United States
Environmental Protection
Agency
Water and Waste Management
Effluent Guidelines Division
WH-552
Washington DC 20460
EPA 440/I-84/075
February 1984
Development
Document for
Effluent Limitations
Guidelines and
Standards for the
Electrical and
Electronic Components
Point Source Category
Phase II
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DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES
for the
ELECTRICAL AND ELECTRONIC COMPONENTS
POINT SOURCE CATEGORY
PHASE 2
William D. Ruckelshaus
Admini strator
Steven Schatzow
Director
Office of Water Regulations and Standards
Jeffery Denit, Director
Effluent Guidelines Division
G. Edward Stigall, Chief
Inorganic Chemicals Branch
John Newbrough
Project Officer
December 1983
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Effluent Guidelines Division
Washington, D.C. 20460
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TABLE OF CONTENTS
SECTION TITLE PAGE
EXECUTIVE SUMMARY 1
CONCLUSIONS 1
EFFLUENT LIMITATIONS AND STANDARDS 1
1.0 INTRODUCTION 1-1
1.1 ORGANIZATION AND CONTENT OF THIS DOCUMENT 1-1
1.2 SOURCES OF INDUSTRY DATA 1-1
2.0 LEGAL BACKGROUND 2-1
2.1 PURPOSE AND AUTHORITY 2-1
2.2 GENERAL CRITERIA FOR EFFLUENT LIMITATIONS 2-2
2.2.1 BPT Effluent Limitations 2-2
2.2.2 BAT Effluent Limitations 2-3
2.2.3 BCT Effluent Limitations 2-4
2.2.4 New Source Performance Standards 2-4
2.2.5 Pretreatment Standards for Existing 2-4
Sources
2.2.6 Pretreatment Standards for New Sources 2-5
3.0 INDUSTRY SUBCATEGORIZATION 3-1
3.1 RATIONALE FOR SUBCATEGORIZATION 3-1
3.2 SUBCATEGORIZATION REVIEW 3-1
3.3 CONCLUSIONS 3-1
4.0 DESCRIPTION OF THE INDUSTRY 4-1
4.1 CATHODE RAY TUBES 4-1
4.1.1 Number of Plants and Production 4-1
Capacity
4.1.2 Product Description 4-1
4.1.3 Manufacturing Processes and Materials 4-4
4.2 RECEIVING AND TRANSMITTING TUBES 4-8
4.2.1 Number of Plants and Production 4-8
Capacity
4.2.2 Product Description 4-8
4.2.3 Manufacturing Processes and Materials 4-10
in
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TABLE OF CONTENTS (Continued)
SECTION TITLE PAGE
4.3 LUMINESCENT MATERIALS 4-15
4.3.1 Number of Plants 4-15
4.3.2 Product Description 4-15
4.3.3 Manufacturing Processes and Materials 4-16
5.0 WASTEWATER CHARACTERISTICS 5-1
5.1 SAMPLING AND ANALYTICAL PROGRAM 5-1
5.1.1 Pollutants Analyzed 5-1
5.1.2 Sampling Methodology 5-4
5.1.3 Analytical Methods 5-4
5.2 CATHODE RAY TUBES 5-5
5.2.1 Wastewater Flow 5-5
5.2.2 Wastewater Sources 5-5
5.2.3 Pollutants Found and the Sources of 5-5
These Pollutants
5.3 LUMINESCENT MATERIALS 5-24
5.3.1 Wastewater Flow 5-24
5.3.2 Wastewater Sources 5-24
5.3.3 Pollutants Found and the Sources of 5-24
These Pollutants
5.4 RECEIVING AND TRANSMITTING TUBES 5-34
6.0 SUBCATEGORIES AND POLLUTANTS TO BE REGULATED 6-1
EXCLUDED OR DEFERRED
6.1 SUBCATEGORIES TO BE REGULATED 6-1
6.1.1 Pollutants to be Regulated 6-1
6.2 TOXIC POLLUTANTS AND SUBCATEGORIES NOT 6-4
REGULATED
6.2.1 Exclusion of Pollutants 6-5
6.2.2 Exclusion of Subcategories 6-7
6.3 CONVENTIONAL POLLUTANTS NOT REGULATED 6-8
7.0 CONTROL AND TREATMENT TECHNOLOGY 7-1
7.1 CURRENT TREATMENT AND CONTROL PRACTICES 7-1
7.1.1 Cathode Ray Tube Subcategory 7-1
7.1.2 Luminescent Materials Subcategory 7-2
7.2 APPLICABLE TREATMENT TECHNOLOGIES 7-2
7.2.1 pH Control 7-2
7.2.2 Toxic Metals Treatment 7-2
IV
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TABLE OF CONTENTS (Continued)
SECTION TITLE PAGE
7.2.3 Fluoride Treatment 7-6
7.2.4 Filtration 7-7
7.2.5 Chemical Chromium Reduction 7-7
7.2.6 Total Toxic Organics Control 7-8
7.3 RECOMMENDED TREATMENT AND CONTROL SYSTEMS 7-10
7.4 ANALYSIS OF INDUSTRY PERFORMANCE DATA 7-12
7.4.1 Cathode Ray Tube Subcategory 7-12
7.4.2 Luminescent Materials Subcategory 7-17
7.4.3 Statistical Methodology 7-17
8.0 SELECTION OF APPROPRIATE CONTROL AND TREATMENT 8-1
TECHNOLOGIES AND BASES FOR LIMITATIONS
8.1 CATHODE RAY TUBE SUBCATEGORY 8-1
8.1.1 Pretreatment Standards for Existing 8-1
Sources (PSES)
8.1.2 New Source Performance Standards (NSPS) 8-3
8.1.3 Pretreatment Standards for New Sources 8-4
(PSNS)
8.2 LUMINESCENT MATERIALS SUBCATEGORY 8-5
8.2.1 New Source Performance Standards (NSPS) 8-5
8.2.2 Pretreatment Standards for New Sources 8-6
(PSNS)
9.0 COST OF WASTEWATER TREATMENT AND CONTROL 9-1
9.1 COST ESTIMATING METHODOLOGY 9-1
9.1.1 Direct Investment Costs for Land and 9-2
Facilities
9.1.2 Annual Costs 9-4
9.1.3 Items Not Included in Cost Estimate 9-6
9.2 COST ESTIMATES FOR TREATMENT AND CONTROL OPTIONS 9-6
9.3 ENERGY AND NON-WATER QUALITY ASPECTS 9-17
10.0 ACKNOWLEDGMENTS 10-1
11.0 BIBLIOGRAPHY 11-1
12.0 GLOSSARY 12-1
APPENDIX 1 - PLANT 99797 RAW WASTES SELF-MONITORING DATA
APPENDIX 2 - PLANT 30172 SELF-MONITORING EFFLUENT DATA FOR FLUORIDE
v
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TABLE OF CONTENTS (Continued)
SECTION TITLE PAGE
APPENDIX 3 - PLANT 30172 TTO MONITORING DATA
APPENDIX 4 - PLANT 99798 EFFLUENT MONITORING DATA
APPENDIX A - CALCULATION OF LIMITATIONS FOR THE ELECTRICAL AND
ELECTRONIC COMPONENTS - PHASE II CATEGORY
APPENDIX B - A LISTING OF THE DATA FROM PLANT 99796
APPENDIX C - A LISTING OF THE FLUORIDE DATA FROM PLANT 30172
APPENDIX D - A LISTING OF THE POLLUTANT CONCENTRATION DATA FROM
PLANT 99798
APPENDIX E - DETAILS OF THE NOTATION AND FORMULAE USED TO ESTIMATE
AVERAGES, VARIABILITY FACTORS. AND LIMITATIONS
VI
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LIST OF FIGURES
NUMBER TITLE PAGE
4-1 Color Television Picture Tube 4-3
4-2 Television Picture Tube Manufacture 4-5
4-3 CRT Manufacture 4-7
4-4 Receiving Tube 4-9
4-5 Transmitting Tube 4-11
4-6 Receiving Tube Manufacture 4-12
4-7 Transmitting Tube Manufacture 4-14
4-8 Lamp Phosphor Process 4-17
4-9 Blue Phosphor Process 4-19
5-1 Plant 30172 Sampling Locations 5-8
5-2 Plant 11114 Sampling Locations 5-9
5-3 Plant 99796 Sampling Locations 5-10
5-4 Plant 101 Sampling Locations 5-26
7-1 Theoretical Solubilities of Toxic Metal 7-4
Hydroxides/Oxides as a Function of pH
7-2 Recommended Treatment--Cathode Ray Tube 7-13
Subcategory
7-3 Recommended TreatmentLuminescent Materials 7-14
Subcategory
9-1 Annual Cost vs. Flow for Option 2 Technology - 9-11
Cathode Ray Tubes
9-2 Annual Cost vs. Flow for Option 2 Technology - 9-12
Luminescent Materials
9-3 Annual Cost vs. Flow for Option 3 Technology - 9-15
Cathode Ray Tubes
vn
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LIST OF TABLES
NUMBER TITLE PAGE
1 PSES Regulations for Cathode Ray Tubes 2
2 NSPS Regulations for Cathode Ray Tubes 2
3 PSNS Regulations for Cathode Ray Tubes 2
4 NSPS Regulations for Luminescent Materials 3
5 PSNS Regulations for Luminescent Materials 3
5-1 Toxic Pollutants 5-2
5-2 Cathode Ray Tubes Summary of Raw Waste Data 5-7
5-3 Wastewater Sampling Data Plant 30172 5-11
5-4 Wastewater Sampling Data Plant 11114 5-14
5-5 Wastewater Sampling Data Plant 99796 5-22
5-6 Luminescent Materials Summary of Raw Waste Data 5-25
5-7 Wastewater Sampling Data Plant 101 5-27
5-8 Wastewater Sampling Data Plant 102 5-32
5-9 Wastewater Sampling Data Plant 103 5-33
6-1 Pollutants Comprising Total Toxic Organics 6-2
6-2 Toxic Pollutants Not Detected 6-5
7-1 Treatability of Toxic Organics Using Activated Carbon 7-11
7-2 Performance of In-Place Treatment - Cathode Ray Tube 7-15
Subcategory
7-3 Summary Statistics of Plants Used for Limitation 7-18
Development in the Cathode Ra Tube Subcategory
7-4 Performance of In-Place Treatment - Luminescent 7-19
Materials Subcategory
9-1 Option 2 Treatment Costs - Cathode Ray Tubes 9-7
Vlll
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LIST OF TABLES (Continued)
NUMBER TITLE PAGE
9-2 Option 2 Treatment Costs - Luminescent Materials 9-9
9-3 Option 3 Treatment Costs - Cathode Ray Tubes 9-13
9-4 Plant Monitoring Costs for Organics 9-16
IX
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EXECUTIVE SUMMARY
CONCLUSIONS
A study of the Electrical and Electronic Components Industrial
Point Source Category Phase II was undertaken to establish
discharge limitations guidelines and standards. The industry was
subcategorized into segments based on product type. Of the three
subcategories, one has been excluded under Paragraph 8 of the
NRDC Consent Decree, and for two subcategories, regulations are
being promulgated. The two subcategories are Cathode Ray Tubes
and Luminescent Materials. The Agency is not regulating existing
direct dischargers for the reasons described in Section VI of
this document. Therefore, BPT, BAT, and BCT effluent limitations
are not being promulgated.
In the Cathode Ray Tube Subcategory the pollutants of concern
include cadmium, chromium, lead, zinc, toxic organics, fluoride,
and total suspended solids. Cadmium and Zinc are the major toxic
metals found in phosphors in cathode ray tubes. Sources of these
metals are manufacture, salvage, and phosphor recovery
operations. Chromium occurs as dichromate in photosensitive
materials and is found in wastewater from manufacture and salvage
operations. Lead is found in the wastewater from the tube
salvage operation where the lead frit is dissolved in nitric
acid. Toxic organics occur from the use of solvents in cleaning
and degreasing operations. The major source of fluoride is the
use of hydrofluoric acid for cleaning and conditioning glass
surfaces. Finally, total suspended solids result primarily from
the use of graphite emulsions used to coat the tubes.
For the Luminescent Materials Subcategory the pollutants of
concern include cadmium, antimony, zinc, fluoride, and total
suspended solids. Cadmium and zinc are major constituents of
blue and green phosphors, and are found in the wastewater from
washing and filtering operations. Antimony is used as an
activator and found in the wastewater from lamp phosphor
manufacture. Fluoride results from the manufacture of an
intermediate lamp phosphor, calcium fluoride. Total suspended
solids occur in wastes from washing and filtration operations.
Several treatment control technologies applicable to the
reduction of pollutants generated by the manufacture of cathode
ray tubes and luminescent materials were evaluated, and the costs
of these technologies were estimated. Pollutant concentrations
achievable through the implementation of these technologies were
based on industry data. These concentrations are presented below
as standards for the Cathode Ray Tubes and Luminescent Materials
Subcategories.
EFFLUENT LIMITATIONS AND STANDARDS
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Tables 1 through 5 present regulations for New Source Performance
Standards (NSPS), and Pretreatrnent Standards for New and Existing
Sources (PSNS and PSES). All standards are expressed as
milligrams per liter.
TABLE 1: PSES REGULATIONS FOR CATHODE RAY TUBES
Daily Maximum Monthly Average
Pollutant (mq/1) (mq/1)
Cadmium 0.06 0.03
Chromium 0.65 0.30
Lead 1.12 0.41
Zinc 1.38 0.56
TTO 1.58
Fluoride 35.0 18.0
TABLE 2: NSPS REGULATIONS FOR CATHODE RAY TUBES
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
TSS
PH
Daily Maximum
(mq/1)
0.06
0.56
0.72
0.80
1 .58
35.0
46.0
Monthly Average
(mq/1)
0.03
0.26
0.27
0.33
18.0
24.0
pH Ranqe
6-9
TABLE 3: PSNS REGULATIONS FOR CATHODE RAY TUBES
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
Daily Maximum
(mq/1)
0.06
0.36
0.72
0.80
1 .58
35.0
Monthly Average
(mq/1)
0.03
0.26
0.27
0.33-
18.0
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TABLE 4: NSPS REGULATIONS FOR LUMINESCENT MATERIALS
Daily Maximum Monthly Average
Pollutant (mg/1) (mg/1) pH Range
Cadmium
Antimony
Zinc
Fluoride
TSS
pH
0.55
0. 10
1 .64
35.0
60.0
0.26
0.04
0.67
18.0
31 .0
6-9
TABLE 5: PSNS REGULATIONS FOR LUMINESCENT MATERIALS
Daily Maximum Monthly Average
Pollutant (mg/1) (mq/1)
Cadmium 0.55 0.26
Antimony 0.10 0.04
Zinc 1.64 0.67
Fluoride 35.0 18.0
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SECTION 1
INTRODUCTION
The purpose of this document is to present the findings of the
EPA Phase 2 study of the Electrical and Electronic Components
(E&EC) Point Source Category. The Phase 2 study examines the
Electron Tubes and Luminescent Materials (Phosphorescent
Coatings) subcategories of E&EC, the two subcategories which were
previously deferred from regulatory analysis. (EPA 440/1-82/075b
July 1982.)1 The document (1) explains subcategories and
pollutants are regulated and which are not; (2) discusses the
reasons; and (3) explains how the actual limitations were
developed. Section 1 describes the organization of the document
and reviews the sources of industry data that were used to
provide technical background for the limitations.
1.1 ORGANIZATION AND CONTENT OF THIS DOCUMENT
Data provided by industry are used throughout this report in
support of regulating subcategories or excluding subcategories
from regulation under Paragraph 8 of the NRDC Consent Decree.
Telephone contacts, the literature, and plant visits provided the
information used to subcategorize the industry in Section 3.
These data were also considered in characterizing the industry in
Section 4, Description of the Industry.
Water use and wastewater characteristics in each subcategory are
described in Section 5 in terms of flow and pollutant
concentration. Subcategories to be regulated or excluded are
found in Section 6. The discussion in that section identifies
and describes the pollutants to be regulated and presents the
rationale for subcategory and pollutant exclusion. Section 7
describes the appropriate treatment and control technologies
available. The regulatory limits and the bases for these
limitations are presented in Section 8. Section 9 estimates the
capital and operating costs for the treatment technologies used
as the bases for limitations.
1.2 SOURCES OF INDUSTRY DATA
Data on the two subcategories were gathered from literature
studies, contacts with EPA regional offices, from plant surveys
xFor reasons outlined in section 3.2, EPA has determined that the
Electron Tube subcategory should be divided into Cathode Ray
Tubes (CRT), and Receiving and Transmitting Tubes (RTT)
subcategories. RTT operations do not discharge wastewaters, thus
this document describes effluent limits only for CRT and
Luminescent Materials subcategories.
1-1
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and evaluations, and through contacting waste treatment equipment
manufacturers. These data sources are discussed below.
Published literature in the form of books, reports, papers,
periodicals, promotional materials, Dunn and Bradstreet surveys,
and Department of Commerce Statistics was examined. The
researched material included product descriptions and uses,
manufacturing processes, raw materials consumed, waste treatment
technology, and the general characteristics of plants in the two
subcategories including number of plants, employment levels, and
production levels when available.
All 10 EPA regional offices were telephoned for assistance in
identifying plants in their respective regions.
Three types of data collection were used to supplement available
information pertaining to facilities in the E&EC category.
First, more than 150 plants were contacted by phone or letter to
obtain basic information regarding products, manufacturing
processes, wastewater generation, and waste treatment. Second,
based on this information, eleven plants were visited to view
their operations and discuss their products, manufacturing
processes, water use, and wastewater treatment. Third, six
plants were selected for sampling visits to determine the
pollutant characteristics of their wastewater.
The sampling program at each plant consisted of up to three days
of sampling. Prior to any sampling visit, all available data,
such as layouts and diagrams of the selected plant's production
processes and waste treatment facilities, were reviewed. In most
cases, a visit to the plant was made prior to the actual sampling
visit to finalize the sampling approach.
Representative sample points were then selected. Finally, before
the visit was conducted, a detailed sampling plan showing the
selected sample points and all pertinent seimple data to be
obtained was presented and reviewed.
Various manufacturers of wastewater treatment equipment were
contacted by phone or were visited to obtain cost and performance
data on specific technologies. Information collected was based
both on manufacturers' research and on actual operation.
1-2
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SECTION 2
LEGAL BACKGROUND
2.1 PURPOSE AND AUTHORITY
The Federal Water Pollution Control Act Amendments of 1972
established a comprehensive program to "restore and maintain the
chemical, physical, and biological integrity of the Nation's
waters," Section 101(a). Section 301(b)(l)(A) set a deadline of
July 1, 1977, for existing industrial dischargers to achieve
"effluent limitations requiring the application of the best
practicable control technology currently available" (BPT).
Section 301(b)(2)(A) set a deadline of July 1, 1983, for these
dischargers to achieve "effluent limitations requiring the
application of the best available technology economically
achievable (BAT), which will result in reasonable further
progress toward the national goal of eliminating the discharge of
all pollutants."
Section 306 required that new industrial direct dischargers
comply with new source performance standards (NSPS), based on
best available demonstrated technology. Sections 307(b) and (c)
of the Act required pretreatment standards for new and existing
dischargers to publicly owned treatment works (POTW). While the
requirements for direct dischargers were to be incorporated into
National Pollutants Discharge Elimination System (NPDES) permits
issued under Section 402, the Act made pretreatment standards
enforceable directly against dischargers to POTWs (indirect
dischargers).
Section 402(a)(l) of the 1972 Act does allow requirements to be
set case-by-case. However, Congress intended control
requirements to be based, for the most part, on regulations
promulgated by the Administrator of EPA. Section 304(b) required
regulations for NSPS. Sections 304(f), 307(b), and 307(c)
required regulations for pretreatment standards. In addition to
these regulations for designated industry categories, Section
307(a) required the Administrator to promulgate effluent
standards applicable to all dischargers of toxic pollutants.
Finally, Section 501(a) authorized the Administrator to prescribe
any additional regulations "necessary to carry out his functions"
under the Act.
The EPA was unable to promulgate many of these regulations by the
deadlines contained in the Act, and as a result, in 1976, EPA was
sued by several environmental groups. In settling this lawsuit,
EPA and the plaintiffs executed a "Settlement Agreement" which
was approved by the Court. This agreement required EPA to
develop a program and meet a schedule for controlling 65
"priority" pollutants and classes of pollutants. In carrying out
2-1
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this program, EPA must
guidelines, pretreatment
standards for 21 major
Defense Council, Inc. v,
promulgate
standards,
industries.
Train, 8
modified, 12 ERC 1833 (D.D.C. 1979))
BAT effluent limitations
and new source performance
(See Natural Resources
ERC 2120 (D.D.C. 1976),
Several of the basic elements of the Settlement Agreement program
were incorporated into the Clean Water Act of 1977. This law
made several important changes in the Federal Water pollution
control program. Sections 301(b)(2)(A) and 301(b)(2)(C) of the
Act now set July 1, 1984, as the deadline for industries to
achieve effluent limitations requiring application of BAT for
"toxic" pollutants. "Toxic" pollutants here included the 65
"priority" pollutants and classes of pollutants that Congress
declared "toxic" under Section 307(a) of the Act.
EPA's programs for new source performance standards and
pretreatment standards are now aimed principally at controlling
toxic pollutants. To strengthen the toxics control program,
Section 304 (e) of the Act. authorizes the Administrator to
prescribe "best management practices" (BMPs). These BMPs are to
prevent the release of toxic and hazardous pollutants from: (1)
plant site runoff, (2) spillage or leaks, (3) sludge or waste
disposal, and (4) drainage from raw material storage if any of
these events are associated with, or ancillary to, the
manufacturing or treatment process.
In keeping with its emphasis on toxic pollutants, the Clean Water
Act of 1977 also revises the control program for non-toxic
pollutants. For "conventional" pollutants identified under
Section 304(a)(4) (including biochemical oxygen demand, suspended
solids, fecal coliform, and pH), the new Section 301(b)(2)(E)
requires "effluent limitations requiring the application of the
best conventional pollutant control technology" (BCT) instead of
BATto be achieved by July 1, 1984. The factors considered in
assessing BCT for an industry include the relationship between
the cost of attaining a reduction in effluents and the effluent
reduction benefits attained, and a comparison of the cost and
level of reduction of such pollutants by publicly owned treatment
works and industrial sources. For those pollutants that are
neither "toxic" pollutants nor "conventional" pollutants,
Sections 301(b)(2)(A) and (b)(2)(F) require achievement of BAT
effluent limitations within three years after their establishment
or July 1, 1984, whichever is later, but not later than July 1,
1987.
The purpose of this regulation is to establish NSPS, PSES,
PSNS for the final two subcategories of the Electrical
Electronic Components Point Source Category.
2.2 GENERAL CRITERIA FOR EFFLUENT LIMITATIONS
2.2.1 BPT Effluent Limitations
and
and
2-2
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The factors considered in defining best practicable control
technology currently available (BPT) include: (1) the total cost
of applying the technology relative to the effluent reductions
that result, (2) the age of equipment and facilities involved,
(3) the processes used, (4) engineering aspects of the control
technology, (5) process changes, (6) non-water quality
environmental impacts (including energy requirements), (7) and
other factors as the Administrator considers appropriate. In
general, the BPT level represents the average of the best
existing performances of plants within the industry of various
ages, sizes, processes, or other common characteristics. When
existing performance is uniformly inadequate, BPT may be
transferred from a different subcategory or category. BPT
focuses on end-of-process treatment rather than process changes
or internal controls, except when these technologies are common
industry practice.
The cost/benefit inquiry for BPT is a limited balancing,
committed to EPA's discretion, which does not require the Agency
to quantify benefits in monetary terms. See, e.g., American Iron
and Steel Institute v. EPA, 526 F.2d 1027 (3rd Cir. 1975). In
balancing costs against the benefits of effluent reduction, EPA
considers the volume and nature of existing discharges, the
volume and nature of discharges expected after application of
BPT, the general environmental effects of the pollutants, and the
cost and economic impacts of the required level of pollution
control. The Act does not require or permit consideration of
water quality problems attributable to particular point sources
or water quality improvements in particular bodies of water.
Therefore, EPA has not considered these factors. See
Weyerhaeuser Company v. Costle, 590 F.2d 1011 (D.C. Cir. 1978);
Applachian Power Company et al. v. U.S.E.P.A. (D.C. Cir., Feb.
8, 1972).
2.2.2 BAT Effluent Limitations
The factors considered in defining best available technology
economically achievable (BAT) include the age of equipment and
facilities involved, the processes used, process changes, and
engineering aspects of the technology process changes, non-water
quality environmental impacts (including energy requirements) and
the costs of applying such technology (Section 304(b)(2)(B). At
a minimum, the BAT level represents the best economically
achievable performance of plants of various ages, sizes,
processes, or other shared characteristics. As with BPT,
uniformly inadequate performance within a category or subcategory
may require transfer of BAT from a different subcategory or
category. Unlike BPT, however, BAT may include process changes
or internal controls, even when these technologies are not common
industry practice.
The statutory assessment of BAT "considers" costs, but does not
require a balancing of costs against effluent reduction benefits
2-3
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(see Weyerhaeuser v. Costle, siip_ra_). In developing the proposed
BAT, however, EPA has gi/en substantial weight to the
reasonableness of costs. The Agoncy has considered the volume
and nature of discharges, the volume and nature of discharges
expected after application of BAT, the general environmental
effects of the pollutants, and the costs and economic impacts of
the required pollution control levels. Despite this expanded
consideration of costs, the primary factor for determining BAT is
the effluent reduction capability of the control technology. The
Clean Water Act of 1977 establishes the achievement of BAT as the
principal national means of controlling toxic water pollution
from direct discharging plants.
2.2.3 BCT Effluent Limitations
The 1977 Amendments added Section 301(b)(2)(E) to the Act
establishing "best conventional pollutant control technology"
(BCT) for discharges of conventional pollutants from existing
industrial point sources. Conventional pollutants are those
defined in Section 304(a)(4) [biological oxygen demanding
pollutants (BOD), total suspended solids (TSS), fecal coliform,
and pH], and any additional pollutants defined by the
Administrator as "conventional" oil and grease, 44 FR 44501, July
30, 1979.
BCT is not an additional limitation but replaces BAT for the
control of conventional pollutants. In addition to other factors
specified in Section 304(b)(4)(B), the Act requires that BCT
limitations be assessed in light of a two-part "cost
reasonableness" test (American Paper Institute v. EPA, 660 F.2d
954 (4th Cir. 1981)). The first test compares the costs for
private industry to reduce its conventional pollutants with the
costs to publicly owned treatment works for similar levels of
reduction in their discharge of these pollutants. The second
test examines the cost-effectiveness of additional industrial
treatment beyond BPT. EPA must find that limitations are
"reasonable" under both tests before establishing them as BCT.
In no case may BCT be less stringent than BPT.
2.2.4 New Source Performance Standards
The basis for new source performance standards (NSPS) under
Section 306 of the Act is the best available demonstrated
technology. New plants have the opportunity to design the best
and most efficient processes and wastewater treatment
technologies. Therefore, Congress directed EPA to consider the
best demonstrated process changes, in-plant controls, and end-of-
process treatment technologies that reduce pollution to the
maximum extent feasible.
2.2.5 Pretreatment Standards for Existing Sources
2-4
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Section 307(b) of the Act requires EPA to promulgate pretreatment
standards for existing sources (PSES) which industry must achieve
within three years ot promulgation. PSES are designed to prevent
the discharge of pollutants that pass through, interfere with, or
are otherwise incompatible with the operation of POTWs.
The legislative history of the 1977 Act indicates that
pretreatment standards are to be technology-based, analogous to
the best available technology for removal of toxic pollutants.
Thus this document assesses BAT equivalent PSES. The General
Pretreatment Regulations which serve as the framework for the
proposed pretreatment standards are in 40 CRF Part 403, 46 FR
9404 (January 28, 1981 ).
EPA has generally determined that there is pass-through of
pollutants if the percent of pollutants removed by a
well-operated POTW achieving secondary treatment is less than the
percent removal by the best available technology (BAT) model
treatment system.
A study of 40 well-operated POTWs with biological treatment and
meeting the secondary treatment criteria showed that the toxic
metals regulated by this regulation (cadmium, chromium, antimony,
lead, and zinc) are typically removed at rates varying from 20 to
70 percent. POTWs with only primary treatment have even lower
rates of removal. In contrast to POTWs, BAT level treatment by
sources in this industrial category can remove these metals at
rates of approximately 96 percent or more. Accordingly, these
metals "pass-through" POTWs.
The same POTW study indicates that one-fourth of well-operated
POTWs with secondary treatment achieved removals of less than 40
percent for chloroform, less than 85 percent for
1,1,1-trichloroethane, less than 29 percent for methylene
chloride, less than 34 percent for bis(2-ethylhexyl) pthhalate,
less than 88 percent for toluene, and less than 87 percent for
trichloroethylene. By comparison, sound solvent management
practices achieve a TTO reduction of greater than 99 percent.
Accordingly, pass-through of toxic organic pollutants does occur.
There is no significant removal of fluoride by typical POTW
treatment systems, while BAT level treatment consisting of
precipitation/clarification has been whown to remove as much as
95 percent from these waste streams. Thus, pass-through of
fluoride does occur.
2.2.6 Pretreatment Standards for New Sources
Section 307(c) of the Act requires EPA to promulgate pretreatment
standards for new sources (PSNS) at the same time that it
promulgates NSPS. These standards are intended to prevent the
discharge of pollutants which pass through, interfere with, or
are otherwise incompatible with a POTW. New indirect
2-5
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dischargers, like new direct dischargers, have the opportunity to
incorporate the best available demonstrated technologies
including process changes, in-plant controls, and end-of-process
treatment technologiesand to select plant sites that ensure the
treatment system will be adequately installed. Therefore, the
Agency sets PSNS after considering the same criteria considered
for NSPS.
2-6
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SECTION 3
INDUSTRY SUBCATEGORIZATION
3.1 RATIONALE FOR SUBCATEGORIZATION
The primary purpose of industrial categorization is to provide
groupings within an industry so that each group has a uniform set
of discharge limitations. After the Agency has obtained
wastewater data and process information from facilities within an
industry or industrial segment, a number of factors are
considered to determine if subcategorization is appropriate.
These factors include raw materials, final products,
manufacturing processes, geographical location, plant size and
age, wastewater characteristics, non-water quality environmental
impacts, treatment costs, energy costs, and solid waste
generation.
3.2 SUBCATEGORIZATION REVIEW
A preliminary review of each of these factors revealed that
product type is the principal factor affecting the wastewater
characteristics in the Electrical and Electronic Components
industrial category. This is demonstrated by a comparison of
pollutants found in plant effluent with the products made at
those plants. Luminescent Materials (Phosphorescent Coatings)
and Electron Tubes were identified as two of the twenty-one (21)
subcategories comprising the E&EC category.
Under this study, further review of the same factors revealed
that the Electron Tube Subcategory was comprised of two distinct
product types employing different raw materials and manufacturing
processes. The products included in the Electron Tube
Subcategory are (1) cathode ray tubes, and (2) receiving tubes
and transmitting tubes. The production of receiving and
transmitting tubes uses similar raw materials and manufacturing
processes. Cathode ray tube manufacture, however, employs unique
raw materials and process operations which generate wastes
greatly different from those encountered in the manufacture of
receiving and transmitting tubes.
3.3 CONCLUSIONS
Based on the review of subcategorization factors, the following
subcategories were established under this study and are addressed
as such in this document.
Cathode Ray Tubes
Receiving and Transmitting Tubes (dry process)
Luminescent Materials
3-1
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SECTION 4
DESCRIPTION OF THE INDUSTRY
This section provides a general description of the subcategories
presented in the previous section. It includes a discussion of
the number of plants and production capacity, product lines, and
manufacturing processes including raw materials used.
4.1 CATHODE RAY TUBES
The Cathode Ray Tube Subcategory includes plants which discharge
wastewater from the production of electronic devices in which
high velocity electrons are focused through a vacuum to generate
an image on a luminescent (or phosphorescent) surface. Products
are classified under the Standard Industrial Classification (SIC)
3671. The Cathode Ray Tube (CRT) Subcategory's products are
comprised of two CRT types:
o Aperture Mask Tubes which are cathode ray tubes that
contain multiple color phosphors and use an aperture
(shadow) mask. This type of tube will be referred to
as a color television picture tube.
o Cathode ray tubes that contain a single phosphor and
no aperture mask. This type of tube will be referred
to as a single phosphor tube.
4.1.1 Number of Plants and Production Capacity
Results of an extensive telephone survey to companies classified
under SIC Code 3671 indicated that an estimated 24 plants are
involved in the manufacturing of cathode ray tubes.
Seven plants produce color television picture tubes with a total
production of approximately 12.5 million tubes per year and an
average plant production of 1.78 million tubes per year. It is
estimated that 12,000 production employees are engaged in color
television picture tube manufacturing. Only one of the seven
manufacturers is a direct discharger. In addition, several
rebuilders of color television picture tubes exist, but because
there is no phosphor removal or reapplication, the rebuilding
process is of little concern under this study.
Fifteen plants manufacture single phosphor tubes with an
estimated 3,000 employees engaged in production. No single
phosphor tube manufacturers are known to be direct dischargers.
4.1.2 Product Description
Cathode ray tubes are devices in which electrons are conducted
between electrodes through a vacuum within a gas tight glass
4-1
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envelope. Cathode ray tubes depend upon three basic phenomena
for their operation. The first is the emission of electrons by
certain elements and compounds when the energy of the surface
atoms is raised. The second phenomenon is the control of the
movement of these electrons by the force exerted upon them by
electrostatic and electrodynamic forces. The third is the
luminescent properties of the phosphors when excited by
electrons. The two types of cathode ray tubes which are to be
discussed in this section are described below:
o Color television picture tubes function by the
horizontal scanning of high velocity electrons striking
a luminescent surface. The number of electrons in the
stream at any instant of time is varied by electrical
impulses corresponding to the transmitteed signal. A
typical color television picture tube is shown in
Figure 4-1.
The tube is a large glass envelope. A special
composition of glass is used to minimize optical
defects and to provide electrical insulation for high
voltages. The structural design of the glass bulb is
made to withstand 3 to 6 times the force of atmospheric
pressure. The light-emitting screen is made up of
small elemental areas, each capable of emitting light
in one of the three primary colors (red, green, blue).
An electron gun for each color produces a stream of
high velocity electrons which is aimed and focused by
static and dynamic convergence mechanisms and an
electro-magnetic deflection yoke. An aperture mask
behind the face of the screen allows phosphor
excitation according to incident beam direction.
Commercially available color television tubes are
manufactured in a number of sizes. These tubes are
used in color television sets, arcade games, and
computer display terminals.
o Single phosphor tubes are similar to color television
picture tubes in most respects. They generate images
by focusing electrons onto a luminescent screen in a
pattern controlled by the electrostatic and
electrodynamic forces applied to the tube.. The major
difference is that the light emitting screen is
composed of a single phosphor, and a single beam
electron gun is used for phosphor excitation. In
addition, the tube does not contain an aperture mask
for electron beam control.
Single phosphor tubes are manufactured in a variety of
sizes but are generally smaller in size than color
television picture tubes. They usually range from 2 to
12 inches in diameter. Single phosphor tubes are
manufactured for usage i.n display systems such as word
4-2
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phosphor dots
on screen
blue beam
three electron beams
special glass bulb
static and dynamic
convergence of
three electron
beams (magnetic)
base
connections
three
electron
guns
electromagnetic
deflection yoke
high-voltage contact
fluorescent light-emitting
three-color screen
(with aluminum
mirror backing)
FIGURE 4- 1
COLOR TELEVISION PICTURE TUBE
4-3
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processors, computer systems, arcade video games,
specialized military units, medical and other
electronic testing and monitoring equipment such as
oscilloscopes.
4.1.3 Manufacturing Processes and Materials
The manufacturing processes and materials used for cathode ray
tube production are described in the following paragraphs. Each
type of cathode ray tube with its associated manufacturing
operations is discussed separately because production processes
differ.
Color Television Picture Tubes The manufacture of a color
television picture tube is a highly complex, often automated
process as depicted in Figure 4-2. The tubes are composed of
four major components: the glass panel, steel aperture mask,
glass funnel, and the electron gun mount assembly. The glass
panel is the front of the picture tube through which the picture
is viewed. The steel aperture (shadow) mask is used to
selectively shadow the phosphor from the electron beam as the
beam horizontally scans the phosphor-coated glass panel. The
glass funnel is the casing which extends back from the glass
panel and is the largest component of the picture tube. The
mount assembly is attached to the funnel and contains the
electron gun and the electrical base connections.
Manufacture of a color television picture tube begins with an
aperture mask degrease. The aperture masks, often produced at
other facilities, are received by the color television picture
tube manufacturer, formed to size, degreased, and oxidized.
Common degreasing agents used are methylene chloride,
trichloroethylene, methanol, acetone, isopropanol, and alkaline
cleaning. The aperture masks are inserted within the glass panel
which is commonly then referred to as a panel-mask "mate". The
panel-mask mate is annealed and the mask is removed.
The glass panels proceed to panel wash. Panel wash includes
several hydrofluoric-sulfuric acid glass washes and subsequent
water rinses. The panels are then sent to photoresist
application. The photoresist commonly contains dichromate, an
alcohol, and other materials considered proprietary. The glass
panels are coated with a photoresist and the masks are mated to
the panel. The panel is then exposed to light through the mask.
The mask is removed and the panel is developed, graphite-coated,
re-developed and cleaned with a hydrofluoric-sulfuric acid
solution. The panel at this point has a multitude of clear dots
onto which the phosphors will be deposited. Presently, several
manufacturers are using vertical lines as an alternative to dots.
The panels then proceed to phosphor application.
Many proprietary processes have been observed in applying the
phosphors. Generally, the panels first undergo another
4-4
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Aperture Masks
PANEL WASH
Glass Panels
4
Panel and
Mask Mate
Mask
Degrease
\
^
<
Mask
PHOTORESISTANT
APPLICATION
PICTURE TUBF RECLAIM
Spent
Picture Tubes
Panel-Funnel 1
Defrit t
w
Rejected.
Panels
PHOSPHOR \,
APPLICATION '
Light
Exposure
N!' v
Phosphor
Application
\]/
Panel and
Mask Mate
\i/
Light
Exposure
\L/
Lacquer
Coat
\k
Aluminize
V
Panel and
Mask Mate
V
Panel
Clean
V
Shield
Attachment
\1/
Pariel-Funnel
Fusion
Mask^ X/ \|/
N
_^
N
Electron Shielc
Shield
Degrease
f' ^
Panel -Mask x. Funnel
Separation ^ Clean
4^ ^
^s. Panel j^ ^j Mask ^
\l v v
\/
Return to
Picture Tube Manufacture
1 Glass Funnels
is - > "wash" ' >
Electron Gun
Graphite J
M^,nn1- 1
\j/ Assemble
Lead Frit v/
^C S Clean 1
Figure 4-2
TELEVISION PICTURE TUBE MANUFACTURE
-- = Denotes Water Flov Path
4-5
-------
photoresist application. Each of the three color phosphors is
then applied similarly. The phosphor is applied to the panel as
a slurry or as a powder, the mask is attached, the phosphor is
exposed to light through the mask, the mask is removed and the
unexposed phosphor is washed away. After application of the
three phosphors, toluene-based lacquer and silicate coatings may
be applied to seal the phosphors, aluminum is vacuum-deposited to
enhance reflection, the massk is mated with the panel, and the
panel is cleaned.
Glass funnels are cleaned and coated with graphite to prevent
reflection within the tube. Electron shields are degreased and
attached to the panel. Panel-mask assemblies and glass funnels
are then joined together using a heat-fused lead frit, followed
by annealing. The electron gun mount is cleaned, aged, and heat
sealed to the base of the funnel. At this stage the assembled
panel, funnel, and mount are termed a "bulb." The bulb is
exhausted, sealed, and aged by applying current to the cathode.
The tube is tested, an external graphite coating is applied, and
an implosion band is secured to the tube. The tube is retested
before shipment to facilities that assemble television sets.
Panels may be rejected upon inspection at many points along the
manufacturing process. If rejected, panels may be sent back to
the panel wash at the beginning of the manufacturing sequence.
In addition, there is a picture tube salvage operation to reclaim
spent or rejected picture tubes. Salvage operation processes
include a panel-funnel acid defrit, acid cleaning of panels and
funnels, and cleaning of aperture masks. These reclaimed
components are returned to the process for reuse. Electron guns
are usually discarded.
Wastewater producing operations for manufacture of television
picture tubes are unique and sizeable. Process wastewater
sources include both bath dumps and subsequent rinsing associated
with: glass panel wash, aperture mask degrease, photoresist
application, phosphor application, glass funnel and mount
cleaning, and tube salvage.
Single Phosphor Tubes Single phosphor tubes have several
manufacturing processes that differ from color television picture
tube manufacturing (Figure 4-3). The tube is usually composed of
a single glass bulb; only a small percentage of the tubes
manufactured have a separate panel and funnel connected by a heat
fused lead frit.
The one piece tube manufacturing requires no mask and no
photoresist application. The single phosphor is contained within
an aqueous settling solution that is poured into the glass bulb
and allowed to settle onto the face of the bulb. After a
sufficient time the remaining settling solution is decanted off
and a toluene-based lacquer is applied to seal the phosphor.
4-6
-------
Glass Bulb
Wash
Phosphor
Application
V
Lacquer
Coat
V
Aluminize
V
Attach Mount
Assembly
V
Exhaust
& Seal
Age &
Test
V
External
Coat
V
Test &
Ship
Spent CRT
Electron Gun
Remova1
Electron Gun
Parts Recycle
V
Glass Bulb
Wash
Glass Bulb
Disposal
Electron Gun
= Denotes Water
Flow Path
Figure 4-3
CRT MANUFACTURE
4-7
-------
In some cases where the bulb face needs a special application,
such as reference lines for an oscilloscope, a separate panel and
funnel are used. A photoresist and mask are used for applying
the reference lines on the panel and then the single phosphor is
applied in the same method as a one piece bulb using a settling
solution that contains potassium silicate and usually an
electrolyte.
In addition, there may or may not be a cathode ray tube salvage
operation. The tube salvage is usually comprised of the removal
of the electron gun by cutting the tube at the gun mount and
recycling parts of the gun. The remaining glass tube is then
discarded. At some facilities the tube is washed to remove the
phosphor before disposal.
The decant from the settling solution and the wash from phosphor
removal are usually the main sources of wastewater in single
phosphor tube manufacturing.
4.2 RECEIVING AND TRANSMITTING TUBES
The Receiving and Transmitting Tube Subcategory includes
electronic devices in which conduction of electrons takes place
through a vacuum or a gaseous medium within a sealed glass,
quartz, metal or ceramic casing. Products are classified under
the Standard Industrial Classifications (SIC) 3(571, 3673.
4.2.1 Number of Plants and Production Capacity
Results of an extensive telephone survey to companies classified
under the above SIC Codes indicated that an estimated 23 major
plants are involved in the manufacturing of receiving and
transmitting tubes with an estimated 10,000 employees engaged in
production. Several small receiving and transmitting tube
manufacturers probably exist.
4.2.2 Product Description
Receiving and transmitting tubes conduct electrons or ions
between electrodes through a vacuum or ionized gas such as neon,
argon or krypton, which is within a gas-tight casing of glass,
quartz, ceramic, or metal. Their operation is based on the
emission of electrons by certain elements and compounds when the
energy of the surface atoms is raised by the addition of heat,
light photons, kinetic energy of bombarding particles, or
potential energy. The operation also depends on the control of
the movement of these electrons by the force exerted upon them by
electric and magnetic fields.
o Receiving tubes are multiterminal devices that conduct
electricity more easily in one direction than in the
other and are noted for their low voltage and low power
applications (Figure 4-4). They are used to control or
4-8
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Exhaust tip
Get
Screen grid
Suppressor grid
Glass-metal seal
spacer
Control grid
Cathode
Anode
Base pin
FIGURE 4-4
RECEIVING TUBE
4-9
-------
amplify electrical signals in radio and television
receivers, computers, and sensitive control and
measuring equipment.
Structurally, electron tubes are classified according
to the number of electrodes they contain. The
electrodes are usually made of nickel mounted on a base
penetrated by electrical connections and are
encapsulated in a glass or metal envelope which is
normally evacuated.
Voltage is impressed on the tube normally between the
plate (anode) and the cathode. Because large plate
currents are not required for electron emission,
oxide-coated cathodes are used extensively. A separate
filament heats the cathode which usually consists of a
nickel sleeve coated with oxides such as strontium
oxide or barium oxide. There is no electrical
connection between the cathode and filament causing the
cathode to be heated indirectly.
o Transmitting type electron tubes are characterized by
the use of electrostatic and electromagnetic fields
applied externally to a stream of electrons to amplify
a radio frequency signal. There are several different
types of transmitting tubes such as klystrons,
magnetrons and traveling wave tubes. They generally
are high powered devices operating over a wide
frequency range. They are larger and structurally more
rugged than receiving tubes, and are completely
evacuated. Figure 4-5 is a diagram of a klystron tube,
which is typical of a transmitting type tube. In a
klystron tube, a stream of electrons from a concave
thermionic cathode is focused into a small cylindrical
beam by the converging electrostatic fields between the
anode, cathode, and focusing electrode. The beam
passes through a hole in the anode and enters a
magnetic field parallel to the beam axis. The magnetic
field holds the beam together, overcoming the
electro-static repulsion between electrons. The
electron beam goes through the cavities of the
klystron, emerges from the magnetic field, spreads out
and is stopped in a hollow collector where the
remaining kinetic energy of the electrons is dissipated
as heat.
4.2.3 Manufacturing Processes and Materials
The manufacture of a receiving tube is similar to that of a
transmitting tube and is depicted schematically in Figure 4-6.
Raw materials required for receiving tube manufacture include
glass envelopes, kovar and other specialty metals, tungsten wire,
and copper wire. The metal parts are punched and formed,
4-10
-------
collector
fully bunched
electrons
input
coaxial
transmission
line
high
voltage
supply
spreading
electron beam
magnetic polepiece
output catcher
cavity
output
waveguide
output
couplina iris
antibunch
electron bunch
forming
intermediate
cascade cavity
iron magnet
shell
electomagnet
solenoid coil
input buncher
cavity
anode
converging
election beam
focus electrode
insulating bushing
thermionic cathode
heater filament
heater leads
FIGURE 4-5
TRANSMITTING TUBE
4-11
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Metal Components
Glass Tubes
!ompc
\F
Metal
Form
\
/
Parts
Clean
Electroplate
Tube Mount
Assembly
Weld
Components
Glass Tube
Rinse
Exhaust &
Seal
\L
Glass Tube
Rinse
Age &
Test
Ship
Denotes Water
Flow Path
FIGURE 4-6
RECEIVING TUBE MANUFACTURE
4-12
-------
chemically cleaned, and electroplated with copper, nickel,
chromium, gold, or silver. The iron or nickel cathode is coated
with a getter solution which will be used to absorb gases. The
metal parts are hand assembled into a tube mount assembly. Glass
parts for the tube base are cut and heat treated. Copper
connector pins are sealed in the "glass mount" machine. The
glass mount piece is then heat treated by baking in an oven. The
metal tube mount assembly is then hand welded to the glass mount
piece. The upper glass bulb is rinsed. On a "sealex" machine,
the bulb is evacuated to 10~3 mm of mercury, sealed, and the
glass extensions are cut off. A getter material (usually
magnesium, calcium, sodium, or phosphorus) previously introduced
in the evacuated envelope is flashed. Flashing occurs by
applying an electric current to the electrodes of the tube for
several seconds or by indirect infrared radiation. The getter
material condenses on the inside surface and absorbs (reacts
with) any gas molecules. The result is that the vacuum within
the tube becomes progressively stronger until an equilibrium
value of 10~6 mm is reached. The glass exterior is rinsed and
the completed tube is aged, tested, and packaged.
The manufacture of a typical transmitting tube is presented
schematically in Figure 4-7. Intricately shaped and machined
copper, steel, and ceramic parts are cleaned and rinsed. Some of
these parts are then electroplated using materials such as
copper, gold, and silver. Assembly of the electron tube is
generally a manual operation. The electron tube components
consist of the above-described parts, a tungsten filament, a
glass window, and a glass tube. The components undergo a number
of soldering, brazing, welding, heat treating, and polishing
operations. A significant energy user is the heat treating area
with associated non-contact cooling water. The assembled
electron tube undergoes an extensive series of electrical and
mechanical testing procedures and an aging process before final
shipment. There are specialized types of transmitting type
electron tubes, such as image intensifiers, that are produced in
a manner similar to that described above. However, there are two
wet processes utilized in addition to those depicted in Figure 4-
7. These additional wet processes include alkaline
cleaning/rinsing and alcohol dipping/rinsing of ceramic or glass
envelopes brazed to metal; and acid cleaning of glass tube
bodies. Because these processes are known to exist at only one
facility, they are not included in Figure 4-7 as processes common
to most transmitting type electron tube manufacture.
Process water is used in solutions and rinses associated with
electroplating of anodes, cathodes, and grids. Water is also
used to wash glass and ceramic tube bodies both before and after
seating to the base, or at the conclusion of the manufacturing
process.
Receiving and transmitting electron tube manufacturing processes
produce wastewater discharges primarily through metal finishing
4-13
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Glass
Tube
Y_
Glass
Window
Filament
Metal Components
Metal
Form
\
/
Parts
Clean
Elsctroplate
V
Solder
V
Braze
Weld
V
Anneal
Evacuate
& Seal
Polish
V
Age & Test
V
Ship
Denotes Water
Flow Path
Figure 4-7
TRANSMITTING TUBE MANUFACTURE
4-14
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operations which are covered under the Metal Finishing Category.
A number of ancillary operations such as deionized water
backwash, cooling tower blowdown, and boiler blowdown contribute
sizeable wastewater discharges compared to metal finishing
operations.
In addition, there are some isolated instances of plants
manufacturing specialized transmitting type electron tubes such
as image intensifiers and photomultipliers that require process
water. Alkaline cleaning and acid etching of glass-metal and
ceramic tube components discharge process wastewater as a result
of alkaline and acid bath dumps and their associated water
rinses. These wet processes are similar to several found in
color television picture tube manufacture. There is also a glass
tube rinse (or rinses) which concludes the manufacture of
receiving tubes. Such rinses are intended to remove surface
particulates and dust deposited on the tube body during the
manufacturing process.
4.3 LUMINESCENT MATERIALS
Luminescent materials (phosphors) are those that emit
electromagnetic radiation (light) upon excitation by such energy
sources as photons, electrons, applied voltage, chemical
reactions, or mechanical energy. These luminescent materials are
used for a variety of applications, including fluorescent lamps,
high-pressure mercury vapor lamps, color television picture tubes
and single phosphor tubes, lasers, instrument panels, postage
stamps, laundry whiteners, and specialty paints.
This study is restricted to those materials which are applicable
to the E&EC category, specifically to those used as coatings in
fluorescent lamps and color television picture tubes and single
phosphor tubes.
4.3.1 Number of Plants
A telephone survey of the industry determined that only five
facilities manufacture luminescent materials, and according to
industry personnel, two of these facilities are the major
producers.
Of the five luminescent materials manufacturers, one manufactures
TV phosphors only; three manufacture both lamp and TV phosphors;
and one manufacture only lamp phosphors. At three facilities
wastewater flow from the phosphor operations amount to less than
twenty percent of the total plant flow. Of the five facilities,
one has no discharge, two discharge to a POTW and the remaining
two discharge to surface water.
4.3.2 Product Description
4-15
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The most important fluorescent lamp phosphor is calcium
halophosphate. There are at least 50 types of phosphors used for
cathode ray tubes (television and other video displays).
However, all are similar to or mixes of the three major color
television powders: red, blue, and green. The red phosphor is
yttrium oxide activated with europium; the blue phosphor is zinc
sulfide activated with silver, and the green phosphor is zinc-
cadmium sulfide activated with copper. The major process steps
in producing luminescent materials are reacting, milling, and
firing the raw material; recrystallizing raw materials, if
necessary; and washing, filtering, and drying and intermediate
and final products. The products are then sold and shipped as
powders.
4.3.3 Manufacturing Processes and Materials
Lamp phosphors and TV phosphors with their associated
manufacturing operations are discussed separately because
production processes and raw materials differ. The processes and
materials described were taken from a typical plant; however,
some variations occur between manufacturers. Proprietary
compounds used in process operations are not identified.
Lamp Phosphors Preparation of calcium halophosphate,
Ca5(F,Cl)(P04)3 involves the production of two intermediate
powders and the firing of the combined intermediate powders
(Figure 4-8).
Calcium phosphate intermediate powder is produced by reacting
calcium salts with anions. These raw materials are first
purified and filter pressed separately. The two streams are then
combined to precipitate the soluble calcium. This resultant
material, CaC03. CaHoP4, is subsequently filtered and
recrystallized in heated deionized water for particle size
assurance. The material is then filtered and dried. Liquid
waste originates from washing, filtration (precipitation), wet
scrubber blowdown, and filtration of the recrystallized process
stream.
Calcium fluoride (CaF2) intermediate powder is produced by
reacting calcium hydroxide with nitric acid to make calcium
nitrate solution. This is mixed with ammonium bifluoride
crystals dissolved in water, to precipitate calcium fluoride.
Calcium fluoride is washed by decantation, filtered and dried.
Liquid wastes originate from washing, filtering and scrubber
blowdown.
The intermediate powders are milled together, blended, fired,
washed, filtered and dried to produce calcium halophosphate
phosphor.
TV Phosphors There are three primary TV phosphors currently
being manufactured: red, blue and green. The manufacturing of
4-16
-------
>l
Ammonium
Bifluoride
I Precipitation
V
Filtration
Recrystallization
-^
±
Wet Scrubber
I
Wet
Scrubber
Calcium Carbonate and
Calcium Phosphate
Wet Scrubber
T
Denotes Water
Flow Path
V
V
Calcium Fluoride
Milling & Blending
Firing
Washing
Filtration
V
Drying
V
Screening & Blending
V
Product
FIGURE 4-8
LAMP PHOSPHOR PROCESS
4-17
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both blue and green phosphors requires a two-stage process that
involves the production of an intermediate material and then its
activation and firing. The manufacturing of red phosphor is a
solid state reaction.
Figure 4-9 is a process flow diagram for the production of blue
phosphor, which is primarily a zinc sulfide phosphor activated
with silver (ZnS:Ag). The intermediate material is produced by
dissolving zinc oxide in sulfuric acid. The zinc sulfate
solution is reacted with hydrogen sulfide gas to precipitate zinc
sulfide out of solution. The product is washed, vacuum filtered
and dried. The intermediate powder is blended with the activator
(usually silver), fired, washed, filtered and "dried. Liquid
wastes originate from precipitation, washing, filtration, and
scrubber blowdown.
The green phosphor is produced from zinc-cadmium sulfide that is
activated with copper (Zn(Cd)SrCu). The intermediate material is
produced by dissolving cadmium oxide in sulfuric acid and
deionized water to produce a cadmium sulfate solution. Sulfide
gas and zinc sulfide that was produced in the same method as
described in the blue phosphor, are introduced to the solution.
The precipitate is washed several times and then dried to produce
the cadmium-zinc sullfide intermediate powder. The intermediate
powder is mixed with the activator copper, and fired. The
material is washed, vacuum filtered, and dried to produce the
final product zinc-cadmium phosphor. Liquid wastes originate
from precipitation, washing, filtration, and scrubber blowdown.
The red phosphor is a rare earth phosphor manufactured from
yttrium oxide that is activated with europium (Y203:Eu(III)).
The production is a solid state reaction in which yttrium oxide,
europium oxide and certain salts are blended, fired, washed, and
dried to produce the final red phosphor. Liquid waste originates
from washing and scrubber blowdown.
4-18
-------
Zinc Oxide
Hydrogen
Sulfide gas
V
Sulfuric Acid
Zinc Sulfate solution
\/
Zinc Sulfide
Precipitation
V
Washed
V
Vacuum Filtered
V
Drying
Activator
I
V
Wet
Scrubber
Zinc Sulfide
Intermediate Powder
Fired
Washed
\/
Filtration
Wet
Scrubber
Drying
V
Product
- Denotes Water
Flow Path
FIGURE 4-9
BLUE PHOSPHOR PROCESS
4-19
-------
SECTION 5
WASTEWATER CHARACTERISTICS
This section presents information related to wastewater flows,
wastewater sources, pollutants found, and the sources of these
pollutants for Cathode Ray Tube, Receiving and Transmitting Tube,
and Luminescent Materials Subcategories. A general discussion of
sampling techniques and wastewater analysis is also provided.
5.1 SAMPLING AND ANALYTICAL PROGRAM
Fifty-two plants were contacted to obtain information on the
three subcategories. Thirteen of these plants were visited for
an on-site study of their manufacturing processes, water used and
wastewater treatment. In addition, wastewater samples were
collected at six of the plants visited in order to quantify the
level of pollutants in raw process wastewater and treatment
effluent.
5.1 . 1 Pollutants Analyzed
The chemical pollutants sought in analytical procedures fall into
three groups: conventional, non-conventional, and toxics. The
latter group comprises the 129 chemicals found in the toxic
pollutant list shown in Table 5-1.
Conventional pollutants are those generally treatable by
secondary municipal wastewater treatment. The conventional
pollutants examined for this study are:
pH
Biochemical Oxygen Demand (BOD)
Oil and Grease (O&G)
Total Suspended Solids (TSS)
Non-conventional pollutants are simply those which are neither
conventional nor on the list of toxic pollutants. The non-
conventional pollutants listed below were examined during this
study.
Fluoride Manganese
Total Organic Carbon Vanadium
Total Phenols Boron
Yttrium Barium
Calcium Molybdenum
Magnesium Tin
Aluminum Cobalt
Sodium Iron
Titanium Platinum
Palladium Gold
Tellurium
5-1
-------
TABLE 5-1
TOX.TC POLLUTANTS
TOXIC POLLUTANT ORGANICS
1. Acenaphthene
2. Acrolein
3. Acrylonitrile
4. Benzene
5. Benzidine
6. Carbon Tetrachloride
(Tetrachloromethane)
7. Chlorobenzene
8. 1,2,4-Trichlorobenzene
9. Hexachlorobenzene
10. 1,2-Dichloroethane
11. 1,1,1-Trichloroethane
12. Hexachloroethane
13. 1,1-Dichloroethane
14. 1,1,2-Trichloroethane
15. 1,1,2,2-Tetrachloroethane
16. Chloroethane
18. Bis(2-Chloroethyl)Ether
19. 2-Chloroethyl Vinyl Ether (Mixed)
20. 2-Chloronaphthalene
21. 2,4,6-Trichlorophenol
22. Parachlorometa Cresol
23. Chloroform (Trichloromethane)
24. 2-Chlorophenol
25. 1,2-Dichlorobenzene
26. 1,3-Dichlorobenzene
27. 1,4-Dichlorobenzene
28. 3,3'-Dichlorobenzidine
29. 1,1-Dichloroethylene
30. 1,2-Trans-Dichloroethylene
31. 2,4-Dichlorophenol
32. 1,2-Dichloropropane
33. 1,2-Dichloropropylene
(1,3-Dichloropropene)
34. 2,4-Dimethylphenol
35. 2,4-Dinitrotoluene
36. 2,6-Dinitrotoluene
37. 1,2-Diphenylhydrazine
38. Ethylbenzene
39. Fluoranthene
40. 4-Chlorophenyl Phenyl Ether
41. 4-Bromophenyl Phenyl Ether
42. Bis(2-Chloroisopropyl) Ether
43. Bis(2-Chloroethoxy)Methane
44. Methylene Chloride
45. Methyl Chloride (Chloromethane)
46. Methyl Bromide (Bromomethane)
47. Bromoform (Tribromomethane)
48. Dichlorobromoethane
51. Chlorodibromomethane
52. Hexachlorobutadiene
53. Hexachlorocyclopentadiene
54. Isophorone
55. Naphthalene
56. Nitrobenzene
57. 2-Nitrophenol
58. 4-Nitrophenol
59. 2,4-Dinitrophenol
60. 4,6-Dinitro-O-Cresol
61. N-Nitrosodimethylamine
62. N-Nitrosodiphenylamine
63. N-Nitrosodi-N-Propylamine
64. Pentachlorophenol
65. Phenol
66. Bis(2-ethylhexyl)Phthalate
67. Butyl Benzyl Phthalate
68. Di-N-Butyl Phthalate
69. Di-N-Octyl Phthalate
70. Diethyl Phthalate
71. Dimethyl Phthalate
72. 1,2-Benzanthracene (Benzo(A)Anthracene)
73. Benzo (A) Pyrene (3,4-Benzo-Pyrene)
74. 3,4-Benzofluoranthene (Benzo(B)
(Fluoranthene)
75. 11,12-Benzofluoranthene (Benzo(K)
Fluoranthene)
76. Chrysene
77. Acenaphthylene
78. Anthracene
79. 1,12-Benzoperylene(Benzo(GHI)-Perylene)
80. Fluorene
81. Phenanthrene
82. 1/2/5,6-Dibenzathracene(Dibenzo(A,H)
Anthracene)
83. Ideno(1,2,3-CD)Pyrene(2,3-0-Phenylene
Pyrene)
84. Pyrene
85. Tetrachloroethylene
86. Toluene
87. Trichloroethylene
88. Vinyl Chloride (Chloroethylene)
89. Aldrin
90. Dieldrin
5-2
-------
TABLE 5-1- continued
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.
121.
122.
123.
124.
125.
126.
127.
128.
129.
Chlordane (Technical Mixture and
Metabolites)
4,4'-DDT
4,4'-DDE (P,P'-DDX)
4,4'-DDD (P,P-TDE)
Alpha-Endolsufan
Beta-Endosulfan
Endosulfan Sulfate
Endrin
Endrin Aldehyde
Heptachlor
Heptachlor Epoxide
Alpha-BHC
Beta-BHC
Ganuna-BHC
Delta-BHC
PCB-1242 (Arochlor 1242)
(Arochlor 1254)
(Arochlor 1221)
(Arochlor 1232)
(Arochlor 1248)
(Arochlor 1260)
(Arochlor 1016)
(BHC-Hexachlorocyclohexane)
PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
Toxaphene
Antimony
Arsenic
Asbestos
Beryllium
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
2,3,4,8-Tetrachlorodibenzo-P-Dioxin (TCDD)
5-3
-------
5.1.2 Sampling Methodology
During the initial visit to a facility, a selection was made of
sampling points so as to best, characterize process wastes and
evaluate the efficiency of any wastewater treatment. The nature
of the wastewater flow at each selected sampling point then
determined the method of sampling, i.e., automatic composite or
grab composite. The sampling points were of individual raw waste
streams, or treated effluent.
Each sample was collected whenever possible by an automatic time
series compositor over a single 24-hour sampling period. When
automatic compositing was not possible, grab samples were taken
at intervals over the same period, and were composited manually.
When a sample was taken for analysis of toxic organics, a blank
was also taken to determine the level of contamination inherent
to the sampling and transportation procedures.
Each sample was divided into several portions and preserved, when
necessary, in accordance with established procedures for the
measurement of toxic and classical pollutants. Samples were
shipped in ice-cooled containers by the best available route to
EPA-contracted laboratories for analysis. Chain of custody for
the samples was maintained through the EPA Sample Control Center
tracking forms.
5.1.3 Analytical Methods
The analytical techniques for the identification and quantitation
of toxic pollutants were those described in Sampling and Analysis
Procedures for Screening of Industrial Effluents for Priority
Pollutants, revised in April 1977.
In the laboratory, samples for organic pollutant analysis were
separated by specific extraction procedures into acid (A),
base/neutral (B/N), and pesticide (P) fractions. Volatile
organic samples (V) were taken separately as a series of grab
samples at four-hour intervals and composited in the laboratory.
The analysis of these fractions incorporated the application of
strict quality control techniques including the use of standards,
blanks, and spikes. Gas chromatography and gas
chromatography/mass spectrometry were the analytical procedures
used for the organic pollutants. Two other analytical methods
were used for the measurement of toxic metals: flameless atomic
absorption and inductively coupled argon plasma spectrometric
analysis (ICAP). The metals determined by each method were:
Flameless AA ICAP
Antimony Beryllium
Arsenic Cadmium
Selenium Chromium
Silver Copper
5-4
-------
Thallium Lead
Nickel
Zinc
Mercury was analyzed by a special manual cold-vapor atomic
absorption technique.
For the analysis of conventional and non-conventional pollutants,
procedures described by EPA were followed. The following
conventions were used in quantifying the levels determined by
analysis:
o Pollutants detected at levels below the quantitation
limit are reported as "less than" the quantitation
limit. All other pollutants are reported as the
measured value.
o The tables show data for total toxic organics, toxic
and non-toxic metals, and other pollutants. Total
toxic organics is the sum of all toxic organics found
at concentrations greater than 0.01 mg/1.
o Blank Entries - Entries were left blank when the
parameter was not detected.
5.2 CATHODE RAY TUBES
5.2.1 Wastewater Flow
Presented below is a summary of the quantities of wastewater
generated by the manufacturers of color television picture tubes
and other single phosphor tubes.
Wastewater Discharge (gpd)
Number of Plants Min. Mean Max.
24 <50 132,500 500,000
5.2.2 Wastewater Sources
Process wastewater sources from the manufacture of cathode ray
tubes are sizeable and include wash and rinse operations
associated with: glass panel wash, mask degrease, photoresist
application, phosphor application, glass funnel and mount
cleaning, and tube salvage.
5.2.3 Pollutants Found and the Sources of_ These Pollutants
The major pollutants of concern from the Cathode Ray Tube
Subcategory are:
pH Chromium
5-5
-------
TSS Lead
Fluoride Zinc
Cadmium Toxic Organics
The process steps associated with the sources of these pollutants
are described in Section 4. Table 5-2 summarizes the occurrence
and levels at which these pollutants are found based on the
Agency's sampling and analysis of wastewater from three
television picture tube manufacturing facilities and raw waste
monitoring data provided by plant 99797, Concentrations
represent total raw wastes after flow-proportioning individual
plant streams. Figures 5-1, 5-2, and 5-3 identify sampling
locations, and Tables 5-3, 5-4, and 5-5 summarize analytical data
and wastewater flows obtained from each of the plants sampled.
Raw waste monitoring data from plant 99797 is presented in
Appendix 1.
pH may be very high or very low. High pH results from caustic
cleaning operations. Low pH results from the use of acids for
etching and cleaning operations.
Total Suspended Solids are common in cathode ray tube
manufacture wastewater arid result primarily from graphite
emulsions (DAG) used to coat the inner and outer surfaces of
glass panels and funnels. Sources include both manufacture and
salvage cleaning operations.
Fluoride has as its source the use of hydrofluoric acid for
cleaning and conditioning glass surfaces. Sources of fluoride in
wastewater include both manufacture and salvage operations.
Cadmium and Zinc are the primary toxic metals found in
phosphors used in cathode ray tubes. Sources of these metals in
wastewater include manufacture, salvage, and phosphor recovery
operations.
Chromium occurs as dichrornate in photosensitive materials used
to prepare glass surfaces for phosphor application. Sources of
chromium in wastewater include both manufacture and salvage
operations.
Lead is present in high concentration in the solder or frit
used to fuse glass panels and funnels together. The major source
of lead in wastewater occurs in tube salvage operations when
acids are used to dissolve the frit and to clean the panels and
funnels.
Toxic Organics result from the use of solvents such as
methylene chloride and trichloroethylene for cleaning and
degreasing operations and from toluene-based lacquer coatings
applied as a sealant over phosphor coatings. Only limited
sampling has been conducted for toxic organics in this
subcategory.
5-6
-------
TABLE 5-2
CATHODE RAY TUBE
SUMMARY OF RAW WASTE DATA
PARAMETER
CONCENTRATION, mg/1
MINIMUM MAXIMUM MEAN
TOXIC METALS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium*
119 Chromium*
120 Copper*
122 Lead*
123 Mercury
124 Nickel*
125 Selenium
126 Silver*
127 Thallium
128 Zinc*
0.036
0.149
<0.001
0.041
0.800
0.012
4.04
0.001
0.020
0.001
0.001
0.001
2.610
0.196
0.284
0.005
0.626
2.149
0.715
70.8
0.003
0.203
0.007
0.059
0.001
19.72
0.097
0.207
0.003
0.314
1.350
0.207
24.8
0.002
0.084
0.004
0.019
0.001
9.76
Total Toxic Organics**
Oil and Grease
Biochemical Oxygen Demand
Total Suspended Solids*
Fluoride*
0.030
2.158
0.107
21.01
31.7
0.150
16.0
17
600
970.8
0.085
7.72
7.38
289
318
*Includes raw waste monitoring data provided by Plant 99797
**3 days of sampling at one plant
5-7
-------
SuKurlc
Acid
I
oo
Concentrated
Chroniu
Haste
Concentrated
Lead
Haste
Other Process Hsstewater
Polyelectrolyte And Non-Contact Cooling Hater
Blue
Phosphor
Haste
Phosphor
Haste
-River
To Phosphor Preparation
Figure 5-1
PLANT 30172 SAMPLING LOCATIONS
-------
Tube
Haste
Hydrofluoric
Haste
1
«, .
2
r*
Sodiusi
Carbonate
*
Settling
Tank
SodiuB
Carbonate
Settling ^
Tank »
TREATMENT SYSTEM I
(Settling
Tank
^
Aperture
Panel Has
Settling
Tank
lask And
i Haste
5
e.
*
3
ff\ i
Cartridge
Filtration
Sodiua
Carbonate
t
Settling
Tank
6
CTl
V
|J
Sodiua
Carbonate
TREATMENT SYSTEM II
Other
ProoeM
Naate
Settling
Tank
01
I
Hydrofluoric
Haste
Sodiua
Carbonate
t
Settling
Tank
Hydrofluoric
Acid
Haste
1 3
-e-
TREATMENT SYSTEM III
Red
Haste
Blue
Haste
Green
Haste
Holding
Tank
Holding
Tank
Holding
Tank
li*
(J\ m
ffl ^
ffl -
Settling
Tank
Settling
Tank
Settling
Tank
Centrifugal
Filtration
Centrifugal
Filtration
Centrifugal
Filtration
1 7
/>
W '
1 8
«_
.
1 9
ffi
V
2 0
^
Other Process Hastewater
And Non-Contact Cooling Hater
2 1
Huiicipal
Treatment
System
Figure 5-2
PLANT 11114 SAMPLING LOCATIONS
-------
HC1 NaOH
ACID
STREAM
t_n
I
NaOH
Supply Water
Plant
CAUSTIC STREAM
Lime Slurry
\
Backwash
Stream
HOLDING
LAGOON
MUNlLIFAL,
-^TREATMENT
SYSTEM
FIGURE 5-3
PLANT 99796 SAMPLING LOCATIONS
-------
TABLE 5-3
PICTURE TUBE PROCESS WASTES
Plant 30172
Stream Identification
Sample Number
Flow Rate Litesrs/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
11 1,1,1-Trichloroethane
39 Fluoranthene
44 Methylene chloride
55 Napthalene
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
78 Anthracene
81 Phenanthrene
84 Pyrene
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Cnromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
*Average of three samples.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sod urn
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
PH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Chromium
Reduction
Influent
1*
440/2790
24
mg/1
<0.010
0.058
<0.010
0.490
<0.010
0.460
0.010
<0.010
<0.010
<0.010
0.029
0.010
1.037
<0.005
0.003
0.005
0.001
<0.002
89.07
0.019
0.125
<0.001
0.006
0.004
0.001
0.017
<0.013
2.82
0.70
8.14
0.037
0.006
0.014
0.122
0.03
0.132
0.101
0.042
0.058
0.105
0.005
0.013
7
706
1.17
5.13
33
8
1.27
Lead
Treatment
Influent
2
45/285
24
mg/1
Not
Analyzed
<0.005
0.092
0.250
0.004
1.070
4.670
<0.05
891.
0.001
18.5
<0.020
0.060
0.002
1510.
87.7
30.9
640
12
5.860
0.161
346
205
1.60
3.010
16.8
2.650
1940
0.314
0.01
160
<2.0
11
<1.0
190
Chromium
Reduction
Effluent
3*
440/2794
24
mg/1
Not
Analyzed
<0.005
0.004
0.017
<0.001
<0.002
73.33
0.016
062
<0.001
<0.005
0.011
<0.001
<0.001
0.02
5.820
1.327
79.8
0.073
0.031
0.006
0.144
0.039
0.125
0.091
0.022
0.050
3.870
<0.002
0.013
773.3
0.433
3.1
121
23.7
1.2
5-11
-------
TABLE 5-3
PICTURE TUBE PROCESS WASTES
Plant 30172 - continued
Stream Identification
Sample Number
Flow Rate Li ters/Hr-Gallon/d.ay
Duration Hours/Day
Lead
Treatment
Effluent
4**
127/268
8
mg/1
Primary
Treatment
Influent
5*
12905/81820
24
mg/1
TOXIC ORGANICS
121 Cyanide
Not
Analyzed
<0.005
Not
Analyzed
0.005
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
*Average of three samples.
"Average of two samples.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil t, Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.069
0.009
<0.001
<0.005
0.022
0.042
1.190
<0.001
0.911
0.006
0.002
<0.006
18.7
29.6
17.3
11950
0.628
0.59
0.017
322.5
10.27
0.214
0.249
<0.01
0.308
0.229
0.032
0.045
89.5
78.5
6.85
11
<1
11
0.153
0.121
<0.001
0.171
2.87
0.066
14.17
<0.001
0.074
<0.004
0.0013
<0.001
6.08
82.93
8.32
145.33
3.83
0.044
0.006
8.59
0.771
0.064
0.056
1.683
<0.05
8.56
0.075
<0.01
49.3
340
2.17
12.3
<1
89.3
5-12
-------
TABLE 5-3
PICTURE TUBE PROCESS WASTES
Plant 30172 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
121 Cyanide
Pr iraary
Treatment
Effluent
6**
12500/79252
24
mg/1
Not
Analyzed
<0.005
Filter
Effluent
7*
12905/81820
24
mg/1
Not
Analyzed
<0.01
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Seleni urn
Silver
Thallium
Zinc
0.117
0.009
<0.001
<0.002
0.244
0.015
0.253
<0.001
0.013
<0.005
<0.001
<0.001
0.131
0.120
0.009
<0.001
<0.002
0.208
0.014
0.163
<0.001
0.015
<0.004
<0.001
<0.001
0.075
*Average of three samples.
**Average of two samples.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
322.5
7.05
132.5
0.397
0.007
0.002
1.97
0.166
0.039
<0.025
0.006
<0.05
0.230
<0.002
0.020
35.5
7.1
7.9
297.33
3.0
3.0
306.3
7.81
145
0.301
0.007
<0.001
2.293
0.144
<0.035
0.07
<0.003
<0.05
0. 115
<0.002
0.023
39.67
11.07
7.73
20.67
5.33
3.13
5-13
-------
TABLE 5-4
PICTUKE TUBE PROCESS WASTES
PLANT 11114
Treatment System I
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
Tube Salvage
Waste Influent
1
10674/67700
24
mg/1
HF - HN03
Tube Salvage
Waste Influent
2
426/2700
Batch
mg/1
Mask Panel
Waste Influent
3
11128/70600
24
mg/1
TOXIC ORGANICS
Not
Analyzed
Not
Analyzed
4 Benzene
23 Chloroform
44 Methylene Chloride
55 Nepthalene
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Trichloroethylene
95 Alpha-Endosulfan
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
0.018
0.250
<0.010
tO.010
<0.010
0.020
<0.010
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System I - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
23 Chloroform
44 Methylene Chloride
55 Nepthalene
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Bar ium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
HF - HN03
Tube Salvage
Post Settle
4
473/3000
Batch
mg/1
<0.010
<0.010
0.010
<0.010
0.130
0.010
<0.010
<0.010
<0.010
0.130
0.185
0.335
0.088
<0.005
1.150
0.024
0.066
2.010
0.001
0.858
<0.010
0.004
<0.010
47.800
0.792
2.310
13100.
17.3
0.248
0.018
155.
1.90
0.092
0.071
0.043
0.602
0.923
0.139
0.026
187
6950
25
0
75
Pre-Filtration
5
11147/70700
24
mg/1
Not
Analyzed
0.011
0.055
0.078
<0.005
0.206
0.035
0.030
12.000
<0.001
0.076
<0.010
0.001
<0.001
18.800
8.260
8.300
1170.
7.070
0.023
<0.002
21.20
0.289
<0.036
<0.026
0.358
<0.051
1.600
0.037
0
7
910
6.2
20
12
39
5-15
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System I - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
121 Cyanide
TOXIC INORGANICS
114
115
116
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Post Filtration
6
11147/70700
24
rag/1
Not
Analyzed
0.185
0.046
0.156
<0.005
0.201
0.027
0.015
6.640
<0.001
0.074
0.010
<0.001
<0.001
18.100
Final Effluent
7
22275/141000
24
mg/1
Not
Analyzed
0. 525
0.061
0.064
<0.005
0.370
0.305
0.030
13.800
<0.001
0.111
<0.002
0.002
<0.001
32.800
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Alumi num
Manganese
Vanadium
Boron
Barlum
Molybdenum
Tin
Yttrium
Cobalt
I r on
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
4.420
6.800
1180.
6.790
0.024
<0.001
18.00
0.163
<0.035
<0.025
0.053
<0.050
1
0
0
4
1070
6.0
20
22
22
120
032
8.310
7.730
1200.
7.610
0.048
<0.001
19.40
0.503
< 0 . 0 3 5
<0.025
0.049
< 0 . 0 5 0
2.040
0.:.22
0.034
89
1140
6.1
51
0
80
5-16
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System II
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
Otner Process
Waste Influent
8
17033/108000
24
mg/1
4 Benzene
29 1,1-Dichloroethylene
38 Ethylbenzene
44 Methylene chloride
66 Bis(2-ethylhexyl)phthalate
68 Di-N-butyl phthalate
86 Toluene
87 Tr ichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
126 Thallium
128 Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluoride
CONVENTIONAL POLLUTANTS
PH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
<0.010
<0.010
<0.010
0.020
0.010
<0.010
<0.010
0.030
0.050
Not Analyzed
0.440
0.266
<0.005
0.076
0.025
0.013
2.570
<0.001
0.014
<0.002
<0.001
<0.001
2.130
26.20
8.270
637.
9.830
0.007
0.002
17.700
1.900
0.074
<0.025
0.681
<0.050
1.220
0.453
0
8
1800
2.3
14
0
137
HF - Dump
9
142/900
Batch
mg/1
Not
Analyzed
0.011
27.000
9.000
<0.010
0.975
1.500
0.074
6.820
0.002
0.420
<0.300
0.001
<0.025
10.300
HF Etch
Settle Effluent
10
20439/86400
16
mg/1
Not
Analyzed
0.003
0.005
<0.005
<0.005
5.580
0.127
<0.050
<0.001
0.144
<0.010
0.001
<0.001
0.194
6.220
2.920
5250.
311.
0.540
0.326
862.
5.110
1.840
0.311
0.047
<0.100
22.20
15.20
0.008
24
8400
19.70
7.080
786.
0.121
0.296
<0.001
0.770
0.034
<0.035
<0.025
0.042
<0.050
80
<0.002
0
5
15
17
0
3350
7.7
18
16
178
5-17
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System II - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TOXIC ORGANICS
4 Benzene
44 Methylene chloride
66 Bis(2-ethylhexyl)phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmi um
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Tnallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barlum
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Fluor ide
CONVENTIONAL POLLUTANTS
pH
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Post Filtration
11
17033/10800
24
mg/1
Not
Analyzed
0.440
0.191
<0.005
0.018
0.015
0.016
0.883
<0.001
<0.013
0.004
0.002
<0.001
0.605
6.090
3.340
1810.
9.410
0.003
0.003
17.800
0.616
<0.036
<0.025
0.152
<0.051
0.636
0.313
0
10
4000
6.6
18
11
16
System II
Final
Effluent
12
30659/194000
24
mg/1
Not
Analyzed
0.520
0.079
0.062
<0.005
0.006
3.750
0.100
0.315
<0.001
0.097
<0.010
-------
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System III
Red phosphor
Waste Influent
14
1703/10800
24
mg/1
Blue Phosphor
Waste Influent
15
1703/10800
24
mg/1
Green Phosphor
Influent
16
1703/10800
24
mg/1
TOXIC ORGANICS
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryll ium
Cadmium
Chromi urn
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Not
Analyzed
<0.001
0 .008
<0.005
0.120
3.710
<0.013
<0.050
<0.001
<0.013
<0.010
0.004
<0.001
2.860
Not
Analyzed
0.001
0.002
<0.005
0.756
4.480
<0.013
<0.050
<0.001
<0.013
<0.010
0.360
<0.001
1910
Not
Analyzed
<0.001
0.006
<0.005
184.
4.970
0.240
<0.050
<0.001
<0.013
<0.010
0.005
<0.001
1540.
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
yttrium
Cobalt
Iron
Titanium
0.271
0.496
149.
0.188
<0.001
0.172
0.721
0.012
0.133
0.591
1300.
4.730
<0.001
0.038
5.120
0.794
1280.
1.010
<0.001
<0.001
<0.002
0.151
<0.035
0.111
8.160
<0.050
0.024
<0.002
0.481
<0.049
787.
0.426
<0.001
<0.003
2.390
0.825
«0.069
0.123
0.411
0.293
0.093
<0.004
CONVENTIONAL POLLUTANTS
pH
Total Suspended Solids
5.0
1840
4.0
2560
4.9
2450
5-19
-------
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System III - continued
Red Phosphor
Effluent
17
1703/10800
24
me/I
Blue Phosphor
Effluent
18
1703/10800
24
mg/1
Green phosphor
Effluent
19
1703/10800
24
mg/1
TOXIC ORGANICS
Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Sliver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barlum
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
CONVENTIONAL POLLUTANTS
pH
Total Suspended Solids
Not
Analyzed
<0.001
<0.002
<0.005
0.065
2.620
<0.013
<0.050
<0.001
O.013
D.020
<3.001
<3.001
0.718
0.157
<0.025
9.930
2.400
<0.001
<0.001
0.383
0.005
<0.035
<0.025
2.460
0.186
0.031
0.007
5.0
8
Not
Analyzed
28
<0.001
<0.002
<0.005
0.020
3.750
<0.013
<0.050
<0.001
<0.013
<0.002
0.008
<0.001
31.500
1.110
0.187
20.200
0.158
<0.001
<0.001
0.137
0.552
<0.035
<0.025
0.142
0.193
0.009
<0.002
36
Not
Analyzed
28
^0.004
<0.002
<0.005
11.600
2.380
<0.013
<0.050
<0.001
<0.013
<0.002
0.001
<0.001
19.100
0.257
<0.025
18.300
0.021
<0.001
<0.001
0.094
0.538
<0.035
<0.025
0.037
0.212
0.004
35
5-20
-------
TABLE 5-4
PICTURE TUBE PROCESS WASTES
PLANT 11114
Treatment System III - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Duration Hours/Day
Total Phosphor
Effluent
20
5110/32400
24
mg/1
Total Plant
Effluent
21
283875/1800000
24
mg/1
TOXIC ORGANICS
4 Benzene <0.010
11 1,1,1-Ttichloroethane <0.010
13 1,1-Dichloroethane
23 Chloroform <0.010
29 1,1-Dichloroethylene <0.010
30 1,2-trans-dichloroethylene
38 Ethylbenzene <0.010
44 Methylene chloride 0.020
48 Dichlorobromomethane
51 Chlorodibromomethane
66 Bis(2-ethylhexyl)phthalate <0.010
68 Di-N-butyl phthalate <0.010
85 Tetrachloroethylene
86 Toluene 0.030
87 Trichloroethylene <0.010
102 Alpha-BHC
105 Delta-BHC
Total Toxic Organics 0.050
Cyanide <0.005
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper Not
122 Lead Analyzed
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium Not
Molybdenum Analyzed
Tin
Yttrium
Cobalt
Iron
Titanium
Phenols 0
Total Organic Carbon 130
Fluoride 45
CONVENTIONAL POLLUTANTS
pH
Oil & Grease 505
Biochemical Oxygen Demand 48
Total Suspended Solids 1080
<0.010
0.050
<0.010
<0.010
<0.010
<0.010
0.060
<0.010
<0.010
<0.010
0.090
0.030
<0.005
<0.005
0.230
0.002
0.052
0.037
<0.005
310
230
0.045
1.960
<0.001
0.047
0.002
<0.001
<0.001
7.310
23.200
8.380
454.
4.100
0.037
0.002
9.420
0.186
<0.035
<0.025
0.237
<0.050
9.930
0.045
0.046
101
480
7.2
49
71
63
5-21
-------
TABLE 5-5
PICTURE TUBE PROCESS WASTES
PLANT 99796
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
Duration/Hours/Day
TOXIC ORGANICS
23 Chloroform
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Clarifier
Influent
1
85626/542880
24
rag/1
0.050
0.025
0.075
<0.01
0.040
0.030
<0.001
0.637
0.776
0.016
20.100
<0.0002
<0.015
<0.010
<0.012
<0.010
31.600
Clarifier
Effluent
2
85626/542880
24
mg/1
0.035
0.021
0.056
0.02
0.060
<0.010
<0.001
0.021
0.150
<0.004
0.400
0.0002
<0.015
<0.010
<0.003
<0.010
0.944
Clarifier
Influent
3
74950/475200
24
mg/1
0.030
0.030
<0.01
0.040
0.030
<0.001
0.434
0.900
0.012
5.300
0.0004
<0.015-
<0.010
<0.015
<0.010
8.72
NON-CONVENTIONAL POLLUTANTS
Phenols
Flouride
<0.02
34
<0.02
32
<0.02
26
CONVENTIONAL POLLUTANTS
Oil & Grease 5
Biochemical Oxygen Demand 17
Total Suspended Solids 410
5
10
15
5
16
320
5-22
-------
TABLE 5-5
Picture Tube Process Wastes
Plant 99796 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
Durat ion/Hours/Day
TOXIC ORGANICS
23 Chloroform
44 Methylene Chloride
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Phenols
Fluoride
CONVENTIONAL POLLUTANTS
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Clarifier
Effluent
4
74950/475200
24
mg/1
0.054
0.008
0.008
0.054
<0.01
0.040
<0.010
<0.001
0.021
0.176
<0.004
0.200
0.0004
<0.015
<0.010
<0.006
<0.010
0.345
<0.02
26
<5
15
20
Clari f ler
Influent
5
84500/535680
24
mg/1
0.124
0.026
0.150
<0.01
0.100
0.050
<0.001
0.807
1.300
0.008
13.600
0.0002
0.030
<0.010
<0.015
<0.010
18.800
0.02
35
Clar if ler
Effluent
6
84500/535680
24
rog/1
0.024
0.021
0.045
0.01
0.060
<0.010
<0.001
0.014
0.164
<0.004
0.300
0.0002
<0.015
<0.010
<0.003
<0.010
0.360
0.02
32
5
18
410
5
15
10
5-23
-------
5.3 LUMINESCENT MATERIALS
5.3.1 Wastewater Flow
Presented below is a summary of the quantities of wastewater
generated by the manufacturers of luminescent materials.
Wastewater Discharge (gpd)
Number of Plants Min. Mean Max.
5 10,000 104,000 247,000
5.3.2 Wastewater Sources
Process wastewater sources from the manufacture of luminescent
materials include the various crystallization, washing, and
filtration steps in the production of intermediate and final
product powders. Additional sources are wet scrubbers used in
conjunction with firing and drying operations.
5.3.3 Pollutants Found and the Sources of_ These Pollutants
The major pollutants of concern from the Luminescent Materials
Subcategory are:
PH
TSS
Antimony
Cadmium
Zinc
The process steps associated with the sources of these pollutants
are described in Section 4. Table 5-6 summarizes the occurrence
and levels of these pollutants based on sampling and analysis
data. Concentrations represent total raw wastes after flow-
proportioning individual plant waste streams. Figure 5-4
identifies the sampling location at one facility. Tables 5-7
through 5-9 present the analytical data for three sampled plants
in the luminescent materials subcategory.
pH may be very low or very high in specific waste streams as a
result of acids used for dissolving raw materials and caustics
used in wet scrubbers.
Total Suspended Solids occur in wastes from washing and
filtration operations and in wet scrubber wastes. The solids
primarily consist of precipitated product materials and raw
material impurities.
Fluoride occurs in wastewaters from lamp phosphor manufacture.
Calcium fluoride, as an intermediate powder product, appears in
wastes from washing and filtration operations.
5-24
-------
TABLE 5-6
LUMINESCENT MATERIALS
SUMMARY OF RAW WASTE DATA
PARAMETER
CONCENTRATION, mg/1
MINIMUM MAXIMUM MEAN
TOXIC METALS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
Total Toxic Organics
Oil and Grease
Biochemical Oxygen Demand
Total Suspended Solids
0.021
0.005
0.003
0.216
0.025
0.005
0.009
0.001
0.025
0.005
0.015
0.027
2.864
0.060
2.64
2
91
6.62
0.020
0.008
9.35
0.067
0.101
0.155
0.005
0.745
0.005
0.044
0.065
350.6
1.292
6.40
8
4008
2.69
0.013
0.005
4.06
0.050
0.051
0.064
0.003
0.322
0.005
0.025
0.041
120.6
0.590
3.01
5
1440
Fluoride
11.05
702
356.5
5-25
-------
CaHP04,CaCO3 1
Process Wastes
3
LAMP 2
PHOSPHOR CaF2 Intermediate Q"V
PROCESS Process Wastes v^/
4
Final Product /~\ \
Process Wastes v> '"'
\
5
intermediate r\ ^
Process Wastes
Ui
^ 6
TV Final Product s\ x.
PHOSPHOR Process Wastes -^
PROCESS
/
PrnnpSK Snruhhpr A \
Ly s
Wastes
Other Plant \,
Process Wastes ^
/
i j
8 pH Primary 9 Secondary TO ll
1
y
Filter Press
River
FIGURE 5- 4
PLANT 101 SAMPLING LOCATIONS
-------
TABLE 5-7
LAMP PHOSPHOR WASTES
PLANT 101
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
TOXIC ORGANICS
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
126
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Calcium
Intermediate
Powder Wastes
1
26810/170000
rog/1
Not
Analyzed
0.016
0.003
<0.003
0.076
0.070
0.050
<0.020
0.005
0.220
<0.005
0.05
<0.030
0.005
Fluoride
Intermediate
Powder Wastes
2
946/6000
mg/1
Not
Analyzed
0.013
0.024
<0.003
<0.030
0.020
0.020
<0.020
0.004
0.090
<0.005
0.010
<0.030
0.289
NON-CONVENTIONAL POLLUTANTS
Magnesium 2.704
Sodium 211.345
Aluminum 2.598
Manganese 0.029
Vanadium 0.252
Boron 0.633
Barium 0.402
Molybdenum 8.378
Tin 0.230
Yttrium 0.418
Cobalt 0.100
Iron 0.208
Titanium 0.127
Fluoride
CONVENTIONAL POLLUTANTS
Biochemical Oxygen Demand <3
Total Suspended Solids 840
0.030
100
1100
5-27
-------
TABLE 5-7
LAMP PHOSPHOR WASTES
PLANT 101
Stream Identification
Sample Number
Flor Rate Liters/Hr-Gallon/day
TOXIC ORGANICS
Composites
1 & 2
3
27760/176000
rag/1
11 1,1,1-Trichloroethane
23 Chloroform
44 Methylene Chloride
66 Bis(2-ethylhexyl)phthalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
70 Diethyl phthalate
Total Toxic Organics
<0.010
0.012
0.470
0.960
0.015
<0.010
1.457
121 Cyanide
TOXIC INORGANICS
<0.004
Not
Analyzed
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Fired Lamp
Powder Wastes
4
3785/24000
mg/1
<0.010
<0.010
0.011
1.200
<0.010
<0.010
1.211
<0.004
14.669
0.116
<0.003
26.210
0.050
0.040
0.080
0.003
0.290
<0.005
0.020
<0.030
0.071
NON-CONVENTIONAL POLLUTANTS
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Phenols
Total Organic Carbon
Fluoride
Ammonia
CONVENTIONAL POLLUTANTS
Total Suspended Solids
<0.002
8.0
0.680
2.288
1.189
32.250
0.050
1.721
0.040
0.052
0.028
0.037
0.005
<0.002
170
7200
3.4
3200
5-28
-------
TABLE 5-7
TV PHOSPHOR WASTES
PLANT 101
Stream Identification
Sample Number
Flow Rate Li ters/Hr-Gallon/day
TOXIC ORGANICS
11 1 ,1,1-Tr ichloroethane
44 Methylene Chloride
66 Bis(2-ethylhexyl) phtnalate
67 Butyl benzyl phthalate
68 Di-N-butyl phthalate
7C Diethyl Phthalate
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Sliver
127 Thallium
128 Zinc 2,
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
yttrium
Cobalt
Iron
Titanium
Phenols
Total Organic Carbon
Intermediate
Powder Wastes
5
4732/30000
mg/1
<0.01
0.018
1.100
<0.01
<0.01
<0.01
1.118
<0.004
0.021
<0.001
<0.003
0.077
0.005
0.020
0.050
0.006
0.040
<0.005
0.010
<0.030
590
1.311
0.083
1.036
0.015
0.008
<0.001
0.021
0.007
2.826
0.224
<0.001
0.043
0.417
0.020
<0.002
20
CONVENTIONAL POLLUTANTS
Total Suspended Solids
24,700
Phosphor
Wastes
6
1577/10000
mg/1
<0.01
0.014
1.200
<0.01
<0.01
1.214
<0.004
0.011
<0.001
<0.003
<0.030
<0.005
0.010
<0.020
0.002
<0.020
<0.005
<0.003
<0.030
866.5
2.219
13.670
2.696
0.771
0.026
0.114
0.038
0.004
1.006
0.053
0.037
0.080
0.142
0.007
<0.002
4.0
1500
Scrubber
Wastes
7
1104/7000
mg/1
Not
Analyzed
0.049
0.040
<0.003
0.058
0.080
0.150
<0.020
0.007
1.290
0.005
0.230
<0.030
0.194
2.819
0.035
2.821
0.017
0.201
6.043
0.033
1.903
0.407
0.699
0.068
0.308
0.048
1100
5-29
-------
TABLE 5-7
TREATMENT SYSTEMS
PLANT 101
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/da/
TOXIC ORGANICS
Treatment
Influent
8
189270/1200000
mg/1
Not
Analyzed
Pr imary
Clarifler
Effluent
9
189270/1200000
mg/1
Not
Analyzed
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
126
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Europium
Yttrium
Cobalt
Iron
Titanium
0.029
0.078
<0.030
0.337
1.730
0.150
<0.020
0.003
0.260
<0.005
0.040
<0.030
5.517
302.707
88.120
3.052
0.783
0.804
1.500
0.319
0.958
0.285
<0.05
<2
1.153
133.988
0.095
0.058
<0.001
<0.003
0.091
0.120
0.090
<0.020
0.005
0.330
<0.005
0.010
<0.030
0.419
513.207
129.602
2.399
0.260
0.872
0.948
0.099
0.568
0.257
<0.01
364
373
560
0.077
CONVENTIONAL POLLUTANTS
Total Suspended Solids
210
110
5-30
-------
TABLE 5-7
TREATMENT SYSTEMS
PLANT 101 - continued
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
TOXIC ORGANICS
Secondary
Clarifier
Effluent
10
189270/1200000
mg/1
Not
Analyzed
Final
Effluent
11
169270/1200000
mg/1
Not
Analyzed
TOXIC INORGANICS
114 Antimony
115 Arsenic
117 Beryllium
118 Cadmium
119 Chromium
120 Copper
122 Lead
123 Mercury
124 Nickel
125 Selenium
126 Silver
127 Thallium
128 Zinc
NON-CONVENTIONAL POLLUTANTS
Calcium
Magnesium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Europium
yttrium
Cobalt
Iron
Titanium
0.146
0.156
<0.003
0.512
4.750
0.220
<0.020
0.003
0.450
<0.005
0.060
<0.030
11.409
595.207
201.602
3.777
.847
.240
.357
.293
.096
.332
.1
.511
.497
191.288
0.127
0.031
0.008
<0.003
0.020
0.050
0.030
<0.020
0.004
0.130
<0.005
0.020
<0.030
0.289
240.200
52.730
0.090
0.107
0.368
0.361
0.091
0.128
0.023
<0.05
0.005
0.096
4.237
0.005
CONVENTIONAL POLLUTANTS
Total Suspended Solids
730
45
5-31
-------
TABLE 5-8
TV PHOSPHOR WASTES
PLANT 102
Stream Identification
Sample Number
Flow Rate Liters/Hr/Gallon/day
TOXIC ORGANICS
23 Chloroform
66 Bis(2-ethylhexyl)phthalate
68 Di-N-t>utyl phthalate
86 Toluene
87 Trichloroethylene
Total Toxic Organics
121 Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
126
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
NON-CONVENTIONAL POLLUTANTS
Phenols
Total Organic Carbon
CONVENTIONAL POLLUTANTS
pH @ 23°C
Oil & Grease
Biochemical Oxygen Demand
Total Suspended Solids
Luminescent
Material Waste
1
4360/9000
mg/1
0.005
0.060
0.006
0.060
<0.002
0.021
<0.005
<0.005
0.216
<0.025
0.005
0.009
<0.001
<0.025
<0.005
<0.015
0.027
8.450
0.012
31
11.1
6.4
,160
91
Final Plant
Effluent
2
39430/250000
mg/1
0.260
0.010
0.060
0.33
0.004
0.008
<0.005
<0.005
0.200
0.200
0.325
0.004
<0.001
0.190
<0.005
0.015
0.038
0.468
6.8
6.8
8.0
12
5-32
-------
TABLE 5-9
LAMP PHOSPHOR WASTES
PLANT 103
Stream Identification
Sample Number
Flow Rate Liters/Hr-Gallon/day
Special Phosphors
Wastes
1
79/500
mg/1
Lamp Phosphor
Wastes
2
790/5000
"9/1
TOXIC ORGANIC5
1 Acenaphene
4 Benzene
23 Chloroform
39 Fluoranthene
44 Methylene Chloride
66 Bis(2-ethylhexyl)phthalate
67 Butyl Benzyl phthalate
68 Di-N-butyl phthalate
70 Diethyl phthalate
78 Anthrancene
81 Phenanthtene
84 Pyrene
86 Toluene
106 PCB-1242
Total Total Organics
Cyanide
TOXIC INORGANICS
114
115
117
118
119
120
122
123
124
125
126
127
128
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
<0.010
=0.010
<0.010
<0.010
0.160
<0.010
<0.160
<0.010
0.036
<0.010
<0.010
<0.010
0.008
0.196
0.009
0.006
0.075
0.091
0.266
0.419
1.070
0.003
3.272
<0.005
0.070
<0.030
7.011
<0.010
<0.010
0.150
<0.010
<0.010
0.011
0.260
0.010
<0.010
0.018
0.439
7.278
0.021
<0.001
10.270
0.047
0.069
0.063
0.004
0.536
<0.005
0.010
<0.030
2.449
NON-CONVENTIONAL POLLUTANTS
Calcium 8.672
Magnesium 3.016
Sodium
Aluminum 3.854
Manganese 0.428
Vanadium 14.812
Boron 49.802
Barium 0.230
Molybdenum 0.462
Tin 0.286
Yttrium 10.605
Cobalt 0.117
Iron 1.399
Titanium 0.079
Total Organic Carbon 98
Fluoride 1.5
432.007
2.070
4.771
0.115
14.060
0.034
0.053
0.283
0.030
0.012
0.019
0.010
0.516
0.010
43
12
CONVENTIONAL POLLUTANTS
Oil & Grease
Total Suspended Solids
29
270
0
215
5-33
-------
Antimony used as an activator in the manufacture of lamp
phosphors was detected at a high concentration in one raw waste
stream.
Cadmium and Zinc as the major metals found in blue (Zn) and
green (Zn, Cd) TV phosphors, occur as sulfides in the
intermediate and final products. Therefore they appear in
Wastewaters from all washing and filtering operations in the
production of blue and green phosphors.
Other toxic metals which are used in very small amounts as
activators (arsenic in lamp phosphors and silver and copper in TV
phosphors) were detected in very low concentrations.
Toxic Organics in the forir of phthalate esters, were found in
significant concentrations in several process wastes. According
to industry personnel, phthalates are not used in the
manufacturing process. The presence of these organics may be due
to sample contamination, since they also occurred in significant
concentrations in sample blanks, or they may result from the use
of plastic storage containers.
5.4 RECEIVING AND TRANSMITTING TUBES
No plants were sampled in the Receiving and Transmitting Tube
Subcategory. Information obtained from plant surveys and
industry contacts indicated that wastewater generated by the
Receiving and Transmitting Tube subcategory results primarily
from processes associated with metal finishing operations.
5-34
-------
SECTION 6
SUBCATEGORIES AND POLLUTANTS TO BE REGULATED,
EXCLUDED OR DEFERRED
This section cites the E&EC subcategories which are being (1)
regulated or (2) excluded from regulation. In addition, this
section explains, for those subcategories being regulated, which
pollutants are being regulated and which pollutants are being
excluded from regulation.
6.1 SUBCATEGORIES TO BE REGULATED
Based on wastewater characteristics presented in Section 5,
discharge effluent regulations are being proposed for the Cathode
Ray Tube and Luminescent Materials subcategories.
6.1.1 Pollutants to be Regulated
The specific pollutants selected for regulation in these
subcategories are: Cathode Ray Tubes - cadmium, chromium, lead,
zinc, fluoride, TSS, pH and TTO; and Luminescent Materials
cadmium, zinc, antimony, fluoride, TSS and pH. The rationale for
regulating these pollutants is presented below.
(pH) Acidity or Alkalinity
During cathode ray tube and luminescent materials manufacture,
both high and low pH levels may occur. High pH results from
caustic cleaning operations or caustics used in wet scrubbers
while low pH results from the use of acids for etching and
cleaning operations.
Although not a specific pollutant, pH is a measure of acidity or
alkalinity of a wastewater stream. The term pH is used to
describe the hydronium ion balance in water. Technically, pH is
the negative logarithm of the hydrogen ion concentration. A pH
of 7 indicates neutrality, a balance between free hydrogen and
free hydroxyl ions. A pH above 7 indicates that the solution is
alkaline, while a pH below 7 indicates that the solution is
acidic.
Waters with a pH below 6.0 are corrosive to water works
structures, distribution lines, and household plumbing fixtures;
this corrosion can add constituents to drinking water such as
iron, copper, zinc, cadmium, and lead. Low pH waters not only
tend to dissolve metals from structures and fixtures, but also
tend to redissolve or leach metals from sludges and bottom
sediments. Waters with a pH above approximately 9.0 can induce
corrosion of certain metals, are detrimental to most natural
organic materials, and are toxic to some living organisms.
6-1
-------
Total Suspended Solids (TSS)
Total suspended solids found in cathode ray tube manufacture
wastewater result primarily from graphite emulsions (DAG) used to
coat the inner and outer surfaces of glass panels and funnels.
Sources include both manufacture and salvage cleaning operations.
The average concentration of TSS in CRT wastewaters is 185 mg/1.
TSS concentrations in the wastewater from the manufacture of
luminescent materials average 1,440 mg/1. These solids consist
primarily of precipitated product materials and raw material
impurities. Major sources are washing and filtration operations
and wet scrubber wastes.
Suspended solids increase the turbidity of water, reduce light
penetration, and impair the photosynthetic activity of aquatic
plants. Solids, when transformed to sludge deposit, may blanket
the stream or lake bed and destroy the living spaces for those
benthic organisms that would otherwise occupy the habitat.
Total Toxic Orqanics (TTO)
Total toxic organics (TTO) are found in the wastewaters from
cathode ray tube facilities. TTO is considered the sum of the
concentrations of toxic organics listed in Table 6-1 which are
found at concentrations greater than 0.01 milligrams per liter.
These organics result from the use of solvents (e.g., methylene
chloride, trichloroethylene) for cleaning and decreasing
operations and from toluene-based lacquer coatings applied as a
sealant over phosphor coatings.. Maximum TTO concentrations of
1.54 milligrams per liter were found in the process wastes from
cathode ray tube facilities.
Table 6-1
Pollutants Comprising Total Toxic Organics
Toxic Pollutant No.
11 1,1,1-trichloroethane 66 bis(2-ethylhexyl)phthalate
23 chloroform 86 toluene
44 methylene chloride 87 trichloroethylene
Antimony
Antimony is being regulated only in the Luminescent Materials
Subcategory. It is used in small amounts as an activitor in the
manufacture of lamp phosphors and was detected at a high
concentration in a sampled raw waste stream. The mean
concentration of antimony for luminescent materials facilities
was 2.69 milligrams per liter.
Antimony compounds are poisonous to humans and are classed as
acutely moderate or chronically severe. Antimony can be
6-2
-------
concentrated by certain forms of aquatic life to over 300 times
the background concentrations. In tests on various fish and
aquatic life, the salts of antimony give mixed results on
toxicity dependent on the salt, temperature, hardness of the
water, and dissolved oxygen present.
Cadmium
Cadmium is found in the wastewater from both cathode ray tube and
luminescent materials facilities at mean concentrations of 0.374
milligrams per liter and 4.06 milligams per liter, respectively.
Cadmium is one of the major metals found in blue and green TV
phosphors and appears in wastewaters from all washing and
filtering operations in the production of these phosphors. In
the CRT industry, cadmium results from manufacture, salvage and
phosphor recovery operations.
Cadmium is a cumulative toxicant, causing progressive chronic
poisoning in mammals, fish and other animals. It is known to
have marked acute and chronic effects on aquatic organisms. The
compound is highly concentrated by marine organisms, primarily
molluscs. The eggs and larvae of fish are apparently more
sensitive than adult fish to poisoning by cadmium, and
crustaceans appear to be even more sensitive than fish eggs and
larvae. Cadmium in drinking water supplies is extremely
hazardous to humans, and conventional treatment does not remove
it. It also acts synergistically with other metals; copper and
zinc substantially increase its toxicity.
Chromium
Chromium is found in the wastewaters from the Cathode Ray Tube
Subcategory. It occurs as dichromate in photosensitive materials
used to prepare glass surfaces for phosphor application. The
mean concentration of chromium in wastewater from manufacture and
salvage operations was 1.31 milligrams per liter.
Chromium is considered hazardous to man, producing lung tumors
when inhaled and inducing skin sensitizations. The toxicity of
chromium salts to fish, and other aquatic life varies widely with
the species, temperature, pH, valence of chromium and synergistic
or antagonistic effects. It appears that fish food organisms and
other lower forms of aquatic life are extremely sensitive to
chromium, which also appears to inhibit algal growth.
Lead
Lead is being regulated in the Cathode Ray Tube Subcategory. It
is present in the solder or frit used to fuse glass panels and
funnels together. The major sources of lead in CRT wastewaters
are tube salvage operations where acids are used to dissolve the
frit and to clean the panels and funnels. The mean concentration
of lead for CRT facilities was 9.41 milligrams per liter.
6-3
-------
Lead levels are cumulative in the human body over long periods of
time with chronic ingestion of low levels causing poisoning over
a period of years. Fish have been shown to have adverse effects
from lead and lead salts in the environment. Small
concentrations of lead may cause a film of coagulated mucus to
form over the fish, leading to suffocation.
Zinc
Zinc is being regulated in both the Cathode Ray Tube and
Luminescent Materials Subcategories. As with cadmium, zinc is
one of the major toxic metals found in phosphors. Sources of
zinc are therefore the same as discussed above for cadmium. Mean
zinc concentrations for the two industries are 11.79 milligrams
per liter (cathode ray tube) and 120.6 milligrams per liter
(luminescent materials).
Zinc can have an adverse effect on man and animals at high
concentrations while lower zinc levels in public water supply
sources can cause an undesirable taste which persists through
conventional treatment. The toxicity of zinc to fish has been
shown to vary with fish species, age and condition, as well as
with the physical and chemical characteristics of the water.
Fluoride
Fluoride is found in the wastewaters of cathode ray tube and
luminescent materials facilities. The source of fluoride from
CRT manufacture is the use of hydrofluoric acid for cleaning and
conditioning glass surfaces. The mean concentration in CRT
process wastes was 360.6. The source of fluoride from
luminescent materials manufacture is an intermediate powder in
lamp phosphor production. The mean concentration of fluoride at
luminescent materials facilities was 356.5 milligrams per liter.
Although fluoride is not listed as a toxic pollutant, it can be
toxic to livestock and plants, and can cause tooth mottling in
humans. The National Academy of Sciences recommends: (1) two
milligrams per liter as an upper limit for drinking water and
watering livestock and, (2) one milligram per liter for
continuous use as irrigation water on acid soils to prevent plant
toxicity and reduced crop yield. Although some fluoride in
drinking water helps to prevent tooth decay, EPA's National
Interim Primary Drinking Water Regulations set limits of 1.4 to
2.4 milligrams per liter in drinking water to protect against
tooth mottling.
6.2 TOXIC POLLUTANTS AND SUBCATEGORIES NOT REGULATED
The Settlement Agreement, explained in Section 2, contained
provisions authorizing the exclusion from regulation, in certain
circumstances, of toxic pollutants and industry categories and
subcategories. These provisions have been rewritten in a Revised
6-4
-------
Settlement Agreement which was approved by the District Court for
the District of Columbia on March 9, 1979, NRDC v. Costle, 12 ERC
1833.
6.2.1 Exclusion of_ Pollutants
Nine (9) pollutants are being excluded from further regulation
for both the Cathode Ray Tube and Luminescent Materisls
subcategories under Paragraph 8(a)(iii) because they are present
in amounts too small to be effectively reduced by technologies
known to the Administrator: arsenic, beryllium, copper, mercury,
nickel, selenium, silver, thallium, and cyanide.
Table 6-2 presents one hundred and six pollutants which are being
excluded from further regulation for both subcategories under
Paragraph 8(a)(iii) because they wwere not detected in the
effluent.
Table 6-2
1. Acenaphthene
2. Acrolein
3. Acrylonitrile
4. Benzene
5. Benzidine
6. Carbon Tetrachloride
7. Chlorobenzene
8. 1,2,4 Trichlorobenzene
9. Hexachlorobenzene
10. 1,2-Dichloroethane
11. Hexachloroethane
12. 1,1-Dichloroethane
13. 1,1,2-Trichloroethane
14. 1,1,2,2-Tetrachloroethane
15. Chloroethane
16. Bis(2-Chloroethyl)Ether
17. 2-Chloroethyl Vinyl Ether (Mixed)
18. 2-Chloronaphthalene
19. 2,4,6 Trichlorophenol
20. Parachlorometa Cresol
21. 2-Chlorophenol
22. 1,2-Dichlorobenzene
23. 1,3-Dichlorobenzene
24. 1,4-Dichlorobenzene
25. 3,3'-dichlorobenzidine
26. 1,1-Dichloroethylene
27. 1,2-Trans-Dichloroethylene
28. 2,4-Dichlorophenol
29. 1,2-Dichloropropane
30. 1,2-Dichloropropylene
31. 2,4-Dimethylphenol
32. 2,4-Dinitrotoluene
6-5
-------
33. 2,6-Dinitrotoluene
34. 1,2-diphenylhydrazine
35. Ethylbenzene
36. Fluorathene
37. 4-Chlorophenyl Phenyl Ether
38. 4-Bromophenyl Phenyl Ether
39. Bis(2-chloroisopropyl) Ether
40. Bis-(2-chloroethyxy) Methane
41. Methyl Chloride
42. Methyl Bromide
43. Bromoform
44. Dichlorobromomethane
45. Chlorodibromomethane
46. Hexachlorobutadiene
47. Hexachlorocyclopentadiene
48. Isophorone
49, Naphthalene
50. Nitrobenzene
51. 2-Nitrophenol
52. 4-Nitrophenol
53. 2,4-dinitrophenol
54. 2.6-dinitro-o-cresol
55. N-nitrosodimethylamine
56. N-nitrosodiphenylamine
57. N-nitrosodi-n-propylamine
58. Pentachlorophenol
59. Phenol
60. Butyl Benzyl phthalate
61. Di-n-butyl phthalate
62. Di-n-octyl phthalate
63. Diethyl phthalate
64. Dimethyl phthalate
65. Benzo(a)anthracene
66. Benzo(a)pyrene
67. 3,4-benzofluorathene
68. Benzo(k)fluoranthane
69. Chrysene
70. Acenaphthylene
71. Anthracene
72. Benzo(ghi)perylene
73. Fluorene
74. Phenanthrene
75. Dibenzo(a,h)anthracene
76. Indeno(1,2,3-cd)pyrene
77. Pyrene
78. Tetrachloroethylene
79. 2,3,7,8-tetrachlorodibenzo-p-dioxin
80. Vinyl Chloride
81. Aldrin
82. Cieldrin
83. Chlordane
84. 4,4'-DDT
85. 4,4'-DDE
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86. 4,4'-DDD
87. A-endosulfan-Alpha
88. B-endosulfan-Beta
89 Endosulfan Sulfate
90. Endrin
91. Endrin Aldehyde
92. Heptachlor
93. Heptachlor Epoxide
94. A-BHC-Alpha
95. B-BHOBeta
96. D-BHC-Delta
97. G.BHC-Gamma
98. PCB-1242
99. PCB-1254
100. PCB-1221
101. PCB-1232
102. PCB-1248
103. PCB-1260
104. PCB-1016
105. Toxaphene
106. Asbestos
For the Cathode Ray Tube subcategory only, an additional toxic
pollutant, antimony, is being excluded from further regulation
under Paragraph 8(a)(iii), because it was found in amounts too
small to be effectively treated.
In the Luminescent Materials subcategory, the six (6) additional
toxic pollutants listed in Table 6-1 are being excluded from
regulation under Paragraph 8(a)(iii) because EPA believes they
are not present at detectable concentrations using
state-of-the-art analytical methods. Two additional toxic
pollutants are being excluded under paragraph 8(a)(iii). These
are lead and chromium which were not detected in effluents from
this subcategory.
6.2.2 Exclusion of Subcategories
All subcategory exclusions are based on either Paragraph 8(a)(i),
or Paragraph 8(a)(iv) of the Revised Settlement Agreement.
Paragraph 8(a)(i) permits exclusion of a subcateogry for which
"equally or more stringent protection is already provided by an
effluent, new source performance, or pretreatment standard or by
an effluent limitation. . ." Paragraph 8(a)(iv) permits
exclusion of a category or subcategory where "the amount and the
toxicity of each pollutant in the discharge does not justify
developing national regulations . . ." These exclusions are
supported by data and information presented in Section 5.
The Receiving and Transmitting Tube Subcategory is being excluded
from regulation under the provisions of Paragraph 8(a)(i) on the
basis that the assembly of these tubes is a dry process. Those
6-7
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unit operations which use water for cleaning, degreasing, and
plating are covered under metal finishing limitations.
Existing direct dischargers in the Cathode Ray Tube Subcategory
are being excluded from regulation under the provisions of
Paragraph 8(a)(iv). Only one plant of the 24 plants in the
Cathode Ray Tube subcategory is a direct discharger and that
plant has precipitation/clarification plus filtration treatment
in place. The discharge of toxic pollutants is insignificant,
less than 2 pounds/day after current treatment.
All existing dischargers in the Luminescent Materials Subcategory
are being excluded from regulation. Of the five plants in this
subcategory, only two are direct dischargers. These two plants
discharge after treatment less than one pound/plant of toxic
metals per day. For this reason, exclusion under the provision
fo paragraph 8(a)(iv) is proposed. In the case of the indirect
dischargers, exclusion under the provision of paragraph 8(b)2 is
proposed on the basis that, the amount of toxic pollutants
introduced into POTW's is insignificant.
6.3 CONVENTIONAL POLLUTANTS MOT REGULATED
BOD, and oil and grease are not being regulated for either
subcategory because they were found at concentrations below
treatability. BOD was found at an average of 7.4 milligrams per
liter in cathode ray tube facilities and 5 milligrams per liter
in luminescent materials plants; oil and grease was found at an
average concentration of 7.7 milligrams per liter in cathode ray
tube plants and 3.0 milligrams per liter in luminescent materials
plants; and fecal coliform was not present in the process
discharge from either subcategory.
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SECTION 7
CONTROL AND TREATMENT TECHNOLOGY
The wastewater pollutants of concern generated by the manufacture
of cathode ray tubes and luminescent materials are identified by
the processes described in Section 5. They are pH, suspended
solids, fluoride, antimony, chromium, cadmium, lead, zinc, and
toxic organics. A discussion of the treatment technologies
currently practiced and most applicable for the reduction of
these pollutants is presented below. It is followed by an
identification of three recommended treatment and control systems
and an analysis of the performance of these systems.
7.1 CURRENT TREATMENT AND CONTROL PRACTICES
Pollutant control technologies currently used in the cathode ray
tube and luminescent materials industries include both in-process
and end-of-pipe technologies. In-process waste control
technologies are meant to remove pollutants from process
wastewater by treatment at some point in the manufacturing
process, or to limit the introduction of pollutants into process
wastewater by control techniques. End-of-pipe treatment is
wastewater treatment at the point of discharge.
7.1.1 Cathode Ray Tube Subcategory
In-process Control In-process control techniques with
widespread use in this subcategory are collection of spent
solvents for resale, reuse or disposal, and segregation of other
waste streams for treatment or contract hauling; i.e., the
industry practice of contracting a firm to collect and transport
wastes for off-site disposal.
Available data and information indicate that all color
television tube manufacturing plants collect spent solvents for
either contractor disposal or reclamation. One plant does not
use solvents for a degreasing operation, but rather uses alkaline
cleaners. In addition information from several smaller CRT
manufacturers indicates that these plants collect and contract
haul their solvent wastes. Two plants also have their lead-
bearing nitric acid wastes contract-hauled. Four plants have in-
process treatment of chromium wastes, and two of these plants
also have in-process treatment of strong lead-bearing wastes.
End-of-Pipe Treatment Six plants in the Cathode Ray Tube
Subcategory use end-of-pipe precipitation/clarification for
control of toxic metals, and two plants have combined treatment
systems designed to treat CRT process wastes along with metal
finishing wastes from other plant manufacturing operations. One
plant, which currently only neutralizes its discharge, is
planning a new treatment system for control of metals. The one
7-1
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direct discharger in this subcategory also filters its treated
process wastewater after treating it by precipitation/
clarification. Some facilities only neutralize their wastes. In
addition, some small plants have provisions for solids removal
prior to discharge.
7.1.2 Luminescent Materials Subcategory
In the Luminescent Materials Subcategory the two direct
dischargers have combined end-of-pipe treatment systems that
utilize precipitation/clarification technologies. Of the three
other plants in the subcategory, one plant achieves zero
discharge through the use of an evaporation pond, one plant
neutralizes its wastes at end-of-pipe and the third plant uses
precipitation/clarification technology to control toxic metals
prior to discharge.
7.2 APPLICABLE TREATMENT TECHNOLOGIES
7.2.1 pJ3 Control
Acids and bases are commonly used in the production of cathode
ray tubes and luminescent materials. They result in process
waste streams exhibiting high or low pH values. Acids and bases
are used frequently in cleaning operations for cathode ray tube
manufacture. In the production of luminescent materials, acids
are used to dissolve raw materials and bases are used in alkaline
scrubbers.
There are several methods that can be used to treat acidic or
basic wastes resulting in a pH of 6-9. These methods include
mixing acidic and basic wastes, and neutralizing high pH streams
with acid or low pH streams with bases. The method of
neutralization used is generally selected on the basis of overall
cost. Process waters are treated either continuously or on a
batch basis. Neutralization can be used alone but is often used
in conjunction with precipitation of metals.
Hydrochloric or sulfuric acid may be used to neutralize alkaline
wastewaters, however,sulfuric acid is most often chosen because
of its lower cost.
Sodium hydroxide (caustic soda), sodium carbonate (soda ash), or
calcium hydroxide (lime) may be used to neutralize acidic
wastewater. The factors considered in selection include price,
neutralization rate, storage and equipment costs, and
neutralization end products. Sodium hydroxide is more expensive
than most other alkalies but is often selected due to its ease of
storage, rapid reaction rate and the solubility of its end
product.
7.2.2 Toxic Metals Treatment
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Toxic metals appear in process wastewaters from the manufacture
of luminescent materials and cathode ray tubes. Zinc and cadmium
are major constituents of luminescent materials and, as such,
appear in most process waste streams at luminescent materials
manufacturing plants and in many waste streams at cathode ray
tube plants. Lead, found in the solder used to fuse cathode ray
tube panels and funnels, appears in tube salvage wastes at these
plants. Chromium, a constituent of photoresist materials, is
found in the hexavalent form in several wastes at cathode ray
tube plants.
The most commonly used method to remove toxic metals from
wastewaters is to precipitate the metals as hydroxides or
carbonates and then remove the insoluble precipitates by
clarification or settling.
Hydroxide precipitation uses lime or caustic soda to supply the
hydroxide ions. The chemistry of the process is simple but must
be understood for each metal. To the degree that pH approaches
the optimum point, treatment will tend to avoid forming soluble
complexes. A simple form of the reaction may be written as:
M++ + 20H- = M(OH)2, where M represents the metal ion
The treatment levels attainable by hydroxide precipitation can be
forecast from a knowledge of the pH system. Figure 7-1 shows the
theoretical solubility of those toxic metals which form insoluble
hydroxides. It is clear from the figure that for wastewaters
containing more than one metal, optimum pH cannot be achieved for
each metal. Instead optimum pH for the total waste stream must
be based on the comparative concentrations of each metal of
concern. For successful application as a wastewater treatment
technology, careful control of pH must be practiced if the best
removals are to be achieved. Effluent data indicate that pH can
be maintained at levels that allow all regulated metals to be
controlled effectively at the same time. In practice, hydroxide
precipitation is often supplemented by the use of coagulating
agents to improve solids removal.
Sodium carbonate is often used for specific treatment of lead-
bearing wastes. Lead carbonate precipitates (or
lead/hydroxide/carbonate precipitates if hydroxides are also
used) are formed. This allows improved settling characteristics
for lead.
Hydroxide precipitation has proven to be an effective technique
for removing many pollutants from industrial wastewater. Metal
ions are precipitated as hydroxides and fluoride is precipitated
as insoluble calcium fluoride. The system operates at ambient
conditions and is well suited to automatic control. Lime is
usually added as a slurry when used in hydroxide precipitation.
The slurry must be kept well mixed and the addition lines
periodically checked to prevent blocking, which may result from a
7-3
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I I 1 I
10 11 12 13
FIGURE 7-1
Theoretical solubilities of toxic metal hydroxides/oxides
as a function of pH.
NOTE: Solubilities of metal hydroxides/oxides are from data by
M.Pourbaix, Atlas of Electrochemical Equilibria in Aqueous
Solutions,Pergamon Press, Oxford, 1966.
7-4
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build-up of solids. The use of hydroxide precipitation does
produce sludge requiring disposal following precipitation.
The performance of a precipitation system depends on several
variables. The most important factors affecting precipitation
effectiveness are:
1. Addition of sufficient excess chemicals to drive the
precipitation reaction to completion. If treatment
chemicals are not present in slight excess of the
required stoichiometric amount, some pollutants will
remain dissolved in the waste stream.
2. Maintenance of an alkaline pH throughout the
precipitation reaction and subsequent settling.
3. Effective removal of precipitated solids.
The process of removing suspended solids or precipitates by
gravitational forces is referred to as sedimentation and may be
conducted in a settling tank, clarifier or lagoon. The operation
is effected by establishing quiescent conditions so that
gravitational settling can occur. High retention times are
generally required. Accumulated sludge can be collected and
removed either periodically or continuously and either manually
or mechanically.
Inorganic coagulants or polyelectrolytic flocculants are added to
enhance coagulation. Common inorganic coagulants include sodium
sulfate, sodium aluminate, ferrous or ferric sulfate, and ferric
chloride. Organic polyelectrolytes vary in structure, but all
usually form larger floccules than coagulants used alone.
The use of a clarifier for sedimentation reduces space
requirements, reduces retention time, and increases solids
removal efficiency. Conventional clarifiers generally consist of
a circular or rectangular tank with a mechanical sludge
collecting device or with a sloping funnel-shaped bottom designed
for sludge collection. In advanced clarifiers, inclined plates,
slanted tubes, or a lamellar network may be included within the
clarifier tank in order to increase the effective settling area.
A more recently developed "clarifier" utilizes centrifugal force
rather than gravity to effect the separation of solids from a
liquid. The precipitates are forced outward and accumulate
against an outer wall, where they can later be collected. A
fraction of the sludge stream is often recirculated to the
clarifier inlet, promoting formation of a denser sludge.
The major advantage of simple sedimentation is the simplicity of
the process itself - the gravitational settling of solid
particulate waste in a holding tank or lagoon. The major
disadvantage of sedimentation involves the long retention times
necessary to achieve complete settling, especially if the
7-5
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specific gravity of the suspended matter is close to that of
water.
A clarifier is more effective in removing slow settling suspended
matter in a short time and in less space than a simple
sedimentation system. Also, effluent quality is often better
from a clarifier. The cost of installing and maintaining a
clarifier is however, substantially greater than the costs
associated with sedimentation lagoons.
Depending on the quantity of waste flow, the treatment can either
be a batch or continuous operation, with batch treatment favored
for small flows. In batch treatment the equipment usually
consists of two tanks, each with the capacity to direct the total
wastewater volume. For large daily flows, a typical continuous
flow scheme consists of an equalization tank, flash mixer,
flocculator, settling unit or clarifier and a sludge thickening
unit.
7.2.3 Fluoride Treatment
Fluoride appears in cathode ray tube manufacture wastewater
because of the use of hydrofluoric acid for cleaning and
conditioning glass surfaces. In the production of luminescent
materials fluoride appears as ammonium bifluoride in the raw
material used, and as calcium fluoride in intermediate and final
products.
The most common treatment procedure practiced today in the United
States for reducing the fluoride concentration in wastewater is
precipitation by the addition of lime (Ca(OH)2) followed by
clarification. That addition forms calcium fluoride by the
following reaction:
Ca(OH)2 + 2F- = CaF2 + 20H
The theoretical solubility of calcium fluoride in distilled water
is 7.8 mg fluoride ion per liter at 18°C. The precipitate forms
slowly, requiring about 24 hours for completion and the
solubility of calcium fluoride soon after its formation is about
ten milligrams of fluoride per liter. Data indicates that the
effectiveness of this treatment can be improved by the addition
of calcium chloride which provides excess calcium for
precipitating the fluoride.
Data from the Cathode Ray Tube Subcategory indicate that plants
using precipitation and clarification treatment technologies are
achieving a long-term average effluent concentration of 14.5
milligrams of fluoride per liter. Addition of a filtration unit
would not further reduce the fluoride concentration significanty
since 14.5 mg/1 of fluoride is approximately equal to the
dissolved calcium fluoride concentration soon after formation of
the precipitate. It has also been shown in a treatability study
7-6
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for the Hydrofluoric Acid Subcategory that dual media filtration
following alkaline precipitation and settling is not generally
effective for the reduction of fluoride. Insoluble, filterable
calcium fluoride would probably constitute only a small fraction
of the 14.5 mg/1 fluoride.
7.2.4 Filtration
A filtration unit can achieve further removal of fine
precipitates. Filtration is basic to water treatment technology,
and experience with the process dates back to the 1800's. A
filtration unit commonly consists of a container holding a
granular filter medium or combination of media through which is
passed the liquid stream. The unit can operate by gravity flow
or under pressure. Silica sand, anthracite coal, and garnet are
common filter media used in water treatment plants. These are
usually supported by gravel. The multi-media filters may be
arranged to maintain relatively distinct layers by virtue of
balancing the forces of gravity, flow and buoyancy on the
individual particles. This is accomplished by selecting
appropriate filter flow rates (gpm/sq ft), media grain size, and
density. The flow pattern is usually top-to-bottom, but other
patterns are sometimes used.
The usual granular bed filter operates by gravity flow. However,
pressure filters are also used. Pressure filters permit higher
solids loadings before cleaning and are advantageous when the
filter effluent must be pressurized for further downstream
treatment. In addition, pressure filter systems are often less
costly for low to moderate flow rates.
The principal advantages of granular bed filtration are its low
initial and operating costs and reduced land requirements over
other methods to achieve the same level of solids removal.
However, the filter may require pretreatment if the solids level
is high (from 100 to 150 mg/1). Operator training costs may be
fairly high due to controls and periodic backwashing.
Improvements in filter technology have significantly increased
filtration reliabiity. Control systems, improved designs, and
good operating procedures have made filtration a highly reliable
method of wastewater treatment. Filters may be operated with
either manual or automatic backwash. In either case, they must
be periodically inspected for media attrition, partial plugging,
and leakage. Filter backwash is generally recycled within the
wastewater treatment system, so that the solids ultimately appear
in the clarifier sludge stream for subsequent dewatering.
Alternatively, the backwash stream may be dewatered directly. In
this situation there is a solids disposal problem similar to that
of clarifiers.
7.2.5 Chemical Chromium Reduction
7-7
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Reduction is a chemical reaction in which electrons are
transferred to the chemical being reduced from the chemical
initiating the transfer (the reducing agent). Sulfur dioxide,
sodium bisulfite, sodium metabisulfite, and ferrous sulfate form
strong reducing agents in aqueous solution and are, therefore,
useful in industrial waste treatment facilities for the reduction
of hexavalent chromium to the trivalent form. The reduction
enables the trivalent chromium to be separated from solution in
conjunction with other metallic salts by alkaline precipitation.
Gaseous sulfur dioxide is a widely used reducing agent and
provides a good example of the chemical reduction process.
Reduction using other reagents is chemically similar. The
reactions involved may be illustrated as follows:
3S02 + 3H20 = 3H2S03
3H2S03 + H2Cr04 = Cr2 (S04)3 + 5H20
The above reaction is favored by low pH. A pH of 2 to 3 is
normal for situations requiring complete reduction. At pH levels
above 5, the reduction rate is slow. Oxidizing agents such as
dissolved oxygen and ferric iron interfere with the reduction
process by consuming the reducing agent.
A typical treatment consists of two hours retention in an
equalization tank followed by 45 minutes retention in each of two
reaction tanks connected in series. Each reaction tank has an
electronic recorder-controller device to control process
conditions with respect to pH and oxidation reduction potential
(ORP). Gaseous sulfur dioxide is metered to the reaction tanks
to maintain the ORP within the range of 250 to 300 millivolts.
Sulfuric acid is added to maintain a pH level of 1.8 to 2.0.
Each of the reaction tanks is equipped with a propeller agitator
designed to provide approximately one turnover per minute.
Following reduction of the hexavalent chromium, the waste is
combined with other waste streams for final adjustment to an
appropriate alkaline pH and sedimentation.
7.2.6 Total Toxic Organics Control
The sources of toxic organics in the Cathode Ray Tube Subcategory
are solvents used for cleaning and degreasing operations and
toluene-based coatings used to protect phosphors. They can enter
wastewaters as a result of contamination of process streams or
through dumping of spent solvents. The primary technique in this
subcategory for controlling the discharge of toxic organics is
the segregation of spent solvents for contract hauling (disposal)
or for sale to companies which purify the solvents in bulk for
resale. This control technology of solvent management also
includes good housekeeping practices such as controlling leaks
and spills. EPA also considered the use of carbon adsorption to
control basic organics since it is used for this purpose in other
industries.
7-8
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Solvent Management - Solvent management refers to the practice of
preventing spent solvents, containing toxic organics, from
entering the plant wastewater streams. While a small amount of
the solvents will enter the wastewaters through process
contamination (e.g., drag out), plants substantially reduce toxic
organic discharges by transferring the used solvents to tanks or
drums for disposal. Transfer is done both manually and
mechanically through minor piping modifications.
Available data and information show that the above practice of
collecting solvents is done at all plants to some degree. The
effectiveness of solvent management (i.e., the effluent reduction
of toxic organics achieved) depends upon the extent to which
plants collect the spent solvents and the extent to which they
are handled properly in transferring the spent solvents to tanks
and drums for disposal. Plants with the best solvent management
programs use well designed segregation controls or practices to
minimize solvent spills into rinse or other process streams, have
some type of system for collecting routine spills and leaks
during handling, and have implemented rigorous employee training
programs.
A number of CRT plants have demonstrated that solvent management
will reduce toxic organic discharges to low concentrations. This
in-process control is effective because it reduces the sources of
toxic organics in the effluent to that of contaminated process
wastewater streams (e.g., drag out). Available data show that
contaminated process streams contribute a very small amount of
toxic organics to the effluent and this amount of toxic organics
is difficult to reduce or eliminate because the concentrations
approximate the level of treatability.
In addition to being relatively inexpensive, especially when
compared to more sophisticated end-of-pipe treatment such as
carbon absorption, solvent management has another advantage.
After plants have collected the spent solvents in tanks or drums
for disposal, they are able to sell the solvents to companies
which purify the used solvents in bulk and then resell these
solvents. (Note: Names of some companies which provide this
reclaim service can be found in the public record for the
electrical and electronic components regulation.) The revenue
obtained from the sale of these solvents can in some cases offset
the costs of collecting the solvents.
Carbon Absorption Another applicable technology for the
control of toxic organic discharges is end-of-pipe treatment
using carbon adsorption. Frequently used in advanced wastewater
treatment, adsorption is a process in which soluble substances
become chemically or physically bonded to a solid surface. In
operation, wastewater relatively free of suspended matter is
passed through a chamber containing activated carbon which has a
high capacity for adsorbing organic substances from the stream.
7-9
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Once the capacity of the carbon is exhausted, it must be replaced
or regenerated.
The effectiveness of carbon in removing specific organics varies
and is dependent on molecular weight and polarity of the
molecules, and on operating conditions such as contact time,
temperature and carbon surface area. Table 7-1 presents the
theoretical treatability using activated carbon for the 6 toxic
organics found in CRT wastewaters.
Four of the six toxic organics have estimated treatabilities
between 0.10 and 1.0 milligrams per liter. The other two toxic
organics are theoretically treatable by activated carbon to 0.05
and 0.01 milligrams per liter.
In order to assess the effectiveness of using activated carbon
for removal of toxic organics, the Agency used a model plant
approach. Data from wastewater sampling in these subcategories
have shown that only a few toxic organics occur in any particular
plant effluent. The estimated lower limit would consist of a
plant having one of the four most difficult pollutants to treat
and two organics that can be reduced to 0.05 and 0.01 mg/1. An
estimated upper limit could be approximated from a plant having
all four of the most difficult pollutants to treat and the
remaining 2 reducible to 0.05 and 0.01 mg/1. The TTO effluent
concentrations based on these occurrences would range from 0.56
mg/1 to 2.06 mg/1.
Because this range approximates the TTO effluent level achievable
by solvent management, the use of carbon adsorption would result
in minimal, if any additional removal of toxic organics beyond
solvent management. While plants could use carbon adsorption to
achieve approximately the same effluent concentration of toxic
organics as they could using solvent management, carbon
adsorption is unlikely to be used since plants have found solvent
management to be much less expensive, relatively simple to
institute, and approximately as effective in controlling toxic
organic discharges.
7.3 RECOMMENDED TREATMENT AND CONTROL SYSTEMS
Based on the pollutants of concern in the Cathode Ray Tube and
Luminescent Materials Subcategories, applicable treatment
technologies for the control of these pollutants, and the current
technologies observed within the two subcategories, five options
for control and treatment have been identified.
Option 1 treatment consists of neutralization for pH control.
Option 2 treatment consists of Option 1 treatment with the
addition of: chemical precipitation and clarification of all
metals-bearing process wastes using lime, calcium chloride (to
control fluoride), a coagulant and/or polyeletrolyte, and sludge
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TABLE 7-1
TREATABILITY OF TOXIC ORGANICS
USING ACTIVATED CARBON
Treatability
Toxic Pollutant mg/1
11 1,1,1-trichloroethane 0.1 - 1.0
23 chloroform 0.1 - 1.0
44 methylene chloride 0.1 - 1.0
66 bis(2-ethylhexyl) phthalate 0.010
86 toluene 0.050
87 trichloroethylene 0.1 - 1.0
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dewatering. In addition, for the Cathode Ray Tube Subcategory,
Option 2 treatment includes ciromium reduction with the use of
sulfuric acid and sodium bisulfite, and sodium carbonate
precipitation and clarification for lead-bearing wastes. Option
2 is presented schematically in Figure 7-2, for CRTs and Figure
7-3 for Luminescent Materials.
Option 3 treatment consists of Option 2 treatment with the
addition of multi-media filtration technology. Option 3
treatment is also depicted in Figure 7-2, for CRTs and Figure 7-3
for Luminescent Materials.
Option 4 (Cathode Ray Tube Subcategory only) consists of solvent
management for control of toxic organics. Solvent management is
not a treatment system, but rather an in-plant control to collect
spent solvents for resale or contract disposal. EPA, therefore,
considered it in conjunction with Options 1 through 3.
Option 5 (Cathode Ray Tube Subcategory only) adds end-of-pipe
carbon adsorption for further removal of toxic organics.
7.4 ANALYSIS OF INDUSTRY PERFORMANCE DATA
The following subsections present data on the peformance of in-
place treatment systems in the Cathode Ray Tube and Luminescent
Materials Subcategories as they relate to the identified options
presented in Section 7.3 Also presented are the results of
analyses of available long-term effluent monitoring data and a
discussion of the statistical methodology used to analyze the
data.
7.4.1 Cathode Ray Tube Subcategory
Table 7-2 presents a summary (average influent and effluent
concentrations) of the performance of Option 2 and Option 3
treatment technologies from results of the three-day samplings of
three color television picture tube manufacturing plants.
Plant 30172 uses chromium reduction of concentrated chromium
wastes and carbonate precipitation and settling of concentrated
lead-bearing wastes. The effluents from these two treatment
units are then combined with other process wastes and sent
through a precipitation/clarification/filtration treatment
system. The treatment system effluent is then combined with
dilute process wastes and cooling water in a holding lagoon prior
to direct discharge (see Figure 5-1). Sampling data from this
plant were not used to derive toxic metals limits for Option 2
performance because not all wastewater sources of toxic metals at
this plant do not pass through the precipitation/clarification
treatment system (see Figure 5-1, showing that phosphor wastes
bypass the clarification system). However, sampling data on the
performance of the filtration unit (percent removals) were used
to derive toxic metals limits for Option 3 performance. Effluent
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Chemical
and Settling
Sludge to
Filter Press
H2SO4 NaHS03
1 1
Chromium -*. Chromium \
Wastes ^ Reduction ^
Other Prorpss Wastes- ..... _ ^^.
Poly electrolyte
Lime Cad-)
1 .. 1
Chemical
and Clarification Adjustment
v
^
Solids Contract -Hauled
OPTION 3
1
M
U>
Lead Wastes
Polyelectrolyte
Solids Contract-Hauled
FIGURE 7-2
RECOMMENDED TREATMENT
CATHODE RAY TUBE SUBCATEGORY
-------
OPTION 2
Polyelectrolyte
Lime
CaCl,
Solids Contract-Hauled
-J
I
Polyelectrolyte
Lime
CaCl
Solids Contract-Hauled
FIGURE 7-3
RECOMMENDED TREATMENT
LUMINESCENT MATERIALS SUBC/1 TEGORY
-------
TABLE 7-2
PERFORMANCE OF IN-PLACE TREATMENT
CATHODE RAr TUBE SUBCATEGORY
Parameter
Option 2 Treatment
Lead
Waste Treatment
Inf.
(mg/1)
Eff .
(mg/1)
Precipitation/
Clarification
Inf.
(mg/1)
Eff.
(mg/1)
Option 3 Treatment
Dual-Media Filtration
inf. Eff.
(mg/1) (mg/1)
PLANT 30172
Toxic Metals
Cadmium
Chromium
Lead
Zinc
1.070
4.670
891
1510
<0.005
0.022
1.2
18.7
0.171
2.87
14.2
6.08
<0.002
0.244
0.253
0.131
<0.002
0.244
0.253
0.131
<0.002
0.208
0.163
0.075
Other Pollutants
TSS
Fluoride
190
160
11
78.5
89
340
2.5
7.1
2.5
7.1
3.1
11.1
PLANT 99796
Toxic Metals
Cadmium
Chromium
Lead
Zinc
0.063
0.990
13.0
19.7
0.019
0.163
0.300
0.550
Other Pollutants
TSS
Fluoride
380
31.7
15
30.00
(1) Data from Tables 5-3 and 5-5.
-------
TTO sampling data (Appendix 3) submitted to the Agency by this
facility were used to derive TTO limits since filters will
achieve little additional removal of organics once most oil and
grease has been removed by precipitation/clarification.
Furthermore, since this plant had the highest reported usable TTO
effluent data, it represented the maximum observed treated
effluent TTO concentration resulting from unavoidable
contaminations.
Plant 99796 performs chromium reduction on a chromium-bearing
waste stream within a primary tank. A concentrated lead bearing
waste is periodically batch discharged to the primary tank for
treatment. Overflow from the primary tank is combined with a
caustic stream in a secondary tank, lime is added, and the waste
is sent through a clarification system. The treatment system
effluent enters a holding lagoon prior to indirect discharge (see
Figure 5-3). Sampling data from this plant were used in
calculating limits for toxic metals. Data were not used for
fluoride limits because the plant was not using calcium chloride
to treat for fluoride.
Plant 11114, was also sampled. It is a color television picture
tube plant which has three separate treatment systems serving
different areas of the plant (see Figure 5-2). The sampling
results indicated that, although some components achieve
pollutant reduction, wastewater treatment is generally
ineffective at Plant 11114. Fluoride for example, was present in
the effluent at 480 mg/1. For this reason, treatment performance
data from this plant were not used to calculate limits.
In addition to sampling data, long-term effluent self-monitoring
data were submitted by five plants.
Plant 30172 (described above) submitted data based on monitoring
its treatment system effluent following filtration. In addition,
several phosphor waste streams bypass the plants clarifier and
its filters (see figure 5-1). For both these reasons the data
were generally not suitable for use in defining what toxic metals
controls could be achieved by precipitation/clarification.
However, the long-term data were used to derive limits for
fluoride (Appendix 2). This was appropriate because fluoride
levels are not affected significantly by filters (see discussion
under fluoride treatment).
Plants 99797 and 99798 monitored the final effluents from their
precipitation/clarification treatment systems. Data from Plant
99797, however, was considered to show poor treatment performance
because of extremely high total suspended solids (TSS) levels in
the effluent. Of 33 data points nine were over 100 mg/1, two
were over 360 mg/1, and one exceeded 600 mg/1. By comparison
other plants had data showing TSS consistently below 100 mg/1.
Data from Plant 99798 were used to calculate fluoride and metals
7-16
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limits (data are presented in Appendix 4), however it could not
be used for TTO calculations since it submitted no TTO data.
The two other plants that submitted long-term effluent self
monitoring data were not used to calculate limits for the
following reasons: Plant 99796 self monitoring data was not used
to calculate fluoride limits because, as noted above, the plant
does not treat for fluoride with calcium chloride. Its self
monitoring data were not used to calculate toxic metals limits
because the self submited data was based on sampling effluent
from a large holding lagoon which allows additional removal of
pollutants not included in Option 2 technology. In contrast,
EPA's sampling data from that plant was based on effluent from
the plants precipitation/clarification system. Wastewater
treatment at Plant 11114 as discussed above, is generally
ineffective.
Table 7-3 presents the results of statistical analyses of long-
term and sampling data from the three plants that EPA visited.
The derivation of the variability factors presented in Table 7-3
is discussed under statistical methodology in Section 7.4.3.
7.4.2 Luminescent Materials Subcateqory
Table 7-4 presents a summary (average influent and effluent
concentrations) of available Option 2 performance data for the
Luminescent Materials Subcategory. Both Plants 101 and 102 have
combined treatment systems which treat wastes from other
manufacturing operations. The treatment systems consist of flow
equalization, precipitation, clarification and pH adjustment.
Influent and effluent data were taken on three days of sampling
conducted under this study. Influent data was taken before and
after process waste streams were combined for treatment.
7.4.3 Statistical Methodology
Introduction
To establish effluent guideline limitations for the Electrical
and Electronic Components Phase 2 Category, the available data
were examined to determine the performance levels that were
attained by properly operated treatment systems in the category.
Two souces of pollutant concentration measurement data were
available for this assessment/ data that had been collected under
the Agency's supervision and data that had been supplied by
industry. The Agency's data consist of pollutant concentrations
that had been measured in samples taken from untreated or raw
influent wastewater streams and from treated effluent wastewater
streams. The Agency's sampling was conducted in both cathode ray
tube and luminescent materials plants over periods of one to
three days.
7-17
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TABLE 7-3
SUMMARY STATISTICS OF PLANTS USED FOR LIMITATION DEVELOPMENT
IN THE CATHODE RAY TUBE SUBCATEGORY
POLLUTANT SOURCE1 PLANT
N 2 AVERAGE3
DAILY4
VF
Fluoride
Cadmium
Chromium
Lead
Zinc
1)
2)
3)
4)
5)
6)
IND
IND
EPA
IND
EPA
IND
EPA
IND
EPA
IND
99798
30172
Overall6
99796
99798
Overall6
99796
99798
Overall6
99796
99798
Overall6
99796
99798
Overall6
20
27
3
20
3
20
3
8
3
20
12.6
16.4
14.5
0.019
0.020
0.020
0.163
0.294
0.229
0.300
0.238
0.269
0.550
0.243
0.397
2,
2,
2.
1,
3,
16
64
40
69
85
2.77
1.20
4.50
2.85
2.16
6.16
4.16
3.37
3.59
3.48
MONTHLY5
VF
1.21
1.28
1.25
1.14
1.46
1.30
1,
1.
1,
1,
1,
1,
04
55
30
,22
,86
,54
1.42
1.41
1.42
SOURCE: indicates who conducted the wastewater sampling.
IND is industry. EPA is the Agency.
N:
is the number of pollutant observations.
AVERAGE: is the arithmetic average of all the values for a
pollutant from a plant. Values that were recorded as below
a detection limit were used in the average at the detection
limit.
DAILY VF: is the ratio of the estimate of the 99th
percentile of the lognormally described daily values to an
estimate of the expected or average pollutant
concentrations.
MONTHLY VF: ic the ratio of the estimate of the 95th
percentile of the lognormally distributed averages of 10
values to an estimate of the expected or average pollutant
concentrations.
Overall: is the unweighted arithmetic average of the
individual plant estimates of AVERAGE, DAILY VF, and MONTHLY
VF. THe overall averages are used for limitation
development.
7-18
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TABLE 7-4
PERFORMANCE OF IN-P'LACE TREATMENT
Luminescent Materials Subcategory(1)
Option 2 Treatment
Precipitation/Clarification
Parameter
Plant 101
Influent
mg/1
Effluent
mg/1
Plant 102
Effluent
mg/1
Toxic Metals
Antimony
Cadmium
Z inc
Other Pollutants
TSS
0.029
0.34
5.52
210
0.031
0.020
0.289
0.008
0.20
0.47
45
12
(1) Data are from Tables 5-7 and 5-8.
7-19
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The pollutant concentration data supplied by industry are from
the Cathode Ray Tube Subcategory. These data were pollutant
concentrations measured in isamples taken from wastewaters at
various stages of treatment. The rationale for excluding or
including wastewater sampling data are presented in Sections
7.4.1 and 7.4.2 and summaries of these data used for limitation
development are presented in Tables 7-2, 7-3 and 7-4. In all
cases summary statistics from individual plants were given equal
weight regardless of the source (Agency or industry), the purpose
for which the data were used (to estimate long term averages or
variability), or the sample sizes. Because of the detailed
technical evaluation, (presented in sections 7.4.1 and 7.4.2) the
Agency has determined that all the plants used for limitation
development are representative of the category; thus the Agency
finds it reasonable to apply equal weights to the summary
statistics of individual plants regardless of the amount of data
available from a plant.
Daily and monthly variability estimates are used with the average
effluent polluant concentration estimates to yield daily and
monthly effluent limitations. The statistical methodology used
to calculate the variability estimates, averages, and limitations
for pollutants regulated in the Cathode Ray Tube and Luminescent
Materials Subcategories is described below.
Variability Factors
Even well operated wastewater treatment systems experience
fluctuations in pollutant concentrations discharged. These
fluctuations result from the variation in process flow, raw waste
loading of pollutants, treatment chemical feed, mixing
effectiveness during treatment, and combinations of these or
other factors. The variation among daily measurements of
effluent pollutant concentrations is expected to be larger than
the variation among the averages of several measurements of
pollutant concentrations measured during a month. To estimate
these two sources of variation daily and monthly average
estimates of variability are determined for each pollutant. The
Agency's data and industry's data from the Cathode Ray Tube
Subcategory were used for the development of variability
estimates for the metals (cadmium, chromium, lead, zinc). These
variability estimates were used for the development of metals
limitations for all standards in the category. Industry data
from the Cathode Ray Tube Subcategory were used to develop
variability estimates for fluoride and were used for the
development of fluoride limitations for all standards in the
category.
The variability of pollutant concentrations measured in
wastewater effluents for the daily and monthly maximum
limitations were estimated separately for each plant (Table 7.2).
The variability is expressed as a variability factor. The one
day maximum variability factor is the ratio of the estimated 99th
7-20
-------
percentile of the distribution of individual daily observations
to the expected value (i.e., an estimate of the long-term
average) of the pollutant concentration from that plant. The
monthly average variability factor is the ratio of the estimated
95th percentile of the distribution of averages of ten daily
observations to the expected value.
The basic assumption underlying the methodology used to estimate
percentiles and expected values is that the concentration
measurement that are greater than or equal to the limit of
detection are lognormally distributed. Shapiro-Wilk goodness-of-
fit tests applied to the natural logarithm transformed pollutant
(cadmium, chromium, fluoride, lead, zinc) concentrations (greater
than or equal to the detection limit) measured in the effluent
wastewaters of plant 99798 indicate that the untransformed
pollutant concentrations are not significantly different
lognormal. Plant 99798 is the only plant with adequate data for
testing lognormality. The results of the goodness-offit tests
applied to the pollutant concentrations from Plant 99798 and the
fact that lognormality has been shown to apply to a variety of
pollutants in a wide range of industrial categories indicate that
the assumption of lognormality is reasonable. Plant 99796 only
has three observations for each pollutant. Although
distributional goodness-of-fit tests can be applied to small data
sets, a data set with three observations is not large enough to
allow discrimination among distributional forms. Goodness-of-fit
tests could not be applied to the fluoride concentration
measurements from Plant 30172 because these data were averages of
four daily measurements taken during a month. To use these data
for the estimation of the lognormal parameters described below,
the log standard deviation of the four-day averages was
multiplied by the square root of four.
The percentiles and the expected value of the pollutant
concentrations were estimated using the delta lognormal
distribution, a generalized form of the lognormal distribution,
which allows consideration of pollutant concentrations reported
below a limit of detection. In the delta lognormal distribution,
measurements greater than or equal to the detection limit are
assumed to follow a lognormal distribution and measurements at or
below the detection limit occur with a discrete probability. The
delta lognormal distribution is described by Aitchison and Brown
(1963f The Lognormal Distribution, Cambridge University Press,
Cambridge England, Chapter 9).
An arithmetic average of the daily and ten day variability
factors from each plant were calculated for each pollutant and
used as the overall estimate of variability (Table 7-3).
Lonq-Term Averages
In addition to estimates of variability, limitations also require
that an estimate be made of the average pollutant concentrations
7-21
-------
that can be expected in the treated effluent waste stream of a
properly designed and well operated wastewater treatment system.
As described above, daily pollutant concentration measurements
will fluctuate above and below an average effluent pollutant
concentration. Except for TSS in both subcategories and fluoride
in the Luminescent Materials Subcategory the average effluent
pollutant concentrations for a subcategory were determined using
data from plants in each subcategory.
Averages were estimated for each pollutant concentration measured
in the effluent stream of each plant with acceptable data (Tables
7-3 and 7-4). The Cathode Ray Tube Subcategory averages for the
metals and fluoride were calculated by taking the arithmetic
average of the untransformed effluent pollutant concentrations.
The values reported below a limit of detection were assigned the
detection limit value prior to averaging. The long-term averages
(Table 7-3) were determined by averaging the plant averages for
each pollutant. The total suspended solids long-term average was
transferred from the Metal Finishing Category.
An estimate of long-term averages for antimony, zinc, and cadmium
in the Luminescent Materials Subcategory was made by using the
highest effluent concentration measurement found in plants 101
and 102 (Table 7-4). The fluoride long-term average was
transferred from the Cathode Ray Tube Subcategory and the total
suspended solids long-term average was transferred from Metal
Finishing Category.
Calculation of_ Effluent Limitations
The effluent limitations are based on the premise that a plant's
treatment system can be operated to maintain average effluent
concentrations equivalent to those concentrations observed in the
effluent data base. As explained above day-to-day concentrations
will fluctuate below and above an average concentration.
Effluent limitations are set far enough above the average
concentration so that plants with properly operated treatment
systems will be within the limits most of the time (roughly 99
percent of the time in the case of daily values and 95 percent of
the time in the case of monthly averages based on ten days of
daily sampling).
Effluent limitations are obtained for each pollutant by
multiplying the long-term average concentration by the
appropriate daily and monthly variability factors. Expresses as
an equation:
L = VF x A.
Where L is the effluent limitation, VF is the variability factor,
and A is the long term average concentration.
7-22
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SECTION 8
SELECTION OF APPROPRIATE CONTROL AND
TREATMENT TECHNOLOGIES AND BASES FOR
LIMITATIONS
Discharge regulations for the Cathode Ray Tube Subcategory and
the Luminescent Materials Subcategory are presented in this
section. The technology bases and the numerical bases are also
presented for each regulation. The statistical methodology used
to develop limitations was presented in Section 7.4.
8.1 CATHODE RAY TUBE SUBCATEGORY
The Agency is not regulating direct dischargers in the Cathode
Ray Tube Subcategory for reasons presented in Section 6.2.
Therefore, BPT, BAT and BCT limitations are not being
promulgated.
8.1.1 Pretreatment Standards for Existing Sources (PSES)
Long Term
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
Average
(LTA)
(mg/1)
0.020
0.229
0.269
0.397
14.5
Monthly
Average Daily Maximum
VF
1 .30
1 .30
1 .54
1 .42
1 .25
Limit (mg/1)
0.03
0.30
0.41
0.56
*
18.0
VF
2.77
2.85
4. 16
3.48
2.40
Limit (mg/1)
0.06
0.65
1.12
1 .38
1 .58
35.0
*The Agency is not promulgating
reasons presented below.
monthly TTO limitations for
EPA is promulgating PSES based on Option 2 and Option 4. Option
4 is solvent management to control toxic organics. Option 2
consists of neutralization, and precipitation/clarification of
the final effluent to reduce toxic metals and fluoride along with
inprocess control for lead and chromium. Solvent management is
widely practiced at cathode ray tube facilities, as is
neutralization. Precipitation/clarification technology is known
to be currently practiced at six CRT facilities. Option 1,
neutralization, was not selected because it will not control
toxic metals or fluoride. Option 3, filtration, was not selected
because the demonstrated national pollutant reduction of 5.9
pounds per day beyond that achieved by Option 2 is not considered
significant for existing sources. Precipitation/clarification
technology achieves greater than 96 percent reduction of metals.
1-1
-------
Option 5 (carbon adsorption for toxic organics) was rejected for
technical reasons. EPA calculated the theoretical concentrations
of organics that Option 5 would achieve, and found that it would
result in TTO levels equal to, or perhaps worse than, those
achieved by proper solvent management.
Toxic Metals and Fluoride The limitations for toxic metals
(cadmium, chromium, "lead and zinc) and fluoride are based on
demonstrated performance at CRT plants employing
precipitation/clarification treatment technologies. As described
in Section 7, both on-site sampling and long-term effluent
monitoring data are reflected in the limitations. They therefore
incorporate both the plant-to-plant variations in raw wastes and
treatment practices and the day-to-day variability of treatment
system performance. The concentrations shown are all applicable
to the treated effluent prior to any dilution with sanitary
wastewater, noncontact cooling water, or water from other
processes.
The achievable long-term average concentrations used to develop
the limitations are based on EPA sampling data and long-term
self-monitoring data as shown in Table 7-3. The averages for the
toxic metals represent the average effluent concentrations
following Option 2 treatment at Plants 99796 and 99798. The
average for fluoride incorporates self monitoring data from the
filtered effluent from Plant 30172 as well as the clarifier
effluent concentration reported by Plant 99798. Since the EPA
sampling data from Plant 30172 show no removal of fluoride
following filtration, the data likely reflect performance for
Option 2 technology.
The variability factors used to develop these limitations are
based on statistical analysis of long-term self monitoring data
and EPA data. For cadmium, chromium, lead, zinc, and fluoride
EPA averaged self monitoring and EPA monitoring data separately,
then used the median of those two averages.
Total Toxic Organics (TTO) A daily maximum limit of 1.58
milligrams per liter is being promulgated based on the control
technology of solvent management. The Agency is regulating total
toxic organics rather than individual organics. TTO represents
the sum of toxic organics found in the effluents of CRT
facilities at concentrations greater than 0.01 milligrams per
liter. Organic compounds included in TTO are listed in Table 61.
The Agency is establishing a daily maximum TTO limit but not a
monthly average TTO limit. This is because solvent management is
not a treatment technology and therefore not subject to
significant performance variation. In addition, the final limit
is already the highest of several observations.
The Agency also considered an alternative way of developing a TTO
limit. EPA had visited or sampled representative CRT facilities.
All practiced solvent management by segregating and collecting
3-2
-------
spent solvents used in the manufacturing process. Sampling data
generally showed very low quantities of TTO. Data from another
plant (11114) were unusable because of dilution problems.
Because of limited data, the proposed limit for TTO (0.15 mg/1)
was in fact based on the maximum TTO observed during three days
of sampling at one plant. Recognizing the limited data base, EPA
requested in the preamble to the proposed regulations that
additional data be submitted by industry.
In response to this request one facility submitted data for one-
day sampling. One other plant submitted data; however, the
sampling methodology used did not comply with EPA sampling
protocol since it did not composite its grab samples before
analysis. Additionally, Plant 11114 submitted flow-data which
allowed us to calculate the TTO value by deleting the effect of
dilution by cooling water and other non-related process streams.
Combining these data provided five data points from three plants.
Based on these data, we calculated a median TTO value of 1.13
mg/1. Even when multiplied by a significant variability factor
that limit would be only 1.47 mg/1. That concentration did not
differ significantly from the maximum TTO reported (1.58 mg/1) in
the effluent of plants practicing solvent management in this
subcategory. Therefore a daily maximum TTO limit of 1.58 is
being promulgated.
Finally because only limited TTO data were available from the CRT
industry, EPA reviewed data from other industries, including
other E&EC subcategories, to assess the reasonableness of this
limitation. The TTO limit for the E&EC Phase I subcategories was
1.37 mg/1; that for Metal Finishing was 2.13 mg/1. The limit
selected here (1.58 mg/1) appears reasonable in light of likely
sources of TTO for this industry and in view of reported
concentrations in this subcategory.
8.1.2 New Source Performance Standards (NSPS)
Pollutant
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
TSS
pH
LTA
(mg/1)
0.020
0. 196
0. 174
0.229
14.5
12.8
range
Monthly
Average
VF Limit (mg/1)
1.30 0.03
1.30 0.26
1.54 0.27
1 .42 0.33
1 .25 18.0
1.85 24.0
from 6 to 9
Daily Maximum
VF
2.77
2.85
4.16
3.48
2.40
3.59
Limit (mg/1)
0.06
0.56
0.72
0.80
1 .58
35.0
46.0
The Agency is promulgating NSPS based on Option 3. This
technology consists of neutralization and solvent management plus
8-3
-------
end-of-pipe precipitation/clarification followed by filtration
along with in-process control for lead and chromium. Option 1
was not selected because it will not control toxic metals or
fluoride. Option 3 was selected over Option 2 because new plants
have the opportunity to install the best demonstrated
technologies. The installation of filtration technology will
accomplish an additional 1.4 percent reduction in toxic metals.
Filters are not expected to produce a measurable reduction in
fluoride or TTO. Thus the proposed limitations for these
pollutants do not change from PSES.
Toxic Metals The percent reduction of each metal following
filtration as calculated from Table 7-2 were applied to the long-
term average concentrations in PSES to develop the achievable
long-term average. Variability factors are the same as those
derived for Option 2 technology.
Total Suspended Solids (TSS) TSS limitations represent a
transfer of data from the Metal Finishing Category. The average
effluent concentration of 12.8 milligrams per liter of TSS was
derived from EPA sampling data from several metal finishing
plants practicing solids removal by clarification and filtration
technology. Excluded from the data base were plants with
improperly operated treatment systems. The variability factors
of 1.85 (monthly) and 3.59 (daily) represent the median of
variability factors from 17 metal finishing plants with longterm
monitoring data. The rationale for transferring technology from
this industry is (1) the raw waste TSS concentrations are similar
to those found in CRT wastes, and (2) the treatment technology
used for solids reduction in metal finishing plants mentioned
above and used to derive these limits, is the same as Option 3
for Cathode Ray Tubes Subcategory.
pH Properly operated end-of-pipe neutralization of wastewater
will ensure discharges in the pH range of 6 to 9 as demonstrated
by sampling data.
8.1.3 Pretreatment Standards for New Sources (PSNS)
Pollutant
LTA
(mg/1)
Monthly
Average Daily Maximum
VF Limit (mg/1)
VF Limit (mg/1)
Cadmium
Chromium
Lead
Zinc
TTO
Fluoride
0.020
196
174
229
14.5
1 .30
30
54
42
1 .25
0.03
0.26
0.27
0.33
18.0
2.77
2.85
4.16
3.48
3.40
0.06
0.56
0.72
80
0
1
58
35.0
8-4
-------
The Agency is promulgating PSNS based on Option 3. This
technology consists of neutralization and solvent management plus
end-of-pipe precipitation/clarification followed by filtration
along with in-process control for lead and chromium. As with
NSPS the addition of filtration is expected to further reduce
toxic metals in the effluent over that expected from
precipitation/clarification (Option 2), but no meaningful
reduction in fluoride or TTO is expected.
The basis for the toxic metals, total toxic organics (TTO) and
fluoride limitations were presented under NSPS. These
limitations do not change for PSNS. TSS and pH are not regulated
under PSNS because they are conventional pollutants which can be
removed by a POTW.
8.2 LUMINESCENT MATERIALS SUBCATEGORY
The Agency is not regulating existing dischargers in
the Luminescent Materials Subcategory for reasons presented in
Section 6.2.
8.2.1 New Source Performance Standards (NSPS)
Monthly
Pollutant
Cadmium
Antimony
Zinc
Fluoride
TSS
pH
LTA
(mg/1
0.20
0.03
0.47
14.5
16.8
range
Average
) VF Limi
1 .
1
1
1
1
from
30
.42
.42
.25
.85
6-9
t
0
1
3
,
0
0
8
1
(mg/1
26
.04
.67
.0
.0
Daily
Max
) VF
2.
3
3
2
3
77
.48
.48
.40
.59
imum
Limit
0
3
,
0
1
5
60
(mg/1)
55
. 10
.64
.0
.0
EPA is promulgating NSPS based on
consists of precipitation/clarification
technology controls pH, total suspended
cadmium, antimony, and zinc. All but
Option 2 technology which
and neutralization. This
solids (TSS), fluoride,
one of the dischargers in
the Luminescent Materials Subcategory are currently practicing
this technology. Option 1 was not selected because Option 2
achieves for greater removals and is economically achievable.
Option 3, filtration, was not selected because it would only
accomplish an additional 0.16 percent reduction in toxic metals.
The bases for pH and fluoride limitations were presented in
Section 8.1 for the Cathode Ray Tubes Subcategory. The
limitations for these pollutants are the same for the Luminescent
Materials Subcategory. Fluoride levels are similar in the raw
waste streams of these two subcategories. pH levels will also be
controlled to similar levels following
3-5
-------
precipitation/clarification
metals and suspended solids
treatment.
limitations
The bases for toxic
are presented below.
Toxic Metals The NSPS limitations for toxic metals (cadmium,
antimony and zinc) are based on sampling data from two
luminescent materials plants employing
precipitation/clarification technologies. Because the available
data are limited, the higher value of each toxic metal from the
two plants was selected as the achievable long-term average.
Variability factors are the same as those derived for the CRT
industry, which practices the same treatment technology. These
variability factors are discussed in Section 8.1.1. Because no
long-term monitoring data were available for antimony, the higher
of the variability factors for the other metals, those for zinc
were applied for antimony.
Total Suspended Solids (TSS) Proposed TSS limitations
represent a transfer of data from the Metal Finishing Category.
The average concentration of 16.8 milligrams per liter was
derived from EPA sampling data from numerous metal finishing
plants practicing solids removal by clarification technology.
Excluded from the data base were plants with improperly operated
treatment systems. The daily and monthly variability factors
each represent the median of variability factors from 17 metal
finishing plants with long-term monitoring data. The rationale
for transferring technology from this industry is (1) the raw
waste TSS concentrations are similar to those found in
luminescent materials wastes, and (2) the treatment technology
used for solids reduction in the metal finishing plants mentioned
above and used to derive these limits is the same as Option II
for the Luminescent Materials Subcategory.
8.2.2 Pretreatment Standards; for New Sources (PSNS)
Pollutant
Cadmium
Antimony
Zinc
Fluoride
LTA
(mg/1)
0.20
0.03
0.47
14.5
Monthly
Average
VF Limit (mg/1)
1 .30 0.26
1.42 0.04
1.42 0.67
1 .25 18.0
Daily Max
VF
2.77
3.48
3.48
2.40
imum
Limit (m
0.55
0. 10
1 .64
35.0
For PSNS, the Agency is promulgating limitations based on Option
2, neutralization and end-of-pipe precipitation/clarification for
control of toxic metals and fluoride. Option 1 was not selected
because it will not control toxic metals or fluoride as well as
Option 2, which has been demonstrated and is economically
achievable. Option 3 was not selected for reasons presented
under NSPS.
8-6
-------
PSNS limitations for luminescent materials producers are the same
as those for NSPS except that pH and TSS are not regulated for
pretreatment since they are adequately controlled by POTWs. The
basis for limitations were presented in Section 8.2.1.
i-7
-------
SECTION 9
COST OF WASTEWATER TREATMENT AND CONTROL
This section presents estimates of the costs of implementation of
wastewater treatment and control systems for the Cathode Ray Tube
and Luminescent Materials subcategories of the Electrical and
Electronic Components category. The systems for which cost
estimates are presented are those options identified in Section
7. The cost estimates then provide the basis for possible
economic impact of regulation on the industry. The general
approach or methodology for cost estimating is presented below
followed by the treatment and control costs.
9.1 COST ESTIMATING METHODOLOGY
Costs involved in setting up and operating a wastewater treatment
unit are comprised of investment costs for construction,
equipment, engineering design, and land, and operating costs for
energy, labor, and chemicals. There are also costs for disposing
of sludge and for routine analysis of the treated effluent.
The costs presented in this section are based on model plants
which closely resemble the types and capacities of waste
treatment facilities needed for each product subcategory. Model
plants are not set up as exemplary plants, but as typical of
sufficient design to represent the range of plants and treatment
facilities present in the industry. Data are based on plant
visits and contacts with industries to verify treatment
practices and to obtain data on size, wastewater flow, and solid
waste disposal systems. The differences in treatment capacities
are reflected in the choice of model plants which are presented
for different flow rates covering the existing range of flows at
average concentrations of pollutants.
Unit process equipment costs were assembled from vendors and
other commercial sources. Information on the costs of equipment,
the present costs of chemicals and average costs for hauling
sludge was developed with data from industry, engineering firms,
and equipment suppliers. Appropriate factors were applied to
determine total investment costs and annual costs.
The costs which will actually be incurred by an individual plant
may be more or less than presented in the cost estimate. The
major variations in treatment costs between plants result from
differences in pollutant concentrations and site dependent
conditions, as reflected in piping lengths, climate, land
availability, water and power supply and the location of the
point of final discharge. In addition, solids disposal costs and
material costs will vary depending on geographical locations. A
broad range of actual costs could exist that would not be
9-1
-------
fundamentally different from those analyzed here. However, in
general, EPA believes that these are a conservative set of
estimates of actual costs.
The following assumptions were employed in the cost development:
1. All non-contact cooling water was excluded from
treatment and treatment costs.
2. Source water treatment, cooling tower and boiler
blowdown discharges were not considered process
wastewater.
3. Sanitary sewage flow is excluded.
4. The treatment facilities were assumed to operate 24-
hours per day five days per week.
5. Excluded from the estimates were any costs associated
with permits, reports or hearings required by regula-
tory agencies. These are independent of the costs of
actually meeting these substantive performance standards,
Investment costs are expressed in mid-year 1982 dollars to
construct facilities at various wastewater flow rates.
Operation, maintenance, and amortization of the investment are
expressed as elements of annual costs.
9.1.1 Direct Investment Costs for Land and Facilities
Types of direct investment costs for waste treatment facilities
and criteria for estimating major components of the model plants
are presented below.
Construction Costs Construction costs include site
preparation, grading, enclosures, buildings, foundations,
earthworks, roads, paving, and concrete. Since few if any
buildings will be utilized, construction co-sts have been
calculated using a factor of 1.15 applied to the installed
equipment cost.
Equipment Cost Equipment for wastewater treatment consists of
a combination of items such as pumps, chemical feed systems,
agitators, flocculant feed systems, tanks, clarifiers and
thickeners. Cost tables for these items were developed from
vendor's quotations for a range of sizes, capacities and motor
horsepowers. Except for large size tanks and chemical storage
bins, the cost represents packaged, factory-assembled units.
Critical equipment is assumed to be installed in a weatherproof
structure. Chemical storage feeders and feedback controls
include such items as probes, transmitters, valves, dust filters
9-2
-------
and accessories. Critical pumps are furnished in duplicate as a
duty and a spare, each capable of handling the entire flow.
Equipment-In-Place Costs (includes installed equipment costs)
Equipment-in-place is defined to include all services,
activities, and miscellaneous material necessary to implement the
described wastewater treatment and control system, including
piping, fittings, and electrical work. Many factors can affect
the cost of installing equipment modules. These include wage
rates, manpower availability, who does the job (outside
contractor or regular employees), new construction versus
modification of existing systems, and site-dependent conditions
(e.g., the availability of sufficient electrical service). In
these estimates, installation costs were chosen for each model
based upon average site conditions taking into consideration the
complexity of the system being installed. An appropriate cost is
allowed for interconnecting piping, power circuits and controls.
Monitoring Equipment It is assumed that monitoring equipment
will be installed at the treated effluent discharge point. It
will consist of an indicating, integrating, and recording type
flow meter, pH meter, sensor, recorder, alarms, controls and an
automatic sampler.
Land Land availability and cost of land can vary
significantly, depending upon geographical location, degree of
urbanization and the nature of adjacent development. Land for
waste treatment is assumed to be contiguous with the production
plant site. For the purpose of the report land is valued at
$24,000 per acre.
Investment Costs for Supporting Services Engineering design
and inspection are typical services necessary to advance a
project from a concept to an operating system. Such services
broadly include laboratory and pilot plant work to establish
design parameters, site surveys to fix elevation and plant
layout, foundation and groundwater investigation, and operating
instructions, in addition to design plans, specifications and
inspection during construction. These costs, which vary with job
conditions, are often estimated as percentages of construction
costs, with typical ranges as follow:
Preliminary survey and construction surveying
Soils and groundwater investigation
Laboratory and pilot process work
Engineering design and specifications
Inspection during construction
Operation and maintenance manual
From this range of 14 to 26 percent, a value of
(except for the 10,000 gpd estimate where 10 percent
equipment-in-place plus construction costs has been
to 2 %
1 to 2 %
2 to 4 %
7 to 12%
2 to 3 %
1 to 3 %
17 percent
was used) of
used in this
9-3
-------
study to represent the engineering and design cost applied to
model plant cost estimates.
The Contractor's Fee and Contingency These costs are usually
expressed as a percentage of equipment-in-place plus construction
costs, and include such general items as temporary utilities,
small tools, field office overhead and administrative expense.
The contractor is entitled to a reasonable profit on his
activities and to the cost of interest on capital tied up during
construction. Although not all of the above cost will be
incurred on every job, an additional 25 percent (except for the
10,000 gpd estimate where 10 percent was used) of the
equipment-in-place plus construction costs has been used to cover
related cost broadly described as contractor's fees, incidentals,
overhead, and contingencies.
9.1.2 Annual Costs
Operation and Maintenance Costs Annual operation and
maintenance costs are described and calculated as follows:
Labor and Supervision Costs:
Personnel costs are based on an hourly rate of $20.00. This
includes fringe benefits and an allocated portion of costs for
management, administration and supervision. Personnel are
assigned for specific activities as required by the complexity of
the system, ranging from 1-8 hours per day.
Energy Costs:
Energy costs are based on the cost of $219 per horsepower
operating 24 hours per day arid 250 days per year. For batch
processes appropriate adjustments were made to suit the
production schedule. The cost per horsepower year is computed as
follows:
Cy = 1.1 (0.746 HP x Hr. x Ckw)/(E x P)
where Cy = Cost per year
HP = Total Horsepower Rating of Motor (1 HP = 0.746 kw)
E = Efficiency Factor (0.9)
P = Power Factor (1.00)
Hr. = Annual Operating Hours (250 x 24 = 6000)
Ckw = Cost per Kilowatt-Hour of Electricity ($0.040)
Note: The 1.1 factor in the equation represents allowance for
incidental energy used such as lighting, etc. It is assumed that
no other forms of energy are used in the waste treatment system.
Chemicals:
9-4
-------
Prices for the chemicals were obtained from vendors and the
Chemical Marketing Reporter. Unit costs of common chemicals
delivered to the plant site are based on commercial grade of the
strength or active ingredient percentage with prices as follows:
Lime (Calcium Hydroxide) Bulk $54/Ton
Sulfuric Acid $84/Ton
Flocculant $ 2/Lb
Sodium Bisulfite $0.32/Lb
Soda Ash $0.14/Lb
Calcium Chloride $0.24/Lb
Maintenance:
The annual cost of maintenance is estimated as ten percent (10%)
of the investment cost, excluding land.
Taxes and Insurance:
An annual provision of three percent of the total investment cost
has been included for taxes and insurance.
Residual Waste Disposal:
Sludge disposal costs can vary widely. Chief cost determinants
include the amount and type of waste. Off-site hauling and
disposal costs are taken as $50/ton for bulk hauling, with
appropriate increases for small quantities in steel containers.
Information available to the Agency indicates that the selected
treatment technologies for controlling pollutants in this
industry will not result in hazardous wastes as defined by RCRA.
Monitoring, Analysis and Reporting:
The manpower requirements covered by the annual labor and
supervision costs include those activities associated with the
operation and maintenance of monitoring instruments, recorder and
automatic samplers as well as the taking of periodic grab
samples. Additional costs for analytical laboratory services
have been estimated for each subcategory assuming that sampling
takes place three times a week at the point of discharge. A cost
of $7500/year has been used for monitoring analyses and
reporting.
Amortization:
9-5
-------
Amortization of capital costs (investment costs) are computed as
follows:
CA = B (r(l+r)n)/((l+r)n-l)
where CA = Annual Cost
B = Initial amount invested excluding cost of land
r = Annual interest rate (assumed 13 percent)
n = Useful life in years
The multiplier for B in equation (1) is often referred to as the
capital recovery factor and is 0.2843 for the assumed overall
useful life of 5 years. No residual or sludge value is assumed.
9. 1 . 3 Items not Included jji Cost Estimate
Although specific plants may encounter extremes of climate, flood
hazards and lack of water, the cost of model plants have been
estimated for average conditions of temperature, drainage and
natural resources. It is assumed that any necessary site
drainage, roads, water development, security, environmental
studies and permit costs are already included in production
facilities costss. Therefore, the model costs are only for
facilities, suppliers and services directly related to the
treatment and disposal of waterborne wastes, including land
needed for treatment and on-site sludge disposal. Air pollution
control equipment is not included, except for dust collectors
associated with treatment, chemical transfer and feeding. Raw
wastes from various sources are assumed to be delivered to the
treatment facility at sufficient head to fill the influent
equalization basin, and final effluent is discharged by gravity.
Cost of pumps, pipes, lines etc., necessary to deliver raw
wastewater to the treatment plant or to deliver the treated
effluent to the point of dischcirge are not included in the cost
estimates.
9.2 COST ESTIMATES FOR TREATMENT AND CONTROL OPTIONS
Option 1 treatment consists of neutralization for pH control.
All direct dischargers in the CRT and Luminescent Materials
Subcategories currently practice neutralization of their
effluent, therefore no costs are associated with this option.
Option 2 treatment consists of Option 1 treatment with the
addition of: chemical precipitation and clarification of all
metals-bearing process wastes using lime, calcium chloride (to
control fluoride), a coagulant and/or polyelectrolyte, and sludge
dewatering. In addition, thr the Cathode Ray Tube Subcategory,
Option 2 treatment includes chromium reduction with the use of
sulfuric acid and sodium bisulfite, and sodium carbonate
precipitation and clarification or lead-bearing wastes. The
capital and annual costs for this option are presented in Table
9-1 for CRTs and Table 9-2 for luminescent materials. The range
9-6
-------
TABLE 9-1
CATHODE RAY TUBES
OPTION 2 TREATMENT COSTS
FLOW
A. INVESTMENT COSTS
10,000
GPD
Construction 7 ,100
Equipment in place
including piping,
fittings, electrical
work and controls... 85,900
Monitoring equipment
in place 6,000
Engineering Design
and inspection 9, 300
Incidentals, overhead,
fees, contigencies.. 9,300
Land 6,000
TOTAL INVESTMENT COST 123,600
B. OPERATION AND
MAINTENANCE COST
Labor and supervision 10,000
Energy 180
Chemicals 1,220
Maintenance 11,750
Taxes and insurance. 3,700
Residual waste
disposal 1,550
Monitoring, analysis
and reporting 7 ,500
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
35,900
33,450
69,350
50,000
GPD
15,000
180,500
6,000
33,200
48,900
6,000
289,600
25,000
900
6,000
28,400
8,700
5,000
7,500
81,500
80,600
162.100
100,000
GPD
37,000
448,400
6,000
82,500
121,400
6,000
701,300
30,000
1,900
12,800
69,500
21,000
11,000
7,500
153,700
197,700
351.400
9-7
-------
TABLE 9-1
(Continued)
CATHODE RAY TUBES
OPTION 2 TREATMENT COSTS
FLOW
A. INVESTMENT COSTS
200,000
GPD
Construction 61,100
Equipment in place
including piping,
fittings, electrical
work and controls... 741,100
Monitoring equipment
in place 6 ,000
Engineering Design
and inspection 136,400
Incidentals, overhead,
fees, contigencies.. 200,600
Land " 6,000
TOTAL INVESTMENT COST 1,151,200
B. OPERATION AND
MAINTENANCE COST
Labor and supervision 40,000
Energy ' 3,000
Chemicals 24,000
Maintenance 114,500
Taxes and insurance. 34,500
Residual waste
disposal 22,000
Monitoring, analysis
and reporting 7 ,500
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
245,500
325,600
571,100
500,000
GPD
84,000
1,019,200
6,000
187,500
275,800
6,000
1,578,500
40,000
9,000
60,000
'157,300
47,400
58,000
7,500
379,200
447,100
826,300
9-3
-------
TABLE 9-2
LUMINESCENT MATERIALS
OPTION 2 TREATMENT COSTS
FLOW
10,000
GPD
A. INVESTMENT COSTS
Construction 5, 600
Equipment in place
including piping,
fittings, electrical
work and controls... 68,100
Monitoring equipment
in place 6,000
Engineering Design
and inspection 7,400
Incidentals, overhead,
fees, contingencies.. 7,400
Land 6,000
TOTAL INVESTMENT COST 100,500
B. OPERATION AND
MAINTENANCE COST
Labor and supervision 10,000
Energy 190
Chemicals 815
Maintenance 9,450
Taxes and insurance. 3,OOP
Residual waste
disposal 1,150
Monitoring, analysis
and reporting 7,500
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
32,100
26,900
59,000
100,000
GPD
33,500
406,200
6,000
74,750
109,950
6,000
636,400
30,000
1,900
8,200
63,050
19,100
9,950
7,500
139,700
179,200
318,900
250,000
GPD
62,650
760,000
6,000
139,850
205,700
6,000
1,180,200
40,000
4,750
21,000
117,400
35,400
24,500
7,500
250,550
335,550
586,100
9-9
-------
of model plant wastewater flows reflects the range of flows that
currently exist in the subcategories. Figures 9-1 and 9-2
graphically present the annual costs for this option versus plant
wastewater flow for CRTs and Luminescent Materials, respectively.
Option 3 (Cathode Ray Tube Subcategory only) treatment consists
of Option 2 treatment with the addition of multi-media filtration
technology. The capital and annual costs are presented in Table
9-3. Figure 9-3 graphically presents the annual costs versus
plant wastewater flows for this option. The costs are
incremental and therefore only reflect the additional costs of
adding filtration technology end-of-pipe.
Option 4 (Cathode Ray Tube Subcategory only) consists of solvent
management for the control of toxic organics. Solvent management
is not a treatment system, but rather in-plant control to
segregate and collect spent solvents for resale or contract
disposal. EPA, therefore, considered it in conjunction with
Options 1 through 3. All plants in the data base currently
practice solvent management.
Those plants that are not already in compliance will have to
improve the effectiveness of their solvent management program.
EPA has assumed the real costs of compliance for such plants are
minimal. Primarily, this is because the costs are small
increments above existing costs. That is, a discharger who is
currently handling and disposing solvents contained in drums or
tanks may have some additional amounts of solvents to deal with.
He already would have incurred the basic costs of setting up such
systems. However, to the extent that there may be incremental
costs they may be offset by the resale value of the additional
solvents. Data in the record show that resale of spent solvents
is commonly practiced.
Although we expect most plant:s will want to take advantage of the
certification alternative, some may decide to monitor. While it
is difficult to estimate monitoring frequency for total toxic
organics in the absence of significant historical experience,
based on a survey of state and regional permitting authorities,
we estimate that, on an average, monitoring for TTO will be
required once per quarter. In some cases plants may be required
to monitor as frequently as once a month. Thus, EPA has done an
economic sensitivity analysis to assess the impact of monthly
monitoring costs as part of its economic impact analysis. The
capital and annual costs of both quarterly and monthly monitoring
for TTO, in 1983 dollars, are presented in Table 9-4.
EPA has also performed an economic sensitivity analysis for RCRA
costs. As stated above, EPA believes that minimal costs are
associated with TTO compliance. Nevertheless, EPA Has costed out
and assessed the economic impact if plants presently not in
compliance sent the additional solvents to hazardous waste
disposal facilities covered by the Resource Conservation and
9-10
-------
CATHODE RAY TUBES
VD
I
1000 -
900-
800-
700 -
o
o
^ 600
to-
g 500
u
400
300
200
100-
20
50
100
FLOW (GPD/1000)
FIGURE 9-1
Annual Cost vs. Flow for
Option 2 Technology
200
500
-------
LUMINESCENT MATERIALS
I
h-1
to
600
550
500
450
o 400
o
o
350-
g 300
u
250-
200
150
100
50-
50
100
FLOW (GPD/1000)
FIGURE 9- 2
Annual Cost vs. Flow for
Option 2 Technology
200
500
rrr
-------
TABLE 9-3
CATHODE RAY TUBES
OPTION 3 TREATMENT COSTS
FLOW
10,000
GPD
50,000
GPD
100,000
GPD
A. INVESTMENT COSTS
Construction
Equipment in place
including piping,
fittings, electrical
work and controls...
Monitoring equipment
in place
Engineering Design
and inspection
Incidentals, overhead,
fees, contigencies..
Land
TOTAL INVESTMENT COST
B. OPERATION AND
MAINTENANCE COST
Labor and supervision
Energy
Chemicals
Maintenance
Taxes and insurance.
Residual waste
disposal
Monitoring, analysis
and reporting
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
400
4,900
530
5,830
580
170
750
1,650
2,400
1,000
11,600
3,200
15,800
1,600
500
2,100
4,500
6,600
3,600
43,700
11,800
59,100
5,900
1,800
7,700
16,800
24,500
9-13
-------
TABLE 9-3
(Continued)
CATHODE RAY TUBES
OPTION 3 TREATMENT COSTS
FLOW
A. INVESTMENT COSTS
Construction
Equipment in place
including piping,
fittings, electrical
work and controls...
Monitoring equipment
in place
Engineering Design
and inspection
Incidentals, overhead,
fees, contigencies..
Land
TOTAL INVESTMENT COST
B. OPERATION AND
MAINTENANCE COST
Labor and supervision
Energy
Chemicals
Maintenance
Taxes and insurance.
Residual waste
disposal
Monitoring, analysis
and reporting
TOTAL OPERATION AND
MAINTENANCE COST
C. AMORTIZATION OF
INVESTMENT COST
TOTAL ANNUAL COST
200,000
GPD
7,000
84,400
22,900
114,300
11,400
3,400
14,800
32,500
500,000
GPD
13,900
168,900
45,700
228,500
22,900
6,900
29,800
65,000
47,300
94,800
9-14
-------
CATHODE RAY TUBES
100-
90-
80-
o
o
o
70-
60-
P
01 en
O 50
U
(0
c 40'
30'
20-
10-
Jo '
20
50
200
500
FLOW (GPD/1000)
FIGURE 9-3
Annual Cost vs. Flow for
Option 3 Technology
-------
TABLE 9-4
PLANT MONITORING COSTS
FOR ORGANICSd)
INVESTMENT COSTS
Isco 2100 Sampler.
Complete 2,500
TOTAL INVESTMENT COST $ 2,500
ANNUAL COSTS
Quarterly analysis $ 860 x 4 3,440
Sample kit $ 50 x 4 200
Sampling personnel
@ $22/hr x 8hrs/episode $ x 4 704
TOTAL OPERATION AND
MAINTENANCE COST $ 4,344
AMORTIZATION OF
INVESTMENT COST 711
TOTAL ANNUAL COST $ 5,055
(1) 1983 Dollars
(2) Assumes quarterly sampling analysis,
9-16
-------
Recovery Act. These costs were calculated and were found to be
minimal. The analysis is contained in the administrative record
supporting this rulemaking.
9.3 ENERGY AND NON-WATER QUALITY ASPECTS
Compliance with the proposed regulations will have no effect on
air, noise, or radiation pollution and will only result in
minimal energy usage. The amount of solid waste generated will
be approximately 1200 metric tons per year. It has not been
determined whether the solid wastes generated at CRT and
luminescent materials manufacturing plants are hazardous as
defined in the Resource Conservation and Recovery Act (RCRA). It
is believed that further testing will find the wastewater
treatment sludge to be nonhazardous. With regard to solvent
wastes resulting from solvent management, EPA has conducted a
sensitivity analysis to consider likely economic impacts
resulting from the disposal of these wastes as hazardous wastes.
Energy requirements associated with these regulations will be
535,000 kilowatt-hours per year or only 214 kilowatt-hours per
day per facility. Based on the above non-water quality impacts
from these regulations, EPA has concluded that the proposed
regulations best serve overall national environmental goals.
9-17
-------
SECTION 10
ACKNOWLEDGEMENTS
The Environmental Protection Agency was aided in the preparation
of this Development Document by Jacobs Engineering Group Inc.
Jacobs' effort was managed by Ms. Bonnie Parrott. Major
contributions were made by Mr. Thomas Schaffer, Mr. Robert
Mueller, and Ms. Suzanne Phinney.
Mr. John Newbrough of EPA's Effluent Guidelines Division served
as Project Officer during the preparation of this document. Mr.
Jeffrey Denit, Director, Effluent Guidelines Division, and Mr.
Gary E. Stigall, Branch Chief, Effluent Guidelines Division,
Inorganic Chemicals Branch, and Mr. David Pepson, Effluent
Guidelines Division, offered guidance and suggestions during this
project.
Finally, appreciation is extended to the plants that participated
in and contributed data for the formulation of this document.
10-1
-------
SECTION 11
BIBLIOGRAPHY
Amick, Charles L., Fluorescent Lighting Manual, McGraw-Hill, 3rd
ed., (1961).
Bogle, W.S., Device Development, The Western Electric Engineer,
(July, 1973).
Buchsbaum, Walter H., Fundamentals of Television, 2nd ed., Hayden
Book Co., (1974).
Cockrell, W.D., Industrial Electronics Handbook, McGraw-Hill
(1958).
Elenbaas, W., Fluorescent Lamps and Lighting, (1959).
The New Encyclopedia Americana, International Edition, Grolier
Inc. Vol. 10pp. 179-184 (1982).
Forsythe, William, E., Fluorescent and Other Gaseous Discharge
Lamps, 1948).
Gray, H.J., Dictionary of_ Physics, Longmans, Green and Co.,
London (1958).
Hall, Edwin, "Flat Panels Challenge CRTs for Large-Area
Displays," Electronic Design, pp. 61-68., May 28, 1981.
Helwig, Jane T. and Council, Kathryn A., SAS Users Guide, SAS
Institute IAC (1979).
Hewitt, Harry, Lamps and Lighting, American Elsevier Publishing
Co. (1966).
Hickey, Henry V. and Villings, William M., Elements of.
Electronics, 3rd ed., McGraw-Hill, (1970).
Henney, K. and Walsh, C., Eds., Electronic Components Handbook,
McGraw-Hill (1975).
IEEE Standards Committee, IEEE, Standard Dictionary of_ Electrical
and Electronic Terms, J. Wiley and Sons (Oct., 1971).
Illuminating Engineering Society, IES Lighting Handbook, 3rd ed.,
(1962).
Kirk and Othmer, Encyclopedia of_ Chemical Technology,
Interscience, 2nd ed., Vol. 8, pp. 1-23, (1967).
11-1
-------
Kirk and Othmer, Encyclopedia of_ Chemical Technology,
Interscience, 2nd ed., Vol. 12, pp. 616-631, (1967).
Kirk and Othmer, Encyclopedia of Chemical Technology, Volume 17,
McGraw-Hill (1968).
McGraw-Hill, Dictionary of_ Scientific and Technical Terms, 2nd
ed., McGraw-Hill (1978).
McGraw-Hill, Encyclopedia of_ Science and Technology, McGraw-Hill
(1960).
Meyer, Paul L., Introductory Probability and Statistical
Applications, Addison-Wesley Publishing Company, 2nd ed.,
1970).
Meyer, Stuart L., Data Analysis for Scientists and Engineers,
John Wiley & Sons, Inc. (1975).
The New Encyclopedia Britannica, Wilbur Denton Publish., Vol. 6,
pp. 687-691.
Simon and Schuster, The Way Things Work, An Illustrated
Encyclopedia of Technology, Simon and Schuster (1967).
Upton, Monroe, Inside Electronics, Devin-Adair Co. (1964).
U.S. Government Public Law 94-469, Toxic Substances Control Act,
(Oct. 11, 1976).
Warring, R.H., Understanding Electronics, TAB Boooks (1978).
Webster's Seventh New Collegiate Dictionary, G & C Merriam Co.
(1963).
Zar, Jerrold H., Biostatistical Analysis, Prentice-Hall Inc.
(1974).
11-2
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SECTION 12
GLOSSARY
Absorb - To take up matter or radiation.
Act - Federal Water Pollution Control Act.
Activate - To treat the cathode or target of an electron tube in
order to create or increase the emission of electrons.
Adjustable Capacitor - A device capable of holding an electrical
charge at any one of several discrete values.
Adsorption - The adhesion of an extremely thin layer of molecules
(of gas, liquid) to the surface of solids (granular
activated carbon for instance) or liquids with which they
are in contact.
Aging - Storage of a permanent magnet, capacitor, meter or other
device (sometimes with a voltage applied) until the
characteristics of the device become essentially constant.
Algicide - Chemicals used to retard the growth of phytoplankton
(algae) in bodies of water.
Aluminum Foil - Aluminum in the form of a sheet of thickness not
exceeding 0.005 inch.
Anneal - To treat a metal, alloy, or glass by a process of
heating and slow cooling in order to remove internal
stresses and to make the material less brittle.
Anode - The collector of electrons in an electron tube. Also
known as plate; positive electrode.
Anodizing - An electrochemical process of controlled aluminum
oxidation producing a hard, transparent oxide up to several
mils in thickness.
Assembly or_ Mechanical Attachment - The fitting together of pre-
viously manufactured parts or components into a complete
machine, unit of a machine, or structure.
Autotransformer - A power transformer having one continuous wind-
ing that is tapped; part of the winding serves as the
primary coil and all of it serves as the secondary coil, or
vice versa.
12-1
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Ballast - A circuit element that serves to limit an electric
current or to provide a starting voltage, as in certain
types of lamps, such as in fluorescent ceiling fixtures.
Binder - A material used to promote cohesion between particles of
carbon or graphite to produce solid carbon and graphite rods
or pieces.
Biochemical Oxygen Demand - (1) The quantity of oxygen used in
the biochemical oxidation of organic matter in a specified
time, at a specified temperature, and under specified
conditions. (2) Standard test used in assessing wastewater
quality.
Biodegradable - The part of organic matter which can be oxidized
by bioprocesses, e.g., biodegradable detergents, food
wastes, animal manure, etc.
Biological Wastewater Treatment - Forms of wastewater treatment
in which bacteria or biochemical action is intensified to
stabilize, oxidize, and nitrify the unstable organic matter
present. Intermittent sand filters, contact beds, trickling
filters, and activated sludge processes are examples.
Breakdown Voltage - Voltage at which a discharge occurs between
two electrodes.
Bulb - The glass envelope which incloses an incandescent lamp or
an electronic tube.
Busbar - A heavy rigid, metallic conductor, usually uninsulated,
used to carry a large current or to make a common connection
between several circuits.
Bushing - An insulating structure including a central conductor,
or providing a central passage for a conductor, with
provision for mounting on a barrier (conducting or
otherwise), for the purpose of insulating the conductor from
the barrier and conducting current from one side of the
barrier to the other.
Ca1cining - To heat to a high temperature without melting or
fusing, as to heat unformed ceramic materials in a kiln, or
to heat ores, precipitates, concentrates or residues so that
hydrates, carbonates or other compounds are decomposed and
volatile material is expelled, e.g., to heat limestone to
make lime.
Calibration - The determination, checking, or correction of the
graduation of any instrument giving quantitative
measurements.
12-2
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Capacitance - The ratio of the charge on one of the plates of a
capacitor to the potential difference between the plates.
Capacitor - An electrical circuit element used to store charge
temporarily, consisting in general of two conducting
materials separated by a dielectric materials.
Carbon - A nonmetallic, chiefly tetravalent element found native
or as a constituent of coal, petroleum, asphalt, limestone,
etc.
Cathode - The primary source of electrons in an electron tube; in
directly heated tubes the filament is the cathode, and in
indirectly heated tubes a coated metal cathode surrounds a
heater.
Cathode Ray Tube - An electronic device in which electrons focus
through a vacuum to generate a controlled image on a
luminescent surface.
Central Treatment Facility - Treatment plant which co-treats
process wastewaters from more than one manufacturing
operation or co-treats process wastewaters with noncontact
cooling water or with non-process wastewaters (e.g., utility
blow-down, miscellaneous runcff, etc.).
Centrifuge - The removal of water in a sludge and water slurry by
introducing the water and sludge slurry into a centrifuge.
The sludge is driven outward with the water remaining near
the center. The dewatered sludge is usually landfilled.
Ceramic - A product made by the baking or firing of a nonmetallic
mineral such as tile, cement, plaster, refractories, and
brick.
Chemical Coagulation - The destabilization and initial
aggregation of colloidal and finely divided suspended matter
by the addition of a floe-forming chemical.
Chemical Oxidation - The addition of chemical agents to
wastewater for the purpose of oxidizing pollutant material,
e.g., removal of cyanide.
Chemical Oxygen Demand (COD) - (1) A test based on the fact that
all organic compounds, with few exceptions, can be oxidized
to carbon dioxide and water by the action of strong
oxidizing agents under acid conditions. Organic matter is
converted to carbon dioxide and water regardless of the
biological assimilability of the substances. One of the
chief limitations is its inability to differentiate between
biologically oxidizable and biologically inert organic
matter. The major advantage of this test is the short time
12-3
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required for evaluation (2 hours). (2) The amount of oxygen
required for the chemical oxidation of organics in a liquid.
Chemical Precipitation - (1) Formation of insoluble materials
generated by addition of chemicals to a solution. (2) The
process of softening water by the addition of lime and soda
ash as the precipitants.
Chlorination - The application of chlorine to water or wastewater
generally for the purpose of disinfection, but frequently
for accomplishing other biological or chemical results.
Circuit Breaker - Device capable of making, carrying, and
breaking currents under normal or abnormal circuit
conditions.
Cleaning - The removal of soil and dirt (including grit and
grease) from a workpiece using water with or without a
detergent or other dispersing agent.
Coil - A number of furns of wire used to introduce inductance
into an electric circuit, to produce magnetic flux, or to
react mechanically to a changing magnetic flux.
Coil-Core Assembly - A unit made up of the coil windings of a
transformer placed over the magnetic core.
Coking - (1) Destructive distillation of coal to make coke. (2)
A process for thermally converting the heavy residual
bottoms of crude oil entirely to lower-boiling petroleum
products and by-product petroleum coke.
Colloids - A finely divided dispersion of one material called the
"dispersed phase" (solid) in another mciterial called the
"dispersion medium" (liquid). Normally negatively charged.
Composite Wastewater Sample - A combination of individual samples
of water or wastewater taken at selected intervals and mixed
in proportion to flow or time to minimize the effect of the
variability of an individual sample.
Concentric Windings - Transformer windings in which the low-
voltage winding is in the form of a cylinder next to the
core, and the high-voltage winding, also cylindrical,
surrounds the lowvoltage winding.
Conductor - A wire, cable, or other body or medium suitable for
carrying electric current.
Conduit - Tubing of flexible metal or other material through
which insulated electric wires are run.
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Contamination - A general term signifying the introduction into
water of microorganisms, chemicals, wastes or sewage which
renders the water unfit for its intended use.
Contractor Removal - The disposal of oils, spent solutions, or
sludge by means of a scavenger service.
Conversion Coating - A metal-surface coating consisting of a
compound of the base metal.
Cooling Tower - A device used to cool manufacturing process water
before returning the water for reuse.
Copper - A common, reddish, chiefly univalent and bivalent
metallic element that is ductile and malleable and one of
the best conductors of heat and electricity.
Core (Magnetic Core) - A quantity of ferrous material placed in a
coil or transformer to provide a better path than air for
magnetic flux, thereby increasing the inductance of the coil
or increasing the coupling between the windings of a
transformer.
Corona Discharge - A discharge of electricity appearing as a
bluishpurple glow on the surface of or adjacent to a
conductor when the voltage gradient exceeds a certain
critical value; caused by ionization of the surrounding air
by the high voltage.
Curing - A heating/drying process carried out in an elevated-
temperature enclosure.
Current Carrying Capacity - The maximum current that can be
continuously carried without causing permanent deterioration
of electrical or mechanical properties of a device or
conductor.
Dag (Aquadag) - A conductive graphite coating on the inner and
outer side walls of some cathode-ray tubes.
Degreasing - The process of removing grease and oil from the
surface of the basis material.
Dewatering - A process in which water is removed from sludge.
Dicing - Sawing or otherwise machining a semiconductor wafer into
small squares or dice from which transistors and diodes can
be fabricated.
Die - A tool or mold used to cut shapes to or form impressions on
materials such as metals and ceramics.
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Die Cutting (Also Blanking) - Cutting of plastic or metal sheets
into shapes by striking with a punch.
Dielectric - A material that is highly resistant to the
conductance of electricity; an insulator.
Di-n-octyl-phthaiate - A liquid dielectric that is presently
being substituted for a PCB dielectric fluid.
Diode (Semiconductor), (Also Crystal Diode, Crystal Rectifier) -
A two-electrode semiconductor device that utilizes the
rectifying properties of a p-n junction or point contact.
Discrete Device - Individually manufactured transistor, diode,
etc.
Dissolved Solids - Theoretically the anhydrous residues of the
dissolved constituents in water. Actually the term is
defined by the method used in determination. In water and
wastewater treatment, the Standard Methods tests are used.
Distribution Transformer - An element of an electric distribution
system located near consumers which changes primary
distribution voltage to a lower consumer voltage.
Dopant - An impurity element added to semiconductor materials
used in crystal diodes and transistors.
Dragout - The solution that adheres to the part of workpiece and
is carried past the edge of the tank.
Dry Electrolytic Capacitor - An electrolytic capacitor with a
paste rather than liquid electrolyte.
Drying Beds - Areas for dewatering of sludge by evaporation and
seepage.
Dry Slug - Usually refers to a plastic-encased sintered tantalum
slug type capacitor.
Dry Transformer - Having the core and coils neither impregnated
with an insulating fluid nor immersed in an insulating oil.
Effluent - The quantities, rates, and chemical, physical,
biological and other constituents of waters which are
discharged from point sources.
Electrochemical Machining - Shaping of an anode by the following
process: The anode and cathode are placed close together
and electrolyte is pumped into the space between them. An
electrical potential is applied to the electrodes causing
anode metal to be dissolved selectively, producing a shaped
anode that complements the shape of the cathode.
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Electrolyte - A nonmetallic electrical conductor in which current
is carried by the movement of ions.
Electron Beam Lithography - Similar to photolithography - A fine
beam of electrons is used to scan a pattern and expose an
electronsensitive resist in the unmasked areas of the object
surface.
Electron Discharge Lamp - An electron lamp in which light is
produced by passage of an electric current through a
metallic vapor or gas.
Electron Gun - An electrode structure that produces and may
control, focus, deflect and converge one or more electron
beams in an electron tube.
Electron Tube - An electron device in which conduction of
electricity is accomplished by electrons moving through a
vacuum of gaseous medium within a gas-tight envelope.
Electroplating - The production of a thin coating of one metal on
another by electrode position.
Emissive Coating - An oxide coating applied to an electrode to
enhance the emission of electrons.
Emulsion Breaking - Decreasing the stability of dispersion of one
liquid in another.
End-pf-Pipe Treatment - The reduction and/or removal of
pollutants by chemical treatment just prior to actual
discharge.
Epitaxial Layer - A (thin) semiconductor layer having the same
crystaline orientation as the substrate on which it is
grown.
Epitaxial Transistor - Transistor with one or more epitaxial
layers.
Equalization - The process whereby waste streams from different
sources varying in pH, chemical constituents, and flow rates
are collected in a common container. The effluent stream
from this equalization tank will have a fairly constant flow
and pH level, and will contain a homogeneous chemical
mixture. This tank will help to prevent unnecessary shock
to the waste treatment system.
Etch - To corrode the surface of a metal in order to reveal its
composition and structure.
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Extrusion - Forcing the carbon-binder-mixture through a die under
extreme pressure to produce desireable shapes and
characteristics of the piece.
Field-effect Transistors - Transistors made by the metal-oxide-
semiconductor (MOS) technique, differing from bipolar ones
in that only one kind of charge carrier is active in a
single device. Those that employ electrons are called n-MOS
transistors; those that employ holes are p-MOS transistors.
Filament - (1) Metallic wire which is heated in an incandescent
lamp to produce light by passing an electron current through
it. (2) A cathode in a fluorescent lamp that emits
electrons when electric current is passed through it.
Filtering Capacitor - A capacitor used in a power-supply filter
system to provide a low-reactance path for alternating
currents and thereby suppress ripple currents, without
system to provide a low-reactance
currents and thereby suppress rippl
affecting direct currents.
Fixed Capacitor - A capacitor having a definite capacitance value
that cannot be adjusted.
Float Gauge - A device for measuring the elevation of the surface
of a liquid, the actuating element of which is a buoyant
float that rests on the surface of the liquid and rises or
falls with it. The elevation of the surface is measured by
a chain or tape attached to the float.
Floe - A very fine, fluffy mass formed by the aggregation of fine
suspended particles.
Flocculation - In water and wastewater treatment, the
agglomeration of colloidal and finely divided suspended
matter after coagulation by gentle stirring by either
mechanical or hydraulic means. In biological wastewater
treatment where coagulation is not used, agglomeration may
be accomplished biologically.
Flocculator - An apparatus designed for the formation of floe in
water or sewage.
Flow-proportioned Sample - A sampled stream whose pollutants are
apportioned to contributing streams in proportion to the
flow rates of the contributing streams.
Fluorescent Lamp - An electric discharge lamp in which phosphor
materials transform ultraviolet radiation from mercury vapor
ionization to visible light.
Forming - Application of voltage to an electrolytic capacitor,
electrolytic rectifier or semiconductor device to produce a
12-8
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desired permanent change in electrical characteristics as
part of the manufacturing process.
Frit Seal - A seal made by fusing together metallic powders with
a glass binder for such applications as hermatically sealing
ceramic packages for integrated circuits.
Funnel - The rear, funnel-shaped portion of the glass enclosure
of a cathode ray tube.
Fuse - Overcurrent protective device with a circuit-opening
fusible part that would be heated and severed by overcurrent
passage.
Gate - One of the electrodes in a field effect transistor.
Getter - A metal coating inside a lamp which is activated by an
electric current to absorb residual water vapor and oxygen.
Glass - A hard, amorphous, inorganic, usually transparent,
brittle substance made by fusing silicates, and sometimes
borates and phosphates, with certain basic oxides and then
rapidly cooling to prevent crystallization.
Glow Lamp - An electronic device, containing at least two
electrodes and an inert gas, in which light is produced by a
cloud of electrons close to the negative electrode when a
voltage is applied between the electrodes.
Grab Sample - A single sample of wastewater taken at an "instant"
in time.
Graphite - A soft black lustrous carbon that conducts electricity
and is a constituent of coal, petroleum, asphalt, limestone,
etc.
Grease - In wastewater, a group of substances including fats,
waxes, free fatty acids, calcium and magnesium soaps,
mineral oil and certain other nonfatty materials. The type
of solvent and method used for extraction should be stated
for quantification.
Grease Skimmer - A device for removing grease or scum from the
surface of wastewater in a tank.
Green Body - An unbaked carbon rod or piece that is usually soft
and quite easily broken.
Grid - An electrode located between the cathode and anode of an
electron tube, which has one or more openings through which
electrons or ions can pass, and which controls the flow of
electrons from cathode to anode.
12-9
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Grinding - The process of removing stock from a workpiece by the
use of abrasive grains held by a rigid or semi-rigid binder.
Hardness - A characteristic of water, imparted by calcium,
magnesium, and ion salts such as bicarbonates, carbonates,
sulfates, chlorides, and nitrates. These cause curdling of
soap, deposition of scale in boilers, damage in some
industrial processes and sometimes objectionable taste.
Hardness may be determined by a standard laboratory
procedure or computed from the amounts of calcium and
magnesium as well as iron, aluminum, manganese, barium,
strontium, and zinc, and is expressed as equivalent calcium
carbonate.
Heavy Metals - A general name given to the ions of metallic
elements such as copper, zinc, chromium, and nickel. They
are normally removed from wastewater by an insoluble
precipitate (usually a me.'tallic hydroxide).
Holding Tank - A reservoir to contain preparation materials so as
to be ready for immediate service.
Hybrid Integrated Circuits - A circuit that is part integrated
and part discrete.
Impact Extrusion - A cold extrusion process for producing tubular
components by striking a slug of the metal, which has been
placed in the cavity of the die, with a punch moving at high
velocity.
Impregnate - To force a liquid substance into the spaces of a
porous solid in order to change its properties.
Incandescent Lamp - An electric lamp producing light in which a
metallic filament is beared white-hot in a vacuum by passage
of an electric current through it.
Industrial Wastes - The liquid wastes from industrial processes
as distinct from domestic or sanitary wastes.
Influent - Water or other liquid, either raw or partly treated,
flowing into a reservoir basin or treatment plant.
In-Process Control Technology - The regulation and conservation
of chemicals and rinse water at their point of use as
opposed to end-of-pipe treatment.
Insulating Paper - A standard material for insulating electrical
equipment, usually consisting of bond or kraft paper coated
with black or yellow insulating varnish on both sides.
Insulation (Electrical Insulation) - A material having high elec-
trical resistivity and therefore suitable for separating
12-10
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adjacent conductors in an electric circuit or preventing
possible future contact between conductors.
Insulator - A nonconducting support for an electric conductor.
Integrated Circuit - Assembly of electronic devices
interconnected into circuits.
Interleaved Winding - An arrangement of winding coils around a
transformer core in which the coils are wound in the form of
a disk, with a group of disks for the low-voltage windings
stacked alternately with a group of disks for the high-
voltage windings.
Intermittent Filter - A natural or artificial bed of sand or
other fine-grained material onto which sewage is
intermittently flooded and through which it passes, with
time allowed for filtration and the maintenance of aerobic
conditions.
Ion Exchange - A reversible chemical reaction between a solid
(ion exchanger) and a fluid (usually a water solution) by
means of which ions may be interchanged from one substance
to another. The superficial physical structure of the solid
is not affected.
Ion Exchange Resins - Synthetic resins containing active groups
(usually sulfonic, carboxylic, phenol, or substituted amino
groups) that give the resin the ability to combine with or
exchange ions with a solution.
Ion Implantation - A process of introducing impurities into the
near surface regions of solids by directing a beam of ions
at the solid.
Junction - A region of transition between two different
semiconducting regions in a semiconductor device such as a
p-n junction, or between a metal and a semiconductor.
Junction Box - A protective enclosure into which wires or cables
are led and connected to form joints.
Knife Switch - Form of switch where moving blade enters
stationary contact clips.
Klystron - An evaculated electron-beam tube in which an initial
velocity modulation imparted to electrons in the beam
results subsequently in density modulation of the beam; used
as an amplifier in the microwave region or as an oscillator.
Lagoon - A man-made pond or lake for holding wastewater for the
removal of suspended solids. Lagoons are also used as
retention ponds after chemical clarification to polish the
12-11
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effluent and to safeguard against upsets in the clarifier;
for stabilization of organic matter by biological oxidation;
for storage of sludge; and for cooling of water.
Landfill - The disposal of inert, insoluble waste solids by
dumping at an approved site and covering with earth.
Lapping - The mechanical abrasion or surface planing of the
semiconductor wafer to produce desired surface and wafer
thickness.
Lime - Any of a family of chemicals consisting essentially of
calcium hydroxide made from limestone (calcite) which is
composed almost wholly of calcium carbonates or a mixture of
calcium and magnesium carbonates.
Limiting Orifice - A device that limits flow by constriction to a
relatively small area. A constant flow can be obtained over
a wide range of upstream pressures.
Luminescent Materials - Materials that emit electromagnetic
radiation (light) upon excitation by such energy sources as
photons, electrons, applied voltage, chemical reactions or
mechanical energy and which are specifically used as
coatings in fluorescent lamps and cathode ray tubes.
Machining - The process of removing stock from a workpiece by
forcing a cutting tool through the workpiece and removing a
chip of basis material. Machining operatings such as
tuning, milling, drilling, boring, tapping, planing,
broaching, sawing and cutoff, shaving, threading, reaming,
shaping, slotting, hobbing, filling, and chambering are
included in this definition.
Maqnaflux Inspection - Trade name for magnetic particle test.
Make-up Water - Total amount of water used by any process/process
step.
Mandrel - A metal support serving as a core around which the
metals are wound and anealled to form a central hole.
Mask (Shadow Mask) - Thin sheet steel screen with thousands of
apertures through which electron beams pass to a color
picture tube screen. The color of an image depends on the
balance from each of three different electron beams passing
through the mask.
Metal Oxide Semiconductor Device - A metal insulator
semiconductor structure in which the insulating layer is an
oxide of the substrate material; for a silicon substrate,
the insulating layer is silicon dioxide (Si02).
12-12
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Mica - A group of aluminum silicate minerals that are
characterized by their ability to split into thin, flexible
flakes because of their basal cleavage.
Miligrams Per Liter (mg/1 - This is a weight per volume
designation used in water and wastewater analysis.
Mixed Media Filtration - A filter which uses two or more filter
materials of differing specific gravities selected so as to
produce a filter uniformly graded from coarse to fine.
MOS - (See Metal Oxide Semiconductor).
Mount Assembly - Funnel neck ending of picture tube holding
electron gun(s).
National Pollutant Discharge Elimination System (NPDES) - The
federal mechanism for regulating point source discharge by
means of permits.
Neutralization - Chemical addition of either acid or base to a
solution such that the pH is adjusted to approximately 7.
Noncontact Cooling Water - Water used for cooling which does not
come into direct contact with any raw material, intermediate
product, waste product or finished product.
Oil-Filled Capacitor - A capacitor whose conductor and insulating
elements are immersed in an insulating fluid that is
usually, but not necessarily, oil.
Outfall - The point or location where sewage or drainage
discharges from a sewer, drain, or conduit.
Oxide Mask - Oxidized layer of silicon wafer through which
"windows" are formed which will allow for dopants to be
introduced into the silicon.
Panel - The front, screen portion of the glass enclusre of a
cathode ray tube.
PCS (Polychlorinated Biphenyl) - A colorless liquid, used as an
insulating fluid in electrical equipment. (The future use
of PCB for new transformers was banned by the Toxic
Substances Control Act of October 1976).
pH - The negative of the logarithm of the hydrogen ion
concentration. Neutral water has a pH value of 7. At pH
lower than 7, a solution is acidic. At pH higher than 7, a
solution is alkaline.
12-13
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pH Adjustment - A means of maintaining the optimum pH through the
use of chemical additives. Can be manual, automatic, or
automatic with flow corrections.
Phase - One of the separate circuits or windings of a polyphase
system, machine or other appartus.
Phase Assembly - The coil-core assembly of a single phase of a
transformer.
Phosphate Coating - A conversion coating on metal, usually steel,
produced by dipping it into a hot aqueous solution of iron,
zinc, or manganese phosphate.
Phosphor - Crystalline inorganic compounds that produce light
when excited by ultraviolet radiation.
Photolithography - The process by which a microscopic pattern is
tranferred from a photomask to a material layer (e.g., Si02)
in an actual circuit.
Photomask - A film or glass negative that has many high-
resolution images, used in the production of semiconductor
devices and integrated circuits.
Photon - A quantum of electromagnetic energy.
Photoresist - A light-sensitive coating that is applied to a sub-
strate or board, exposed, and developed prior to chemical
etching; the exposed areas serve as a mask for selective
etching.
Picture Tube - A cathode ray tube used in television receivers to
produce an image by varying the electron beam intensity as
the beam scans a fluorescent screen.
Plate - (1) Preferably called the anode. The principal electrode
to which the electron stream is attracted in an electron
tube. (2) One of the conductive electrodes in a capacitor.
Polar Capacitor - An electrolytic capacitor having an oxide film
on only one foil or electrode which forms the anode or
positive terminal.
Pole Type Transformer - A transformer suitable for mounting on a
pole or similar structure.
Poling - A step in the production of ceramic piezoelectric bodies
which orients the oxes of the crystallites in the preferred
direction.
Polishing - The process of removing stock from a workpiece by the
action of loose or loosely held abrasive grains carried to
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the workplace by a flexible support. Usually, the amount of
stock removed in a polishing operation is only incidental to
achieving a desired surface finish or appearance.
Pollutant - The term "pollutant" means dredged spoil, solid
wastes, incinerator residue, sewage, grabage, sewage sludge,
munitions, chemical wastes, biological materials,
radioactive materials, heat, wrecked or discarded equipment,
rock, sand, cellar dirt and industrial, municipal and
agricultural waste discharged into water.
Pollutant Parameters - Those constituents of wastewater
determined to be detrimental and, therefore, requiring
control.
Pollution Load - A measure of the unit mass of a wastewater in
terms of its solids or oxygen-demanding characteristics, or
in terms of harm to receiving waters.
Polyelectrolytes - Synthetic or natural polymers containing ionic
constituents, used as a coagulant or a coagulant aid in
water and wastewater treatment.
Power Regulators - Transformers used to maintain constant output
current for changes in temperature output load, line current
and time.
Power Transformer - Transformer used at a generating station to
step up the initial voltage to high levels for transmission.
Prech1orination - (1) Chlorination of water prior to filtration.
(2) Chlorination of sewage prior to treatment.
Precipitate - The discrete particles of material settled from a
liquid solution.
Pressure Filtration - The process of solid/liquid phase
separation effected by passing the more permeable liquid
phase through a mesh which is impenetrable to the solid
phase.
Pretreatment - Any wastewater treatment process used to reduce
pollution load partially before the wastewater is introduced
into a main sewer system or delivered to a treatment plant
for substantial reduction of the pollution load.
Primary Feeder Circuit (Substation) Transformers - These
transformers (at substations) are used to reduce the voltage
from the subtransmission level to the primary feeder level.
Primary Treatment - A process to remove substantially all
floating and settleable solids in wastewater and partially
to reduce the concentration of suspended solids.
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Primary Winding - Winding on the supply (i.e., input) side of a
transformer.
Priority Pollutant - The 129 specific pollutants established by
the EPA from the 65 pollutants and classes of pollutants as
outlined in the consent decree of June 8, 1976.
Process Wastewater - Any water which, during manufacturing or
processing, comes into direct contact with or results from
the production or use of any raw materials, intermediate
product, finished product, by-product, or waste product.
Process Water - Water prior to its direct contact use in a
process or operation. (This water may be any combination of
a raw water, service water, or either process wastewater or
treatment facility effluent to be recycled or reused.)
Pyrolysis - The breaking apart of complex molecules into simpler
units by the use of heat, as in the pyrolysis of heavy oil
to make gasoline.
Quenching - Shock cooling by immersion of liquid of molten
material in a cooling medium (liquid or gas). Used in
metallurgy, plastics forming, and petroleum refining.
Raceway - A channel used to hold and protect wires, cables or
busbars.
Rapid Sandfilter - A filter for the purification of water where
water which has been previously treated, usually be
coagulation and sedimentation, is passed through a filtering
medium consisting of a layer of sand or prepared anthracite
coal or other suitable material, usually from 24 to 30
inches thick and resting on a supporting bed of gravel or a
porous medium such as carborundum. The filtrate is removed
by a drain system. The filter is cleaned periodically by
reversing the flow of the water through the filtering
medium. Sometimes supplemented by mechanical or air
agitation during backwashing to remove mud and other
impurities.
Raw Wastewater - Plant water prior to any treatment or use.
Receiving Tubes - Multiterminal devices that conduct electricity
more easily in one direction than in the other and are noted
for their low voltage and low power applications. They are
used to control or amplify electrical signals in radio and
television receivers, computers, and sensitive control and
measuring equipment.
Rectifier - (1) A device for converting alternating current into
direct current. (2) a nonlinear circuit component that,
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ideally, allows current to flow in one direction unimpeded
but allows no current to flow in the other direction.
Recycled Water - Process wastewater or treatment facility
effluent which is recirculated to the same process.
Resistor - A device designed to provide a definite amount of
resistance, used in circuits to limit current flow or to
provide a voltage drop.
Retention Time - The time allowed for solids to collect in a
settling tank. Theoretically retention time is equal to the
volume of the tank divided by the flow rate. The actual
retention time is determined by the purpose of the tank.
Also, the design residence time in a tank or reaction vessel
which allows a chemical reaction to go to completion, such
as the reduction of hexavalent chromium or the destruction
of cyanide.
Reused Water - Process wastewater or treatment facility effluent
which is further used in a different manufacturing process.
Rinse - Water for removal of dragout by dipping, spraying,
*fogging etc.
Sanitary Sewer - A sewer that carriers liquid and water wastes
from residences, commercial buildings, industrial plants,
and institutions together with ground, storm, and surface
waters that are not admitted intentionally.
Sanitary Water - The supply of water used for sewage transport
and the continuation of such effluents to disposal.
Secondary Settling Tank - A tank through which effluent from some
prior treatment process flows for the purpose of removing
settleable solids.
Secondary Wastewater Treatment - The treatment of wastewater by
biological methods after primary treatment by sedimentation.
Secondary Winding - Winding on the load (i.e. output) side of a
transformer.
Sedimentation - Settling of matter suspended in water by gravity.
It is usually accomplished by reducing the velocity of the
liquid below the point at which it can transport the
suspended material.
Semiconductor - A solid crystalline material whose electrical
conductivity is intermediate between that of a metal and an
insulator.
12-17
-------
Settleable Solids - (1) That matter in wastewater which will not
stay in suspension during a preselected settling period,
such as one hour, but either settles to the bottom or floats
to the top. (2) In the Imhoff cone test, the volume of
matter that settles to the bottom of the cone in one hour.
Sewer - A pipe or conduit, generally closed, but normally not
flowing full, for carrying sewage and other waste liquids.
Silvering - The deposition of thin films of silver on glass, etc.
carried by one of several possible processes.
Skimming Tank - A tank so designed that floating matter will rise
and remain on the surface of the wastewater until removed,
while the liquid discharges continuously under walls or scum
boards.
Sludge - The solids (and accompanying water and organic matter)
which are separated from sewage or industrial wastewater.
Sludge Cake - The material resulting from air drying or
dewatering sludge (usually forkable or spadable).
Sludge Disposal - The final disposal of solid wastes.
Sludge Thickening - The increase in solids concentration of
sludge in a sedimentation or digestion tank.
Snubber - Shock absorber.
Soldering - The process of joining metals by flowing a thin
(capillary thickness) layer of nonferrous filler metal into
the space between them. Bonding results from the intimate
contact produced by the dissolution of a small amount of
base metal in the molten filler metal, without fusion of the
base metal.
Solvent - A liquid capable of dissolving or dispersing one or
more other substances.
Solvent Degreasing - The removal of oils and grease from a
workpiece using organic solvents or solvent vapors.
Sputtering - A process to deposit a thin layer of metal on a
solid surface in a vacuum. Ions bombard a cathode which
emits the metal atoms.
Stacked Capacitor - Device containing multiple layers of
dielectric and conducting materials and designed to store
electrical charge.
12-18
-------
Stamping - Almost any press operations including blanking,
shearing, hot or cold forming, drawing, blending, or
coining.
Steel - An iron-based alloy, malleable under proper conditions,
containing up to about 2% carbon.
Step-Down Transformers - (Substation) - A transformer in which
the AC voltages of the secondary windings are lower than
those applied to the primary windings.
Step-Up Transformer - Transformer in which the energy transfer is
from a low-voltage primary (input) winding to a high-voltage
secondary (output) winding or windings.
Studs - Metal pins in glass of picture tube onto which shadow
mask is hung.
Substation - Complete assemblage of plant, equipment, and the
necessary buildings at a place where electrical energy is
received (from one more power-stations) for conversion
(e.g., from AC to DC by means of rectifiers, rotary
converters), for stepping-up or down by means of
transformers, or for control (e.g. by means of switch-gear,
etc.).
Subtransmission (Substation) Transformers - At the end of a
transmission line, the voltage is reduced to the
Subtransmission level (at substations) by subtransmission
transformers.
Suspended Solids - (1) Solids that are either floating or in
suspension in water, wastewater, or other liquids, and which
are largely removable by laboratory filtering. (2) The
quantity of material removed from wastewater in a laboratory
test, as prescribed in "Standard Methods for the Examination
of Water and Wastewater" and referred to as non-filterable
residue.
Tantalum - A lustrous, platinum-gray ductile metal used in making
dental and surgical tools, penpoints, and electronic
equipment.
Tantalum Foil - A thin sheet of tantalum, usually less than 0.006
inch thick.
Terminal - A screw, soldering lug, or other point to which
electric connections can be made.
Testing - A procedure in which the performance of a product is
measured under various conditions.
12-19
-------
Thermoplastic Resin - A plastic that solidifies when first heated
under pressure, and which cannot be remelted or remolded
without destroying its original characteristics; examples
are epoxides, melamines, phenolics and ureas.
Transformer - A device used to transfer electric energy, usually
that of an alternating current, from one circuit to another;
especially, a pair of multiply-wound, inductively coupled
wire coils that effect such a transfer with a change in
voltage, current, phases, or other electric characteristics.
Transistor - An active component of an electronic circuit
consisting of a small block of semiconducting material to
which at least three electrical contacts are made; used as
an amplifier, detector, or switch.
Transmitting Tubes - These tubes are characterized by the use of
electrostatic and electromagnetic fields applied externally
to a stream of electrons to amplify a radio frequency
signal. There are several different types of transmitting
tubes such as klystrons, magnetrons and traveling wave
tubes. They generally are high powered devices operating
over a wide frequency range. They are larger and
structurally more rugged than receiving tubes, and are
completely evacuated.
Trickling Filter - A filter consisting of an artificial bed of
coarse material, such as broken stone, clinkers, slats, or
brush over which sewage is distributed and applied in drops,
films, or spray, from troughs, drippers, moving distributors
or fixed nozzles and through which it trickles to the
underdrain giving opportunity for the formation of zoogleal
slimes which clarify the oxidized sewage.
Trimmer Capacitors - These are relatively small variable
capacitors used in piarallel with larger variable or fixed
capacitors to permit exact adjustment of the capacitance of
the parallel combination.
Vacuum Filter - A filter consisting of a cylindrical drum mounted
on horizontal axis, covered with a filter cloth revolving
with a partial submergence in liquid. A vacuum is
maintained under the cloth for the larger part of a
revolution to extract moisture and the cake is scraped off
continuously.
Vacuum Metalizing - The process of coating a workpiece with metal
by flash heating metal vapor in a high-vacuum chamber
containing the workpiece. The vapor condenses on all
exposed surfaces.
12-20
-------
Vacuum Tube - An electron tube vacuated to such a degree that its
electrical characteristics are essentially unaffected by the
presence of residual gas or vapor.
Variable Capacitor - A device whose capacitance can be varied
continuously by moving one set of metal plates with respect
to another.
Voltage Breakdown - The voltage necessary to cause insulation
failture.
Voltage Regulator - Like a transformer, it corrects changes in
current to provide continuous, constant current flow.
Welding - The process of joining two or more pieces of material
by applying heat, pressure or both, with or without filler
material, to produce a localized union through fusion or
recrystallization across the interface.
Wet Air Scrubber - Air pollution control device which uses a
liquid or vapor to absorb contaminants and which produces a
wastewater stream.
Capacitor - (See oil-filled capacitor;
Wet Slug Capacitor - Refers to a sintered tantalum capacitor
where the anode is placed in a metal can, filled with an
electrolyte and then sealed.
Wet Tantalum Capacitor - A polar capacitor the cathode of which
is a liquid electrolyte (a highly ionized acid or salt
solution).
Wet Transformer - Having the core and coils immersed in an
insulating oil.
Yoke - A set of coils placed over the neck of a magnetically
deflected cathode-ray tube to deflect the electron beam
horizontally and vertically when suitable currents are
passed through the coils.
12-21
-------
APPENDIX 1
PLANT 99797 RAW WASTES SELF MONITORING DATA
Pollutant Concentrations (mg/1)
1
2
3
4
5
6
7
8
9
> 10
V 11
M 12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Lead
73
23
77
--
58
52
46
Zinc
2.9
2.9
2.7
2.1
2.1
2.8
2.6
5.5
2.8
1.9
2.6
3.0
3.1
3.1
3.1
1.9
3.3
3.4
3.5
3.6
4.3
4.2
4.4
3.7
3.5
3.7
3.9
Chromium
2.7
0.3
2.7
0.7
1.1
1.3
0.5
3.2
2.7
4.0
2.5
0.8
1.3
1.6
2.6
0.8
1.6
2.1
2.1
0.07
0.07
0.18
0.36
1.32
0.92
0.92
1.3
Cadmium
0.09
0.04
0.04
0.1
0.1
0.05
0.04
0.03
0.1
0.07
0.06
0.13
0.15
0.12
0.09
0.11
0.17
0.24
0.22
0.18
0.19
0.11
0.14
0.14
0.10
0.08
0.11
Copper
0.7
0.2
0.2
0.3
0.1
0.02
0.4
0.3
0.2
0.3
0.4
1.9
0.4
1.4
3.2
0.4
0.2
0.3
0.3
0.5
0.5
0.7
0.6
0.4
0.7
1.2
0.9
Silver
<0.05
<0.05
<0.05
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
<0.06
Nickel
0.1
0.1
<0.1
0.2
0.1
0.2
0.2
0.2
0.2
0.2
<0.15
<0.15
<0.15
0.08
0.25
<0.15
0.2
0.2
0.2
0.2
0.3
<0.15
<0.15
0.3
0.17
0.08
<0.01
Fluoride
104
236
221
26
240
292
TSS
150
182
135
2046
992
140
619
725
117
146
42
142
200
62
84
85
365
652
902
51
436
138
908
625
91
70
620
-------
APPENDIX 1 - continued
PLANT 99797 RAW WASTE SELF MONITORING DATA (continued)
28
29
30
31
32
33
34
35
> 36
" 37
10 38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
Lead Zinc Chromium
3.7 0.9
99 3.7 0.9
3.7 0.9
3.8 1.0
3.7 0.9
84 3.8 1.9
112
132 3.4 2.17
3.4 1.46
3.5 2.46
50
72
68
58
117
44
17
48
45
79
192
139
67
167
65
33
152
158
60
9
Cadmium Copper Silver Nickel Fluoride
0.26 0.3 <0.06 0.3
0.20 0.3 <0.06 0.11 115
0.22 0.9 <0.06 0.22
0.19 0.4 <0.06 0.33
0.05 1.8 <0.06 0.33
0.30 0.9 <0.06 1.00 80
45
0.16 2.8 <0.06 <0.09 175
0.11 0.5 0.27
0.14 1.12 <0.06 0.15
210
154
250
240
585
210
250
205
175
63
260
235
390
215
220
250
460
309
24
40
TSS
2172
1479
1423
1912
170
1391
260
271
1792
-------
APPENDIX 1 - continued
PLANT 99797 RAW WASTE SELF MONITORING DATA (continued)
58
59
60
61
62
H
1
OJ
Lead Zinc Chromium Cadmium
15
13
29
10
14
Copper Silver Nickel Fluoride TSS
48
67
60
165
53
-------
APPENDIX 2
PLANT 30172 SELF MONITORING
EFFLUENT DATA FOR FLUORIDE
Fluoride Concentration mg/1
1 14.71
2 15.33
3 14.18
4 15.27
5 15.30
6 13.47
7 36.40
8 12.68
9 14.98
10 20.2
11 16.5
12 19.1
13 13.8
14 15.7
15 13.0
16 16.4
17 16.2
18 17.4
19 15.5
20 11.0
21 12.2
22 18.8
23 11.9
24 21.2
25 18.3
26 16.4
27 15.9
A2-1
-------
APPENDIX 3
PLANT 30172 TTO MONITORING DATA
Parameters (>0.01 mg/1)
- Trichloroethane - 1.142 mg/1
Plant Effluent - 425 gpm
Cooling Water - 117 gpm
Net Flow 308 gpm
A3-1
-------
>£>.
I
APPENDIX 4
PLANT 99798 EFFLUENT MONITORING DATA
POLLUTANT CONCENTRATIONS (mg/1)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Sampler
Source
Industry
POTW
Industry
Industry
POTW
Industry
Industry
Industry
POTW
Industry
Industry
Industry
Industry
POTW
Industry
Industry
Industry
POTW
Industry
Industry
Fluoride
11.2
16.6
11.9
12.4
14.4
14.8
10.8
11.5
4.3
11.5
12.4
12.0
9.0
8.6
9.0
9.2
16.0
26.6
13.9
15.8
Cadmium
0.010
0.03
0.020
0.020
0.01
0.010
0.020
0.018
0.01
0.010
0.020
0.005
0.01
<0.01
0.01
0.09
0.03
0.01
0.03
0.02
Chromium
0.250
0.28
0.240
0.208
0.47
0.810
0.104
0. 150
0.14
0.150
0.241
0.040
0.14
0.75
0.54
0.22
0.24
0.69
0.11
0.11
Lead
0.45
--
0.50
--
--
0.20
--
--
--
0.26
0.08
<0.096
<0.30
<0.02
Zinc
0.590
0.45
0.058
0.323
0.15
0.260
0.169
0.230
0.13
0.230
0.400
0.100
0.09
0.27
0.31
0.15
0.25
0,37
0.25
0.07
-------
APPENDIX A
Calculation of Limitations for the Electrical and Electronic
Components - Phase II Category.
Introduction
This memorandum describes the development of final effluent
limitations for fluoride (F), cadmium (Cd), chromium (Cr), lead
(Pb) and zinc (Zn) which are regulated in the Cathode Ray Tube
(CRT) subcategory of the Electrical and Electronic Components -
Phase II (EEC) category. Since proposal of the EEC regulation
changes have been made to the data base used for development of
the concentration limitations. The data base changes include the
deletion of data for technical reasons and the addition of data
supplied by industry. The Inorganic Chemicals Branch, Effluent
Guidelines Division has evaluated the wastewater treatment
systems in the EEC plants that provided data to ensure that only
the data from CRT plants which have technically acceptable lime
and settle wastewater treatment systems were used for limitation
development (see Chapter VII of the EEC Development Document).
Plants in the Luminescent Materials (LM) subcategory of the EEC
category were also sampled by the Agency. The LM limitations
incorporate both the Agency's LM data and variability estimates
from the CRT category which are described in this memorandum.
The details of limitation development for the LM subcategory are
explained in Chapter VII of the EEC Development Document.
Data
Two sources of pollutant concentration measurement data were
used; data that had been collected under the Agency's supervision
and data that had been collected and supplied by industry. The
Agency's data consists of Cd, Cr, Pb and Zn concentrations
measured in samples taken over 3 consecutive days from the raw
untreated wastewaters and treated effluent wastewater of CRT
plant number 99796. The Agency's data from plant 99796 are
listed in Appendix B.
This analysis used industry supplied concentrations of F, Cd, Cr,
Pb and Zn that had been measured in samples taken from the
treated wastewater streams of two CRT plants. Plant 30172
provided 27 F monthly averages that were reported from
January 1979 to June 1982. Each of the 27 monthly values is an
average of four F concnetration values that were measured during
the month. The F data from plant 30172 are listed in Appendix C.
Plant 99798 supplied concentrations of F, Cd, Cr, Pb, and Zn
measured in samples taken from the plant's treated wastewaters by
either the local publicly owned treatment works or plant
personnel. Plant 99798 lad eight Pb concentration measurements
and 20 F, Cd, Cr, and Zn concentration measurements.
Concentration measurements at plant 99798 were reported from 13
A-l
-------
January 1982 to 23 March 1983. Appendix D is a listing of the
effluent data from plant 99798.
Analysis
The pollutant concentration limitations for F, Cd, Cr, Pb, and Zn
were determined on the basis of a lognormal distribution fit to
the data. The basic assumption underlying this procedure is that
the pollutant concentration data are lognormally distributed by
plant. The lognormal has been found to provide a satisfactory
fit to effluent data in a wide range of industrial categories for
a variety of pollutants and usually provides a good approximation
for the distribution of treated effluent pollutant concentration
measurements. Shapiro-Wilk goodness-of-fit tests were performed
on the pollutant concentration data from plant 99798 because a
reasonable number of daily concentration measurements (8 to 20
depending on the pollutant) were available. The test results
indicated that the use of the lognormal is not inconsistent with
these data; each of the distributions of daily F, Cd, Cr, Pb, and
Zn concentrations were not statistically different from
lognormal. Goodness-of-fit tests were applied to the data from
plant 99796 and indicate that the use of the lognormal is not
inconsistent with the Cr, Pb, and Zn concentrations. Two of the
three Cd values were the same. A small data set with two or more
identical values will reject nay hypothesized distributional
form. In general goodness-of-fit tests applied to extremely
small data sets are not very powerful.
Lognormal goodness-of-fit tests were not applied to the F data
from plant 30172 because the only available data were 27 averages
of four daily observations taken during each month. The
goodness-of-fit tests, used in this analysis, are intended to
examine if the distribution of daily values are significantly
different from lognormal. The distribution of four day averages
from plant 30172 cannot be used to perform a goodness-of-fit test
on the distribution of daily values. The individual daily
observations that comprise these averages were not provided by
industry.
A generalized form of the lognormal distrubition, known as the
delta lognormal (DLN) distribution, was used to model the data.
The DLN models the data as a mixture of zeroes and values above
zero that are lognormal distributed. This distribution is
described in Chapter 9 of The Loqnormal Distribution, by
Aitchison and Brown, Cambride University Press, 1963. The DLN
was used because of the presence in the data of observations
below the detection limit. Owen, W.J. and DeRouen, T.A. (1980.
Estimation of the Mean for LOgnormal Data Containing Zeros and
Left Censored values, Biometrics 36, 707-719), recommended that
when data contain below detection limit values the estimate of
the mean is most stable and has the lowest mean square error when
the below detection limit values are set to zero and the DLN
distribution is used to model the data. Plant 99798 is the only
A-2
-------
plant with values reported below the detection limit; the
detection limit values from plant 99798 have been set to zero.
The DLN distribution parameters (delta, logvariance, and logmean)
were estimated for each pollutant from each plant.
The daily maximum limitations are based upon estimates of the
99th percentile of the distribution of individual daily values.
These estimates were determined by substituting estimates of the
DLN distribution parameters, described above, into the
mathematical expression for the 99th percentile of the DLN
distribution. The monthly average limitations were based on the
95th percentile of the distribution of averages of 10 samples
drawn from the distribution of daily values.
Variability factors (VF) were calculated by dividing the
percentile estimates for each pollutant at each plant by the
estimated mean of the distribution daily effluent concentrations.
The plant VFs and plant arithmetic averages were arithmetically
averaged to determine an overall average and an overall VF for
each pollutant. Table 1 contains the VFs and averages used for
limitation development. The methodological details are presented
in Appendix E. This method of averaging gives equal
consideration to the information from each plant. These plants
are equally representative of the effluent pollutant
concentrations that can be achieved by plants in the EEC industry
and have therefore been weighted equally. The use of various
measures of central tendency in the context of effluent
guidelines development previously had been discussed in a
memorandum from Henry D. Kahn to George M. Jett titled "Averaging
Methods Used in Determining BPT Effluent Guidelines Limitations
for the Pesticide Industry", March 13, 1978.
Daily maximum limitations and 10 day average limitations are
estimated by multiplying the appropriate overall VF by the
corresponding overall arithmetic average. Table 2 presents the
final overall average, variability factors, and limitations for
the CRT subcategory of the EEC category.
A-3
-------
Table 1: Summary Statistics of Plants Used for Limitation
Development in the Cathode Ray Tube Subcategory of the
Electrical and Electronic Components - Phase II
Category
POLLUTANT
(mq/1)
FLUORIDE
CADMIUM
CHROMIUM
LEAD
ZINC
i SOURCE
SOURCE i
IND
IND
EPA
IND
EPA
IND
EPA
IND
EPA
IND
indicates
PLANT
99798
30172
Overall*'
99796
99798
Overall*'
99796
99798
Overall*'
99796
99798
Overall*1
99796
99798
Overall «
N2
20
27
3
20
3
20
3
8
3
20
who conducted the
AVERAGE 3
12.
16.
14.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
0.
6
4
5
019
020
020
163
294
229
300
238
269
550
243
397
DAILY
VF
2.
2.
2.
1 .
3.
2.
1 .
4.
2.
2.
6.
4.
3.
3.
3.
16
64
40
69
85
77
20
50
85
16
16
16
37
59
48
wastewater sampling.
MONTHLY
VF
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
.21
.28
.25
. 14
.46
.30
.04
.55
.30
.22
.86
.54
.42
.41
.42
IND is
industry. EPA is the Agency.
2N is the number of pollutant concentration measurements.
3AVERAGE is the arithmetic average of all the values for a pollutant
from a plant. Values that were recorded as below a detection
limit were set at the detection limit in computing the average
This may slightly increase the amount of pollutant that
appears to be present,
4DAILY VF is the ratio of the estimate of the 99th percentile of the
lognormally distributed daily values to an estimate of the
expected or average pollutant concentration.
SMONTHLY VF is the ratio of the estimate of the 95th percentile of the
lognormally distributed averages of 10 values to an estimate
of the expected or average pollutant concentrations.
'Overall is the unweighted arithmetic average of the individual plant
A-4
-------
estimates of AVERAGE, DAILY VF, and MONTHLY VF. These
overall averages are used for limitation development.
A-5
-------
Table 2: A Listing of the Overall Average, Overall Daily VF's,
Overall Monthly VFs, Daily Limitations, and Monthly
Limitations for the Cathode Ray Tube Subcategory of the
Electrical and Electronic Components - Phase II
Category
POLLUTANT
(mq/1)
FLUORIDE
CADMIUM
CHROMIUM
LEAD
ZINC
OVERALL
AVERAGE
14.0
0.020
0.229
0.269
0.397
DAILY
MAXIMUM
MONTHLY
AVERAGE (10 Values)
VF
2.40
2.77
2.85
4.16
3.48
LIMITATION VF
35.0 1.25
0.055 1.30
0.653 1.30
1.120 1.54
1 .38 1 .42
LIMITATION
18.0
0.026
0.298
0.414
0.564
A-6
-------
APPENDIX B
A Listing of the Data from Plant 99796
-------
A Listing of the Pollutant Concentrations Measured in
Samples Taken from the Treated Effluent Wastestream of
Cathode Ray Tube Plant 99796
Pollutants (mg/1)
DATE Cd Cr Pd ZN
10/6/82 0.021 0.150 0.400 0.944
10/7/82 0.021 0.176 0.200 0.345
10/8/82 0.014 0.164 0.300 0.360
B-l
-------
APPENDIX C
A Listing of the Fluoride Data from Plant 30172
-------
A Listing of Monthly Average1 Fluoride Concentrations from
the Treated Effluent Wastestream of
Cathode Ray Tube Plant 30172
Date
1/79
2/79
3/79
4/79
5/79
6/79
7/79
8/79
1/81
2/81
3/81
4/81
5/81
6/81
F(mq/l)
14.
15.
14.
15.
15.
13.
36.
12.
14.
20.
16.
19.
13.
15.
71
33
18
27
30
47
40
68
98
20
50
10
80
70
Date
7/81
8/81
9/81
10/81
11/81
12/81
1/81
2/82
3/82
4/82
5/82
6/82
F(mq/l)
16.
16.
17.
15.
1 1 .
12.
18.
1 1 .
21 .
18.
16.
15.
40
20
40
50
00
20
80
90
20
30
40
90
Each Monthly Average is Calculated Using Four Daily
Values Taken During the Month. The Individual Daily
Values were not Available.
C-l
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APPENDIX D
A Listing of the Pollutant Concentration Data from Plant 99798
-------
A Listing of the Pollutant Concentrations Measured in
Samples Taken from the Treated Effluent Wastestreams of
Cathode Ray Tube Plant 99798
DATE
1/13/82
1/13/82
2/1 1/82
3/29/82
4/05/82
4/30/82
5/25/82
6/28/82
7/ /82
7/21/82
8/ /82
9/ /82
10/12/82
1 1/8/82
1 1/16/82
12/16/82
1/25/83
1/31/83
3/15/83
3/23/83
F
11.2
16.6
11.9
12.4
14.4
14.8
10.8
11.5
11.5
4.3
12.4
12.0
9.0
8.6
9.0
9.2
16.0
26.6
13.9
15.8
Pol]
Cd
0.010
0.030
0.020
0.020
0.010
0.010
0.020
0.018
0.010
0.010
0.020
0.005
0.010
<0.010
0.010
0.090
0.030
0.010
0.030
0.020
Lutants
Cr
0.250
0.280
0.240
0.208
0.470
0.810
0. 104
0. 150
0.150
0. 140
0.241
0.040
0.140
0.750
0.450
0.220
0.240
0.690
0.110
0.110
(mg/1)
Pb
0.450
0.240
0.500
0.200
0.260
0.080
<0.096
<0.030
<0.020
Zn
0.590
0.450
0.058
0.323
0. 150
0.260
0. 169
0.230
0.230
0.130
0.400
0.100
0.090
0.270
0.310
0.150
0.25
0.37
0.25
0.07
PH
6.00
6.50
6.00
6.00
6.80
6.00
6.00
6.58
7.20
6.27
6.60
6.68
7.40
6.50
6.24
5.64
6.20
6.37
6.53
D-l
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APPENDIX E
Details of the Notation and Formulas Used to
Estimate Averages, Variability Factors, and Limitations
-------
Definitions
K
= N -
6 =
i
= (.99-6 )/(l - 6 )
i i
total number of plants.
total number of observations at plant i.
total number of below detection limit
observations at plant i.
total number of values that were not
below the detection limit at plant i.
delta , percent of the observations from
plant i that were below the detection
limit.
the 99th quantile of the delta lognormal
distribution.
the quantile of order q^ of the N(0 ,1)
distribution.
the concentraton of a pollutant in mg/1.
Observation j at plant i; j-l...Ni;
natural logarithm of the pollutant con-
centration values that are not below
the detection limit.
mean of the logarithms at plant i.
nl
= 1
(Y, - Y.-^/Nl, - 1
, i LJ i
within plant i logvariance.
a = /a'
i i
within plant i log standard deviation.!
Y.99 = e
estimated 99th percentile of the distri-
bution of Yi.
L Because the F data front plant 30172 were averages of four measurements taken
during the month thelogvariance of daily observations was estimated by multi-
plying the logvariance of the monthly averages by 4 and the log standard
deviation of the daily observations was estimated by muliplying the log
standard deviation of the monthly averages by the square root of 4.
E-l
-------
y (10)i = y + o2 /2 -
i i
o2
(0.5)ln,e x . 10-11
V10~ 10 '
o?
ln(
10
e 1 + 10-1
6 (10)i =6 - 0
i
X(10).95i =
y (10)^+1.6450
arithmetic mean of the pollutant concen-
trations. Values reported as below a
detection limit were averaged using the
detection limit value.
ten day log mean estimate for plant i.
ten day logvariance estimate for plant i.
the estimate of 6 for the ten day average
distribution.
the ten day average 95th percentile
estimate.
t = 0.5( o2 )
i
ni
(t) = efc { l-
[t2(3t2+22t+21)/6n2]
argument of the Bessel Function approxi-
mation.
an approximation of the Bessel function
used in the maximum efficiency estimate
for E(X)i.
E(X)i =
VFi = X.95i/E(X)i
K
the estimated mean (expected value) of
the distribution of X.
the daily variability factor for plant i,
the overall daily variability factor.
VF(10)i = X(10)<95i/E(X)i
K
VF(10) = I VF(10)iA
the ten day average variability factor
for plant i.
the overall ten dsiy variability factor.
K
X =
the overall average for a pollutant.
E-2
-------
Daily Limit = VF (X) Daily Limitation.
10 Day Average Limit = VF(10)(X) 10 Day Average Monthly Limitation.
E-3
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