 (-)
252 (-)
54(72)
15(-)
27(-)
148(-)
8(90)
2(-)
—
5(-)
94(-)
3K-)
219(->
— -
200(-)
57(-)
47(-)
100(0)
28(-)
60(-)
133(-)
lOOO(-)
1000 (-)
1606(-)
1250(-)
Color
(APHA Units)
1887(-)
337(21)
-—
-------
TABLE VII-12 (continued)
PERFORMANCE OF ACTIVATED SLUDGE IN THE TREATMENT
OF TRADITIONALLY MONITORED POLLUTANTS
DESIGN DATA
EFFLUENT CONCENTRATIONS (% REMOVAL]
Direct/
Suhcategory/Mill Indirect
(continued)
Woven Fabric
Finishing (Desizing)
40074
40087
40097
40099
40103
40118
40120
40140
40145
40151
40153
Knit Fabric
1\5 ;Finisbing (Simple)
tn 50008
^° ; 50015
50026
50057
50081
50082
50098
50108
50113
50116
Knit Fabric
Finishing (Complex)
50013
50035
50052
50056
50063
50099
50115
50123
Knit Fabric
Finishing (Hosiery)
5H028
5II029
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
I
D
D
D
-
D
D
Detention
(hrs)
72
120
39
48
45
8
168
60
120
120
60
31
120
432
24
48
264
144
22
141
60
24
72
200
48
96
48
60
72
130
48
Aer. /Mixing
(Hp/mil.Ral)
80
43
248
63
120
2000
63
79
57
84
6.7
77
40
5.4
133
74
29
8.3
64
38
75
133
37
40
60
60
65
113
163
67
667
Settling BOD5
Pond (niR/1)
No
Yes
No
No
Yes
No
Yes
No
No
No
No
Yes
No
No
Yes
No
No
No
Yes
No
No
Yes
No
No
No
No
No
Yes
No
No
No
10(99)
30(-)
23(88)
16(95)
19(98)
14(89)
7(99)
105(84)
7(-)
43(94)
62(88)
14(-)
1K-)
19(-)
21(94)
19(90)
13(94)
139(66)
6(95)
13(93)
5(97)
143(-)
21(86)
24(-)
45(83)
37(82)
1K-)
4(-)
6(99)
63(0)
98(42)
COD
272(-)
594(68)
252(73)
227(60)
181(92)
664(46)
164(81)
199(92)
464(55)
277(-)
744(-)
164(56)
250(53)
533(33)
154(64)
226(70)
124(-)
1752(-)
277(55)
272(-)
354(49)
232(57)
174(-)
291(-)
!«(-)
596(-)
Total Total
TSS O&G Phenols Chromium
(«8/l) (raR/1) (MR/1) (MR/I)
69(63) 14(-)
41(-) 6(-)
44(-)
49(18) 9(-)
21(83) ll(-)
124(42)
57(82)
176(0)
54(-)
67(-) 5(0)
132(0)
20(-)
22(-)
15(-)
35(0) 8(-)
63(34)
71(0) 90(-)
180(0)
11(48)
62(0) 8(-)
18(0)
187(-) 110(-)
116(84)
65(-)
55(0) 32(-)
53(0)
26(~)
27(-)
27(96)
99(1)
347(-)
22C-)
17(-)
47(-)
100(-)
18(-)
132(-)
41(-)
32(-)
72(-)
323(-)
2(-)
100(0)
83(-)
28(-)
46(-)
22(-)
16(20)
l(-)
10(-)
28(-)
18(-)
40(0)
59(-)
.
58C-)
l(-)
11(15)
62(40)
63(-)
25(-)
— :
—
12(-)
100(0)
—
15(-)
66(-)
Total
Sulfide
(M8/D
300(-)
100(-)
—
224(-)
90(-)
126(-)
222(-)
U13(-)
75(-)
100(0)
73(-)
46(-)
Color
(APHA Units)
118(-)
52(-)
321(~)
-------
TABLE VI1-12 (continued)
PERFORMANCE OF ACTIVATED SLUDGE IN THE TREATMENT
OF TRADITIONALLY MONITORED POLLUTANTS
DESIGN DATA
EFFLUENT CONCENTRATIONS (% REMOVAL)
Subcategory/Mill
Carpet Finishing
60005
60013
60018
60034
60037
60039
Stock and Yarn
Finishing
70009
70031
70034
70036
70054
ro i70075
0) | 70084
0 ,70087
i 70089
! 70096
70102
70104
70106
70126
Felted Fabric
Finishing
80025
Direct/
Indirect
D
D
D
D
D
D
D
D
D
D
I
D
D
D
I
D
D
D
D
D
D
Detention
(hrs)
96
60
30
96
192
128
62
36
48
384
48
' 40
58
126
24
65
5664
24
96
40
160
Aer. /Mixing
(HP/nil. gal)
60
83
19
44
40
125
46
80
92
30
500
91
33
14
80
107
3.4
56
114
200
60
Settling
Pond
No
No
No
No
Yes
Yes
Yes
No
No
No
No
No
No
No
No
No
No
Yes
Yes
No
Yes
BODS
(»g/l3
27(-)
54(-)
33(-)
29(87)
36(-)
38(-)
5(94)
6(96)
6(-)
15(-)
233(86)
7(95)
21(93)
21(93)
5(96)
29(-)
16(-)
3(97)
7(99)
73(-)
40(89)
COD
(mg/1)
546 (-)
31U-)
286(-)
227(52)
274(-)
106(71)
124(75)
179(-)
203 (-)
1844(61)
146(73)
268(62)
148(62)
158(-)
204 (-)
134(-)
96(71)
119(93)
176(-)
383(82)
TSS
(mg/1)
113(-)
57(-)
70(-)
50(50)
33(-)
9K-)
9(76)
27(25)
6(-)
35(-)
195(0)
36(47)
71(89)
24(27)
21(55)
24(-)
46(-)
20(38)
10(97)
60(-)
66(23)
Total
O&G Phenols
(mg/1) (Mg/D
100(-)
ao(-)
— —
128(2)
100(-)
6(-) 370(-)
4U-)
186(-)
91(-)
40(-)
56(-)
240(-)
12(-)
192(0) 29(97)
Total
Chromium
(MS/1)
29(-)
22(-)
17(-)
45(-)
42(-)
18(-)
265(61)
14(13)
146 (-)
138(-) ]
Total
Sulfide
(PB/1)
60(-)
67(-)
92(-)
14K-)
185(-)
27(-)
U93(-)
Color
(APHA Units)
309(-)
225 (-)
—
719(-)
Source: EPA Industry 308 Study
-------
1.5
75
0.8--
ro
01
ui
uj
v>
qc
0.6--
0.4-•
0.2-•
FIGURE VII-1
DETENTION TIME VS AERATION HORSEPOWER PER UNIT VOLUME OF BASIN
PLANTS WITH ACTIVATED SLUDGE TECHNOLOGY
O
A
A
A
A
\
AY
O
A
O
°
1.9
A
1.7
I
A
A
O
LEQEND
A Meeting 1977 BPT limitations
O Not meeting 1977 BPT limitation*
O
A 334
A—514
A—417
A— 331,384,384
O 381
A 703
O
o
.— 513
— 7000
.1200
24 48 72 96 120 144 168 192
DETENTION TIME, hrs.
216
240
264
288
312
-------
TABLE VII-13
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
WOOL SCOURING MILLS
Parameter
10006
Mill
10015
Discharge type
Detention, hrs
Mixing, hp/mil gal
D
48
343
Average Effluent Concentration,
Benzene
Hexachlorobenzene
1,1, 1-Trichloroethane
1 , 1-Dichloroethane
Ethylbenzene
Fluoranthene
Phenol
Bis(2-ethylhexyl) Phthalate
Di-n-butyl Phthalate
Diethyl Phthalate
Benzo(a)anthracene
Benzo(a)pyrene
3,4-Benzofluoranthene
Anthracene
Pyrene
Toluene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
ND
ND
ND
ND
TA
ND
ND
ND
ND
m
ND
ND
ND
ND
ND
ND
NA
ND
17
16
658
92
ND
52
TA
25
(100)
(100)
(100)
(100)
(100)
.(100)
(NC)
(92)
(96)
CNR)
(88)
(100)
(83)
(NR)
(99)
D
77
160
ug/1
ND
ND
ND
ND
ND
TA
TA
31
ND
ND
TA
TA
TA
TA
TA
TA
ND
270
21
72
TA
161
110
1779
TA
1030
298
795
Subcategory
Average
(Removal, %) ug/1 %
(100)
(100)
(100)
(NC)
(100)
(»R)
(NO
(NO
(NC)
(NC)
(NC)
(84)
(100)
(NC)
(NR)
(NR)
(17)
(57)
(NR)
(NR)
(NR)
(NR)
(NR)
(53)
ND
ND
ND
ND
ND
TA
TA
16
ND
ND
TA
TA
TA
TA
TA
TA
ND
135
21
36
14
89
384
936
TA
541
154
410
100
100
100
100
100
NC
100
50
100
100
NC
NC
NC
NC
NC
84
100
NC
NR
NR
55
77
NR
44
50
42
NR
76
Note: ND indicates "not detected."
NA indicates "not analyzed."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program 262
-------
TABLE VII-14
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
WOOL FINISHING MILLS
Mill
Parameter
20011
20021
Discharge type D I
Detention, hrs 36 24
Mixing, hp/mil gal 67 145
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal, %) ug/1 %
Benzene
Chlorobenzene
1,2,4-Trichlorobenzene
1,1, 1-Trichloroethane
Parachlorometa Cresol
Chloroform
1 , 2 -Di chlorobenzene
1 ,3-Dichloroben2ene
1 ,4-Dichlorobenzene
2 , 4-Dimethylphenol
Ethylbenzene
Fluoranthene
Methylene Chloride
Trichlorofluorome thane
Naphthalene
N-nitrosodiphenylamine
Pentachlorophenol
Phenol
Bis(2-ethylhexyl) Phthalate
Di-n-butyl Phthalate
Diethyl Phthalate
Dimethyl Phthalate
Anthracene
Phenanthrene
Pyrene
Tetrachloroethylene
Toluene
Trichloroethylene
Heptachlor
Antimony (Total)
ND
ND
ND
ND
TA
ND
TA
ND
TA
TA
19
TA
23
ND
ND
ND
TA
ND
374
TA
TA
ND
TA
ND
TA
TA
TA
ND
ND
TA
(NC)
(97)
(95)
(NR)
(96)
(NC)
(NC)
(100)
(NC)
(100)
(NR)
(NC)
(NC)
(NC)
(NC)
(NC)
(61)
(100)
(NC)
TA
TA
1,257
TA
ND
TA
TA
12
TA
ND
TA
ND
TA
TA
TA
ND
ND
ND
34
ND
ND
ND
TA
TA
ND
TA
12
TA
TA
29
(NC)
(100)
(74)
(100)
(9)
(65)
(98)
(68)
(NC)
(MR)
(NR)
(77)
(100)
(100)
(100)
(63)
(100)
(100)
(17)
(17)
(100)
(NR)
(NC)
(NC)
(17)
TA
TA
629
TA
TA
TA
TA
TA
TA
TA
15
TA
17
TA
TA
ND
TA
ND
204
TA
TA
ND
TA
TA
TA
TA
11
TA
TA
20
NC
100
74
100
NC
9
81
98
82
NR
96
NC
NR
NR
89
.100
100
100
32
NC
100
100
17
17
NC
100
31
100
NC
17
263
-------
Parameter
TABLE VII-14 (Cont.)
Mill
20011 20021
Arsenic (Total)
Asbestos (MFL)*
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Zinc (Total)
TA
24
ND
584
TA
ND
ND
ND
TA
ND
TA
10,296
(NC)
(NR)
(100)
(NR)
(50)
(100)
(MR)
(NC)
(NR)
16
NA
TA
142
28
TA
58
ND
64
TA
35
3,371
(NC)
(NC)
(NC)
(49)
(38)
(HR)
(NR)
(100)
(NR)
(8)
(NC)
(24)
13
24
TA
363
19
TA
29
ND
37
TA
23
6,834
NC
NR
100
25
44
NR
NR
100
NR
8
NC
12
* Values reported as million fibers per liter.
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
264
-------
TABLE VII-15
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
LOW WATER USE PROCESSING MILLS (GENERAL)
Parameter
Mill
30*
Discharge type
Detention, hrs
Mixing, hp/mil gal
Average Effluent Concentration, ug/1 (Removal
Chloroform
Phenol
Bis(2-ethylhexyl) Phthalate
Di-n-tmtyl Phthalate
Toluene
Trichloroethylene
Asbestos (MFL)**
Cadmium (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
10
ND
TA
ND
TA
ND
ND
TA
12
37
84
120
50
2300
(79)
(100)
(62)
(100)
(NR)
(100)
(100)
(NC)
(NR)
(5)
(NR)
(NR)
(NR)
(NR)
Subcategory
Average
, %) ug/1 %
10
ND
TA
ND
TA
ND
ND
TA
12
37
84.
120
50
2300
79
100
62
100
NR
100
100
NC
NR
5
NR
NR
NR
NR
* Data is for POTWs to which mill discharges.
** Value reported as million fibers per liter.
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
265
-------
TABLE VII-16
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
WOVEN FABRIC FINISHING MILLS (SIMPLE)
Parameter
Discharge type
Detention, hrs
Mixing, hp/mil gal
Average Effluent
Acenaphthene
1,2,4-Trichlorobenzene
Hexachlorobeuzene
1 , 2-Dichlorobenzene
Ethylbenzene
Methylene Chloride
Pentachlorophenol
Bis(2-ethylhexyl) Phthalate
Di-n-butyl Phthalate
Dimethyl Phthalate
Anthracene
Toluene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Nickel (Total)
Silver (Total)
Zinc (Total)
Mill
40023
D
120
38
Concentration, ug/1 (Removal, %)
ND (100)
ND (100)
ND (100)
TA (NC)
ND (100)
12 (NC)
17 (NC)
TA (NR)
TA (NC)
ND (100)
TA (NC)
36 (NR)
19 (NC)
13 (NR)
TA (NC)
ND (100)
TA (NC)
105 (26)
17 (NR)
12 (NC)
TA (NC)
248 (26)
Subcategory
Average
HaZiX
ND 100
ND 100
ND 100
TA NC
ND 100
12 NC
17 NC
TA NR
TA NC
ND 100
TA NC
36 NR
19 NC
13 NR
TA NC
ND 100
TA NC
105 26
17 NR
12 NC
TA NC
248 26
Note: ND indicates "not detected."
TA indicates "trace.amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
266
-------
TABLE VII-17
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
WOVEN FABRIC FINISHING MILLS (COMPLEX)
Parameter
Mill
40160
Discharge type
Detention, hrs
Mixing, hp/rail gal
D
240
20
Average Effluent Concentration, ug/1 (Removal,
Benzene
Chlorobenzene
Parachlorometa Cresol
Chloroform
Ethylbenzene
Penta chlo rophenol
Bis(2-ethylhexyl) Phthalate
Di-n-butyl Phthalate
Diethyl Phthalate
Tetrachloroethylene
Toluene
Beta-BHC
Chromium (Total)
Copper (Total)
Zinc (Total)
ND
ND
32
ND
29
56
12
ND
TA
ND
17
TA
140
290
210
(100)
(100)
(MR)
(100)
(99)
(MR)
(90)
(100)
(MO
(100)
(94)
(NR)
(MR)
(43)
(13)
Subcategory
Average
%) ug/1 %
ND
ND
32
ND
29
56
12
ND
TA
ND
17
TA
140
290
210
100
100
NR
100
99
NR
90
100
NR
100
94
NR
NR
43
13
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
NR indicates "no removal."
Source: Field Sampling Program
267
-------
TABLE VII-18
PERFORMANCE OF ACTIVATED SLUDGE IN THE TREATMENT OF TOXIC POLLUTANTS
WOVEN FABRICJ1NISHING_MILLS (DESIZING)
ro
o>
CO
Parameter
Discharge type
Detention, hrs
Mixing, hp/mil gal
Acenaphthene
Benzene
Chlorobenzene
1,2, 4-Trichlorobenzene
1,1, 1-Trichloroethane
1,1-Dichloroethane
2,4, 6-Trichlorophenol
Parachlorometa Cresol
Chloroform
1,2-Dichlorobenzene
1,4-Dichlorobenzene
1 , 1-Dichloroethylene
1 , 2-Tr ans -Dichloroethylene
2 , 4-Dichlorophenol
1,2-Dichloropropane
1 , 3-Dichloropropylene
Ethylbenzene
Methylene Chloride
Dichlo rob romome thane
Trichlorofluoromehtane
Chlorodibromomethane
Naphthalene
2-Nitrophenol
4-Nitrophenol
40
D
48
88
ND
ND
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND
ND (100)
ND
ND
40034*
I
86
45
Average
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
51 (NR)
ND
ND
ND
ND
ND (100)
ND
ND
40059
D
72
41
Mill
40072
D
120
57
Effluent Concentration,
TA (NR)
ND
ND
TA (NR)
ND
ND
ND
ND
ND
TA (NC)
TA (NC)
ND
ND
ND
ND
ND
TA (91)
ND
ND
ND
TA (NC)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND (100)
ND
58 (NR)
ND
ND
ND
ND
ND
ND
ND
TA (84)
ND
ND
ND
ND
TA (NR)
ND
ND
40081*
I
_
-
40097
D
39
248
40099
D
48
63
ug/1 (Removal, %)
ND
33 (42)
ND
ND
ND
ND
ND
TA (NC)
ND
ND
ND
44 (NR)
ND (100)
ND
ND
ND
TA (86)
58 (NR)
ND
ND
ND
ND (100)
ND
ND
ND (100)
ND
ND
ND
TA (92)
ND (100)
ND
ND
TA (25)
ND (100)
ND
ND
ND
ND
ND
TA (NR)
ND (100)
12 (64)
TA (NR)
ND
ND
TA (50)
ND
ND
ND (100)
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND (100)
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND
2138 (NR)
ND
ND (100)
ND (100)
ND (100)
Data is for POTWs to which the mill discharges.
-------
TABLE VII-18 (Cont.)
Parameter
40
40034*
40059
Mill
40072
Average Effluent Concentration
N-nitrosodiphenylamine
Pentachlorophenol
Phenol
Bis(2-ethylhexyl) Phthalate
Butyl Benzyl Phthalate
Di-n-butyl Phthalate
Di-n-octyl Phthalate
Diethyl Phthalate
Dimethyl Phthalate
Anthracene
Pyrene
Tetrachloroethylene
Toluene
Trichloroethylene
Gamma -BHC
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Thallium (Total)
Zinc (Total)
ND
ND
ND
10
ND
ND
ND
TA
ND
ND
ND
ND
TA
ND
ND
TA
31
TA
56
18
105
TA
ND
22
ND
TA
ND
225
(100)
(NC)
(100)
(NR)
(NC)
(NC)
(41)
(NC)
(NC)
(100)
(NR)
(NC)
(100)
(100)
(NR)
ND
ND
ND
35
ND
TA
ND
ND
ND
ND
TA
ND
TA
ND
ND
ND
ND
ND
25
100
ND
ND
ND
90
ND
ND
ND
800
(78)
(57)
(100)
(NR)
(72)
(100)
(48)
(96)
(100)
(7)
(100)
(62)
ND
TA
12
TA
ND
TA
ND
ND
ND
TA
ND
ND
23
ND
ND
50
TA
TA
19
39
TA
74
TA
70
ND
40
ND
142
(NC)
(100)
(93)
(NC)
(100)
(NR)
(100)
(87)
(100)
(NC)
(NC)
(NC)
(11)
(NR)
(NR)
(NR)
(NR)
(7)
(NC)
(NR)
ND
ND (100)
ND
TA (NR)
ND
ND
ND
ND (100)
ND
ND
ND
ND
24 (1?)
TA (NR)
TA (NR)
TA (NC)
ND (100)
ND (100)
TA (47)
15 (42)
ND
ND (100)
ND
ND (100)
ND
ND (100)
ND
110 (27)
40081*
40097
40099
ug/1 (Removal, %)
ND
ND
TA (NC)
15 (76)
TA (85)
TA (41)
ND
ND
ND
ND (100)
ND
51 (NR)
TA (69)
TA (100)
ND
ND
TA (NC)
ND
53 (79)
55 (59)
210 (13)
ND
ND
49 (NR)
ND (100)
15 (NR)
ND
90 (59)
ND
TA (92)
ND (100)
87 (21)
TA (NR)
TA (34)
ND
TA (46)
ND
ND
ND
TA (47)
TA (50)
ND
ND
15 (2)
21 (40)
ND
TA (83)
27 (49)
212 (NR)
ND
ND
ND (100)
TA (100)
ND
ND (100)
137 (71)
ND
ND
ND
231
ND
ND
ND
ND
ND
ND
ND
ND
12
ND
ND
TA
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
960
(100)
(NR)
(100)
(54)
(NC)
(100)
(100)
(100)
(100)
(75)
* Data is for POTWs to which mill discharges.
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
-------
TABLE VII-18 (Cont.)
Parameter
40103
40120
Mill
40145 40146 40150 40156
ro
Discharge type
Detention, hrs
Mixing, hp/mil gal
D
45
120
D
168
63
D
120
57
D
120
16
Average Effluent Concentration, ug/1
Acenaphthene
Benzene
Chlorobenzene
1,2, 4-Tr i Chlorobenzene
1,1, 1-Trichloroethane
1 , 1-Dichloroethane
2 ,4 , 6-Trichlorophenol
Parachlorometa Cresol
Chloroform
1 ,2-Dichlorobenzene
1 , 4-Dichlorobenzene
1 , 1-Dichloroethylene
1 , 2-Trans-Dichloroethylene
2 , 4-Dichlorophenol
1 ,2-Dichloropropane
1 ,3-Dichloropropylene
Ethylbenzene
Methylene Chloride
Dichlorobromome thane
Trichlorofluoromehtane
Chi orodibromome thane
Naphthalene
2-Nitrophenol
4-Nitrophenol
N-nitrosodiphenylamine
Pent a chl o r opheno 1
Phenol
ND
ND
ND
TA (94)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND (100)
ND (100)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
12
(100)
(100)
(100)
(100)
(100)
(100)
(100)
(77)
ND
ND
TA (NR)
ND (100)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
3018 (NR)
ND
ND
89 (NR)
ND
ND (100)
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
21 (89)
D
40
150
D
24
115
Subcategory
Average
(Removal, %) ug/
ND
ND
ND
ND
ND
ND
ND
ND
ND
TA
TA
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
(100)
(100)
(100)
(100)
(NR)
(NC)
(100)
(100)
(100)
(100)
(100)
ND
TA (50)
ND
ND
ND
ND
ND
ND
TA (89)
ND
ND
ND
ND
ND
ND
ND
TA (89)
TA (NR)
ND
ND
ND
ND (100)
ND
ND (100)
ND
ND
ND (100)
TA
TA
TA
TA
TA
ND
ND
TA
TA
TA
TA
TA
ND
ND
ND
TA
239
TA
TA
171
TA
TA
ND
ND
ND
TA
TA
1 %
67
64
50
65
96
100
100
100
69
67
NC
NR
100
100
100
NR
77
41
NR
NR
NC
85
100
100
100
99
96
-------
TABLE VII-18 (Cont.)
ro
Parameter
40103
40120
Mill
40145 40146
40150
40156
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal, %) ug/1 %
Bis(2-ethylhexyl) Phthalate
Butyl Benzyl Phthalate
Di-n-butyl Phthalate
Di-n-octyl Phthalate
Diethyl Phthalate
Dimethyl Phthalate
Anthracene
Pyrene
Tetrachloroethylene
Toluene
Trichloroethylene
Gamma -BHC
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Thallium (Total)
Zinc (Total)
ND (100)
ND
58 (NR)
ND
ND
ND
ND
ND
ND
TA (NR)
ND
ND
TA (NC)
ND
ND
ND
TA (NC)
ND
ND
ND
ND
ND
ND
ND
410 (66)
ND (100)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
50 (NR)
23 (NR)
ND
ND (100)
32 (62)
TA (NR)
ND (100)
ND
93 (60)
ND (100)
ND (100)
ND
429 (39)
TA (95)
ND
ND
ND
ND
ND
ND
ND
ND (100)
111 (NR)
ND
ND
12 (NR)
ND
ND
ND
50 (48)
ND
ND
ND
ND (100)
ND
ND
ND
370 (NR)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
NA (NC)
NA (NC)
ND
ND (100)
26 (49)
TA (5)
61 (11)
ND (100)
ND (100)
NA (NC)
ND (100)
ND
45 (30)
18 (NR)
ND
ND
ND
TA (NR)
TA (NR)
ND
TA (NR)
ND
TA (84)
ND (100)
ND
TA (NC)
ND
TA (NC)
TA (9)
30 (96)
ND
ND (100)
ND
40 (NR)
ND
ND (100)
ND
5100 (35)
TA (100)
ND
TA (NC)
TA (NC)
ND
ND
TA (NC)
ND
TA (NR)
TA (NR)
67 (NR)
ND
22 (NR)
67 (8)
TA (NR)
TA (NR)
TA (NR)
27 (NR)
27 (NR)
ND
55 (33)
ND
21 (NR)
ND
426 (NR)
34
TA
TA
TA
TA
TA
TA
TA
TA
18
TA
TA
17
14
TA
15
32
45
13
TA
32
TA
TA
ND
711
60
43
55
NC
58
NR
50
NR
49
43
60
NR
20
38
50
58
58
3
59
50
59
100
78
100
36
Note: NA indicates "not analyzed."
ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program.
-------
TABLE VII-19
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
KNIT FABRIC FINISHING MILLS (SIMPLE)
Parameter
Discharge type
Detention, hrs
Mixing, hp/mil gal
50108
D
22
64
Mill
50112
D
32
148
50116
D
60
75
Average Effluent Concentration, ug/1 (Removal, %)
Acenaphthene
1,2,4-Trichlorobenzene
1,1, 1-Trichloroethane
1 , 1-Dichloroethane
Chloroform
1 , 2~Dichlorobenzene
1 , 4-Dichlorobenzene
1 , 2-Dichloropropane
1,3-Dichloropropylene
2 , 4-Dimethylphenol
Kthylbenzeae
Trichlorofluoromethane
Naphthalene
2-Nitrophenol
Pentachlorophenol
Phenol
Bis(2-ethylhexyl) Phthalate
Diethyl Phthalate
Dimethyl Phthalate
Fluorene
Tetrachloroethylene
Toluene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Zinc (Total)
ND
TA
ND
ND
ND
ND
ND
ND
10
TA
TA
TA
ND
ND
ND
ND
23
ND
ND
ND
ND
TA
ND
TA
ND
10
TA
130
ND
TA
TA
60
ND
80
570
(100)
(92)
(100)
(100)
(100)
(100)
(100)
CNR)
(NR)
(NR)
(78)
(100)
(100)
(NR)
(100)
(100)
(17)
(NC)
(NR)
(NC)
(78)
(88)
(NR)
(40)
(20)
(NR)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
TA
ND
ND
15
ND
ND
ND
17
ND
ND
673
ND
ND
32
104
ND
24
ND
ND
41
TA
49
(100)
(100)
(100)
(NR)
(100)
(63)
(NR)
(100)
(100)
(NR)
(NR)
(NR)
(100)
(NR)
(100)
(NR)
(NR)
(16)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
TA
ND
TA
ND
ND
ND
ND
NA
70
TA
20
92
TA
48
NA
150
NA
56
68
(100)
(100)
(100)
(100)
(100)
(100)
(NR)
(NR)
(100)
(100)
(NC)
(30)
(NC)
(NR)
(NR)
(NC)
(20)
(NC)
(NR)
(NC)
(3)
(NR)
Subcategory
Average
ug/1 %_
ND
TA
ND
ND
ND
ND
ND
ND
TA
TA
TA
TA
ND
TA
ND
ND
16
ND
TA
ND
TA
TA
ND
342
23
TA
21
109
TA
27
TA
70
21
49
229
100
97
100
100
100
100
100
100
NR
NR
67
78
100
NR
100
100
21
100
NR
100
50
59
100
NR
30
NR
NR
26
100
36
NR
47
NR
8
5
Note: NA indicates "not analyzed."
ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
272
-------
TABLE VII-20
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
KNIT FABRIC FINISHING MILLS (COMPLEX)
Parameter
Discharge type
Detention, hrs
Mixing, hp/mil gal
50013
D
24
133
Mill
50035
D
72
37
50099
D
48
65
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal, %)
Acenaphthene
Benzene
Chlorobenzene
1,2, 4-Trichlorobenzene
1,1, 1-Trichloroethane
1,1,2 , 2-Tetrachloroethane
Chloroform
1 ,2-Dichlorobenzene
1,2-Trans-dichloroethylene
2,4-Dimethylphenol
Ethylbenzene
Methylene Chloride
Naphthalene
N-nitrosodi-n-propylamine
Phenol
Bis(2-ethylhexyl) Phthalate
Butyl benzyl Phthalate
Di-n-butyl Phthalate
Diethyl Phthalate
Dimethyl Phatalate
Acenaphthylene
Anthracene
Tetrachloroethylene
Toluene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
TA
ND
ND
ND
TA
41
ND
TA
TA
ND
TA
ND
ND
TA
TA
ND
TA
ND
ND
ND
ND
317
TA
24
454
TA
TA
TA
14
TA
47
ND
151
16
54
(100)
(100)
(52)
(NR)
(NC)
(NC)
(NC)
(100)
(100)
(NR)
(100)
(NC)
(100)
(100)
(64)
(NC)
(33)
(12)
(NC)
(NR)
(NC)
(69)
(72)
(25)
(NR)
(NR)
(28)
TA
TA
ND
135
ND
ND
128
ND
ND
ND
14
ND
36
ND
TA
21
ND
TA
ND
ND
ND
ND
TA
TA
TA
676
ND
TA
ND
66
ND
40
TA
52
11
77
(NC)
(100)
(NR)
(100)
(87)
(NR)
(NC)
(70)
(NC)
(74)
(66)
(NC)
(NR)
(100)
(NC)
(100)
(NR)
(100)
(NC)
(NC)
(NC)
(NC)
(30)
ND
TA
ND
TA
ND
ND
20
TA
ND
ND
26
TA
TA
TA
TA
40
ND
TA
TA
ND
ND
TA
ND
TA
ND
83
ND
TA
21
12
13
TA
TA
87
21
1046
(NC)
(100)
(NC)
(41)
(NC)
(77)
(NC)
(100)
(NR)
(100)
(NR)
(100)
(100)
(100)
(NC)
(39)
(NC)
(NC)
(100)
(NC)
(26)
(100)
(NC)
(60)
(67)
(30)
ug/1 %
TA
TA
TA
48
ND
TA
63
TA
TA
TA
13
TA
15
TA
TA
24
ND
TA
TA
ND
ND
TA
109
TA
11
404
TA
TA
10
31
TA
32
TA
97
16
392
NC
100
100
NR
100
52
47
NC
NC
NC
82
NC
67
NR
100
23
100
100
100
100
100
NC
69
53
33
6
100
NR
100
35
66
63
NC
30
34
29
Note: ND indicates "not detected."
TA indicates "trace amount,11 less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
273
-------
TABLE VII-21
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
KNIT FABRIC FINISHING MILLS (HOSIERY)
Parameter
Mill
5H034
Discharge type
Detention, hrs
Mixing, hp/mil gal
I
12
250
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal, %) ug/1 %
Acrylonitrile
Naphthalene
N-nitrosodiphenylamine
Phenol
Bis(2-ethylhexyl) Phthalate
Tetrachloroethylene
Toluene
Antimony (Total)
Chromium (Total)
Copper (Total)
Selenium (Total)
Zinc (Total)
400 (75)
TA (NR)
ND (100)
14 (NR)
172 (NR)
ND (100)
TA (NR)
ND (100)
199 (70)
14 (NR)
97 (87)
112 (NR)
400
TA
ND
14
172
ND
TA
ND
199
14
97
112
75
NR
100
NR
NR
100
NR
100
70
NR
87
NR
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
NR indicates "no removal."
Source: Field Sampling Program
274
-------
TABLE VII-22
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
CARPET FINISHING MILLS
Parameter
60008
Mill
60034
60037
Discharge type
Detention, hrs
Mixing, hp/mil gal
I
48
73
D
96
44
D
192
40
Average Effluent Concentration, ug/1 (Removal,
Subcategory
Average
Note: NA indicates "not analyzed."
ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
Acenaphthene
Chlorobenzene
Hexachlorobenzene
Chloroform
1 , 2-Diphenylhydrazine
Ethylbenzene
Dichlorobromomethane
Naphthalene
Phenol
Bis(2-ethylhexyl) Phthalate
Diethyl Phthalate
Fluorene
Toluene
Antimony (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
ND
ND
ND
ND
ND
ND
45
18
ND
ND
ND
105
ND
356
ND
TA
ND
NA
NA
NA
(100)
(100)
(100)
(100)
(100)
(100)
(25)
(36)
(NC)
(NR)
(100)
(NC)
(NC)
(NC)
(NC)
ND
ND
ND
ND
ND
ND
ND
ND
ND
27
ND
ND
ND
NA
TA
170
46
ND
25
79
33
130
(100)
(NR)
(NC)
(NC)
(NR)
(2)
(100)
(24)
(19)
(21)
(NR)
TA
ND
TA
ND
ND
ND
ND
ND
TA
10
11
ND
TA
11
ND
TA
28
TA
ND
13
ND
260
(96)
(NR)
(100)
(100)
(NC)
(47)
(NR)
(100)
(NR)
(79)
(NC)
(56)
(NR)
(100)
(54)
(100)
(42)
TA
ND
TA
ND
ND
ND
ND
ND
18
18
TA
ND
TA
58
TA
179
25
TA
TA
46
17
195
96
100
NR
100
100
100
100
100
63
28
NR
100
NR
79
NC
NR
53
50
62
37
61
21
275
-------
TABLE VII-23
PERFORMANCE OF ACTIVATED SLUDGE IN THE TREATMENT OF TOXIC POLLUTANTS
STOCK & YARN FINISHING MILLS
Parameter
70009
70072
Mill
70081 70087 70096
70120
Discharge type
Detention, hrs
Mixing, hp/mil gal
D
62
46
Average
Acenaphthene
Benzene
Chlorobenzene
1,2, 4-Trichlorobenzene
Hexachlorobenzene
Bis(chloromethyl) Ether
2,4,6-Trichlorophenol
Parachlorometa Cresol
Chloroform
1 , 2-Dichlorobenzene
1 , 4-Dicixlorobenzene
2 , 4-Dichlorophenol
1 ,2-Dichloropropane
2 , 4-Dimethyphenol
2 , 6-Dinitro toluene
Ethylbenzene
Methylene Chloride
Trichlorofluorome thane
Naphthalene .
N-uitrosodi-n-propylamine
Penta chl o ropheno 1
Phenol
Bis(2-ethylhexyl)
Phthalate
Butyl Benzyl Phthalate
ND
ND
ND
ND
TA
ND
ND
ND
TA
TA
ND
ND
ND
ND
ND
ND
ND
10
TA
ND
ND
ND
25
ND
(NR)
(NR)
(NC)
(100)
(NR)
(NC)
(100)
(7D
D
55
140
D
120
114
D
126
14
D
65
107
D
24
150
Subcategory
Average
Effluent Concentration, ug/1 (Removal, %) ug/1 %
ND
ND
ND
ND
ND
ND
ND
TA
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
TA
ND
ND
TA
134
ND
(100)
(100)
(NR)
(100)
(100)
(NC)
(47)
(NR)
ND
TA
ND
27
TA
ND
TA
TA
ND
TA
ND
ND
ND
ND
ND
TA
TA
ND
TA
ND
12
ND
169
TA
(NR)
(90)
(NR)
(100)
(79)
(77)
(88)
(100)
(100)
(100)
(100)
(NC)
(87)
(NR)
(100)
(65)
(NR)
ND (100)
TA (NR)
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND (100)
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND
ND
ND
TA (NC)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND
ND
ND
ND
ND
TA (NR)
ND (100)
TA (NR)
ND
ND
TA (NC)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND (100)
ND
ND
ND
ND
ND
ND
ND (100)
ND
48 (NR)
ND
ND
ND
ND
40 (NR)
ND
ND
TA
ND
TA
TA
ND
TA
TA
TA
TA
ND
ND
ND
ND
ND
TA
TA
11
TA
TA
TA
TA
65
TA
100
NR
100
90
NR
100
79
39
80
88
100
100
100
100
100
100
NC
NR
94
NR
NR
82
34
NR
-------
TABIE VII-23 (Cont.)
Parameter
Mill
70009 70072 70081 70087 70096 70120
Di-n-butyl Phthalate
Diethyl Phthalate
Dimethyl Phthalate
Anthracene
Fluorene
Indeno(l,2,3-cd) Pyrene
Pyrene
Tetrachloroethylene
Toluene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Beryllium (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Mercury (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Zinc (Total)
Average
TA (NR)
TA (NR)
ND
ND
ND
ND
ND
ND
ND
ND
TA (38)
ND
ND
ND
TA (62)
110 (NR)
ND
ND
ND
ND (100)
ND
ND
91 (62)
Effluent Concentration, ug/1 (Removal, %)
ND
12
ND
ND
ND
ND
ND
ND
15
ND
ND
ND
NA
TA
290
ND
29
160
NA
160
NA
57
100
(20)
(100)
(NR)
(NC)
(NC)
(55)
(100)
(NR)
(NR)
(NC)
(20)
(NC)
(16)
(23)
TA C58)
TA (NR)
ND (100)
TA (NR)
ND (100)
ND
TA (NR)
TA (99)
13 (50)
ND (100)
157 (4)
TA (47)
TA (NR)
TA (NR)
76 (NR)
119 (NR)
ND
12 (NR)
ND
ND
ND
ND
250 (50)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
TA
ND
ND
ND
30
96
172
ND
ND
35
ND
ND
720
(100)
(100)
(NC)
(NR)
(68)
(NR)
(100)
(35)
(28)
ND
ND (100)
ND
ND (100)
ND
ND
TA (NR)
ND
ND (100)
ND
ND
ND
NA (NC)
ND (100)
TA (17)
30 (59)
ND (100)
ND
TA (NC)
ND
ND
ND
170 (43)
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
TA
ND
ND
TA
10
ND
36
ND
ND
ND
TA
865
(100)
(100)
(100)
(NC)
(NR)
(72)
(NR)
(100)
(NR)
(NR)
Sub category
Average
ug/1 %
TA
TA
ND
TA
ND
ND
TA
TA
TA
ND
30
TA
TA
TA
71
61
34
35
TA
33
ND
11
366
29
30
100
50
100
100
NR
99
70
100
21
47
NR
50
22
50
33
25
NC
52
100
8
34
Note: NA indicates "not analyzed."
ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
-------
TABLE VII-24
PERFORMANCE OF ACTIVATED SLUDGE
IN THE TREATMENT OF TOXIC POLLUTANTS
FELTED FABRIC FINISHING MILLS
Parameter
Mill
80025
Discharge type
Detention, hrs
Mixing, hp/mil gal
D
160
60
Average Effluent Concentration, ug/1 (Removal,
Subcategory
Average
Naphthalene
Phenol
Bis(2-ethylhexyl) Phthalate
Tetrachloroethylene
Toluene
Trichloroethylene
Vinyl Chloride
Asbestos (MFL)*
Chromium (Total)
Copper (Total)
Selenium (Total)
Zinc (Total)
56
TA
18
ND
ND
ND
ND
TA
35
ND
32
45
(NR)
(88)
(31)
(100)
(100)
(100)
(100)
(NC)
(NR)
(100)
(44)
(NR)
56
TA
18
ND
ND
ND
ND
TA
35
ND
32
45
NR
88
31
100
100
100
100
NC
NR
100
44
NR
* Value reported as million fibers per liter.
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
NC indicates "not able to calculate removal."
NR indicates "no removal."
Source: Field Sampling Program
278
-------
Mill
TABLE VII-25
PERFORMANCE OF ACTIVATED SLUDGE
IN THE REMOVAL OF COLOR
Average Color, ADMI (pH =7.6)
Influent Effluent Average Removal, %
10013
20021
40081
40097
40156
50112
50013
5H034
70081
70120
80025
343*
390
148
253
380
278
121
816
134
312
194
113
210
62
880
114
187
82
898
114
208
283
68
43
58
NR
70
33
32
NR
15
33
NR
* Value for untreated wastewater from finishing plant.
Note: NR indicates "no removal."
Source: Field Sampling Program
279
-------
disks. While the physical structures differ, the biological
process is the same in all of these systems.
As wastewater contacts the supporting media, a thin film of
biological mass__ develops and coats the surfaces. The film
consists primarily of bacteria, protozoa and fungi that feed on
material in the wastewater. Organic matter and dissolved oxygen
are extracted from the wastewater and the metabolic end products
are released. Because the biological mass layer is anaerobic
near the supporting media, hydrogen sulfide, methane and organic
acids are generated. Periodically the mass separates (sloughs
off) from the supporting media and is carried through the system
with the hydraulic flow. The sloughed biomass is typically
removed in a clarifier.
Trickling filters are classified by hydraulic or organic loading
as low or high rate. Low rate filters have a hydraulic loading
rate of 9350 to 37400 cu m/hectare/day (1 to 4 mil gal/acre/day),
an organic loading rate of 136 to 454 kg/hectare/meter/day (300
to 1000 Ib BOD5/acre ft/day), a depth of 1.8 to 3.0 m (6 to 10
ft), and no recirculation. High rate filters have a hydraulic
loading rate of 93500 to 374000 cu m/hectare/day (10 to 40 mil
gal/acre/day), an organic loading rate of 453 to 2265
kg/hectare/meter/day (1000 to 5000 Ib BOD5/acre ft/day), a depth
of 0.9 to 3.0 m (3 to 10 ft), and a recirculation rate of 0.5 to
4. High rate filters have one or two stages. The most suitable
trickling filter media are crushed stone or gravel graded to a
uniform size within the range of 2.5 to 7.6 cm (1 to 3 in. in
diameter. The media must be strong and durable so that it does
not deteriorate.
Biological towers are similar to conventional trickling filters
but with manufactured media instead of crushed rock or gravel
media. The manufactured media are corrugated plastic packing or
rough-sawn redwood slats, both of which are effective in
retaining biological films. The advantages of this type of media
are a high specific surface [(sq m/cu m) (sq ft/cu ft)], a high
percentage of void volume, uniformity for better liquid
distribution, light weight allowing construction of deeper beds,
resistance to chemical reactivity, and the ability to treat high
strength and unsettled wastewaters. Biological towers are used
in flow patterns similar to normal high rate natural media filter
systems. For strong wastewater, two towers are set in series and
settled solids from the final clarifier are returned to the first
tower influent. Because of the increased void space, activated
sludge will build up in the flow and the system will perform as
both a filter, with fixed biological growth, and as a mechanical
aeration system. Biological beds have a hydraulic loading rate
of up to 0.8 1/sec/sq cm (2 gpm/sq ft), an organic loading rate
of from 0.4 to 2.4 kg/cu m/day) (25 to 150 Ib BOD5/1000 cu
ft/day), and a depth of 6.1 m (20 ft).
280
-------
The rotating biological disk makes use of the advantages of the
manufactured plastic media used in the packed tower to increase
the contact time between the wastewater and fixed biological
growth. A series of disks constructed of corrugated plastic
plate and mounted on a horizontal shaft are placed in a tank and
immersed to approximately 40 percent of the diameter. The disks
rotate as wastewater passes through the tank and a fixed film
biological growth, similar to that on trickling filter media,
adheres to the surface. Alternating exposure to the wastewater
and the oxygen in the air results in biological oxidation of the
organics in the wastes. Biomass sloughs off, as in the trickling
filter and packed tower systems, and is carried out in the
effluent for gravity separation. Direct recirculation usually is
not practiced with the rotating biological disk.
Industry Application - Based on the industry survey there
are only three textile mills that utilize biological beds in
their wastewater treatment systems. Two direct discharging woven
fabric finishers use trickling filters. One of these mills uses
a modified approach to the standard filtration process. The beds
are square, 4.3 to 4.9 m (14 to 16 ft) deep, wastewater is
applied continuously, and forced ventilation insures aerobic
conditions throughout. The system obtains 96 percent BOD5.
reduction. The other mill uses a standard high rate trickling
filter as a polishing process after activated sludge treatment.
The overall system performance is 98 percent BOD5. removal and 93
percent COD removal. The third mill uses a rotating biological
disk as an intermediate step between filtration and biological
aeration. This mill is a direct discharger and practices
recovery of dyestuff.
Stabilization Lagoons Stabilization lagoons are a popular
biological treatment process. They are often called lagoons or
oxidation ponds and are classified aerobic, facultative,
anaerobic, and polishing. They are used extensively in the
treatment of municipal wastewater in small communities and in the
treatment of industrial or combined industrial and muncipal
wastewaters that are amenable to biological treatment.
Aerobic lagoons contain bacteria and algae in suspension, and
aerobic conditions prevail throughout the depth. Wastewater is
stabilized as a result of the symbiotic relationship between
aerobic bacteria and algae. Bacteria break down waste and
generate carbon dioxide and nutrients (primarily nitrogen and
phosphorus). Algae, in the presence of sunlight, utilize the
nutrients and inorganic carbon; they in turn supply oxygen that
is utilized by aerobic bacteria. Aerobic lagoons are usually
less than 45 cm (18 in) deep (the typical depth of light
penetration) and are periodically mixed to maintain aerobic
conditions throughout. In order to achieve effective organic and
suspended solids removal with aerobic lagoons, some means of
removing algae (coagulation, filtration, multiple cell design) is
281
-------
necessary. Algae have a high degree of mobility and do not
settle well using conventional clarification.
In facultative lagoons, the bacterial reactions include both
aerobic and anaerobic decomposition. The symbiotic relationship
between aerobic bacteria and algae exists, as in aerobic lagoons,
and anaerobic decomposition takes place by bacteria that feed on
settled solids. Facultative lagoons are up to 1.5 m {5 ft) in
depth and require the same types of provisions for removing algae
if effective pollutant removals are to be realized. Most of the
textile mills reporting use of stabilization lagoons are
operating facultative lagoons.
Anaerobic lagoons are anaerobic throughout their depth and have
the advantage of a low production of waste biological sludge and
low operating costs. Stabilization is accomplished by a
combination of precipitation and anaerobic decomposition of
organics to carbon dioxide, methane, other gaseous end products,
organic acids, and cell tissue. Lagoons are constructed with
depths up to 6 m (20 ft) and steep side walls to minimize the
surface area relative to total volume. This allows grease to
form a natural cover, which retains heat, suppresses odors, and
maintains anaerobic conditions. Wastes enter near the bottom and
the discharge is located on the opposite end below the grease
cover. Sludge recirculation is not necessary because
gasification and the inlet-outlet flow pattern provides adequate
mixing. The anaerobic lagoon is not particularly suitable for
treating textile wastewaters, with the possible exception of wool
scouring waste.
Polishing ponds serve as a polishing step following other
biological treatment processes. They are often called maturation
ponds and primarily serve the purpose of reducing suspended
solids. Water depth is generally limited to 0.6 or 1.0 m (2 or
3) ft and mixing is usually provided by surface aeration at a low
power-to-volume ratio. Polishing ponds are popular as a final
treatment step for textile wastewater treated with the extended-
aeration activated sludge process.
Industry Application - Current use of stabilization lagoons
by the textile mills surveyed is summarized in Table VII-26.
Forty-four direct dischargers and 17 indirect dischargers report
using stabilization lagoons as part of their treatment system.
Three direct dischargers rely on facultative lagoons alone for
treatment; 15 use facultative lagoons following aerated lagoons;
25 use polishing lagoons following activated sludge; and one uses
a polishing lagoon after activated sludge and prior to chemical
coagulation. Fifteen indirect dischargers rely on facultative
lagoons alone for treatment, one uses a facultative lagoon
following an aerated lagoon, and one uses two parallel anaerobic
lagoons prior to activated sludge.
282
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TABLE VII-26
USE OF STABILIZATION LAGOONS BY TEXTILE INDUSTRY - RESULTS OF INDUSTRY SURVEY
Subcategory
Facultative Lagoon
Direct Indirect
Aerated Lagoon +
Facultative Lagoon
Direct Indirect
* One mill follows polishing lagoon with chemical coagulation.
Source: EPA Industry Survey, 1977.
Activated Sludge
+ Polishing Lagoon
Direct Indirect
1.
2.
4.
5.
no
CO
CO
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Woven Fabric Finishing
Knit Fabric Finishing
Fabric Processing
Hosiery Processing
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
All Subcategories
0
0
2
0
0
0
0
1
0
3
2
0
3
7
2
0
2
1
_o
17
0
2
3
3
0
3
4
0
_0
15
0
0
0
0
0
0
1
0
_q
1
1
0
11
5*
0
2
5
1
_0
25
0
0
0
1
0
0
0
0
JO
1
-------
Historical Data - Only one mill reported both influent and
effluent monitoring data for the lagoon portion of their
treatment system. However, several of the mills employing
facultative lagoons alone for treatment or pretreatment provided
effluent data. These data are presented in Table VII-27. The
general effectiveness of the lagoons can be established by
comparing the effluent concentration with those presented earlier
in this section for aerated lagoons and activated sludge.
Field Sampling - Although a number of textile mills use
polishing lagoons as a final treatment step (see Industry
Application), there are limited historical data available to
demonstrate the effectiveness of the lagoons in treating
conventional, nonconventional and toxic pollutants. Sampling was
conducted around the polishing lagoons at a stock and yarn
finishing and at a felted fabric processing mill where polishing
ponds are used after activated sludge treatment. Analytical
results do not demonstrate any significant improvement in
effluent quality. Because only single 24 hour composite samples
were obtained, these results are not conclusive. The detailed
results of this sampling episode can be found in the field
sampling results in the administrative record for mills 70120 and
80025.
Chemical Processes
Coagulation/Sedimentation Suspended sol ids (TSS) are a
significant constituent of most textile mill wastewaters. The
larger solids are removed in preliminary treatment steps but a
variety of colloidal particulates remain even after biological
treatment. Besides fiber, these solids include color bodies,
soaps, fine mineral particulates, oil and grease and microscopic
organisms. The wastewater from carpet mills, other adhesive
related processing mills, and nonwoven manufacturing facilities
may, in addition, contain considerable amounts of latex.
Coagulation/sedimentation can be used to remove these pollutants.
Coagulation is the process by which chemicals are used to
destabilize suspended material so that the particles agglomerate.
Two forces, hydration, which results in a protective shell of
water molecules, and electrostatic charge keep small particles
apart and lead to a stable, colloidal suspension. Most colloidal
particles carry a characteristic negative charge and are unable
to coalesce because of to this electrostatic repulsion.
Neutralization of these repulsive forces by the addition of
multivalent cations attracts the particles together. The weight
of the coagulated particles results in sedimentation (20).
The most effective inorganic coagulants for wastewater treatment
are alum (aluminum sulfate), copperas (ferrous sulfate), lime
(calcium hydroxide), ferric chloride, and ferric sulfate. The
multivalent cation (Al+3, Fe+3) enters into a series of
hydrolytic reactions to form multivalent positively charged
284
-------
TABLE VII-27
PERFORMANCE OF STABILIZATION LAGOONS
IN THE TREATMENT OF TRADITIONALLY MONITORED POLLUTANTS
Subcategory Mill
Discharge
Average Effluent Concentration, mg/1
BODS COD TSS
4c
4c
4b
5b
5b
5a
5c
7
7
8
8
40014
40065
40038
50023
50045
50069
5H049
70023
70122
80027
80014
Direct
Direct
Indirect
Indirect
Indirect
Indirect
Indirect
Indirect
Indirect
Direct
Indirect
53
35
482
325
145
141
211
233
111
17
79
175
115
2186
810
-
862
548
634
789
-
-
14
35
18
40
-
-
-
59
945
29
179
Source: EPA Industry Survey, 1977
285
-------
hydrous oxide species that are adsorbed onto the negatively
charged colloid. This neutralizes the colloidal system and
allows the particles to agglomerate.
Because these chemical reactions are instantaneous, a rapid mix
process is used to mix the coagulant with the wastewater. This
brief mixing provides a complete dispersion of the coagulant
throughout the wastewater but is not long enough for
agglomeration to take place. The second stage of the process,
flocculation, promotes interparticle contact of the stabilized
colloids to form a floe that is removed in the final stage of the
process, sedimentation.
In addition to the coagulants noted, polyelectrolytes (polymers)
are used as coagulants or as coagulant aids. These compounds
contain repeating units of small molecular weight, combined to
form a molecule of colloidal size. Each of the repeating units
carries one or more electrical charges or ionizable groups.
Because of their large size, the major benefit of
polyelectrolytes is an increase in floe size. It is generally
agreed that a "bridging" mechanism is responsible for
flocculation enhancement. One end of the polymer molecule
attaches itself to the surface of a suspended particle at one or
more sites and the free end is able to adsorb onto yet another
suspended particle forming a "bridge" between the two. This
union increases the mass of the colloidal-polymer system and
increases the settling velocity. As the particle settles, it
entraps other colloids and polymers and thus clarifies the
wastewater with a "sweep floe" effect.
Industry Application - Thirty-four of the wet processing
mills surveyed report that chemical coagulation is employed in
their wastewater treatment system. Sixteen of these mills are
direct dischargers, 15 are indirect dischargers, 2 practice
complete recycle and one discharges to an evaporation lagoon
after coagulation. At 13 of these mills, coagulation is used for
the treatment of latex or printing wastewater, 10 of these mills
are indirect dischargers, which is two-thirds of all the indirect
discharge mills that identify coagulation as part of their
treatment system. Of the direct dischargers using coagulation
for treatment of wastewater other than latex or print wastes, two
employ it as a last step after biological treatment, six add
polymer and/or alum to the effluent from an aeration basin prior
to secondary sedimentation, two coagulate as an intermediate step
between activated sludge and filtration, and two coagulate in
place of biological treatment. The use of coagulation at two
mills was unclear from the survey results.
Historical Data - Based on the above breakdown, there are
only two mills of the thirty-four presently using coagulation as
their principal treatment process and 6 mills (4 direct
dischargers and 2 recycle) that employ coagulation as an advanced
treatment measure. However, because of the nature of the
286
-------
historical data available from these mills, i.e., influent and
effluent data for the entire treatment systems, the effectiveness
of the chemical coagulation process alone cannot be determined.
The performance of the treatment systems that include coagulation
are presented in Table VII-20. The concentrations generally
represent average values for the year 1976 for those mills that
provided historical monitoring data.
Literature/Research Coagulation of textile wastewater has
received considerable attention from the engineering and research
communities. Much of the work is general and does not address
adaptability to high volume textile discharges. Some of the
studies are specific to individual wastewater streams and are not
applicable to total mill effluent performance. The following
cases offer relevant information on studies that are applicable.
In addition to the laboratory and full-scale studies presented,
two mills with full scale systems were sampled during the field
sampling program. The results of this sampling are included with
the other cases.
In case 1_ a laboratory study performed in 1974(68) evaluated
coagulation using alum in removing color from a dyehouse
effluent. The effluent was from a woven fabric finishing mill
that processes cotton-polyester broadwoven fabrics. The types of
processing performed and the types of dye utilized were not
provided by the author.
The mill's dyehouse wastewater, boiler blowdown, and air
conditioning condensate were being treated in a two-stage aerated
lagoon. Approximately 50 percent removal of BOD was achieved
prior to discharge to a small creek.
The study used a jar test apparatus to conduct a series of
coagulation investigations using various dosages of alum. The
results, which are presented in Table VII-29, establish the
feasibility of removing COD and color from the dyehouse
wastewater prior to biological treatment.
In case 2 a laboratory study was performed to evaluate
coagulation of textile mill printing waste. The waste studied
was collected from the discharge line of the printing department
of a large woven fabric finishing-desizing facility. The
facility dyes and/or prints sheets, and the wastewater streams
resulting from the dyeing and printing operations are segregated.
The waste from the printing department contained printing
pigment, adhesives, an acrylic latex emulsion, and varsol (print
paste carrier). These constituents are typically suspended in
the wastewater in particulate or colloidal form and are not
readily solubilized by microorganisms when subjected to
biological treatment.
A series of jar test experiments were performed using ferric
chloride, ferric sulfate and aluminum sulfate. The experiments
287
-------
TABLE VII-28
PERFORMANCE OF CHEMICAL COAGULATION IN THE TREATMENT
OF TRADITIONALLY MONITORED POLLUTANTS
ro
oo
GO
Sub cat-
egory
Mill
Coagulant(s)
Treatment Step
BODS, mg/1
Inf# Eff
COD, mg/1
Inf# Eff
TSS,
Inf#
mg/1
Eff
(Direct Dischargers)
2
4b
4b*
4c
4c
4c*
4c*
5a
5a
5a
7
7
8
20009
40022
40126
40130
40145
40150
40156
50030
50052
50112
70072
70105
80016
Alum, Polymer
Alum
-
-
Polymer
Ferric Chloride,
Lime
-
-
Polymer
Polymer
Alum, Polymer
Copperas, Lime
-
Secondary Clarifier
Secondary Clarifier
Flotation Unit
Secondary Clarifier
Secondary Clarifier
Coag/Floc - Raw Waste
-
Coag/Floc - Secondary
Secondary Clarifier
Injection Prefiltration
Secondary Clarifier
Secondary Clarifier
Flotation-Post Biolo-
gical
150
83
-
200
-
-
760
334
-
279
327
60
-
25
14
51
51
7
4
12
24
24
5
20
15
6
900
308
-
845
846
1,400
1,600
1,265
-
934
1,572
331
-
_
152
482
663
164
99
248
206
272
196
480
129
-
175
43
-
82
-
168
420
-
-
41
26
31
-
64
35
188
142
54
30
99
40
65
7
23
11
14
(Indirect Dischargers)
2
4a*
4c*
4a**
4a*
4a*
20022
40001
40081
40112
40124
40144
Lime
Lime, Alum
Ferric Chloride
Aluminum Chloride
Alum
Alum
Coag/Floc - Raw Waste
Flotation
Coag/Clarify-Print Waste
Flotation-Print Waste
Coag/Clarify-Print Waste
(Recycle Mill)
Flotation
_
-
-
-
322
298
_
250
420
341
126
10
1,328
-
-
-
1,985
-
556
400
695
885
263
1,550
_
-
-
-
460
-
560
30
118
206
72
5
* Fabric printing is a significant portion of production.
** Latex and PVC coating operation.
# Influent indicates raw waste concentration not influent to coagulation/sedimentation.
Source: EPA Industry Survey, 1977.
-------
TABLE VII-29
CASE 1 - LABORATORY STUDY OF
CHEMICAL COAGULATION ON DYEHOUSE EFFLUENT
Total
Alum Dosage, mg/1
as
A12(S04)3 18H20
660
660
550
440
440
440
330
COD,
Inf*
935
903
1,590
1,030
973
954
805
mg/1
Eff**
490
471
598
525
590
573
398
Soluble
COD,
Inf
582
-
667
' 730
-
740
mg/1
Eff
429
-
559
335
-
519
TSS,
Inf
132
-
590
-
-
-
"
mg/1
Eff
49
-
12
-
-
-
"
Color,
Inf
12,800
10,200
8,800
7,700
11,000
12,200
11,800
APHA
Eff
580
288
428
450
442
340
690
* "Inf" represents dyehouse effluent
** "Eff" represents supernatant from jar test after 1 hr settling
Source: Reference 68.
TABLE VII-30
CASE 2 - LABORATORY STUDY OF CHEMICAL COAGULATION
ON A PRINTING WASTE STREAM
Dosage, mg/1
Coagulant of Metal+3
Ferric
Ferric
Chloride
Sulfate
Aluminum Sulfate
25
25
25
PH
6.
7.
6.
6
1
6
Turbidity, JTU
Inf Eff
270
270
270
19
26
14
COD,
Inf
2,100
2,100
2,100
mg/1
Eff
665
155
235
Source: Reference 69.
289
-------
reported here consisted of: placing a one-liter sample into a
standard flocculation vessel and stirring at 100 rpm; adding the
desired quantity of coagulant and adjusting the pH with HC1 or
NaOH; mixing for one minute after pH adjustment at 100 rpm and
flocculating for two minutes at 10 rpm; and quiescent settling
for 30 minutes followed by analysis. Results are presented in
Table VII-30 for removal of suspended and colloidal materials.
In case 3. the results of a full-scale investigation of activated
sludge and alum coagulation treatment of the wastewater from a
knit fabric finishing - simple processing mill are summarized.
The investigations were supported by an EPA Demonstration
Grant(24), and were conducted over a 1 year period.
At the time of the study, the mill was producing velour fabric
for the apparel trade (approximately 56 percent), nylon fabric
for the automotive industry (approximately 13 percent), fabric of
polyester/nylon blends for the uniform trade (approximately 13
percent), and various other fabrics each at less significant
production levels.
During the study period, the mill's daily production ranged from
a low monthly average of approximately 14,790 kg (34,000) Ibs to
a high monthly average of approximately 24,800 kg (57,000) Ibs.
Average daily production was approximately 20,900 kg (48,000
Ibs). The production was pressure beam-dyed (approximately 54
percent), atmospheric beck-dyed (approximately 27 percent), or
pad-dyed (approximately 17 percent). Approximately 30 percent of
the dyestuff utilized was of the disperse class and 20 percent
was of the acid class. Besides dyeing, the production was
scoured and various functional finishes (water repellents,
softeners, and flame retardants) were applied.
The wastewater treatment system included heat reclamation,
equalization, activated sludge (aerated lagoon plus clarifier),
alum coagulation, chlorination, and mechanical sludge processing
(horizontal scroll centrifuge). Each component of the treatment
system was evaluated. The performance of the alum coagulation
component throughout the study period is presented in Table VII-
31 for the parameters of primary concern here.
As part of the field sampling program sampling was performed at a
woven fabric finishing-desizing mill that performs desizing,
scouring, bleaching and dyeing to produce finished woven goods.
Piece dyeing accounts for approximately 90 percent of the
production. No production figures were reported for the sampling
period. The processing operations result in a wastewater
discharge of 4,730 cu m/day (1.25 mgd).
Wastewater treatment at this mill consists of static screening,
mixed equalization, aeration (1 basin), secondary sedimentation,
chemical addition, clarification, a polishing pond and
disinfection (chlorine). Aeration detention time is
290
-------
TABLE VII-31
CASE 3 - FULL SCALE CHEMICAL COAGULATION AT A
KNIT FABRIC FINISHING MILL
Parameter/Pollutant
Influent
(yearly median)"
Effluent
(yearly median)*
BODS, mg/1
COD, mg/1
TOG, mg/1
TSS, mg/1
Dissolved Solids, mg/1
Phenolics, ug/1
Color, APHA Units
Chromium, ug/1
Copper, ug/1
Lead, ug/1
Nickel, ug/1
Zinc, ug/1
Mercury, ug/1
122
1,056
200
368
619
30
804
360
30
28**
-I A*Xi»Ad
i(Jnn
220
1.8**
33
416
105
122
600
40
320
280
ND
23**
10**
110
1.7**
* Samples were collected daily and daily analyses were performed
for all parameters listed except phenolics and metals; the
samples for these parameters were combined into a composite
sample and analyzed once per month.
** average value
Note: ND indicates "not detected."
Source: Reference 70.
291
-------
approximately 24 hours, and air is provided by surface aerators
with a total power-to-volume ratio of approximately 325 kwh/1000
cu m (115 hp/million gal).
Three 24 hour composite samples were collected over a typical 72-
hour period of operation of the raw waste stream, the effluent
from the biological clarifiers, the effluent from the chemical
clarifiers, and the effluent from the chlorine contact tank. The
results presented in Table VII-32 demonstrate the effectiveness
of chemical coagulation in treating toxic, nonconventional and
conventional pollutants.
Sampling was also performed at a stock and yarn finishing mill
that used chemical coagulation after aerated equalization. The
processing operations result in a wastewater discharge of 1,770
cu m/day (467,000 gpd).
Wastewater treatment at this mill consists of aerated
equalization, chemical addition (ferric chloride), flocculation,
clarification, and filtration. The discharge from the treatment
plant is recycled for reuse in the mill operations.
Three 24 hour composite samples were collected over a typical 72-
hour period of operation at the discharge from the equalization
basin, at the discharge from the chemical clarifiers, and at the
discharge from the clear well following the filters. The results
are presented in Table VII-33.
EPA/Industry Field Studies In a joint research effort
between EPA and the textile industry (ATMI, NTA, and CRI), pilot
plant studies were conducted during 1977 and 1978 at 19 textile
mills to evaluate the effectiveness of alternative advanced
wastewater treatment technologies. The studies were performed on
the effluent from treatment systems using extended aeration
activated sludge. One of the technologies was chemical
coagulation using a 6,245 liter (1,650 gallon) reactor/clarifier.
Prior to initiating the pilot plant studies, jar testing was
performed to determine the coagulant(s) and dosage(s) most
effective for removal of suspended solids and organic material.
Among the coagulants evaluated were alum, ferric chloride,
polymers and lime, individually and in various combinations. The
jar tests established operating conditions for the
reactor/clarifier during screening (comparison) experiments
against other treatment modes. Based on the comparisons,
promising modes were selected for more extensive study in
candidate process evaluations. The effectiveness of
precoagulation on filtration effectiveness also was studied.
These experiments are discussed later (see Filtration).
Chemical coagulation was included as the first treatment step in
the selected candidate process modes at 10 of the 19 mills
studied. Processing information, waste treatment information,
and statistical summaries of the results of the pilot plant
292
-------
TABLE VII-32
FULL SCALE CHEMICAL COAGULATION AT A
WOVEN FABRIC FINISHING (DESIZING) MILL
Parameter/Pollutant
Biological
Effluent
Min Max n
Chemical Clarifier
Effluent
Min Max n
Conventional & Nonconventional Pollutants
COD, mg/1 184 343 3
TSS, mg/1 7 13 3
Sulfide, ug/1 4 41
Color, ADMI Units 107 135 3
Color, ADMI Units (pH 7.6) 100 134 3
Toxic Pollutants ug/1
23
ND
3
40
47
50 3
3 3
3 1
70
79
Total Phenols
Bis(2-ethylhexyl) Phthalate
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
14
ND
TA
12
61
TA
TA
26
ND
ND
11
416
17
13
130
28
71
10
13
27
49
95
36
434
3
3
3
3
3
3
3
3
3
3
3
3
16
ND
ND
ND
58
ND
ND
27
ND
36
13
406
40
22
140
16
70
TA
10
30
34
47
18
442
3
3
3
3
3
3
3
3
3
3
3
3
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at less
than 10 ug/1 in the influent and/or effluent: Benzene;
Chlorobenzene; 1,2,4-Trichlorobenzene; Chloroform;
Ethylbenzene; Methylene Chloride; Dichlorobromomethane;
Di-n-butyl Phthalate; Di-n-octyl Phthalate; Diethyl
Phthalate; Anthracene; Tetrachloroethylene; Toluene;
Cadmium.
Source; EPA Field Sampling Results for Mill 40156, August 1978
293
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TABLE VII-33
FULL SCALE CHEMICAL COAGULATION AT A STOCK
AND YARN FINISHING MILL
Parameter/Pollutant
Raw
Waste
Chemical Clarifier
Effluent
Min Max n
Conventional & Nonconventional Pollutants
COD, rag/1
TSS, mg/1
Sulfide, ug/1
Color, ADMI Unit
Color, ADMI Unit (pH 7.6)
736
58
420
140
114
426
30
25
71
75
722
65
170
108
108
Toxic Pollutants, ug/1
1,2, 4-Trichlorobenzene
Parachlorometa Cresol
2-Chlorophenol
1 , 2-Dichlorobenzene
Naphthalene
2-Nitrophenol
4-Nitrophenol
N-nitrosodi-n-propylamine
Total Phenols
Phenol
Bis(2-ethylhexyl) Phthalate
Trichloroethylene
Antimony (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
10
ND
TA
ND
240
ND
69
ND
22
TA
200
23
40
63
146
51
141
ND
ND
60
ND
TA
92
ND
ND
66
TA
10
TA
51
16
TA
48
128
42
42
18
80
60
45
100
92
ND
32
110
140
190
26
78
24
12
98
148
51
1,790
3
3
1
3
3
1
3
3
3
3
3
3
3
3
3
3
3
3
3
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at
less than 10 ug/1 in the influent and/or effluent:
Benzene; Chlorobenzene; 1,1,2,2-Tetrachloroethane;
2,4,6-Trichlorophenol; Chloroform; 2,4-Dimethylphenol;
Ethylbenzene; Methylene Chloride; Trichlorofluoromethane;
Di-n-butyl Phthalate; Diethyl Phthalate; Anthracene;
Phenanthrene; Tetrachloroethylene; Toluene; Arsenic;
Cadmium; Selenium.
Source: EPA Field Sampling Results for Mill 70, August 1978.
294
-------
studies during the candidate process evaluations at each of these
mills is included in the administrative record. In addition to
the regular pilot plant testing, sampling was conducted at
selected mills to evaluate the performance of chemical
coagulation in the treatment of toxic pollutants. The detailed
results of the sampling at each mill also are included in EPA's
administrative record.
The data from these studies are summarized in Tables VII-34 and
VII-35 for wool finishing mills and for all other mills in Tables
VII-36 and VII-37.
Precipitation Precipitation is a chemical unit process in which
undesirable soluble metallic ions are removed from water or
wastewater by conversion to an insoluble form. It is a commonly
used treatment technique for removal of hardness (calcium,
magnesium, strontium, ferrous iron, and manganous ions and other
metals) and phosphorus. The procedure involves alteration of the
ionic equilibrium to produce insoluble metallic hydroxides that
can be easily settled in a clarifier. The hydroxide is usually
supplied in the form of lime (Ca(OH}2).
For example, a precipitation reaction involving
magnesium ions (Mg+2) with lime is:
the removal of
Mg+2 + S04-2
Ca(OH}2 = Ca+2 + S04-2 + Mg(OH)2
Metallic hydroxides have an optimal pH where they are most
insoluble. For Mg(OH)£, noted in the equation above, 10.8 is
considered optimal. When precipitation of several metals is
required, a pH of about 9 is often useful in practice.
In order to precipitate hexavalent chromium (Cr+6), a pollutant
found in textile wastewaters, it first must be reduced to the
trivalent state (Cr+3). The reducing agents used are ferrous
sulfate, sodium metabisulfate, and sulfur dioxide. If ferrous
sulfate is used, acid must be added for pH adjustment.
Industry Application - Precipitation was not reported as a
treatment method by any of the direct or indirect dischargers
surveyed. One possible reason why this technology is not favored
is that some of the auxiliary chemicals used in dyeing can act as
complexing agents with metals. These chemicals act as chelates
and make the metals less susceptible to precipitation.
Literature/Research - Literature describing the treatment of
textile wastewaters by precipitation is limited. The only
applicable research study (21) compared chemical precipitation
with lime and sulfide.
295
-------
TABLE VII-34
SUMMARY OF RESULTS - EPA/INDUSTRY FIELD STUDIES
CHEMICAL COAGULATION AT WOOL FINISHING MILLS
TRADITIONALLY MONITORED POLLUTANTS
Parameter
Mill
B B
Loading rate, gpd/sq ft
Alum as Al+3, mg/1
400 520 400
35 35 7
Average Effluent Concentration
BOD, mg/1 33 17* 2.5
COD, mg/1 212 216 111
TSS, mg/1 20 82 31
TOC, mg/1 71 77 30
Total Phenols, ug/1 20* - 41
Color, ADMI Units (pH 7.6) 106 - 67
Subcategory
Average
18
180
44
59
41
87
Average Removal
BOD
COD
TSS
TOC
Total Phenols
Color
80
75
81
75
0*
76*
93*
73
69
71
-
"
, Percent
56
33
41
10
27
30
Subcategory
Average
68
60
64
52
27
30
*Value represents a single data point and was not included in calcu-
lating subcategory average.
Source: EPA/Industry Field Studies
296
-------
TABLE VII-35
SUMMARY OF RESULTS - EPA/INDUSTRY FIELD STUDIES
CHEMICAL COAGULATION AT WOOL FINISHING MILLS
TOXIC POLLUTANTS
Parameter/Pollutant
Mill
B
Loading rate, gpd/sq ft 400 - 520
Alum as Al+3, mg/1 27 - 35
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1
1,2,4-Trichlorobenzene
1 , 2-Dichlorobenzene
Bis(2-ethylhexyl)Phthlate
Toluene
Antimony (Total)
Arsenic (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
154 (90)
ND (100)
44 (MR)
14 (55)
32 (NR)
62 (NR)
41 (65)
16 (30)
30 (NR)
57 (25)
172 (NR)
5730 (11)
154
ND
44
14
32
62
41
16
30
57
172
5730
90
100
NR
55
NR
NR
65
30
NR
25
NR
11
Note: ND indicates "not detected."
NR indicates "no removal."
Source: EPA/Industry Field Studies
297
-------
TABLE VII-36
SUMMARY OF RESULTS - EPA/INDUSTRY FIELD STUDIES
CHEMICAL COAGULATION
TRADITIONALLY MONITORED POLLUTANTS
Parameter
BB
Mill
Q Q
EE
Subcategory 4b 4c 5b 5a 5a 6 7 7
Loading rate, gpd/sq ft 100 400 400 400 320 400 400 400
Alum as Al+3, mg/1 120 40 - 20 30 30
Anionic Polymer, mg/1 - 0.75 0.75 1
Cationic Polymer, mg/1 - - 20 - 35 20
Average Effluent Concentration
Average
BOD,
COD,
TSS,
TOC,
Total
Color
BOD
COD
TSS
TOC
Total
Color
Note:
mg/1
mg/1
mg/1
mg/1
Phenols, ug/1
, ADMI Units
(pH 7.6)
Phenols
( ) indicates "
Source : EPA/ Indus try
12
162
60
43
65
189
50
56
38
55
27
50
3.6
352
51
72
-
263
50
8.9
9.8
4.9
-
1.2
less than"
Field
10
124
13
24
52
47
Average
48
50
69
12
14
69
value.
5.4
195
73
-
-
196
3.8
178
61
22
-
133
Removal,
29
26
0.4
-
-
19
59
38
10
29
-
50
7.4
142
28
26
60
164
(2)
93
26
36
(20)
44
6.1
83
19
6.8
-
90
Percent
85
68
61
69
49
54
24
29
14
18
-
73
80
22
41
37
-
64
6.3
166
41
33
49
141
Average
53
37
30
32
30
48
Studies
298
-------
TABLE VII-37
SUMMARY OF RESULTS - EPA/INDUSTRY FIELD STUDIES
CHEMICAL COAGULATION
TOXIC POLLUTANTS
Mill
Parameter/Pollutant
V
Subcategory
Loading rate, gpd/sq ft
Alum as Al+3, mg/1
Polymer, mg/1
4c
400
40
-
5b
400
-
20
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1 %
Benzene
Chloroform
1 , 2-Dichlorobenzene
Phenol
Bis (2-ethylhexyl)Phthalate
Toluene
Antimony (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
13 (NR)
16 (30)
34 (NR)
TA (33)
123 (NR)
17 (NR)
11 (81)
66 (NR)
ND
72 (10)
195 (NR)
TA (NR)
28 (33)
TA (NC)
226 (NR)
13 (29)
ND
14 (44)
TA (90)
m (100)
ND (100)
14 (35)
ND
48 (97)
TA
14
12
121
24
TA
69
14
TA
33
TA
36
122
NR
33
NR
15
15
33
22
45
91
50
35
10
49
Note: NC indicates "not able to calculate removal."
ND indicates "not detected."
NR indicates "no removal."
TA indicates "trace amount," less than 10 ug/1.
Source: EPA/Industry Field Studies
299
-------
The sulfide removes heavy metals from solution as it precipitates
because metal suIf ides are several orders of magnitude less
soluble than the corresponding metal hydroxides. This process is
useful in the removal of hexavalent chromium because prior
reduction to trivalent chromium is unnecessary.
A wastewater sample from the aeration basin of a knit fabric
finishing-complex processing mill was used in the research. The
mill dyes 95 percent of the production. The dyes are: acid (64
percent), direct (32 percent), sulfur (2 percent), dispersed (1
percent), and reactive (1 percent) dyes. Analytical results are
summarized in Table VII-38.
Oxidation Oxidation is a chemical unit process that is used in
wastewater treatment for removal of color and ammonia, reduction
of organics and reduction of bacteria and viruses. The
disinfection of wastewater with chlorine is the most common form
of oxidation used. Other available and tested oxidants include:
hydrogen peroxide, potassium permanganate, chlorine dioxide, and
ozone. Ozone oxidation is favored in the treatment of industrial
wastes.
Ozone (03,) is a faintly blue, pungent-smelling, unstable gas that
exists as an allotropic form of oxygen. Because of its
instability, ozone is generated on-site. Ozone generators use a
corona discharge that occurs when a high-voltage alternating
current is imposed across a discharge gap. Approximately 10
percent of the applied energy directly results in the conversion
of oxygen into ozone. Improvement in the conversion efficiency
is achieved if pure oxygen is used in the generator instead of
air.
Ozone reacts rapidly with most organic compounds and
microorganisms present in industrial wastewaters. Ozone
oxidation is practical for color removal in small segregated
textile wastewater streams but it is not suitable for reducing
the organic concentration of high volume streams because of the
high dosages required.
Industry Application - Sixty direct dischargers and 11
indirect dischargers report using oxidation. Fifty-nine of the
direct dischargers chlorinate for disinfection only. The other
mill adds chlorine in a rapid-mix contact tank for disinfection
and color removal. Four indirect dischargers chlorinate for
disinfection only, while five add chlorine, usually in the form
of hypochlorite, to control color. The other two indirect
dischargers recycle part of their effluents and add chlorine for
disinfection. No survey data are available to demonstrate the
performance of chlorine oxidation for removing color.
Literature/Research - Ozone oxidation of textile wastewaters
to remove color is the subject of several engineering and
research studies. Two of these case studies are discussed below.
300
-------
Metal
TABLE VII-38
EFFECTIVENESS OF LIME AND SULFIDE
IN THE PRECIPITATION OF TOXIC METALS FROM THE
UNTREATED WASTEWATER OF A
KNIT FABRIC FINISHING MILL
Concentration, mg/1
Raw Sample Lime Effluent Sulfide Effluent
Zinc
Nickel
Iron
Cadmium
Copper
Lead
Silver
Total Chromium
3.2 0.11
0.05
2.3 0.17
0.01
0.50 0.03
0.10
0.05
0.93 0.08
0.09
-
0.19
-
0.01
-
-
0.05
Source: Reference 21.
301
-------
In case 1_ Snyder and Porter (22) studied the effect of pH on
ozone reduction of organics and color in dye wastes from three
textile mills. Ozone was produced from compressed air by a
commercial electric-discharge ozone generator and fed at a rate
of 0.5 g/hr through an experimental apparatus containing 500-ml
samples of the dyehouse wastewater. The studies were conducted
at room temperature (approximately 20°C) and a contact time of
approximately one hour was used. To check the effect of pH on
ozone reactivity, each dye waste was studied at neutral, acidic,
and basic pH values. Adjustments in pH were made with sulfuric
acid and sodium hydroxide.
The researchers found no correlation between pH, and the
efficiency of ozonation in reducing the organics in textile
dyehouse wastewater. The greatest COD removals occurred in the
acid pH samples, but this is in contrast to the results obtained
by other researchers. The COD removals for the three samples
were 8, 41 and 55 percent. This indicates that a low
concentration ozone stream (1 g/1) is not feasible as the centra^L
organic treatment operation for textile dyehouse wastewaters.
Excellent color removal was observed in each sample tested, which
the researchers attributed to the susceptibility of the amine
function in the dye molecules to ozone attack.
In case 2_ the Georgia Department of Natural Resources (23)
investigated ozone treatment and disinfection of tufted carpet
dye wastewater. The studies used effluent samples from the City
of Dalton, Georgia, POTW, Approximately 90 percent of the
plant's flow originates from textile mills that dye and finish
carpet. The wastewater from these mills contain significant
amounts of unexhausted color bodies and auxiliary organic dye
chemicals. The Dalton POTW was treating approximately 15,140 cu
m/day (40 mgd) by extended-aeration activated sludge.
The effectiveness of various dosages of ozone were studied by
monitoring color, COD, organic carbon, suspended solids (TSS),
BOD5., total and fecal coliform, anionic detergents, dissolved
oxygen and ozone residual.
Grab samples were collected from the POTW effluent on five
occasions between April 4 and June 21, 1973. Portions of the
samples were placed in a 37.8 1 (10-gal) plexiglas contact column
and ozone was injected at a fixed feed rate. Samples were
withdrawn from the column for analysis at specific time
intervals. Results of the investigations are summarized for the
parameters of most interest here in Table VII-39,
The researchers concluded that:
1. True color was reduced to less than 30 APHA Units at an
ozone dosage of 40 mg/1; suspended solids removal decreased
that ozone dosage to 26.5 mg/1.
302
-------
TABLE VII-39
CASE 2 - OZONATION OF TUFTED CARPET DYE WASTEWATER
SUMMARY OF RESULTS
Parameter
Ozone
Dosage, mg/1
Parameter Concentration, mg/1
Dalton Effluent Ozonated Effluent
Color (Filtered)
Color (Filtered)
Color (Filtered)
Color (Filtered)
Color (Filtered)
COD
COD
COD
COD
COD
SS
SS
SS
SS
BODS
BOD5
BODS
BODS
BODS
Biphenyl
Biphenyl
Biphenyl
Biphenyl
Biphenyl
Biphenyl
5
10
14
26
45
3
6
20
42
60
7
19
24
52
8
14
19
25
33
5
12
20
26
42
89
300*
300*
300*
300*
300*
130
130
130
130
130
20
20
20
20
21
21
21
21
21
2.0
2.0
2.0
2.0
2.0
2.0
125*
95*
60*
32*
18*
125
110
100
75
75
12
8
6
2
27
53
25
20
19
1.98
1.35
1.62
1.19
1.21
0.10
* APHA Units
Source: Reference 23.
303
-------
2.
3.
A 40 percent COD reduction was achieved with a 45 mg/1 ozone
dosage; suspended solids removal did not significantly
enhance COD reduction.
Suspended solids were reduced by
with a 52 mg/1 ozone dosage.
approximately 90 percent
4. The BOD5. was unchanged at all ozone dosages.
5. Biphenyls were reduced from approximately 2 mg/1
than 0.1 mg/1 with an ozone dosage of 89 mg/1.
to less
EPA/Industry Field Studies - EPA and the textile industry
(ATMI, NTA, and CRI) conducted pilot plant studies during 1977
and 1978 at 19 textile mills to evaluate the performance of
advanced wastewater treatment technologies following extended-
aeration activated sludge biological treatment. Ozonation was
tested using a 110 liter (29 gal) contactor [Schedule 80 PVC
column, 196 cm high and 29.5 cm inside diameter (77 in. high and
11.6 in. inside diameter)]. Ozone was generated with a
commercial ozone generator with a capacity of 6 g/hr (pure oxygen
feed) and fed through diffusers of 70 mesh stainless steel
screen. The contactors could be operated in either a batch or a
continuous mode. The offgases were sampled to determine
concentration of ozone for calculation of ozone utilization.
Ozonation was included in the selected process modes at 7 of the
19 mills studied. Multimedia filtration or chemical coagulation
plus multimedia filtration preceded the ozone contactor in the
process mode. Processing information, • waste treatment
information, and statistical summaries of the results of the
pilot plant studies during the process evaluations at each of
these mills are presented in detail in the Agency's
administrative record. In addition to the regular pilot plant
testing, sampling was conducted at selected mills to evaluate the
performance of ozonation in the treatment of toxic pollutants.
Statistical summaries of the results of the toxic pollutant
sampling at each mill are also presented in the record. The data
is summarized in Tables VII-40 through VII-43. Data is presented
separately for wool scouring mills and other textile mills.
Filtration Wastewater filtration is a physical unit operation
that removes suspended materials. It is used to polish an
existing biological effluent, prepare wastewater for subsequent
advanced treatment processes, or reclaim wastewater for reuse.
Applications of filtration discussed in this section include: 1)
filtration of biological treatment effluent alone or as
pretreatment for carbon adsorption or ozonation, 2) filtration of
chemically clarified effluent, and 3) filtration of biological
treatment effluent following in-line chemical injection
(precoagulation).
304
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TABLE VII-40
SUMMARY OF RESULTS
020NATION OF TEXTILE EFFLUENTS
TRADITIONALLY MONITORED POLLUTANTS
WOOL SCOURING MILLS
Parameter
Mill
A
Ozone utilized, mg/1
Batch (B) or Continuous (C)
250
B
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH
BOD5
COD
TSS
TOC
Total Phenols
Color
Average Effluent Concentration
46
825
104
303
7.6) 265
Average Removal, Percent
6.0
4.3
16
1.3
57
Subcategory
Average
46
825
104
303
265
Subcategory
Average
6.0
4.3
16
1.3
57
Source: EPA/Industry Field Studies
305
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TABLE VII-41
SUMMARY OF RESULTS
OZOKATION OF TEXTILE EFFLUENTS
TOXIC POLLUTANTS
WOOL SCOURING MILLS
Parameter/Pollutant
Mill
A
Ozone utilized, mg/1
Batch (B) or Continuous (C)
250
B
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1 %
Phenol
Bis(2-ethylhexyl)Phthalate
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Copper (Total)
Cyanide
Nickel (Total)
Silver (Total)
Zinc (Total)
13 (24)
106 (NR)
1200 (NR)
43 (48)
250 (NR)
590 (NR)
ND (100)
5000 (NR)
1300 (NR)
460 (NR)
13
106
1200
43
250
590
ND
5000
1300
460
24
m
m
48
NR
NR
100
NR
NR
NR
Note: ND indicates "not detected."
NR indicates "no removal."
Source: EPA/Industry Field Studies
306
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TABLE VII-42
SUMMARY OF RESULTS
OZONATION OF TEXTILE EFFLUENTS
TRADITIONALLY MONITORED POLLUTANTS
OTHER MILLS
Parameter
Subcategory
Ozone utilized, mg>
K
4a
a 49
AA
4c
163
D
4c
427
2
4c
60
Mill
Q
5a
1130-1500
S
7
5
S S
7 7
35 60
Batch (B) or
Continuous (C) C C C
Average Effluent Concentration
Average
BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units
(pH 7.6)
BODS
COD
TSS
TOC
Total Phenols
Color
14
52
2.9
-
-
155
5.3
19
43
-
-
58
13
222
12
-
20
125
4.0
23
21
-
-
65
47
18 4
349 414
16
106
15*
264
Average
0 5
25
28
5.4
-
66
3
-
-
91
Removal
.9
11
_
-
-
59
.9
18
.0
15
-
13
j
16
92
66
33
-
88
5.5
81
29
12
22
168
Percent
17
14
5.5
7.4
-
17
12
126
16
12*
(20)
115*
15
0
0
0*
-
59*
10
102
22
7.7
(20)
77
0
16
18
0
.
68*
16
171
14
35
21
128
Average
8.0
25
26
11
-
59
*Value represents a single data point and was not included in calculating
average.
Note: ( ) indicates "less than" value.
Source: EPA/Industry Field Studies
307
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TABLE VII-43
SUMMARY OF RESULTS
OZONATION OF TEXTILE EFFLUENTS
TOXIC POLLUTANTS
OTHER MILLS
Parameter/Pollutant
Mill
K
Subcategory
Ozone utilized, mg/1
Batch (B) or Continuous (C)
4a
49
C
Average Effluent Concentration, ug/1 (Removal,%)
Average
ug/1 %
Methylene chloride
Pentachlorophenol
Bis(2-ethylhexyl)Phthalate
Di-n-butyl Phthalate
Trichloroethylene
Antimony (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
15 (NR)
ND (100)
89 (NR)
TA (17)
TA (50)
44 (NR)
91 (NR)
32 (33)
65 (7)
17 (13)
218 (8)
15
ND
89
TA
TA
44
91
32
65
17
218
NR
100
NR
17
50
NR
NR
33
7
13
8
Note: NR indicates "no removal."
TA indicates "trace amount," less than 10 ug/1.
Source: EPA/Industry Field Studies
308
-------
The filtration process separates suspended material from
wastewater by passing the wastewater through porous material.
The mechanisms responsible for removal include: straining,
sedimentation, inertial impaction, interception, adhesion,
chemical adsorption (bonding and chemical interaction), physical
adsorption (electrostatic, electrokinetic, and Van der Waals
forces), and two accessory actions within the filter bed,
biological growth and flocculation. The mechanisms that will
predominate depend on - the wastewater characteristics and the
characteristics of the filter (media composition; grain size,
shape, density, and porosity; bed depth; and filtration rate).
(20,24)
Filtration systems are broadly classified as either surface or
in-depth. Surface filters include microscreens, diatomaceous
earth filters and moving bed filters. These filters achieve
solids removal primarily by surface straining and, as a result,
yield shorter runs between backwashings. In-depth filters
include deep-bed single, dual, or multimedia units. Graded sand
was commonly used in the past for in-depth filtration but today,
garnet, gravel, resin beads, activated carbon and anthracite coal
are also commonly used. The use of multiple layers of different
media having specific gravities increasing in the direction of
flow permits gradation of the filter bed and allows more
efficient utilization of the total bed depth.
Industry Application - Sixteen mills use filtration as part
of their treatment systems. Ten are direct dischargers, three
are indirect dischargers, and three practice complete recycle.
Nine of the ten direct dischargers use activated sludge or a
similar biological process prior to filtration. Three of these
dischargers also use chemical coagulation or add coagulants in-
line prior to filtration (precoagulation). Most of the direct
dischargers use multimedia filters with sand, gravel, and
anthracite media. They are operated as tertiary filters and are
pressurized.
The filter systems used by the indirect dischargers include an
in-depth sand filter, a vacumite filter which separates the floe
from a chemically . treated (coagulation and flocculation)
wastewater, and a system that included a multimedia (sand and
charcoal) filter following biological aeration. Two mills
practicing recycle are operated by the same company and both
employ multimedia in-depth filters using gravel, sand, and
anthracite media. In both cases the filtration systems follow
extended-aeration activated sludge and chemical coagulation. The
third recycle mill precedes filtration with air flotation,
biological aeration, and chemical coagulation/flocculation.
Historical Data - Many of the filtration systems in use by
the textile . industry are operated to polish biologically or
chemically treated effluents or to allow recycle. The available
data from these mills, i.e.., influent and effluent for the entire
309
-------
treatment system, do not demonstrate the effectiveness of the
filtration systems alone. However, the data presented in Table
VII-44 demonstrate the performance of the entire treatment
systems that include filtration. The data, which in general
represent the results jof monitoring during 1976, are average
values for those mills that provided historical monitoring
reports.
Field Sampling - Little historical or research data exist
that demonstrate the performance of filtration systems. Sampling
was conducted at five mills during this study to provide such
information. The results are summarized in the following cases.
In case ]_ two knit fabric finishing-simple processing mills that
discharge*~to a common treatment plant were sampled as part of the
EPA/Industry pilot plant field studies (Mill Q). Descriptions of
the manufacturing operations, wastewater treatment system, and
pilot plant studies are provided in the administrative record.
One 48 hour composite sample was collected at the influent to the
treatment plant, and two 24 hour composite samples following
secondary clarification, and filtration. The performance of the
biological system and multimedia pressure filter for the
treatment of conventional, nonconventional and toxic pollutants
is presented in Tables VI1-45.
Case 2_ is a woven fabric finishing-simple processing mill that
performs flat bed and rotary screen printing to produce sheets,
towels, and bedspreads. Rotary screen printing accounts for
approximately 90 percent of the production, which was reported as
30,000 kg/day (approximately 65,000 Ib/day). The processing
operations result in a wastewater discharge rate of 19.2 I/kg of
product (2.3 gal/lb of product) and a wastewater discharge of 570
cu m/day (150,000 gpd).
Wastewater treatment at this mill consists of equalization (small
holding tank), grit removal, coarse screening, chemical addition
(alum and caustic), fine screening (vibrating), chemical addition
(cationic polymer) and flocculation, dissolved air flotation (300
gpm), biological aeration (2 lagoons in series), disinfection
(chlorine), secondary clarification (reactor/clarifier in which
alum, caustic, and anionic polymer are added), and dual media
gravity filtration (sand and carbon). Aeration detention time is
approximately 170 hours, and air is provided by surface aerators
at a power-to-volume ratio of approximately 3.56 kw/1000 cu m (18
hp/million gal). The discharge from the treatment plant is
reused in the printing operations.
Samples were collected over a typical 48-hour period of operation
at the bar screen prior to the air flotation unit, at the
Parshall flume prior to the aeration basins, at the chlorine
contact chamber following aeration, and at the effluent from the
dual media filter. The performance of the biological treatment
310
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TABLE VII-44
EFFLUENT CONCENTRATIONS FROM
TEXTILE MILLS USING FILTRATION AS
A FINAL TREATMENT STEP
Subcat- Treatment BOD5, mg/1 COD, mg/1 TSS, mg/1
egory Mill Filter Type Step Inf* Eff Inf* Eff Inf* Eff
5a
5a
5a
5a
5a
7
7
7
4a
50011
50022
50030
50104
50112
70042
70072
70081
40144
Multimedia
In-depth
Dual media
In-depth
-
Sand
In-depth
Multimedia
Pressure
Sand
In-depth
Multimedia
Pressure
Dual media
In-depth
Dual media
Pressure
Direct Discharge
Polishing - 159 -
Polishing - 33 - 188
Polishing 334 24 1265 206
Polishing 327 43 1261 427
Polishing 279 5 934 196
Post - 17 - -
Flotation
Polishing 327 20 1572 480
Polishing 218 23 800 312
Recycle
Polishing 298 10 - 1550
65>
'55
40
119 88
41 7
2,1
26 23
12 93
5
* Inf indicates raw waste concentration not influent to filtration.
Source: EPA Industry Survey, 1977.
311
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TABLE VII-A5
CASE 1 - BIOSYSTEM AND MULTIMEDIA FILTER
SUMMARY OF ANALYTICAL RESULTS
CONVENTIONAL, NONCONVENTZONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Untreated Secondary Filtration
Wastewater* Effluent** Effluent**
Conventional & Nonconventional Pollutants
BODS, mg/1
COD, mg/1
TSS, mg/1
Oil & Grease, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
_
782
17
324
-
288
„
312
28
303
59
187
233
6
476
48
192
Toxic Pollutants, ug/1
1,2, 4-Trichlorobenzene
Ethylbenzene
Naphthalene
Phenol
Bis(2-ethylhexyl) Phthalate
Tetrachloroethylene
Trichloroethylene
Antimony (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Zinc (Total)
2700
101
45
55
41
ND
840
95
14
44
10
36
36
15
12
56
ND
ND
ND
ND
15
17
ND
670#
32#
104#
ND
48#
ND
41#
13#
48#
ND
ND
ND
ND
12
17
ND
700#
32#
79#
10#
33#
ND
102#
TA#
84#
* 48-hour composite sample
** average of two 24-hour composite samples
# average of two 24-hour grab samples
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at less
than 10 ug/1 in the raw waste, secondary effluent, and/or
final effluent: 2,4,6-Trichlorophenol; 2-Nitrophenol.
Source: EPA Field Sampling Results for Mill 50112, October 1977
312
-------
system and reactor/clarifier-dual
Table VII-46.
media filter is presented in
Case 3^ is stock and yarn dyeing facility that performs package
dyeing of polyester, cotton and wool yarn. Dispersed dye is the
primary dye class employed, although some acid and cationia cjyes.
also are used. The processing results in an average wastewater
discharge rate of 154 I/kg of product (18.5 gal/lb of product).
Wastewater treatment at this mill consists of coarse screening,
neutralization, aeration [(1 basin with a total volume of 1990 cu
m (5,250,000 gal)], secondary clarification, dual media gravity
filtration (sand and carbon) and disinfection (chlorine).
Aeration detention time is approximately 120 hours, and air is
provided by eight surface aerators with a total power-to-volume
ratio of approximately 2205 kw/1000 cu m (114 hp/mil gal). It
was reported that the carbon in the filter had not been changed
within the past two years; therefore, the filter may not be
functioning in an adsorptive capacity.
Samples were collected over a 72-hour period of operation of the
raw wastewater, the secondary clarifier effluent, and the .dual
media filter effluent. The performance of the activated sludge
system and dual media filter is presented in Table VI1-47.
Case £ is a stock and yarn finishing mill. The processing
operations result in a wastewater discharge rate of 13.1 I/kg of
product (1.6 gal/lb of product).
Wastewater treatment at this mill consists of aerated
equalization, chemical addition (ferric chloride), flocculation,
clarification and filtration. The discharge from the treatment
plant is recycled for reuse in the mill operations,
Samples were collected over a typical 72-hour period of operation
at the discharge from the equalization basin, at the discharge
from the chemical clarifiers and at the discharge from the clear
well following the filters. The performance of the filter is
presented in Table VII-48.
Case 5^ is a knit fabric finishing-simple processing mill that
performs scouring and piece dyeing on polyester and arnel/nylon
fabric, Premetallized (13 percent) and dispersed (81 percent)
dyes are the primary dyes employed at this mill. The processing
operations result in a wastewater discharge rate of 83.4 I/kg of
product (approximately 10.0 gal/lb of product).
Wastewater treatment at this mill consists of neutralization
(alkali), equalization, aeration [total volume of 1135 cu m (0.30
million gal)], secondary sedimentation, coagulation,
clarification and filtration. Aeration detention time is
approximately 6 hours, and air is provided by surface aerators at
313
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TABLE VII-46
CASE 2 - BIOSYSTEM AND REACTOR/CLARIFIER - DUAL MEDIA FILTER
SUMMARY OF ANALYTICAL RESULTS
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Biological
Influent*
Biological
Effluent*
Filter
Effluent*
Conventional & Nonconventional Pollutants
BOD5, mg/1
COD, mg/1
TSS, mg/1
Total Phenols, ug/1
Sulfide, ug/1
(200)
725
32
26
(200)
(67)
577
17
18
(200)
(20)
543
4
14
(200)
Toxic Pollutants> ug/1
Benzene
Ethylbenzene
Methyl Chloride
4-Nitrophenol
Pentachlorophenol
Phenol
Bis(2-ethylhexyl)
Phthalate
Toluene
Copper (Total)
Lead (Total)
Nickel (Total)
Thallium (Total)
19
160
56
13
34
32
45
200
81**
NS
Q f\ JLuJL
14**
TA
ND
TA
(10)
ND
24
ND
ND
52**
32**
32**
13**
TA
ND
TA
(10)
ND
16
ND
ND
27**
NS
NS
NS
* average of two 24-hour samples
** reported as "less than" value
Notes: ND indicates "not detected."
. NS indicates "no sample."
TA indicates "trace amount," less than 10 ug/1.
( ) indicated "less than" value.
The following pollutants also were detected but at
less than 10 ug/1 in the biological influent, biological
effluent, and/or final effluent: 1,2-Dichloroethane;
1,1,1-Trichloroethane; Tetrachloroethylene; Trichloro-
ethylene; Beryllium; Cadmium; Chromium; Cyanide;
Mercury; Silver; Zinc.
Source: EPA Field Sampling Results for Mill 40144, November 1977
314
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TABLE VII-47
CASE 3 - BIOSYSTEM AND DUAL MEDIA FILTER
SUMMARY OF ANALYTICAL RESULTS
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Biological
Parameter/Pollutant Influent
Conventional &
COD, mg/1
TSS, mg/1
Total Phenols, ug/1
Sulfide, ug/1
Color, ADMI Units (pH 7.6)
Toxic
Acrylonitrile
1,2, 4-Trichlorobenzene
Bis(chloromethyl) Ether
2,4, 6-Trichlorophenol
Parachlorometa Cresol
1 , 2-Dichlorobenzene
2 , 4-Dichlorophenol
1 ,2-Dichloropropane
2,4-Dimethylphenol
Naphthalene
Pentachlorophenol
Bis(2-ethylhexyl)
Phthalate
Di-n-butyl Phthalate
Dimethyl Phthalate
Tetrachloroethylene
Toluene
Trichloroethylene
Clarifier
Effueut
Min Max n
Nonconventional
226
25
810
44
131
Pollutants,
ND
270
59
16
29
56*
20
56
190
18
ND
490
24
18
310
TA
10
116
100
12
6
112
ug/1
ND
19
ND
TA
ND
ND
ND
ND
ND
ND
ND
76
ND
ND
TA
TA
ND
Filter
Effluent
Min Max
n
Pollutants
150
170
21
8
124
(100)
43
ND
TA
TA
TA
ND
ND
ND
13
23
340
TA
ND
TA
38
ND
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
122
38
17
9
105
ND
TA
ND
ND
ND
TA
ND
ND
ND
TA
ND
80
ND
ND
TA
TA
ND
148
115
19
9
113
(100)
21
ND
TA
TA
TA
ND
ND
ND
TA
13
170
TA
ND
TA
TA
ND
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
* Represents sum of concentrations of 1,2-Dichlorobenzene;
1,3-Dichlorobenzene; and 1,4-Dichlorobenzene
315
-------
TABLE VII-47 (cont.)
Parameter
Antimony (Total)
Arsenic (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Thallium (Total)
Zinc (Total)
Biological
Influent
156
19
34
49
(22)
(36)
TA
(50)
493
Clarifier
Effuent
Min Max n
141
TA
68
110
(22)
(36)
TA
ND
228
177
TA
91
132
35
(36)
TA
(50)
283
3
3
3
3
3
3
3
3
3
Filter
Effluent
Min Max n
150
TA
12
20
(22)
42
11
ND
139
162
TA
57
84
(22)
50
15
(50)
436
3
3
3
3
3
3
3
3
3
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
( ) indicates "less than" value.
The following pollutants also were detected but at
less than 10 ug/1 in the biological influent, clarifier
effluent, and/or filter effluent: Benzene; Hexachloro-
benzene; Chloroform; Ethylbenzene; Fluoranthane; Methylene
Chloride; N-nitrosodi-n-propylamine; Phenol; Butyl Benzyl
Phthalate; Diethyl Phthalate; Anthracene; Fluorene; Pyrene;
Beryllium; Cadmium; Cyanide; Mercury; Selenium.
Source: EPA Field Sampling Results for Mill 70081, July 1978.
316
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TABLE VII-48
CASE 4 - MULTIMEDIA FILTER
SUMMARY OF ANALYTICAL RESULTS
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Conventional &
COD, mg/1
TSS, mg/1
Sulfide, ug/1
Total Phenols, ug/1
Color, ADMI Units
Color, ADMI Units (pH 7.6)
Toxic
1,2, 4-Trichlorobenzene
2 , 4 , 6-Trichlorophenol
Parachlorometa Cresol
Chloroform
2-Chlorophenol
1 , 2-Dichl'orobenzene
Naphthalene
2-Nitrophenol
N-nitrosodi-n-propylamine
Phenol
Bis(2-ethylhexyl) Phthalate
Trichloroethylene
Antimony (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
Clarifier
Effluent
Win Max
n
Filter
Effluent
Min Max n
Nonconventional Pollutants
426
30
25
66
71
75
722
65
170
110
108
108
Pollutants,
ND
TA
ND
m
60
ND
TA
92
ND
TA
10
TA
51
16
TA
48
128
42
42
18
TA
80
TA
60
45
100
92
32
140
190
26
78
24
12
98
148
51
1790
3
3
3
3
3
3
ug/1
3
3
3
3
1
3
3
1
3
3
3
3
3
3
3
3
3
3
3
347
8
3
80
39
42
ND
TA
ND
25
TA
ND
TA
ND
ND
TA
47
TA
48
TA
ND
58
119
41
29
523
27
3
109
92
88
28
14
ND
70
TA
13
100
ND
130
100
150
36
78
24
12
70
187
58
58
3
3
3
3
3
3
3
3
3
3
1
3
3
1
3
3
3
3
3
3
3
3
3
3
3
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at
less than 10 ug/1 in the influent and/or effluent:
Benzene; Chlorobenzene; 2,4-Dimethylphenol; Ethylbenzene;
Methylene Chloride; Trichlorofluoromethane; Di-n-butyl
Phthalate; Diethyl Phthalate; Anthracene; Tetrachloro-
ethylene; Toluene; Arsenic; Cadmium; Selenium.
Source: EPA Field Sampling Results for Mill 70, August 1978.
317
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TABLE VII-49
CASE 5 - REACTOR/CLARIFIER AND MULTIMEDIA FILTER
SUMMARY OF ANALYTICAL RESULTS
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Biological
Effluent*
Min Max
Final
Effluent*
Min Max
Conventional & Nonconventional Pollutants
BOD5, mg/1
COD, mg/1
TSS, mg/1
Oil & Grease,
Sulfide, ug/1
Total Phenols,
Color, APHA Units
Toxic Pollutants, ug/1
mg/1
> U8/1
nits
116
285
13
14
460
177
750
120
4477
272
44
10,000
214
875
11
238
12
4
130
133
120
14
1822
13
5
190
140
175
1,2-Dichloroethane
1,1, 1-Trichloroethane
Methylene Chloride
Tetrachloroethylene
Antimony (Total)
Chromium (Total)
Copper (Total)
Cyanide
Zinc (Total)
ND
69
ND
TA
10
140
66
TA
240
ND
130
ND
27
10
150
70
17
240
33
31
ND
TA
23
TA
19
ND
260
110
70
31
12
32
12
19
17
320
* Two 24-hour composite samples except for toxic metals which
were 24-hour grab samples.
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at
less than 10 ug/1 in the influent and/or effluent:
Benzene; 1,1-Dichloroethane; Chloroform; 1,1-Dichloro-
ethylene; Ethylbenzene; Arsenic; Cadmium.
Source: EPA Field Sampling Results for Mill 50030, May 1978.
318
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TABLE VII-50
CASE 6 - SAND FILTER
SUMMARY OF ANALYTICAL RESULTS
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Biological
Effluent
Min Max n*
Filter
Effluent
Min Max
Conventional & Nonconventional Pollutants
COD, mg/1
TSS, mg/1
Sulfide, ug/1
Total Phenols, ug/1
Color, ADMI Units
Color, ADMI Units (pH 7.6)
154
44
8
TA
75
75
254
60
20
15
89
85
3.
3
3
3
3
3
107
28
ND
TA
70
70
Toxic Pollutants, ug/1
40 3
ND 3
14 3
77 3
77 3
Acrolein
Methylene Chloride
Bis(2-ethylhexyl) Phthalate
Trichloroethylene
Antimony (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
28
TA
ND
81
36
54
14
48
87
28
50
41
87
44
65
17
69
2
1
3
3
3
3
3
3
3
ND
33
TA
ND
77
54
46
TA
43
190
33
34
89
84
84
64
15
94
3
1
3
3
3
3
3
3
3
* Three 24-hour composite samples except for toxic metals which
were 24-hour grab samples.
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at
less than 10 ug/1 in the influent and/or effluent:
Parachlorometa Cresol; Chloroform; Pentachlorophenol;
Anthracene; Toluene; Arsenic; Cadmium; Selenium.
Source: EPA Field Sampling Results for Mill 50104, August 1978,
319
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a total power-to-volume ratio of approximately 14.7 kw/1000 cu m
(750 hp/million gal).
Samples were collected over a 48-hour period of operation at the
influent to the neutralization tank, at the discharge from the
biological clarifier and at the discharge from the filters. The
performance of the reactor/clarifier - filtration system is
presented in Table VII-49.
Case 6 is a knit fabric finishing-simple processing mill that
knits, scours and dyes synthetic bolt cloth of polyester and
acetate fiber. Pressure piece dyeing with dispersed dyes is
performed on the total production and 20 percent of the
production is scoured. During the field sampling, wastewater
flow averaged 984 cu m/day (260,000 gpd).
Wastewater treatment at this mill consists of fine screening
(vibratory), equalization (mixed with nitrogen addition),
aeration (two basins operated in series with powdered activated
carbon added to the first basin), secondary sedimentation, sand
filtration, disinfection (chlorine) and post aeration. Total
detention time in the aeration basins is approximately 48 hours,
and air is provided by surface aerators at a power-to-volume
ratio of approximately (15.7 kw/1000 cu m (80 hp/mil gal). The
performance of the sand filter is presented in Table VII-50.
EPA/Industry Field Studies - In a joint research effort
between EPA and the textile industry (ATMI, NTA, and CRI), pilot
plant studies were conducted during 1977 and 1978 at 19 textile
mills to evaluate the effectiveness of alternative advanced
wastewater treatment technologies. The studies were performed on
the effluent from treatment systems using extended-aeration
activated sludge treatment. One of the technologies was downflow
multimedia filtration using one of two filters 1.60 m in height
in diameter (63 in. in height and 14 in. in
The filter provided one foot (0.9-1.5 mm effective
and 0.355 m
diameter).
size), 30.5 cm (12 in. of sand, 0.4-0.8 mm effective
40.6 cm (16 in. of gravel 6-16 mm effective size).
size), and
Multimedia filtration was included in the selected treatment
technology at 18 of the 19 mills. It was used as the first
treatment step following biological treatment, both alone and
with the aid of a precoagulant. Multimedia filtration also was
used following chemical coagulation. of surface area and
contained 30.5 cm (12 in. of anthracite coal The detailed study
reports and analytical results are included in the administrative
record.
The data is summarized in Tables VII-51 through VII-62 of this
section by subcategory (wool scouring mills, wool finishing mills
and other mills) and placement of the filter in the candidate
modes (first treatment step, first treatment step with
precoagulant, and following chemical coagulation). The tables
320
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TABLE VII-51
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (AFTER CLARIFICATION*)
TRADITIONALLY MONITORED POLLUTANTS
WOOL SCOURING MILLS
Parameter
Mill
A
Loading rate, gpm/sq ft
2.0
Average Effluent Concentration
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
29
807
102
289
619
BOD5
COD
TSS
TOC
Total Phenols
Color
Average Removal, Percent
37
11
45
7.9
2.8
Subcategory
Average
29
807
102
289
619
Subcategory
Average
37
11
45
7.9
2.8
* The multimedia filter was not preceded by chemical coagulation at this
plant and no coagulant was used in the reactor/clarifier.
Source: EPA/Industry Field Studies
321
-------
TABLE VII-52
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (AFTER CLARIFICATION-)
TOXIC POLLUTANTS
WOOL SCOURING MILLS
Parameter/Pollutant
Mill
A
Loading rate, gpm/sq ft
2.0
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1 %
Phenol
Bis (2-ethylhexyl)Phthalate
Arsenic (Total)
Copper (Total)
Cyanide
Zinc (Total)
17 (65)
14 (39)
83 (MR)
120 (MO
260 (NR)
400 (NR)
17
14
83
120
260
400
65
39
NR
NR
NR
NR
* The multimedia filter was not preceded by chemical coagulation at
this mill and no coagulant was used in the reactor/clarifier.
Note: NR indicates "no removal."
Source: EPA/Industry Field Studies
322
-------
TABLE VII-53
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (FIRST TREATMENT STEP)
TRADITIONALLY MONITORED POLLUTANTS
WOOL FINISHING MILLS
Parameter
Mill
0
Loading rate, gpm/sq ft
3.0
Average Effluent Concentration
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
BOD5
COD
TSS
TOC
*Total Phenols
Color
2.7
114
6.9
33
40
97
Average Removal, Percent
54
32
82
3.5
30
13
Subcategory
Average
2.7
114
6.9
33
40
97
Subcategory
Average
54
32
82
3.5
30
13
Source: EPA/Industry Field Studies
323
-------
TABLE VII-54
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (FIRST TREATMENT STEP)
TOXIC POLLUTANTS
WOOL FINISHING MILLS
Parameter/Pollutant
Mill
0
Loading rate, gpm/sq ft
3.0
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1 %
Parachlorometa Cresol
Methylene Chloride
Bis(2-ethylhexyl)Phthalate
Antimony (Total)
Chromium (Total)
Copper (Total)
Zinc (Total)
TA
47
42
ND
91
118
489
(78)
(NR)
(92)
(100)
(49)
(NR)
(46)
TA
47
42
ND
91
118
489
78
NR
92
100
49
NR
46
Note: TA indicates "trace amount," less than 10 ug/1
NR indicates "no removal."
ND indicates "not detected."
Source: EPA/Industry Field Studies
324
-------
TABLE VII-55
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (AFTER CHEMICAL COAGULATION)
TRADITIONALLY MONITORED POLLUTANTS
WOOL FINISHING MILLS
Mill
Parameter
Loading rate, gpm/sq ft
BOD5, mg/1
COD7 mg/1
TSS, mg/1
TOC, mg/I
Total Phenols, ug/1
Color, ADMI Units
(pH 7.6)
5.4
Average
20
203
15
41
-
-
6.6
7.0
3.0
Effluent Concentration
23*
157
31
69
-
-
Average Removal
BODS
COD
TSS
TOC
Total Phenols
Color
25
12
48
36
-
"•
0*
34
59
8.3
.
~
31
174
1.8
65
-
5.5*
, Percent
21
12
43
5.3
-
95*
2.0
84
7.2
27
33
65
13
22
78
11
19
4.0
Subcategory
Average
18
155
14
51
33
65
Subcategory
Average
20
20
57
15
19
4.0
* Value represents a single data point and was not included in calculating
subcategory average.
Source: EPA/Industry Field Studies
325
-------
TABLE VII-56
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (AFTER CHEMICAL COAGULATION)
TOXIC POLLUTANTS
WOOL FINISHING MILLS
Parameter/Pollutant
Mill
B
Loading rate, gpm/sq ft
5.4-7.0
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1
1 , 2,4-Trich.lorobenzene
Bis (2-ethylhexyl)Phthalate
Toluene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
94
14
12
12
103
105
41
118
116
73
158
5895
(39)
(68)
(14)
(63)
(NR)
(NR)
(NR)
(NR)
(NR)
(NR)
(8)
(NR)
94
14
12
12
103
105
41
118
116
73
158
5895
39
68
14
63
NR
NR
NR
NR
NR
NR
8
NR
Note: NR indicates "no removal."
Source: EPA/Industry Field Studies
326
-------
TABLE VII-57
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (FIRST TREATMENT STEP)
TRADITIONALLY MONITORED POLLUTANTS
OTHER MILLS
Parameter
Sub category
Loading rate, gpffl/sq ft
K
4a
5.0
BB
4b
3.0
D
4c
4.4
T Y
4c 4c
5-0 5.0
Mill
Z
4c
3.0
Average Effluent
&BOD5, mg/1
-'COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
BODS
COD
TSS
TOC
Total Phenols
Color
14
65
4.6
-
(50)
368
11
15
55
-
-
2.2
23
353
40
93
80
341
12
5.9
21
5.7
23
11
19
630
85
157
-
1035
18
17
36
10
-
0.2
8.5 7.5
478 90
17 10
144 14
530
177 175
Average
47 23
3.7 27
20 67
5.2 6.4
6.9
2.8 1.9
17
461
20
-
-
199
Removal
22
10
42
-
-
9.3
E
5b
3.0
Q
5a
2.0
W
5b
7-0
EE
7
7.0
S
7
5.0
Concentration
11
157
4.3
29
63
140
4.3
206
4.1
22
(20)
226
3.4
55
9.5
11
-
100
2.5
123
8.4
43
(20)
166
7.0
106
12
8.3
-
229
, Percent
29
36
90
4.1
8.3
12
45
24
91
18
-
4.3
26
25
64
18
-
5.4
18
13
46
2.7
-
4.9
78
9.1
65
19
_
9.3
Average
11
248
20
58
127
287
Average
30
17
54
9.9
13
5.8
Note: ( ) Indicates "less than" value,
Source: EPA/Industry Field Studies
-------
TABLE VII-58
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (FIRST TREATMENT STEP)
TOXIC POLLUTANTS
OTHER MILLS
Mill
Parameter/Pollutant
K
BB
W
Subcategory 4a 4b 5b 5b
Loading rate, gpm/sq ft 5.0 3.0 3.0 7.0
Average Effluent Concentration, ug/1 (Removal, %)
Benzene
1 ,2,4-Trichlorobenzene
Chloroform
Ethylbenzene
Methylene Chloride
Methyl Chloride
N-nitrosodi-n-propylamine
Pentachlorophenol
Phenol
Bis(2-ethylhexyl)
Phthalate
Di-n-butyl Phthalate
Tetrachloroethylene
Trichloroethylene
Antimony (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Nickel (Total)
Selenium (Total)
Silver (Total)
Zinc (Total)
ND
ND
ND
ND
13
ND
ND
TA
ND
12
12
ND
TA
22
TA
77
TA
24
23
ND
TA
209
(46)
(43)
(NR)
(NR)
(33)
(NR)
(NC)
(8)
(69)
(NR)
(NR)
(NR)
(8)
TA
ND
ND
TA
19
ND
ND
ND
TA
TA
ND
ND
ND
55
101
103
18
43
96
ND
30
117
(100)
(100)
(23)
(NR)
(100)
(100)
(40)
(5)
W
0)
(NR)
(NR)
(9)
(8)
(25)
TA
TA
TA
ND
TA
ND
TA
ND
212
11
TA
ND
ND
TA
TA
TA
ND
TA
96
TA
27
137
(20)
(NC)
(33)
(NC)
(33)
(NR)
(45)
(NC)
(85)
(31)
(34)
(75)
(18)
(NR)
(10)
(27)
TA
TA
TA
ND
ND
ND
ND
ND
TA
21
TA
ND
TA
763
ND
22
ND
54
86
ND
19
61
(20)
(33)
(50)
(NC)
(11)
(NC)
(100)
(NC)
(2)
(29)
(3)
(9)
(8)
(19)
Average
ug/1 %
TA
TA
TA
TA
TA
ND
TA
TA
58
14
TA
ND
TA
213
30
53
TA
33
75
TA
22
131
47
33
61
23
23
100
33
43
50
24
NR
100
33
23
18
20
35
20
9
NR
7
20
Note: NC indicates "not able to calculate removal."
ND indicates "not detected."
NR indicates "no removal."
TA indicates "trace amount," less than 10 ug/1.
Source: EPA/Industry Field Studies
328
-------
TABLE VII-59
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (WITH PRECOAGULANT)
TRADITIONALLY MONITORED POLLUTANTS
OTHER MILLS
Parameter
Sub category
Loading rate, gpm/sq ft
Alum as AL+3, mg/1
Cationic Polymer, mg/1
Ferric Chloride, mg/1
CO
IS BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
K
4a
2.0
-
-
8
6.3
41
8.9
-
(50)
106
AA
4c
3.0
0.5
-
-
11
292
14
-
21
356
P
4c
3.0
1.5
-
_
15
104
20
23
-
127
P '
4c
5.0 5
1.5 2
-
-
Average
11
118
17
27
20*
-
Mill
P P
4c 4c
.0 7.0
.7 1.5
-
-
Effluent
8* 10
83* 113
12* 20
27* 25
0*
-
Average Removal
BODS
COD
TSS
TOG
Total Phenols
Color
57
44
40
-
NC
72
73
22
81
-
NC
3.8
26
12
23
4.3
-
1.0
0
1.5
46
20
60*
~
69* 10
24* 5.0
0* 45
7* 25
100*
— •*
z
4c
3.0
10
-
-
Q
5a
2.5 5
1
-
-
W
5b
.0
-
3
-
S
7
3-0
-
13
-
S
7
4.5
-
13
-
Concentration
17
438
35
-
-
240
7.1 2.6
258
28
18
-
-
48
13
10
-
68
6.5
59
21
20
-
56*
8.0
123
46
5.3
-
63*
, Percent
27
13
24
-
-
4.3
31
25
70
0
-
~
41
34
48
27
-
30
77
48
33
24
_
74*
86
0
27
25
-
69*
Average
9.5
159
22
18
36
179
Average
43
20
44
18
-
22
*Value represents a single data point and was not included in calculating subcategory average
Note: ( ) indicates "less than" value.
NC indicates "not able to calculate removal."
Source: EPA/Industry Field Studies
-------
TABLE VII-60
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (WITH PRECOAGULANT)
TOXIC POLLUTANTS
OTHER MILLS
Parameter/Pollutant
Sub category
Loading rate, gpm/sq ft
Polymer, mg/1
K
4a
2.0
-
Mill
DD W
4c 5b
1.0 5.0
3
Ferric Chloride, mg/1
Alum as Al+3, mg/1
12
Average Effluent Concentration, ug/1 (Removal, %)
Benzene
1,2, 4-Trichlorobenzene
Chloroform
Methylene Chloride
Penta chlo r opheno 1
Bis(2-ethylhexyl)
Phthalate
Tetrachloroethylene
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
TA
ND
ND
23
ND
16
31
ND
TA
85
18
23
55
13
275
(NC)
(100)
(100)
(NR)
(26)
(NR)
(NC)
(4)
(3)
(NR)
(NR)
(NR)
(NR)
ND
ND
ND
ND
ND
TA
ND
ND
ND
TA
110
28
ND
31
67
28
280
(NC)
(NC)
(NR)
(53)
(16)
(7)
(NR)
(NR)
TA
TA
114
ND
ND
21
ND
TA
753
11
ND
21
ND
45
72
15
62
(67)
(66)
(12)
(17)
(100)
(NC)
(1)
(NR)
(37)
(20)
(7)
(8)
(14)
Average
ug/1 %
TA
TA
41
ND
ND
18
ND
TA
261
TA
40
45
TA
33
65
19
206
67
66
12
100
100
9
100
26
1
NR
NR
31
3
12
5
3
5
Note: NC indicates "not able to calculate removal."
ND indicates "not detected."
NR indicates "no removal."
TA indicates "trace amount," less than 10 ug/1.
Source: EPA/Industry Field Studies
330
-------
TABLE VII-61
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (AFTER CHEMICAL COAGULATION)
TRADITIONALLY MONITORED POLLUTANTS
OTHER MILLS
Parameter
Subcategory
Loading rate, gpm/sq ft
BB
4b
1.5
V
4c
3.0
E
5b
5.0
Q
5a
3.0
Mill
Q
5a
3.0
Average Effluent
BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
BODS
COD
TSS
TOC
Total Phenols
Color
9.3
147
38
41
54
167
10
6.2
28
6.7
18
11
2.5
331
20
62
-
284
26
5.9
60
14
-
0.6
9.3
104
4.2
22
57
53
14
17
48
8.2
-
5.8
3.4
179
24
(20)*
-
195
Average
43
20
68
-
-
2.2
2.9
138
18
-
-
127
Removal
17
21
65
-
-
13
Q
5a
5.0
Concentration
3.1
134
9.2
20
-
-
, Percent
20
24
83
6.3
-
~
F
6
5.0
6.6
120
8.3
25
42
168
18
16
65
11
31
4.2
EE
7
3.0
(2)
67
7.6
33
(20)
43
_
34
71
9.4
-
8.3
S
7
5.0
5.5
67
12
6.4
(20)
95
18
21
37
8,7
-
2.0
Average
5.0
143
16
30
39
142
Average
21
18
58
9.2
25
5.9
* Value represents a single data point and was not included in calculating subcategory average
Note: ( ) Indicates "less than" value.
Source: EPA/Industry Field Studies
-------
TABLE VII-62
SUMMARY OF ANALYTICAL RESULTS
MULTIMEDIA FILTRATION (AFTER CHEMICAL COAGULATION)
TOXIC POLLUTANTS
OTHER MILLS
Parameter/Pollutant
V
Mill
Subcategory
Loading rate, gpm/sq ft
4c
3.0
5b
5.0
Average Effluent Concentration, ug/1 (Removal.%)
Average
ug/1 %
Benzene
Chloroform
1 , 2-Dichlorobenzene
Pentachlorophenol
Phenol
Bis(2-ethylhexyl)Phthalate
Antimony (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
TA (23)
12 (NR)
19 (NR)
TA (71)
136 (NR)
14 (18)
25 (NR)
64 (NR)
ND
77 (NR)
234 (NR)
18 (NR)
ND (100)
TA (NC)
ND
TA (50)
40 (NR)
TA (NR)
TA (NR)
TA (NR)
TA (NR)
76 (NR)
29 (NR)
121 (NR)
TA
ND
TA
TA
15
25
73
12
18
37
38
53
178
NR
100
23
NR
25
36
NR
9
NR
NR
NR
NR
NR
Note: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
NR indicates "no removal."
NC indicates "not able to calculate removal".
Source: EPA/Industry Field Studies
332
-------
summarize the performance of multimedia filtration in the
treatment of traditionally monitored toxic, nonconventional and
conventional pollutants.
Hyperfiltration/Ultrafiltration Hyperfiltration (reverse osmosis)
is a physical separation process that relies on applied pressure
(greater than osmotic pressure) to force flow through a
semipermeable membrane (permeable to water but not dissolved
materials of a specific-molecular size). The process is capable
of removing suspended particles and substantial fractions of
dissolved impurities, including organic and inorganic materials.
The membranes are designed so that water and species smaller in
size than the rejection level of the particular membrane pass
through while larger species are rejected. The process results
in two effluents, one relatively pure, and the other containing
the concentrated pollutants.
The membrane is the most important aspect of the reverse osmosis
system. Those most widely used are manufactured from a mixture
of cellulose acetate, acetone, formamide and magnesium
perchlorate. Noncellulose synthetic polymer membranes also have
been developed and are commercially available; however, these are
more often applicable in ultrafiltration systems. The most
common commercially available hyperfiltration systems include
tubular, spiral wound and hollow fine fiber. The tubular system
has a typical membrane area per unit volume of 65.65 sq m/cu m
(20 sq ft/cu ft) and the membrane is situated along the inner
wall of a 1.27 cm (0.5 in.) diameter tube. The spiral wound
system utilizes a number of flat membranes separated by porous
spacers and rolled into a spiral; these systems typically provide
820 sq m of membrane surface per cu m (250 sq ft per cu ft) of
volume. The hollow fiber system utilizes microscopic fibers that
are in essence very small tubes with thick walls. Pressure is
applied from the outside of the tubes and the filtrate (filtered
effluent) flows into the tubes. The hollow fiber system can
provide from 6565 to 16,410 sq m of membrane surface per cu m of
volume (2000 to 5000 sq ft per cu ft). The tubular system is
easiest to clean or replace and is usually employed in wastewater
applications.
Hyperfiltration systems usually operate at a pressure of 20.4 to
102.1 atm (300 to 1,500 psi) and have a flux rate on the order of
407 1/day/sq m (10 gal/day/sq ft). They generally require
extensive pretreatment (pH adjustment, filtration, chemical
precipitation, activated carbon adsorption) of the waste stream
to prevent rapid fouling or deterioration of the membrane
surface.
Ultrafiltration is similar to hyperfiltration and relies on a
semipermeable membrane and an applied driving force to separate
suspended and dissolved materials from wastewater. The membranes
used in ultrafiltration have pores large enough to eliminate
osmotic pressure as a factor which allows operation at pressures
333
-------
as low as 0.352 to 0.703 kg/sq cm (5 to 10 psi). Sieving is the
predominant removal mechanism, and the process is usually
applicable for removal of materials having a molecular weight
greater than 500 and a very small osmotic pressure at moderate
concentrations. Because of the larger pore sizes, flux rates for
ultrafiltration are normally 814 to 2035 1/day/sq m (20 to 50
gal/day/sq ft). The systems have been used for removal or
concentration of macromolecules such as proteins, enzymes,
starches, and other organic polymers.
Industry Application - None of the textile mills surveyed
during this study report the use of hyperfiltration or
ultrafiltration in their end-of-pipe wastewater treatment
systems.
Literature/Research
Both
hyperfiltration and
ultrafiltration of textile wastewater has been studied by EPA and
others for several years. A research project (25) funded by the
EPA Office of Research and Development investigated the
feasibility of hyperfiltration membranes for the renovation of
composite textile dyeing and finishing wastewater from a woven
fabric finishing-simple processing mill. The processing at the
mill is piece dyeing of upholstery fabrics made of cotton, rayon,
and nylon. The general conclusion of the study is that the
product water quality is satisfactory for direct reuse in all
dyeing and finishing operations at the facility.
A second research project (26), also funded by the EPA Office of
Research and Development, investigated hyperfiltration for
renovation of composite wastewater at eight textile finishing
mills. The objective of the study was to determine the
applicability of the hyperfiltration unit used in the previously
mentioned study (25) as a general treatment technology for the
textile industry. The study involved the measurement of membrane
performance with minimum pretreatment, the evaluation of reuse of
both the purified product water and the concentrated residue, and
the determination of the treatability of the concentrate by
conventional treatment technologies. The conclusions of the
study are that the product water (filtrate) is satisfactory for
reuse in scouring, bleaching, dyeing and finishing and that the
residual concentrate is treatable by the technology currently
installed at each facility. Evaluations of equipment performance
and projected treatment cost also are provided.
Based on the finding of these hyperfiltration studies, a full-
scale demonstration project has been funded by EPA and is
currently in the design and construction phase.
Research has been conducted on the recovery of synthetic sizes
from scouring wastes, and a full-scale ultrafiltration system is
in place.
334
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Dissolved Air Flotation Dissolved air flotation is a physical
separation operation that is used to separate solid or liquid
particles from a liquid phase, A portion of the flow is
pressurized to 2.7 to 3.4 atm (40 to 50 psi) in the presence of
sufficient air to approach saturation. The pressurized air-
liquid mixture is released in a flotation unit through which the
remaining waste stream flows. The entrained air is released as
fine bubbles that attach to the particulate matter. The buoyant
force of the gas bubbles causes the particles to rise to the
surface where the solids are removed by skimming.
The performance of a flotation unit is related to the air-solids
ratio, which is defined as pounds of air released per pound of
solids in the influent waste. A typical range of the air to
solids ratio is 0.01 to 0.1.
The design variables for flotation units are the quantity of air
used, the influent solids or oil concentration and the overflow
rate. When the flotation process is used primarily for
clarification, a detention period of 20 to 30 minutes is adequate
for separation and concentration. Rise rates of 61 to 204 1/sq m
(1.5 to 5.0 gpm/sq ft) are commonly employed. (27)
The principal components of a dissolved air flotation system are
a pressurizing pump, air injection facilities, a retention tank,
a back pressure regulating device and a flotation unit. The
pressurizing pump creates an elevated pressure to increase the
solubility of air. Air is usually added through an injector on
the suction side of the pump. Of the total air induced, 30 to 45
percent is usually dissolved.
Chemicals such as aluminum and iron salts and activated silica
commonly are used in dissolved air flotation to increase the
flocculent properties of the floated particles and aid the
capture of gas bubbles. A variety of organic chemicals
(polymers) also are used to change the nature of either the air-
liquid interface or the solid-liquid interface, or both.
Industry Application - Seven mills use air flotation in
their waste treatment systems. Four are direct dischargers, two
are indirect dischargers, and one practices complete recycle.
One of the direct dischargers uses flotation to separate print
pastes from a segregated print department discharge, one reclaims
indigo dyestuff for reuse from a yarn dyeing operation, one
separates wool grease from a wool scouring discharge, and one
separates biological floe from the effluent of a secondary
clarifier. One indirect discharger separates print pastes from
the discharge of a sheet printing operation while the other
removes latex from a coating operation. The recycle plant
separates print paste from the discharge of large woven fabric
printing operation. Historical monitoring data are not available
to describe the performance of the air flotation units alone.
335
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Field Sampling - During this study, sampling was conducted
at three of the mills noted above to provide performance data for
air flotation. The results are discussed in the following cases.
Case 1_ is a wool scouring mill that scours raw grease wool and
converts it, usually blended with other fibers, into fabric by
combing, spinning and weaving. The wool scouring operations
result in a wastewater discharge rate of 33.4 I/kg of product
(4.0 gal/lb of product) and a wastewater discharge of 2,300 cu
m/day (0.6 mgd). The mill operates in conjunction with a wool
finishing mill that converts the product of the wool scouring
mill into finished fabric.
After preliminary dissolved air flotation of the wool scouring
wastewater and screening of the wool finishing wastewater, the
mills share an extended-aeration activated sludge treatment
facility. The preliminary treatment of the wool scouring
wastewater consists of equalization (mixed), chemical addition
(ferric chloride, caustic and polymer) and dissolved air
flotation 18.9 Ips (300 gpm). The remainder of the treatment
facility consists of aeration (1 basin with a total volume of
49,211 cu m (13 million gal), secondary clarification and
disinfection (chlorine). Aeration detention time is
approximately 60 hours, and air is provided by surface aerators
at a power-to-volume ratio of 10.2 kw/1000 cu m (52 hp/million
gal).
Samples were collected over a typical 72-hour period of operation
at the screens before the finishing plant effluent enters the
aeration basin, at the equalization basin prior to the dissolved
air flotation unit, at the effluent pipe from the dissolved air
flotation unit, and at the effluent from the secondary
clarifiers. The performance of the dissolved air flotation unit
in treating toxic, nonconventional and conventional pollutants is
presented in Table VII-63.
Case "l_ is a woven fabric finishing-simple processing mill that
performs flat bed and rotary screen printing to produce sheets,
towels, and bedspreads. Rotary screen printing accounts for
approximately 90 percent of the production. Wastewater is
discharge data rate of 19.2 I/kg of product (2.3 gal/lb of
product).
Wastewater treatment at this mill consists of equalization (small
holding tank), grit removal, coarse screening, chemical addition
(alum and caustic), fine screening (vibrating), chemical addition
(cationic polymer) 'and flocculation, dissolved air flotation (300
gpm), aeration (2 lagoons in series), disinfection (chlorine),
secondary clarification (reactor/clarifier in which alum,
caustic, and anionic polymer are added) and dual media gravity
filtration (sand and carbon). Aeration detention time is
approximately 170 hours, and air is provided by surface aerators
at a power-to-volume ratio of approximately 3.53 kw/1000 cu m (18
336
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TABLE VII-63
SUMMARY OF ANALYTICAL RESULTS
CASE 1 - DISSOLVED AIR FLOTATION UNIT
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Influent
Min Max n
Effluent
Min Max
Conventional & Nonconventional Pollutants
BOD5, mg/1
COD, mg/1
TSS, mg/1
Oil & Grease, mg/1
Total Phenols, ug
Color, APHA Units
Color, ADMI Units
(pH 7.6)
mg/1
ug/1
tits
tits
4,700
10,000
3,700
63
1,900
65
A
9,200
21,000
6,400
2,000
3,200 •
197
*
3
3
3
3
3
3
*
1,000
1,700
32
220
580
9
446
1,900
2,600
76
560
1,400
83
581
Toxic Pollutants, ug/1
Acenaphthene
Chlorobenzene
Ethylbenzene
Methylene Chloride
Isophorone
Pentachlorophenol
Phenol
Bis(2-ethylhexyl)
Phthalate
Di-n-octyl Phthalate
Toluene
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Zinc (Total)
ND
ND
ND
TA
ND
ND
TA
ND
ND
TA
162
11
240
59
437
81
613
ND
20
23
10
111
24
221
20
10
43
225
13
269
77
491
133
724
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
ND
TA
ND
TA
ND
ND
ND
ND
ND
TA
30
TA
163
ND
154
88
241
16
TA
ND
10
ND
ND
517
50
ND
TA
39
10
391
ND
250
123
382
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
* No analytical result, clear filtrate could not be obtained.
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at
less than 10 ug/1 in the influent or effluent: Benzene;
1,2,4-Trichloroethane; Chloroform; 1,2-Diphenylhydrazine;
N-nitrosodiphenylamine; Butyl Benzyl Phthalate; Di-n-butyl
Phthalate; Tetrachloroethylene; Dieldrin; 4,4'-DDD; Alpha
Endosulfan; Beta Endosulfan; Heptachlor Epoxide; Alpha-BHC;
Beta-BHC; Gamma-BHC; Delta-BHC; PCB-1242; Antimony;
Beryllium; Selenium; Silver; Thallium.
Source: EPA Field Sampling Results for Mill 10013, March 1980.
337
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hp/million gal). The discharge from the treatment plant is
recycled for reuse in the printing operations.
Samples were collected over a typical 48-hour period of operation
at the bar screen prior to the air flotation unit, at the
Parshall flume prior to the aeration basins, at the chlorine
contact chamber following aeration, and at the effluent from the
dual media filters. The performance of the dissolved air
flotation unit in treating toxic, nonconventional and
conventional pollutants is presented in Table VII-64.
Case 3, is a knit fabric finishing-complex processing mill that
knits7 scours and piece dyes cloth of wool, cotton, polyester or
nylon. Wastewater is discharged at a rate of 129 I/kg of product
(15.5 gal/lb of product).
Wastewater treatment at this mill consists of coarse screening,
aeration (1 basin), secondary sedimentation, chemical addition
(alum, caustic, and polymer), dissolved air flotation,
disinfection (chlorine), and a polishing pond. The aeration
detention time is approximately 24 hours, and air is provided by
surface aerators at a total power-to-volume ratio of 26.1 kw/1000
cu m (133 hp/million gal).
Samples were collected over a typical 72-hour period of operation
at the bar screen, at the discharge from the secondary
clarifiers, and at the discharge from the dissolved air flotation
unit. The performance of dissolved air flotation in treating
toxic, nonconventional and conventional pollutants is presented
in Table VII-65.
Stripping Stripping refers to the removal of relatively volatile
components from a wastewater by the passage of air, steam or
other gas through the liquid. For example, ammonia nitrogen has
been removed from high pH municipal wastewater by air stripping
in a limited number of applications. The exhaust gas usually is
vented to the atmosphere without treatment. Steam stripping of
ammonia-rich water followed by recovery of the ammonia as
ammonium salt in an acidic absorbing liquid is a newer process
under development. (28,29) Stripping odorous substances from
kraft pulp mill waste streams by steam is another example (30).
Stripping of volatile toxic pollutants under controlled
conditions that prevent release to the atmosphere could
theoretically be used as a treatment process for textile
wastewater. However, this is an expensive process because of the
relatively low volatile pollutant concentrations typically
present. There is no information available providing design
criteria, performance, or detailed costs for treatment systems
using stripping of volatile pollutants from industrial wastewater
similar to that produced by the textile industry.
338
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TABLE VII-64
SUMMARY OF ANALYTICAL RESULTS
CASE 2 - DISSOLVED AIR FLOTATION UNIT
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant -
Influent*
Effluent*
Conventional & Nonconventional Pollutants
BOD5, mg/1
COD, mg/1
TSS, mg/1
Total Phenols, ug/1
Sulfide, ug/1
400
1050
195
92
(200)
Toxic Pollutants, ug/1
(200)
725
32
26
(200)
Benzene
1,1, 1-Trichloroethane
Ethylbenzene
Methylene Chloride
Naphthalene
Penta chlo r opheno 1
Phenol
Bis(2-ethylhexyl) Phthalate
Di-n-butyl Phthalate
Toluene
Copper (Total)
Lead (Total)
Nickel (Total)
Thallium (Total)
Zinc (Total)
18
11
460
26
250
37
94
570
13
320
323
14
28
TA
25
12
TA
160
30
ND
30
26
45
ND
132
81
ND
32
14
TA
* average of two 24-hour samples
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
( ) indicates "less than" value.
The following pollutants also were detected at less than
10 ug/1 in the influent or effluent: 1,2-Dichloroethane;
Chloroform; Tetrachloroethylene; Beryllium; Cadmium;
Chromium; Cyanide; Mercury; Selenium; Silver; Thallium.
Source: EPA Field Sampling Results for Mill 40144, November 1977
339
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TABLE VII-65
SUMMARY OF ANALYTICAL RESULTS
CASE 3 - DISSOLVED AIR FLOTATION
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Biological
Effluent
Min Max n
Final
Effluent
Min Max n
Conventional & Nonconventional Pollutants
COD, mg/1
TSS, mg/1
Total Phenols, ug/1
Color, ADMI Units
Color, ADMI Units (pH 7.6)
314
16
13
77
74
706
36
33
87
95
3
3
3
3
3
146
ND
21
46
46
Toxic Pollutants, ug/1
9 3
48 3
52 3
Chloroform
1 , 2-Trans-dichloroethylene
Bis(2-ethylhexyl) Phthalate
Tetrachloroethylene
Trichloroethylene
Antimony (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
TA
ND
270
ND
436
12
46
136
12
47
81
TA
15
370
47
478
16
48
164
20
64
2
1
3
3
3
3
3
3
3
3
3
ND
14
11
200
ND
364
ND
18
76
ND
44
25
14
540
250
TA
393
TA
39
146
28
45
3
1
3
3
3
3
3
3
3
3
3
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
The following pollutants also were detected but at
less than 10 ug/1 in the influent or effluent:
Benzene; 1,1,2,2-Tetrachloroethane; 2,4-Dimethylphenol;
Methylene Chloride; Phenol; Di-N-butyl Phthalate; Anthracene;
Toluene; Arsenic; Cadmium; Chromium; Cyanide.
Source: EPA Field Sampling Results for Mill 50013, August 1978.
340
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Electrodialysls Electrodialysis is a membrane separation process
that is used to separate ionic components from a liquid phase.
The process makes use of an induced electric current that causes
migration of cations toward a negative electrode and migration of
anions toward a positive electrode. Separation is accomplished
by alternately placing membranes which preferentially allow
passage of anions or cations across the current path. Because of
the alternate spacing, cells of concentrated and dilute solutions
are formed. Electrodialysis shares the same operating
difficulties as hyperfiltration and ultrafiltration systems in
that pretreatment is usually necessary to prevent rapid fouling
of the membranes.
Industry Application - There are currently no known textile
mills that use electrodialysis as part of their wastewater
treatment systems. Because the process primarily is applicable
to the separation of soluble inorganic ions, it has not been
given much consideration except in the case of wastewater
renovation for reuse.
Sorption Systems
Activated Carbon Adsorption Activated carbon adsorption is a
physical separation process in which substances in water are
removed on the surface of highly porous carbon particles.
Various raw materials are used in the production of activated
carbon. The carbonized material is activated, usually by steam,
to remove tars and other impurities and open up and enlarge the
pores. Pore size depends, in part, on the source material and is
increased through regeneration (31). Therefore, different
activated carbons are used for different applications, such as
gaseous versus liquid systems for example.
The primary removal mechanism of activated carbon is adsorption,
the physical attraction and accumulation of the removed material
on the surface of the carbon. Activated carbons typically have
surface areas of 500 to 1,400 sq m/g (152,700 to 427,600 sq
ft/oz).
Many factors have been identified as important in describing the
adsorption of materials on activated carbon. It is not
appropriate for this discussion to include all of the factors
relating to the nature of the carbon and its surface area,
particle size, pore size, etc. Instead, the focus is on the
materials in the wastewater that are to be adsorbed. Information
has been developed about the molecular structure of compounds
which relates to adsorbability, polarity, and degree of
ionization (32). Molecular structure also is reflected in the
solubility of the compound. As a result, materials that are less
attracted to water tend to be more attracted to activated carbon
surfaces.
341
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In general, molecules are more readily adsorbed than ionized
compounds. The aromatic compounds tend to be more readily
adsorbed than the aliphatics. Larger molecules are more readily
adsorbed then smaller ones, although extremely high molecular
weight materials are too large to penetrate the pores in the
carbon. Treatment of wastes with activated carbon is generally
considered for organic rather than inorganic components, although
metals and other inorganics are adsorbed on carbon surfaces or on
organic solids that are removed in granular carbon filters.
The concentration of the constituents removed is important in
several ways, including competition for sites with other organic
materials in the water and displacement of molecules already
adsorbed by compounds more favored by the carbon. An important
consideration related to toxic pollutant concentration is that
the behavior of many of the 129 toxic pollutants have not yet
been widely studied at the concentrations that have been observed
in textile wastewaters. A last but very important factor in
adsorption phenomena is the pB of the solution. Usually, the
lower the pH of the solution the greater the adsorption of many
materials.
As pointed out by Ford (33) and others, adsorption with activated
carbon has limitations and must be evaluated for particular
situations. Preliminary treatment of the wastewater, such as pH
adjustment, coagulation, or chemical oxidation may improve the
adsorbability of some pollutants.
There are two forms of activated carbon in common use, granular
and powdered. To date, the granular form has been preferred for
most wastewater applications because it can be readily
regenerated. Regeneration of powdered activated carbon by steam
is currently under development. Granular carbon is commonly used
in columns operated in series. The columns are operated downflow
packed bed, upflow packed bed, or upflow expanded bed. Although
the upflow expanded bed theoretically is the best alternative
because of its ability/to process more turbid wastewaters without
clogging, operational difficulties have limited its development.
The upflow packed bed offers an important advantage. The column
is operated continuously, with the exhausted carbon being removed
at the bottom of the column with virgin, or regenerated, carbon
added at the top. This eliminates the need for an auxiliary
column for use when an exhausted column is being serviced.
Spent carbon is commonly regenerated thermally at 815°C (1500°F)
in a multiple hearth furnace in the presence of steam. In this
process, the adsorbed organics are oxidized to gases in the form
of either CO or C02_. Some elemental carbon is lost in the
process, but this is usually limited to less than 10 percent by
weight. After regeneration, the carbon is returned to the
columns for reuse.
342
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An aspect of granular carbon columns that is currently receiving
attention is the role and possible benefits of biological growths
on the carbon surfaces. In some applications, much of the
pollutant removal has been found to result from biodegradation
rather than adsorption.
Powdered activated carbon (PAC) use in wastewater treatment
applications has increased rapidly in the past decade. Various
application points in the treatment sequence have been used, with
the activated sludge aeration tank being the most common. The
spent carbon is discarded without regeneration in most systems.
This process results in a transfer of the pollutants from the
water to the carbon. Biorefractory materials remain intact in
the sludge or other residue containing the spent carbon.
Treatment using powdered activated carbon is discussed as a
separate topic below.
Industry Application - Only one of the mills surveyed in
this study reports the use of granular activated carbon in its
wastewater treatment system. Several additional textile mills
also are using activated carbon as part of closed (recycle)
systems for at least a part of their wastewater. However, the
application at these mills is not considered typical and
information on the characteristics of these systems was not
obtained during this study.
Literature/Research - Activated carbon adsorption has
received considerable attention as an industrial wastewater
treatment technology. Much of the information available on
textile wastewater has to do with treatment of individual waste
streams discussed in the next section.
EPA/Industry Field Studies - In a joint research effort
between EPA and the textile industry (ATMI, NTA, and CRI), pilot
plant studies were conducted during 1977 and 1978 at 19 textile
mills to generate performance data for alternative advanced
wastewater treatment technologies. The studies were performed on
secondary clarifier effluent from treatment systems using
extended-aeration activated sludge. One of the pilot scale
technologies was granular activated carbon adsorption using three
carbon columns operated in series in the downflow mode. Each
column was 2.36 m (7.75 ft) in height and 19.0 cm (7.5 in) in
diameter. They were constructed of Schedule 80 PVC pipe and had
a carbon capacity of 18.2 kg (40 Ibs), allowing for sufficient
expansion volume during backwashing. Depending on the results of
isotherm testing, either Westvaco WV-L, Westvaco WV-I, or ICI
Hydrodarco granular carbon was utilized.
Activated carbon was included in the treatment technology
selected for further study at 18 of the 19 mills. The columns
were designed to remove soluble organic material and were
preceded by either multimedia filtration or chemical coagulation
plus multimedia filtration. In addition to the regular pilot
343
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plant testing, sampling was conducted at selected mills to
determine the performance of activated carbon in the treatment of
toxic pollutants.
The data generated for granular activated carbon technology is
summarized in Tables VII-66 through VII-71 of this section by
subcategory grouping (wool scouring mills, wool finishing mills,
and other mills). The data are presented in aggregate form
without regard to location of the carbon columns in the pilot
scale treatment technology. The aggregation of data is
appropriate because the preceeding treatment steps sufficiently
reduced the TSS in the influent to the carbon columns in all
cases. Therefore, the performance of the carbon is related
solely to its ability remove soluble organic material. The
summaries demonstrate the effectiveness of activated carbon in
the treatment of conventional, nonconventional, and toxic
pollutants.
Powdered Activated Carbon (PAC) Treatment Powdered activated
carbon treatment typically refers to the addition of powdered
activated carbon to the activated sludge process. It is a
recently developed process that has shown to upgrade effluent
quality in conventional activated sludge plants. A general
discussion of powdered activated carbon is provided in the
previous activated carbon section. In the PACT process, the
carbon concentration in the mixed liquor is generally equal to or
greater than the MLSS concentration. The carbon and adsorbed
substances are discarded as part of the biological sludge.
Industry Application - Three of the mills surveyed use
powdered activated carbon in their wastewater treatment systems.
Two mills manually add powdered carbon to the aeration basins and
maintain a specified concentration of carbon in the MLSS. The
other mill operates a semi-continuous system in which raw
dyehouse wastewater is pumped to a tank containing a designated
amount of powdered carbon, mixed to form a slurry, and pumped
through a filter press. The filter cake is discarded as solid
waste. The operation and effectiveness of one continuous system
and the semi-continuous system are discussed as case studies in
the next section.
Literature/Research - Bench-scale laboratory studies have
been conducted by EPA (34) on the wastewaters from 10 textile
finishing mills and the results are presented later in this
section. The treatment process at one of the textile mills
reporting full scale use of powdered activated carbon addition to
the activated sludge process and the semi-continous system
treating raw textile wastewater were sampled during this study.
The results also are presented below. In addition to the field
sampling, information is presented on an existing municipal PAC
treatment system that treats textile mill wastewater.
344
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TABLE VII-66
SUMMARY OF ANALYTICAL RESULTS
GRANULAR ACTIVATED CARBON ADSORPTION
TRADITIONALLY MONITORED POLLUTANTS
"WOOL SCOURING MILLS
Parameter
Mill
A
Contact time, minutes
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
BOD5
COD
TSS
TOC
Total Phenols
Color
45
Average Effluent Concentration
13
431
31
191
307
Average Removal, Percent
43
47
66
34
51
Subcategory
Average
13
431
31
191
307
Subcategory
Average
43
47
66
34
51
Source; EPA/Industry Field Studies
345
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TABLE VII-67
SUMMARY OF ANALYTICAL RESULTS
GRANULAR ACTIVATED CARBON ADSORPTION
TOXIC POLLUTANTS
WOOL SCOURING MILLS
Parameter/Pollutant
Mill
A
Contact time, minutes
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal,%) ug/1
Phenol
Bis(2-ethylhexyl)Phthalate
Arsenic (Total)
Copper (Total)
Cyanide
Zinc (Total)
17 (NR)
26 (NR)
42 (49)
ND (100)
40 (85)
120 (70)
17
26
42
ND
40
120
NR
NR
49
100
85
70
Note; ND indicates "not detected,"
NR indicates "no removal."
Source: EPA/Industry Field Studies
346
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TABLE VII-68
SUMMARY OF ANALYTICAL RESULTS
GRANULAR ACTIVATED CARBON ADSORPTION
TRADITIONALLY MONITORED POLLUTANTS
WOOL FINISHING MILLS
Parameter
Mill
B
B
B
0
Contact time, minutes
BOD5, rag/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Total Phenols, ug/1
Color, ADMI Units
(pH 7.6)
25 28 30 45
Average Effluent Concentration
8.3
40
2.1
18
20
11*
20
4.8
17
20
16
26
0.9
15
20
2.2
18
2.9
6.7
24
30*
16
29
Subcategory
Average
26
2.7
14
21
23
Average Removal, Percent
BODS
COD •
TSS
TOC
Total Phenols
Color
61
79
57
46
-
—
52*
75
86
68
-
—
47
84
28
73
-
^
16
84
52
80
37
65
Subcategory
Average
41
81
56
67
37
65
* Value represents a single data point and was not included in calculating
subcategory average.
Source: EPA/Industry Field Studies
347
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TABLE VII-69
SUMMARY OF ANALYTICAL RESULTS
GRANULAR ACTIVATED CARBON ADSORPTION
TOXIC POLLUTANTS
WOOL FINISHING MILLS
Mill
Parameter/Pollutant
B
Contact time, minutes
25-30
Subcategory
Average
Average Effluent Concentration, ug/1 (Removal>%) ug/1
1,2, 4-Trichlorobenzene
Methylene Chloride
Bis(2-ethylhexyl)Phthalate
Toluene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Zinc (Total)
ND
ND
TA
ND
TA
ND
13
29
51
12
82
151
5964
(100)
(29)
(100)
(17)
(100)
(88)
(29)
(57)
(90)
(NR)
(4)
(NR)
ND
27
33
ND
ND
TA
ND
TA
11
ND
ND
ND
374
(43)
(41)
(NC)
(93)
(91)
(22)
ND
14
17
ND
TA
TA
TA
20
31
TA
41
76
3170
100
43
35
100
17
100
88
61
74
90
NR
4
11
Note: NC indicates "not able to calculate removal."
ND indicates "not detected."
NR indicates "no removal."
TA indicates "trace amount," less than 10 ug/1.
Source: EPA/Industry Field Studies
348
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TABLE VII-70
SUMMARY OF ANALYTICAL RESULTS
GRANULAR ACTIVATED CARBON ADSORPTION
TRADITIONALLY MONITORED POLLUTANTS
OTHER MILLS
Parameter
Subcategory
Contact time, minutes
K
4a
35
BB
4b
45
AA
4c
45
D
4c
45
Mill
P
4c
15
P
4c
25
Average Effluent
BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, rag/1
Total Phenols, ug/1
Color, ADMI Units (pH 7.6)
BODS
COD
TSS
TOC
Total Phenols
Color
9.4
21
2.5
-
(50)
59
34
70
39
_
_
84
19
210
28
44
53
197
20
41
27
53
28
41
8.8
169
13
-
20
167
19
44
19
_
-
54
13
422
23
101
-
820
44
33
51
37
-
4.3
8.4
93
-
12
20
51
Average
5.0
7
-
49
-
60
15* 6
70*
-
11* 7
10*
-
Removal
61*
46*
-
56*
-
~
P
4c
45
T
4c
60
V
4c
45
Y
4c
45
Concentration
.0
37
19
.0
20
-
,
41
53
14
74
0
~*
6
411
* 16
98
* 237
49
Percent
32
21
* 28
28
* 56
70
1.2
176
20
36
-
79
48
48
11
42
-
72
6.1
33
2.1
4.4
-
43
18
64
42
70
-
74
* Value represents a single data point and was not included in calculating subcategory average.
Note: ( ) Indicates "less than" value.
Source: EPA/Industry Field Studies
-------
TABLE VII-70 (Cent.)
Parameter
Subcategory
Contact time, minutes
Z
4c
49
E
5a
45
Q
5a
22
Mill
Q W
5a 5a
30 45
F
6
45
EE
7
45
S
7
45
Average Effluent Concentration
BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
w Total Phenols, ug/1
g Color, ADMI Units (pH 7.6)
BODS
COD
TSS
TOC
Total Phenols
Color
12
346
11
—
—
127
30
23
43
—
—
35
3.8
32
2.3
5.3
50
57
62
78
35
82
1.5
57
1.7
74
2.3
—
(20)*
109
Average
55
64
38
—
—
36
2.1 1.5
70 19
2.5 2.1
14 2.9
—
97 27
Removal,
55 55
67 65
33 75
37 78
__
64 70
5.9
45
4.7
4.9
22
35
Percent
16
67
54
80
32
80
(2)
29
4.3
10
(20)
23
12
76
45
75
—
87
6.0
72
6.1
4.4
22
103
19
36
44
45
—
43
Average
6.6
133
9.3
26
55
128
Average
33
51
39
58
31
58
* Value represents a single data point and was not included in calculating subcategory average.
Note: ( ) Indicates "less than" value.
Source: EPA/Industry Field Studies
-------
TABLE VII-71
SUMMARY OF ANALYTICAL RESULTS
GRANULAR ACTIVATED CARBON ADSORPTION
TOXIC POLLUTANTS
OTHER MILLS
Pa rame te r/Pol lutant
K
BB
Mill
V
Subcategory 4a 4b 4c
Contact time,
minutes 35 45 45
Average Effluent Concentration,
Benzene
Chloroform
Methylene chloride
Trichlorofluoro-
me thane
N-nitrosodi-n-
propylamine
Pent a chl o r opheno 1
Phenol
Bis(2-ethylhexyl)
Phthalate
Di-n-butyl
Phthalate
Trichloroethylene
Antimony (Total)
Arsenic (Total)
Cadmium (Total)
Chromium (Total)
Copper (Total)
Cyanide
Lead (Total)
Nickel (Total)
Selenium (Total)
Silv«r (Total)
Zinc (Tbtal)
ND
ND
17
ND
ND
ND
ND
TA
ND
ND
35
TA
ND
TA
•15
ND
26
55
ND
15
70
(NR)
(100)
(33)
(100)
(100)
(NR)
(NC)
(NC)
(80)
(8)
(NR)
(NR)
(66)
TA
ND
19
ND
ND
ND
ND
23
ND
ND
(NR) ND
ND
(NR) ND
ND
ND
ND
ND
(13) 11
TA
ND
39(27) 116
ND
ND
93
94
TA
TA
121
ND
36
306
ND
10
(8) 15
(8) 35
(86) ND
(50) 64
(4) 32
ND
(4) 91
(NR) 83
(100)
(100)
(NR)
(NC)
(15)
(NR)
(NR)
(NR)
(NR)
(NR)
(NR)
(65)
E
W
5b 5b
45 45
ug/1 (Removal, %)
ND
ND
TA
ND
ND
ND
ND
38
ND
ND
TA
12
TA
TA
TA
ND
ND
85
ND
28
19
(100)
(NC)
(100)
(100)
(5)
(2)
(NR)
(NR)
(1)
(17)
(100)
(13)
(100)
(4)
(86)
ND
TA
ND
69
ND
ND
ND
69
ND
TA
747
11
TA
ND
15
ND
54
84
ND
20
39
(67)
(NR)
(2)
(NC)
(8)
(NR)
(NC)
(36)
(15)
(18)
(22)
(38)
Average
ug/1 %
TA
TA
TA
14
ND
ND
ND
30
TA
TA
189
TA
TA
26
34
TA
31
75
ND
38
103
NR
84
NR
NR
100
100
100
11
100
100
10
NR
NR
1
28
86
35
7
100
6
51
Note: NC indicates "not able to calculate removal."
ND indicates "not detected."
NR indicates "no removal."
TA indicates "trace amount," less than 10 ug/1
Source: EPA/Industry Field Studies
351
-------
Case J_ is a knit fabric finishi-ng-simple processing mill that
knits, scours and dyes synthetic bolt cloth of polyester and
acetate fiber. Pressure piece dyeing with dispersed dyes is
performed on the total production and 20 percent of the
production is scoured. During the field sampling, the wastewater
discharge averaged 984 cu m/day (260,000 gpd).
Wastewater treatment at this mill consists of fine screening
{vibratory), equalization (mixed, with nitrogen addition),
aeration (two basins operated in series with powdered activated
carbon added to the first basin), secondary clarification, sand
filtration, disinfection (chlorine) and post aeration. Total
detention time in the aeration basins is approximately 48 hours,
and air is provided by surface aerators at a power-to-volume
ratio of approximately 15.7 kw/1000 cu m (80
The results presented in Table VI1-72
effectiveness of the full-scale process in
nonconventional and conventional pollutants.
hp/million gal).
demonstrate the
treating toxic,
Case 2_ a carpet finishing mill that piece dyes and backs (jute
using latex adhesive) carpet made from polyester and nylon
fibers. The processing results in a wastewater discharge rate of
36.7 I/kg of product (4.4 gal/lb of product).
Wastewater treatment at this mill consists of coarse screening,
equalization (storage tank), mixing (wastewater and powdered
activated carbon) and solids separation (filter press). The
results presented in Table VII-73 demonstrates the performance of
the system in treating toxic pollutants.
Case 3. is a municipal PAC treatment system in the northeastern
United States. A sizeable portion of the wastewater comes from a
woven fabric finishing-desizing mill that desizes, scours, and
dyes synthetic cloth comprised of polyester, rayon, nylon, and
acetate. Wastewater discharge averages 2,840 cu m/day (0.75 mgd)
at this mill. This is approximately 20 percent of the total flow
to the POTW, The organic loading contributed by the textile mill
is greater than 20 percent.
Wastewater treatment at the POTW consists of coarse screening,
comminution, aerated grit removal, primary clarification, PAC and
polymer addition, aeration (four basins), secondary
clarification, filtration (dual media filters) and disinfection
(chlorine). Total detention time is approximately 4.5 hours at
the current flow, and air is provided by coarse bubble diffusers.
Waste activated sludge and spent PAC are treated by a wet air
oxidation unit that oxidizes the organic material in the sludge
and regenerates the PAC. The performance of the system is shown
in Table VI-74.
EPA/Industry Field Studies - As part of the joint research
effort between EPA and the textile industry (ATMI, NTA, and CRI),
bench-scale laboratory studies were conducted on the raw
352
-------
TABLE VII-72
SUMMARY OF ANALYTICAL RESULTS
CASE 1 - PAC PROCESS
CONVENTIONAL, NONCONVENTIONAL, AND TOXIC POLLUTANTS
Parameter/Pollutant
Conventional &
COD, mg/1
TSS, mg/1
Total Phenols, ug/1
Sulfide, ug/1
Color, ADMI Units (pH 7.6)
Toxic
Acrolein
Acrylonitrile
Chloroform
Methylene Chloride
Bis(2-Ethylhexyl) Phthalate
Trichloroethylene
Antimony (Total)
Copper (Total)
Lead (Total)
Nickel (Total)
Silver (Total)
Thallium (Total)
Zinc (Total)
Biological
Influent*
Clarifier Effluent**
Min Max n
Nonconventional Pollutants
1744
204
34
50
158
Pollutants,
199
90
ND
30
430
TA
186
17
99
69
19
(50)
343
154
44
TA
8
75
us/1
ND
ND
ND
ND
TA
ND
81
TA
36
54
14
(50)
48
254
60
15
20
89
87
(100)
TA
28
50
41
87
TA
44
65
17
(50)
69
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
* 72-hour composite sample
** 24-hour composite samples
Notes: ND indicates "not detected."
TA indicates "trace amount," less than 10 ug/1.
( ) indicates "less than" value.
The following pollutants also were detected but at less
than 10 ug/1 in the biological influent or secondary
clarifier effluent: Benzene; 1,2,4-Trichlorobenzene;
2,4,6-Trichlorophenol; Parachlorometacresol; 1,2-Dichloro-
benzene; Ethylbenzene; Naphthalene; N-nitrosodi-n-propylamine;
Pentachlorophenol; Phenol; Anthracene; Tetrachloroethylene;
Toluene; Trichloroethylene; Arsenic; Beryllium; Cadmium;
Chromium; Cyanide; Mercury; Selenium.
Source: EPA Field Sampling Results for Mill 50104, August 1978.
353
-------
TABLE VII-73
SUMMARY OF ANALYTICAL RESULTS
CASE 2 - PAC PROCESS
TOXIC POLLUTANTS
Pollutant
Naphthalene
Phenol
Bis(2-ethylhexyl) Phthalate
Antimony (Total)
Zinc (Total)
Influent*
240
67
400
(12)
20
Effluent**
Min Max n
TA
TA
TA
140
40
TA
TA
TA
160
120
2
2
2
2
2
* composite and grab samples during a 24-hour period; concentrations
expressed in ug/1
** two grab samples during 24-hour period; concentrations expressed in ug/1
Notes: TA indicates "trace amount," less than 10 ug/1.
( ) indicates "less than" value.
The following pollutants also were detected but at less
than 10 ug/1 in the influent or effluent: 1,1,1-Tri-
chloroethane; Methylene Chloride; Cadmium; Copper; Mercury.
Source: EPA Field Sampling Results for Mill 60031, December 1977.
TABLE VII-74
SUMMARY OF ANALYTICAL RESULTS
CASE 3 - PACT PROCESS
TRADITIONALLY MONITORED CONVENTIONAL AND
NONCONVENTIONAL POLLUTANTS
Pollutant
BODS, mg/1
COD, mg/1
TSS, mg/1
Turbidity, NTU
Raw
Waste*
217
789
406
^ ™
Primary
Effluent**
79
322
97
50
Clarifier
Effluent**
1.5
80
24
6.5
* One month average.
** Two month average.
Source: Reference 71
354
-------
wastewater (influent to the biological aeration system) at 10 of
the 19 pilot plant locations to evaluate the performance of
powdered activated carbon treatment. Each textile mill shipped
wastewater to the laboratory each week during a six-week study
period. A description of the experimental procedures employed on
the waste from each mill is summarized below.
1
Three 10-liter plexiglas bioreactors were seeded with
activated sludge from the study mill and a
municipal/industrial treatment plant and acclimated to the
textile waste.
Following acclimation, the residual TOC
effluents was established.
of the bioreactor
3.
4.
5.
6.
Carbon adsorption isotherms were performed on the bioreactor
effluent, and based on several considerations (the effects
on residual TOC, experience gained in past studies, flow of
full-scale plant, sludge age, economics), a high and low
carbon make-up dosage was selected.
Two or three types of carbons were evaluated on an isotherm
level and the most effective was used in the experiments.
The three bioreactors were designated as control (no carbon
addition), high carbon, and low carbon, and were operated
for approximately three weeks with carbon addition and
sludge wastage each day.
Following the initial three-week period of operation
(equilibrium period), two weeks of analytical data were
generated to evaluate performance.
It should be stressed that the testing performed was for
determination of technical feasibility and to provide an
indication of the achievable effluent quality. Long term
operating characteristics and costs were not considered.
Results from the laboratory studies of PACT for the treatment of
conventional and nonconventional pollutants are presented in
Tables VII-75 through VII-77. The data are aggregated for wool
scouring mills, wool finishing mills, and all other mills.
Development of_ Treatment and Control Options
Many demonstrated control and treatment technologies have been
discussed and information presented on their capabilities for
removal of toxic, nonconventional and conventional pollutants
from textile industry wastewaters. Alternative control and
treatment technology options that represent a range of pollutant
removal capability and cost were selected for detailed analysis.
The options that were considered in determining BPT, BAT, NSPS,
PSES and PSNS limitations and standards are presented below as
355
-------
TABLE VII-75
SUMMARY OF ANALYTICAL RESULTS
POWDERED ACTIVATED CARBON TREATMENT
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
WOOL SCOURING MILLS
Parameter
Mill
A
Carbon:
Type
Cone., mg/1 (low)
(high)
Dosage, mg/1 (low)
(high)
BOD5, mg/1
COD, mg/1
TSS, mg/1 (control)
(low)
(high)
TOC, mg/1
Color, ADMI units (pH 7
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Color, ADMI units (pH 7
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Color, ADMI units (pH 7
6)
w-sc*
2000
10000
139
694
Influent
2580
5542
2977
5295
14837
1784
Control Reactor Effluent
69
543
568
373
705
6)
Low Carbon Reactor Effluent
54
563
366
387
.6) 629
High Carbon Reactor Effluent
Subcategory
Average
2580
5542
2977
5295
14837
1784
69
543
568
373
705
54
563
366
387
629
BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Color, ADMI units (pH 7.6)
51
457
402
336
253
51
457
402
336
253
* Westvaco SC carbon
356
-------
TABLE VII-75 (Cont.)
Parameter
Mill
A
BOD5
COD
TSS
TOC
Color
BOD5
COD
TSS
TOC
Color
BOD5
COD
TSS
TOC
Color
Control Reactor, % Removal
97
90
81
79
Low Carbon Reactor, % Removal
98
90
93
78
High Carbon Reactor, % Removal
98
92
97
81
Subcategory
Average
97
90
81
79
98
90
93
78
98
92
97
81
Source: Reference 34.
357
-------
TABLE VII-76
SUMMARY OF ANALYTICAL RESULTS
POWDERED ACTIVATED CARBON TREATMENT
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
WOOL FINISHING MILLS
Parameter
Mill
Carbon:
Type W-SA*
Cone., mg/1 (low) 2000
(high) 8000
Dosage, mg/1 (low) 97
(high) 388
W-SC**
1000
5000
25
125
Influent
BOD5, mg/1 407
COD, mg/1 1919
TSS, mg/1 (control) 2986
(low) 7012
(high) 9774
TOC, mg/1 461
Color, ADMI units (pH 7.6) 71
247
1098
3360
4373
7792
344
Control Reactor Effluent
BOD5, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Color, ADMI units (pH 7.6)
27
148
29
41
114
16
102
30
30
105
Low Carbon Reactor Effluent
BOD5, mg/1 29
COD, mg/1 107
TSS, rag/1 33
TOC, mg/1 44
Color, ADMI units (pH 7.6) 81
63
16
23
66
High Carbon Reactor Effluent
Westvaco SA carbon
Westvaco SC carbon
Subcategory
Average
327
1509
3173
5693
8783
403
71
22
125
30
36
110
19
85
25
34
74
BODS, mg/1
COD, mg/1
TSS, mg/1
TOC, mg/1
Color, ADMI units (pH 7.6)
18
73
23
38
64
6.5
33
11
11
43
12
53
17
25
54
358
-------
Parameter
TABLE VII-76 (Cont.)
Mill
B 0
BODS
COD
TSS
TOC
Color
BODS
COD
TSS
TOC
Color
BODS
COD
TSS
TOC
Color '
Note:
Control Reactor, %
93
92
99
91
0
Low Carbon Reactor,
93
94
(99)
90
0
High Carbon Reactor,
96
96
(99)
92
10
( ) indicates a "greater than" value
Removal
94
91
99
91
-
% Removal
97
94
(99)
93
-
% Removal
97
97
(99)
97
**
Subcategory
Average
94
92
99
91
0
95
94
(99)
92
0
97
97
(99)
95
10
Source: Reference 34.
359
-------
TABLE VII-77
SUMMARY OF ANALYTICAL RESULTS
POWDERED ACTIVATED CARBON TREATMENT
TRADITIONALLY MONITORED CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
OTHER MILLS
Parameter
D
P
Y
Mill
E
Q
F
S
4c
4c
4c
5b
5a
Subcategory
Carbon:
Type W-SA* W-SC# ICI-H** W-SC# W-SC# ICJ-K## W-SC##
Cone., mg/1 (low) 3000 1000 2000 2000 1000 2000 2000
(high) 6000 5000 5000 5000 5000 5000 5000
Dosage, mg/1 (low) 105 122 210 216 35 277 122
(high) 210 608 526 540 173 694 304
Influent
BODS,
COD,
TSS,
TOC,
mg/1
rag/1
mg/1 (control)
(low)
(high)
mg/1
1169
2115
4121
5686
8514
624
400
572
2310
4052
4610
243
Color, ADMI units+
BODS,
COD,
TSS,
TOC,
mg/1
mg/1
mg/1
mg/1
46
556
15
157
Color, ADMI units+
BODS,
COD,
TSS,
TOC,
Color
mg/1
mg/1
mg/1
mg/1
, ADMI units*
24
390
45
113
-
8
119
30
57
324
Low
8
96
18
42
293
114
301
1538
2070
4657
91
268
Control
6
98
29
24
198
Carbon
5
60
51
12
88
505
1737
6086
5978
8818
446
61
Reactor
57
1765
26
91
85
Reactor
21
103
17
52
36
318
963
4687
5435
6577
383
-
Effluent
17
215
24
99
387
Effluent
14
175
17
56
325
471
1454
5128
6318
8488
390
100
11
127
43
57
236
6
67
50
35
125
Average
95
956
3168
4585
7183
390
-
8.5
143
4
57
512
8.5
74
25
35
263
439
1157
3863
4875
6978
367
443
22
432
24
77
290
12
138
32
49
188
High Carbon Reactor Effluent
BODS,
COD,
TSS,
TOC,
rag/1
rag/1
mg/1
mg/1
24
447
38
105
Color, ADMI units+
8.5
82
10
34
236
4
37
60
9
148
21
69
28
40
49
11
119
24
44
242
4
40
19
18
77
6
35
16
18
140
11
118
28
38
149
* Westvaco SA carbon
# Westvaco SC carbon
** ICI Hydrodarco carbon
## ICI-KB carbon
+ pH = 7.6
360
-------
TABLE VII-77 (Cont.)
Parameter
D
P
Y
Mill
E
Control Reactor, %
BODS
COD
TSS
TOC
Color
BODS
COD
TSS
TOC
Color
BODS
COD
TSS
TOC
Color
Note: ( )
96
74
(99)
75
-
98
82
99
82
-
98
79
(99)
83
_.
98
79
99
77
-
Low
98
83
(99)
83
-
High
98
86
(99)
86
*•
95
67
98
Ik
26
Carbon
96
80
98
87
67
Carbon
96
88
99
90
45
89
0
(99)
80
0
Reactor,
96
94
(99)
88
41
Reactor,
96
96
(99)
91
20
Q F
Removal
95 98
78 91
99 99
74 85
76
% Removal
96 99
82 95
(99) 99
85 91
88
% Removal
97 99
88 97
(99) (99)
89 95
92
S
91
85
(99)
85
-
91
92
99
91
-
94
96
(99)
95
~
Average
95
68
99
79
34
96
87
99
87
65
97
90
(99)
90
52
indicates a "greater than" value.
Source: Reference 34.
361
-------
are the methodology and calculation of raw waste loads and final
effluent limitations and standards for each option.
Best Practicable Control Technology Currently Available (BPT
General
Two new subcategories and a new subdivision of an existing
subcategory have been identified: the nonwoven manufacturing and
felted fabric processing subcategories and the water jet weaving
subdivision of the low water use processing subcategory.
As stated previously, the Act establishes the requirements for
the development of BPT limitations, which are generally based on
the average of best existing performance within that category or
subcategory. Where existing performance is uniformly inadequate,
BPT may be transferred from a different subcategory or category.
Limitations based on transfer technology must be supported by a
conclusion that the technology is, indeed, transferable and a
reasonable prediction that it will be capable of achieving the
prescribed effluent limits. The best practicable control
technology currently available for water jet weaving, nonwoven
manufacturing and felted fabric processing has been identified as
biological treatment, the technology on which BPT limitations are
based for all other subcategories of the textile mills point
source category.
Raw Waste Loads Raw waste loads for these two new subcategories
and the new subdivision have been determined to be the medians of
historical and field sampling data for mills in each
subcategory/subdivision. (Table V-19). These raw waste loads
have been used to calculate costs and pollutant removals.
BPT Limitations The final effluent limitations are
The
presented in
methodology for the development of
Section VIII. The general
these limitations is discussed below.
Water Jet Weaving Subdivision - Long-term average final
effluent characteristics have been calculated as the average of
the two mills where biological treatment systems are employed.
362
-------
' Nonwoven Manufacturing Subcategory - BPT effluent
limitations are based on the transfer of the performance of
biological treatment from the carpet finishing subcategory
because currently existing wastewater treatment systems in the
nonwoven manufacturing subcategory are not representative of best
practicable control technology currently available.
Raw material and production processes are similar in the nonwoven
manufacturing and carpet finishing subcategories. In addition,
raw waste characteristics of wastewaters discharged from mills in
the nonwoven manufacturing subcategory are similar to those
discharged from mills in the carpet finishing subcategory. (As
shown in Table VIII-3, BOD5. and COD raw waste concentrations in
the nonwoven manufacturing subcategory are equal to or lower than
BOD5. and COD concentrations in the carpet finishing subcategory.)
Felted Fabric Processing Subcategorv - BPT effluent
limitations are based on the transfer of the performance of
biological treatment from the wool finishing subcategory because
currently existing wastewater treatment systems in the felted
fabric processing subcategory are uniformly inadequate and not
representative of the best practicable control technology
currently available.
Raw material and production processes are similar in the felted
fabric processing subcategory and wool finishing subcategories.
In addition, raw was.te characteristics of wastewaters discharged
from mills in the felted fabric processing subcategory are
similar to those discharged from mills in the wool finishing
subcategory. (As shown in Table VIII-3, BOD5. and COD raw waste
concentrations in the felted fabric processing subcategory are
equal to or lower than BOD5. and COD concentrations in the wool
finishing subcategory.)
Best Available Technology Economically Achievable (BAT)
General
The factors considered in establishing best available technology
economically achievable (BAT) limitations include the cost of
applying the control technology, the age of process equipment and
facilities, the process employed, process changes, the
engineering aspects of applying various types of control
techniques ajid environmental considerations such as air
pollution, energy consumption and solid waste generation (Section
304(b)(2)(B). In general, the BAT technology level represents,
at a minimum, the best existing economically achievable
performance of plants of shared characteristics. Where existing
performance is uniformly inadequate, BAT may be transferred from
a different subcategory or industrial category. BAT may include
process changes or internal controls, even when not common
industry practice.
363
-------
The primary determinant of BAT is effluent reduction capability
using economically achievable technology. As a result of the
Clean Water Act of 1977, the achievement of BAT has become the
national means of controlling the discharge of toxic pollutants.
Best available treatment technology must be implemented no later
than July 1, 1984, for the control of toxic and nonconventional
pollutants.
As a result of the toxic pollutant screening and verification
sampling program, 15 toxic organics pollutants and 12 toxic
metals were identified as being present at levels of 10 ug/1 or
greater in textile industry wastewaters. Nonconventional
pollutants which were identified as being of concern included
those previously regulated under BPT, and color which had been
regulated under previously remanded BAT (See Section VI). In
addition, EPA considered regulating TSS as an indicator of toxic
pollutants during the development of the final rules. (See 44 FR
62204, October 29, 1979.)
From the control and treatment technologies previously discussed
four technology options were identified for the evaluation of
pollutant removal capability and calculation of costs. The four
options were:
OPTION 1 - The current level of control
based on biological treatment.
OPTION 2 - The level of control achievable by
biological treatment (Option 1) plus
the addition of multimedia filtration.
OPTION 3 - The level of control achievable by
biological treatment (Option 1) plus
the addition of chemical coagulation/
sedimentation.
OPTION 4 - The level of control achievable by
biological treatment (Option 1) plus
the addition of chemical coagulation/
sedimentation followed by multimedia
filtration.
Assessment of Treatment Capability Options 2, 3 and 4 were based
on the addition of end-of-pipe technology to treat further
biologically treated effluent. The methodology for determining
the capability of each technology option included identifying the
effluent quality resulting from the application of biological
treatment technology in each subcategory of the textile industry
and then applying appropriate reductions associated with the
technologies included in each treatment option.
364
-------
Option 1 - Effluent characteristics for BOD_5, COD, TSS and
phenol sin each subcategory were calculated as the product of
long-term average effluent concentrations and wastewater flows
for that subcategory. Effluent concentrations used were medians
from each subcategory from a data base of 72 plants where
biological treatment was employed.
The following criteria were used in
plants to be included in the data base:
the selection of the 72
1. Biological treatment generally representative of the
type that formed the basis of BPT is used.
2. Treatment system performance is characteristic of,
although not necessarily achieving, BPT limitations.
3. Sufficient long-term data were available to reflect
seasonal variability.
4. Overall response to the industry data request was
accurately and conscientiously prepared.
5. Production and flow data were available.
This 72 plant data base is presented in Table VII-78. Table VII-
79 presents the medians used for each subcategory. Because
biological treatment data for mills meeting the above criteria in
the hosiery products, nonwoven manufacturing and felted fabric
processing subcategories is not available, concentrations were
transferred f-rom appropriate subcategori es. As discussed above,
and later in Section VIII, raw materials, production processes,
and raw waste characteristics for these subcategories are similar
to those „ from which the performance of biological treatment is
transferred. In addition, raw waste concentrations of BOD£ and
COO are equal to or less than those in the similar subcategories.
Wastewater flows used in the calculation are subcategory median
flows for all the plants that submitted raw was data and are
presented in Table V-ll.
A similar approach was used for the development of effluent
characteristics for the toxic metals total chromium, total copper
and total zinc as well as total toxic metals and total toxic
organics. Effluent concentrations utilized in the calculation of
toxic pollutant discharge are presented in Table VII-80. The
concentrations are average values rounded to the closest 10 ug/1,
for the data collected during the toxic pollutant field sampling
program. As presented in Tables VII-81 to VII-83, total toxic
organics are the summation of all the detected toxic organics and
total toxic metals are the summation of all the detected toxic
metals.
365
-------
TABLE VII-78
LONG-TERM AVERAGE EFFLUENT CONCENTRATIONS
72 SELECTED TREATMENT FACILITIES
Subcategory
1
1
2
2
2
2
2
4a
4a
4a
4a
4a
4a
4a
4b
4b
4b
4b
4b
4b
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
4c
Report
No.
10006
10015
20005
20009
20011
20020*
20021
40023
40035
40050
40098
40100
40109
40143
40022
40091
40111
40148
40154
40160
40012
40017
40034
40037
40059
40064
40072
40074
40087
40097
40099
40103
40120
40140
40145
40151
40153
BODS
(mg/1)
61
42
24
26
26
12
154
5
22
15
12
46
124
9
15
69
24
5
6
44
20
27
15
27
24
43
8
11
31
23
16
20
7
106
7
43
62
COD
(mg/1)
1443
810
-
-
212
183
800
139
307
384
177
409
-
159
152
301
426
-
126
452
-
155
254
214
336
-
252
272
-
594
252
-
181
664
164
199
464
TSS
(mg/1)
166
297
49
64
61
23
80
19
38
36
56
49
55
18
35
95
24
48
15
105
91
21
54
15
27
148
8
69
41
44
49
21
57
176
54
67
132
Total Phenols
(ug/1)
_
37
-
Ill
45
76
-
114
56
13
17
35
87
20
250
-
25
'
-
30
-
15
-
-
2
-
.
347
22
-
17
47
-
-
18
-
132
366
-------
TABLE VII-78 (Cont.)
Subcategory
5a
5a
5a
5a
5a
5a
5a
Sa
5a
5b
5b
5b
5b
5b
5c
5c
6
6
6
6
6
6
6
6
7
7
7
7
7
7
7
7
7
7
7
Report
No,
50008
50015
50057
50081
50082
50098
50108
50113
50116
50035
50056
50065*
50099
50123
5H028
5H029
60001*
60005
60013
60018
60021*
60034
60037
60039
70009
70031
70036
70075
70084
70087
70089
70096
70104
70106
70126
BODS
(mg/D
15
12
21
20
13
139
7
13
6
22
45
63
12
6
64
106
21
27
54
34
78
30
37
38
6
6
15
8
21
22
5
29
3
7
74
COD
(ng/D
_
277
744
164
250
533
154
226
124
277
354
491
174
145
596
592
133
546
311
286
376
227
-
274
106
124
203
146
268
148
158
204
96
119
176
TSS Total Phenols
(mg/1) (ug/1)
20
22
35
63
71
180
11
62
18
116
55
52
26
27
99
107
25
113
57
70
85
50
33
91
9
27
35
36
71
24
21
24
20
10
60
^
41
-
-
32
-
-
72
-
_
100
15
83
-
28
21
84
100
80
. -
285
128
100
370
41
186
91
-
40
56
-
-
-
-
12
* Aerated Lagoon
Note: A dash indicates "no historical data available."
Source: EPA Industry Surveys, 1977 & 1980.
367
-------
TABLE VII-79
MEDIAN LONG-TERM AVERAGE TREATED EFFLUENT CONCENTRATIONS
Subcategory
1.
2.
3.
4.
5.
6.
7.
8.
9.
Wool Scouring
Wool Finishing
Low Water Use Processing
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BOD5
(mg/1)
50
25
(No
(No
15
20
25
15
20
15*
35
10
35**
25#
COD
(mg/D
1,125
215
BAT Effluent
BAT Effluent
245
300
255
240
280
240*
285
150
285**
215#
TSS Total Phenols
(mg/1) (ug/1)
230
60
Limitations)
Limitations)
40
40
55
35
50
35*
65
25
65**
60#
40
80
35
30
20
40
85
40*
100
50
100**
80#
* Concentrations transferred from Knit Fabric Finishing - Simple
Processing Subcategory,
** Concentrations transferred from Carpet Finishing Subcategory.
# Concentrations transferred from Wool Finishing Subcategory.
Note: All concentrations rounded to the nearest 5 units/liter.
Source: Table VII-78 and EPA Engineering Analysis.
368
-------
TABLE VII-80
BIOLOGICAL TREATMENT EFFLUENT CONCENTRATIONS
AVERAGE OF FIELD SAMPLING DATA
Concentration
Subcategory
1. Wool Scouring
2. Wool Finishing
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5. Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7 . Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
Total
Chromium
(mg/1)
0.040
0.360
ND
0.090
ND
0.060
0.030
0.200
0.220
0.070
0.010
0.035
* Atypical maximum value of 38.4 mg/1 was not
# Values are for untreated wastewater since no
Total
Copper
(mg/1)
0.080
0.020
0.090
0.120
0.030
0.060
0.040
0.010
0.040
0.090
0.030
ND
included in
biological
Total Total Toxic
Zinc
(mg/1)
0.300
2 . 320*
0.250
0.190
0.500
0.150
0.610
0.110
0.200
0.340
0.070
0.040
the average.
treatment is
Organics
(mg/1)
0.260
1.600
0.190
0.300
1.860
0.330
0.920
0.590
0.060
0.230
0.440
0.080
performed.
Total Toxic
Metals
(mg/1)
2.150
3.020
0.450
0.600
0.750
0.730
1.320
0.420
0.620
0.810
0.310
0.110
Note: ND indicates "not detected."
Source: Field Sampling Program.
-------
TABLE VIJ-81
SUMMARY OF POLLUTANT REMOVALS FOR ADD-ON COMPONENTS OF CONTROL OPTIONS
WOOL SCOURING MILLS
Technology
Total Total
Total Toxic Toxic
BOD5 COD TSS Phenols Organics Metals
Multimedia Filtration (MMF)
Chemical Coagulation (CC)
MMF After CC
CC + MMF After CC- (CC + MMF)
35 10 45 30*
50
NR
* Value transferred from wool finishing data base,
Notes: 1. A dash indicates that no data are available to calculate
a removal.
2. NR indicates "no removal."
Source; Table VII-50.
370
-------
TABLE VII-82
SUMMARY OF POLLUTANT REMOVALS FOR ADD-ON COMPONENTS OF CONTROL OPTIONS
WOOL FINISHING MILLS
Technology
Total Total
Total Toxic Toxic
BOD5 COD TSS Phenols Organics Metals
Multimedia Filtration (MMF)
Chemical Coagulation (CC)
MMF After CC
CC + MMF After CC (CC + MMF)*
55
70
20
75
30
70
15
75
80
70
55
85
30
25
20
40
55
60
40
75
50
15
10
40
* Removal for CC + MMF calculated by applying removal for MMF after CC to
the percentage of each pollutant (parameter) remaining after CC, except
for toxic organics and toxic metals.
Source: Tables VII-34, -35, -37, -49, -53, -54, -55, -56, -62, and
Field Sampling Data for Mills BB and Q.
371
-------
TABLE VII-83
SUMMARY OF POLLUTANT REMOVALS FOR ADD-ON COMPONENTS OF CONTROL OPTIONS
ALL OTHER MILLS
Technology
Total Total
Total Toxic Toxic
BOD5 COD TSS Phenols Organics Metals
Multimedia Filtration (MMF)
Chemical Coagulation (CC)
MMF After CC
CC + MMF After CC (CC + MMF)*
25
50
20
60
15
45
20
55
45
40
65
80
10
15
25
35
30
15
30
50
10
40
NR
40
* Removal for CC + MMF calculated by applying removal for MMF after CC to
the percentage of each pollutant (parameter) remaining after CC, except
for toxic organics and toxic metals.
Note: NR indicates "no removal."
Source: Tables VII-31, -32, -35, -36, -37, -45, -47, -49, -56, -57, -58,
-59, -60, -61, -62, and Field Sampling Data for Mills BB and Q,
372
-------
Options 2., 3, and £ - Effluent quality for options 2, 3 and 4
were determined by applying appropriate percent removals from the
biological treatment effluent quality determined to be
representative of biological treatment in each subceitegory.
Percent removals for each technology option are presented in
Table VII-81 for wool scouring subcategory mills. Table VII-82
for wool finishing subcategory mills and in Table VII-83 for all
other subcategories. The percent removals are median percent
removals for mills in the EPA/Industry field studies. Percent
removals for each mill and each technology are presented in
Section VII. The detailed analysis is included in the record for
this rulemaking.
Summary of BAT Effluent Quality - The long-term average effluent
characteristics developed for each technology option in each
subcategory are presented in Tables VII-84 and VII-85 for toxic,
nonconventional and conventional pollutants. The design criteria
for each technology option are presented in detail in Appendix-A,
Cost of Treatment and Control Systems.
New Source Performance Standards (NSPS-)
General
Section 306 of the Clean Water Act of 1977 requires that new
source performance standards (NSPS) be established for industrial
dischargers based on the best demonstrated technology. NSPS
establish control of toxic, 'nonconventional and conventional
pollutants. The same pollutants considered for control under BAT
were considered for control under NSPS.
Control and treatment technologies that were considered include:
OPTION 1 - Biological treatment as demonstrated
by best performing mills.
OPTION 2 - Multimedia filtration
OPTION 3 - Extended aeration activated sludge
treatment (Option 1} followed by
chemical coagulation/sedimentation
and multimedia filtration.
Assessment of Treatment
calculation of
Capability The methodology and
effluent characteristics for each of the NSPS
control and treatment options is discussed below.
Option 1_ - Long-term average effluent characteristics for
BOD, COD, and TSS for option 1 were calculated as the median mass
discharge of best performers in each subcategory. Using the 72
plant data base presented in Table X-2, best performers were
identified as those where long-term average BOD^, TSS and COD
373
-------
TABLE VII-84
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 1 - BIOLOGICAL TREATMENT
Subcategory
1. Wool Scouring
2. Wool Finishing
Low Water Use Processing*
a. General Processing
b. Water Jet Weaving
Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
Carpet Finishing
Stock & Yarn Finishing
Nonwoven Manufacturing
9. Felted Fabric Processing
BODS
(kg/kkg)
0.59
7.61
1.15
1.95
2.65
1.76
2.45
1.13
1.63
0.97
1.40
5.32
COD
(kg/kkg)
13.16
65.45
18.80
29.28
27.00
28.22
34.33
18.02
13.31
14.51
11.40
45.73
TSS
(kg/kkg)
2.70
18.26
3.07
3.90
5.82
4.12
6.13
2.63
3.04
2.42
2.60
12.76
Total
Phenols
(g/kkg)
0.47
24.35
2'.69
2.93
2.12
4.70
10.42
3.00
4.67
4.84
4.00
17.02
* BAT Options beyond BPT were not considered for low water use
processing.
374
-------
TABLE VII-84 (continued)
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 1 - BIOLOGICAL TREATMENT
Subcategory
1. Wool Scouring
2-. Wool Finishing
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desiziag
5. Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. "NonW6vfn*Mariufacturing
9. Felted Fabric Processing
Total Toxic
Organics
(s/kkg)
3.05
487.04
14.58
29.28
196.97
38.81
112.79
44.31
2.80
22.24
17.60
17.02
Total Toxic
Metals
(*/kkg)
25.24
919.29
34.53
58.56
79.43
85.85
161.83
31.54
28.95
78.33
12.40
23.40
375
-------
TABLE VII-85
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 2 - BIOLOGICAL TREATMENT PLUS
MULTIMEDIA FILTRATION
Subcategory
1. Wool Scouring
2. Wool Finishing
Low Water Use Processing*
a. General Processing
b. Water Jet Weaving
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5. Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
BODS
(kg/kkg)
0.38
3.43
0.86
1.46
1.98
1.32
1.84
1.13
1.23
0.73
1.05
3.99
COD
(kg/kkg)
11.85
45.81
15.98
24.89
22.95
23.99
29.18
18.02
11.31
12.33
9.69
38.87
TSS
(kg/kkg)
1.49
3.65
1.69
2.15
3.20
2.26
3.37
2.63
1.67
1.33
1.43
7.02
Total
Phenols
(g/kkg)
0.33
17.08
2.42
2.64
1.91
4.23
9.38
3.00
4.20
4.36
3.60
15.30
* BAT Options beyond BPT were not considered for low water use
processing.
376
-------
TABLE VII-85 (continued)
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 2 - BIOLOGICAL TREATMENT PLUS
MULTIMEDIA FILTRATION
Subcategory
1. Wool Scouring
2. Wool Finishing
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5. Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
Total Toxic
Organics
(g/kkg)
1.53
21.92
10.22
20.51
137.90
27.16
78.95
1.96
15.57
12.32
11.91
Total Toxic
Metals
(g/kkg)
25.0
45.95
31.05
52.74
71.10
77.22
145.65
26.06
70.50
11.16
21.05
377
-------
effluent discharges were less than the maximum 30-day average BPT
effluent limitations for these parameters. The best performers
are identified and the median subcategory long-term averages used
as the basis for NSPS are presented in Table X-3. As discussed
in Section VIII, insufficient data are available on the
performance of biological treatment in the new nonwoven
manufacturing and felted fabric processing subcategories. Long-
term averages for these subcategories were, therefore, based on
flow-adjusted long-term averages for the carpet finishing and
wool finishing subcategories for the reasons presented in Section
VIII, Similarly, as described in Section X, in the knit fabric
finishing subcategory performance levels for the hosiery products
subdivision have been transferred from the simple processing
operations subdivision.
Options 2., and 3. - NSPS Options 2 and 3 are identical to BAT
options 2 and 4. "" The methodology and development of effluent
characteristics are presented above under BAT.
Summary of. NSPS Effluent Characteristics - The long-term average
effluent characteristics developed for each subcategory and each
technology option are presented in Table VI1-86 for conventional
and nonconventional pollutants and in Table VII-87 for toxic
pollutants. Design details and costs for each technology option
are presented in Appendix-A, Cost of Treatment and Control
Systems.
Pretreatment Standards for Existing and
PSNS)
General
New Sources (PSES and
The Clean Water Act requires that pretreatment standards prevent
the discharge of pollutants which pass through, interfere with or
are otherwise incompatible with the operation of POTWs. The Act
also requires pretreatment for pollutants that limit sludge
management alternatives at POTWs, including the beneficial use of
sludges on agricultural lands.
Three toxic pollutants, total chromium, total copper and total
zinc that can pass through POTWs or could cause sludge disposal
problems have been identified in textile industry wastewaters.
Two pretreatment options were considered for control of these
toxic metals. They were:
OPTION 1 - Screening, equalization and/or
neutralization as required to
meet General Pretreatment
Regulations.
OPTION 2 - Screening, equalization and/or
neutralization (Option 1) plus
chemical coagulation/precipitation.
378
-------
TABLE VII-86
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 3 - BIOLOGICAL TREATMENT PLUS
CHEMICAL COAGULATION
Subcategory
1. Wool Scouring**
2. Wool Finishing
3. Low Water Use Processing*
a. General Processing
b. Water Jet Weaving
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5. Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
BODS
(kg/kkg)
2.28
0.58
0.98
1.33
0.88
1.23
0.56
0.82
0.48
0.70
2.66
COD
(kg/kkg)
19.64
10.34
16.10
14.85
15.52
18.88
9.91
7.32
7.98
6.27
24.69
TSS
(kg/kkg)
5.48
1.84
2.34
3.49
2.47
3.68
1.58
1.82
1.45
1.56
7.66
Total
Phenols
(g/kkg)
18.30
2.29
2.49
1.80
3.99
8.86
2.55
3.97
4.11
3.40
14.46
* BAT Options beyond BPT were not considered for low water use
processing.
** Chemical coagulation was not considered for wool scouring.
379
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TABLE VII-86 (continued)
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 3 - BIOLOGICAL TREATMENT PLUS
CHEMICAL COAGULATION
Subcategory
1. Wool Scouring
2. Wool Finishing
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5- Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
Total Toxic
Organics
(8/kkg)
194.80
12.41
24.91
167.45
32.98
95.87
37.66
2.38
18.90
14.96
14.46
Total Toxic
Metals
781.20
20.70
35.16
47.40
51.48
97.10
18.92
17.37
47.00
7.44
14.04
380
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TABLE VII-87
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 4 - BIOLOGICAL TREATMENT PLUS
CHEMICAL COAGULATION PLUS
MULTIMEDIA FILTRATION
Subcategory
1. Wool Scouring**
2. Wool Finishing
3. Low Water Use Processing*
a. General Processing
b. Water Jet Weaving
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5. Knit Fabric Processing
a. Simple Processing
b. Complex processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
BODS
(kg/kkg)
1.90
0.46
0.78
1.06
0.71
0.98
0.45
0.65
0.39
0.55
2.13
COD
(kg/kkg)
16.36
8.46
13.18
12.15
12.70
15.45
8.11
5.99
6.53
5.13
20.58
TSS
(kg/kkg)
2.74
0.61
0.78
1.16
0.82
1.23
0.53
0.61
0.48
0.52
2.55
Total
Phenols
(g/kkg)
14.64
1.75
1.90
1.38
3.06
6.77
1.95
3.04
3.15
2.60
11.06
* BAT Options beyond BPT were not considered for low water use
processing.
** Option 4 not considered for wool scouring.
381
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TABLE VII-87 (continued)
LONG-TERM AVERAGE EFFLUENT CHARACTERISTICS
OPTION 4 - BIOLOGICAL TREATMENT PLUS
CHEMICAL COAGULATION PLUS
MULTIMEDIA FILTRATION
Subcategory
1. Wool Scouring
2. Wool Finishing
4. Woven Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
5. Knit Fabric Processing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
6. Carpet Finishing
7. Stock & Yarn Finishing
8. Nonwoven Manufacturing
9. Felted Fabric Processing
Total Toxic
Organics
(8/kkg)
121.80
7.30
14.65
98.50
19.40
56.40
22.15
14.01
11.12
8.80
8.51
Total Toxic
Metals
(8/kkg)
551.40
20.70
35.16
47.40
51.48
97.10
18.92
17.37
47.00
7.44
14.04
382
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Assessment of Treatment Capability - Under option 1 no specific
limitations for toxic or nonconventional pollutants are developed
beyond requirements of the General Pretreatment Regulations found
at 40 CFR Part 403 {43 FR 27736, June 26, 1978; 46 FR 9462,
January 28, 1981 ).
Final effluent characteristics resulting from the application of
Option 2 were developed based on effluent concentrations
determined to be representative of the application of lime
settling technology in treating metals in the electroplating
industry (88). These studies have demonstrated that the
technology can achieve 30-day average concentrations of 0.8 mg/1
for copper and 0.7 mg/1 for chromium and zinc. Achievable
maximum day concentrations are 2.0 mg/1 for copper, 1.8 mg/1 for
chromium and 1.5 mg/1 for zinc. Effluent limitations for each
subcategory were then calculated as the product of these
concentrations and median subcategory wastewater flows. PSES and
PSNS effluent characteristics for Option 2 are presented in Table
VII-88.
383
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TABLE VII-88
PSES and PSNS - OPTION 2
CHEMICAL COAGULATION/PRECIPITATION
EFFLUENT CHARACTERISTICS*
Average of
30 days Maximum
1. Wool Scouring
2. Wool Finishing
3. Woven Fabric
Finishing
a. Simple Processing
b. Complex Processing
c. Desizing
4. Knit Fabric Finishing
a. Simple Processing
b. Complex Processing
c. Hosiery Products
5. Carpet Finishing
6. Stock and Yarn
Finishing
7. Nonwoven Manu-
facturing
8. Felted Fabric
Processing
Total
Copper
9.4
243.5
61.4
78.1
84.7
94.1
98.1
60.1
37.4
77.4
32.0
170.2
Total
Chromium
8.2
213.1
53.7
68.3
74.1
82.3
85.8
52.6
32.7
67,7
28.0
148.9
Total
Zinc
8.2
213.1
53.7
68.3
74.1
82.3
85.8
52.6
32.7
67.7
28.0
148.9
Maximum Day
Total
Copper
23.4
608.8
153.4
195.2
211.8
235.2
245.2
150.2
93.4
193.4
80.0
425.4
Total
Chromium
21.1
547.9
138.1
175.7
190.6
211.7
220.7
135.2
84.1
174.1
72.0
382.9
Total
Zinc
17.6
456.6
115.1
146.4
158.9
176.4
183.9
112.7
70.1
145.1
60.0
319.1
*Eff1uent characteristics in g of pollutant per kkg of product.
384
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SECTION VIII
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
GENERAL
The best practicable control technology currently available (BPT)
generally is based on the average of the best existing
performance, in terms of treated effluent discharged, by plants
of various sizes, ages and unit processes within an industry or
subcategory. Where existing performance is uniformly inadequate,
BPT may be transferred from a different subcategory or category.
Limitations based on transfer of technology must be supported by
a conclusion that the technology is, indeed, transferable and a
reasonable prediction that it will be capable of achieving the
prescribed effluent limits (see Tanners' Council of America v.
Train. 540 F. 2d 1188 (4th Cir. 1976)). BPT focuses on
end-of-pipe treatment technology rather than process changes or
internal controls, except where such changes or controls are
common industry practice.
BPT considers the total cost of the application of technology in
relation to the effluent reduction benefits to be achieved from
the technologies. The cost/benefit inquiry for BPT is a limited
balancing, which does not require the Agency to quantify benefits
in monetary terms (see, e.g., American Iron and Steel Institute
v. EPA, 526 F.2d 1027 (3rd Cir. 1975)). In balancing costs in
relation to effluent reduction benefits, EPA considers the volume
and nature of existing discharges, the volume and nature of
discharges after application of BPT, the general environmental
effects of the pollutants and the costs and economic impacts of
the required pollution control level. The Act does not require
or permit consideration of water quality problems attributable to
particular point sources or industries, or water quality
improvements in particular water bodies (see Weyerhaeuser Company
v. Costle, 590 F.2d 1101 (D.C. Cir. 1978)).
REGULATED POLLUTANTS
i
Pollutants regulated under BPT are BOD5., TSS and pH (conventional
pollutants), and COD (a nonconventional pollutant) for the water
jet weaving subdivision of the low water use processing
subcategory, the nonwoven manufacturing subcategory and the
felted fabric processing subcategory. In addition, the
nonconventional pollutants sulfide and phenols and the toxic
pollutant total chromium are regulated in the nonwoven
manufacturing and felted fabric processing subcategories.
385
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IDENTIFICATION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
BPT for the water jet weaving subdivision of the low water use
processing subcategory, the nonwoven manufacturing subcategory
and the felted fabric processing subcategory has been identified
as biological treatment, which is the same technology on which
BPT limitations are based for all other subcategories of the
textile industry.
BPT EFFLUENT LIMITATIONS
BPT effluent limitations are presented in Table VIII-1.
RATIONALE FOR THE SELECTION OF BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE
As discussed in Section IV, the Agency has identified two new
subcategories (nonwoven manufacturing and felted fabric
processing) and one new subdivision of an existing subcategory
(water jet weaving in the low water use processing subcategory}
of the textile mills point source category. The Clean Water Act
requires the establishment of BCT limitations for industry
subcategories from which conventional pollutants are discharged.
In order to develop BCT limitations, a base level BPT
determination is necessary because the "cost-reasonableness
test," required as part of the BCT determination, rests on the
incremental cost of removal of BOD5. and TSS from BPT to BCT.
Therefore, to aid in development of BCT limitations and to
provide uniform national BPT effluent limitations for all
segments of the textile industry, the Agency is establishing BPT
effluent limitations for the nonwoven manufacturing subcategory,
the felted fabric processing subcategory and the water jet
weaving subdivision of the low water use processing subcategory.
EPA did not specifically propose BPT effluent limitations for the
two new subcategories or the new subdivision; the Agency did
propose BAT limitations and provided information on the pollutant
removal effectiveness of biological treatment and multimedia
filtration of biologically-treated effluents. Public comments on
the proposed BAT limitations predominantly favored establishing
BAT limitations based on the performance of biological treatment
alone. As discussed in Section IX, EPA is establishing BAT
effluent limitations for the textile industry based on the
performance of biological treatment. Therefore, the technology
basis of BPT and BAT effluent limitations for the nonwoven
manufacturing and the felted fabric processing subcategory and
for the water jet weaving subdivision of the low water use
processing subcategory are identical.
386
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CO
Subcategory
Low Water Use Processing
Water Jet Weaving
Nonwoven Manufacturing
Felted Fabric Processing
TABLE VIII-1
BPT EFFLUENT LIMITATIONS*
Maximum
any one
BODS
8.9
4.4
15-2
Conventional
for
day
TSS
5.5
6.2
55.4
Pollutants
Average of daily values
for 30 consecutive days
BODS TSS
4.6 2.5
2.2 3.1
17.6 27.7
pH shall be within the range 6.0 to 9.0 at all times.
Toxic and Nonconventional Pollutants
Subcategory
Low Water Use Processing
Water Jet Weaving
Nonwoven Manufacturing
Felted Fabric Processing
Maximum for
any one day
Total
COD Sulfide Phenols Chromium
Average of daily values
for 30 consecutive days
COD
Sulfide Phenols
Total
Chromium
21.3 ~ -- -- 13.7
40.0 0.046 0.023 0.023 20.0 0.023
256.8 0.44 0.22 0.22 128.4 0.22
* Expressed as kg pollutant/kkg of product (lb/1000 Ib)
0.011
0.11
0.011
0.11
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METHODOLOGY USED FOR DEVELOPMENT OF BPT LIMITATIONS
Water Jet Weaving Subdivision
The water jet weaving process is a recent technological
development. In fact, sufficient data on which effluent
limitations and standards can be based are available from only
two mills. At both of. these mills, biological treatment is
employed. EPA is establishing BPT limitations equal to the
average performance levels achieved at these two mills.
Long-term average effluent discharges for the pollutants BOD5.,
TSS and COD were calculated based on treatment performance at
these two mills. Maximum 30-day and maximum day effluent
limitations were then calculated by multiplying long-term
average effluent limitations by the variability factors
determined through statistical analysis of individual
conventional pollutant data. The statistical analysis is
described in detail in Section X. The data on which BPT effluent
limitations are based is presented in Table VIII-2.
Nonwoven Manufacturing and Felted Fabric Processing
Sufficient data on the performance of biological treatment is not
available for these new subcategories. BPT effluent limitations,
therefore, are based on the transfer of performance of biological
treatment from subcategories with similar raw wastes.
Raw material usage and production processes are similar in (a)
the nonwoven manufacturing and carpet finishing subcategories and
(b) the felted fabric processing and the wool finishing
subcategories. In addition, raw waste characteristics of
wastewaters discharged from mills in the nonwoven manufacturing
subcategory and the felted fabric processing subcategory are
similar to those discharged from mills in the carpet finishing
and wool finishing subcategories, respectively. (As shown on
Table VIII-3, BOD5. and COD raw waste concentrations in the
nonwoven manufacturing and felted fabric processing subcategories
are equal to or lower than BOD5. and COD concentrations in the
subcategories to which they are compared.)
BPT limitations were calculated as the product of median flows
for the new subcategories and BPT final effluent concentrations
for the subcategory used as the basis for technology transfer.
The computation of BPT limitations is presented in Table VIII-4.
In making the decision to base BPT effluent limitations for these
two new subcategories on the performance of technology in two
existing subcategories, the Agency determined that biological
treatment is clearly available and could be employed at the mills
in the nonwoven manufacturing and felted fabric processing
subcategories. The BPT limitations are based on the ability of
biological treatment to remove the same pollutants from
388
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TABLE VIII-2
CALCULATION OF BPT LIMITATIONS*
Water Jet Weaving Subdivision
Long Term Average
Effluent Limitation**
Pollutant
BOD5
COD
TSS
Mill
G3114
3.54
8.94
1.86
Mill
G3117
1.91
9.14
0.97
Average
2.72
9.04
1.42
Maximum
8.9
21.3
5.5
Average of 30
days maximum
4.6
13.7
2.5
* Expressed as kg pollutant/kkg (Ib pollutant/1000 Ib of product)
** Effluent limitations are the product of the subcategory long-term
average and the variability factors developed in Section X.
389
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TABUS VIII-3
COMPARISON OF RAW WASTE LOADS
Felted Fabric Processing and Noawoven Manufacturing Subcategories
Subcategory
Wool Finishing
Felted Fabric Processing
Carpet Finishing
Nonwoven Manufacturing
FLOW
I/kg
135.0
212.7
70.0
40.0
k*/
63
70
25
6
BOD.
• -t J
.6
.2
.6
.7
fflg/1
471
330
366
168
kg/k
204
186
82
38
kg
.8
.0
.3
.4
COD
mg/1
1517
874
1176
960
kg/kkg
54.0
301.4
4.7
2.2
TSS
mg/1
400
1417
67
55
CO
ir>
o
Notes: 1. Raw waste loads in kg/kkg and flow for felted fabric processing and
nonwoven manufacturing are median subcategory values from historical
data base.
2. Flows for wool finishing and carpet finishing are flows upon which
BPT was based.
3. Concentrations shown are calculated from mass discharge and flows
presented.
-------
TABLE VIII-4
CALCULATION OF BPT LIMITATIONS
Felted Fabric Processing and Nonwoven Manufacturing Subcategories
Maximum of 30-Day Average
Subcategory
Wool Finishing
Felted Fabric
Carpet Finishing
Nonwoven Manufacturing
BOD
11.2
17.6
3.9
2.2
COD
81.5
128.4
35.1
20.0
TSS
17.6
27.7
5.5
3.1
Sulfide
0.14
0.22
0.04
0.023
Phenols
0.07
0.11
0.02
0.011
Chromium
0.07
0.11
0.02
0.011
CO
NOTE: 1. Felted fabric limitation is equal to (Wool Finishing Limitation)(Felted Fabric
Flow/Wool Finishing Flow). In this case, Felted Fabric Limitation =
Wool Finishing Limitation)(212.7/135)
Similarly, Nonwoven Manufacturing Limitation =
(Carpet Finishing Limitation)(40.0/70.0)
2. Maximum day limitations are equal to two times the Maximum 30-Day Average.
-------
wastewaters discharged from mills in the carpet finishing and
wool finishing subcategories and, when applied at mills in these
two subcategories, is capable of attaining the limitations
presented in Table VIII-4.
COST OF APPLICATION AND EFFLUENT REDUCTION BENEFITS
The total costs (4th quarter 1979} of attainment of the BPT
effluent limitations, assuming biological treatment must be
installed at all mills in the two new subcategories and the new
subdivision, have been estimated to be about $2.6 million dollars
in capital costs with an associated total annual cost of about
$1.4 million dollars per year. Five nonwoven mills, three water
jet weaving mills and one felted fabric processing mill are
direct dischargers.
Conventional pollutant removals from raw waste discharges from
the two new subcategories and the new subdivision have been
estimated to be 173 thousand kg/yr (381 thousand Ibs/yr) of BOD£
and 43 thousand kg/yr (94 thousand Ibs/yr) of TSS. These
represent removals of 81 percent of the BOD5, and 56 percent of
the TSS present in raw wastes discharged from mills in the two
new subcategories and the new subdivision. Removal costs are
about $6.48 per kg ($2.95 per Ib) of conventional pollutant
removed.
NONWATER QUALITY ENVIRONMENTAL IMPACTS
Energy
Attainment of BPT at mills in the two new subcategories and the
new subdivision will require the use of the equivalent of 668
thousand liters (4200 barrels) of residual fuel oil per year, a
1.6 percent increase over estimated current total industry energy
usage for wastewater treatment.
Solid Waste
Attainment of BPT at mills in the two new subcategories and the
new subdivision will result in an additional 282 kkg/yr (311
tons/yr) of wastewater treatment solids. This represents a 0.7
percent increase in current total industry biological treatment
solids generation.
Air and Noise
Attainment of BPT at mills in the two new subcategories and the
new subdivision will have no measurable impact on air or noise
pollution.
392
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SECTION IX
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION
OF BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
EFFLUENT LIMITATIONS GUIDELINES
GENERAL
As a result of the Clean Water Act of 1977, the achievement of
BAT has become the principal national means of controlling
wastewater discharges of toxic pollutants. The factors
considered in establishing the best available technology
economically achievable (BAT) level of control include the costs
of applying the control technology, the age of process equipment
and facilities, the process employed, process changes, the
engineering aspects of applying various types of control
technologies and nonwater quality environmental considerations
such as energy consumption, solid waste generation and air
pollution (Section 304(b)(2)(B)). In general, the BAT technology
level represents, at a minimum, the best economically-achievable
performance of plants of shared characteristics. Where existing
performance is uniformly inadequate, BAT technology may be
transferred from a different subcategory or industrial category.
BAT may include process changes or internal controls, even when
not common industry practice.
The statutory assessment of BAT "considers" costs, but does not
require a balancing of costs against effluent reduction benefits
(see Weyerhaeuser v. Costle, 590 F.2d 1101 (D.C. Cir. 1978)). In
assessing the proposed BAT, EPA has given substantial weight to
the reasonableness of costs. The Agency has considered the
volume and the nature of discharges, the volume and nature of
discharge expected after application of BAT, the general
environmental effects of the pollutants and the costs and
economic impacts of the required pollution control levels.
Despite this expanded consideration of costs, the primary
determinant of BAT is effluent reduction capability using
economically-achievable technology.
PRIOR REGULATIONS
EPA promulgated BPT and BAT limitations, NSPS and PSNS for the
textile mills point source category on July 5, 1974 (39 FR 24736;
40 CFR Part 410, Subparts A-G). Pollutants regulated under BAT
included the conventional pollutants BOD£, TSS, fecal coliform
and pH for all subcategories and oil and grease for the wool
scouring subcategory. Nonconventional pollutants regulated
included COD, total pehnols, sulfide and color in all
subcategories except low water use processing (formerly dry
processing), where only COD was regulated. The toxic pollutant
total chromium was regulated in all subcategories except low
water use processing. The technology bases for the BAT
393
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regulations included biological treatment, multimedia filtration,
chemical coagulation and chloririation with variations in the
respective subcategories.
Industry representatives challenged these regulations in the
Fourth Circuit Court of Appeals. In response to a joint motion
of petitioners and EPA to hold the case in abeyance while EPA
reconsidered the BAT limitations, the Court remanded all the
regulations except BPT to EPA for reconsideration. In the joint
motion, petitioners withdrew their challenge to the BPT
limitations and those limitations are, therefore, in effect. As
a result of the Court Order, the Agency and the American Textile
Manufacturers Institute (ATMI) began a joint study to collect
information and data necessary to reconsider the BAT, NSPS and
PSNS regulations.
As a result of the court ordered review as well as the revisions
to the Clean Water Act making BAT the principal national means of
controlling toxic pollutant discharges, the Agency has reassessed
BAT. BAT regulations presented in this document supersede prior
BAT regulations.
REGULATED POLLUTANTS
One toxic pollutant, total chromium, and three nonconventional
pollutants (chemical oxygen demand (COD), sulfide and total
phenols (as measured by the procedures listed in 40 CFR Part
136)) are regulated in all subcategories except the low water use
processing subcategory where only COD is regulated.
IDENTIFICATION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE
BAT limitations for toxic and nonconventional pollutants are
equal to previously promulgated BPT limitations. The technology
basis for BAT is, therefore, the same as the technology basis of
BPT and includes preliminary screening, primary settling (wool
scouring only), latex coagulation (carpet finishing and low water
use processing - general processing only) and biological
treatment.
BAT EFFLUENT LIMITATIONS
BAT effluent limitations are presented in Table IX-1. Allowances
for manufacturing operations and fiber type are presented in
Table IX-2.
RATIONALE FOR THE SELECTION OF BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE
In October of 1979, EPA published proposed BAT effluent
limitations based on biological treatment followed by multimedia
filtration, except in the case of the wool scouring and the wool
394
-------
TABLE IX-1
BAT EFFLUENT LIMITATIONS*
CO
Subcategory
Wool Scouring**
Wool Finishing**
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing**
Knit Fabric Finishing**
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Maximum for any
COD
138.0
163.0
2.8
21.3
60.0
60.0
70.2
84.6
40.0
256.0
Sulfide
0.20
0.28
-
0.20
0.20
0.08
0.24
0.046
0.44
one day
Phenols
0.10
0,14
-
0.10
0.10
0.04
0.12
0.023
0.22
Total
Chromium
0.10
0.14
-
0.10
0.10
0.04
0.12
0.023
0.22
Average
for 30
COD
69.0
81.5
1.4
13.7
30.0
30.0
35.1
42.3
20.0
128.4
of daily values
consecutive days
Sulfide
0.10
0.14
-
0.10
0.10
0.04
0.12
0.023
0.22
Phenols
0.05
0.07
-
0.05
0.05
0.02
0.06
0.011
0.11
Total
Chromium
0.05
0.07
-
0.05
0.05
0.02
0.06
0.011
0.11
* Expressed as kg pollutant/kkg of product (lb/1000 Ib) except for wool scouring, which is
expressed as kg pollutant/kkg of wool processed and wool finishing which is expressed as kg
pollutant/kkg of fiber processed.
** For commission finishers, an additional allocation of 100% of the limitations is allowed.
-------
TABLE IX-2
BAT ALLOWANCES*
CHEMICAL OXYGEN DEMAND (COD)
Simple Manufacturing Operations
employing a synthetic fiber or
complex manufacturing operations
employing a natural fiber.
Woven Fabric Finishing
Simple Manufacturing Operations
employing a natural and synthetic
fiber blend or complex manufacturing
to operations employing a synthetic
fiber.
Woven Fabric Finishing
Knit Fabric Finishing
Complex manufacturing Operations
employing a natural and synthetic
fiber blend.
Woven Fabric Finishing
Knit Fabric Finishing
Complex Manufacturing Operations
Carpet Finishing
Maximum for
any one day
Average of daily values
for 30 Consecutive dayg
20.0
40.0
20.0
60.0
40.0
20.0
10.0
20.0
10.0
30.0
20.0
10.0
* Quantities of pollutant which may be discharged by a point source in addition to
the BAT limitations in Table IX-1.
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finishing subcategories and the hosiery subdivision of the knit
fabric finishing subcategory where limitations were based on
biological treatment, chemical coagulation and dissolved air
flotation and in the case of the felted fabric processing
subcategory where limitations were based on biological treatment.
The proposed BAT effluent limitations would have controlled three
toxic pollutants (total chromium, total copper and total zinc).
Three nonconventional pollutants would have been controlled
(chemical oxygen demand (COD), total phenols (as measured by the
procedure listed in 40 CFR Part 136, Standard Methods) and color
(as measured by the method developed by the American Dye
Manufacturers Institute (ADMI) and described in the proceedings
of the 28th Industrial Waste Conference, Purdue University)).
One conventional pollutant (total suspended solids (TSS)) was
proposed as an indicator for the control of toxic organic
pollutants discharged from textile mills.
Comments received on the proposed regulations questioned the need
for controls more stringent than existing BPT for these
pollutants. The commenters stated that the level of control
proposed for existing mills was too costly in relation to the
effluent reduction benefits.
After proposal, EPA completed an analysis of all available data
to determine the quantity of pollutants discharged by this
industry, the treatability of pollutants present in BPT
effluents, the cost per pound of pollutant removed by the
proposed BAT technology and the economic impact that would result
from the implementation of proposed BAT limitations.
EPA determined that the amount of toxic pollutants being
discharged from the textile industry when BPT limitations are
attained is less than 3.2 kg (7 Ibs) per day per plant and that
the total industry discharge is about 209 kkg (230 tons) per
year. The total chromium being discharged is less than 1.2 kg
(2.7 Ibs) per day per plant. The Agency calculated that
attainment of proposed BAT would result in costs of over $346 per
pound equivalent of total toxics removed. [A pound equivalent is
calculated by multiplying the number of pounds of pollutant
discharged by a weighting factor for that pollutant. The
weighting factor is equal to the water quality criterion for a
standard pollutant, copper, divided by the water quality
criterion for the pollutant being evaluated.] This cost is
significantly higher than for other industries for which BAT
limitations have been established (e.g., iron and steel,
inorganic chemicals). EPA has been unable to identify any
reasonable, less costly, technology option. In addition, EPA has
estimated that attainment of proposed BAT limitations might cause
the closure of nine mills and the unemployment of some 1800
workers. The Agency found that these closures might affect the
local communities in which the mills are located because of the
unavailability of alternative employment.
397
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The proposed BAT limitations were aimed at controlling 15 organic
toxic pollutants and 12 toxic metals. All the other toxic
pollutants were excluded from regulation under Paragraph 8 of the
modified Settlement Agreement (44 FR 62218; October 29, 1979).
After proposal, EPA compared the concentrations of these 27 toxic
pollutants present in textile industry wastewaters to the lowest
concentration of each pollutant that can reasonably be achieved
by the application of known technologies. (These lowest
achievable concentrations have also been called "lowest
theoretical treatability levels.") EPA also determined the degree
and frequency that these lowest concentrations are exceeded (see
Section VI). The Agency found that of the 27 toxic pollutants of
interest, 17 pollutants were found above lowest theoretical
treatability levels in the raw waste only in a few isolated
instances, 6 pollutants were found above lowest theoretical
treatability levels in treated effluents only in a few isolated
instances, 2 pollutants were detected at only a small number of
sources and are uniquely related to those sources and 1 pollutant
was not detectable with the use of state-of-the-art analytical
methods because it is a common laboratory contaminant. The
remaining pollutant, total chromium, is controlled by existing
BPT effluent limitations. Establishment of BAT as proposed would
result in only an estimated 10 percent reduction in the discharge
of chromium (i.e., only 0.14 kg (0.3 pounds) per day per plant)
at an estimated capital cost of $41 million. The costs of
additional removal of chromium and the potential economic impact
do not justify further control.
In reviewing all available data and information, EPA found that
(1) the amounts of toxic pollutants discharged at the BPT level
of control are generally low, (2) the removal costs at the
proposed BAT level of control are relatively high when compared
to other industries, (3) toxic pollutants are found above lowest
theoretical treatability levels in only isolated instances, and
(4) attainment of proposed BAT limitations might result in the
closure of nine mills and the loss of 1800 jobs. Based on these
findings, the Agency has determined that more stringent
regulation of toxic pollutant discharges from the textile
industry is not justified and that BAT effluent limitations
should be established equal to BPT limitations. The Agency
recently completed an environmental assessment in which we
compared the predicted in-stream concentrations of toxic
pollutants found in textile discharges after attainment of BPT
and after attainment of proposed BAT effluent limitations with
EPA's ambient water quality criteria. This analysis confirms the
Agency's decision not to control toxics beyond a BPT level.
The Agency recognizes that the quantity of toxic pollutants
discharged from individual mills may, in some cases, be higher
than the industry average and may not be insignificant when
viewed as a single point source discharge. As explained in
Section VI, several toxic pollutants have been found above
minimum treatability levels in a few isolated instances. These
398
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include 1,2,4-trichlorobenzene, 2,4,6-trichlorophenol, toluene
and tetrachloroethylene used as dye carriers and napthalene,
pentachlorophenol and ethylbenzene used in the synthesis of dyes.
Permit-issuing authorities may find it necessary to require
representatives of individual mills to provide information on
toxic pollutant usage, to analyze for specific toxic pollutants,
and/or to conduct bioassay testing prior to issuing a NPDES
permit. Permit-issuing authorities may limit specific pollutants
on a case-by-case basis when limitations are necessary to carry
out the purposes of the Act, even if the pollutant is not
controlled by BAT limitations.
EPA has also decided that the nonconventional pollutant color
should be controlled on a case-by-case basis as dictated by water
quality considerations, rather than through establishing uniform
national standards. Color, in many instances, is an aesthetic
pollutant, although in some instances color can interfere with
sunlight transmission and the process of photosynthesis in the
aquatic environment. Color is a mill-specific problem related to
the combination of dyes and finishing chemicals used.
In addition, the Agency has found that the quantity of the
nonconventional pollutants sulfide and total phenols now
discharged by the textile industry are adequately controlled by
existing BPT limits. Accordingly, more stringent BAT limitations
are not needed. This is because of several factors including (a)
substitution of sulfur dyes, (b) use of nonphenolic dye carriers
and preservatives and (c) the effectiveness of biological
treatment in removing these pollutants. EPA has not identified a
technology option that is more effective than current industry
practices. Therefore, EPA is promulgating BAT limitations equal
to existing BPT limitations for sulfides and total phenols.
Furthermore, EPA has determined that it is not appropriate to
establish more stringent COD limitations. Biological treatment
is capable of removing on the order of 70 percent of the COD raw
waste load typical of this industry. The technology on which
proposed BAT limitations were based is relatively ineffective in
reducing COD. (The application of multimedia filtration in
addition to biological treatment increases COD removal to only
about 75 percent.) The application of other technologies
considered during development of the proposed rules (e.g.,
multimedia filtration plus granular activated carbon, or chemical
coagulation, sedimentation, multimedia filtration plus granular
activated carbon) can be very effective in reducing COD
discharges. However, these technologies have total annual costs
as much as three to six times that of the proposed BAT. EPA
predicts that nine mills might close if required to attain
proposed BAT limitations. In addition, if more advanced
technology were required, as many as 12 to 27 mills might close.
Because the costs of application of more advanced technologies to
control COD are high in relation to the effluent reduction
benefits and because of a potential for adverse economic impact,
399
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the Agency has determined that COD should continue to be
controlled at the BPT level.
For the reasons discussed above, EPA is establishing BAT
limitations for toxic and nonconventional pollutants equal to the
previously promulgated BPT limitations (for the seven
subcategories established in the 1974 regulations) or equal to
the BPT limitations developed in Section VIII (for the two new
subcategories and for the water jet weaving subdivision of the
low water use processing subcategory). We expect that Federal
and State permitting authorities will establish toxic and
nonconventional pollutant limitations more stringent than the
existing BPT, where needed, to account for unusual manufacturing
or treatment circumstances or to achieve or maintain the
receiving water quality.
NONWATER QUALITY IMPACTS
As BAT effluent limitations are equal to BPT effluent
limitations, there are no incremental nonwater quality impacts
associated with attainment of BAT effluent limitations.
400
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SECTION X
NEW SOURCE PERFORMANCE STANDARDS
GENERAL
The basis for new source performance standards (NSPS) under
section 306 of the Act is the best available demonstrated
technology. At new plants, the opportunity exists to design the
best and most efficient production processes and wastewater
treatment facilities, so Congress directed EPA to consider the
best demonstrated process changes, in-plant controls and
end-of-pipe treatment technologies that reduce pollution to the
maximum extent feasible.
PRIOR REGULATIONS
NSPS for the textile mills point source category were promulgated
on July 5, 1974 (39 FR 24736; 40 CFR Part 410, Subparts A-G).
The original NSPS established limitations for: conventional
pollutants (BODS, total suspended solids (TSS), fecal coliform
and pH for all subcategories and oil and grease for the wool
scouring subcategory), one toxic pollutant (total chromium) and
three nonconventional pollutants (COD, total phenols and sulfide
(as measured by the procedures listed in 40 CFR Part 136)), The
technology basis for NSPS was biological treatment followed by
multimedia filtration (except for the carpet finishing
subcategory where NSPS were based on biological treatment plus
chemical coagulation). However, in 1974 the Agency concluded
that at most new mills, NSPS could be attained by applying
in-plant controls and biological treatment.
Industry representatives challenged these regulations in the
Fourth Circuit Court of Appeals. In response to a joint motion
of petitioners and EPA to hold the case in abeyance while EPA
reconsidered the BAT limitations, the Court remanded all the
regulations except BPT to EPA for reconsideration. In the joint
motion, petitioners withdrew their challenge to the BPT
limitations and those limitations are, therefore, in effect. As
a result of the Court Order, the Agency and the American Textile
Manufacturers Institute (ATMI) began a joint study to collect
information and data necessary to reconsider the BAT, NSPS and
PSNS regulations.
As a result of the court ordered review as well as the revisions
to the Clean Water Act, the Agency has completely reassessed
NSPS. The standards presented in this document supersede NSPS
contained in the 1974 regulation.
401
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REGULATED POLLUTANTS
Pollutants regulated under NSPS include three conventional
pollutants, BOD5., TSS and pH; one toxic pollutant, total
chromium; and three nonconventional pollutants, COD, total
phenols and sulfide.
IDENTIFICATION OF THE TECHNOLOGY BASIS OF NSPS
The technology basis for NSPS in all nine subcategories is
biological treatment as demonstrated by the best performing
biological treatment systems now employed in the textile
industry. As discussed in Section IV, NSPS are established for
separate subdivisions of the woven fabric finishing subcategory
(simple, complex and desizing operations) and the knit fabric
finishing subcategory (simple, complex and hosiery operations),
taking into account actual wastewater treatment performance at
mills in each subcategory.
NSPS EFFLUENT LIMITATIONS
NSPS effluent limitations are presented in Table X-l.
RATIONALE FOR THE SELECTION OF NSPS
As explained previously, the regulations promulgated in 1974 were
challenged by industry. In January of 1975, all of the
regulations except BPT were remanded to EPA for reconsideration.
After further study, EPA proposed revised NSPS for nine
subcategories (44 FR 62204, October 29, 1979). The proposed
standards, with one exception, were based on the performance of
biological treatment followed by chemical coagulation and
filtration. In the low water use processing
proposed standards were based on the performance of
treatment only. NSPS, as proposed, would have
controls on BOD5, COD, TSS, total phenol, total
multimedia
subcategory,
biological
established
chromium, total copper, total zinc, color and pH.
Comments received on the proposed regulation questioned the need
for controls more stringent than proposed BAT, which were
generally based on the application of biological treatment plus
the addition of multimedia filtration (see Section IX).
Subsequent to proposal, the Agency evaluated all available
information and determined that biological treatment provides
adequate control of the discharge of toxic pollutants and results
in a significant reduction of nonconventional and conventional
pollutants. Application of biological treatment at new sources
will not change the rate of entry into the industry or slow the
industry growth rate. Therefore, the Administrator selected
biological treatment as the technology basis of NSPS.
Promulgated NSPS for BOD5., COD and TSS are more stringent than
BPT/BAT effluent limitations. Specific standards are generally
402
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o
U)
Subcategory
TABLE X-l
NEW SOURCE PERFORMANCE STANDARDS*
CONVENTIONAL POLLUTANTS**
Maximum for any one day
Average of daily values
for 30 consecutive days
Wool Scouring
Wool Finishing
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing
Simple Operations
Complex Operations
De sizing
Knit Fabric Finishing
Simple Operations
Complex Operations
Hosiery Products
Carpet Finishing
Stock and Tarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
BODS
3.6
10.7
1.4
8.9
3.3
3.7
5.5
3.6
4.8
2.3
4.6
3.6
2.6
16.9
TSS
30.3
32.3
1.4
5.5
8.8
14.4
15.6
13.2
12.2
8.4
8.6
9.8
4.9
50.9
BODS
1.9
5.5
0.7
4.6
1.7
1.9
2.8
1.9
2.5
1.2
2.4
1.9
1.4
8.7
TSS
13.5
14.4
0.7
2.5
3.9
6.4
6.9
5.9
5.4
3.7
3.8
4.4
2.2
22.7
* Expressed as kg pollutant/kkg of product (lb/1000 Ib) except for wool scouring which is
expressed as kg pollutant/kkg of wool processed and wool finishing which is expressed as
kg pollutant/kkg of fiber processed.
** For all subcategories, pH within the range 6.0 to 9.0 at all times.
-------
TABLE X-l (cont'd)
NEW SOURCE PERFORMANCE STANDARDS*
TOXIC AND NONCONVENTIONAL POLLUTANTS
Maximum for any one day
Average of daily values
for 30 consecutive days
COD
52.4
113.8
2.8
21.3
41.7
68.7
59.5
48.1
51.0
30.7
26.6
33.9
15.2
179.3
Sulfide
0.20
0.28
-
0.20
0.20
0.20
0.20
0.20
0.20
0.08
0.24
0.046
0.20
Phenols
0.10
0.14
-
0.10
0.10
0.10
0.10
0.10
0.10
0.12
0.12
0.023
0.10
Total
Chromium
0.10
0.14
-
0.10
0.10
0.10
0.10
0.10
0.10
0.04
0.12
0.023
0.22
COD
33.7
73.3
1.4
13.7
26.9
44.2
38.3
31.0
32.9
19.8
17.1
21.9
9.8
115.5
Sulfide
0.10
0.14
-
0.10
0.10
0.10
0.10
0.10
0.10
0.04
0.12
0.023
0.10
Phenols
0.05
0.07
-
0.05
0.05
0.05
0.05
0.05
0.05
0.06
0.06
0.011
0.05
Total
Chromium
0.05
0.07
-
0.05
0.05
0.05
0.05
0.05
0.05
0.02
0.06
0.011
0.05
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
General Processing
Water Jet Weaving
Woven Fabric Finishing
Simple Operations
Complex Operations
Desizing
Knit Fabric Finishing
Simple Operations
Complex Operations
Hosiery Products
Carpet Finishing
Stock and Tarn Finishing
Nonwoven Manufacturing
Felted Fabric Manufacturing 179.3
* Expressed as kg pollutant/kkg of product (lb/1000 Ib) except for wool scouring which is based
on kg/kkg of wool processed and wool finishing which is based on kg/kkg of processed fiber.
-------
based on the median discharge levels attained at existing best
performers in each subcategory of the textile industry.
Exceptions occur (a) in the nonwoven manufacturing and the felted
fabric processsing subcategories where, for the reasons discussed
in Section VIII, NSPS are based on transfer of technology from
the carpet finishing and wool finishing subcategories,
respectively, and (b) for the hosiery products subdivision of the
knit fabric finishing subcategory where, for the reasons
discussed below, NSPS are based on transfer of technology from
the simple manufacturing operations subdivision of the knit
fabric finishing subcategory. The promulgated NSPS level of
control represents the best demonstrated performance of existing
biological treatment systems in this industry.
EPA has also decided that the nonconventional pollutant color
should be controlled on a case-by-case basis as dictated by water
quality considerations, rather than through establishing uniform
national standards. Color, in many instances, is an aesthetic
pollutant, although in some instances color can interfere with
sunlight transmission and the process of photosynthesis in the
aquatic environment. Color is a mill-specific problem related to
the combination of dyes and finishing chemicals used.
In addition, the Agency has found that the quantity of the
nonconventional pollutants sulfide and total phenols now
discharged by the textile industry are adequately controlled by
existing BPT limits. Accordingly, more stringent NSPS are not
needed. This is because of several factors including (a)
substitution of sulfur dyes, (b) use of nonphenolic dye carriers
and preservatives and (c) the effectiveness of biological
treatment in removing these pollutants. EPA has not identified a
technology option that is more effective than current industry
practices. Therefore, EPA is promulgating NSPS equal to existing
BPT limitations for sulfides and total phenols.
METHODOLOGY USED FOR DEVELOPMENT OF NSPS
NSPS were calculated as the product of (a) long-term average
discharge levels of each specific pollutant and (b) an
appropriate variability factor for each specific pollutant.
Data Base
•The data base used for the development of NSPS includes 72 mills
where biological treatment is in"place that is representative of
the best practicable control technology currently available. The
following criteria were used in the selection of the 72 plants to
be included in the data base:
1. Biological treatment generally representative
type that formed the basis of BPT is used.
of the
405
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2.
3.
4.
5.
Treatment system performance is characteristic of,
although not necessarily achieving, BPT limitations.
Sufficient long-term data were
seasonal variability.
available to reflect
Overall response to the industry data request was
accurately and conscientiously prepared.
Production and flow data were available.
Long-term average BOD5., TSS and COD discharges per unit of
production for the 72 plant data base are presented in Table X-2.
Calculation of Subcateqory Long-Term Average Discharge Levels
Best performers were identified as those where long-term average
BOD5., TSS and COD effluent discharges were less than the maximum
30-day average BPT effluent limitations for each parameter. For
each subcategory, the median long-term average BOD!>, TSS and COD
characteristic of the best performing mills forms the basis of
NSPS limitations for these parameters. The best performers are
identified and the median subcategory long-term averages used as
the basis of NSPS are presented in Table X-3.
As discussed previously, insufficient data are available on the
performance of biological treatment in the new nonwoven
manufacturing and felted fabric processing subcategories.
Long-term averages for these subcategories were, therefore, based
on flow-adjusted long-term averages for the carpet finishing and
wool finishing subcategories for the reasons presented in Section
VIII.
In addition, no best performing mills have been identified in the
hosiery products subdivision of the knit fabric finishing
subcategory. Therefore, as explained in the Notice of
Availability of Additional Information (46 FR 8590, January 27,
1981), long-term average biological treatment performance levels
for the hosiery products subdivision are based on transfer of
technology from the simple processing subdivision of the knit
fabric finishing subcategory. This transfer is justifed because
(a) manufacturing operations, raw material usage, and wastewater
characteristics are similar at mills in both subdivisions, (b)
biological treatment is available and can be employed at new
sources in the hosiery products subdivision, and (c) biological
treatment, when applied at -new hosiery mills, is capable of
attaining the long-term average performance levels presented in
Table X-3.
Effluent Variability Analysis
Pollutant quantities discharged from a wastewater treatment
system vary. This variability is accounted for .in deriving
406
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TABLE X-2
LONG TERM AVERAGE EFFLUENT DISCHARGE
BIOLOGICAL TREATMENT (72 PLANT) DATA BASE
BOD
Subcategory/Plant No. (kg/kRg)
Wool Scouring
10006
10015
BPT Max. 30 day limit
Wool Finishing
20005
20009
20011
20020
20021
BPT Max. 30 day limit
Woven Fabric (Simple Processing)
40023
40035
40050
40098
40100
40109
40143
BPT Max. 30 day limit
Woven Fabric (Complex Processing)
40022
40091
40111
40148
40154
40160
BPT Max. 30 day limit
0.40
1.82
5.30
10.39
3.28
6.43
2.93
50.5
11.2
0.36
5.05
1.84
2.59
3.44
18.77
1.01
3.3
4.05
5.30
3.19
.54
1.14
5.03
3.3
COD
(kg/kkg)
8.93
35.58
69.0
52.13
44.33
104.7
81.5
7.63
71.71
45.99
36.22
31.02
17.67
30.0
42.47
23.79
55.88
29.06
44.42
60.0
TSS
(kg/kkg)
1.00
14.56
16.10
20.64
8.30
14.10
5.47
27.5
17.6
1.38
8.95
4.43
11.26
3.92
8.60
2.27
8.9
10.11
7.55
3.20
4.83
3.70
11.42
8.9
Best
Performer
X
X
X
X
X
X
X
X
X
407
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TABLE X-2 (continued)
LONG TERM AVERAGE EFFLUENT DISCHARGE
BIOLOGICAL TREATMENT (72 PLANT) DATA BASE
BOD
SubcategorPlant No.
Woven Fabric (Desizing)
40012
40017
40034
40037
40059
40064
40072
40074
40087
40097
40099
40103
40120
40140
40145
40151
40153
BPT Max. 30 day limit
Knit Fabric (Simple Processing)
50008
50015
50057
50081
50082
50098
50108
50113
50116
BPT Max. 30 day limit
Knit Fabric (Complex Processing)
50035
50056
50065
50099
50123
BPT Max. 30 day limit
1.17
.87
1.75
3.17
3.02
3.01
.73
2.31
1.87
.76
2.14
1.61
.51
4.66
1.12
3.13
9.76
3.3
2.45
2.67
2.02
.89
1.52
9.68
.87
1.30
.42
2.5
3.31
8.31
7.46
1.47
.14
2.5
COD
(kg/kks)
TSS
(kg/kkg)
Best
Performer
1.17
.87
1.75
3.17
3.02
3.01
.73
2.31
1.87
.76
2.14
1.61
.51
4.66
1.12
3.13
9.76
3.3
-
4.69
30.12
25.17
41.61
-
21.73
58.92
-
21.53
32.99
-
14.67
29.40
25.48
14.48
69.36
60.0
5.43
.65
6.43
1.84
3.40
10.62
.71
15.14
2.54
1.59
6.52
1.73
4.56
7.66
8.65
4.91
19.38
8.9
X
X
X
X
X
X
X
X
X
X
X
X
X
2.45
2.67
2.02
.89
1.52
9.68
.87
1.30
.42
2.5
.
64.02
71.94
8.68
28.58
37.61
20.40
22.45
9.13
30.0
3.24
5.22
3.29
3.53
8.28
12.68
1.56
6.21
1.32
10.9
X
X
X
X
X
X
3.31
8.31
7.46
1.47
.14
2.5
40.45
68.26
58.00
21.62
3.31
70.0
17.17
11.60
6.19
3.13
.66
8.9
X
X
408
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TABLE X-2 (continued)
LONG TERM AVERAGE EFFLUENT DISCHARGE
BIOLOGICAL TREATMENT (72 PLANT) DATA BASE
Subcategory/Plant No.
Knit Fabric (Hosiery Products)
5H028
5H029
BPT Max. 30 day limit
Carpet Manufacturing
60001
60005
60013
60018
60021
60034
60037
60039
BPT Max,
30 day limit
Stock and Yarn Finishing
70009
70031
70036
70075
70084
70087
70089
70096
70104
70106
70126
BPT Max. 30 day limit
BOD
(kg/kgg)
2.47
6.62
2.5
98
01
45
37
58
84
1.73
4.77
3.9
COD
(kg/kkg)
23.43
37.09
70.0
6.41
19.06
8.72
11.27
26.02
15.31
33.71
35.1
TSS
(kg/kkg)
3.94
6.70
8.9
.81
3.85
1.58
2.80
6.10
3.42
1.64
10.93
5.5
Best
Performer
X
X
X
X
X
X
X
.94
.57
3.31
.55
1.85
1.27
1.85
1.75
.71
.23
10.13
3.4
17.24
11.24
42.94
10.17
23.85
8.34
55.31
11.53
21.15
4.99
24.21
42.3
1.56
2.43
7.24
2.61
6.42
1.43
7.60
1.44
4.36
.34
8.28
8.7
X
X
X
X
X
X
X
X
409
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TABLE X-3
CALCULATION OF NSPS LONG-TERM AVERAGE
Mill
Wool Scouring
10006
10015
MEDIAN
Wool Finishing
20011
20009
20020
MEDIAN
Woven Fabric Finishing
40143
MEDIAN
Woven Fabric Finishing
40148
40154
MEDIAN
Woven Fabric Finishing
40120
40012
40072
40097
40037
40151
40145
40099
40103
40034
40059
40087
MEDIAN
BOD,
(kg/kfcg)
0.40
1.82
1.11
6.43
3.28
2.93
3.28
(Simple)
1.01
1,01
(Complex)
0.54
1.14
0.84
(Desizing)
0.51
1.17
0.73
0.76
3.17
3.13
1.12
2.14
1.61
1.75
3.02
1.87
1.68
COD
(kg/kkg)
8.9
35.6
22.2
52.13
44.33
48,23
17.67
17.67
29.1
29.1
14.67
21.73
21.53
25.17
14.48
25.48
32.99
30.12
41.61
25.2
TSS
(kg/kkg)
1.0
14.56
7.8
14.10
8.30
5.47
8.30
2.27
2.27
4.83
3.70
4.30
4.56
5.43
0.71
1.59
1.84
4.91
8.66
6.52
1.73
6.43
3.40
2.54
4.00
410
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TABLE X-3 (continued)
CALCULATION OF NSPS LONG-TERM AVERAGE
Mill
Knit Fabric (Simple)
50008
50081
50108
50116
50082
50113
MEDIAN
Knit Fabric (Complex)
50099
MEDIAN
Knit Fabric (Hosiery)
BOD
(kg/kJg)
2.45
0.69
0.87
0.42
1.52
1.30
1.10
1.47
1.47
COD
(kg/kkg)
8.68
20.40
9.13
28.58
22.45
20.4
21.62
21.62
TSS
(kg/kkg)
3.24
3.53
1.56
1.32
8.28
6.21
3.4
3.13
3.13
Due to insufficient data to apply the general methodology
hosiery numbers were based on the simple processing group
adjusted for flow (simple x 75.1/117/6).
Annual Ave.
Carpet Manufacturing
0.69
13.0
2.16
60018
60005
60013
60037
60001
60034
1.37
1.01
1.45
1.73
0.98
1.84
11.27
19.06
8.72
.
6.41
15.31
2.80
3.85
1.58
1.64
0.81
3.42
MEDIAN
1.41
11.27
2.22
411
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TABLE X-3 (continued)
CALCULATION OF NSPS LONG-TERM AVERAGE
Mill
BOD
(kg/kSg)
Stock and Yarn Finishing
COD
(kg/kkg)
TSS
(kg/kkg)
70087
70096
70104
70009
70075
70031
70036
70084
MEDIAN
1.27
1.75
0.71
0.94
0.55
0.57
3.31
1.85
1.10
8.34
11.53
21.15
17.24
10.17
11.27
42.94
23.85
14.38
1.43
1.44
4.36
1.56
2.61
2.43
7.24
6.42
2.52
Non Woven Manufacturing
As in proposal the wastewater characteristics are taken from
Carpet Mills adjusted for flow: (Carpet Mills) (40.0/46.7)
Annual Ave.
1.21
9.68
1.90
Felted Fabric Processing
As in proposal the wastewater characteristics are taken from
Wool Finishing adjusted for flow: (Wool Finishing) (212.7/304.4)
Annual Ave.
2.66
34.4
6.00
412
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limitations regulating the amount of pollutants that may be
discharged by individual plants in the textile industry. The
statistical procedures employed in analyzing variability for the
conventional pollutants, BOD5, and TSS, and for the
nonconventional pollutant COD are described below.__
Effluent Limitations Guidelines An effluent limitation is an
upper bound on the amount of pollutant discharge allowed per day
or the average amount of pollutant discharge allowed for a period
of 30 days. The limitations are generally determined by
calculating the product of two numbers which may be derived from
effluent data: one is referred to as a variability factor and the
other as a long-term average. Two types of variability factors
are derived for the guidelines: a daily maximum factor and a
30-day maximum factor. The daily factor is the ratio of (a) a
value that would be exceeded rarely by the daily pollutant
discharge to (b) the long-term average daily discharge. The
30-day factor is the ratio of (a) a value that would be exceeded
rarely by the average of 30 daily discharge measurements to (b)
the long-term average daily discharge. The long-term average
daily discharge quantity is an expression of the long-run
performance of the treatment process. Given a daily maximum
variability factor for a pollutant (denoted by VF) and a
plant-specific long-term average for the same pollutant (denoted
by LTA), the plant-specific daily limitation is the product of
the variability factor and the long-term average (VF x LTA).
Similarly, given a 30-day maximum variability factor (VF30), a
plant specific limit for the average of 30 daily observations is
VF30 x LTA.
Data Base The data base for the calculation of effluent
variability included data for 39 of the 72 mills included in the
total data base. These data were obtained in the initial
industry surveys and a subsequent data request for long-term
daily data sent to representatives of ten facilities.
Variability Factors Both daily maximum and maximum 30-day average
variability factors were determined that are representative of
the variation in treatment system performance in treating textile
industry BOD5., TSS and COD discharges.
Daily Maximum Variability Factors - - Daily maximum
variability factors were derived from daily effluent measurements
for each of the three pollutants. Goodness-of-fit tests were
performed to determine whether the data could be assumed to
follow either a normal or lognormal distribution. [If data are
assumed to follow either of these distributional forms,
convenient estimation techniques associated with distribution
theory may be applied in order to estimate variability factors.]
The overall results of the goodness-of-fit tests are somewhat
inconclusive in the sense that the data are not consistently
normal or lognormal. This is not surprising because the small
sample sizes available for some of the mills substantially reduce
413
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the probability of correctly rejecting the hypothesis under
consideration. With sufficiently large numbers of observations,
variability factors and limitations' may be determined without
making assumptions about the functional form of the underlying
distribution of the data. However, because of the small sample
sizes, conventional distribution-free (or nonparametric)
techniques were not appropriate in this case.
The lognormal distribution was assumed for the underlying
distribution of the data because plots of the empirical
distribution function suggest that daily pollutant measurements
are described reasonably well by the lognormal distribution.
Daily maximum variability factors for BOD!>, COD and TSS at all
mills in the data base are presented in Table X-4. Average and
median variability factors for all mills in the data base are
also shown in Table X-4. Various alternatives present reasonable
possibilities for determining daily maximum variability factors
to be used in establishing NSPS for this industry.
It is reasonable to expect that at new mills, personnel will be
able to control effluent variability at least as well as the best
25 percent of the mills for which sufficient data are available
to determine effluent variability. Overall industry variability
factors were, therefore, based on the 25th percentile .of
individual mill values presented in Table X-4.
30-Day Maximum Variability Factors - - Thirty-day maximum
variability factors were calculated using a modification of the
Central Limit Theorem. This theorem states that the distribution
of sample means of size "n" drawn from any one of a large class
of different distributional forms will be approximately normally
distributed. The normal distribution provides a good
approximation of the distribution of the sample mean for samples
as small as 25 or 30 data points (13). Sample sizes of at least
150 data points yield five successive 30-day averages and
represent a reasonable minimum number of averages from which to
assess the distributional form of the sample mean.
The mill-specific 30-day averages were found to fit the normal
distribution on the basis of the Lilliefors goodness-of-fit test.
The sample mean
-------
TABLE X-4
MAXIMUM DAY VARIABILITY FACTORS
LOGNORMAL DATA DISTRIBUTION
BOD
TSS
COD
Mill
Number
10006
10015
20009
20020
20021
40091
40098
40099
40100
40140
40143
40151
40154
40160
50008
50015
50035
50056
50057
50065
50081
50082
50098
50099
50116
50123
5H028
5H029
60001
60018
60021
70075
70084
70087
70089
70009
70031
70106
70126
MEAN
MEDIAN
25 percentile
Number
of Data
Points
46
93
4
46
182
15
192
172
234
-
-
8
221
135
157
-
181
140
34
117
49
173
67
9
-
52
24
16
14
29
24
16
153
105
12
51
48
175
17
Maximum
Day
7.021
5.428
4.425
5.492
4.652
3.805
3.825
3.354
4.809
-
-
3.942
3.799
2.194
2.017
-
4.017
3.298
4.927
3.909
5.749
4.122
3.835
2.928
-
1.718
11.253
2.865
4.016
4.505
3.535
4.708
3.640
4.223
1.463
2.870
3.328
3.188
5.881
4.14
3.94
3.27
Number
of Data
Points
47
95
4
45
192
8
192
173
234
19
13
8
52
140
157
-
185
142
56
115
49
174
56
4
18
52
24
13
3
29
24
16
154
105
12
51
50
180
17
Maximum
Day
5.781
6.360
2.258
4.532
4.818
4.185
3.789
4.010
4.842
1.850
6.073
5.421
7.065
4.257
4.448
-
5.062
5.221
5.072
6.719
6.464
4.751
3.993
1.685
4.822
2.292
8.393
3.098
4.719
4.315
4.309
5.088
3.703
4.577
5.108
2.931
4.112
4.094
2.142
4.54
4.55
3.89
Number
of Data
Points
46
95
0
46
1
15
192
-
234
19
16
8
77
136
-
12
185
95
11
125
47
174
69
9
18
14
24
-
3
29
24
16
154
105
12
51
49
3
17
Maximum
Day
4.360
4.661
-
2.871
-
1.600
3.693
-
3.345
1.810
2.368
3.570
4.377
2.338
-
1.789
2.912
2.370
3.254
2.490
4.769
3.336
3.500
2.761
1.844
1.981
2.723
-
4.526
3.312
1.914
2.567
3.235
3.237
3.169
1.381
2.291
2.760
2.517
2.93
2.82
2.36
415
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where X denotes the long-term mill-specific average. Table X-5
presents the maximum 30-day average variability factors for each
mill for which sufficient BOD5., TSS and COD data were available,
EPA tested this method to see if it would yield a reasonable
approximation of the maximum 30-day average discharge likely to
occur at an individual mill. The Agency found that 100 percent
of the individual 30-day averages were less than the predicted
maximum 30-day average for each mill. Based on this analysis,
EPA concluded that this was a reasonable method of estimating
maximum 30-day average variability factors.
Maximum 30-day average variability factors for BOD5,, COD and TSS
could be determined for only five to ten facilities. Because of
the limited data available, the Agency based final maximum 30-day
average NSPS on median maximum 30-day average variability
factors, rather than 25th percentile values. Median variability
factors are shown in Table X-5.
COST OF APPLICATION AND EFFLUENT REDUCTION BENEFITS
The cost of attainment of NSPS varies by subcategory as discussed
in detail in Appendix A. Substantial reductions of BODS., COD,
TSS, phenols, sulfide and total chromium will resulF upon
attainment of NSPS at new direct discharging textile mills.
NONWATER QUALITY IMPACTS
Energy costs and the cost of disposal of solid wastes have been
included in the costs of NSPS. As the technology basis for NSPS
is the same as for BPT, there will be no significant impact over
the energy required and solid waste generated to achieve BPT.
Attainment 'of NSPS will have no measurable impact on noise or air
pollution.
416
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TABLE X-5
MAXIMUM 30-DAY AVERAGE VARIABILITY FACTORS FOR
BOD, TSS, AND COD
Plant
Number
020021
040098
004099
040100
040154
050008
050035
050082
070084
070106
Minimum
Variability
Factor
Maximum
Variability
Factor
Median
Variability
Factor
Maximum
BODS
2.01 (182)
1.71 (192)
1.63 (174)
2.49 (234)
2.03 (221)
1.57 (157)
1.66 (181)
1.51 (173)
1.89 (153)
1.60 (175)
1.51
2.49
1.69
30-Day Average Variability
TSS
1.88 (192)
1.42 (192)
1.35 (173)
2.39 (234)
(b)
1.88 (157)
2.29 (185)
1.35 (174)
1.54 (154)
1.73 (180)
1.35
2.39
1.73
Factors (a)
COD
(b)
1.52 (192)
(b)
1.67 (234)
(b)
(b)
1.47 (185)
1.38 (174)
1.77 (154)
(b)
1.35
1.77
1.52
(a) Number of daily data points given in parentheses.
(b) Insufficient daily data for analysis, or daily data not available.
417
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SECTION XI
PRETREATMENT STANDARDS FOR EXISTING
AND NEW SOURCES
GENERAL
Section 307 (b) of the Clean Water Act of 1977 requires EPA to
promulgate pretreatment standards for existing sources (PSES)
that must be achieved within three years of promulgation and
section 307(c) of the Act requires EPA to promulgate pretreatment
standards for new sources (PSNS) at the same time that it
promulgates NSPS. New indirect dischargers, like new direct
dischargers, have the opportunity to incorporate the best
available demonstrated technologies including process changes,
in-plant control measures and end-of-pipe treatment.
Pretreatment standards for existing and new sources are designed
to control the discharge of pollutants that pass through,
interfere with, or are otherwise incompatible with the operation
of a publicly owned treatment works (POTW). The Clean Water Act
of 1977 requires pretreatment for pollutants that pass through
the POTWs in amounts that would violate direct discharger
effluent limitations or interfere with the POTW's treatment
process or chosen sludge disposal method. The legislative
history of the 1977 Act indicates that pretreatment standards are
to be technology-based, analogous to the best available
technology. EPA has generally determined that there is pass
through of pollutants if the percent of pollutants removed by a
well-operated POTW achieving secondary treatment is less than the
percent removed by the BAT model treatment system. The general
pretreatment regulations, which served as the framework for the
categorical pretreatment regulations, are found at 40 CFR Part
403.
PRIOR REGULATION
PSNS were promulgated on July 5, 1974 (39 FR 24739) and were
equal to the standard set forth in 40 CFR Part 128 with the
exception that pretreatment standards for incompatible pollutants
would be equal to NSPS. Industry representatives challenged
these regulations in the Fourth Circuit Court of Appeals. In
response to a joint motion of petitioners and EPA to hold the
case in abeyance while EPA reconsidered the BAT limitations, the
Court remanded all the regulations except BPT to EPA for
reconsideration. Subsequently, in a joint motion, petitioners
withdrew their challenge to the BPT limitations and those
limitations are, therefore, in effect. As a result of the Court
Order, the Agency and the American Textile Manufacturers
419
-------
Institute (ATMI) began a joint study to collect information and
data necessary to reconsider the BAT, NSPS and PSNS regulations.
PSES were promulgated on May 26, 1977 (42 FR 26983) establishing
general pretreatment requirements (no specific pollutants were
limited) that included the elements of what later became the
General Pretreatment Regulations, now included in 40 CFR Part
403.
As a result of the court ordered review as well as the revisions
to the Clean Water Act, the Agency has reassessed PSES and PSNS.
The standards presented in this document supersede the previously
published PSES and PSNS.
REGULATED POLLUTANTS
Categorical pretreatment standards are not being established for
new or existing sources; therefore, no specific pollutants are
regulated.
IDENTIFICATION OF PRETREATMENT STANDARDS FOR EXISTING AND NEW
SOURCES
PSES and PSNS for the textile mills point source category shall
be the General Pretreatment Regulations found at 40 CFR Part 403
(43 FR 27736, June 26, 1978).
RATIONALE FOR THE SELECTION OF PRETREATMENT STANDARDS FOR
EXISTING AND NEW SOURCES
As discussed previously, industry challenged the PSNS promulgated
in 1974 and the regulation was remanded to the Agency for
reconsideration. PSES, establishing general pretreatment
requirements (no specific pollutants were limited), were
promulgated in 1977 (42 FR 26983; May 26, 1977). Revised PSNS
and PSES were proposed in 1979 (see 44 FR 62204, October 29,
1979). The proposed pretreatment standards would have
established controls on total chromium, total copper and total
zinc.
Commenters argued that pollutants discharged by the textile
industry do not interfere with or pass through POTWs. Following
proposal, the Agency reviewed available information and
determined that textile wastewaters are susceptible to treatment
in and do not interfere with the operation of POTWs. Comparison
of metal removal efficiencies at 20 POTWs and at textile industry
biological treatment systems shows that POTW removal of copper,
chromium and zinc is equal to or better than removal in industry
biological treatment systems. Therefore, these pollutants do not
pass through POTWs.
420
-------
Accordingly, under the authority of Paragraph 8(b)(i) of the
modified Settlement Agreement, this,regulation does not establish
categorical pretreatment standards for the textile industry. The
textile industry will, however, remain subject to the General
Pretreatment Regulations. Section VII includes information on
the capability of various technologies applicable to controlling
textile industry discharges to POTWs. We expect that operators
of POTWs will be able to control the discharge of specific
pollutants, if required, on a case-by-case basis and could make
use of the information contained herein.
COST OF APPLICATION
As no specific pollutants are regulated under PSES and PSNS,
there are no costs associated with this regulation.
NONWATER QUALITY IMPACTS
As no specific pollutants are regulated under PSES and PSNS,
there are no nonwater quality impacts associated with this
regulation.
421
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SECTION XII
ACKNOWLEDGEMENTS
Dr. James E. Gallup, James R. Berlow and Richard E. Williams, all
of the Effluent Guidelines Division, served as project officers
during the technical study of the textiles industry. Robert W.
Dellinger, Acting Chief, Wood Products and Fibers Branch provided
direction and guidance in the maturation of the regulatory
strategy and the development of final rules. Jeffery D. Denit,
Director, Effluent Guidelines Division, contributed counsel and
support during the study.
Other EPA personnel who contributed to the completion of this
project include Debra Maness, Louis DuPuis, Jessica Pollner,
Clifton Bailey and James Spattarella of the Office of Regulations
and Standards. In addition, Lee Schroer and Susan Lepow, both of
the Office of General Counsel - Water, provided valuable guidance
and direction.
The Sverdrup Corporation St. Louis, Missouri, and the E.G. Jordan
Co., Portland, Maine, were the technical contractors to the
Agency, they collected the technical data and information,
organized it, and provided it to the Agency. Special recognition
and appreciation is expressed to Larry J. Oliver, P.E. and Conrad
R. Bernier, P.E., project managers for Sverdrup and Jordan,
respectively. These gentlemen's contributions and assistance
played a major role in the completion of the project.
The cooperation of textiles industry companies and personnel
during the data and information collection phase of the study is
also gratefully acknowledged. Without their cooperation, the
promulgation of final effluent guidelines and standards would
have been greatly delayed. The assistance of the industry trade
and technical associations, especially the American Textile
Manufacturers Association, the Northern Textile Association and
the Carpet and Rug institute is appreciated.
Finally, the performance of the Effluent Guidelines Division's
word processing department is acknowledged. The efforts of Pearl
Smith, Carol Swann and Glenda Nesby, in the face of what seemed
to be insurmountable odds at times, are greatly appreciated.
423
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SECTION XIII
REFERENCES
1. "Development Document for Effluent Limitations Guidelines
and New Source Performance Standards for the Textile Mills Point
Source Category," U.S. Environmental Protection Agency,
Washington, DC, Ref. No. EPA 440/1-74-022-a.
2• Davison's Textile Blue Book, 111th
Publishing Company, Ridgewood, NJ (1977).
Edition, Davison
3, "In-Plant Control of Pollution - Upgrading Textile
Operations to Reduce Pollution," U.S. Environmental Protection
Agency, Washington, DC, Ref. No. EPA 625/3-74-004.
4. "Draft Development Document: Pretreatment Standards for
Textile Mills (Addendum to the Development Document for Effluent
Limitations Guidelines and New Source Performance Standards for
the Textile Mills Point Source Category)," Sverdrup & Parcel and
Associates, Inc., St. Louis, MO (November, 1976).
5. "Textile Industry Technology and Costs of Wastewater
Control," Lockwood-Greene, New York, NY (June, 1975).
6. "Cost of Clean Water - Volume III, Industrial Waste Profiles
- No. 4, Textile Mill Products, The," Federal Water Pollution
Control Administration, Washington, DC (September, 1967).
7. "Census of Manufactures, 1972," Social and Economic
Statistics Administration, Bureau of the Census, U.S. Department
of Commerce Publication (1975).
8. "CoUnty Business Patterns, 1975," County Business Patterns,
Bureau of the Census, Ref. No. CBP-75-1.
9. "Textiles - U.S. Industrial Outlook," U.S. Department of
Commerce, Domestic and International Business Administration,
Washington, DC (1978), pp. 239-244.
10. Trotman, E. R., Dyeing and Chemical Technology of. Textile
Fibers, Fifth Edition, Chas. Griffin & Co., Ltd., London, GB
(1975).
11. "Sources and Strengths of Textile Wastewaters," Lockwood-
Greene Engineers (Technology Transfer Report on Raw Waste Loads,
Chapter 4), pp. 4-1 to 4-65.
12. Walpole, R. F., and Myers, R. H., Probability and Statistics
for Engineers and Scientists (1972).
425
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13. Miller, I., and Freund, J. E., Probability and Statistics
for Engineers (1965).
14. Snedecor, G. W., and Cochran, W. G., Statistical Methods,
6th_ed* (1967).
15. Masselli, J. W., MasselH, N. W., and Burford, M. G., "A
Simplification of Textile Waste Survey and Treatment," New
England Interstate Water Pollution Control Commission, Boston, MA
(1959).
16. "Quality Criteria for Water," U.S. Environmental Protection
Agency, Washington, DC, Ref. No. EPA 440/9-76-023.
17. Faro, R. C., Kartiganer, H. L., Schneider, A., and Albano,
D. J., "Pretreatment Provides Constant Effluent Quality," Water .&
Wastes Engineering (October, 1974), pp. 52-55.
18. Stone, R., "Carpet Mill Industrial Waste System," Journal oj
the Water pollution Control Federation, Vol. 44, No. 3 (March,
1972), pp. 470-478. :
19. Frye, W. H., and DiGiano, F. A., "Adsorptive Behavior of
Dispersed and Basic Textile Dyes on Activated Carbon,"
Proceedings of the 29th Industrial Waste Conference, Purdue
University, Lafayette, IN (1974), pp. 21-28.
20. Metcalf and Eddy, Inc., Wastewater Engineering: Collection,
Treatment, Disposal, McGraw-Hill Book Company, New York, NY
(1972).
21. Feigenbaum, H. N., "Removing Heavy Metals In Textile Waste,"
Industrial Wastes (March/April, 1972), pp. 32-34.
22. Snider, E. H., and Porter, J. J., "Ozone Treatment of Dye
Waste,M Journal oj the ftater pollution. Contro^ Federation, Vol.
46, No. 5 (May, 1974), pp. 886-894.
23. Stuber, L. M., "Tertiary Treatment and Disinfection of
Tufted Carpet Dye Wastewater," Proceedings of the 29th Industrial
Waste Conference, Purdue University, Lafayette, IN (1974), pp.
964-977.
24. Hammer, M. J., Water and Wastewater Technology, John Wiley &
Sons, Inc., New York, NY (1975T
25. Brandon, C. A., and Porter, J. J., "Hyperfiltration for
Renovation of Textile Finishing Plant Wastewater," Ref. No. EPA
600/2-76-060.
26. Brandon, C. A., Porter, J. J., and Todd, D. K.,
"Hyperfiltration for Renovation of Composite Wastewater at Eight
426
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Textile Finishing Plants," Ref. No. EPA 600/2-78-047 (March,
1978).
27. "Survey of Textile Wastewater Treatment, State of the Art,
Add-on Treatment Processes," Hydroscience, Inc., Westwood, NJ
(April, 1976).
28. "Process Design Manual for Nitrogen Control," U.S. EPA
Technology Transfer (October, 1975).
29. Gulp, R. L., and Gulp, G. L., "Advanced Wastewater
Treatment," Van Nostrand Reinhold Company, New York, 310 pp
(1971).
30. Hrutfiord, B. F., Johanson, L. N., and McCarthy, J. L.,
"Steam Stripping Odorous Substances from Kraft Effluent Streams,"
U.S. EPA, ORM, EPA-R2-73-196 (April, 1973).
31. "Process Design Manual for Carbon Adsorption," U.S. EPA
Technology Transfer (October, 1973).
32. Weber, W. J., "Physiochemical Processes for Water Quality
Control," Wiley-Interscience, New York, 640 pp. (1972).
33. Ford, D. L., "Putting Activated Carbon in Perspective to
1983 Guidelines," .Industrial Water Engineering, p. 20 (May/June,
1977).
34. "Activated Sludge with Powdered Activated Carbon Treatment
of Textile Wastewaters, Feasibility Study Report," Engineering-
Science, Atlanta, GA (May, 1978).
35. "Final Development Document for Existing Source Pretreatment
Standards for the Electroplating Point Source Category," U.S.
Environmental Protection Agency, Washington, D.C. Ref. No. EPA
440/1-79/003.
36. Fate of Priority Pollutants in Publicly Owned Treatment
Works, Environmental Protection AGency, Washington, D.C. EPA
440/1-80-301, October 1980.
37. "Proposed Development Document for Effluent Limitations
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427
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40. Smith, R., "Cost of Conventional and Advanced Treatment of
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51. Fisher Scientific Co., Catalog 77.
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428
-------
55. Smith, J* E., "Inventory of Energy Use in Wastewater Sludge
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56. Maggiolo, A., and Sayles, J. H., "Automatic Exchange Resin
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64. Water & Wastewater Analysis - Fee Schedule, St. Louis
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429
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70. Rinker, T. L., "Treatment of Textile Wastewater by Activated
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430
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Massachusetts, on Process Revisons - Pilot Plant Study of the
Proposed Wastewater Treatment Fac i1i ty," Cu11i nan Eng i neer i ng
Co., Inc. Auburn, MA (August, 1973).
123. "Revised Executive Summary to Economic Analysis of Proposed
Effluent Guidelines: Textile Industry," U.S. Environmental
Protection Agency, Washington, DC, Ref. No. EPA 230/1-73-028
(1974).
124. Rhame, G. A., "Treatment of Textile Finishing Wastes by
Surface Aeration," Proceedings of the 26th Industrial Waste
Conference, Purdue University, Lafayette, IN (1971), pp. 702-712.
125. Richardson, M. B., and Stepp, J. M., "Costs of Treating
Textile Wastes in Industrial and Municipal Treatment Plants; Six
Case Studies," Water Resources Research Institute, Clemson
University, Clemson, SC (March, 1972).
126. Rinker, T. L., "Treatment of Textile Wastewater by Activated
Sludge and Alum Coagulation," Ref. No. EPA 600/2-75-055.
127. Rinker, T. L., and Sargent, T. N., "Activated Sludge and
Alum Coagulation Treatment of Textile Wastewaters," Proceedings
of the 29th Industrial Waste Conference, Purdue University,
Lafayette, IN (1974), pp. 456-471.
440
-------
128. Rodman, 0. A., and Shunney, E. L., "Bio-Regenerated
Activated Carbon Treatment of Textile Dye Wastewater,"
Environmental Protection Agency, -Washington, DC, Water Pollution
Control Research Series - 12090 DWM (January, 1971).
129. Sercu, C., "National Committee on Water Quality Report," Dow
Chemical Co., Midland, MI (March, 1977).
130. Shelley, M. L., Randall, C. W., and King, P. H., "Evaluation
of Chemical-Biological and Chemical-Physical Treatment for
Textile Dyeing and Finishing Waste," Journal of the Water
Pollution Control Federation, Vol. 48, No. 4 (April, 1976), pp.
753-761.
131. Shriver, L. E., and Dague, R. R., "Textile Dye Process Waste
Treatment with Reuse Consideration," Proceedings of 32nd
Industrial Waste Conference, Purdue University, Lafayette, IN
(1978), pp. 581-592.
132. Smith, J. E., "Inventory of Energy Use in Wastewater Sludge
Treatment and Disposal," Industrial Water Engineering
(July/August, 1977).
133. Smith, R., "Cost of Conventional and Advanced Treatment of
Wastewater," Journal pf the Water Pollution Control federation
Vol. 40, No. 9 (September, 1968), pp. 1546-1574.
134. Smith R., "Electrical Power Consumption for Municipal
Wastewater Treatment," Ref. No. EPA R2-73-281.
135. Snider, E. H., and Porter, J. J., "Ozone Treatment of Dye
Waste," Journal of the Water Pollution Control Federation, Vol.
46, No. 5 (May, T?747T PP. 886-894."
136. Snyder, A. J., and Alspaugh, T. A., "Catalyzed Bio-Oxidation
and Tertiary Treatment of Integrated Textile Wastewaters," Ref.
No. EPA 660/2-74-039.
137. "Specifications - 1976 ATMI/EPA Study of 1983 BATEA Effluent
Standards for the Textile Industry - Phase I," American Textile
Manufacturers Institute, Inc., Charlotte, NC (1976).
138. Stark, M. M., and Rizzo, J. L., "Carbon Adsorption - Case
Studies at Several Textile Plants," Presented at Midwinter
Conference on Textile Wastewater and Air Pollution Control,
Hilton Head Island, SC (January 23-25, 1974).
139. Stone, R., "Carpet Mill Industrial Waste System," Journal of
Jbhe Water Pollution Control Federation^ Vol. 44, No. 3 (March,
1972), pp. 470-478.
140. Stuber, L. M., "Tertiary Treatment and Disinfection of
Tufted Carpet Dye Wastewater," Proceedings of the 29th industrial
441
-------
Waste Conference, Purdue University, Lafayette, IN
964-977.
(1974), pp,
141, "Study of the Biological and Chemical Treatability of Hyper-
filtration {Reverse Osmosis) Textile Waste Concentrates, A,"
Texidyne, Inc., Clemson, SC (August, 1975).
142. Suchecki, S. M., "Canton's Futuristic Waste Treatment
System," Textile Industries, Vol. 140, No. 3 (March, 1976), pp.
43-49.
143. "Supplemental Studies on the Vanity Fair Waste, Monroeville,
Alabama," Thompson and Tuggle Environmental Consultants,
Montgomery, AL (April, 1974).
144. "Survey of Textile Wastewater Treatment State of the Art,
Add-on Treatment Processes," Hydroscience, Inc., Westwood, NJ
{April, 1976).
145. Talbot, R. S., "Literature Review: Textile Wastes - 1976,"
Journal of the Water Eollution Control Federation, Vol. 48, No. 6
(June, 'I'tfeTTpp- 1282-1284.
146. Talbot, R. S., "Literature Review: Textile Wastes - 1977,"
Journal of the Water Pollution Control Federation,. Vol. 49, No. 6
{June, 1977), pp. 1161-1163.
147. "Textile Industry Technology and Costs of Wastewater
Control," Lockwood-Greene, New York, NY (June, 1975).
148. "Textile Technology Digest, Vol. 34," Institute of Textile
Technology, Charlottesville, VA (January, 1977).
149. "Textile Technology/Ecology Interface - 1977,"
(Environmental Symposium), American Association of Textile
Chemists and Colorists, Research Triangle Park, NC (March, 1977).
150. Thiansky, D. P., "Historical Development of Water Pollution
Control Cost Function," Journal of the, Water Pollution Control^
Federation Vol. 46, No. 5 (May, 1974), p. 813.
151. Thompson, Barbara, "The Effects of Effluent from the
Canadian Textile Industry on Aquatic Organisms - A Literature
Review," Fisheries and Marine Service, Freshwater Institute,
Winnipeg, Manitoba, Canada (1974).
152. Throop, W. M., "Why Industrial Wastewater Pretreatment?"
Industrial Wastes (July/August, 1976), pp. 32-33.
153. Tincher, W. C., "Chemical Use and Discharge in Carpet
Dyeing," Georgia Institute of Technology, Atlanta, GA (September,
1975).
442
-------
154. Trotman, E. R., Dyeing and Chemical Technology of Textile
Fibers, Fifth Edition, Chas. Griffin & Co., Ltd., London, Great
Britain (1975).
155. "U.S. Industrial Outlook," U.S. Department of Commerce,
Domestic and International Business Administration, Washington,
DC (1978), pp. 239-244.
156. Van Note, R. H., Herbert, P. V., Patel, R. M., Chupek, C.,
and Feldman, L., "A Guide to the Selection of Cost-Effective
Wastewater Teatment Systems," Ref. No. EPA 430/9-75-002.
157. Van Winkle, T. L., Edeleanu, J., Prosser, E. A., and Walker,
C. A., "Cotton versus Polyester," American Scientist, Vol. 66
(1978), pp. 280-289.
158. Wachter, R. A., Archer, S. R., and Blackwood, T. R., "Source
Assessment: Overview and Priorization of Emissions from Textile
Manufacturing," Ref. No. EPA 600/2-77-107h (September, 1977), pp.
1-131.
159. "Wastewater Treatment Systems: Additional Case Studies,"
Metcalf & Eddy, Inc., Boston, MA (January, 1975).
160. "Wastewater Treatment Systems - Upgrading Textile Operations
to Reduce Pollution," U.S. Environmental Protection Agency,
Washington, DC, Ref. No. EPA 625/3-74-004.
161. Weeter, D. W., and Hodgson, A. G., "Dye Wastewaters -
Alternatives for Biological Waste Treatment," Proceedings of the
32nd Industrial Waste Conference, Purdue University, Lafayette,
IN (1978) pp. 1-9.
162. Whi'ttaker, C. B., "ITT Publications: 1944-1976," Institute
of Textile Technology, Charlottesville, VA (April, 1977).
163. 'Whittaker, C. B., "The Textile Library: A Selected List of
Books," Institute of Textile Technology, Charlottesville, VA
(January, 1977).
164. Wight, J. L., "Biological Treatment System Measures Up
During High Solids Load Condition," Pollution Engineering
(October, 1977), pp. 52-55.
165. Williamson, R., "Handling Dye Waste in a Municipal Plant,"
Public Works, Vol. 102, No. 1 (January, 1971), pp. 58-59.
166. Wynn, C. S., Kirk, B. S., and McNabney, R., "Pilot Plant for
Tertiary Treatment of Wastewater with Ozone," Ref No. EPA R2-73-
146.
167. Zwerdling, D., "Spraying Dangers in the Air," Washington,
Post (January 25, 1976), Section F.
443
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-------
SECTION XIV
GLOSSARY
Animal Hair Fibers
Fibers obtained from animals for purposes of weaving, knitting,
or felting into fabric; some animal fibers are alpaca, angora
goat hair, camel hair, cashmere, cow hair, extract wool, fur,
horse hair, llama, mohair, mungo, noil, shoddy, silk, vicuna, and
wool.
Anti-static Agents
Functional finishes applied to fabric to overcome deleterious
effects of static electricity. Compounds commonly used are PVA,
styrene-base resins, polyalkylene glycols, gelatine, PAA, and
polyvinyl acetate.
Batch Processing
Operations which require loading of discrete amounts of material,
running the process to completion, and then removing the
material. This is in contrast to continuous processing in which
material in rope or open width form runs without interruption
through one or more processes, obviating the need for loading and
unloading.
Best Available Technology Economically Achievable (BAT)
Level of technology applicable to effluent limitations to be
achieved by July 1, 1984, for industrial discharges to surface
waters as defined by Section 301 (b) (2) of the Federal Water
Pollution Control Act, As Amended.
Best Practicable Control Technology Currently Available (BPT)
The level of technology applicable to effluent limitations to be
achieved by July 1, 1977, for industrial discharges to surface
waters as defined by Section 301 (b) (1) (A) of the Federal Water
Pollution Control Act, As Amended.
Complex Processing
Woven or knit fabric finishing operations that may consist of
fiber preparation, scouring, functional finishing, and bleaching,
dyeing, or printing.
Consent Decree
The Settlement Agreement entered into by EPA with the Natural
Resources Defense Council and other environmental groups and
445
-------
approved by the U.S. District Court for the District of Columbia
on June 7, 1976. One of the principal provisions of the
Settlement Agreement was to direct EPA to consider an extended
list of 65 classes of pollutants in 21 industrial categories,
including Textile Mills, in the development of effluent
limitations guidelines and new source performance standards.
Conventional Pollutants
Constituents of wastewater as determined by Section 304 (a) (4)
of the Clean Water Act of 1977, including but not limited to,
pollutants classified as biological oxygen demanding, suspended
solids, fecal coliform, and pH.
Direct Discharger
An industrial discharger that introduces wastewater to a
receiving body of water or land, with or without treatment by the
discharger.
Effluent Limitation
A maximum amount per unit of production (or other unit) of each
specific constituent of the effluent that is subject to
limitation from an existing point source.
End-of-Pipe Technologies
Treatment processes used to remove or alter the objectionable
constituents of the spent water from manufacturing operations.
Environmental Protection Agency - Sewage
STP)
Treatment Plant (EPA-
A sewage treatment plant construction cost index originating in
1957 with a base cost index of 100.
Environmental Protection Agency - Small City Conventional
Treatment (EPA-SCCT)
A sewage treatment plant construction cost index originating in
the 3rd Quarter, 1973, and based on a cost index of 100 for St.
Joseph, Missouri.
Federal Water Pollution Control Act Amendments of 1972
Public' Law 92-500 which provides the legal authority for current
EPA water pollution abatement projects, regulations, and
policies. The Federal Water Pollution Control Act was amended
further in 1977 in legislation referred to as The Clean Water
Act.
446
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Functional Finish Chemicals
Substances applied to fabric to provide desirable properties such
as wrinkle-resistance, water-repellency, flame-resistance, etc.
Greiqe Mills
Facilities which manufacture unfinished woven or knit goods
(greige goods) for finishing at other locations. If process
wastewater is generated, it is usually small in quantity.
Indirect Discharger
An industrial discharger that
publicly-owned collection system.
In-plant Control Technologies
introduces wastewater to a
Controls or measures applied within the manufacturing process to
reduce or eliminate pollutant and hydraulic loadings of raw
wastewater. Typical inplant control measures include chemical
substitution, material reclamation, water reuse, water reduction,
and process changes.
Internal Subcategorization
Divisions within a subcategory to group facilities that, while
producing related products from similar raw materials, have
differing raw waste characteristics due to the complexity of
manufacturing processes employed.
Low-Water-Use Processing Mills
Establishments primarily engaged in manufacturing greige goods,
laminating or coating fabrics, texturizing yarn, producing tire
cord fabric, and similar activities in which cleanup is the
primary w&ter use or process water requirements are small.
National Polllutant Discharge Elimination System (NPDES)
A Federal program requiring industry and municipalities to obtain
permits to discharge plant effluents to the nation's water
courses.
New Source
Industrial facilities from which there is, or may be, a discharge
of pollutants, and whose construction is commenced after the
publication of the proposed regulations.
Non-Conventional Pollutants
Parameters selected for use in developing effluent limitation
guidelines and new source performance standards which have not
447
-------
been previously designated as either conventional pollutants or
priority pollutants.
Non-Water Quality Environmental Impact
Deleterious aspects of control and treatment technologies
applicable to point source category wastes, including, but not
limited to, air pollution, noise, radiation, sludge and solid
waste generation, and energy usage.
Physical-Chemical Treatment
Processes that utilize physical (i.e., sedimentation, filtration,
centrifugation, activated carbon, reverse osmosis, etc.) and/or
chemical means (i.e., coagulation, oxidation, precipitation,
etc.) to treat wastewaters.
Point Source Category
A collection of industrial sources with similar function or
product, established by Section 306 (b) (1) (A) of the Federal
Water Pollution Control Act, As Amended for the purpose of
establishing Federal standards for the disposal of wastewater.
Pollutant Loading
Ratio of the total daily mass discharge of a particular pollutant
to the total daily wet production of a mill expressed in terms of
(kg pollutant)/{kkg wet production).
Pretreatment Standard
Industrial waste effluent quality required
publicly-owned treatment works.
Product Line
for discharge to a
Goods which are similar in terms of raw materials, method of
manufacture, and/or function (e.g., scoured wool, wool goods,
woven goods, knit goods, carpet, stock and yarn, nonwovens,
felts, etc.).
Publicly-Owned Treatment Works (POTW)
A facility that collects, treats, or otherwise disposes of
wastewaters, owned and operated by a village, town, county,
authority, or other public agency.
Raw Waste Characteristics
A description of the constituents and properties of a
before treatment.
wastewater
448
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Simple Processing
Woven or knit fabric finishing operations that may consist of
fiber preparation, scouring, functional finishing, and one of the
following processes applied to more than five percent of total
production; bleaching, dyeing, or printing.
Standard Industrial Classification (SIC)
A numerical categorization scheme used by the U.S. Department of
Commerce to denote segments of industry.
Standard of Performance
A maximum weight discharged per unit of production for each
constituent that is subject to limitations. Standards of
performance are applicable to new sources, as opposed to existing
sources which are subject to effluent limitations.
Synthetics
As used in this report, synthetics refers to all man-made fibers,
including those manufactured from naturally occurring raw
materials (regenerated fibers). Strictly speaking, synthetic
fibers are those that are made by chemical synthesis.
Toxic Pollutants
All compounds specifically named or referred to in the Consent
Decree, as well as recommended specific compounds representative
of the nonspecific or ambiguous groups or compounds named in the
agreement. This list of pollutants was developed based on the
use of criteria such as known occurrence in point source
effluents, in the aquatic environment, in fish, in drinking
water, and through evaluations of carcinogenicity, other chronic
toxicity, bioaccumulation, and persistence.
Water Usage
Ratio of the spent water from a manufacturing operation to the
total wet production by the mill, expressed in terms of (liters
of wastewater/day)/(kilogram of wet production/day).
Wet Processing Mills
As used in this report, it refers to all manufacturing facilities
having major wet manufacturing operations. Any mill in the
following manufacturing segments is a wet processing mill: Wool
Scouring, Wool Finishing, Woven Fabric Finishing, Knit Fabric
Finishing (including Hosiery Finishing), Carpet Finishing, Stock
& Yarn Finishing, Nonwoven Manufacturing, and Felted Fabric
Processing.
449
-------
Wet Production
Mass of textile goods that goes through one
processes in a specified time period.
or more major wet
450
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APPENDIX A
COSTS OF TREATMENT AND CONTROL SYSTEMS
INRODUCTION
This appendix presents the results and methodology for the
calculation of capital and annual costs for the treatment
technologies that have been considered for the development of
effluent limitations and standards for the control of toxic,
conventional and nonconventional pollutants. The costs have been
developed for the purpose of evaluation of cost versus pollutant
reduction benefit and for the purposes of determination of the
economic impact of the several regulatory options that have been
considered for the textile mills point source category.
Although, many of the technologies will not serve as the basis
for promulgated effluent limitations and standards considerable
time and effort has been devoted to these calculations and they
represent a valuable resource for the evaluation of treatment and
control technologies where additional end-of-pipe treatment may
be required for water quality reasons.
GENERAL APPROACH
A model plant approach has been used for the calculation of
alternative technology costs for textile mills as the resources
required by the Agency and industry for specific mill cost
estimates would be prohibitive. The model approach has been used
successfully in several other industries to calculate technology
cost. From a review of production capacity, flow per unit of
production, and plant discharge data in all subcategories eight
different flow models ranging from 0,05 mgd to 5.0 mgd were
selected for the detailed calculation of investment and annual
costs. The eight flow models selected provided a sufficient
range of sizes to represent three model sizes in most
subcategories and thus properly represent the range of existing
plant sizes. As the model plants are flow sized models they can
be related to production sizes by the respective flow per unit of
production for the respective subcategories.
SUMMARY OF MODEL PLANT COSTS
The treatment and control options considered for BPT, BAT, NSPS,
PSES, and PSNS were presented in section VII and are summarized
here in Table A-l. The raw waste loads for each option, the
methodology for calculation of effluent characteristics and the
final effluent characteristics are also presented in section VII.
These technology options are summarize here in Table A-l. Model
plant costs for each subcategory and option are presented in
Table A-2.
451
-------
BPT
BAT
NSPS
TABLE A-l
TREATMENT AND CONTROL OPTIONS
Option 1 Screening plus extended aeration activated sludge treatment
Option 1 No additional treatment beyond BPT biological treatment.
Option 2 Multimedia filtration of Option 1 effluent.
Option 3 Chemical Coagulation/Sedimentation of Option 1 effluent.
Option 4 Chemical Coagulation/Sedimentation followed by multimedia
filtration of Option 1 effluent.
Option 1 Screening plus extended aeration activated sludge.
Option 2 Option 1 treatment plus chemical coagulation/sedimentation
and multimedia filtration.
PSES & PSNS
Option 1
Option 2
No additional treatment beyond screening and equalization,
Option 1 plus chemical coagulation/sedimentation.
452
-------
TABLE A-2
MODEL MILL COST SUMMARY
BPT OPTION 1
SCREENING AND EXTENDED AERATION ACTIVATED SLUDGE
Subcategory
Low Water Use Processing
(Water Jet Weaving)
Nonwoven Manufacturing
Felted Fabric Processing
Model Size
Production (Ib/day) Flow (MGD)
Costs ($1000)
Capital Total Annual
10,600
24,100
22,900
52,100
2,000
4,300
0.11
0.25
0.11
0.25
0.05
0.11
308
404
308
404
239
308
161
204
161
204
130
161
453
-------
TABLE A-2
(Cont'd)
MODEL MILL COST SUMMARY
BAT OPTION 2 MULTIMEDIA FILTRATION
Subcategory
Wool Scouring
Wool Finishing
Model Size
Production (Ib/day) Flow (MOD)
35,700
78,600
178,600
0.05
0.11
0.25
Costs ($1000)
Capital Total Annual
93
133
200
Multimedia Filtration Not Considered
66
80
104
Low Water Use Processing
(Water Jet Weaving)
BAT options beyond BPT not considered.
Woven Fabric Finishing
(Simple Operations)
Woven Fabric Finishing
(Complex Operations)
Woven Fabric Finishing
(Desizing)
Knit Fabric Finishing
(Simple Operations)
Knit Fabric Finishing
(Complex Operations)
Knit Fabric Finishing
(Hosiery Products)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
12,000
65,200
163,000
51,300
256,400
427,400
47,200
118,100
393,700
17,700
70,900
354,600
17,000
40,800
68,000
5,600
12,200
44,600
107,100
267,900
21,600
51,700
86,200
129,300
22,900
52,100
0.11
0.60
1.5
0.60
3.00
5.00
0.60
1.50
5.00
0.25
1.00
5.00
0.25
0.60
1.00
0.05
0.11
0.25
0.60
1.50
0.25
0.60
1.00
1.50
0.11
0.25
133
297
488
297
747
1,018
297
488
1,018
200
387
1,018
200
297
387
93
133
200
297
488
200
297
387
488
133
200
80
147
226
148
333
444
148
229
444
103
185
442
104
148
187
66
80
104
148
229
103
147
185
226
80
104
Multimedia Filtration Not Considered
454
-------
BAT
TABLE A-2
(Cont'd)
MODEL MILL COST SUMMARY
OPTION 3 CHEMICAL COAGULATION
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
(Water Jet Weaving)
Woven Fabric Finishing
(Simple Operations)
Woven Fabric Finishing
(Complex Operations)
Woven Fabric Finishing
(Desizing)
Knit Fabric Finishing
(Simple Operations)
Knit Fabric Finishing
(Complex Operations)
Knit Fabric Finishing
(Hosiery Products)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Model Size
Production (Ib/day)
Flow (MGD)
Costs ($1000)
Capital Total Annual
35,700
78,600
178,600
16,400
41,100
82,200
BAT options
12,000
65,200
163,000
51,300
256,400
427,400
47,200
118,100
393,700
17,700
70,900
354,600
17,000
40,800
68,000
5,600
12,200
44,600
107,100
267,900
21,600
51,700
86,200
129,300
22,900
52,100
2,000
4,300
0.05
0.11
0.25
0.60
1.50
3.00
beyond BPT not
0.11
0.60
1.50
0.60
3.00
5.00
0.60
1.50
5.00
0.25
1.00
5.00
0.25
0.60
1.00
0.05
0.11
0.25
0.60
1.50
0.25
0.60
1.00
1.50
0.11
0.25
0.05
0.11
Chemical
consider
365
536
778
considered.
206
365
528
365
763
1,112
365
528
1,112
263
447
1,112
263
365
447
172
206
263
365
528
263
365
447
528
206
263
172
206
246
373
556
150
244
370
244
555
796
244
370
796
179
302
796
179
244
302
134
151
179
244
370
179
244
302
370
151
180
134
151
45!
-------
TABLE A-2
(Cont'd)
MODEL MILL COST SUMMARY
BAT OPTION 4 CHEMICAL COAGULATION/SEDIMENTATION
PLUS MULTI MEDIA FILTRATION
Subcategory
Wool Scouring
Wool Finishing
Low Water Use Processing
(Water Jet Weaving)
Woven Fabric Finishing
(Simple Operations)
Woven Fabric Finishing
(Complex Operations)
Woven Fabric Finishing
(Desizing)
Knit Fabric Finishing
(Simple Operations)
Knit Fabric Finishing
(Complex Operations)
Knit Fabric Finishing
(Hosiery Products)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
Model Size
Production (Ib/day)
Flow (MGD)
Costs ($1000)
Capital Total Annual
35,700
78,600
178,600
16,400
41,100
82,200
BAT options
12,000
65,200
163,000
51,300
256,400
427,400
47,200
118,100
393,700
17,700
70,900
354,600
17,000
40,800
68,000
5,600.
12,200
44,600
107,100
267,900
21,600
51,700
86,200
129,300
22,900
52,100
2,000
4,300
0.05
0.11
0.25
0.60
1.50
3.00
beyond BPT not
0.11
0.60
1.50
0.60
3.00
5.00
0.60
1.50
5.00
0.25
1,00
5.00
0.25
0.60
1.00
0.05
0.11
0.25
0.60
1.50
0.25
0.60
1.00
1.50
0.11
0.25
0.05
0.11
Option
611
959
1,449
considered.
303
611
950
611
1,434
2,039
611
950
2,039
420
773
2,039
420
611
773
231
303
420
611
950
420
611
773
950
303
420
231
303
329
520
784
180
328
518
328
786
1,121
328
518
1,121
229
416
1,121
229
328
416
152
181
229
328
518
229
328
416
518
180
320
152
181
456
-------
TABLE A-2
(Cont'd)
MODEL MILL COST SUMMARY
NSPS OPTION 1
SCREENING PLUS AERATION ACTIVATED SLUDGE
Subcategory
Wool Scouring*
Model Size
Production (Ib/day) Flow (MGD)
Costs ($1000)
Capital Total Annua.
Wool Finishing
Low water Use Processing
(Water Jet Weaving)
41,100
10,600
1.50
0.11
2,275
308
783
162
Woven Fabric Finishing
(Simple Operations)
65,200
0.60
573
346
Woven Fabric Finishing
(Complex Operations)
256,400
3.00
3,624
1,184
Woven Fabric Finishing
(Desizing)
118,100
1.50
2,275
783
Knit Fabric Finishing
(Simple Operations)
70,900
1.00
1,744
635
Knit Fabric Finishing
(Complex Operations)
40,800
0.60
573
346
Knit Fabric Finishing
(Hosiery Products)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
12,200
44,600
51,700
52,100
9,800
0.11
0.25
0.60
0.25
0.25
310
405
573
405
405
210
257
346
257
257
*NSPS costs for the wool scouring subcategory were not calculated as no new
sources are anticipated.
457
-------
TABLE A-2
(Cont'd)
MODEL MILL COST SUMMARY
NSPS OPTION 2
EXTENDED AERATION ACTIVATED SLUDGE PLUS
CHEMICAL COAGULATION/SEDIMENTATION PLUS
MULTIMEDIA FILTRATION
Subcategory
Wool Scouring*
Model Size
Production (Ib/day) Flow (MGD)
Costs ($1000)
Capital Total Annual
Wool Finishing
Low water Use Processing
(Water Jet Weaving)
41,100
10,600
1.50
0.11
3,234
1,303
Woven Fabric Finishing
(Simple Operations)
65,200
0.60
1,184
674
Woven Fabric Finishing
(Complex Operations)
256,400
3.00
5,058
1,970
Woven Fabric Finishing
(Designing)
118,100
1.50
3,225
1,301
Knit Fabric Finishing
(Simple Operations)
70,900
1.00
2,517
1,051
Knit Fabric Finishing
(Complex Operations)
40,800
0.60
1,184
674
Knit Fabric Finishing
(Hosiery Products)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
12,200
44,600
51,700
52,100
0,11
0.25
0.60
0.25
613
825
1,184
825
391
487
674
487
Felted Fabric Processing
9,800
0.25
825
*NSPS costs for the wool scouring subcategory were not calculated as no new
sources are anticipated.
458
487
-------
TABLE A-2
(Cont'd)
MODEL MILI COST SUMMARY
PSES & PSNS OPTION 2
CHEMICAL COAGULATION/SEDIMENTATION
Subcategory
Wool Scouring
Model Size
Production (Ib/day) Flow (MGD)
178,600
0.25
Costs ($1000)
Capital Total Annual
459
299
Wool Finishing
41,100
1.50
745
440
Low Water Use Processing
(Water Jet Weaving)
24,100
0.25
366
207
Woven Fabric Finishing
(Simple Operations)
18,100
0.25
366
207
Woven Fabric Finishing
(Complex Operations)
51,300
0.60
493
289
Woven Fabric Finishing
(Designing)
118,100
1.50
765
441
Knit Fabric Finishing
(Simple Operations)
47,200
0.60
493
288
Knit Fabric Finishing
(Complex Operations)
40,800
0.60
493
288
Knit Fabric Finishing
(Hosiery Products)
Carpet Finishing
Stock and Yarn Finishing
Nonwoven Manufacturing
Felted Fabric Processing
12,200
107,100
21,600
52,100
10,000
0.11
0.60
0.25
0.25
0.25
293
493
366
366
366
170
288
207
207
207
459
-------
CALCULATION OF COMPONENT TECHNOLOGY COSTS
Treatment Technologies Considered
Several distinct technologies comprise the treatment and control
options considered for the textile industry. These technologies
which have been selected for the detailed calculation of costs
are as follows:
Screening.
Equalization
Activated Sludge
Chemical Coagulation/Precipitation
Vacuum Filtration
Multimedia Filtration
Dissolved Air Flotation
Granular Activated Carbon
Powdered Activated Carbon
(GAC)
(PAC)
Model Plant Cost Estimates
Total investment and annual cost estimates are prepared for the
alternatives applicable to each model. The example computation
sheet (Figure A-l) is used as an aid in this task. The
investment costs include the cost of purchasing and installing
the components of each alternative technology and allowance for
contingencies and engineering. The annual costs include the cost
of capital, depreciation, operation and maintenance labor,
maintenance materials, sludge disposal, energy, chemicals, and
monitoring.
Details of the methodology used in preparing the cost estimates
are discussed below. The basic assumptions and the rationale
supporting the estimates are based primarily on data collected
during the industry survey and information obtained from the
literature. References are cited throughout the section to
provide the reader with a clear understanding of the sources of
the information.
Component Technology Investment Costs
Cost curves are presented in Figures A-2 through A-l 1 for the
component technologies used in establishing the alternative
control technologies. The curves provide the total installed
costs relative to flow rate and represent the following
distributions between equipment and construction costs.
Component Technology
Screening {BAT and NSPS)
Screening (PSES and PSNS)
Equalization (NSPS)
Equalization (PSES and PSNS)
Activated Sludge
Installed Cost Breakdown
percent of total
Equipment Construction
20 80
35 65
20 80
35 65
20 80
460
-------
FIGURE A-l
TEXTILE INDUSTRY BAT REVIEW
TREATMENT COST COMPUTATION SHEET
SUBCATEGORY 4a. Woven Fabric Finishing-Simple Processing REGULATION
MODEL FLOW 0.6 MGD TREATMENT ALTERNATIVE F CC + MMF + AC
C-12,200
KLBS
BAT
MGD TREATMENT ALTERNATIVE
C-12,200
ANNUAL PRODUCTION 0-13,900
ANNUAL CAPACITY 16,300
KLBS
1-13,000
INVESTMENT COSTS
No.
1
2
3
4
5
Component
PT AS CC VF OAF MMF
AS CC VF DAF MMF AC
CC VF DAF MMF AC OZ
VF DAF MMF AC OZ
MONITORING
Equipment
39,900
24,700
39,900
452,200
20,000
Construction
159,600
45,800
159,600
452.200
Total
199,500
70,500
199.500
904,400
None
20.000
EQUIPMENT & CONSTRUCTION COSTS (E&C)
CONTINGENCIES ( 15 % OF E&C)
ENGINEERING ( 7 % OF A&B)
(A) $ 1,393,900
(B) 209,100
(C)
112,200
TOTAL INVESTMENT COSTS (TIC) * * * * * $_
1,715,000
ANNUAL COSTS
COST OF CAPITAL ( 15 % of TIC)
DEPRECIATION ([A + B] -f 18 YEARS AVERAGE USEFUL LIFE)
O&M LABOR ( 5,140 MRS X 20 $/HR)
MAINTENANCE MATERIALS
SLUDGE DISPOSAL ( 359 TONS X 20 $/TON)
257,300
89.100
102,800
60,500
7,200
ENERGY & POWER ( 283,000
( 39,000
kwhr x 3.4
-------
FIGURE A-2
SCREENING-INSTALLED COST
O)
1000
(0
o
100
10
0.01
0.1
1.0
10.0
Flow, mgd
SOURCE: Refereace Ko. 3 (4th quarter 1979 dollars)
-------
FIGURE A-3
EQUALIZATION-INSTALLED COST
CO
1000
Jg
o
•o
CO
O 100
10
t a i l i i II
0.01
lilt
t I l 1 i i i i
I 3
0.1
1.0
10.0
Flow, mgd
SOURCE: Reference No. 3 (4th quarter 1979 dollars)
-------
1000
o
•o
a
O 100
10
FIGURE A-4
ACTIVATED SLUDGE-INSTALLED COST
I I
I I I II
aeri tlon
24-hour
(Constructed)
24-hour aeration
(Package)
•-hour aeration
'(Package)
i l i i i i i i
0.01
0.1
1.0
10.0
Flow, mgd
SOURCE: Reference No. 3 (4th quarter 1979 dollars)
-------
1000
o
»>
o
(0
O 100
10
0.01
FIGURE A-5
CHEMICAL COAGULATION-INSTALLED COST
0.1
1.0
10.0
Flow, mgd
SOURCE: References 28, 30, 31 (4th quarter 1979 dollars)
-------
FIGURE A-6
VACUUM FILTRATION-INSTALLED COST
1000
o
•o
CO
O 100
10
10
100
1000
FHter Area, ft.2
10000
SOURCE: References 28, 30, 81, 82 (4th quarter 1979 dollars)
-------
ch
1000
o
TJ
<0
O 100
10
0.01
FIGURE A-7
MULTIMEDIA FILTRATION-INSTALLED COST
With polymeric filter aid
0.1
1.0
10.0
Flow, mgd
SOURCE: References 28, 30, 31, 32, 33, 34 (4th quarter 1979 dollars)
-------
FIGURE A-8
DISSOLVED AIR FLOTATION-INSTALLED COST
00
1000
10
w
o
"o
TJ
O 100
10
C.01
0.1
1.0
10.0
Flow, mgd
SOURCE: Reference 34 (4th quarter 1979 dollars)
-------
-p*
en
1000
Cft
o
9
O
a
O 100
10
0.01
FIGURE A-9
GRANULAR ACTIVATED CARBON-INSTALLED COST
With on-»ft* rageneiation
0.1
1.0
10.0
Flow, mgd
SOURCE: References 30, 31, 33, 35 (4th quarter 1979 dollars)
-------
FIGURE A-10
POWDERED ACTIVATED CARBON-INSTALLED COST
10000
CO
o
•Q
CO
o 1000
PACT2 (full application
carbon, regenerated)
PAC2 (addition to biological treatment
carbon regenerated )
100 I
0.01
I I I I I II
PACT! (full application .
carbon discarded)
PAC . (addition to biological treatment.
carbon discarded)
I I I I I i i
0.1
1.0
10.0
Flow, ragd
SOURCE: Reference 83 (4th quarter 1979 dollars)
-------
FIGURE A-ll
OZONATION-INSTALLED COST
1000
0
k.
JS
o
•o
CO
O 100
10
1 f 511(11
0.01
0.1
1.0
10.0
Flow, mgd
SOURCE: References 33, 37, 38, 50 (4th quarter 1979 dollars)
-------
Chemical Coagulation/
Precipitation
Vacuum Filtration
Multimedia Filtration
Dissolved Air Flotation
Granular Activated Carbon
Powdered Activated Carbon
(Not Regenerated)
Addition to EAAS
Full Application
Powdered Activated Carbon
(Regenerated)
Addition to EAAS
Full Application
Ozonation
2Q
35
20
35
50
32
25
45
34
50
80
65
80
65
50
68
75
55
66
50
The features, applicable design parameters, and source of cost
information for each of these technologies are described below.
In all cases, the cost curves for the component technologies
represent 4th Quarter 1979 dollars. The original equipment and
construction costs, which were taken from the sources given for
each component technology, were adjusted to achieve this
uniformity. The adjustment was accomplished in two steps. The
original equipment and construction cost estimates presented in
the Textile Mills Point Source Category Proposed Development
Document (37) were based on 4th quarter 1976 dollars. The
individual cost information was updated to that time frame by
establishing adjustment ratios based on the EPA-STP and EPA-SCCT
indexes. These ratios varied depending on the date of the
original cost information. The 4th Quarter 1976 equipment and
construction costs were subsequently updated to 4th Quarter 1979
dollars by increasing the costs by one third. This increase was
based on a change in the EPA-SCCT index from a 4th Quarter 1976
base city average of 119 to a 4th Quarter 1979 base city average
of 162.
Screening Screening is used as a preliminary treatment step for
new sources and is included ahead of extended aeration activated
sludge for existing direct.dischargers. Figure A-2 includes the
costs fort site preparation; structural concrete; equipment
housing; purchase and installation of mechanical screening
equipment; pumps, piping, and valves; and instrumentation.
Screening is used to remove lint, floe, rags, and other coarse
suspended solids that tend to clog' pumps, foul bearings and
aerators, float in basins, and otherwise interfere with the
operation of treatment plants. The costs were taken from the
Development Document (Proposed Regulation) (4) and updated to 4th
Quarter 1979 dollars.
Equalization Equalization is used as a preliminary treatment
step for new sources. The technology includes earthen wall
basins providing 12 hours detention time with mixing by surface
aerators. The assumed depth is 3 meters (approximately 10 feet).
472
-------
Figure A-3 includes the costs for site preparation, basin
construction, wet wells, pumps, and floating mechanical aerators.
The costs were taken from background calculation used in
preparing the Development Document (Proposed Regulation) (4)
and updated to 4th Quarter 1979 dollars.
Activated Sludge Activated sludge is the technology in place
for most existing direct dischargers. Consequently, it is not
included in estimating the costs of the alternative treatment
technologies for all mills. Because the Hosiery Products,
Nonwoven Manufacturing, and Felted Fabric Processing
Subcategories are new, and activated sludge is not generally in
place, activated sludge is included, for cost purposes, as a
major treatment step for existing direct dischargers. It also is
included as a component technology for all new source direct
discharge mills. Figure A-4 includes costs for 8- and 24-hour
package aeration systems and a 24-hour detention site constructed
system. The basic unit operations and processes included in the
site constructed system are aeration, secondary clarification
with solids recycle, sludge thickening, and vacuum filtration for
sludge dewatering. The costs were taken from background
calculations used in preparing the Development Document {Proposed
Regulation) (3) and updated to 4th Quarter 1979 dollars.
Chemical Coagulation/Precipitations. Chemical coagulation/precip-
itation after biological treatment is used for direct dischargers
and as pretreatment for indirect dischargers. In all
applications, the technology is based on the use of alum (as
A12(S04)3 18 H20) as the coagulant and includes sedimentation.
The assumed alum dosage was based on the following conditions:
Condition
1
2
Influent TSS, mq/1
700 or greater
less than 700
Alum Dosage/ mq/1
1,000
100
Figure A-5 includes the costs for site preparation, purchase of
coagulation and sedimentation equipment, and installation of
equipment and instrumentation. The costs were developed by
averaging the costs found in References 38, 39, and 40.
Vacuum Filtration For existing direct dischargers, vacuum
filtration accompanies chemical coagulation/precipitation for
sludge dewatering purposes. Backwash solids from multimedia
filtration also are processed by vacuum filtration if the
multimedia filter is used in conjunction with chemical
coagulation. Vacuum filtration is included with all treatment
alternatives for existing indirect dischargers. The cost was
calculated as a function of filter area, -which is determined by
using a dry solids loading rate of 19.5 kg/sq m/hr
(4 Ib/sq ft/hr) and an operating period of ten hours per day.
The specific chemical coagulation and multimedia filtration
conditions given below are used in determining vacuum filter
requirements.
473
-------
Chemical Coagulation
Condition
1
2
3
4
5
Multimedia Filtration
Condition
1
2
3
Alum Added
mq/1
1 ,000
1,000
100
100
100
TSS Removed
mq/1
40
20
5
Figure A-6 includes the costs of site preparation, equipment
housing, purchase and installation of filtration equipment,
piping, pumping, and instrumentation. The curve is based on the
average of costs given in References 38, 39, 40, and 42.
Multimedia Filtration Multimedia filtration is used in the same
capacity as chemical coagulation/precipitation. The technology
utilizes a granular media bed of anthracite coal, sand, and
gravel, with polymeric filter aid added in applications without
prior chemical coagulation. In all applications, the hydraulic
loading rate used is 9.8 cu m/hr/sq m (4 gpm/sq ft). Filter aid
is added at a rate of 1 mg/1.
Figure A-7 includes the costs for site preparation and the
purchase and installation of filtration equipment, piping,
pumping, and instrumentation. The curve is based on the average
of costs given in References 38, 39, 40, 43, 44, and 45.
Dissolved Air Flotation Dissolved air flotation is used to
remove suspended solids and oil & grease in the Wool Scouring
Subcategory. It is used in conjunction with chemical
coagulation/ precipitation after the biological treatment step
for direct dischargers and as a pretreatment step for indirect
dischargers. In all applications, a surface hydraulic loading
rate of 163.2 cu m/day/sq m (4,000 gpd/ sq ft) is used.
Figure A-8 includes the costs for purchase and installation of
tanks, air pressurizing equipment, recycle pumping equipment,
operating valves, instrumentation, and piping. The costs are
based on those developed in EPA's Process Design Manual for
Removal of Suspended Solids (45).
Granular Activated Carbon. Granular activated carbon is used as
a post-biological treatment step and as a pretreatment step for
both existing and new sources. It is usually applied following
chemical coagulation/precipitation and/or multimedia filtration.
The technology utilizes granular carbon columns and on-site
carbon regeneration for wastewater flows of greater than
450 cu m/day (0.12 mgd). Carbon for smaller flows is assumed to
474
-------
be discarded after use. An exhaustion rate of 0.66 kg/cu m
{5,500 Ib/mil gal) of water treated is used.
Figure A-9 includes the costs for site preparation and the
purchase and installation of carbon columns, regeneration
equipment, piping, pumping, and instrumentation. The curve is
based on information found in References 39, 40, 44, and 46.
Powdered Act i vated Carbon Add i t ion
to Biological
to existing
Treatment
Powdered activated carbon addition to existing biological
treatment systems is considered for existing direct dischargers.
The technology utilizes addition of carbon to the activated
sludge basin and on-site wet air oxidation for wastewater flows
of greater than 7,500 cu m/day {2.0 mgd). Carbon for smaller
flows is assumed to be discarded after use. An exhaustion rate
of 0.14 kg/cu m {1,200 Ib/mil gal) of wastewater treated is used.
Figure A-10 includes the costs for site preparation; purchase of
carbon and chemical feeding equipment, regeneration equipment,
instrumentation; and installation of all equipment and
instrumentation. The curve is based on costs found in
Reference 47.
Powdered Activated Carbon Treatment Powdered activated carbon
treatment is considered as a treatment technology for new direct
dischargers. The technology uses screening followed by addition
of carbon to an activated sludge basin. Sludge is dewatered and
regenerated by wet air oxidation for wastewater flows of greater
than 7,500 cu m/day {2.0 mgd). Carbon for smaller flows is
assumed to be discarded after use. An exhaustion rate of
0.14 kg/cu m (1,200 Ib/mil gal) of water treated is used.
Figure A-10 includes the costs for site preparation; construction
of basins, clarifiers, and facilities; purchase of equipment for
screening, aeration, settling, pumping, carbon feed, chemical
feed, sludge handling, regeneration and instrumentation; and
installation of all equipment and instrumentation. The curve is
based on costs found in Reference 47.
Ozonation Ozonation is considered as a post-biological
•treatment step and as a pretreatment step for existing sources.
It is usually applied following chemical
coagulation/precipitation and/or multimedia filtration. However,
for the textile industry, it is applied after biological
treatment for direct dischargers. The cost calculations are
based on the on-site generation of ozone and on a generation
capacity of 100 mg/1 of ozone.
Figure A-ll includes the costs for site preparation and the
purchase and installation of ozone contactors, ozone generation
equipment, piping, pumping, and instrumentation. The curve is
based on the average of costs found in References 44, 48, 49, and
50. 50.
475
-------
Installed Investment Costs Matrix
The installed equipment and construction investment costs for
each of the component technologies are presented in Table A-3 for
each model plant size. The tabulated values are the base costs
taken from the component technology installed cost curves
(Figures A-2 through A-11) updated to 4th Quarter 1979 dollars.
Other Investment Costs
Monitoring Equipment The investment costs for monitoring
equipment are based on collecting samples of the influent and
effluent streams of the treatment plant. The sampling consists
of 24-hour composite samples taken at each location twice weekly
for direct dischargers and once per week for indirect
dischargers. For direct dischargers, grab samples are taken once
per week of the receiving water both upstream and downstream of
the discharge. Continuous monitoring of pH and flow is provided
for the influent and effluent of all treatment plants.
The equipment items include two flow meters, two primary and one
back-up refrigerated samplers, two pH meters, and refrigerated
sample storage containers. The costs were based on equipment
manufacturers' price lists (51, 52, and 53).
It should be noted that the equipment described here is an
estimate of the requirements for a complete monitoring program
for major direct and indirect dischargers. Existing facilities,
especially larger direct discharge mills, normally already own
most of this equipment and the investment costs incurred by these
mills are considerably less.
Land Costs
Because all of
the alternative technologies have
small space requirements, and because most plants have some land
available, the cost of additional land is not included in the
estimates.
Contingencies An allowance of 15 percent of the total installed
costs of the alternative treatment technologies is used to cover
contingencies and differences between actual systems and the
costs used for estimates. No allowance is made for mill shutdown
during construction.
Engineering Costs Engineering costs are estimated as a
percentage of the total installed costs plus contingencies. The
values used are taken from the curve presented in Figure A-12.
Annual Costs
In estimating annual costs, it is assumed that the wastewater
treatment technologies will operate 300 days/year. The operation
of the treatment technology should not be confused with the
476
-------
TABLE A-3
INSTALLED EQUIPMENT AND CONSTRUCTION INVESTMENT COSTS FOR COMPONENT TECHNOLOGIES
Technology
0.05 0.11
(189) (416)
Model Size, mgd (cu m/day)
0.25 0.60 1.0 1.5 3.0 5.0
(946) (2,271) (3,785) (5,678) (11,355) (18,925)
Cost, thousands of dollars
Screening
Equalization
Activated Sludge (8-hour)
Activated Sludge (24-hour)
Chemical Coagulation/
Precipitation
Vacuum Filtration
Condition 1*
Condition 2
Condition 3
Condition 4
Condition 5
Multimedia Filtration
Filtration (with polymer)
Dissolved Air Flotation
Granular Activated Carbon
(without regeneration)
Granular Activated Carbon
(with regeneration)
32
32
37
68
44
75
71
71
71
71
48
52
52
53
718
35
36
54
120
72
100
71
71
71
71
79
84
71
86
758
39
44
102
193
117
146
96
71
71
71
128
137
94
146
798
49
56
173
319
200
279
140
71
71
71
200
216
133
239
904
67
64
239
1,330
266
426
206
76
71
71
266
289
164
333
1,104
100
77
293
1,729
333
599
273
87
77
71
346
371
192
495
1,436
146
88
532
2,793
505
1,197
479
114
101
89
545
581
293
958
2,128
180
101
-
-
771
2,022
825
148
125
108
758
803
383
1,585
3,205
-------
CO
TABLE A-3 (Cent.)
Model Size, mgd (cu m/day)
Technology
Powdered Activated Carbon
(without regeneration)
Added to EAAS
Full Application
Powdered Activated Carbon
(with regeneration)
Added to EAAS
Full Application
Ozonation
0.05
(189)
162
-
1,556
-
61
0.11
(416)
169
1,131
1,583
2,075
112
0.25
(946) (2
Cost,
186
1,144 1,
1,609 1,
2,261 2,
213
0.60
,271)
1.0
(3,785)
1.5
(5,678)
3.0
(11,355)
5.0
(18,925)
thousands of dollars
239
330
649
660
399
293
1,543
1,729
2,926
612
352
1,862
1,756
3,259
825
525
2,653
2,022
4,256
1,397
812
-
2,252
—
2,062
* These conditions are defined in the section on vacuum filtration.
Source: Figures A-2 to A-ll updated to 4th quarter 1979 dollars.
-------
FIGURE A-12
ESTIMATED ENGINEERING COMPENSATION
16
15
14
13
12
< 10
CO
z
a 9
2
O
(j p
7
i i i t I I it
0.01
O.I 1.0
NET CONSTRUCTION COST, 106 dollars
10.0
SOURCE: Reference No. 40
-------
operation of the textile mill, which is assumed to be 250
days/year.
Capital Costs The cost of money is assumed to be 15 percent of
the total investment.
Depreciation Estimated lives for the components of each
alternative are established and related to the investment costs
to determine the estimated design life for the alternative. The
installed cost is depreciated by the straight-line method for the
calculated life.
Operation and Maintenance (O&M) Labor Estimates of the annual
man-hours required to operate and maintain the various component
technologies are presented in Table A-4 for each model plant
size. The estimates are developed from information in
References 49, 54 and 47. Man-hour requirements for laboratory,
supervisory, administrative, and clerical activities also are
presented in Table A-7 for the various levels of control. Total
O&M labor includes the cost of operating and maintaining the
component technologies and the cost of laboratory, supervisory,
administrative, and clerical requirements. A productive work
value of 6.5 hr/day/person, or 1950 hr/yr/person, is assumed and
a rate of $20/hr is used as the total cost for wages, benefits,
and payroll processing expenses when converting the hours to
dollar costs.
Maintenance Materials Estimates of the costs of materials and
parts needed to maintain each component technology are presented
in Table A-5. The requirements are developed from information in
References 39, 49, and 47 and from contact with equipment
manufacturers. manufacturers.
Sludge Disposal The costs for sludge disposal include the
hauling and deposition of dewatered sludge and exhausted
activated carbon in an approved sanitary landfill. The costs are
developed by estimating the quantities of sludge that are
generated by the various component technologies, determining the
total quantity of sludge requiring disposal for each treatment
alternative, and applying an estimated unit cost (dollars/ton of
sludge) applicable to the total quantity of sludge requiring
disposal.
A matrix of the estimated sludge quantities by model size for the
various component technologies is presented in Table A-6.
Estimates of the sludge generated by screening are based on data
collected from the textile industry in 1976 (4). Estimates for
activated sludge are based on established typical generation
rates available in References 20 and 24. A value of 150 mg of
dry solids per liter of wastewater is used. The estimates for
chemical coagulation/precipitation, multimedia filtration, and
dissolved air flotation are based on the quantity of suspended
solids removed by the technologies. Values are presented for the
480
-------
TABLE A-4
ANNUAL OPERATION AND MAINTENANCE MAN-HOURS
Technology
Model Size, mgd (cu m/day)
0.05 0.11 0.25 0.60 1.0 1.5 3.0 5.0
(189) (416) (946) (2,271) (3,785) (5,678) (11,355) (18,925)
CO
Hours to Operate & Maintain Technology
560 560 580 590 600 600 640 750
460 520 620 720 780 840 950 1,050
660 970 1,450 2,230 2,900 3,550 5,000 6,500
126 192 298 482 640 810 1,180 1,580
2,270 2,310 2,360 2,510 2,685 2,900 3,555 4,425
56 113 225 450 625 780 1,150 1,525
Screening
Equalization
Activated Sludge
Chemical Coagulation/
Precipitation
Vacuum Filtration
Multimedia Filtration
Dissolved Air
Flotation
Granular Activated Carbon
(without regeneration)
Granular Activated Carbon
(with regeneration)
Powdered Activated Carbon
(without regeneration)
Added to EAAS
Full Application
144 221 325 515
46
80 145 280
675
400
830 1,220 1,610
550
950 1,430
250 400 700 1,250 1,850 2,400 4,100 6,350
1,810 1,850 2,260 2,645 2,820 2,950 3,285 3,450
5,375 5,905 6,780 7,633 8,490 11,400
-------
TABLE A-4 (Cont.)
Technology
Model Size, mgd (cu m/day)
0.05 0.11 0.25 0.60 1.0 1.5 3.0 5.0
(189) (416) (946) (2,271) (3,785) (5,678) (11,355) (18,925)
-*»
oo
Hours to Operate & Maintain Technology
Powdered Activated Carbon
(with regeneration)
Added to EAAS 1,840 1,916 2,410 3,005 3,420 3,850 5,085 6,450
Full Application - 5,441 6,055 7,140 8,233 9,390 13,200
Ozonation
Regulation
BAT
PSES, NSPS, PSNS
840 940 1,100 1,240 1,340 1,450 1,600 1,800
Hours for Laboratory, Supervisory, Administrative, & Clerical Requirements
15 65 100 440 600 750 1,100 1,500
35 125 210 830 1,150 1,505 2,400 3,370
Source: References 30 and 83.
-------
TABLE A-5
ANNUAL MAINTENANCE MATERIALS COSTS
Technology
Model Size, mgd (cu m/day)
0.05 0.11 0.25 0.60 1.0 1.5 3.0 5.0
(189) (416) (946) (2,271) (3,785) (5,678) (11,355) (18,925)
Activated Sludge
Chemical Coagulation/
Precipitation
Vacuum Filtration
Multimedia Filtration
oo Dissolved Air Flotation
Granular Activated Carbon
(without regeneration)
Powdered Activated Carbon
(without regeneration)
Add to EMS
Full Application
Powdered Activated Carbon
(with regeneration)
Add to EMS
Full Application
Ozonation
2,300 3,900
1,500 3,300
Cost, thousands of dollars
7,100 13,200 19,500 25,500 43,500 63,000
7,500 18,000 27,800 42,800 84,000 136,500
4,400 5,400 7,500 11,300 15,000 19,500 31,500 46,500
3,900 6,800 11,700 21,000 30,000 40,500 64,500 91,500
1,800 3,200 5,700 11,100 16,500 22,500 36,000 54,000
900 2,000 4,400 10,200 16,500 25,500 49,500 82,500
1,800 1,800 2,600 3,400 1,400
- 15,200 18,200 24,700 31,000
1,900 2,100 3,300
- 15,500 19,000
5,200 4,500
26,500 34,000
300
600 1,800 3,500 5,600
2,100 5,400 6,000
40,200 63,000
6,700 14,600 24,400
44,800 72,200
8,700 16,700 27,600
Source: References 30, 37, 38, and 83 updated to 4th quarter 1979 dollars.
-------
00
TABLE A-6
ESTIMATED ANNUAL SLUDGE QUANTITIES FOR COMPONENT TECHNOLOGIES
Model Size, mgd (cu m/day)
Technology
0.05
(189)
0.11
(416)
0.25 0.60 1.0
(946) (2,271) (3,785)
1.5 3.0 5.0
(5,678) (11,355) (18,925)
Dewatered Sludge, tons
Screening
Activated Sludge
Chemical Coagulation/Precipitation
Condition 1*
Condition 2
Condition 3
Condition 4
Condition 5
Dissolved Air Flotation
Multimedia Filtration
Condition 1*
Condition 2
Condition 3
Granular Activated Carbon
(without regeneration)
Powdered Activated Carbon
(without regeneration)
Add to EAAS
Full Application
Powdered Activated Carbon
(with regeneration)
Add to EAAS
Full Application
25
70
870
335
45
32
24
2
13
6
2
120
34
-
-
—
50
150
1,920
735
98
71
52
5
28
14
3
270
75
213
-
50
100
320
4,360
1,670
223
162
118
11
63
31
8
620
171
471
-
100
240
740
10,460
4,010
535
391
284
26
150
75
19
1,500
411
1,131
-
240
380
1,200
17,440
6,690
891
651
472
44
250
125
31
2,500
685
1,865
-
380
570
1,800
26 , 160
10,030
1,337
976
709
66
375
188
47
3,700
1,028
2,798
-
570
960
3,400
52,320
20,060
2,673
1,952
1,417
132
750
375
94
7,400
2,055
5,415
-
960
1,300
5,600
87,200
33,430
4,435
3,253
2,361
219
1,250
625
156
12 , 400
3,425
-
-
~
* These conditions are defined in the section on vacuum filtration.
Source: Technical Contractor Engineering Analysis
-------
TABLE A-7
ESTIMATED ANNUAL POWER REQUIREMENTS FOR COMPONENT TECHNOLOGIES
Model Size, mgd (cu m/day)
CO
CJ1
Technology
Screening
Equalization
Activated Sludge
Chemical Coagulation/
Precipitation
Vacuum Filtration
Condition 1*
Condition 2
Condition 3
Condition 4
Condition 5
Multimedia Filtration
Dissolved Air Flotation
Granular Activated Carbon
(without regeneration)
Granular Activated Carbon
(with regeneration, kwh)
Granular Activated Carbon
(with regeneration, therm/yr)
0.05
(189)
4.2
4.8
190.0
9.0
20.4
20.4
20.4
20.4
20.4
1.2
35.0
6.0
12.0
3.3
0.11
(416)
5.6
4.8
280.0
19.8
38.3
20.4
20.4
20.4
20.4
2.6
39.0
13.0
26.0
6.9
0.25
(946)
Power
10.0
5.8
430.0
45.0
68.9
33.2
20.4
20.4
20.4
6.0
59.0
30.0
65.0
15.4
0.60
(2,271) (3
, thousands
23.0
11.0
670.0
108.0
140.0
64.0
20.4
20.4
20.4
14.4
110.0
70.0
140.0
38.5
1.0
,785)
1.5
(5,678)
3.0
(11,355)
5.0
(18,925)
of kilowatt- hours
39.0
18.0
870.0
180.0
212.0
100.0
20.4
20.4
20.4
24.0
155.0
120.0
235.0
65.0
58.0
30.0
1,070.0
270.0
288.0
135.0
25.5
23.0
20.4
36.0
205.0
180.0
355.0
97.0
115.0
62.0
1,530.0
540.0
577.0
232.0
48.5
38.3
25.5
72.0
310.0
350.0
700.0
185.0
195.0
104.0
2,000.0
900.0
990.0
408.0
68.9
51.0
43.4
120.0
375.0
600.0
1,200.0
330.0
These conditions are defined in the section on vacuum filtration.
-------
TABLE A-7 (Cont.)
Model Size, mgd (cu m/day)
4s*
00
Technology
0.05 0.11
(189) (416)
0.25
(946)
0.60
(2,271)
1.0
(3,785)
1.5
(5,678)
3.0
(11,355)
5.0
(18,925)
Power, thousands of kilowatt-hours
Powdered Activated Carbon
(without regeneration)
Add to EAAS
Full Application
Powdered Activated Carbon
(with regeneration, kwh)
Add to EAAS
Full Application
Powdered Activated Carbon
(with regeneration, therms/yr)
Add to BPT
Full Application
Ozonation
16.1 20.
93.
26.1 34.
107.
344.0 352.
352.
175.0 385.
1
0
1
0
0
0
0
57.7
183.0
87.7
213.0
361.0
361.0
875.0
103
356
163
416
378
378
2,101
.6
.0
.6
.0
.0
.0
.0
165
606
285
726
404
404
3,502
.2
.0
.2
.0
.0
.0
.0
318.3
920.0
488.3
1,090.0
430.0
430.0
5,252.0
575.
1,713.
875.
2,013.
482.
482.
10,505.
8
0
8
0
0
0
0
809.7
-
1,319.7
-
559.0
-
17,508.0
Source: References 36, 41, 45, 46, 47, 48, 49, 50, and 83 updated to 4th quarter 1979 dollars.
-------
conditions noted earlier under the discussion of vacuum
filtration. It is assumed that the solids concentration for all
sludges is 20 percent by weight. The estimates for the quantity
of spent granular activated carbon are based on the carbon
containing its own weight plus an equivalent weight of water.
When powdered activated carbon is regenerated, it is assumed that
only screening operation sludges are generated.
The estimated costs to haul and deposit dewatered sludge in an
approved sanitary landfill are graphically presented in Figure A-
13. The curve is developed from information obtained during the
survey of the textile industry and represents the best fit
polynomial for the data points noted.
Energy and Power The costs for energy and power represent the
expense of purchasing electricity and fuel to operate equipment
and facilities. The costs are developed by estimating power
requirements for the various component technologies for each
model size and applying unit costs for electric power and fuel.
It was assumed that fuel oil would be used for the regeneration
of activated carbon. All other treatment components were assumed
to be powered by electricity.
A matrix of the estimated power requirements for the various
component technologies is presented in Table A-7. The values are
established from information in References 55, 51, 56, 57, 58,
59, 60, 50, and 47. It is assumed that all equipment, with the
exception of the vacuum filters, will operate 24 hr/day and
300 days/yr. Vacuum filters are sized to operate 10 hr/day. An
electric motors efficiency of 88 percent is assumed.
For most of the component technologies, energy consumption is
based solely on flow. For vacuum filtration, flow (quantity of
sludge) as well as sludge characteristics (such as solids content
and dewaterability) affects energy consumption.
In converting power requirements to dollars, the cost for
electricity is assumed to be 3.4 cents/kwh. The cost represents
a typical value taken from the industry survey responses for the
southeastern region of the U.S. updated to represent 4th quarter
1979 dollars. This region was chosen because the majority of the
country's textile mills are located there (see Table III-l).
Fuel oil is assumed to cost 33 cents/therm. This cost, which
represents 4th quarter 1979 dollars, is taken from the industry
survey responses and Reference 46. It also represents costs for
the southeastern region of the U.S.
Chemicals The costs for the chemicals required to operate the
various component technologies are given by model size in
Table A-8. They are developed by applying 4th quarter 1979 unit
costs to estimated quantities of the chemicals required.
487
-------
FIGURE A-13
COST FOR HAULING AND DISPOSING DEWATERED SLUDGE
00
00
25
20
"5
(0
o
S 10
O
0
5OO
2500
IOOO I5OO 2000
QUANTITY, tons/year
SOURCE: EPA Industry Survey, 1977; updated to 4th quarter 1979 dollars
3000
-------
Technology
TABLE A-8
ESTIMATED ANNUAL CHEMICAL COSTS FOR COMPONENT TECHNOLOGIES
Model Size, mgd (cu m/day)
0.05 0.11 0.25 0.60 1.0 1.5
(189) (416) (946) (2,271) (3,785) (5,678)
3.0 5.0
(11,355) (18,925)
CO
Cost, thousands of dollars
Chemical Coagulation/Precipitation
Condition 1 (1000 mg/1 alum) 15.0
Condition 2 (1000 mg/1 alum) 15.0
Condition 3 (100 mg/1 alum)
Condition 4 (100 mg/1 alum)
Condition 5 (100 mg/1 alum)
5.0
5.0
1.5
1.5
1.5
33.0
33.0
3.3
3.3
3.3
75.0
75.0
7.5
7.5
7.5
180.0
180.0
18.0
18.0
18.0
300.0
300.0
30.0
30.0
30.0
450.0
450.0
45.0
45-0
45.0
900.0
900.0
90.0
90.0
90.0
1,500.0
1,500.0
150.0
150.0
150.0
Multimedia Filtration
Granular Activated Carbon
(without regeneration)
Granular Activated Carbon
(with regeneration)
Powdered Activated Carbon
(without regeneration)
0.2
0.4
0.9
2.3
3.8
5.7
11.3
5.0
11.0
24.8
59.4
99.0
148.5
297.0
18.8
61.5 136.5 310.5 667.5 1,237.5 1,857.0 3,712.5 6,187.5
495.0
Add to EMS
Full Application
Powdered Activated Carbon
(with regeneration)
Add to EAAS
Full Application
10.5 23.0
24.1
2.0 4.3
5.4
52.3
54.7
9.8
12.2
125.6
131.4
23.5
29.3
209.3
218.9
39.2
48.8
313.9
328.4
58.7
73.2
627.9
656.9
117.5
146.4
1,046.5
195.8
Source: Reference 52.
-------
For chemical coagulation, alum is the coagulant of choice based
on its proven effectiveness and reasonable cost. A dosage of
1000 mg/1 (as alum) is was assumed for coagulation conditions 1
and 2, and a dosage of 100 mg/1 was assumed for conditions 3, 4,
and 5, These coagulation conditions are defined earlier in this
section under the discussion of vacuum filtration. For
multimedia filtration, 1 mg/1 of polymeric filter aid is included
whenever filtration is not preceded by chemical coagulation. For
granular activated carbon, an exhaustion rate of 0.66 kg/cu m
(5,500 Ib/mil gal) is assumed when regeneration is practiced. An
exhaustion rate of 0.14 kg/cu m (1,200 Ib/mil gal) is used for
powdered activated carbon.
costs used in developing the chemical costs are as
The unit
follows:
Chemical
Alum (technical)
Polymer
Carbon (granular)
Carbon (powdered)
Unit Cost
$0.26-0.28 per kg ($0.12-0.13 per Ib)
$3.30 per kg ($1.50 per Ib)
$1.65 per kg ($0.75 per Ib)
$1.10 per kg ($0.50 per Ib)
Monitoring Monitoring costs include outside laboratory
analytical charges and time for reporting results to regulatory
agencies. The costs associated with collecting and delivering
samples are included under operation and maintenance labor.
Separate monitoring costs were developed for direct and indirect
dischargers. Direct dischargers were assumed to sample in order
to comply with a discharge permit. This entails regular sampling
of influent and effluent waste streams and receiving waters.
Samples for the conventional pollutants are collected twice per
week, and nonconventional pollutants are collected once per week.
Samples for toxic pollutants are collected semiannually.
Indirect dischargers are assumed to sample in order to comply
with the local sewer ordinances. Conventional and
nonconventional pollutants are collected weekly and toxic
pollutants semiannually.
Laboratory cost estimates are based on commercial laboratory
price lists (53, 61, 62, 63, 64, 65, 66, and 67) updated to 4th
Quarter 1979 dollars. Reporting costs were based on $20/hr and
allowed 1 hr/week for compiling data plus 8 hr/month for
preparing reports.
Annual monitoring costs are based on a complete program for major
direct and indirect dischargers. As mentioned under "Monitoring
Equipment," many of the larger facilities have existing programs
that would result in considerably less additional cost in this
area. The monitoring frequencies are assumed for cost estimation
purposes only and are not intended to provide a model for
compliance monitoring.
490
-------
CALCULATION OF MODEL PLANT COSTS•
Example Calculation
Using the component investment and annual costs presented in
Tables A~6 through A-8 and the methodology presented in Figure
A-l the costs for several possible treatment options can be
calcualted for each model plant. As an example of the use of the
methodology model will costs for a 470 kkg wool finishing model
mill are presented in Table A-9 for four treatment options which
are, as follows:
BAT Option 2 Multimedia Filtration
BAT Option 3 Chemical Coagulation followed by Multimedia
Filtration
BAT Option 4 Chemical Coagulation,
and Granular Activated Carbon
Multimedia Filtration
Cost Curves
In the analysis of treatment alternatives for regulatory options
selection costs were calculated for a sufficient range of model
sizes to plot curves of costs versus model flow. These cost
curves relating investment and annual costs to flow for each of
the treatment alternatives are presented in Figures A-l4 through
A-32. As noted in earlier discussion, the curves represent the
best fit of the cost estimates developed for the various model
plants. The curves provide the means for quickly estimating the
investment and annual costs for a range of treatment plants
(based on flow size) covering existing and anticipated new
facilities.
The following index is provided as an aid to the user in locating
specific curves.
Figure Treatment Alternatives
A-l4 Screening and Extended Aeration
Activated Sludge
A-l5 Chemical Coagulation/Sedimentation
and Multimedia Filtration
A-l6 Multimedia Filtration
A-l7 Chemical Coagulation/Sedimentation
and Multimedia Filtration
A-l8 Multimedia Filtration and Granular
Activated Carbon
A-l9 Chemical Coagulation/Sedimentation,
Multimedia Filtration, and Granular
Activated Carbon
A-20 Ozonation
A-21 Chemical Coagulation/Sedimentation
491
-------
A-22
A-23
A-24
A-25
A-26
A-27
A-28
and Ozonation
Powdered Activated Carbon Addition to EAAS
Multimedia Filtration and Ozonation
Chemical Coagulation/Sedimentation,
Multimedia Filtration, and Ozonation
Chemical Coagulation and Dissolved Air
Flotation
Chemical Coagulation, Dissolved Air
Flotation, and Granular Activated Carbon
Chemical Coagulation, Dissolved Air
Flotation, and Ozonation
Screening and Powdered Activated Carbon
Treatment
492
-------
TABLE A-9
MODEL PLANT CONTROL COST SUMMARY
BAT: 5,678 CU M/DAY (1.5 MGD) MODEL
Subcategory: WOOL FINISHING
Daily Production Capacity: 18,700 kg
INVESTMENT COSTS
Chemical Coagulation
Equipment
Construction
Vacuum Filtration
Equipment
Construction
Multimedia Filtration
Equipment
Construction
Granular Carbon
Equipment
Construction
Ozonation
Equipment
Construction
Powdered Carbon
Equipment
Construction
Monitoring
Engineering
Contingencies
Total Investment
ANNUAL COSTS
Capital
Depreciation
Useful Life (years)
O&M Labor
Employees (persons)
Maintenance
Sludge Disposal
Energy & Power
Chemicals: Polymer
Alum
Carbon
Monitoring
Total Annual
BAT Option
234
Cost, thousands of dollars
66.5
266.0
27.0
50.1
66.5
266.0
27.0
50.1
69.2
276.6
66.5
266.0
27.0
50.1
69.2
276.6
718.2
718.2
20.0
42.0
64.4
536.0
80.4
33.0
15
89.2
3.0
62.3
12.2
10.0
45.0
40.5
372.6 520.4 1,132.7
20.0
66.9
116.3
958.6
143.9
59.4
15
104.8
3.5
102.8
12.8
.11.2
45.0
-
40.5
20.0
178.1
331.8
2,721.7
408.3
141.3
18
152.8
5.1
128.3
12.8
55.2
45.0
148.5
40.5
493
-------
FIGURE A-14
ALTERNATIVE A: SCREENING AND EXTENDED AERATION ACTIVATED SUJDGfi
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
Flow, mgd
1,0
10
10,000 ri
-------
lOpOOr:
FIGURE A-15
ALTERNATIVE B: CHEMICAL COAGULATION/SEDIMENTATION
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
0.10 1.0
Flow, mgd
10
10,000 r:
0.10 1.0
Flow, mgd
10
495
-------
FIGURE A-16
ALTERNATIVE C: MULTIMEDIA FILTRATION
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
ICyOOOr:
CO
5
"o
•o
to
O
15
o
O
e
15
-------
10,000
FIGURE A-17
ALTERNATIVE D: CHEMICAL COAGULATION/SEDIMENTATION
AND MULTIMEDIA FILTRATION
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
0.10 IX)
Flow.mgd
10
10,000 r:
o
•o
K>
O
w
o
O
C
^ 1000 -
0.01
0.10 1.0
Flow.mgd
497
-------
FIGURE A-18
ALTERNATIVE E: MULTIMEDIA FILTRATION AND GRANULAR ACTIVATED CARBON
INVESTMENT AND ANNUAL COST FOR EXISTING MILLS
10,000 rr
at
o
•o
H>
O
8 1000
O
c
0>
E
CO
-------
Annual Cost, 10 dollars
Investment Cost, 10 dollars
-------
10,000 r:
(A
in
O
g 1000
o
o>
e
c
100
0.01
FIGURE A-20
ALTERNATIVE G: OZONATKiN
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
II
0.10
Flow.mgd
1.0
10
10,000 r:
-------
Annual Cost, 10 dollars
Investment Cost, 10 dollars
o
o
o
o
o
.0
o
o
o
p
o
o
o
o
£
t I I ! I I I
-------
FIGURE A-2 2
ALTERNATIVE I: POWERED ACTIVATED CARBON ADDITION TO BIOLOGICAL TREATMENT
INVKSTMENT AND ANNUAL COSTS FOR EXISTING MILLS
10,000 r:
10
O
3
*-
c
I
1000
too
0.01
11
PAC2
-------
FIGURE A-23
ALTERNATIVE J: MULTIMEDIA FILTRATION AND OZONAT10N
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
Flow, mgd
10,000 r:
o
•o
10
O
J 1000
0>
3
"5
3
I
100
0.01
I I
I I I I I M I
0.10
Flow, mgd
l.O
10
B03
-------
Annual Cost, 10 dollars
Investment Cost, 10 dollars
o
o
o
o
o
p
o
£>
o
o
o
rr T nil
p
o
Ul
O
O
ia
a.
I I I I II II
-------
FIGURE A-25
ALTERNATIVE M: CHEMICAL COAGULATION ANP l^SSOLVED AIR FLOTATION
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
10,000 rr
o
•O
O
tooo
c
0>
E
-------
FIGURE A-26
ALTERKATIVE N: CHEMICAL COAGULATION, DISSOLVED AIR FLOTATION,
MULTIMEDIA FILTRATION, AND GRANULAR ACTIVATED CARBON
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
10,000 rr
S2
J5
"o
TJ
10
O
8 1000
c
O)
e
(A
0)
0.01
0.10
Flow, mgd
10
10,000 rr
(fl
100
0.01
0.10 . 1.0
Flow, mgd
506
-------
FIGURE A-27
ALTERNATIVE P: CHEMICAL COAGULATION, DISSOLVED AIR FLOTATION,
AND OZONATION
INVESTMENT AND ANNUAL COSTS FOR EXISTING MILLS
Flow, mgd
10,000 rr
^ 1000
CO
o
O
C
100
I I I I 111
I I I I II11
0.0!
0.10
Flow, mgd
1.0
10
507
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CONVERSION TABLE
Multiply (English Units) By
English Unit Abbreviation Conversion
To Obtain
Abbreviation
Metric Units)
Metric Unit
acre
acre-feet
British Thermal
Unit
British Thermal
Unit/pound
cubic feet
per minute
cubic feet
per second
cubic feet
cubic feet
cubic inches
degree Farenheit
feet
gallon
gallon per
minute
gallon per ton
horsepower
inches
pounds per
ac
ac ft
BTU
BTU/lb
cfm
cfs
cu ft
cu ft
cu in
OF
ft
gal
gpm
gal/ton
hp
in
psi
0.405
1233.5
0.252
0.555
0.028
1.7
0.028
28.32
16.39
0.555
-------
(continued)
Multiply (English Units) By To Obtain (Metric Units
English Unit Abbreviation Conversion Abbreviation Metric Unit
million gallons
per day
pounds per square
inch (gauge)
pounds
board feet
ton
mile
square feet
MGD
psi
Ib
b.f .
ton
mi
ft2
3.7 x 10-3
(0.06805 psi + 1)*
0.454
0.0023
0,907
1.609
.0929
cu m/day
atm
kg
cu m, m3
kkg
km .
m2
. cubic meters
per day
atmospheres
kilograms
cubic meters
metric ton
kilometer
square meters
* Actual conversion, not a multiplier.
509
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