United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
EPA-600/D-84-218
October 1984
?/EPA QECHNOLOGY
MQRANSFErT
R '985
PROTECTION
The Bridge Between
Research and Use
New Technology Transfer Publications
Available
Five new Technology Transfer publications are now being
distributed: (1) Handbook on Improving Publicly Owned Treat-
ment Works (POTW) Performance Using the Composite Correc-
tion Program Approach; (2) Process Design Manual Supplement
for Land Treatment of Municipal Wastewater; (3) Environmental
Regulations and Technology Report on Use and Disposal of
Municipal Wastewater Sludge; (4) Handbook for Septage Treat-
ment and Disposal; and (5) Capsule Report on Benefits of
Microprocessor Control of Curing Ovens for Solvent-Based
Coatings.
1. The Handbook on Improving POTW Performance Using the
Composite Correction Program Approach provides information
on methods to economically improve the performance of existing
POTWs. It is "how-to" oriented, and describes an approach called
the Composite Correction Program (CCP) that POTW owners can
use to improve treatment without making major capital expendi-
tures. The CCP approach consists of an evaluation phase and a
performance improvement phase.
The evaluation phase is a thorough review and analysis of a
POTW's design capabilities and associated administration,
operation, and maintenance practices. It is accomplished by
assessing the capability of major unit processes and by identifying
and ranking those factors that limit performance and can be
corrected to improve performance. The performance improve-
ment phase is a systematic approach to eliminating those factors
that limit performance in existing POTWs. Its major benefit is that
it optimizes the capability of existing facilities to perform better
jnd/or treat more wastewater.
This Handbook focuses on POTWs treating typical municipal
wastewater, compatible with common biological wastewater
treatment processes. It has been written mainly for POTWs with
flow up to about 40,000 m3/d (10 mgd). The Handbook further
focuses on mechanical plants, using activated sludge, trickling
filters and variations of these processes for secondary treatment.
A series of Technology Transfer seminars on the CCP approach
have been scheduled for 1985, as described below.
The order number for this publication is 6008.
2. The Process Design Manual Supplement for Land Treat-
ment of Municipal Wastewater presents new information on two
processes, and is intended to be an addendum to the 1981
Manual (EPA-625/1-81-013). Chapter I of the supplement covers
rapid infiltration systems and Chapter II discusses overland flow
systems. New information on both the systems and their
performance, developed since 1981, is included. Also presented
are special concerns with respect to rapid infiltration, since some
of the systems constructed in recent years have experienced
problems or do not satisfy all design expectations. An analysis of
those experiences indicates that the majority of the problems
could have been avoided. It is, therefore, the intent of Chapter I to
provide additional guidance and detail on planning, design,
construction, and operation of rapid infiltration systems so that
similar problems can be avoided in the future. The basic criteria in
the 1981 manual are still valid and are not repeated in this text.
Both documents are necessary for design of rapid infiltration and
overland flow systems.
The order numbers for these publications are: Manual 1013;
Supplement 1013a.
3. The report on Environmental Regulations and Technology:
Use and Disposal of Municipal Wastewater Sludge is intended to
be a guidance document, describing all available alternatives for
effectively managing the ultimate use and disposal of sludge.
Sludge production is expected to about double to approximately
13 mil lion dry metric tons(14 mill ion dry tons) per year by the year
2000 as the population increases, as more municipalities comply
with the Clean Water Act requirements, and as more sophisti-
cated wastewater treatment systems are developed and installed.
In addition, the sludges generated by more advanced treatment
are more difficult to handle than the sludges produced by less
advanced treatment.
When properly used, sludge can be a valuable resource as a soil
conditioner and partial fertilizer and, to a certain extent, as a
source of methane for producing energy. The U.S. Environmental
Protection Agency (EPA), the primary federal regulatory agency
responsible for sludge management, encourages the beneficial
use of sludge wherever environmentally feasible.
Topics discussed in the report include land application, distri-
bution and marketing of sludge products, land filling, incineration
and ocean disposal.
The order number for this publication is 10003.
4. The Handbook for Septage Treatment and Disposal presents
information on the receiving, treatment, and disposal of septage
(the liquid and solid material pumped from a septic tank or
cesspool when it is cleaned). It is designed to serve as a practical
guide for planners, design engineers, state and Federal re-
viewers, and local government officials involved in planning,
evaluating, and designing septage handling facilities. Information
is provided to facilitate the design of septage receiving stations,
pretreatment processes, new sewage treatment plants with
provisions for receiving septage, and independent septage
treatment and disposal alternatives. Individual treatment pro-
cesses are discussed in detail and specific design guidance is
provided. Methods for septage treatment and disposal discussed
are:
1. Land treatment and disposal;
2. Co-treatment at existing wastewater treatment facilities;
3. Independent facilities for treatment and disposal.
Included in the Handbook are: technical options applicable for
the management of septage; detailed discussion of septage
characteristics; septage receiving station design; specific tech-
nical advice for design of land treatment, co-treatment, and
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independent septage treatment facilities; facility operation and
program management considerations; and fact sheets (a series of
two-page capsule summaries of selected septage treatment
methods) that give the generalized capital, operation, and
maintenance costs of septage treatment.
The order number for this publication is 6009.
5. Benefits of Microprocessor Control of Curing Ovens for
Solvent-Based Coatings—Curing ovens are a major source of
VOC emissions. The organic solvents, or hydrocarbons, in the
coating are evaporated in the oven at temperatures which range
from 100°F to 700°F, depending upon the curing properties of the
coating and the product. Because great volumes of air containing
low concentrations of VOCs are involved, the fuel and investment
cost of controlling these VOC emissions can be significant.
Most curing ovens operate at ventilation air flow rates far in
excess of the rate required to cure the product and to maintain the
solvent concentration below its lower explosive limit. This over-
ventilation results in higher than necessary investment costs for
pollution control equipment and high fuel costs for both curing
and incineration.
Recognizing the potential for reducing the fuel and investment
costs of meeting VOC regulations, the Chemical Coaters Associ-
ation, the Environmental Protection Agency, and the Department
of Energy cooperatively funded a program to develop a micro-
computer-based system to control curing oven ventilation by
continually monitoring and controlling operating parameters
(including solvent concentrations and pressure). Such a system
can also monitor the efficiency of pollution control equipment.
This capsule report highlights the results of that program, the
performance of a prototype system at Mack Trucks, Inc.,
Allentown, PA, and applications for other curing operations.
The report includes a discussion of the microprocessor concept,
the performance and cost savings of the system installed on the
Mack Truck curing line, and applications on other systems in the
coating industry.
The order number for this publication is 2031.
Technology Transfer Seminars—Improving
POTW Performance Using the Composite
Correction Program Approach
A series of ten Technology Transfer seminars presenting
information on utilizing the Composite Correction Program (CCP)
to improve the performance of publicly owned treatment works
(POTWs) will be conducted across the country beginning in
January 1985.
This series will consist of ten 2-day seminars conducted in the
following locations:
Tallahassee, FL
Charlotte, NC
Denver, CO
San Francisco, CA
Dallas, TX
Kansas City, MO
Chicago, IL
January 7-8,
January 10-11,
January 21-22,
January 23-24,
February 11-12,
February 14-15,
February 25-26,
1985
1985
1985
1985
1985
1985
1985
Philadelphia, PA February 28-March 1, 1985
Albany, NY March 11-12, 1985
Boston, MA March 14-15, 1985
Topics to be discussed include: EPA's National Municipal
Policy; Comprehensive Performance Evaluation (CPE) Method-
ology; Conducting CPEs; Assessing Ability to Improve POTW
Performance Without Major Capital Expenditures; Prioritizing
and Improving Factors Limiting POTW Performance; Evaluating
CPE Results; Composite Correction Program (CCP) Methodology;
and Conducting CCPs.
Two workshop sessions are included in each seminar: one on
conducting CPEs, and one on conducting CCPs. Preregistration is
a requirement for attendance at these seminars since the
workshop sessions will be limited in size to an effective number of
workgroup participants.
If you are interested in receiving registration information on
these seminars contact Sheri Marshall, Dynamac Corp., (301)
468-2500.
Seminar Series
Protection of Public Water Supplies from
Groundwater Contamination
The USEPA's Office of Drinking Water and Center for Envi-
ronmental Research Information, in cooperation with regional
offices, have developed a series of Technology Transfer seminars
that present not only a general approach to managing contam-
ination but also include a regional perspective of the problem.
Through cooperative planning between the program and regional
offices, each meeting agenda is tailored to address particular
needs and issues of concern of the attending Region or state.
The purpose of the seminar is to provide information to state,
local and municipal officials on the methods available for dealing
with public water supplies that are threatened by ground-water
contamination. Speakers during the two and one-half day meeting
will discuss general principles of hydrogeology and local hydro-
geologic considerations, potential sources of ground-water
contamination, approach to identifying contamination threats,
management alternatives for dealing with ground-water contam-
ination, as well as case studies of actual situations.
Efforts in the ground-water area by the Offices of Solid Waste,
Drinking Water, Water Program Operations, and Research and
Development will be brought together to provide the latest
information available which can be used by managers in
developing a practical approach to decision making.
Seminars are scheduled to be conducted in the following
locations:
Pittsburgh, PA
Baton Rouge, LA
Plainview, NY
Boston, MA
November 14-15, 1984
November 27-29, 1984
December 3-5, 1984
December 10-11, 1984
Registration for these seminars is handled by Dynamac Corp.,
11140 Rockville Pike, Rockville, MD 20852.
EPA Displays Exhibit at Air Pollution
Control Association Meeting
The 77th Air Pollution Control Association (APCA) annual
meeting and exhibition was held this summer, June 24-29, in the
San Francisco Civic Center.
EPA was represented at the meeting by staff members from the
Office of Research and Development (ORD) and the Office of Air
Quality Planning and Standards (OAQPS) who presented papers,
attended technical committee meetings and also helped plan and
manage the Agency's 60-foot-long booth at the exhibition.
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REQUEST FOR TECHNOLOGY TRANSFER MATERIAL
PROCESS DESIGN MANUALS
Sulfide Control in Sanitary Sewerage Systems (Oct. 1974) 1005 D
Nitrogen Control (Oct. 1975) 1007 D
Wastewater Treatment Facilities for Sewered Small
Communities (Oct 1977) 1009 O
Municipal Sludge Landfills (Oct. 1978) 1010 D
Sludge Treatment and Disposal (Oct. 1979) 1011 D
Onsite Wastewater Treatment and Disposal Systems (Oct. 1980) 1012 D
Land Treatment of Municipal Wastewater (Oct. 1981) 1013 D
• Supplement for Land Treatment of Municipal
Wastewater (Oct. 1984) 1013a D
Dewatering Municipal Wastewater Sludges (Oct 1982) 1014 D
Municipal Wastewater Stabilization Ponds (Oct. 1983) 1015 D
Land Application of Municipal Sludge (Oct. 1983) 1016 D
TECHNICAL CAPSULE REPORTS
First Progress Report: Wellman-Lord SO2 Recovery Process—Flue
Gas Desulfurization Plant 2011 D
Double Alkali Flue Gas Desulfurization System Applied at the
General Motors Parma, OH Facility 2016 O
Recovery of Spent Sulfunc Acid from Steel Pickling Operations 2017 D
Fourth Progress Report- Forced-Oxidation Test Results at the EPA
Alkali Scrubbing Test Facility 2018 D
Paniculate Control by Fabric Filtration on Coal-Fired
Industrial Boilers 2021 D
Bahco Flue Gas Desulfurization and Paniculate Removal System 2022 D
First Progress Report. Physical Coal Cleaning Demonstration at
Homer City, PA 2023 D
Acoustic Monitoring to Determine the Integrity of Hazardous
Waste Dams 2024 D
Disposal of Flue Gas Desulfurization Wastes: Shawnee
Field Evaluation 2028 D
Adipic Acid-Enhanced Lime/Limestone Test Results at the
EPA Alkali Scrubbing Facility 2029 D
Environmental Controls at a Secondary Lead Smelter 2030 D
• Benefits of Microprocessor Control of Curing Ovens for
Solvent Based Coatings 2031 D
SEMINAR PUBLICATIONS
Benefit Analysis for Combined Sewer Overflow Control 4013 D
BROCHURES
Environmental Pollution Control Alternatives. Municipal
Wastewater 5012 D
Environmental Pollution Control Alternatives: Economics of Wastewater
Treatment Alternatives for the Electroplating Industry 5016 D
Environmental Pollution Control Alternatives- Centralized Waste
Treatment Alternatives for the Electroplating Industry 5017 D
Environmental Pollution Control Alternatives: Sludge Handling,
Dewatering, and Disposal Alternatives for the
Metal Finishing Industry 5018 D
HANDBOOKS
Industrial Guide for Air Pollution Control (June 1978) 6004 D
Identification/Correction of Typical Design Deficiencies at
Municipal Wastewater Treatment Facilities (Oct 1982) 6007 D
• Improving Publicly Owned Treatment Works Performance Using the
Composite Correction Program Approach (Oct. 1984) 6008 D
• Handbook for Septage Treatment and Disposal (Oct 1984) 6009 D
INDUSTRIAL ENVIRONMENTAL
POLLUTION CONTROL MANUALS
Pulp and Paper Industry—Part 1 /Air (Oct. 1976) 7001 O
SUMMARY REPORTS
Control and Treatment Technology for the Metal Finishing
Industry Series- Sulfide Precipitation 8003 D
Sulfur Oxides Control Technology Series: FGD Dual
Alkali Process 8004 D
Sulfur Oxides Control Technology Series: FGD Magnesium
Oxide Process 8005 D
Sulfur Oxides Control Technology Series: FGD Lime/Limestone
Processes 8006 D
Control and Treatment Technology for the Metal Finishing
Industry Series: Ion Exchange 8007 D
Control and Treatment Technology for the Metal Finishing
Industry Series: In-Plant Changes 8008 D
Sulfur Oxides Control Technology Series- FGD Spray
Dryer Process 8009 D
EXECUTIVE BRIEFINGS
Short-Term Tests for Carcinogens, Mutagens, and Other
Genotoxic Agents
9003 D
ENVIRONMENTAL REGULATIONS AND
TECHNOLOGY PUBLICATIONS
• Environmental Regulations and Technology.
Use and Disposal of Municipal Wastewater Sludge
.10003 D
ATTENTION PUBLICATION USERS
Due to the increasing costs of printing and mailing, it has become necessary to institute positive management controls over distribution of Technology Transfer
publications. Although these publications will be distributed on a no-cost basis, any request for more than five documents total, or for more than one copy of a single
document must be accompanied by written justification, preferably on organization letterhead. In the event your order cannot be filled as requested, you will be contacted
and so advised.
If you are not currently on the mailing list for the Technology Transfer Newsletter, do you want to be added? Yes D No D
Name
Street,
City/State/Zip Code
• Publication listed for first time.
Note: Forward to CERI, Technology Transfer, U.S. Environmental Protection Agency, P.O. Box 15948, Cincinnati, OH 45215
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The exhibit, one of the largest in the show, presented
summaries of major programs from the ORD Laboratories and
OAQPS Offices. In addition, handout material was available,
describing ORD monitoring and control technology, OAQPS
enforcement, clearinghouse and training activities, as well as
ORD's Publications Announcement and selected Project Sum-
maries. Exhibit preparation was a joint effort by ORD and OAQPS:
production was coordinated by the Center for Environmental
Research Information in cooperation with APCA.
The booth attracted a large audience who showed particular
interest in Agency programs pertaining to acid deposition,
hazardous and toxic air pollutants and indoor air pollution.
Next year's meeting is scheduled to be held June 23-28,1985,
in Detroit, Ml. We plan to display a similar exhibit, again planned
by ORD and OAQPS, which will highlight the Agency's major air
programs.
New Operating Mode for Sludge Incinerators
Saves Fuel/Costs
A cooperative research project between the Office of Research
and Development and the City of Indianapolis, IN, resulted in a
reduction in fuel costs to the city of close to $1,000,000 per year
by installing $250,000 worth of instrumentation in the city's
eight incinerators burning sewage sludge.
In addition, four other cities in the U.S. are now using the
operating and training procedures established at Indianapolis
and save over 50 percent of their fuel costs without any additional
instrumentation and controls.
Equally important is the accompanying reduction in particulate
emissions that occurs when the incinerators are operated in their
optimum fuel consumption mode. At Indianapolis, scheduled
construction of $3,000,000 worth of air pollution control
equipment was cancelled because the project brought the incin-
erators into compliance with air pollution requirements.
These savings are the result of a project to determine whether
an existing sewage sludge incinerator could be made to operate
more efficiently. At the Indianapolis Belmont Wastewater Treat-
ment Plant, researchers demonstrated that fuel consumption can
be reduced 34 to 70 percent by improving existing instrumenta-
tion and control systems, using a more fuel-efficient operational
mode, and providing operator training. Indianapolis experienced
a fuel savings payback period of less than three months. The other
four cities adapting the fuel savings method of operation have
experienced a payback period of one to three months.
One of the biggest problems facing municipalities operating
sludge incinerators is the high cost of energy required both for the
actual incineration process and for air pollution control. A recent
survey shows that approximately 15 to 20 percent of the sludge
incinerators constructed since 1970 are no longer in operation
due to high energy costs. Those still in operation use about 80
gallons of fuel to burn one ton of dry sludge.
The research project involved several activities. A combustion
engineering analysis was made of the multiple hearth incinerator
operations, with extensive instrumentation to measure air, gas,
temperature, and flow rates. Tests were then conducted to
determine the effect of many incinerator variables on fuel
consumption. Analytical and test data were compared to deter-
mine the relationship between specific fuel consumption and key
incinerator operating variables, and a model was developed to
predict the lowest possible fuel consumption obtainable by
optimum incinerator operation. Key factors in this model are gas
temperatures, the sludge moisture to volatile ratio (MN), and the
desired flow rate for sludge through the incinerator.
The test results and model were used to specify a new, more
fuel-efficient operating mode. The key to operation of the inciner-
ators in an optimum mode is to clearly define operating
procedures and provide process control flexibility. To achieve this,
the existing instrumentation and control systems were upgraded
to allow operator remote control. New systems were designed
and installed for air flow control, measurement of fuel flow and
sludge cake load rate. Key features of the operating mode were
developed into guidelines, techniques, and instructions and
included in operator training and an operating manual for the
furnace.
Since completion of the Indianapolis study, similar orders of
magnitude in fuel reduction requirements and cost savings have
been realized and documented at all locations. Average fuel
savings of over 50 percent of that formerly used have been
documented for over a year after the new method of operation
was initiated. This saves $180,000 in fuel costs per year for the
average multiple hearth furnace incinerating sludge.
One plant also showed that a change in the equipment used to
dewater sewage sludge further reduced fuel usage. With the
installation of continuous belt press filters, in addition to
incinerator operational changes and operator training, total fuel
usage for incineration was reduced 83 percent during a four-year
period.
To obtain more information about these projects, contact
Howard O. Wai!, Jr., the EPA Project Officer, at:
Municipal Environmental Research Laboratory
U.S. Environmental Protection Agency
Cincinnati, OH 45268
United States
Environmental Protection
Agency
Center for Environmental Research
Information
Cincinnati OH 45268
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