-------
Table VI-4
DISTRIBUTION OF NUMBER OF PROCESSES IN QUESTIONNAIRE DATA BASE
WITH ZERO DISCHARGE*
Contact Cooling Cleaning and
Zero Discharge Method and Heating Water Finishing Water
100 Percent Recycle 89 2
Ponded for Evaporation 5 2
Septic Tank with Leach Field 10 2
Evaporation from Process Equipment 7 1
Land Application 10 0
Contract Haul 0 2_
TOTAL 121 9
*Based on information from 1979 and 1983 questionnaire surveys,
89
-------
Table VI-5
PM&F TREATMENT TECHNOLOGIES SUMMARY*
Treatment Technologieg
Plant ID
640
4051 08A
6021 95C
564076A
1400
95821 8R
95821 8U
1420
1946
29640A
362544S
580294E
1330
721018
580294B
95821 8Q
1500
2722
10650
2500
95821 8T
603007C
480
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Indirect
Indirect '
Indirect
Indirect
Indirect
Indirect
Indirect
Indirect
Indirect
Zero
PM&F
Waste-
water
100
100
100
100
99
97
95
88
86
81
80
61
50
100
100
100
100
100
100
100
95
50
100
BO
a
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XXX
X X
X
X X
X
X X
X
X
XX XX
X X
X
X
X
X
X
XX X
X
X
K -g
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X
X X
XX X
X
X
t
X
TOTAL
12 5336515 11 111211
*Based on information reported in 1979 and 1983 questionnaire surveys.
90
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(2) 43 plants (10.5 percent) have processes using only
cleaning and finishing water, and
(3) 33 plants (8.1 percent) have processes that use con-
tact cooling and heating water and processes that use
cleaning and finishing water.
Based on that information, 365 plants (332 + 33) have processes
that use contact cooling and heating water and 76 plants (43 +
33) have processes that use cleaning and finishing water.
Estimate of Number of Processes in PM&F Category That Use
Process Water
The process and plant information listed above from the question-
naire data base was applied to the estimated 1,898 wet plants in
the PM&F category to obtain a preliminary estimate of the number
of wet plants and processes in each subcategory. The calcula-
tions for the category preliminary plant estimate are-.
(category\
1,898 wet ]
plants /
1,545 plants with processes
(0.814) = that use only contact
cooling and heating water
(categoryX
1,898 wet )
plants /
199 plants with processes
(0.105) = that use only cleaning and
finishing water
CcategoryX
1,898 wet I
plants /
154 plants with processes that
(0.081) = use contact cooling and heating
water and processes that use
cleaning and finishing water
This equates to 1,699 plants (1,545 + 154) in the PM&F category
with processes that use contact cooling and heating water and 353
plants (199 + 154) with processes that use cleaning and finishing
water. The total category process estimate is:
category plants \
M,699 with processes I
that use cooling j
and heating water/
448 data
base processes
365 data
base plants
2,085 processes
that use contact
cooling and
heating water
92
-------
category plants \ / 94 data \ 437 processes
353 with processes V /base processes\ = that use cleaning
that use cleaning 11 76 data I and finishing
and finishing water/ \ base plants / water
Applying the percentages for direct, indirect, and zero dis-
chargers from Table VI-1 to the number of wet processes gives an
estimate of 667 direct discharge processes, 855 indirect dis-
charge processes, and 563 zero discharge processes for the con-
tact cooling and heating water subcategory and 122 direct dis-
charge processes, 262 indirect discharge processes, and 53 zero
discharge processes for the cleaning and finishing water
subcategory.
Estimate of Number of Plants in PM&F Category With Processes That
Use Process Water
To project the number of direct, indirect, and zero discharge
plants in the PM&F category, the number of plants in the data
base was distributed by the type of discharge mode (see Table
VI-7). A plant can have processes that use more than one type of
process water and can have more than one type of discharge mode.
For example, a plant can have a process that uses contact cooling
and heating water and recycles 100 percent of the process water,
making the plant a zero discharger. The same plant can also have
a process that uses cleaning and finishing water that is dis-
charged to a publicly owned treatment works (POTW), making the
plant an indirect discharger.
For plants with processes that use contact cooling and heating
water, the number of plants with direct discharges was calculated
by counting the numbers in Table VI-7 in columns one and three
for rows one, four, and five. There are 103 plants with contact
cooling and heating water processes in the data base that have
direct discharges (103 =90 +8+1 +1 +3+0 from Table VI-7).
This number accounts for the types of process water used and the
types of discharge modes.
Similarly, the number of plants in the data base with processes
that use cleaning and finishing water with direct discharges was
calculated by summing the numbers in columns two and three for
rows one, four, and five in Table VI-7. There are 19 plants with
processes that use cleaning and finishing water in the data base
that have direct discharges (i.e., 10+8+1 +0+0=19). This
same technique was used to determine the number of plants in the
data base that have indirect discharges and that have zero dis-
charge. The number of direct, indirect, and zero discharge
plants in the data base is presented in Table VI-8.
93
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94
-------
Table VI-8
NUMBER OF PLANTS IN DATA BASE
Contact Cooling Cleaning and
and Heating Water Finishing Water
Subcategory (%) Subcategory (_%_)_
Number of Plants
with Direct
Discharge* 103 (27) 19 (24)
Number of Plants
with Indirect
Discharge** 165 (44) 49 (62)
Number of Plants
with Zero
Discharge*** 111 (29) 11 (14)
TOTAL 379 (100) 79 (100)
*Calculated by summing columns one and three for rows one,
four, and five in Table VI-7 for contact cooling and heating
water, and columns two and three for rows one, four, and
five in Table VI-7 for cleaning and finishing water.
**Calculated by summing columns one and three for rows two,
four, and six in Table VI-7 for contact cooling and heating
water, and columns two and three for rows two, four, and
six in Table VI-7 for cleaning and finishing water.
***Calculated by summing columns one and three for rows three,
five, and six in Table VI-7 for contact cooling and heating
water, and columns two and three for rows three, five and
six in Table VI-7 for cleaning and finishing water.
95
-------
The 1,699 preliminary plant projection for the contact cooling
and heating water subcategory and the 353 preliminary plant pro-
jection for the cleaning and finishing water subcategory accounts
for plants with processes that use more than one type of process
water, but not for plants with more than one type of discharge
mode. Those projections were adjusted to account for more than
one type of discharge mode by multiplying the preliminary plant
projections by the ratio of the number of plants from the ques-
tionnaire data base that account for type of process water and
type of discharge mode to the number of plants that account only
for the type of process water used. The final PM&F category
estimate for plants using process water is:
hPM&F plants with
processes that use
,699 contact cooling
and heating
water
PM&F plants with
processes that use
1,764 contact cooling
and heating
water
353
PM&F plants with
processes that use
cleaning and
finishing water
= 367
PM&F plants with
processes that use
cleaning and
finishing water
These projections account for plants having more than one type of
water use and more than one mode of discharge. For this reason,
the total number of plants (2,131 = 1,764 + 367) exceeds the
estimated 1,898 wet plants presented in Section IV.
The 1,764 plants with contact cooling and heating water processes
and the 367 plants with cleaning and finishing water processes
were multiplied by the percentages in Table VI-8 to estimate the
numbers of direct, indirect, and zero plants in the PM&F category
that use process water. These projections are presented in Table
VI-9.
Estimate of PM&F Category Process Water Use
For each discharge mode, the estimated number of wet processes
for the PM&F category was distributed by flow range based on the
percentage of processes from the questionnaire data base in the
flow ranges presented in Table VI-2. The annual water use for
the PM&F category was calculated by multiplying the average oper-
ating hours per year and the average liters of water used per
hour listed in Table VI-2 and the estimated number of wet pro-
cesses in the PM&F category in each flow range.
96
-------
Table VI-9
PM&F CATEGORY PLANT PROJECTIONS BY DISCHARGE MODE
Contact Cooling Cleaning and
and Heating Water Finishing Water
Subcategory Subcategory
Number of Plants with
Direct Discharges 477 88
Number of Plants with
Indirect Discharges 778 228
Number of Plants with
Zero Discharges 512 51
TOTAL 1,767 367
97
-------
Table VI-10 presents the distribution of processes in the PM&F
category by discharge mode and by type of process water.
Approximately 70 percent of the contact cooling and heating water
and 65 percent of the cleaning and finishing water is used by
processes with a flow rate greater than 300 gpm. However,
processes with flow rates greater than 300 gpm are only seven
percent of the total number of processes that use contact cooling
and heating water and only seven percent of the total number of
processes that use cleaning and finishing water.
Estimate of PM&F Category Process Wastewater Discharged
Plants in the plastics molding and forming category discharge
approximately 47.3 billion liters per year of wastewater. Table
VI-11 contains a distribution of the amount of wastewater dis-
charged by type of process water and discharge mode.These esti-
mates were calculated by multiplying the average operating hours
per year listed in Table VI-3, the average liters of wastewater
discharged per hour listed in Table VI-3 and the estimated number
of wet processes in each flow range. The estimated number of wet
processes in the PM&F category was distributed among the flow
ranges by multiplying the total number of processes by the per-
centage of processes in each flow range from the questionnaire
data base (see Table VI-3). Approximately 57 percent of the
processes that discharge contact cooling and heating water and
approximately 73 percent of the processes that discharge cleaning
and finishing water have a discharge flow rate of eight gallons
per minute or less. However, wastewater discharged by those
processes is only approximately five percent of the estimated
annual amount of wastewater discharged by contact cooling and
heating water processes and only approximately 10 percent of the
wastewater discharged by cleaning and finishing processes.
SAMPLING PROGRAMS
The sampling programs for this project were undertaken to iden-
tify pollutants in the PM&F wastewater. Samples were collected
at plastics molding and forming plants and analyzed for conven-
tional, selected nonconventional, and priority pollutants. This
section discusses the sampling programs and presents the results
of the sample analyses.
Plant Selection
Criteria used to select PM&F plants for sampling included the
number and types of PM&F processes, water use and wastewater
discharge practices, and differences in production processes and
plastics materials used. The primary source of this information
was the questionnaires. The Agency selected plants for sampling
believed to represent a full range of PM&F processes and raw
materials. Those plants usually had more than one PM&F process.
98
-------
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Table VI-11
ESTIMATED WASTEWATER DISCHARGE - PM&F CATEGORY
Contact Cooling and Heating Water Subcategory
Discharge
Flow Range
(gpm)
X < 0.3
0.3 < X < 2
2 < X < 8
8 < X < 20
20 < X < 50
50 < X < 100
100 < X < 200
200 < X < 300
300 < X
TOTAL
Direct Dischargers
Estimated
Number of
Processes
79
83
148
148
116
51
28
5
9
667
Estimated Waste-
water Discharge
(billion 1/yr)
0.007
0.145
0.932
2.73
4.83
6.14
4.01
2.18
5.26
26.234
Indirect Dischargers
Estimated
Number of
Processes
159
210
192
173
66
32
9
14
0
855
Estimated Waste-
water Discharge
(billion 1/yr)
0.016
0.211
0.867
2.75
2.36
3.32
1.56
5.15
0
16.234
Cleaning and Finishing Water Subcategory
Discharge
Flow Range
Direct Dischargers
X < 0.3
0.3 < X < 2
2 < X < 8
8 < X <: 20
20 < X <_ 50
50 < X < 100
100 < X < 200
200 < X <: 300
300 < X
TOTAL
Estimated Estimated Waste-
Number of water Discharge
Processes (billion 1/yr)
14
28
28
19
23
5
5
0
0
0.001
0.032
0.146
0.301
0.832
0.241
1.61
0
0
Indirect Dischargers
Estimated Estimated Waste-
Number of water Discharge
Processes (billion 1/yr)
78
69
64
28
14
9
0
0
0
0.007
0.092
0.177
0.280
0.191
0.917
0
0
0
122
3.163
262
1.664
100
-------
Field Sampling
After selection of candidate plants, each plant was contacted by
telephone to verify their operations and to inform them that EPA
had included them in the sampling program. Presampling site
visits were conducted to identify sample locations, sampling
conditions, and plant operations.
Eleven plants were sampled during this project. Plants C, E, F,
and 1 were sampled in 1980 and the remaining seven plants, A, B,
D, G, H, J, and K, were sampled in 1983. Figures VI-1 through
VI-11 present wastewater flow diagrams for the 11 plants indicat-
ing the location of the sample points. Eighteen contact cooling
and heating water processes were sampled at nine PM&F plants.
Five different types of contact cooling and heating water
processes were sampled at those plants. Thirteen cleaning and
finishing water processes were sampled at seven PM&F plants.
Twelve of those processes were cleaning processes and one was a
finishing process. Table VI-12 lists the processes sampled in
each subcategory and the process water usage flow rate for each
process.
Sample Collection, Preservation, and Transportation
Collection, preservation, and transportation of samples were
performed in accordance with procedures outlined in Appendix III
of "Sampling and Analysis Procedures for Screening of Industrial
Effluents for Priority Pollutants" (published by the Environmen-
tal Monitoring and Support Laboratory, Cincinnati, Ohio, March
1977, revised, April 1977) and in "Sampling Screening Procedure
for the Measurement of Priority Pollutants" (published by the EPA
Effluent Guidelines Division, Washington, D.C., October 1976).
The procedures for collection, preservation, and transportation
of samples to be tested for conventional and nonconventional
pollutants were performed as described in the test methods (see
Table VI-14).
Sample Analysis
Once collected in the field, samples were prepared and shipped
via overnight air express to EPA contract laboratories for
analysis. Pollutants for which analyses were conducted are
presented in Table VI-13. The analytical methods used are listed
in Table VI-14. The analytical detection limits for the priority
pollutants are listed in Table VI-15.
Field Quality Assurance/Quality Control (QA/QC)
Field QA/QC procedures for the sampling program included taking
duplicate, blank, preserved blank, and source water samples.
101
-------
Source
Water
Cleaning
and
Finishing
Product
Cleaning
A-l
A-2
To
To
POTV7
Source
Water w
Cleaning
and
Finishing
Equipment
Cleaning
A- 3*
-®-+
To
POTW
LEGEND:
- Sample Point
- PM&F Process
*Data from this point were not used in data analyses because
production data were not available for this process.
Figure VI-1
SAMPLING POINTS AT PLANT A
102
-------
Source
Water
Source
Water
Source
Water
Source
Water
To
POTW
Direct
Discharge
Other Plant
Wastewater
LEGEND:
- Sample Point
- PM&F Process
- Treatment System
Figure VI-2
SAMPLING POINTS AT PLANT B
103
-------
Source
Water
Cooling
Tower
C-3*
Therrao-
forming
Slush
Mol ding
C-l
Discharge
Source
Water
LEGEND:
Wastewater From
Paint Spraying
Operation and
Glove Washings
Direct
Discharge
- Sample Point
- PM&F Process
- Treatment System
*Data from this point were not used in data analyses because
process is no longer in operation.
Figure VI-3
SAMPLING POINTS AT PLANT C
104
-------
Source ^
Water
Source
Water
Cleaning and
Finishing
Equipment
Cleaning
Cleaning and
Finishing
Equipment
Cleaning
D-l
D-2
/Qv
-Q$)
-*. To
POTW
To
"*" POTW
Source^
Water tL
LEGEND:
Extrusion
and
D-3
Water Chiller
To POTW
- Sample Point
- PM&F Process
Figure VI-4
SAMPLING POINTS AT PLANT D
105
-------
Source _.
'.Jater
Source
Water *"
Source
Water *
Source »,
Water
Extrusion
Calendering
Extrusion
Calendering
E-l
E-2
E-3
E-4
Direct
Discharge
Plastics Noncontact
Cooling Water and
Treated Electroplating
Water
LEGEND:
- Sample Point
- PM&F Process
- Treatment System
Figure VI-5
SAMPLING POINTS AT PLANT E
106
-------
Source
Water
Source
Water
Source
Water
Source
Water
Source
Water
F-3
To POTW
F-8
F-9
Direct
Discharge
Plastics Noncontact Cooling
Water, Rain Water Run-Off,
Boiler Slowdown, and Com-
pression Cooling Water
LEGEND:
- Sample Point
- PM&F Process
- Treatment System
Figure VI-6
SAMPLING POINTS AT PLANT F
107
-------
Source,
Water
Extrusion
and
Pelletizing
G-l
Direct
Discharge
Steam
Solution
Casting
Solvent
Recovery
G-2*
/Ov Condensed Steam
^VyDirect Discharge
LEGEND:
- Sample Point
- PM&F Process
^Solvent recovery wastewater is not regulated by the
proposed effluent limitations guidelines.
Figure VI-7
SAMPLING POINTS AT PLANT G
108
-------
Source
Water
Casting
H-l
09 ^
Source
Water
Cleaning
and
Finishing
Equipment
Cleaning
H-2*
iO
LEGEND:
- Sample Point
- PM&F Process
*Data from this point were not used in data analyses
because production data were not available for this
process.
Figure VI-8
SAMPLING POINTS AT PLANT H
109
-------
Source
Water
1-6*
f &
Source.
Water
Filter Aid
LEGEND:
- Sample Point
- PM&F Process
- Treatment System
1-5
To POTW
*Data from this point were not used in data analyses because
production data were not available for this process.
Figure VI-9
SAMPLING POINTS AT PLANT I
110
-------
Cooling Water
Expandable
Bead Foam
Molding
J-2
Mold
Release
Water
J-l
Con-
densed
Steam
Sump
t
Source
Water
Steam
Cooling
Tower
Boiler
Boiler
Slowdown
Cooling
Tower
Slowdown
Direct
^Discharge
LEGEND:
Sample Point
PM&F Process
Figure VI-10
SAMPLING POINTS AT PLANT J
111
-------
Source,
Water
To POTW
Source.
Water
LEGEND:
Cooling Tower
Cooling
Tower
i
r
Slowdown to FOTW
Extrusion
Extrusion
Extrusion
K-2
K-3
K-4
- Samnle Point
- PM&F Process
Figure VI-11
SAMPLING POINTS AT PLANT K
112
-------
Table VI-12
SAMPLED PROCESSES
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Process
Water Usage
Process Flow Rate
Code Type of Process (gpm)
B-1 extrusion 0.8
B-4 injection molding 0.025
C-1 slush molding 0.28
D-3 pelletizing (extrusion) 50 gal/batch
E-1 wire coating (extrusion) 5
E-2 calendering 14
E-3 wire coating (extrusion) 35
E-4 calendering 40
F-1 calendering 2.3
F-2 vacuum forming 1.8
F-6 extrusion 2
G-1 pelletizing (extrusion) 1.45
H-1 dip casting 0.07
J-1 foam injection molding 120
J-2 molding 9
K-2 extrusion 4
K-3 extrusion 2
K-4 extrusion 167
CLEANING AND FINISHING WATER SUBCATEGORY
A-1 parts washing 10 gal/batch
A-2 oxalic acid parts washing 40 gal/batch
B-2 rolling (finishing operation) 1.8
B-3 lens cleaning 20
C-2 parts washing 2.0
D-1 tank cleaning 15 gal/batch
D-2 tank cleaning 15 gal/batch
F-3 parts washing and rinsing 3.4
F-4 parts washing and rinsing 7.4
1-1 resin application equipment cleanup 1.4
1-2 resin application equipment cleanup 0.7
1-3 resin application equipment cleanup 1.6
K-1 parts washing 0.5
113
-------
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-------
Table VI-14
ANALYTICAL METHODS SUMMARY
USEPA Methodst
405.1
410.1, 410.2
415.1
160.2
340.1
350.1
351.3
353.2
365.1
405
375.2
376.2
425.1
150.1
335.3
420.2
503C
404B
51 2A
Conventional and Nonconventional Standard
Pollutants USEPA Methodst Methodstt
BOD5
COD
TOG
TSS
Bromide
Fluoride
Ammonia
Total Kjeldahl Nitrogen (TKN)
Nitrate-Nitrite Nitrogen (as N)
Oil and Grease
Phosphorus (total)
Boron
Sulfate (as S04=)
Sulfide (as S)
Surfactants (MBAS)
pH
Cyanide (total)
Phenols (total)
Metals
Calcium
Magnesium
Sodium
Aluminum
Manganese
Vanadium
Boron
Barium
Molybdenum
Tin
Yttrium
Cobalt
Iron
Titanium
tUSEPA Methods for Chemical Analysis of Water and Wastes,
USEPA, Environmental Monitoring and Support Laboratory,
Cincinnati, Ohio, March 1979, EPA-600/4-79-020.
ttStandard Methods for the Examination of Water and Wastewater,
15 Edition, 1981.
tttProcedures are described in "Guidelines Establishing Test Pro-
cedures for Analysis of Pollutants; Proposed Regulations,
Appendix IV," Federal Register, December 3, 1979, p. 69559.
Inductively Coupled Plasma
(ICP) Opticals - Emission
Spectrometer Method
(Task 1)ttt
115
-------
Table VI-14 (Continued)
ANALYTICAL METHODS SUMMARY
Priority Toxic Pollutants
Acid Extraction
Base/Neutral Extraction
Volatile Organics
Pesticides and PCB's
Metals
Lead
Beryllium
Cadmium
Chromium
Copper
Nickel
Zinc
Metals
Selenium
Thallium
Silver
Arsenic
Antimony
Mercury
Metals
Lead
Beryllium
Cadmium
Chromium
Copper
Nickel
Zinc
USEPA Methodt
1625*
1625*
1624*
608
Inductively Coupled Plasma (ICP)
Optical - Emission Spectrometer
Method (Task 1)tt
Flameless Atomic Absorption
Spectrometer Method (Task 2)t
Flame Atomic Absorption
Spectrometer Method (Task 2)t
*In cases where isotopes were not available USEPA Methods 624
and 625 were used.
tUSEPA Methods for Chemical Analysis of Water and Wastes,
USEPA, Environmental Monitoring and Support Laboratory,
Cincinnati, Ohio, March 1979, EPA-600/4-79-020.
ttProcedures are described in "Guidelines Establishing Test Pro-
cedures for Analysis of Pollutants; Proposed Regulations,
Appendix IV," Federal Register, December 3, 1979, p. 69559.
116
-------
Table VI-15
DETECTION LIMITS FOR PRIORITY POLLUTANTS
Analytical*
Detection Limit
Pollutant (ug/1)
Base/Neutral Extractable Compounds
N-nitrosodimethylamine 250
isophorone 50
hexachlorocyclopentadiene 250
benzidine 50
3,3'-dichlorobenzidene 50
indeno(1,2,3-cd)pyrene 25
dibenzo(ah)anthracene 25
benzo(ghi)perylene 25
all other base/neutral compounds 10
Acid Extractable Compounds
2,4-dimethylphenol 250
2,4-dinitrophenol 250
2-methyl-4,6-dinitrophenol 250
pentachlorophenol 125
all other acid compounds 25
Volatile Compounds
acrolein 100
acrylonitrile 100
all other volatile compounds 10
Pesticides
aldrin 0.003
dieldrin 0.006
chlordane 0.04
4,4'-DDT 0.016
4,4'-DDE 0.006
4,4'-DDD 0.012
a-endosulfan 0.005
B-endosulfan 0.010
endosulfan sulfate 0.03
endrin 0.009
endrin aldehyde 0.023
heptachlor 0.002
heptachlor epoxide 0.004
117
-------
Table VI-15 (Continued)
DETECTION LIMITS FOR PRIORITY POLLUTANTS
Analytical*
Detection Limit
Pollutant (ug/1)
Pesticides (Continued)
a-BHC 0.002
B-BHC 0.004
Y-BHC 0.004
6-BHC 0.002
PCB-1242 0.05
PCB-1254 0.06
PCB-1221 0.10
PCB-1232 0.10
PCB-1248 0.06
PCB-1260 0.15
PCB-1016 0.04
toxaphene 0.40
Metals
antimony 100
arsenic 53
beryllium 0.3
cadmium 4
chromium 7
copper 6
lead 42
mercury 0.1
nickel 15
selenium 75
silver 7
thallium 100
zinc 2
Others
cyanide 20
*These analytical detection limits are from the USEPA test method
for the organic acid, base neutral, and volatile pollutants.
The limits for the pesticides and metals are from the Federal
Register, Monday, December 3, 1979, "Guidelines Establishing
Test Procedures for the Analysis of Pollutants; Proposed
Regulations."
118
-------
Field Duplicates. Duplicate samples were collected at one
sampling point at each of the sampled plants. The identity of
the duplicate samples was not made known to the laboratories.
Oil and grease and organic volatile (VOA) samples were collected
in duplicate and shipped to the laboratory.
Field Blanks. As required by sampling protocol, organic-free
water wasFlushed through each automatic sampler prior to the
start of sampling at each plant. One gallon of that water was
collected and shipped to the contract laboratory. This sample
was the non-volatile organic pollutant blank sample.
Duplicate volatile organics (VOA) blanks were supplied in 40
milliliter vials at each sampling point by the laboratory. Both
preserved and unpreserved VOA blanks were supplied by the labora-
tory. The VOA blanks were prepared in the laboratory, trans-
ported to the sampling site, placed at selected locations at the
sampling site, and then returned to the laboratory after
conclusion of the sampling period.
Preservative/Container Blanks. To verify that there was no con-
tamination from the various chemicals used as preservatives or
from the sample containers, organic free water supplied by the
laboratory was poured into the appropriate sample containers.
These samples were preserved and shipped to appropriate
laboratories for analysis.
Fresh Water Samples. To assess potential presence of conven-
tional, nonconventional, and toxic pollutant parameters in the
source water for each plant, samples of the source water were
collected, preserved, shipped to the laboratory, and analyzed for
the pollutants listed in Table VI-13.
Bottle/Glassware Preparation. Sample containers and glassware
that come in contact with the wastewater samples were prepared
according to the procedures outlined in Table VI-16. With the
exceptions of grease and oil jars, field blank and preservative
blank containers, and the nonvolatile (NVO) composite jug, sample
containers were rinsed with wastewater prior to use.
Composite Samples. Composite samples were collected using an
ISCO Model 1580 Sampler equipped with new silastic pump tubing
and new teflon sample lines. An aluminum rod was used to anchor
the sample line in place if necessary. The equipment was pro-
grammed to collect a minimum of nine quarts (8,516 milliliters)
of wastewater over the duration of each sampling day. The
minimum aliquot size was 100 milliliters and the maximum interval
between aliquot collection was 30 minutes.
119
-------
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-------
The operation of each sampler was checked periodically throughout
the sampling day. Batteries used with the samplers were changed
on a daily basis to avoid problems.
At the conclusion of collection of each composite sample period,
contents of the jug were thoroughly mixed by shaking before being
transferring to individual containers. Graduate cylinders were
used to transfer the sample from the sample jug to the container
to avoid spillage.
Free Chlorine Determination. A free chlorine determination was
made with potassium iodide paper at each sampling point at the
beginning of each sampling day. The appropriate samples were
preserved if free chlorine was present in excess of one ppm.
Sample Preservation. All samples were maintained at 4°C during
the sampling period. All preservatives were purchased fresh and
placed in new containers. Cyanide and phenol samples were col-
lected via grab samples and preserved with appropriate chemicals
as soon as they were collected. Grease and oil samples were
single grab samples preserved with sulfuric acid. VGA samples
were individual grab samples collected four times per day and
preserved with sodium metabisulfate, if necessary. Individual
pipets were used for each preservative and discarded after use to
avoid cross-contamination.
pH Measurement. pH was monitored at each sampling location using
pH meters. The meter was buffered before use with pH 4, 7, and
10 buffering agents.
Temperature Measurement. Temperature was measured with metal
dial thermometers. Mercury thermometers were not used because of
potential contamination of the wastewater in case the thermometer
broke.
Laboratory Quality Assurance/Quality Control (QA/QC)
Quality control measures used in the laboratory are presented in
"Handbook for Analytical Quality Control in Water and Wastewater
Laboratories" (published by EPA Environmental Monitoring and Sup-
port Laboratory, Cincinnati, Ohio, 1976). As part of the analy-
tical quality control program, duplicates and blanks (including
sealed VGA samples of blank water carried to each sampling site
and returned unopened and samples of preserved and unpreserved
equipment blank water) were analyzed. Standards and spiked
samples were also analyzed. As part of the analytical QA/QC, all
instruments (such as balances, spectrophotometers, and recorders)
were routinely maintained and calibrated.
121
-------
WASTEWATER POLLUTANT CHARACTERISTICS
Analytical data for each type of process wastewater were sum-
marized and are presented in this section. The tables that
present the data contain the following information for each
analyzed pollutant:
1. number of samples analyzed;
2. number of times a pollutant was detected;
3. number of times a pollutant was detected above the
source water (i.e., plant intake water) and above the
test method analytical detection limit;
4. subcategory concentration range; and
5. subcategory average concentration.
Table VI-17 presents this summarized data for both subcategories.
The daily data used to calculate the summaries in Table VI-17 are
presented in Appendix A. Table VI-18 presents the data editing
rules and the concentration averaging technique methodology used
to calculate the concentration values reported in Table VI-17.
As shown in Table VI-18, priority pollutant data were first
eliminated for a process because the pollutant was never detected
or detected at or below the analytical detection limit., Data
were next eliminated if the source water concentrations were
equal to or greater than the effluent concentrations. After
these data editing steps, the remaining pollutant data for days
one, two, three, and the duplicate of a process were averaged.
For each pollutant, the process averages were averaged to
calculate an overall subcategory average concentration. The
concentration range for the processes within a subcategory was
determined by finding the smallest and largest concentration
values remaining after the data elimination procedure. The
subcategory average concentrations and the ranges for the tested
pollutants are presented in Table VI-17.
Priority organic pollutant analytical results were frequently
reported from the laboratory as less than values. Values that
were less than 0.01 milligrams per liter for acids, base neutrals
and volatile organic priority polltuants were listed as asterisks
in Appendix A. These values were not used to obtain the average
concentration because 0.01 milligrams per liter is the analytical
detection limit for those pollutants. Values of less than 0.005
milligrams per liter for pesticide priority pollutants were
listed as double asterisks in Appendix A. The double asterisks
values for the pesticides were averaged as zeroes because those
122
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values are above the analytical detection limit for the
pesticides.
The conventional and nonconventional pollutant data were edited
in a similar manner. However, when a less than value was repored
for those pollutants the absolute value of that value was used to
calculate the averages. Less than values for the conventional
and nonconventional pollutants were eliminated only if they were
equal to or less than the value for that pollutant in the source
water.
Less than values for the priority and nonconventional metals were
often reported by the laboratory. These less than values were
considered as not detected and were not used in the averaging
processes. For the priority metal pollutants, when both the
Task 1 (Inductively Coupled Plasma Optical) and Task 2 (Flame
Atomic Absorption) analyses were performed, only the Task 1 test
results were used in the averaging process.
SAMPLED PLANTS WITH WASTEWATER TREATMENT SYSTEMS
Wastewater treatment technolgies exist at four of the plants
(i.e., plants C, E, F and I) that were sampled in 1980 and at one
plant (i.e., plant B) sampled in 1983. Of the four 1980 plants,
only Plant I had a wastewater treatment system primarily for PM&F
wastewaters.
The treatment at Plant I consists of equalization, pH adjustment,
and filtration. Effluent data for this treatment plant are pre-
sented in Appendix A.
The treatment system at Plants B, C, E, and F consists of a
lagoon that treats a combined wastewater. Effluent from the
treatment systems at Plants E and F were sampled during this
project. The effluent data were not used in the data analyses
for this project because the treatment system treats more than
just PM&F wastewater. Those data are presented in the adminis-
trative record for the project.
SOLUTION CASTING/SOLVENT RECOVERY SAMPLING DATA
Wastewater is also generated by the solvent recovery operation in
the solution or solvent casting process. However, this waste-
water does not result from the blending, molding, forming, or any
processing of the plastic material and is not a process water.
Samples of this wastewater indicate that its pollutant character-
istics are different from the characteristics of PM&F process
wastewater. In addition, the Agency estimates that only eight
plants in the category generate solvent recovery wastewater. For
these reasons, the Agency believes that solvent recovery waste-
water is best controlled on a case-by-case basis by the permit
130
-------
writer or control authority. Analytical data for this type of
wastewater from the Agency's study of the plastics molding and
forming category may be used as a guide by the permit writer.
Appendix A presents wastewater pollutant characteristics for a
solution casting process at Plant G. See Figure VI-7 for a
process diagram.
131
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SECTION VII
POLLUTANTS IN PLASTICS MOLDING AND FORMING WASTEWATER
The Agency studied the plastics molding and forming category to
determine the presence of conventional, selected nonconventional,
and priority toxic pollutants in PM&F wastewater.
CONVENTIONAL POLLUTANTS
As previously mentioned, conventional pollutants are those
defined in Section 304(a)(4) of the Act and any other pollutants
defined by the Administrator as conventional pollutants. The
list of conventional pollutants currently includes: biochemical
oxygen demand (8005), total suspended solids (TSS), fecal coli-
form, pH, and oil and grease.
Samples collected during the 1980 and 1983 sampling episodes for
this project were analyzed for 6005, TSS, oil and grease, and
pH. All of these pollutants warrant further consideration for
the control because they were found in significant concentrations
in the PM&F wastewater.
NONCONVENTIONAL POLLUTANTS
Samples collected during the 1980 and 1983 sampling episodes were
also analyzed for the nonconventional pollutants listed in Table
VI-13. These pollutants were selected for analysis based on
knowledge of the raw materials used in the PM&F category and on
the potential for those pollutants to be discharged in
wastewater.
Results of the sample analyses indicate that only three noncon-
ventional pollutants were found in significant concentrations in
PM&F wastewater. They are: chemical oxygen demand (COD), total
organic carbon (TOG), and total phenols.
PRIORITY TOXIC POLLUTANTS
List of Pollutants
One hundred and twenty-nine priority toxic pollutants were
studied in this project pursuant to the requirements of the Clean
Water Act of 1977. These pollutants, which are listed in Table
VI-13, are members of the 65 compounds and classes of compounds
referred to in Section 307(a)(1) of the Act.
133
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From the original list of 129 priority pollutants, three pollu-
tants were deleted in two separate amendments to 40 CFR Subchap-
ter N, Part 401. Dichlorodifluoromethane and trichlorofluoro-
methane were deleted first (46 FR 79692; January 8, 1981)
followed by the deletion of bis(chloromethyl) ether (46 FR 10723;
February 4, 1981). The Agency concluded that deleting these com-
pounds does not compromise adequate control over their discharge
into the aquatic environment and that no adverse effects on the
aquatic environment or on human health will occur as a result of
deleting them from the list of priority toxic pollutants.
Concentration data were obtained for these pollutants during this
project because some of the PM&F samples were collected and
analyzed prior to the deletion of these pollutants from the list
of priority pollutants. These pollutants were not considered,
however, further for regulation.
Data on the concentration of asbestos in PM&F wastewater are
available from a small number of samples taken during the 1980
sampling plan. Those data indicate that asbestos was not present
or could not be interpreted because of the limited number of
fibers counted. Asbestos was not analyzed for in the 1983
sampling program.
Exclusion of Pollutants and Subcategories
The modified Settlement Agreement in NRDC v. Train, supra,
contains provisions that authorize the exclusion of priority
toxic pollutants and industry subcategories from regulation in
certain instances. These provisions are presented in Paragraph 8
of the modified Settlement Agreement. They are:
"1. For a specific pollutant or a subcategory or category,
equally or more stringent protection is already provided
by an effluent, new source performance standard, or
pretreatment standard or by an effluent limitation and
guideline promulgated pursuant to Section(s) 301, 304,
306, 307(a), 307(b), and 307(c) of the Act.
2. For a specific pollutant, except for pretreatment stand-
ards, the specific pollutant is present in the effluent
discharge solely as a result of its presence in intake
waters taken from the same body of water into which it
is discharged and, for pretreatment standards, the
specific pollutant is present in the effluent which is
introduced into treatment works (as defined in Section
212 of the Act) which are publicly owned solely as a
result of its presence in the point source's intake
waters, provided however, that such point source may be
subject to an appropriate effluent limitation for such
pollutant pursuant to the requirements of Section 307.
134
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3. For a specific pollutant, the pollutant is not detect-
able (with the use of analytical methods approved
pursuant to 304(h) of the Act, or in instances where
approved methods do not exist, with the use of analy-
tical methods which represent state-of-the-art capabil-
ity) in the direct discharges or in the effluents which
are introduced into publicly-owned treatment works from
sources within the subcategory or category; or is
detectable in the effluent from only a small number of
sources within the subcategory and the pollutant is
uniquely related to only those sources; or the pollutant
is present only in trace amounts and is neither causing
nor likely to cause toxic effects; or is present in
amounts too small to be effectively reduced by technol-
ogies known to the Administrator; or the pollutant will
be effectively controlled by the technologies upon which
are based other effluent limitations and guidelines,
standards of performance, or pretreatment standards.
4. For a category or subcategory, the amount and the
toxicity of each pollutant in the discharge does not
justify developing national regulations in accordance
with the schedule contained in Paragraph 7(b)."
The basis for exclusion in subparagraph 2 is that if a pollutant
was found in a higher concentration in the plant intake water
(i.e., source water) than in the wastewater generated by the PM&F
process, that pollutant would be excluded from control. Data
obtained from the sampling episodes were reviewed, therefore, to
determine which, if any, of the priority pollutants were excluded
from control because of this reason.
With respect to subparagraph 3 for the PM&F project, a pollutant
was considered not detected if the laboratory reported that it
was not detected or if the laboratory reported that it was
detected at or below the analytical detection limit. Pollutants
were excluded from control if they were not detected or detected
at or below their detection limit. Also for this project,
"detected in a small number of sources" was defined as detected
in two or less samples when 20 or more samples were analyzed. If
a pollutant was found in two or less samples when 20 or more
samples were analyzed for that pollutant, it was excluded from
further consideration. In most cases when this criterion
applied, the pollutant was also unique to the particular plant
that was sampled.
The PM&F category was reviewed to determine if any of the prior-
ity pollutants could be excluded based on Paragraph 8 of the
Settlement Agreement. Each subcategory was also reviewed to
determine if any priority pollutants could be excluded by
subcategory. Results of those reviews are presented below.
135
-------
PM&F Category. The Agency first applied the exclusion criterion
that a pollutant was not detected or was detected at or below the
analytical detection limit to data for the entire category.
Table VII-1 lists 75 priority toxic pollutants that were not
detected in any of the wastewater samples analyzed or were
detected at or below the pollutant analytical detection limit.
These pollutants are excluded from regulation for the PM&F cate-
gory and were not considered further. Table VII-2 lists the
priority pollutants that were considered further because they
were detected above their analytical detection limit.
PM&F Subcategories. Priority pollutants listed in Table VII-2
were reviewed by subcategory to determine whether:
1. A pollutant was never detected in wastewater samples
for this subcategory or was detected at or below the
analytical detection limit;
2. A pollutant was found in a higher concentration in
the plant intake water (i.e., source water) than in
the wastewater generated by the PM&F process; and
3. A pollutant was detected in two or less samples when
20 or more samples were analyzed for that pollutant.
A pollutant was first reviewed to determine if it was found above
the detection limit. If it was, the data were reviewed to deter-
mine if the pollutant was present in a higher concentration in
the source water than in the wastewater. If the concentration
was higher in the effluent, the pollutant was examined for
occurrence in more than two samples if 20 or more samples were
analyzed. If the pollutant passed all of these criteria, it was
considered further for possible regulation. Table VII-3 presents
an example of this exclusion methodology. Table VII-4 presents
priority pollutants excluded from control for the PM&F subcate-
gories using this methodology.
POLLUTANTS CONSIDERED FURTHER
Table VII-5 lists the pollutants considered further for control
by the PM&F effluent limitations guidelines and standards. Also
presented in Table VII-5 are the pollutant average effluent con-
centrations (see Table VI-17). The conventional pollutants
considered for control are BOD5, oil and grease, TSS, and pH.
The nonconventional pollutants considered further are COD, TOG,
and total phenols. Twenty-eight priority pollutants were
considered for control including 20 organic pollutants and eight
metal pollutants.
136
-------
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137
-------
Table VII-2
PRIORITY POLLUTANTS DETECTED IN PMfcF WASTEWATER
Priority Pollutant
4. benzene 114. antimony
6. carbon tetrachloride 115. arsenic
(tetrachloromethane) 117. beryllium
11. 1,1,1-trichloroethane 118. cadmium
12. hexachloroethane 119. chromium (Total)
22. parachlorometa cresol 120. copper
23. chloroform (trichloro- 121. cyanide (Total)
methane) 122. lead
30. 1,2-trans-dichloro- 123. mercury
ethylene 124. nickel
44. methylene chloride 125. selenium
(dichloromethane) 126. silver
47. bromoform (tribromo- 127. thallium
methane) 128. zinc
48. dichlorobromomethane
55. naphthalene
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl)
phthalate
68. di-n-butyl phthalate
69. di-n-octyl phthalate
70. diethyl phthalate
71. dimethyl phthalate
73. benzo (a)pyrene
(3,4-benzopyrene)
85. tetrachloroethylene
86. toluene
87. trichloroethylene
89. aldrin
90. dieldrin
92. 4,4'-DDT
93. 4,4'-DDE(p,p'DDX)
94. 4,4'-DDD(p,p'TDE)
96. -endosulfan
97. endosulfan sulfate
98. endrin
99. endrin aldehyde
100. heptachlor
101. heptachlor epoxide
102. ot-BHC
103. 6-BHC
104. Y-BHC
105. S-BHC
138
-------
Table VII-3
EXCLUSION METHODOLOGY EXAMPLE - POLLUTANT X
Method
Detection Pollutant X
Limit Concentration (mg/1)
Operation (mg/1) Source Da'y 1 Day 2 Day 3 Day 4 Day 5
1 2 4 -NB- (3) -KB- -N&- (4)
2 2 5 (5) -HB- © -NB- -NB-
3 2 ND •*- © •*B- ~we" •**•
4 2 3 4- -2- (3) -HB- -HB-
Exclusion Methodology
1. Data are first eliminated because the pollutant was never
detected or detected at or below the analytical detection
limit. See sample data that have a straight line through
them.
2. Data are next eliminated if the source water concentrations
are equal to or greater than the effluent concentrations.
See sampled data enclosed by parentheses.
3. Data are finally eliminated if only analytical results for
2 or less samples from a total data base for 20 or more
samples remain. See sample data that are circled.
Pollutant X was excluded because it was found in two or less
samples after the other data were eliminated.
139
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140
-------
Table VII-5
POLLUTANTS CONSIDERED FOR CONTROL BY SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
pH
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
4. benzene
6. carbon tetrachloride
(tetrachloromethane)
11. 1 ,1 ,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl)
phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE
100. heptachlor
102. a-BHC
103. B-BHC
104. Y-BHC
105. 6-BHC
Average*
Concentration
Contact Cooling
and Heating Water
(mg/D
102
21
17
(5.4-8.3)
241
74
149
0.029
1.176
0.037
0.042
0.097
0.086
**
0.316
0.333
0.012
0.030
0.016
315t
411
44t
203t
250t
176t
132t
104t
Average*
Concentration
Cleaning and
Finishing Water
(mg/1)
100
130
1,840
(1.6-11.5)
410
1,370
134
0.026
**
**
**
0.045
0.067
0.036
1.334
0.059
**
**
0.120
52t
**
**
18t
5t
**
534t
116t
141
-------
Table VII-5 (Continued)
POLLUTANTS CONSIDERED FOR CONTROL BY SUBCATEGORY
Priority Pollutants
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
125. selenium
128. zinc
Average*
Concentration
Contact Cooling
and Heating Water
(mg/1)
0.023
0.050
0.228
0.248
0.0004
0.686
**
0.190
Average*
Concentration
Cleaning and
Finishing Water
**
0.112
0.401
**
**
0.136
0.175
3.375
*Average concentrations presented in Table VI-17.
**Pollutant is not considered for control in this subcategory,
tConcentrations are in nanograms per liter.
142
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The following discussions address the pollutants listed in Table
VII-5. The discussions include the source of the pollutant;
whether it is a naturally occurring element, processed metal, or
a manufactured product; general physical properties and the form
of the pollutant; and toxic effects of the pollutant on humans
and other animals.
Conventional Pollutants
Biochemical Oxygen Demand (BOD^). Biochemical oxygen demand is
not a specific pollutant, but a measure of the relative oxygen
requirements of wastewaters, effluents, and polluted waters. The
BOD5 test measures the oxygen required for the biochemical
degradation of organic material (carbanaceous demand) and the
oxygen used to oxidize inorganic material such as sulfides and
ferrous iron. It also may measure the oxygen used to oxidize
reduced forms of nitrogen (nitrogenous demand) unless their oxi-
dation is prevented by an inhibitor to prevent ammonia oxidation.
Most wastewaters contain more oxygen-demanding materials than the
amount of dissolved oxygen available in air-saturated water.
Therefore, it is necessary to dilute the sample, add nutrients,
and maintain the pH in a range suitable for bacterial growth.
Complete stabilization of a sample may require a period of
incubation too long for practical purposes. Five days is the
accepted standard incubation period.
Oil and Grease. Oil and grease are taken together as one pollu-
tant parameter. Some of its components are:
1. Light Hydrocarbons - These include light fuels such as
gasoline, kerosene, and jet fuel, and miscellaneous solvents used
for industrial processing, degreasing, or cleaning purposes. The
presence of these light hydrocarbons may make the removal of
other heavier oil wastes more difficult.
2. Heavy Hydrocarbons, Fuels, and Tars - These include the
crude oils, diesel oils, #6 fuel oil, residual oils, slop oils,
and in some cases, asphalt and road tar.
3. Lubricants and Cutting Fluids - These generally fall
into two classes: non-emulsifiable oils such as lubricating oils
and greases and emulsifiable oils such as water soluble oils,
rolling oils, cutting oils, and drawing compounds. Emulsifiable
oils may contain fat, soap, or various other additives.
4. Vegetable and Animal Fats and Oils - These originate
primarily from processing of foods and natural products.
143
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These compounds can settle or float and may exist, as solids or
liquids depending on factors such as method of use, production
process, and temperature of water.
Oil and grease even in small quantities cause troublesome taste
and odor problems. Scum lines from these agents are produced on
water treatment basin walls and other containers. Fish and water
fowl are adversely affected by oils in their habitat. Oil emul-
sions may adhere to the gills of fish causing suffocation, and
the flesh of fish is tainted when microorganisms that were
exposed to waste oil are eaten. Deposition of oil in the bottom
sediments of water can serve to inhibit normal benthic growth.
Oil and grease exhibit an oxygen demand.
Many of the toxic organic pollutants will be found distributed
between the oil phase and the aqueous phase in industrial waste-
waters. The presence of phenols, PCB's, PAH's, and almost any
other organic pollutant in the oil and grease make characteriza-
tion of this parameter almost impossible. However, all of these
other organics add to the objectionable nature of the oil and
grease.
Levels of oil and grease that are toxic to aquatic organisms vary
greatly, depending on the type and the species susceptibility.
However, it has been reported that crude oil in concentrations as
low as 0.3 mg/1 is extremely toxic to freshwater fish., It has
been recommended that public water supply sources be essentially
free from oil and grease.
Oil and grease in quantities of 100 liters per square kilometer
cause a sheen on the surface of a body of water. The presence of
oil slicks decreases the aesthetic value of a waterway.
pH. Although not a specific pollutant, pH is related to the
acidity or alkalinity of a wastewater. It is not, however, a
measure of either. The term pH is used to describe the hydrogen
ion concentration (or activity) present in a given solution.
Values for pH range from 0 to 14; these numbers are the negative
logarithms of the hydrogen ion concentrations. A pH of 7 indi-
cates neutrality. Solutions with a pH above 7 are alkaline,
while those solutions with a pH below 7 are acidic. The rela-
tionship of pH and acidity and alkalinity is not necessarily
linear or direct. Knowledge of the water pH is useful in deter-
mining necessary measures for corrosion control, sanitation, and
disinfection. Its value is also necessary in the treatment of
industrial wastewaters to determine amounts of chemicails required
to remove pollutants and to measure their effectiveness. Removal
of pollutants, especially dissolved solids is affected by the pH
of the wastewater.
144
-------
Waters with a pH below 6.0 are corrosive to treatment facilities,
distribution lines, and household plumbing fixtures and can thus
add constituents to drinking water such as iron, copper, zinc,
cadmium, and lead. The hydrogen ion concentration can affect the
taste of the water; at a low pH water tastes sour. The bacteri-
cidal effect of chlorine is weakened as the pH increases, and it
is advantageous to keep the pH close to 7.0. This is significant
for providing safe drinking water.
Extremes of pH or rapid pH changes can exert stress conditions or
kill aquatic life outright. Even moderate changes from accept-
able criteria limits of pH are deleterious to some species.
The relative toxicity to aquatic life of many materials is
increased by changes in the water pH. For example, metallocya-
nide complexes can increase a thousand-fold in toxicity with a
drop of 1.5 pH units.
Because of the universal nature of pH and its effect on water
quality and treatment, it is selected as a pollutant parameter
for many industry categories. A neutral pH range (approximately
6 to 9) is generally desired because either extreme beyond this
range has a deleterious effect on receiving waters or the pollu-
tant nature of other wastewater constituents.
Total Suspended Solids (TSS). Suspended solids include both
organic and inorganic materials. The inorganic compounds include
sand, silt, and clay. The organic fraction includes such materi-
als as grease, oil, tar, and animal and vegetable waste products.
These solids may settle out rapidly; bottom deposits are often a
mixture of both organic and inorganic solids. Solids may be
suspended in water for a time and then settle to the bed of the
stream or lake. These solids discharged with man's wastes may be
inert, slowly biodegradable materials, or rapidly decomposable
substances. While in suspension, suspended solids increase the
turbidity of the water, reduce light penetration, and impair the
photosynthetic activity of aquatic plants.
Suspended solids in water interfere with many industrial pro-
cesses and cause foaming in boilers and incrustations on equip-
ment exposed to such water, especially as the temperature rises.
They are undesirable in process water used in the manufacture of
steel, in the textile industry, in laundries, in dyeing, and in
cooling systems.
Solids in suspension are aesthetically displeasing. When they
settle to form sludge deposits on the stream or lake bed, they
often damage the life in the water. Solids, when transformed to
sludge deposit, may do a variety of damaging things, including
blanketing the stream or lake bed and thereby destroying the
living spaces for those benthic organisms that would otherwise
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occupy the habitat. When of an organic nature, solids use a
portion or all of the dissolved oxygen available in the area.
Organic materials also serve as a food source for sludgeworms and
associated organisms.
Disregarding any toxic effect attributable to substances leached
out by water, suspended solids may kill fish and shellfish by
causing abrasive injuries and by clogging the gills and respira-
tory passages of various aquatic fauna. Indirectly, suspended
solids are inimical to aquatic life because they screen out
light, and they promote and maintain the development of noxious
conditions through oxygen depletion. This results in the killing
of fish and fish food organisms. Suspended solids also reduce
the recreational value of the water.
Nonconventional Pollutants
Chemical Oxygen Demand (COD). The COD is a test that measures
the content of organic matter in wastewater by chemical oxida-
tion. It is not a measure of one particular pollutant. The
oxygen equivalent (i.e., carbon dioxide, C02) of the organic
matter that can be oxidized is measured by using a strong chemi-
cal oxidizing agent in an acidic medium. Potassium dichromate is
an excellent oxidizing agent for this test. The principal reac-
tion using dichromate as the oxidizing agent may be generally
represented by the following unbalanced equation:
Organic Matter (CaHbOc) + Cr207= + H+ c
Cr3+ + C02 + H20
The COD of wastewater is usually higher than the BOD^ test
because more compounds can be chemically oxidized than can be
biologically oxidized. COD can be correlated with 6005 for
many kinds of wastewater. This can be quite useful as the COD
test results can be obtained in three hours versus five days for
BOD5 test results.
Total Organic Carbon (TOG). TOG is another test method to deter
mine the organic matter present in water and it is especially
applicable to small concentrations of organic matter. The test
is performed by injecting a known quantity of sample into a
high-temperature furnace. The organic carbon is oxidized to car
bon dioxide in the presence of a catalyst and the carbon dixoide
is quantitatively measured with an infrared analyzer. TOG is
also not a measure of only one pollutant.
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Phenols (Total). Total phenols is the result of analysis using
the 4-AAPp (4-aminoantipyrene) method. This analytical procedure
measures the color development of reaction products between 4-AAP
and some phenols. The results are reported as phenol. Thus,
"total phenols" is not total phenols because many phenols
(notably nitrophenols) do not react. Also, since each reacting
phenol contributes to the color development to a different
degree, and each phenol has a molecular weight different from
others and from phenol itself, analyses of several mixtures
containing the same total concentration of several phenols will
give different numbers depending on the proportions in the
particular mixture.
Despite these limitations of the analytical method, total phenols
is a useful parameter when the mix of phenols is relatively con-
stant and an inexpensive monitoring method is desired. In any
given plant or even in an industry subcategory, monitoring of
"total phenols" provides an indication of the concentration of
this group of priority pollutants as well as those phenols not
selected as priority pollutants. A further advantage is that the
method is widely used in water quality determinations.
It must be recognized, however, that six of the eleven priority
pollutant phenols could be present in high concentrations and not
be detected. Conversely, it is possible, but not probable, to
have a high "total phenols" concentration without any phenol
itself or any of the ten other priority pollutant phenols pre-
sent. A characterization of the phenol mixture to be monitroed
to establish constancy of composition will allow "total phenols"
to be used with confidence.
Priority Pollutants
4. Benzene. Benzene (C^E^) is a clear, colorless liquid
obtained mainly from petroleum feedstocks by several different
processes. Some is recovered from light oil obtained from coal
carbonization gases. It boils at 80°C and has a vapor pressure
of 100 mm of mercury at 26°C. It is slightly soluble in water
(1.8 g/1 at 25°C) and it dissolves in hydrocarbon solvents.
Annual production in the United States is three to four million
tons.
Most of the benzene used in the United States goes into chemical
manufacture. About half of that is converted to ethylbenzene
which is used to make styrene. Some benzene is used in motor
fuels.
Benzene is harmful to human health, according to numerous pub-
lished studies. Most studies relate effects of inhaled benzene
vapors. These effects include nausea, loss of muscle coordina-
tion, and excitement, followed by depression and coma. Death is
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usually the result of respiratory or cardiac failure. Two spe-
cific blood disorders are related to benzene exposure. One of
these, acute myelogenous leukemia, represents a carcinogenic
effect of benzene. However, most human exposure data are based
on exposure in occupational settings and benzene carcinogenesis
is not considered to be firmly established.
Oral administration of benzene to laboratory animals produced
leukopenia, a reduction in the number of leukocytes in the blood.
Subcutaneous injection of benzene-oil solutions has produced sug-
gestive, but not conclusive, evidence of benzene carcinogenesis.
Benzene demonstrated teratogenic effects in laboratory animals,
and mutagenic effects in humans and other animals.
For maximum protection of human health from the potential carcin-
ogenic effects of exposure to benzene through ingestion of water
and contaminated aquatic organisms, the ambient water concentra-
tion is zero. Concentrations of benzene estimated to result in
additional lifetime cancer risk at levels of 10"^, 10"^, and
10~5 are 0.000066 mg/1, 0.00066 mg/1, and 0.0066 rag/1,
respectively.
6. Carbon Tetrachloride. Carbon tetrachloride (CCl^), also
called tetrachloromethane, is a colorless liquid produced primar-
ily by the chlorination of hydrocarbons - particularly methane.
Carbon tetrachloride boils at 77°C and has a vapor pressure of 90
mm of mercury at 20°C. It is slightly soluble in water (0.8 gm/1
at 25°C) and soluble in many organic solvents. Approximately
one-third of a million tons is produced annually in the United
States.
Carbon tetrachloride, which was displaced by perchloroethylene as
a dry cleaning agent in the 1930's, is used principally as an
intermediate for production of chlorofluoromethanes for refriger-
ants, aerosols, and blowing agents. It is also used as a grain
fumigant.
Carbon tetrachloride produces a variety of toxic effects in
humans. Ingestion of relatively large quantities - greater than
five grams - has frequently proved fatal. Symptoms are burning
sensation in the mouth, esophagus, and stomach, followed by
abdominal pains, nausea, diarrhea, dizziness, abnormal pulse, and
coma. When death does not occur immediately, liver and kidney
damage are usually found. Symptoms of chronic poisoning are not
as well defined. General fatigue, headache, and anxiety have
been observed, accompanied by digestive tract and kidney dis-
comfort or pain.
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Data concerning teratogenicity and mutagenicity of carbon tetra-
chloride are scarce and inconclusive. However, carbon tetrachlo-
ride has been demonstrated to be carcinogenic in laboratory
animals. The liver was the target organ.
For maximum protection of human health from the potential carcin-
ogenic effects of exposure to carbon tetrachloride through inges-
tion of water and contaminated aquatic organisms, the ambient
water concentration is zero. Concentrations of carbon tetrachlo-
ride estimated to result in additional lifetime cancer risk at
risk levels of 10~7, 10~6, and 10~5 are 0.00004 mg/1,
0.0004 mg/1, and 0.004 mg/1, respectively.
11. 1,1,1-Trichloroethane. 1,1,1-Trichloroethane is one of the
two possible trichlorethanes. It is manufactured by hydrochlori-
nating vinyl chloride to 1,1-dichloroethane which is then chlori-
nated to the desired product. 1,1,1-Trichloroethane is a liquid
at room temperature with a vapor pressure of 96 mm of mercury at
20°C and a boiling point of 74°C. Its formula is CC^Cl^.
It is slightly soluble in water (0.48 g/1) and is very soluble in
organic solvents. The United States annual production is greater
than one-third of a million tons. 1,1,1-Trichloroethane is used
as an industrial solvent and degreasing agent.
Most human toxicity data for 1,1,1-trichloroethane relates to
inhalation and dermal exposure routes. Limited data are avail-
able for determining toxicity of ingested 1,1,1-trichloroethane,
and those data are all for the compound itself, not solutions in
water. No data are available regarding its toxicity to fish and
aquatic organisms. For the protection of human health from the
toxic properties of 1,1,1-trichloroethane ingested through the
comsumption of water and fish, the ambient water criterion is
18.4 mg/1. The criterion is based on bioassays for possible
carcinogenicity.
22. Para-chloro-meta-cresol. Para-chloro-meta-cresol
(ClCyHgOH)is thought to be a 4-chloro-3-methyl-phenol
(4-chloro-meta-cresol, or 2-chloro-5-hydroxy-toluene), but is
also used by some authorities to refer to 6-chloro-3-methyl-
phenol (6-chloro-meta-cresol, or 4-chloro-3-hydroxy-toluene),
depending on whether the chlorine is considered to be para to the
methyl or to the hydroxy group. It is assumed for the purposes
of this document that the subject compound is 2-chloro-5-hydroxy-
toluene. This compound is a colorless crystalline solid melting
at 66 to 68°C. It is slightly soluble in water and soluble in
organic solvents. This phenol reacts with 4-aminoantipyrene to
give a colored product and therefore contributes to the non--
conventional pollutant parameter designated "Total Phenols." No
information on manufacturing methods or volumes produced was
found.
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Para-chloro-meta cresol (abbreviated here as PCMC) is marketed as
a microbicide, and was proposed as an antiseptic and disinfectant
more than 40 years ago. It is used in glues, gums, paints, inks,
textiles, and leather goods.
Although no human toxicity data are available for PCMC, studies
on laboratory animals have demonstrated that this compound is
toxic when administered subcutaneously and intravenously. Death
was preceded by severe muscle tremors. At high dosages kidney
damage occurred. On the other hand, an unspecified isomer of
chlorocresol, presumed to be PCMC, is used at a concentration of
0.15 percent to preserve mucous heparin, a natural product
administered intravenously as an anticoagulant. The report does
not indicate the total amount of PCMC typically received. No
information was found regarding possible teratogenicity, or
carcinogenicity of PCMC.
23. Chloroform. Chloroform, also called trichloromethane, is a
colorless liquid manufactured commercially by chlorination of
methane. Careful control of conditions maximizes chloroform
production, but other products must be separated. Chloroform
boils at 61°C and has a vapor pressure of 200 mm of mercury at
25°C. It is slightly soluble in water (8.22 g/1 at 20°C) and
readily soluble in organic solvents.
Chloroform is used as a solvent and to manufacture refrigerants,
Pharmaceuticals, plastics, and anesthetics. It is seldom used as
an anesthetic.
Toxic effects of chloroform on humans include central nervous
system depression, gastrointestinal irritation, liver and kidney
damage and possible cardiac sensitization to adrenalin. Carcino-
genicity has been demonstrated for chloroform on laboratory
animals.
For the maximum protection of human health from the potential
carcinogenic effects of exposure to chloroform through ingestion
of water and contaminated aquatic organisms, the ambient water
concentration is zero. Concentrations of chloroform estimated to
result in additional lifetime cancer risks at the levels of
ID'7, 10~6, and 10~5 were 0.000019 mg/1, 0.00019 mg/1, and
0.0019mg/l, respectively.
44. Methylene Chloride. Methylene chloride, also called dichlo-
romethane (CH2C12),is a colorless liquid manufactured by
chlorination of methane or methyl chloride followed by separation
from the higher chlorinated methanes formed as coproducts.
Methylene chloride boils at 40°C, and has a vapor pressure of 362
mm of mercury at 20°C. It is slightly soluble in water (20 g/1
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at 20°C) , and very soluble in organic solvents. The United
States annual production is about 250,000 tons.
Methylene chloride is a common industrial solvent found in insec-
ticides, metal cleaners, paint, and paint and varnish removers.
Methylene chloride is not generally regarded as highly toxic to
humans. Most human toxicity data are for exposure by inhalation.
Inhaled methylene chloride acts as a central nervous system
depressant. There is also evidence that the compound causes
heart failure when large amounts are inhaled.
Methylene chloride does produce mutation in tests for this
effect. In addition, a bioassay recognized for its extremely
high sensitivity to strong and weak carcinogens produced results
that were marginally significant. Thus potential carcinogenic
effects of methylene chloride are not confirmed or denied, but
are under continuous study. These studies are difficult to
conduct for two reasons. First, the low boiling point (40°C) of
methylene chloride makes it difficult to maintain the compound at
37°C during incubation. Secondly, all impurities must be removed
because the impurities themselves may be carcinogenic. These
complications also make the test results difficult to interpret.
62. N-nitrosodiphenylamine. N-nitrosodiphenylamine
[(C5H5>2NNO],also called nitrous diphenylamide, is a
yellow crystalline solid manufactured by nitrosation of diphenyl-
amine. It melts at 66°C and is insoluble in water, but soluble
in several organic solvents other than hydrocarbons. Production
in the United States has approached 1,500 tons per year. The
compound is used as a retarder for rubber vulcanization and as a
pesticide for control of scorch (a fungus disease of plants).
N-nitroso compounds are acutely toxic to every animal species
tested and are also poisonous to humans. N-nitrosodiphenylamine
toxicity in adult rats lies in the mid range of the values for 60
N-nitroso compounds tested. Liver damage is the principal toxic
effect. N-nitrosodiphenylamine, unlike many other N-nitroso-
amines, does not show mutagenic activity. N-nitrosodiphenylamine
has been reported by several investigations to be non-carcino-
genic. However, the compound is capable of trans-nitrosation and
could thereby convert other amines to carcinogenic N-nitroso-
amines. Sixty-seven of 87 N-nitrosoamines studied were reported
to have carcinogenic activity. No water quality criterion have
been proposed for N-nitrosodiphenylamine.
66-71. Phthalate Esters. Phthalic acid, or 1,2-benzenedicar-
boxylic acid,is one of three isomeric benzenedicarboxylic acids
produced by the chemical industry. The other two isomeric forms
are called isophthalic and terephthalic acids. The formula for
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all three acids is C^H^COOH^. Some esters of phthalic
acid are designated as toxic pollutants. They will be discussed
as a group here, and specific properties of individual phthalate
esters in PM&F wastewater will be discussed afterwards.
Phthalic acid esters are manufactured in the United States at an
annual rate in excess of one billion pounds. They are used as
plasticizers - primarily in the production of polyvinyl chloride
(PVC) resins. The most widely used phthalate plasticizer is bis
(2-ethylhexyl) phthalate (66) which accounts for nearly one-third
of the phthalate esters produced. This particular ester is com-
monly referred to as dioctyl phthalate (DOP) and should not be
confused with one of the less used esters, di-n-octyl phthalate
(69), which is also used as a plasticizer. In addition to these
two isomeric dioctyl phthalates, four other esters, also used
primarily as plasticizers, are designated as toxic pollutants.
They are: butyl benzyl phthalate (67), di-n-butyl phthalate
(68), diethyl phthalate (70), and dimethyl phthalate (71).
Industrially, phthalate esters are prepared from phthalic anhy-
dride and the specific alcohol to form the ester. Some evidence
is available suggesting that phthalic acid esters also nay be
synthesized by certain plant and animal tissues. Tine extent to
which this occurs in nature is not known.
Phthalate esters used as plasticizers can be present in concen-
trations up to 60 percent of the total weight of the PVC plastic.
The plasticizer is not linked by primary chemical bonds to the
PVC resin. Rather, it is locked into the structure of intermesh-
ing polymer molecules and held by van der Waals forces. The
result is that the plasticizer is easily extracted. Plasticizers
are responsible for the odor associated with new plastic toys or
flexible sheet that has been contained in a sealed package.
Although the phthalate esters are not soluble or are only very
slightly soluble in water, they do migrate into aqueous solutions
placed in contact with the plastic. Thus, industrial facilities
with tank linings, wire and cable coverings, tubing, and sheet
flooring of PVC are expected to discharge some phthalate esters
in their raw waste. In addition to their use as plasticizers,
phthalate esters are used in lubricating oils and pesticide car-
riers. These also can contribute to industrial discharge of
phthalate esters.
From the accumulated data on acute toxicity in animals, phtha-
late esters may be considered as having a rather low order of
toxicity. Human toxicity data are limited. It is thought that
the toxic effect of the esters is most likely due to one of the
metabolic products, in particular the monoester. Oral acute tox-
icity in animals is greater for the lower molecular weight esters
than for the higher molecular weight esters.
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Orally administered phthalate esters generally produced enlarging
of liver and kidney, and atrophy of testes in laboratory animals.
Specific esters produced enlargement of heart and brain, spleen-
itis, and degeneration of central nervous system tissue.
Subacute doses administered orally to laboratory animals produced
some decrease in growth and degeneration of the testes. Chronic
studies in animals showed similar effects to those found in acute
and subacute studies, but to a much lower degree. The same
organs were enlarged, but pathological changes were not usually
detected.
A recent study of several phthalic esters produced suggestive but
not conclusive evidence that dimethyl and diethyl phthalates have
a cancer liability. Only four of the six toxic pollutant esters
were included in the study. Phthalate esters do bioconcentrate
in fish. The factors, weighted for relative consumption of
various aquatic and marine food groups, are used to calculate
ambient water quality criteria for four phthalate esters. The
values are included in the discussion of the specific esters.
Studies of toxicity of phthalate esters in freshwater and salt
water organisms are scarce. A chronic toxicity test with bis(2-
ethylhexyl) phthalate showed that significant reproductive
impairment occurred at 0.003 mg/1 in the freshwater crustacean,
Daphnia magna. In acute toxicity studies, saltwater fish and
organisms showed sensitivity differences of up to eight-fold to
butyl benzyl, diethyl, and dimethyl phthalates. This suggests
that each ester must be evaluated individually for toxic effects.
66. Bis(2-ethylhexyl) phthalate. In addition to the general
remarks and discussion on phthalate esters, specific information
on bis(2-ethylhexyl) phthalate is provided. Little information
is available about the physical properties of bis(2-ethylhexyl)
phthalate. It is a liquid boiling at 387°C at 5mm of mercury and
is insoluble in water. Its formula is CfcH^COOCgHi 7)2-
This toxic pollutant constitutes about one-third of the phthalate
ester production in the U.S. It is commonly referred to as
dioctyl phthalate, or DOP, in the plastics industry where it is
the most extensively used compound for the plasticization of
polyvinyl chloride (PVC). Bis(2-ethylhexyl) phthalate has been
approved by the FDA for use in plastics in contact with food.
Therefore, it may be found in wastewaters coming in contact with
discarded plastic food wrappers as well as the PVC films and
shapes normally found in industrial plants. This toxic pollutant
is also a commonly used organic diffusion pump oil, where its low
vapor pressure is an advantage.
For the protection of human health from the toxic properties of
bis(2-ethylhexyl) phthalate ingested through water and through
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contaminated aquatic organisms, the ambient water quality criter-
ion is determined to be 15 mg/i. If contaminated aquatic organ-
isms alone are consumed, excluding the consumption of water, the
ambient water criteria is determined to be 50 mg/1.
68. Di-n-butyl Phthalate. In addition to the general remarks
and discussion on phthalate esters, specific information on di-
n-butyl phthalate (DBF) is provided. DBF is a colorless, oily
liquid, boiling at 340°C. Its water solubility at room tempera-
ture is reported to be 0.4 g/1 and 4.5 g/1 in two different chem-
istry handbooks. The formula for DBF, CeH^COOC^Hg^
is the same as for its isomer, di-isobutyl phthalate. DBF
production is one to two percent of total United States phthalate
ester production.
Dibutyl phthalate is used to a limited extent as a plasticizer
for polyvinyl chloride (PVC) . It is not approved for contact
with food. It is used in liquid lipsticks and as a diluent for
polysulfide dental impression materials. DBF is used as a plas-
ticizer for nitrocellulose in making gun powder, and as a fuel in
solid propellants for rockets. Further uses are insecticides,
safety glass manufacture, textile lubricating agents, printing
inks, adhesives, paper coatings, and resin solvents.
For protection of human health from the toxic properties of
dibutyl phthalate ingested through water and through contami-
nated aquatic organisms, the ambient water quality criterion is
determined to be 34 mg/1. If contaminated aquatic organisms
alone are consumed, excluding the consumption of water, the
ambient water criterion is 154 mg/1.
85. Tetrachloroethylene. Tetrachloroethylene
also called perchloroethylene and PCE, is a colorless, nonflam-
mable liquid produced mainly by two methods - chlorination and
pyrolysis of ethane and propane, and oxychlorination of dichloro-
ethane. The United States annual production exceeds 300,000
tons. PCE boils at 121°C and has a vapor pressure of 1 9 mm of
mercury at 20°C. It is insoluble in water but soluble in organic
solvents.
Approximately two-thirds of the United States production of PCE
is used for dry cleaning. Textile processing and metal degreas-
ing , in equal amounts consume about one-quarter of the United
States production.
The principal toxic effect of PCE on humans is central nervous
system depression when the compound is inhaled. Headache,
fatigue, sleepiness, dizziness, and sensations of intoxication
are reported. Severity of effects increases with vapor concen-
tration. High integrated exposure (concentration times duration)
produces kidney and liver damage. Very limited data on PCE
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ingested by laboratory animals indicate liver damage occurs when
PCE is administered by that route. PCE tends to distribute to
fat in mammalian bodies.
One report found in the literature suggests, but does not con-
clude, that PCE is teratogenic. PCE has been demonstrated to be
a liver carcinogen in B6C3-F1 mice.
For the maximum protection of human health from the potential
carcinogenic effects of exposure to tetrachlorethylene through
ingestion of water and contaminated aquatic organisms, the ambi-
ent water concentration is zero. Concentrations of tetrachloro-
ethylene estimated to result in additional lifetime c ncer risk
levels of 1(T7, 10~6, and 1(T5 are 0.00008 mg/1, 0.0008
mg/1, and 0.008 mg/1, respectively.
86. Toluene. Toluene is a clear, colorless liquid with a
benzene-like odor. It is a naturally occuring compound derived
primarily from petroleum or petrochemical processes. Some
toluene is obtained from the manufacture of metallurgical coke.
Toluene is also referred to as totuol, methylbenzene, methacide,
and phenylmethane. It is an aromatic hydrocarbon with the
formula Cgi^Ct^. It boils at 111°C and has a vapor pres-
sure of 30 mm Hg at room temperature. The water solubility of
toluene is 535 mg/1, and it is miscible with a variety of organic
solvents. Annual production of toluene in the United States is
greater than two million metric tons. Approximately two-thirds
of the toluene is converted to benzene and the remaining 30 per-
cent is divided approximately equally into chemical manufacture,
and use as a paint solvent and aviation gasoline additive. An
estimated 5,000 metric tons is discharged to the environment
anually as a constituent in wastewater.
Most data on the effects of toluene in human and other mammals
have been based on inhalation exposure or dermal contact studies.
There appear to be no reports of oral administration of toluene
to human subjects. A long term toxicity study on female rats
revealed no adverse effects on growth, mortality, appearance and
behavior, organ to body weight ratios, blood-urea nitrogen
levels, bone marrow counts, peripheral blood counts, or morphol-
ogy of major organs. The effects of inhaled toluene on the cen-
tral nervous system, both at high and low concentrations, have
been studied in humans and animals. However, ingested toluene is
expected to be handled differently by the body because it is
absorbed more slowly and must first pass through the liver before
reaching the nervous system. Toluene is extensively and rapidly
metabolized in the liver. One of the principal metabolic prod-
ucts of toluene is benzoic acid, which itself seems to have
little potential to produce tissue injury.
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Toluene does not appear to be teratogenic in laboratory animals
or man. Nor is there any conclusive evidence that toluene is
mutagenic. Toluene has not been demonstrated to be positive in
any in vitro mutagenicity or carcinogenicity bioassay system, nor
to be carcinogenic in animals or man.
Toluene has been found in fish caught in harbor waters in the
vicinity of petroleum and petrochemical plants. Biocoricentration
studies have not been conducted, but bioconcentration factors
have been calculated on the basis of the octanol-water partition
coefficient.
For the protection of human health from the toxic properties of
toluene ingested through water and through contaminated aquatic
organisms, the ambient water criterion is determined to be 14.3
mg/1. If contaminated aquatic organisms alone are consumed
excluding the consumption of water, the ambient water criterion
is 424 mg/1. Available data show that the adverse effects on
aquatic life occur at concentrations as low as 5 mg/1.
Acute toxicity tests have been conducted with toluene and a
variety of freshwater fish and Daphnia magna. The latter appears
to be significantly more resistant than fish. No test results
have been reported for the chronic effects of toluene on
freshwater fish or invertebrate species.
89. Aldrin. Aldrin is highly toxic by ingestion and inhalation,
and is absorbed through the skin. It has been found to be
carcinogenic to the liver of mice. For the protection of human
health against the carcinogenic properties of aldrin, EPA has
proposed a limit of 4.6 x 1 0~3 ng/1 at a risk factor of 10~"
for the ingestion of water and contaminated aquatic organisms.
Aldrin is regulated under Section 307(a), and is banned from
manufacture and use by EPA.
90. Dieldrin. Dieldrin is highly toxic by ingestion, inhala-
tion, and skin absorption. Dieldrin has been found to cause
cancer in the liver of mice. Dieldrin is regulated under Section
307(a), and is banned from manufacture and use by EPA.
93. 4,4'-DDE. DDE is significantly more stable than DDT and
results in more serious consequences that DDT. Evidence exists
to suggest that it cause cancer of the liver in mice.
100. Heptachlor. Heptachlor is a nonsystemic stomach and con-
tact insecticide which has fumigant action. It is a soft waxy
solid with a melting range of 46 to 75°C and is practically
insoluble in water. Heptachlor is very toxic to mammals with an
acute oral LD50 of 100 mg/kg for male rats and an acute dermal
LD50 for male rats of 195 mg/kg. Heptachlor and its epoxide
bioaccumulate in fatty tissue and persist for lengthy periods of
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time. Several uses of hepatachlor have been discontinued to
avoid contamination of milk and animal products. Heptachlor is a
suspected carcinogen. The total number of tumors in both male
and female rats increased in one long-term study after heptachlor
exposure. It has been recommended that human daily intake of
heptachlor should not exceed 0.005 mg/kg of body weight. A ban
was placed on heptachlor in Canada in 1969 because of concern for
residues in milk and deleterious effects on birds.
102. a-BHC. a-BHC is toxic by ingestion, skin absorption, is an
eye and skin irritant, and a central nervous system depressant.
103. B-BHC. (3-BHC is moderately toxic by inhalation, highly
toxic by ingestion, and is a strong irritant by skin absorption.
It acts as a central nervous system depressant.
104. Y-BHC. Y-BHC, also known as lindane, is highly toxic by
ingestion and moderately toxic by inhalation.
105. 6-BHC. 6-BHC is moderately toxic by inhalation and highly
toxic by ingestion. It is a strong irritant to the skin and
eyes, is absorbed by the skin, and is a central nervous system
depressant.
118. Cadmium. Cadmium is a relatively rare metallic element
that is seldom found in sufficient quantities in a pure state to
warrant mining or extraction from the earth's surface. It is
found in trace amounts of about 1 ppm throughout the earth's
crust. Cadmium is, however, a valuable by-product of zinc pro-
duction.
Cadmium is used primarily as an electroplated metal, and is found
as an impurity in the secondary refining of zinc, lead, and
copper.
Cadmium is an extremely dangerous cumulative toxicant, causing
progressive chronic poisoning in mammals, fish, and probably
other organisms. The metal is not excreted.
Toxic effects of cadmium on man have been reported from through-
out the world. Cadmium may be a factor in the development of
such human pathological conditions as kidney disease, testicular
tumors, hypertension, arteriosclerosis, growth inhibition,
chronic disease of old age, and cancer. Cadmium is normally
ingested by humans through food and water as well as by breathing
air contaminated by cadmium dust. Cadmium is cumulative in the
liver, kidney, pancreas, and thyroid of humans and other animals.
A severe bone and kidney syndrome known as itai-itai disease has
been documented in Japan as caused by cadmium ingestion via
drinking water and contaminated irrigation water. Ingestion of
as little as 0.6 mg/day has produced the disease. Cadmium acts
157
-------
synergistically with other metals. Copper and zinc substantially
increase its toxicity.
Cadmium is concentrated by marine organisms, particularly
molluscs, which accumulate cadmium in calcareous tissues and in
the viscera. A concentration factor of 1,000 for cadmium in fish
muscle has been reported, as have concentration factors of 3,000
in marine plants and up to 29,600 in certain marine animals. The
eggs and larvae of fish are apparently more sensitive than adult
fish to poisoning by cadmium, and crustaceans appear to be more
sensitive than fish eggs and larvae.
For the protection of human health from the toxic properties of
cadmium ingested through water and through contaminated aquatic
organisms, the ambient water criterion is determined to be 0.010
mg/1. Available data show that adverse effects on aquatic life
occur at concentrations in the same range as those cited for
human health, and they are highly dependent on water hardness.
119. Chromium. Chromium is an elemental metal usually found as
a chromite (FeO. C^OO. The metal is normally produced by
reducing the oxide with aluminum. A significant proportion of
the chromium used is in the form of compounds such as sodium
dichromate (Na2Cr04), and chromic acid (CrC^) - both are
hexavalent chromium compounds.
Chromium is found as an alloying component of many steels and its
compounds are used in electroplating baths, and as corrosion
inhibitors for closed water circulation systems.
The two chromium forms most frequently found in industry waste-
waters are hexavalent and trivalent chromium. Hexavalent chro-
mium is the form used for metal treatments. Some of it is
reduced to trivalent chromium as part of the process reaction.
The raw wastewater containing both valence states is usually
treated first to reduce remaining hexavalent to trivalent chro-
mium, and second to precipitate the trivalent form as the hydrox-
ide. The hexavalent form is not removed by lime treatment.
Chromium, in its various valence states, is hazardous to man. It
can produce lung tumors when inhaled, and induces skin sensitiza-
tions. Large doses of chromates have corrosive effects on the
intestinal tract and can cause inflammation of the kidneys.
Hexavalent chromium is a known human carcinogen. Levels of chro-
mate ions that show no effect in man appear to be so low as to
prohibit determination, to date.
The toxicity of chromium salts to fish and other aquatic life
varies widely with the species, temperature, pH, valence of the
chromium, and synergistic or antagonistic effects, especially the
effect of water hardness. Studies have shown that trivalent
158
-------
chromium is more toxic to fish of some types than is hexavalent
chromium. Hexavalent chromium retards growth of one fish species
at 0.0002 mg/1. Fish food organisms and other lower forms of
aquatic life are extremely sensitive to chromium. Therefore,
both hexavalent and trivalent chromium must be considered harmful
to particular fish or organisms.
For the protection of human health from the toxic properties of
chromium (except hexavalent chromium) ingested through water and
contaminated aquatic organisms, the ambient water quality crite-
rion is 170 mg/1. If contaminated aquatic organisms alone are
consumed, excluding the consumption of water, the ambient water
criterion for trivalent chromium is 3,443 mg/1. The ambient
water quality criterion for hexavalent chromium is recommended to
be identical to the existing drinking water standard for total
chromium which is 0.050 mg/1.
120. Copper. Copper is a metallic element that sometimes is
found free, as the native metal, and is also found in minerals
such as cuprite (CuoO), malechite [CuC03.Cu(OH)2l, azurite
[2CuC03.Cu(OH)2l, chalcopyrite (CuFeSo), and bornite
(Cu5FeS4). Copper is obtained from tnese ores by smelting,
leaching, and electrolysis. It is used in the plating, electri-
cal, plumbing, and heating equipment industries, as well as in
insecticides and fungicides.
Traces of copper are found in all forms of plant and animal life,
and the metal is an essential trace element for nutrition.
Copper is not considered to be a cumulative systemic poison for
humans as it is readily excreted by the body, but it can cause
symptoms of gastroenteritis, with nausea and intestinal irrita-
tions, as relatively low dosages. The limiting factor in domes-
tic water supplies is taste. To prevent this adverse organolep-
tic effect of copper in water, a criterion of 1 mg/1 has been
established.
The toxicity of copper to aquatic organisms varies significantly,
not only with the species, but also with the physical and chemi-
cal characteristics of the water, including temperature, hard-
ness, turbidity, and carbon dioxide content. In hard water, the
toxicity of copper salts may be reduced by the precipitation of
copper carbonate or other insoluble compounds. The sulfates of
copper and zinc, and of copper and calcium are synergistic in
their toxic effect on fish.
Relatively high concentrations of copper may be tolerated by
adult fish for short periods of time; the critical effect of
copper appears to be its higher toxicity to young or juvenile
fish. Concentrations of 0.02 to 0.03 mg/1 have proved fatal to
some common fish species. In general the salmonoids are very
sensitive and the sunfishes are less sensitive to copper.
159
-------
The recommended criterion to protect freshwater aquatic life is
0.0056 mg/1 as a 24-hour average, and 0.012 mg/1 maximum concen-
tration at a hardness of 50 mg/1 CaC03. For total recoverable
copper the criterion to protect freshwater aquatic life is 0.0056
mg/1 as a 24-hour average.
Copper salts cause undesirable color reactions in the food indus-
try and cause pitting when deposited on some other metals such as
aluminum and galvanized steel. To control undesirable taste and
odor quality of ambient water due to the organoleptic properties
of copper, the estimated level is 1.0 mg/1 for total recoverable
copper.
Irrigation water containing more than minute quantities of copper
can be detrimental to certain crops. Copper appears in all
soils, and its concentration ranges from 10 to 80 ppm. In soils,
copper occurs in association with hydrous oxides of manganese and
iron, and also as soluble and insoluble complexes with organic
matter. Copper is essential to the life of plants, and the
normal range of concentration in plant tissue is from 5 to 20
ppm. Copper concentrations in plants normally do not build up to
high levels when toxicity occurs. For example, the concentra-
tions of copper in snapbean leaves and pods was less than 50 and
20 mg/kg, respectively, under conditions of severe copper toxic-
ity. Even under conditions of copper toxicity, most of the
excess copper accumulates in the roots; very little is moved to
the aerial part of the plant.
122. Lead. Lead is a soft, malleable, ductile, blueish-gray,
metallic element, usually obtained from the mineral galena (lead
sulfide, PbS), anglesite (lead sulfate, PbSC>4), or cerussite
(lead carbonate, PbCC^). Because it is usually associated with
minerals of zinc, silver, copper, gold, cadmium, antimony, and
arsenic, special purification methods are frequently used before
and after extraction of the metal from the ore concentrate by
smelting.
Lead is widely used for its corrosion resistance, sound and
vibration absorption, low melting point (solders), and relatively
high imperviousness to various forms of radiation. Small amounts
of copper, antimony and other metals can be alloyed with lead to
achieve greater hardness, stiffness, or corrosion resistance than
is afforded by the pure metal. Lead compounds are used in glazes
and paints. About one third of U.S. lead consumption goes into
storage batteries. About half of U.S. lead consumption is from
secondary lead recovery. U.S. consumption of lead is in the
range of one million tons annually.
Lead ingested by humans produces a variety of toxic effects
including impaired reproductive ability, disturbances in blood
chemistry, neurological disorders, kidney damage, and adverse
160
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cardiovascular effects. Exposure to lead in the diet results in
permanent increase in lead levels in the body. Most of the lead
entering the body eventually becomes localized in the bones where
it accumulates. Lead is a carcinogen or cocarcinogen in some
species of experimental animals. Lead is teratogenic in experi-
mental animals. Mutagenicity data are not available for lead.
The ambient water quality criterion for lead is recommended to be
identical to the existng drinking water standard which is 0.050
mg/1. Available data show that adverse effects on aquatic life
occur at concentrations as low as 7.5 x 10"^ mg/1 of total
recoverable lead as a 24-hour average with a water hardness of 50
mg/1 as CaC03.
123. Mercury. Mercury is an elemental metal rarely found in
nature as the free metal. Mercury is unique among metals as it
remains a liquid down to about 39 degrees below zero. It is
relatively inert chemically and is insoluble in water. The
principal ore is cinnabar (HgS).
Mercury is used industrially as the metal and as mercurous and
mercuric salts and compounds. Mercury is used in several types
of batteries. Mercury released to the aqueous environment is
subject to biomethylation - conversion to the extremely toxic
methyl mercury.
Mercury can be introduced into the body through the skin and the
respiratory system as the elemental vapor. Mercuric salts are
highly toxic to humans and can be absorbed through the gastro-
intestinal tract. Fatal doses can vary from 1 to 30 grams.
Chronic toxicity of methyl mercury is evidenced primarily by
neurological symptoms. Some mercuric salts cause death by kidney
failure.
Mercuric salts are extremely toxic to fish and other aquatic
life. Mercuric chloride is more lethal than copper, hexavalent
chromium, zinc, nickel, and lead towards fish and aquatic life.
In the food cycle, algae containing mercury up to 100 times the
concentration in the surrounding sea water are eaten by fish
which further concentrate the mercury. Predators that eat the
fish in turn concentrate the mercury even further.
For the protection of human health from the toxic properties of
mercury ingested through water and through contaminated aquatic
organisms the ambient water criterion is determined to be 0.00014
mg/1.
124. Nickel. Nickel is seldom found in nature as the pure ele-
mental metal. It is a relatively plentiful element and is widely
distributed throughout the earth's crust. It occurs in marine
organisms and is found in the oceans. The chief commercial ores
161
-------
for nickel are pentlandite [ (Fe.NiOgSg], and a lateritic ore
consisting of hydrated nickel-iron-magnesium silicate.
Nickel has many and varied uses. It is used in alloys and as the
pure metal. Nickel salts are used for electroplating baths.
The toxicity of nickel to man is thought to be very low, and sys-
temic poisoning of human beings by nickel or nickel salts is
almost unknown. In non-human mammals nickel acts to inhibit
insulin release, depress growth, and reduce cholesterol. A high
incidence of cancer of the lung and nose has been reported in
humans engaged in the refining of nickel.
Nickel salts can kill fish at very low concentrations. However,
nickel has been found to be less toxic to some fish than copper,
zinc, and iron. Nickel is present in coastal and open ocean
water at concentrations in the range of 0.0001 to 0.006 mg/1
although the most common values are 0.002 to 0.003 mg/1. Marine
animals contain up to 0.4 mg/1 and marine plants contain up to 3
mg/1. Higher nickel concentrations have been reported to cause
reduction in photosynthetic activity of the giant kelp,. A low
concentration was found to kill oyster eggs.
For the protection of human health based on the toxic properties
of nickel ingested through water and through contaminated aquatic
organisms, the ambient water criterion is determined to be 0.0134
mg/1. If contaminated aquatic organisms are consumed, excluding
consumption of water, the ambient water criterion is determined
to be 0.100 mg/1. Available data show that adverse effects on
aquatic life occur for total recoverable nickel concentrations as
low as 0.0071 mg/1 as a 24-hour average.
125. Selenium. Selenium (chemical symbol Se) is a non-metallic
element existing in several allotropic forms. Gray selenium,
which has a metallic appearance, is the stable form at ordinary
temperatures and melts at 220°C. Selenium is a major component
of 38 minerals and a minor component of 37 others found in
various parts of the world. Most selenium is obtained as a
by-product of precious metals recovery from electrolytic copper
refinery slimes. U.S. annual production at one time reached one
million pounds.
Principal uses of selenium are in semi-conductors, pigments,
decoloring of glass, zerography, and metallurgy. It also is used
to produce ruby glass used in signal lights. Several selenium
compounds are important oxidizing agents in the synthesis of
organic chemicals and drug products.
While results of some studies suggest that selenium may be an
essential element in human nutrition, the toxic effects of
selenium in humans are well established. Lassitude, loss of
162
-------
hair, discoloration and loss of fingernails are symptoms of
selenium poisoning. In a fatal case of ingestion of a larger
dose of selenium acid, peripheral vascular collapse, pulmonary
edema, and coma occurred. Selenium produces mutagenic and tera-
togenic effects, but it has not been established as exhibiting
carcinogenic activity.
For the protection of human health from the toxic properties of
selenium ingested through water and through contaminated aquatic
organisms, the ambient water criterion is determined to be 0.010
mg/1, i.e., the same as the drinking water standard. Available
data show that adverse effects on aquatic life occur at concen-
trations higher than that cited for human toxicity.
128. Zinc. Zinc occurs abundantly in the earth's crust, con-
centrated in ores. It is readily refined into the pure, stable,
silver-white metal. In addition to its use in alloys, zinc is
used as a protective coating on steel. It is applied by hot dip-
ing (i.e., dipping the steel in molten zinc) or by electroplat-
ing.
Zinc can have an adverse effect on man and animals at high con-
centrations. Zinc at concentrations in excess of 5 mg/1 causes
an undesirable taste which persists through conventional treat-
ment. For the prevention of adverse effects due to these organo-
leptic properties of zinc, 5 mg/1 was adopted for the ambient
water criterion. Available data show that adverse effects on
aquatic life occur at concentrations as low as 0.047 mg/1 as a
24-hour average.
Toxic concentrations of zinc compounds cause adverse changes in
the morphology and physiology of fish. Lethal concentrations in
the range of 0.1 mg/1 have been reported. Acutely toxic concen-
trations induce cellular breakdown of the gills, and possibly the
clogging of the gills with mucous. Chronically toxic concentra-
tions of zinc compounds cause general enfeeblement and widespread
histological changes to many organs, but not to gills. Abnormal
swimming behavior has been reported at 0.04 mg/1. Growth and
maturation are retarded by zinc. It has been observed that the
effects of zinc poisoning may not become apparent immediately, so
that fish removed from zinc-contaminated water may die as long as
48 hours after removal.
In general, salmonoids are most sensitive to elemental zinc in
soft water; the rainbow trout is the most sensitive in hard
waters. A complex relationship exists between zinc concentra-
tion, dissolved zinc concentration, pH, temperature, and calcium
and magnesium concentration. Prediction of harmful effects has
been less than reliable and controlled studies have not been
extensively documented.
163
-------
The major concern with zinc compounds in marine waters is not
with acute lethal effects, but rather with the long-term sub-
lethal effects of the metallic compounds and complexes. Zinc
accumulates in some marine species, and marine animals contain
zinc in the range of 6 to 1,500 rag/kg. From the point of view of
acute lethal effects, invertebrate marine animals seem to be the
most sensitive organism tested.
MASS OF POLLUTANTS
In Section VI, the pollutant concentrations in the PM&F waste-
water were presented by PM&F subcategories. Of equal importance
is the mass of pollutants in the wastewater. The pollutant
masses generated per year are estimated in this section for the
pollutants in PM&F wastewater and are presented by subcategory.
The estimated pollutant masses were calculated by multiplying the
following for each pollutant:
1. average subcategory production per year per process;
2. estimated number of wet processes;
3. average subcategory raw waste value (kg pollutant/
kg plastic material processed), and
4. pollutant detection fraction.
Average Subcategory Production Rate
The average subcategory production rate per process was based on
the results of the questionnaire data base. The production rates
for the direct and indirect discharge processes were listed by
subcategory and summed. The average subcategory production rate
was calculated by dividing the total production rate for the
direct and indirect discharge processes by the number of direct
and indirect discharge processes. For the contact cooling and
heating water subcategory, the average production rate was 4,232
kkg of plastic material processed per year per process and for
the cleaning and finishing water subcategory, the average produc-
tion rate was 1,522 kkg of plastic material processed per year
per process.
Estimated Number of Wet Processes
The number of wet processes was estimated in Section VI. There
are 1,607 direct and indirect processes that use process water in
the contact cooling and heating water subcategory; 667 are direct
dischargers and 855 are indirect dischargers. In the cleaning
and finishing water subcategory, there are 384 direct and
164
-------
indirect dischargers that use process water; 122 are direct dis-
chargers and 262 are indirect dischargers. The zero dischargers
were not used in estimating the pollutant masses because a zero
discharger does not discharge wastewater.
Subcategory Average Raw Waste Values
The sampling data obtained from the sampling episodes for this
project were used to calculate the subcategory average raw waste
values for the pollutants in PM&F wastewater. The subcategory
average raw waste value is the mass of pollutant discharged per
kkg of plastic material processed.
A subcategory average raw waste value was calculated using the
following:
1. a daily process raw waste value;
2. an average process raw waste value; and
3. an overall average raw waste value of all processes
in the subcategory.
The daily process raw waste value is the product of the pollutant
concentration (kg/1) found in samples collected during the sample
episodes for this project and the production normalized flow for
the sampled process. The production normalized flow is the
liters of wastewater discharged per kkg of plastic material pro-
cessed by the process on the sampling day. The daily process raw
waste value is the mass of pollutant per kkg of plastic material
processed (kg pollutant/kkg plastic). If the process was sampled
on more than one day, the daily process raw waste values were
summed and divided by the number of values to obtain the average
process raw waste value. Pollutant concentrations above the
source water concentrations and above the test method analytical
detection limit were used in the average process raw waste
concentration calculations.
The subcategory average raw waste value for a pollutant was
obtained by adding the average process raw waste values for a
subcategory and dividing that sum by the number of average
process raw waste values. This calculation procedure is
presented in Table VII-6.
The subcategory average raw waste values for the pollutants in
PM&F wastewater are presented in Table VII-7.
165
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Table VII-7
ESTIMATED POLLUTANT MASS IN PROCESS WATER
(CONTACT COOLING AND HEATING WATER SUBCATEGORY)
Average Subcategory Production - 4,232 kkg plastic/yr/process
Estimated Number of Direct and Indirect Processes - 1,522
Detection
Conventional Pollutants Fraction*
BOD5 0.714
Oil and Grease 0.556
TSS 0.667
TOTAL
Nonconventional Pollutants
COD 0.778
TOG 1.0
Total Phenols 0.444
TOTAL
Priority Pollutants
4. benzene 0.444
6. carbon tetrachloride 0.222
11. 1,1,1-trichloroethane 0.556
22. parachlorometa cresol 0.222
23. chloroform 0.333
44. methylene chloride 0.889
(dichloromethane)
65. phenol 0.556
66. bis(2-ethylhexyl) 0.889
phthalate
68. di-n-butyl phthalate 1.0
85. tetrachloroethylene 0.333
86. toluene 0.444
89. aldrin 0.333
90. dieldrin 0.333
93. 4,4'-DDE 0.222
100. heptachlor 0.222
Subcategory
Average Raw
Waste Value
kg Pollutant
kkg Plastic
3.910
0.450
0.156
8.798
2.690
0.185
490 x TO'3
600 x TO'2
950 x 10-3
214 x TO'3
109 x 10-3
2.260 x 10-3
1.026 x TO'3
1.200 x 10-2
4.560 x 10~4
5.927 x 10-6
8.347 x 10~5
1.58 x 10-5
4.555 x 10-6
2.312 x 10~7
1.644 x 10-5
Estimated**
Pollutant
Mass
(kg/vr)
18,000,000
1,610,000
670,000
20,280,000
44,100,000
17,300,000
529,000
61,929,000
9,
137,
U,
4,
11.
980
000
100
600
000
12,900
3,670
68,700
2,940
13
239
34
10
0.
24
167
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Table VII-7 (Continued)
ESTIMATED POLLUTANT MASS IN PROCESS WATER
(CONTACT COOLING AND HEATING WATER SUBCATEGORY)
Average Subcategory Production - 4,232 kkg plastic/yr/process
Estimated Number of Direct and Indirect Processes - 1,522
Conventional Pollutants
102.
103.
104.
105.
118.
119.
120.
122.
123.
124.
128.
a-BHC
3-BHC
Y-BHC
6-BHC
cadmium
chromium
copper
lead
mercury
nickel
zinc
Detection
Fraction*
0.778
0.333
0.556
0.556
0.333
0.556
0.333
0.333
0.111
0.333
0.667
Subcategory
Average Raw
Waste Value
kg Pollutant
kkg Plastic
1.
2.
1.
7.
1.
2.
2.
2.
1.
4.
1 .
306
911
753
964
772
796
364
501
750
519
856
X
X
X
X
X
X
X
X
X
X
X
1
1
1
1
1
1
1
1
1
1
1
0-5
0-6
0-6
0-6
0-4
0-4
0-4
0-3
0-7
0-4
0-3
Estimated**
Pollutant
Mass
(kg/yr)
1,
5,
7,
65
6
6
29
380
000
507
360
0. 1
969
970
TOTAL
281,502.4
*Number of plants where pollutant concentration was greater than
the concentration of the pollutant in the source water divided by
the number of sampled plants.
**Pollutant mass = (average subcategory production) x (estimated
number of processes) x (detection fraction) x (average raw
waste value).
168
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Table VII-7 (Continued)
ESTIMATED POLLUTANT MASS IN PROCESS WATER
(CLEANING AND FINISHING WATER SUBCATEGORY)
Average Subcategory Production - 1,607 kkg plastic/yr/process
Estimated Number of Direct and Indirect Processes - 384
Conventional Pollutants
BOD5
Oil and Grease
TSS
TOTAL
Nonconventional Pollutants
COD
TOG
Total Phenols
TOTAL
Priority Pollutants
Detection
Fraction*
0.833
0.429
0.857
0.857
1.0
0.714
4.
23.
44.
62.
65.
66.
86.
89.
100.
102.
104.
105.
119.
120.
124.
benzene
chloroform
methylene chloride
(dichlorome thane)
N-nitrosodiphenylamine
phenol
bis(2-ethylhexyl)
phthalate
toluene
aldrin
heptachlor
a-BHC
Y-BHC
5-BHC
chromium
copper
nickel
0.857
0.286
1.0
0.714
0.714
0.857
0.571
0.333
0.333
0.222
0.556
0.444
0.714
0.571
0.286
Subcategory
Average Raw
Waste Value
kg Pollutant
kkg Plastic
1.815
0.409
2.230
2.836
2.100
0.306
4.
3.
1.
1.
5.
7.
1.
3.
5.
4.
2.
3.
2.
5.
5.
203
963
537
055
149
402
751
035
118
569
083
270
818
691
356
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0-6
0-4
0-3
0-4
0-4
0-5
0-5
0-6
0-7
0-8
0-6
0-6
0-4
0-4
0-4
Estimated**
Pollutant
Mass
(kg/yr)
933,000
108,000
1,180,000
2,221,000
1,500,000
1,300,000
135,000
2,935,000
2
70
948
46
227
39
6
0.6
0.1
0.006
0.
0.
124
201
95
169
-------
Table VII-7 (Continued)
ESTIMATED POLLUTANT MASS IN PROCESS WATER
(CLEANING AND FINISHING WATER SUBCATEGORY)
Average Subcategory Production - 1,607 kkg plastic/yr/process
Estimated Number of Direct and Indirect Processes - 384
Conventional Pollutants
125. selenium
128. zinc
TOTAL
Detection
Fraction*
0.142
1.0
Subcategory
Average Raw
Waste Value
kg Pollutant
kkg Plastic'
3.317 x 10~5
1.657 x 10~3
Estimated**
Pollutant
Mass
(kg/yr)
3
1,023
2,786.306
*Number of plants where pollutant concentration was greater than
the concentration of the pollutant in the source water divided by
the number of sampled plants.
**Pollutant mass = (average subcategory production) x (estimated
number of processes) x (detection fraction) x (average raw
waste value).
170
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Pollutant Detection Fraction
The pollutant detection fraction was calculated by counting the
number of plants where a pollutant was detected during the sam-
pling episodes and dividing that sum by the total number of
plants sampled. Only plants with pollutant concentrations above
the concentrations in the source water were used to calculate
this fraction. Pollutant detection fractions are listed in Table
VII-7.
Estimated Pollutant Masses in Process Water by Subcategory
To calculate the estimated pollutant generated mass per year, the
average subcategory production rate, the estimated number of wet
processes, the pollutant subcategory average raw waste value, and
the pollutant detection fraction were multiplied. Table VII-7
contains the estimated annual pollutant masses per PM&F subcate-
gory for the pollutants in PM&F wastewater. These masses are for
the number of direct and indirect dischargers in a subcategory.
171
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SECTION VIII
TREATMENT TECHNOLOGY AND FLOW REDUCTION OPTIONS
Treatment technologies that can be used to control pollutants in
wastewater generated by plants in the plastics molding and form-
ing (PM&F) category are discussed in this section. These treat-
ment technologies are divided into two types: in-plant control
technologies and end-of-pipe treatment technologies. The primary
literature sources relied upon during the development of this
section were EPA's Treatability Manual, Volume III, Technologies
for Control/Removal of Pollutants and Innovative and Alternative
Technology Assessment Manual.Metcalf and Eddy,Inc.'s Waste-
water Engineering, Treatment/Disposal/Reuse served as a general
reference and provided supporting information.
IN-PLANT TECHNOLOGY
The purpose of in-plant technology for plants in the plastics
molding and forming category is to reduce or eliminate the amount
of wastewater requiring end-of-pipe treatment and thereby reduce
the existing wastewater treatment technology or eliminate the
need for the treatment technology. In-plant technologies con-
sidered for the PM&F category are: (1) 100 percent recycle; (2)
recycle with a discharge from the recycle unit; and (3) PM&F
process modifications.
Process Water Recycle
Recycling of process water is the practice of recirculating water
to be used again for the same purpose. Recycle is an important
water conservation measure because the demand for raw water is
reduced when process water is recycled. By reducing the amount
of flow discharged the size and therefore the cost of any end-
of-pipe treatment technology is also reduced. Treatment system
performance may also be improved when recycle systems are used
because pollutants are concentrated in the wastewater. Usually
end-of-pipe treatment systems perform more effectively with
higher pollutant concentrations.
One Hundred Percent Recycle Units. Process water that requires
cooling is recycled through a unit that lowers the temperature of
the water so that it can be reused. Two types of equipment are
used for 100 percent recycle of the cooling water. The first and
simplest piece of equipment is a holding tank. Cooling water is
held up in a tank until the temperature drops sufficiently,
through passive heat transfer to the environment, to allow the
water to be recycled. A holding tank is only practical for low
flow rates because tank sizes increase dramatically when the flow
rate increases. Cooling water can also be recycled 100 percent
173
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through chillers that cool the water by mechanical refrigeration.
In a chiller, the cooling water is passed through a heat
exchanger that is cooled by a low boiling, vaporized refrigerant.
Chillers can be used with processes with medium flow rates
because they can be purchased as self-contained units that are
easy to install. Their use has been demonstrated in the PM&F
category, predominantly at flow rates between 20 and 50 gpm. At
higher flow rates, the chiller's high energy usage per unit of
cooling makes its use less attractive. One hundred percent
recycle systems such as cooling tanks or chiller units are
generally cleaned out once every one or two years.
Recycle Units with a Discharge. Cooling water can also be
recycled through cooling towers that lower water temperatures by
evaporative cooling. In a typical cooling tower configuration,
water is distributed at the top of the tower in a manner that
provides a large contact area between air and water. Air circu-
lates countercurrently to the water to be cooled. Heat is trans-
ferred from the water to the air as water evaporates. A cross
section of a typical cooling tower is presented in Figure VIII-1.
Cooling towers can be used with processes with flows from as low
as 15 gpm to several hundred gpm.
Total recycle through cooling towers is prohibited because of the
concentration of dissolved solids in process waters. Dissolved
solids are introduced into the cooling tower system in the water
that replaces the water lost by evaporation. A bleed stream is
needed to reduce the concentration of these dissolved solids
below the concentration where they would precipitate and cause
pipe plugging, and scaling on the cooling equipment.
Process water that requires the removal of solids and oil and
grease before it can be recycled can be recycled r.b rough a sedi-
mentation tank. Sedimentation is a process chat reraoves solid
particles from a liquid matrix by gravitational force. This is
done by reducing the velocity of the influent flow so that gravi-
tational settling of solids can occur. The settled solids are
collected at the bottom of the tank as sludge. A sedimentation
tank can be designed so that oil and grease separation also
occur. Oil and grease and other floatable materials can be
removed from the sedimentation tank by surface skimming. Gener-
ally, process water that requires removal of suspended solids and
oil and grease has to be replaced after a period of time. This
can be done by replacing a small continuous discharge flow with
fresh water or periodically changing all of the processes within
the recycle unit.
Technology Status. Process water recycle is currently practiced
by 42 percent of wet processes in the contact cooling and heating
water subcategory and 13 percent of the wet processes in the
174
-------
Figure VIII-1
CROSSFLOW COOLING TOWER
Adapted from Cooling Tower Fundamentals, The Marley Cooling Tower
Company.
175
-------
cleaning and finishing water subcategory. When recycle is used,
the recycle percentage generally ranges from 90 to 100 percent.
Table VIII-1 contains a distribution of the number of processes
using various recycle percentages by PM&F subcategory based on
data from the questionnaire data base.
Limitations. A potential problem with the recycle of contact
cooling and heating water through a cooling tower is the buildup
of dissolved solids which could result in scaling. Scaling can
usually be controlled by depressing the pH and increasing the
bleed flow. Recycling cleaning and finishing water requires the
installation of a settling tank to remove suspended solids and
floating oil and grease. Depending on the application,, recycled
cleaning and finishing water may be batch dumped periodically.
Reliability. The recycle of process water has been demonstrated
at plants in the PM&F category and is also widely used by other
industries. The basis of the technology, heat transfer for con-
tact cooling and heating water and gravity settling for cleaning
and finishing water is well established. Both systems have few
components with moving parts; most of the routine maintenance is
needed to service the recirculating pump.
Environmental Impact. Settled solids removed from sedimentation
units are generally disposed of by a contract hauler. Small
quantities of scale and settled solids may also be periodically
removed from cooling towers, tanks and chillers. Evaporative
water loss from cooling towers may be a problem in arid regions.
PM&F Process Modification
Two opportunities exist for plants to reduce the quantity of
water used by PM&F processes. One is to decrease the quantity of
water that flows through the process, the other is to modify the
process so that the use of process water is no longer necessary.
The Agency believes that based on observations made during plant
visits some plants may not pay close attention to water use.
Satisfactory operation may be achieved with smaller rinse or con-
tact cooling water flows. The practice of shutting off process
water during periods when a production unit is inoperative and
adjusting flow rates during periods of low activity can reduce
the volume of water to be treated or discharged. Producers with
a high water use should be able to reduce their water use through
simple flow reduction procedures such as more careful adjustment
of process water flow rates and reduction of overflow and dragout
from quench tanks.
Since approximately 80 percent of the processes in the PM&F cate-
gory do not require the use of process water, the possibility of
176
-------
Percent Recycle
100
95 - 99.9
90 - 94.7
75 - 89.9
50 - 74.9
0.1 - 49.9
0
TOTAL
Table VIII-1
RECYCLE PERCENTAGES BY SUBCATEGORY
Number of Processes in Questionnaire
Data Base With Recycle
(Percent of Subcategory)
Cleaning
Contact Cooling and and Finishing
Heating Water Subcategory Water Subcategory
89
56
15
16
9
5
258
448
(19.8)
(12.5)
( 3.3)
( 3.6)
( 2.0)
( 1.1)
(57.7)
(100)
2
6
2
1
1
0
82
94
( 2.1)
( 6.4)
( 2.1)
( 1-1)
( 1.1)
(87.2)
(100)
177
-------
eliminating the use of process water by the other 20 percent that
use process water was studied. Investigation into the specific
uses of process water revealed that the 20 percent of manufac-
turers who are using process water need that water for efficient
and effective operation of their processes. The majority of PM&F
process water is contact cooling water used during extrusion
processes. This water is necessary for effective heat transfer,
particularly during pelletizing processes and for the extrusion
of tube, pipe, profiles, or plastic coverings on wire and cable.
Process water is also needed for contact cooling during other
molding and forming process to maintain product integrity. It is
also used to clean and finish plastic products and to clean shap-
ing equipment used to produce those products. Water is required
in cleaning and finishing processes as a carrier media. Process
water is required for certain PM&F processes, those processes
cannot be converted to dry processes. Therefore, process modifi-
cation to eliminate the use of process water is not applicable
for those processes.
END-OF-PIPE TREATMENT TECHNOLOGY
End-of-pipe treatment technologies are treatment technologies
used to reduce the levels of pollutants in wastewater,. Pollu-
tants or pollutant properties that were found at significant
concentrations in PM&F wastewaters are presented in Table VIII-2.
End-of-pipe treatment technologies that will treat some, or all,
of the above pollutants include: activated sludge, fixed growth
biological treatment systems, package aerobic treatment units,
sedimentation, gravity oil separation, neutralization, carbon
adsorption, granular media filtration, and septic tanks followed
by adsorption beds.
Activated Sludge
The activated sludge treatment process is used to remove dis-
solved and colloidal biodegradable organic pollutants from waste-
water. It is a continuous flow, biological treatment process
characterized by a suspension of aerobic microorganisms main-
tained in a relatively homogeneous state by the mixing and turbu-
lence induced by aeration. Figure VIII-2 contains a flow diagram
of a conventional activated sludge process. The microorganisms
oxidize soluble and colloidal organic pollutants to carbon diox-
ide and water in the presence of molecular oxygen. The mixture
of microorganisms and wastewater (called mixed liquor) formed in
the aeration basin is transferred to a gravity sedimentation unit
for liquid solids separation. A large portion of the microorgan-
isms that settle in the clarifier is recycled to the aeration
basin to be mixed with incoming wastewater; the remainder of the
microorganisms is transferred to sludge handling processes.
Microorganism solids not settled are lost in the effluent.
178
-------
Table VIII-2
POLLUTANTS AND POLLUTANT PROPERTIES FOUND IN SIGNIFICANT
CONCENTRATIONS IN PM&F WASTEWATER
Conventional Pollutants
BOD5
Oil and Grease
TSS
pH
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
4. benzene
6. carbon tetrachloride (tetrachloromethane)
11. 1,1,1-trichlorethane
22. parachlorometa cresol
23. chloroform (trichloromethane)
44. methylene chloride (dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl) phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE (p.p'DDX)
100. heptachlor
102. a-BHC
103. (3-BHC
104. Y-BHC
105. 6-BHC
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
125. selenium
128. zinc
179
-------
Flow Diagram, Conventional Activated Sludge Process
Primary Clarifier Effluent
-#•
Aeration Tank
To Final Clarifier
Return Sludge
Sludge from Final Clarifier
Excess Sludge
Mechanical Surface Aeration
Dri
Diffused Aeration (Sparger)
, Compressor
1 f-
t
t.
»
Sparger Cr—
1* -' •. •-'.-.AfeUL'^. . TAv. .; -.-.-. , ...-J „.... .. .1 -. I. .'.
1 Air
»
»
»
Figure VIII-2
ACTIVATED SLUDGE TREATMENT TECHNOLOGY
Figures adapted from Innovative and Alternative Technology
Assessment Manual, EPA 430/9-78-009.
180
-------
During the oxidation process, organic material is synthesized
into new cells, some of which undergo auto-oxidation (self-
oxidation or endogenous respiration) in the aeration basins; the
remainder form a net increase of microorganisms in the mixed
liquor or excess sludge. Oxygen is required in this process to
support the oxidation and synthesis reactions.
Various aeration methods are employed to transfer oxygen to
wastewater. They include: diffused aeration, mechanical aera-
tion, and pure oxygen.
Diffused Aeration. In a diffused air system compressors are used
to supply air to a diffusion network. Diffused air systems may
be classified as fine bubble or coarse bubble. Diffusers com-
monly used in the activated sludge process include porous ceramic
plates laid in the basin bottom (fine bubble), porous ceramic
domes or ceramic or plastic tubes connected to a pipe header and
lateral system (fine bubble), tubes covered with synthetic fabric
or wound filaments (fine or coarse bubble), and specifically
designed spargers with multiple openings (coarse bubble). A
diffused aeration sparger system is depicted in Figure VIII-2.
Mechanical Aeration. Mechanical aeration methods include a sub-
merged turbine with compressed air spargers (agitator/sparger
system) and surface mechanical entrainment aerators. The
agitator/sparger system consists of a radial-flow turbine located
below the mid-depth of the basin with compressed air supplied to
the turbine through a sparger. The surface-type aerators entrain
atmospheric air by producing a region of intense turbulence at
the water surface. They are designed to pump large quantities of
liquid, thus dispersing the entrained air and agitating and
mixing the basin contents. Figure VIII-2 also contains a
schematic diagram of a mechanical surface aeration unit.
Pure Oxygen. The use of pure oxygen for activated sludge treat-
ment has become competitive with the use of air due to the devel-
opment of efficient oxygen dissolution systems. The main bene-
fits of substituting pure oxygen for air include reduced power
requirements for dissolving oxygen in the wastewater, reduced
aeration tank volume, and improved biokinetics of the activated
sludge. Lower amounts of excess sludge are generated and the
activated sludge thickening capability is generally greater than
the thickening capability of the air activated sludge process.
Applications. The activated sludge process is employed in domes-
tic and industrial wastewater treatment for the removal of con-
ventional, nonconventional, and priority pollutants. Limited
metals removal has also been observed through activated sludge
systems. Activated sludge processes can be used to treat PM&F
wastewater to remove the pollutants found in significant concen-
trations (see Table VIII-2). Industrial wastewater that is
181
-------
amenable to biological treatment and degradation may be jointly
treated with domestic wastewater in a conventional activated
sludge process.
Limitations. Activated sludge treatment processes can be upset
with variations in hydraulic and organic loadings. For example,
shock loadings of phenolic compounds will kill the microorganisms
that oxidize the organic materials and make the activated sludge
process work. Under steady state conditions, phenols can be
treated in concentrations up to 500 mg/1 (Metcalf & Eddy, Inc.).
Activated sludge processes are not designed for an intermittent
wastewater flow. Other disadvantages are high operating costs,
operational complexity, and energy consumption. The activated
sludge process must be well maintained for it to work properly.
Reliability. Activated sludge has not been demonstrated for the
treatment of wastewater generated solely by PM&F processes. How-
ever, it is a widely demonstrated, effective biological treatment
process that has been used to treat wastewaters with similar
characteristics to PM&F wastewater. In particular, it is used to
treat wastewater generated by processes in the organic chemicals,
plastics, and synthetic fibers category.
Environmental Impact. The activated sludge process requires
proper disposal of sludge to avoid solid waste pollution prob-
lems. Excess sludge suspended solids generation is generally in
the range of 0.15 to 0.7 pound per pound BOD removed (EPA Treat-
ability Manual). Energy requirements are approximately 200
kwh/yr per 1,000 gpd treated (Innovative and Alternative Technol-
ogy Assessment Manual). Improperly operated systems can cause
odor problems.
Treatability Data. Treatability data for activated sludge pro-
cess systems treating PM&F wastewater are not available; however,
treatability data for activated sludge processes for conventional
pollutants are available from several studies of other industrial
categories. The available treatability data that are most appli-
cable to the PM&F category are data from the organic chemicals,
plastics, and synthetic fibers category because wastewaters
generated by procceses in each category are similar with respect
to conventional pollutants. Those data are presented in Table
VIII-3. A statistical analysis comparing raw wastewater gener-
ated by proccesses in the PM&F category to wastewater generated
by processes in the organic chemicals, plastics, and synthetic
fibers category, particularly the plastics only subcategory, is
presented in Appendix D. Performance data for the activated
sludge process for selected nonconventional and priority pollu-
tants are presented in Table VIII-4. The sources of these data
are indicated on the table.
182
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Table VIII-3
EFFLUENT CONCENTRATION VALUES FOR ACTIVATED SLUDGE PROCESS
TRANSFERRED FROM THE ORGANIC CHEMICALS, PLASTICS
AND SYNTHETIC FIBERS CATEGORY*
One Day Maximum Maximum 30-Day
Effluent Average Effluent
Pollutant Parameter Concentration (mg/1) Concentration (mg/1)
BOD5 49 22
Oil and Grease 71 17
TSS 117 36
*See Appendix D.
183
-------
Table VIII-4
REMOVAL EFFICIENCIES FOR NONCONVENTIONAL POLLUTANTS
AND TREATABILITY LIMITS FOR PRIORITY POLLUTANTS
FOR ACTIVATED SLUDGE PROCESSES
Mean Effluent Mean Removal
Nonconventional Concentration Efficiency
Pollutant (mg/1) %
COD 890 63
TOG 427 63
Total Phenols 18.7 60
Priority Pollutants Treatability Limit (mg/1)
4. benzene 0.005
11. 1,1,1-trichloroethane 0.005
23. chloroform (trichloromethane) 0.005
44. methylene chloride 0.005
(dichloromethane)
62. N-nitrosodiphenylamine 0.005
66. bis(2-ethylhexyl) phthalate 0.200
68. di-n-butyl phthalate 0.005
86. toluene 0.005
104. Y-BHC 0.005
Sources:
Nonconventional Pollutants: USEPA, Treatability Manual, Volume
III, Technologies for Control/Removal of Pollutants, July 1980,
EPA-600/8-80-042c.
Priority Pollutants: USEPA, Contractors Engineering Report,
Analysis of Organic Chemicals and Plastics and Synthetic Fibers
Industries Toxic Pollutants, November 16, 1981 , Contract: No.
61-01-6024.
184
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Fixed Growth Biological Treatment Systems
Fixed growth biological treatment processes bring wastewater to
be treated in contact with media covered by microbiological
growth. Either the wastewater is passed over the media or the
media is passed through the wastewater. Organic material in the
wastewater is oxidized by the microbiological growth. The two
most common forms of fixed growth biological treatment systems
are trickling filters and rotating biological contactors.
Trickling Filters. A trickling filter consists of a fixed bed of
rock or plastic media over which wastewater is applied for aero-
bic biological treatment. Zoogleal slimes form on the mixed
media and assimilate and oxidize biodegradable material in the
wastewater. The bed is dosed by a distributor system; treated
wastewater is collected by an underdrain system. Primary treat-
ment is normally required to optimize trickling filter perfor-
mance. If filter effluent is recycled through the filter, the
filter is known as a high rate trickling filter. If no recycle
is used the filter is designated a low rate trickling filter.
Rotating Biological Contactors. Rotating biological contactors
(RBC) use a fixed-film biological reactor consisting of plastic
media mounted on a horizontal shaft and placed in a tank. Common
media forms are a disc-type made of styrofoam and a denser
lattice-type made of polyethylene. While wastewater flows
through the tank the media are slowly rotated about 40 percent
immersed. The media contact the wastewater and the organic pol-
lutants are oxidized by the biological film that develops on the
media. Rotation results in exposure of the film to the atmosphere
where aeration occurs. Excess biomass on the media is stripped
off by rotational shear forces and the stripped solids are main-
tained in suspension by the mixing action of the rotating media.
Suspended solids settle in the sedimentation unit following the
RBC. Multiple staging of RBCs increases treatment efficiency and
aids in achieving nitrification.
Applications. Fixed growth biological processes can be used to
treat domestic and industrial wastewaters amenable to aerobic
biological treatment.
Technology Status. The trickling filter process is in widespread
use in older treatment plants. The process is highly dependable
in moderate climates; they are less effective in colder climates.
The RBC process has been in use in the United State only since
1969 and is not yet in widespread use. Use of the process is
growing, however, because of its characteristic modular construc-
tion, low hydraulic head loss, and shallow excavation, which
makes it adaptable to new or existing treatment facilities.
185
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Limitations. Fixed growth biological treatment systems are
vulnerable to climatic changes and low temperatures. Recycle of
water through trickling filters may be restricted during cold
weather because after the first pass through the filter the water
may be too cold for re-application to the filter. Rotating bio-
logical contactors are often housed or covered to protect them
from low temperatures. Trickling filters are susceptable to
filter fly and odor problems and require long recovery times
after upsets. High organic loadings in RBCs can result in
septicity and supplemental aeration may be required.
Reliability. Fixed media biological treatment processes perform
reliably if wastewater characteristics do not vary and if instal-
lation is in a climate where wastewater temperatures do not fall
below 55°F for prolonged periods.
Environmental Impact. Odors can result if septic conditions
develop in the process. Filter flies can also grow in trickling
filters; these flys may transmit disease.
Treatability Data. Mean removal efficiencies for certain conven-
tional, nonconventional, and priority pollutants for trickling
filters are presented in Table VI1I-5. Mean removal efficiences
for certain conventional and nonconventional pollutants for RBCs
are presented in Table VIII-6. The sources of these data are
referenced on the tables.
Package Aerobic Treatment Units
There are two types of package aerobic treatment units commer-
cially available today. These are: (1) suspended growth units
and (2) fixed growth units. Each unit has its own unique opera-
tional characteristics and design features, but both provide
oxygen transfer to the wastewater and intimate contact between
microbes and the oxygenated wastewater. The microorganisms
oxidize soluble and colloidal organics to carbon dioxide and
water. Biomass is also formed during the oxidation step and is
removed from the effluent in a solids separation step.
Suspended Growth Systems - Extended Aeration. Extended aeration
is a modification of the activated sludge process whereby a high
concentration of microorganisms are maintained in an aeration
tank followed by separation of the biomass and recycle of all or
a portion of the biomass back to the aeration tank. There are a
variety of proprietary extended aeration package plants available
on the market today. A typical design features three chambers.
The influent enters the first chamber where scum and sludge are
separated. The second chamber is where the aeration occurs. The
third and final compartment is a settling chamber where sludge
settles by gravity and is returned to the aeration portion of the
unit. Figure VIII-3 presents a diagram of an extended aeration
unit.
186
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Table VIII-5
TRICKLING FILTER PERFORMANCE DATA FOR CERTAIN CONVENTIONAL,
NONCONVENTIONAL, AND PRIORITY POLLUTANTS
Influent Effluent
Conventional Concentration Concentration Percent
Pollutants (mg/1) (mg/1) Removal Reference*
TSS
BOD5
120
390
49
39
59
90
1
1
Nonconventional
Pollutants
COD 807 541 33 1
Priority Pollutants
23. chloroform --- 0.019 0 1
44. methylene 0.001 0 1
chloride
55. naphthalene 0.005 0 1
65. phenol 0.105 0.009 91 2
0.037 0 1
400 288-308 23-28 1
25 1 96 1
31 <1.0 >97 1
66. bis(2-ethyl- 0.035 0.006 83 1
hexyl)
phthalate
70. diethyl --- 0.140 0 1
phthalate
Dashes indicate that data were not available.
*1 - Treatability Manual, Volume III, Technologies for Control/
Removal of Pollutants, July 1980, EPA-600/8-80-042C.
2 - Vela, G. R. and J. R. Ralston, Canadian Journal of Micro-
biology, 1366 (1978).
187
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Table VIII-6
REMOVAL EFFICIENCIES FOR CERTAIN CONVENTIONAL AND NONCONVENTIONAL
POLLUTANTS FOR ROTATING BIOLOGICAL CONTACTORS*
Pollutant Parameter
BOD5
TSS
Oil and Grease
COD
Mean Effluent
Concentration
(mg/1)
31
54
28
710
Mean Removal
Efficiency
74
8
9
41
*Treatability data are not available for the priority pollutants.
Source: Treatability Manual, Volume III, Technologies for
Control/Removal of Pollutants, July 1980,
EPA-600/8-80-042c (July 1980).
188
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Batch - Extended Aeration
Blower
Influent
High Water
Alarm
Pump Shut-off
Elevation
Diffuser
Effluent
Pump
Flow-Through Extended Aeration
A
V A. Mechanical or
r A Diffused Aeration
Influent
Effluent
Settling
Chamber
Sludge
VIII-3
EXAMFLii 0F EXTENDED AERATION PACKAGE PLANTS
Lit
-------
Fixed Growth Systems. Fixed growth package plants employ the
same technology as large scale trickling filters and RBCs
described in the previous section. Figure VIII-4 presents
various fixed growth package plant configurations.
Applications. There are no physical site conditions that limit
application. Package aerobic units can be used whenever bio-
logical treatment of wastewater is appropriate. Package aerobic
units can be used to treat PM&F wastewater to remove the pollu-
tants found at significant concentrations (see Table VIII-2).
Fixed growth units should be housed when used in cold climates.
Technology Status. Package aerobic treatment plants are avail-
able in several configurations from various manufacturers. They
have been used effectively in both domestic and industrial appli-
cations.
Limitations. Package aerobic units are susceptible to upsets.
Without regular supervision and maintenance the aerobic unit may
produce low-quality effluents. The biological treatment process
is temperature-dependent; package aerobic treatment units may
need to be insulated as climate dictates.
Reliability. Package aerobic treatment plants, particularly the
associated blowers and pumps, require regular supervision and
maintenance to insure optimum operation.
Environmental Impacts. The aeration systems require power and
some noise and odor may be associated with them. Sludge produced
by these plants has to be removed periodically (e.g., once every
8 to 12 months).
Treatability Data. Performance data for package aerobic treat-
ment units are available from National Sanitation Foundation
studies conducted on domestic sewage. These studies showed a
mean BODj removal efficiency of 90 percent on raw waste with a
171 mg/1 BODs influent concentration and a mean TSS removal
efficiency of 90 percent on raw waste with a 232 mg/1 TSS
influent concentration. These values are based on data from the
following NSF Wastewater Performance Evaluations-.
Report S40-1 October 1982
Report S40-5 April 1974
Report S40-6 April 1974
Report S40-7 August 1979
Report S40-8 June 1979
Report S40-9 August 1979
Report S40-10 November 1981
Report S40-11 May 1982
190
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191
-------
Package aerobic treatment plants are generally subject: to the
same applications and constraints as the larger scale units that
employ the same technology. Extended aeration is actually a
small scale activated sludge treatment process and the fixed
growth package plants are similar to either larger scale trick-
ling filters or rotating biological contactors, depending on the
technology employed. Therefore, package plants have generally
the same treatment effectiveness as larger systems employing the
same technology.
Sedimentation
Sedimentation is a process that removes solid particles from a
liquid matrix by gravitational force. This is done by reducing
the velocity of the influent flow so that gravitation settling
can occur. Simple sedimentation requires long retention times to
achieve high removal efficiencies. Sedimentation tanks are
designed with baffles to eliminate the turbulance caused by
influent water and have sloping bottoms to aid in sludge collec-
tion. Sedimentation tanks are often designed so that gravity oil
separation occurs. Oil and grease and other floatable materials
can be removed by surface skimming.
Applications. Sedimentation can be effectively used to treat
wastewater with high concentrations of oil and grease and sus-
pended solids. Toxic metals removal has also been demonstrated
in sedimentation tanks.
Technology Status. Sedimentation has been effectively demon-
strated in the treatment of numerous industrial wastewaters. It
is one of the oldest wastewater treatment technologies in use.
Twelve plants in the questionnaire data base for the PM&F cate-
gory have sedimentation/clarification units in place to treat
PM&F wastewater.
Limitations. Excessively long retention times may be required
under certain conditions, particularly when the specific gravity
of suspended particles is close to one or the particle sizes are
small. Colloidal particles with diameters less than one micron
may not be effectively settled without the addition of a floccu-
lant or coagulating agent. Additionally, dissolved pollutants
are not removed by sedimentation.
Reliability. The lack of mechanical complexity makes this tech-
nology very reliable,
Environmental Itapaet, Tfrg m»j©£ gnvironwental impact associated
with sedimentation Is the disposal ®£ tht solid material removed
from the
-------
Treatability Data. Mean removal efficiencies for certain conven-
tional, nonconventional, and priority pollutants in sedimentation
tanks are presented in Table VIII-7.
Gravity Oil Separation
Gravity oil separation removes floatable oil and grease. A
gravity oil separator (skimming tank) is a chamber arranged so
that floating matter rises and remains on the surface of the
wastewater until removed, while the liquid flows out continu-
ously through deep outlets or under partitions, curtain walls, or
deep scum boards. Oil and grease separation may be accomplished
in a separate tank or combined with primary sedimentation,
depending on the process and nature of the wastewater.
The objective of skimming tanks is to separate lighter floating
substances from wastewater. The material collected on the
surface of skimming tanks, whence it can be removed, includes
oil, grease, soap, and floating solid material. A gravity oil
separator is depicted in Figure VIII-5.
Gravity separators are the most common devices employed in oily
waste treatment. The effectiveness of a gravity separator
depends on proper hydraulic design and wastewater retention
times. Longer retention times allow better separation of the
floatable oils from the water. Short detention times of less
than 20 minutes result in less than 50 percent oil-water separa-
tion, while more extended holding periods improve oil separation.
Gravity separators are equally effective in removing both greases
and nonemulsified oils. Separators may be operated as batch vats
or as continuous flow-through basins depending on the volume of
wastewater to be treated.
Applications. Used in most industrial wastewater treatment
systems where floatable oil is present.
Technology Status. Gravity oil separation is well-developed for
many industrial wastewater treatment applications. Four plants
in the PM&F category questionnaire data base use oil skimming
technology to treat PM&F wastewater.
Limitations. Gravity oil separation has no limitations. It is a
simple operation that can be used to remove floatable oil and
grease when present in wastewater.
Reliability. Highly dependable, if regularly maintained. Vari-
able wastewater characteristics such as flow, temperature, and pH
can adversely affect performance.
Environmental Impact. If skimmings cannot be reclaimed they are
typically disposed of as solid waste.
193
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Table VIII-7
REMOVAL EFFICIENCIES FOR CERTAIN CONVENTIONAL, NONCONVENTIONAL,
AND PRIORITY POLLUTANTS IN SEDIMENTATION TANKS
Pollutant Parameter
BOD5
Oil and Grease
TSS
COD
TOG
Total Phenols
119. chromium
120. copper
128. zinc
Mean Effluent
Concentration
(mg/1)
Mean Removal
Efficiency
2,
1,
500
70
212
620
63
6.3
2.9
0.072
2.1
33
47
82
71
40
43
76
66
65
Source: Treatability Manual, Volume III, Technologies for
Control/Removal of Pollutants, July 1980,
EPA 600/8-80-042c.
194
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CHEMICALS
(OPTIONAL)
BAFFLE
EFFLUENT
INFLUENT
CHEMICAL MIX TANK
BOTTOM SLUDGE COLLECTOR
OFTEN INCLUDED
Figure VIII-5
GRAVITY OIL SEPARATOR
195
-------
Treatability Data. Gravity oil separation is an effective method
of removing insoluble oil and grease from PM&F wastewater. The
removal of oil and grease lowers the levels of COD and TOG in
wastewater samples. An additional benefit of gravity oil separa-
tion is the reduction of concentrations of any priority pollu-
tants that are more soluble in oil than in water.
Neutralization
Neutralization is the process of adjusting an acidic or a basic
wastewater to a pH of an acceptable value. Neutralization of an
acidic or basic wastewater is necessary for various reasons. The
pH should be adjusted to: (1) prevent metal corrosion and/or
damage to equipment and structures; (2) protect aquatic life and
human welfare; (3) assure effective operation of a. treatment pro-
cess; and (4) provide neutral pH water for recycle. pH adjust-
ment may also be needed to break emulsions, to insolubilize
certain chemical species, or to control chemical reaction rates
(e.g., chlorination). Generally, the pH of a wastewater should
be between 6.0 and 9.0.
The actual process of neutralization is accomplished by the addi-
tion of a basic material to an acidic material or by adding an
acid to an alkaline material. Addition of the neutralization
agent must be carefully controlled to avoid large temperature
increases due to the exothermic nature of most acid-base neutra-
lization reactions. Neutralization chemicals can be added manu-
ally or automatically to a mixed tank. Continuous pH monitoring
is usually included in an automatic system.
Carbon Adsorption
Activated carbon removes pollutants from water by the process of
adsorption (i.e., the attraction and accumulation of one sub-
stance on the surface of another). Activated carbon preferenti-
ally adsorbs organic compounds over other compounds and, because
of this selectivity, is effective in removing organic pollutants
from wastewater. This sorption process occurs when wastewater is
passed over the activated carbon in a packed bed.
The term activated carbon applies to any amorphous form of carbon
specially treated to give high adsorption capacities. The
adsorption of materials onto the active sites in the activated
carbon is a reversible process, allowing the carbon to be regen-
erated for reuse using either heat and steam or solvents.
Carbon adsorption requires preliminary treatment of the waste-
water to remove excess suspended solids, oils, and greases.
Suspended solids in the influent should be less than 50 mg/1 to
minimize backwash requirements; oil and grease should be less
than 10 mg/1.
196
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Activated carbon was considered as a preliminary option for the
control of pollutants in PM&F wastewater. However, activated
carbon treatment is a sophisticated and expensive control tech-
nology that is most effectively used to remove non-polar, high
molecular weight organic chemicals from wastewater. This tech-
nology has specialized applications and the design parameters of
a system are highly site specific. For this reason the Agency
does not believe that the activated carbon technology is feasible
for the plastics molding and forming category. This technology
was not considered further.
Granular Media Filtration
Granular media filtration, one of the oldest and most widely
applied types of filtration for the removal of suspended solids
uses a bed of granular particles (typically sand with coal) as
the filter media. The bed is usually contained within a basin or
tank and is supported by an underdrain system that allows fil-
tered liquid to be drawn off while retaining the filter media in
place. As wastewater passes through the media, solid material is
trapped on top of and within the bed. This reduces the porous
nature of the bed, which either reduces the filtration rate at a
constant pressure or increases pressure needed to force the
wastewater through the filter. If left to continue in this
manner, the filter eventually plugs with solids; therefore, the
solids must be removed. This is done by forcing wash water
through the bed of granular particles in the reverse direction of
the wastewater flow. Wash water is pumped through the bed at a
velocity sufficiently high so that the filter bed becomes fluid-
ized and turbulent. In this turbulent condition, the solids are
dislodged from the granular particles and are discharged in the
spent wash water. When this backwashing cycle is completed, the
filter is returned to service. A diagram of a granular media
filter in filtration and backwashing modes is presented in Figure
VIII-6.
Granular media filtration is an effective and widely used method
for removing total suspended solids from wastewater. Mean
removal efficiencies ranging from 10 to 25 percent for oil and
grease, BOD, TOG, COD, and total phenols have also been achieved
in granular medial filtration systems. (Treatability Manual,
Volume III, Technologies for Control/Removal of Pollutants,EPA
600/8-80-042c.)
Granular media filtration was initially considered as a possible
PM&F wastewater treatment technology but was not considered when
the technology options were selected. Suspended solid levels in
contact cooling and heating water are not high enough to warrant
granular media filtration, while average cleaning and finishing
water suspended solids concentrations indicate that the filter
197
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FILTRATION CYCLE
BED Of FILTER MEDIA
\|
UNDERDRAIN PLATE
WITH STRAINERS \
*\ c * . • ~
v • f * • ' ' .
« • § 0 • ft
I BACKWASH WASTEWATER
—3 it'ASKWATER SUPPLY
V CLOSED
OPEN
FILTERED EFRUENT
BACKWASH CYCLE
FILTER MEDIA BED BECOMES
FLUIDIZED AND TURBULENT
DURING THE BACKWASH CYCLE
\
(t\ /4 >—1\\ <*V—/i V-
SPENT
BACKWASH WATER
WASHWATER
CLOSED
Figure VIII-6
GRANULAR MEDIA FILTRATION PROCESS
198
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would be frequently plugged and require excessive backwashing.
Therefore, this technology was not considered feasible.
Septic Tank-Soil Absorption Bed
A septic tank followed by a soil absorption bed is a traditional
onsite system for the treatment and disposal of wastewater from
individual households or establishments. The system consists of
a buried tank where wastewater is collected and a subsurface
drainage system where clarified effluent percolates into the
soil. Solids are collected and stored in the tank, forning
sludge and scum layers. Anaerobic digestion occurs in these
layers, reducing their overall volume. Effluent is discharged
from the tank to one of three basic types of subsurface systems:
absorption trenches, seepage beds, or seepage pits, ^izes of the
subsurface system are usually determined by site percolation
rates, soil characteristics, and site size and location. Pipes
are laid in the subsurface system to distribute the wastewater
over the absorption area.
Septic tank-soil absorption beds were initially considered as a
possible PM&F wastewater treatment technology, but were not used
to develop the technology options. Since these systems are
dependent on soil and site conditions (e.g., the ability of the
soil to absorb liquid and depth to groundwater) the Agency does
not believe these systems are feasible as the basis for the PM&F
effluent limitations guidelines and standards.
Contract Haul
Instead of being discharged by the plants in the PM&F category,
wastewater could be stored and then removed from the plant site
by a contract hauler. The feasibility of this method of disposal
depends on the plant wastewater production rate. Wastewater
production rates at many of the plants in the PM&F category are
low enough, especially when the possibility of additional process
water reduction and recycle is considered, to make contract haul-
ing a disposal method. There is currently limited use of con-
tract hauling of process wastewater in the PM&F category. Two
cleaning and finishing processes in the questionnaire data base
dispose of process water by contract hauling. One process pro-
duces a finishing wastewater from a polishing step. This waste-
water is disposed of in a landfill as a solid waste. The other
wastewater is generated in a detergent washing process that is
removed by a contract hauler. Contract haul of process waste-
water was considered further for the technology options for the
PM&F category.
199
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SECTION IX
COSTS, ENERGY, AND NON-WATER QUALITY ASPECTS
This section presents estimated costs of the wastewater treatment
and control technologies described in Section VIII. These cost
estimates, together with the estimated pollutant reduction per-
formance for each treatment and control option presented in
Section X, provide a basis to evaluate the treatment and control
technology options and to identify the best practicable technol-
ogy currently available (BPT), best available technology economi-
cally achievable (BAT), best conventional pollutant control tech-
nology (BCT), best demonstrated technology (BDT), and the appro-
priate technology for pretreatment. The cost estimates are also
used as the basis to estimate the economic impact of the proposed
effluent limitations guidelines and standards on the plastics
molding and forming category. In addition, this section
addresses non-water quality environmental impacts of the waste-
water treatment and control options, including energy require-
ments, air pollution, and solid wastes.
BPT TREATMENT TECHNOLOGY OPTIONS
Costs were developed for BPT Options 2 and 3 for the contact
cooling and heating water subcategory and for BPT Options 1, 2,
and 3 for the cleaning and finishing water subcategory. Costs
were not developed for BPT Option 1 for the contact cooling and
heating water subcategory because Option 1 provides no pollutant
removal benefits and thus was rejected as a possible treatment
option. Below are brief descriptions of the BPT treatment
options for which costs were developed. These are the same
treatment options considered for BAT, BCT, and NSPS.
Contact Cooling and Heating Water Subcategory
Option 2:
For processes with an average process water flow rate of 15 gpm
or less - Zero discharge by 100 percent recycle of process water
using either a tank or a chiller.
For processes with an average process water usage flow rate
greater than 15 gpm - Recycle through a cooling tower and treat-
ment of the recycle unit discharge in a package activated sludge
plant. An equalization tank is included as part of the package
plant.
201
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Option 3:
For processes with an average process water usage flow rate of 15
gpm or less - Zero discharge by 100 percent recycle of the waste-
water through either a tank or a chiller.
For processes with an average process water usage flow rate
greater than 15 gpm - Recycle through a cooling tower and zero
discharge by contract haul of the discharge from the recycle
unit.
The flow cut-off for BPT Options 2 and 3 for costing purposes
differs from the flow cut-off for the BPT options presented in
Section X of this document. The original cut-off for the treat-
ment options presented in Section X was 15 gpm and treatment
costs were developed based on that cut-off. The cut-off was
subsequently changed to 35 gpm to reflect the average flow rate
of the best processes that recycle 100 percent of the process
water using a chiller. The Agency believes that the results of
the cost analyses based on the 15 gpm cut-off support the pro-
posed BPT 35 gpm cut-off because technology costs for processes
with flow rates between 15 and 35 gpm are expected to decrease
and benefits for these processes are expected to increase (i.e.,
more processes will achieve zero discharge of pollut^lnts by
recycling 100 percent of the process water) when the 35 gpm cut-
off is used. The Agency will revise these analyses using the 35
gpm cut-off prior to promulgation of the PM&F effluent limita-
tions guidelines.
Cleaning and Finishing Water Subcategory
Option 1:
pH adjustment and sedimentation.
Option 2:
For processes with an average process water usage flow rate of
two gpm or less - Recycle through a sedimentation tank and
contract haul of the discharge from the recycle unit.
For processes with an average process water usage flow rate
greater than two gpm - Recycle through a sedimentation tank and
treatment of the discharge from the recycle unit in a package
activated sludge plant. The treatment system also includes an
equalization unit and pH adjustment.
Costs used to evaluate Option 2 are based on recycle and con-
tract hauling for processes with an average process water usage
flow rate of two gpm or less because the Agency assumes that
plants will comply with the proposed regulation in the least
202
-------
costly manner. Equipment vendors indicate that the smallest com-
mercially available package activated sludge plant is designed
for a flow rate of 600 gallons per day. Assuming a minimum
recycle ratio of 70 percent for the flow reduction unit in the
BPT model treatment technology for this option, a process must
have an average process water usage flow of greater than two gpm
for the package activated plant to function properly. Although
EPA recognizes that plants with cleaning and finishing processes
with a flow rate of two gpm or less may choose to install a cus-
tom built system to achieve the limitations, it is difficult for
EPA to estimate the costs of a custom system. Further, the
Agency believes that for plants with an average process water
usage flow rate of two gpm or less, it may be more economical to
contract haul the wastewater. Thus, the Agency costed contract
hauling for plants with an average water process flow rate of two
gpm or less for this option.
Option 3:
Recycle through a sedimentation tank for all processes and
contract haul of the discharge from the recycle unit.
Costs of Treatment Technology Options for BAT, BCT, and NSPS
Additional costs have not been developed for treatment options
considered for BAT, BCT, and NSPS because the options considered
for BAT, BCT, and NSPS are the same as the options considered for
BPT. Therefore, the costs of these options are the same as the
costs of the BPT options.
Treatment costs for new sources are assumed to be the same as the
treatment costs for existing sources with similar size. This is
a conservative assumption. Costs could be lower for new sources
because new production processes can be designed to reduce the
amount of wastewater discharged. Therefore, for those new
sources there would be no costs associated with retrofitting a
plant or process within the plant.
No costs were developed for the technology basis for pretreatment
standards because, as discussed in Section XIII of this document,
the Agency proposes not to establish pretreatment standards for
either subcategory.
COST ESTIMATES
Sources of Cost Data
Capital and operation and maintenance (O&M) cost data for the
treatment technologies were obtained from two sources: (1)
equipment manufacturers, and (2) the literature. The major
sources of capital costs were contacts with equipment vendors.
203
-------
Most of the O&M cost information was obtained from the
literature.
Cost Components
Capital Costs. Capital costs consist of equipment costs and
system costs. Equipment costs include: (1) the purchase price
of the manufactured equipment and any accessories; (2) delivery
charges, which account for the cost of shipping the purchased
equipment a distance of 500 miles; and (3) installation charges,
which includes charges for labor, excavation, site work, and
materials.
System costs include engineering, administrative, and legal
costs, contingencies, and the contractor's fee. The engineering,
administrative, and legal costs are expressed as a percentage of
the equipment costs. Contingencies and contractor's fee are
expressed as a percentage of the sum of the equipment costs and
the engineering, administrative, and legal costs. Equipment
costs and system costs are added to obtain the capital costs.
The components of capital costs are:
Item No. Item Cost
1 Equipment Costs Cost of installed
equipment
2 Engineering, Administra- 10% of Item 1
tion, and Legal
3 Subtotal Item 1 and Item 2
4 Contingency 15% of Item 3
_5 Contractor's Fee 10% of Item 3
6 Total Capital Costs Items 3 through 5
Operation and Maintenance Costs. Operation and maintenance (O&M)
costsfor thetechnology options include the following:
Raw materials costs - These costs are for chemicals used
in the treatment processes, which include such things as
caustic, sulfuric acid, corrosion inhibitors, and
biocides.
Operation labor and materials costs - These costs account
for the labor and materials directly associated with
operation of the process equipment. Labor requirements
204
-------
are estimated in terms of hours per year. A composite
labor rate of 21 dollars per hour was used to convert the
hour requirements to an annual cost. This composite
labor rate includes a base labor rate of nine dollars per
hour for skilled labor, 15 percent of the base labor rate
for supervision, and plant overhead at 100 percent of the
base rate plus supervision. Nine dollars per hour is the
Bureau of Labor national wage rate for skilled labor.
Maintenance and repair costs - These costs account for
the labor and materials required for repair and routine
maintenance of the equipment. Maintenance and repair
costs were assumed to be five percent of the equipment
costs based on information from literature sources unless
more reliable data could be obtained from vendors.
Energy cost - Energy or power costs were calculated based
on total nominal horsepower requirements (in kw-hrs);
an electricity charge of $0.049/kilowatt-hour; and an
operating schedule of 24 hours/day, 250 days/year unless
specified otherwise. The electricity charge rate (March
1982) is based on the industrial cost derived from the
Department of Energy's Monthly Energy Review.
Cost Update Factors. All costs have been standardized by adjust-
ing them to the first quarter of 1982. The cost indices used for
particular components of costs are described below.
Capital Costs - Capital costs were adjusted using the EPA-Sewage
Treatment Plant Construction Cost Index. The value of this index
for March 1982 is 414.0.
Operation and Maintenance-Labor Costs - The Engineering News-
Record Skilled Labor Wage Index was used to adjust the portion of
operation and maintenance cost attributable to labor. The March
1982 value is 325.0.
Maintenance and Materials Costs - The producer price index pub-
lished by the Department of Labor, Bureau of Statistics was used.
The March 1982 value of this index is 276.5.
Chemical Costs - The Chemical Engineering Producer Price Index
for industrial chemicals was used. This index is published
biweekly in Chemical Engineering magazine. The March 1982 value
of this index is 362.6.
Cost Estimates
To estimate capital and O&M costs for the treatment technologies,
cost data from all sources were plotted on a graph of capital or
O&M costs versus a design parameter (usually flow). These data
205
-------
were usually distributed over a range of flows. Cost data for
unit process equipment gathered from the various sources included
costs for equipment with a variety of auxiliary components, basic
construction materials cost, and costs based on different points
of origin for the equipment. A single line was fitted to the
data points thus arriving at a cost curve that represented an
average of all the costs for a unit process. Since the cost
estimates presented in this section must be applicable to treat-
ment technologies used in varying circumstances and geographic
locations, the Agency believes this approach is best to estimate
the costs of the technology options for this project. For con-
sistency in estimating costs and accuracy in reading the final
cost curves, equations were developed to represent the final cost
curves. Capital and operation and maintenance cost equations are
listed in Table IX-1.
The cost estimates developed for the treatment of PM&F wastewater
are based on the segregation of wastewater. Costs have been
developed for separate recycle systems for cooling and heating
water and cleaning and finishing water. On the questionnaire
process flow diagrams returned by plants in the PM&F category,
segregation of contact and non-contact cooling water was found to
be a general industry practice. Therefore, contact cooling water
was assumed to be segregated from non-contact cooling water when
treatment costs were developed.
TECHNOLOGY COSTS
Recycle Unit - Contact Cooling and Heating Water Subcategory
Equipment used to recycle contact cooling and heating water
includes a recirculating pump, a heat transfer unit (e.g., a
tank, a cooling tower, or a chiller), a cold water holding tank,
and necessary piping and electrical accessories, including
instrumentation. The capital costs for the recycle unit includes
installation costs and delivery costs.
Quench Tank Technology
The Agency assumed that separate tanks are not needed for cooling
for low flow rate processes (i.e., one tank to quench or cool the
plastic product and one tank to cool the quench water). Instead,
a single tank was costed for product cooling. This tank has
enough surface area to allow the quench water to be cooled in the
tank by heat loss to the environment. The design basis for the
quench tank is:
The volume of a quench tank needed for sufficient
cooling is based on a tank surface area of 75 ft^/gpm
and a depth to length ratio of 0.25. The value of 75
is taken from Figure 12-25 in Perry and
206
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Table IX-1
COST EQUATIONS FOR TREATMENT AND CONTROL TECHNOLOGIES
Equipment
Agitators, C-clamp
Agitators, Top Entry
Caustic Feed System
Chiller System
Contract Hauling
Cooling Tower System
Package Activated Sludge
Plant
Equation
Range of Validity
Pumps, Centrifugal
Tank, Fiberglass
Tank, Steel Equalization
C - 417 + 4030 (HP)
A - 104 + 351 (HP)
C - 839.1 + 587.5 (HP)
A - 2739.89 + 403.365 (HP) + 0.7445 (HP)2
C - 1585.55 + 125.302 (HP) - 3.27437 (HP) 2
A - 2739.89 + 403.365 (HP) + 0.7445 (HP)2
C - 2655.77 + 1231.21 (F) - 40.3243 (F)2
C - 2131.34 + 1473.27 (TR) - 11.9265 (TR)2
A - 1092.25 + 435.734 (TR) - 0.413462 (TR)2
c-- o
A - 0.40 (G)(HPY)
C - exp[8.76408 + 0.07048 (InT)
+ 0.050949 (InT)2]
A - exp[9. 08702 - 0.75544 (InT)
+ 0.140379 (InT)2]
C - 2566
A - 910
C • 9165
A - 3055
C - 6500 + 1.71 X
A - 1600 + 0.96 X
C - exp[ 1.57977 + 1.22209 (InX)
- 0.028484(lnX)2]
A - 4538.99 +0.0737513 (X) - 2.77111
x 10-' (X2)
C - exp[6.31076 + 0.228887 (InY)
+ 0.0206172 (InY)2]
A - exp[6. 67588 + 0.031335 (InY)
+ 0.062016 (InY)2]
C - 3100.44 + 1.19041 (V) - 1.7288 x 1 0'5 (V)2
A - 0
C - 14,759.8 + 0.170817 (V) - 8.44271
x 10-8 (v)2
C - 3,100.44 + 1.19041 (V) - 1.7288 x 10~5 (V)2
C - exp[6. 88763 - 0.643189 (InV)
+ 0.11525 (InV)2]
A - 0
0 < HP < 0.25
0.25 < HP < 0.33
0.33 < HP < 5.0
0 < F < 12.5
0.5 < TR < 7.5
Non Hazardous Washes
1 < T < 700
X < 600
600 < X < 1500
1500 < X < 5000
5000 < X < 100,000
3 < Y < 3500
500 < V < 24,000
24,000 .< V < 500,000
1,000 < V < 24,000
V < 1 , 000
C
A
F
HP
HPY
T
TR
V
X
Y
Direct capital, or equipment costs (1982 dollars)
Direct operation and maintenance costs (1982 dollars/year)
Chemical feed rate (pounds/hour)
Power requirement (horsepower)
Plant operating hours (hours/year)
Cooling capacity in evaporative tons (°F gallons/minute)
Cooling capacity in refrigerative tons
Tank capacity (gallons)
Wastewater flow rate (gallons/day)
Wastevater flow rate (gallons/minute)
207
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Chilton's Chemical Engineer's Handbook and is based on
the following assumptions Fen: ambient conditions and
water temperatures:
Relative humidity
Wind velocity
Dry bulb air temperature
Solar heat gain
Thot
Tcold
50 percent
0 miles per hour
75°F
0 Btu/hr-ft2
100°F
85°F
refers to the quench tank effluent water temperature and
refers to the quench tank influent water temperature.
Cost equations used to estimate capital costs for tanks are
presented in Table IX-1. An additional 20 percent of the tank
cost was added to the capital cost to allow for a unique appli-
cation of a tank for product quenching operations. O&M costs are
five percent of the capital cost.
Chiller Technology
A recirculating water chiller system includes the following
equipment:
Air cooled water chiller with recirculating pump and
associated piping
Cold water holding tank
- Associated piping and instrumentation
The design basis for a chiller is:
The temperature change though the chiller system was
assumed to be 10°F, from 60°F to 70°F, based on current
industry practice.
One ton of refrigeration can cool 2.4 gpm of water 10°F
based on thermodynamic considerations, with a chiller
efficiency of 80 percent.
Water holding tank designed with a 0.5 hour retention
time.
100 percent recycle.
Capital costs were obtained through vendor contacts. A capital
cost equation based on information provided by vendors Is
presented in Table IX-1.
208
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Chiller unit O&M costs include:
Labor costs (50 hours/year)
Utility costs for the pump and compressor
Maintenance costs.
A chiller unit O&M cost equation is presented in Table IX-1.
Cooling Tower Technology
Cooling tower capital costs are based on a cooling tower that
consists of the following:
Cooling tower and accessories
Piping or force main (1,000 feet)
Holding/water storage tank
Recirculating pump
Chemical water treatment system
The design basis for the cooling tower is:
A cooling tower size is based on the following
parameters:
Recycle ratio - 0.996
Wet bulb temperature - 75°F
Thot - 95°F
Tcold - 85°F
The recycle ratio of 0.996 is assumed to be the maximum
practicable recycle ratio in a cooling tower system using
total dissolved solids concentration as the limiting
factor. Vendors indicated that using average city makeup
water, cooling tower water should be able to undergo
three to four concentrations. This is equivalent to 99.6
percent recycle for a 10°F temperature range based on
Figure 40 in Marley's Cooling Tower Fundamentals.
1,000 feet of carbon steel pipe with necessary valves and
fittings for yard piping.
Pump size based on the recirculation rate.
A retention time of one hour for the water holding tank.
Based on the design assumptions, the tons of cooling necessary
were determined from the definition of a standard evaporative
ton. One standard evaporative ton is the power required to cool
three gpm of water 10°F:
209
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Recirculated Flow Rate (gpm)
Number of Evaporative _ x Range (°F)
Tons Needed 3 gpm x 10"?"
Standard Evaporative Ton
Because the assumed temperature range is 10°F, the number of
evaporative tons needed is:
Number of Evaporative _ Recirculated Flow Rate (gpm)
Tons Needed 3(gpm/evaporative ton)
Capital and O&M cost equations for a cooling tower and accessory
equipment are presented in Table IX-1.
Cooling tower O&M costs include:
Raw material cost for chemical water treatment (e.g.,
slime, pH, corrosion control) at $15/ton
Operating labor costs (based on five hours/month)
Utility costs for the fan
Maintenance and repair costs (based on 55 hours of labor
a year for cooling towers with less than 100 tons
capacity and 1/6 hour per ton plus 33 hours for cooling
towers greater than 100 tons capacity).
Recycle Unit - Cleaning and Finishing Water Subcategory
The recycle technology for the cleaning and finishing subcategory
includes a sedimentation tank, a recirculating pump, and associ-
ated piping. The sedimentation tank is needed for the gravity
separation of solids and for oil and grease removal.
The design basis for this recycle technology is:
Four hour retention time for sedimentation tank.
Pump size based on recycle ratio.
Recycle ratio of 98.3 percent based on an assumption of
total system blowdown every two weeks. Hours of opera-
tion were assumed to be five days per week, 24 hours per
day. The recycle ratio of 98.3 percent reflects recycle
rates currently achieved by processes in the cleaning and
finishing water subcategory.
210
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Tank and pump capital costs were calculated from the cost equa-
tions given in Table IX-1.
O&M costs include maintenance and utility costs for the pump.
They were calculated using the pump cost equation presented in
Table IX-1.
Sedimentation tank sludge removal costs were also estimated.
Volume of sludge removed is based on 100 percent removal of
suspended solids in the sedimentation tank (suspended solids were
assumed to have a specific gravity of 1.0). Sludge removal cost
is based on a contract hauling charge of $0.40 per gallon. The
$0.40 per gallon rate is based on information from several
sources, including a paint industry survey, comments from the
aluminum forming industry, and the literature.
Equalization
Equalization equipment includes an equalization tank, an agita-
tor, and a pump. The design basis for the equalization equipment
is:
Equalization tank volume is equal to the recycle
sedimentation tank volume for the cleaning and finishing
water subcategory or the recycle water holding tank
volume for the contact cooling and heating water
subcategory. This allows for complete recycle system
blowdown without short circuiting the wastewater treat-
ment unit. If a plant has more then one process, the
equalization tank size is based the largest blowdown
from the recycle system. That assumes that all recycle
systems are not blown down at the same time.
Agitator size based on 3 x 10"^ horsepower per gallon
from theoretical energy requirement calculation and
agitator efficiency of 80 percent.
Pump size based on flow rate.
Equations used to estimate capital and O&M costs for the equali-
zation tank, agitator, and pump are given in Table IX-1.
Package Activated Sludge Plant
Package activated sludge plants usually contain a primary sedi-
mentation unit, an activated sludge unit, and a secondary sedi-
mentation unit. The package activated sludge plant consists of
three chambers. The influent enters the first chamber where scum
and sludge are separated. The second chamber is where aeration
occurs either by mechanical or diffused aeration. The final
211
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compartment is a sedimentation unit where sludge settles by
gravity and is returned to the aeration unit.
Capital costs for package activated sludge plants were obtained
through vendors. Costs include purchase costs of the equipment,
delivery costs, site work costs, installation costs, and asso-
ciated labor costs. A capital cost equation for a package
activated sludge plant is presented in Table IX-1.
O&M costs were also obtained from vendors. O&M costs include
utility costs, labor costs, maintenance costs, and cost associ-
ated with annual tank cleanout. An O&M cost equation for this
technology is also presented in Table IX-1.
pH Adjustment
pH adjustment requires a pH probe and controller, caustic or acid
feed system, a mix tank, and an agitator. The design basis for
pH adjustment is:
pH adjustment takes place in the equalization tank of a
treatment technology if equalization is used.
If equalization is not required, pH adjustment occurs
in a 0.5 hour retention time mix tank with an
appropriately sized agitator.
pH adjustment is based on the adjustment of the pH from
pH 5 to pH 6. An influent pH of 5 was chosen based on
a review of pH's from the sampling data. The adjusted
pH of 6 is the lower limit of the acceptable range of
pH 6 to 9.
Capital costs for pH adjustment include $2,000 for a pH probe and
controller and costs for a caustic feed system. Caustic feed
system costs were assumed to be the same as costs for an alum
feed system. A capital cost equation for the caustic feed system
is presented in Table IX-1.
O&M costs include costs for 12 hours of labor per year, five per-
cent of the capital cost per year for maintenance, and a price of
$0.285 per pound of caustic. Energy requirements are negligible.
Costs of an acid addition feed system are similar to costs of a
caustic feed system. Costs were developed for the caustic feed
system because PM&F wastewater generally has to be adjusted from
acidic to neutral conditions if pH adjustment is necessary. This
approach is conservative because an acid feed system requires a
less sophisticated liquid metering system than a caustic feed
system and the raw material costs are lower.
212
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Sedimentation
Equipment associated with sedimentation includes a sedimentation
tank and a pump and associated piping. The design basis for the
sedimentation unit is:
A four hour retention time sedimentation tank.
Pump size based on flow rate.
Equations used to develop capital costs for pumps and tanks are
given in Table IX-1. Piping cost was assumed to be 15 percent of
the tank cost.
O&M costs for tanks and pumps were estimated using equations in
Table IX-1. Annual sludge and scum removal charges were based
on 82 percent removal of total suspended solids and 47 percent
removal of oil and grease (see Section VIII). Removed pollutants
were assumed to have a specific gravity of 1.0. Sludge and scum
are removed from the sedimentation tank once per month by a
contract hauler at a charge of $0.40 per gallon. The $0.40 per
gallon rate is based on information from a paint industry survey,
comments from the aluminum forming industry, and the literature.
Minimum monthly charge for removal is $75.00, based on telephone
conversations with sludge haulers.
CALCULATION OF INDIVIDUAL PLANT COSTS
To facilitate the calculation of individual plant costs, process
water usage flow ranges were established and a range standardized
flow was selected for each range. Capital and O&M costs for each
regulatory option were calculated for each range standardized
flow. For a treatment option, the capital and O&M costs were
calculated by first determining the process water usage flow
range for the process and then using the capital and O&M costs
for the range standardized flow for that process as the capital
and O&M costs for the treatment option.
The ranges and range standardized flows were chosen so that the
technology costs for the range standardized flow reflect the
average technology costs for processes with flows within a range.
This was done by assigning the ranges and the range standardized
flows so that the difference between the range standardized flow
and the maximum or minimum flows within a range were proportional
to the range standardized flow. The flow ranges and range
standardized flows used are listed below:
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Flow Range Range Standardized Flow
0 < X _< 0.3 gpm - costed at 0.15 gpm
0.3 < X _< 2 gpm - costed at 1 gpm
2 < X _< 8 gpm - costed at .5 gpm
8 < X _< 20 gpm - costed at 1 5 gpm
20 < X <^ 50 gpm - costed at 35 gpm
50 < X < 100 gpm - costed at 75 gpm
100 < X < 200 gpm - costed at 150 gpm
200 < X ^ 300 gpm - costed at 250 gpm
Costs were developed individually for processes with an average
process water usage flow rate above 300 gpm because the popula-
tion of plants in that flow range was too small for the range-
standardized flow approach.
Individual plant costs were calculated for each treatment tech-
nology option using the following methodology. If a plant had
more than one process in a subcategory, the process water flow
rates of each process were summed and the treatment technology
costs for a process with a flow rate equal to the sum of the flow
rates were considered as the plant costs. If the plant had one
or more processes in both subcategories and proces water from
both subcategories was not treated in a common end-of-pipe treat-
ment system, the process water flow rates of processes in each
subcategory were summed and treatment technology costs were
determined for each subcategory based on a process with a flow
rate equal to the sum of the flow rates. The sum of the subcate-
gory treatment technology costs was considered as the plant
costs. If a plant had one or more processes in each subcategory
and process water from processes in both subcategories was
treated in a common end-of-pipe treatment system, plant costs
were based on the costs of a treatment system designed to treat
the combined process water.
Estimated costs for BPT Options 2 and 3 for the contact cooling
and heating water subcatagory are presented in Tables IX-2 and
IX-3. Costs for BPT Options 1, 2, and 3 for the cleaning and
finishing water subcategory subcategory are presented in Tables
IX-4, IX-5, and IX-6, respectively.
214
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Table IX-2
BPT OPTION 2 COSTS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Flow Equipment Total Annual
Range (gpm) Costs Capital Costs O&M Costs
0 < X < 0.3 $ 770 $ 1,060 $ 40
0.3 < X < 2 $ 4,140 $ 5,690 $ 1,310
2 < X < 8 $ 7,420 $ 10,200 $ 2,180
8 < X < 20 $15,380 $ 21,100 $ 4,340
20 < X~< 50 $28,960 $ 39,800 $ 9,710
50 < X < 100 $38,180 $ 52,500 $10,930
100 < X < 200 $60,240 $ 82,800 $15,270
200 < X T 300 $76,240 $105,000 $18,050
Table IX-3
BPT OPTION 3 COSTS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Flow Equipment Total Annual
Range (gpm) Costs Capital Costs O&M Costs
0 < X < 0.3 $ 770 $ 1,060 $ 40
0.3 < X < 2 $ 4,140 $ 5,690 $ 1,310
2 < X < 8 $ 7,420 $10,200 $ 2,180
8 < X < 20 $15,380 $21,100 $ 4,340
20 < X~< 50 $18,250 $25,100 $23,150
50 < X < 100 $24,570 $33,800 $ 51,030
100 < X < 200 $33,880 $46,600 $101,410
200 < X ^ 300 $44,740 $61,500 $187,200
Table IX-4
BPT OPTION 1 COSTS
CLEANING AND FINISHING WATER SUBCATEGORY
Flow Equipment Total Annual
Range (gpm) Costs Capital Costs O&M Costs
0 < X < 0.3 $ 6,340 $ 8,710 $ 1,780
0.3 < X < 2 $ 8,500 $11,700 $ 2,360
2 < X < "8" $11,800 $16,300 $2,440
8 < X < 20 $13,000 $17,900 $ 4,180
20 < X~< 50 $24,800 $34,100 $ 7,250
50 < X < 100 $35,000 $48,200 $15,840
100 < X < 200 $40,700 $55,900 $38,600
200 < X ^ 300 $49,300 $67,800 $62,880
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Table IX-5
BPT OPTION 2 COSTS
CLEANING AND FINISHING WATER SUBCATEGORY
Flow
Range (gpm)
0 < X <^ 0.3
0.3 < X < 2
2 < X < S
8 < X < 20
20 < X < 50
50 < X J 100
100 < X < 200
200 < X < 300
Equipment
Costs
$ 800
$ 2,960
$ 20,850
$ 27,250
$ 38,420
$ 63,650
$109,800
$156,400
Total
Capital Costs
$ 1,100
$ 4,070
$ 28,700
$ 37,500
$ 52,800
$ 87,500
$151,000
$215,000
Annual
O&M Costs
$ 535
$ 3,040
$ 7,130
$ 9,270
$12,830
$25,640
$57,200
$89,170
Table IX-6
BPT OPTION 3 COSTS
CLEANING AND FINISHING WATER SUBCATEGORY
Flow
Range (gpm)
0 < X < 0.3
0.3 < X < 2
2 < X < "8"
8 < X ^ 20
20 < X < 50
50 < X ^ 100
100 < X < 200
200 < X < 300
Equipment
Costs
$ 800
$ 2,960
$ 6,020
$ 9,430
$15,300
$23,900
$45,000
$62,900
Total
Capital Costs
$ 1,100
$ 4,070
$ 8,280
$13,000
$21,000
$32,900
$61,900
$86,500
Annual
O&M Costs
$ 535
$ 3,040
$ 10,500
$ 28,780
$ 59,670
$153,400
$410,800
$683,900
An example that illustrates how the BPT costs were calculated is
presented in Table IX-7. The table presents costs for each piece
of equipment necessary for BPT Option 2 for the contact cooling
and heating water subcategory. These costs were calculated using
the equations in Table IX-1 .
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Table IX-7
BPT OPTION 2 COSTS FOR THE RANGE STANDARDIZED
FLOW OF 150 GPM, CONTACT COOLING AND HEATING WATER SUBCATEGORY
Equipment Annual
Equipment Capital Costs O&M Cost
Cooling tower (55 tons) $19,240 $ 4,080
Recirculating Pump (150 gpm) 2,140 4,430
Holding Tank (9,100 gal) 12,500
Equalization Tank (9,100 gal) 12,500
Agitator (0.34hp) 1,630 2,880
Pump (1 gpm) 730 880
Package Aerobic Treatment 9,100 3,000
Unit (860 gpd)
Piping 2,400 ---
TOTAL $60,240 $15,270
The total capital cost is the equipment costs plus 10 percent of
the equipment costs for engineering, administrative, and legal.
Twenty-five percent of the equipment costs plus engineering,
administrative, and legal costs were added for contingency costs
and contractor's fee:
60,240 Equipment Costs
+ 6,024 + 10% (administrative, engineering and legal)
66,264
+ 16,566 + 25% (contingency and contractor's fee)
82,830 Total Capital Cost
An equipment cost credit for treatment in place was subtracted
for any plants with recycle units currently in place. Credit for
those systems was calculated in the following manner. If a
process had a recycle unit with a recycle rate between 80 and 100
percent, the Agency assumed that the process could meet the
regulatory flow allowance with no additional capital expenditure
for a recycle unit. Thus, a credit equal to the full cost of a
recycle unit was subtracted from the estimated cost.
If a process had a recycle unit with a recycle rate between 60
and 80 percent, the Agency estimated that a 30 percent increase
in recycle capacity would be required for the plant to meet the
regulatory flow allowance. The cost to retrofit a recycle unit
for a 30 percent increase in recycle capacity was assumed to
equal 60 percent of the cost of installing a new unit. There-
fore, there is a 40 percent cost savings achieved by increasing
the capacity of an existing recycle unit. A credit equivalent to
40 percent of the cost of a new recycle unit was subtracted from
217
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the technology cost for each process with between 60 and 80
percent recycle. If a process had below 60 percent recycle, no
credit for treatment in place was allowed.
No treatment in place credits were allowed for annual costs
because plants with treatment in place have to continue to
operate their recycle units to meet the effluent limitations
guidelines and standards in this proposed regulation.
ENERGY AND NON-WATER QUALITY IMPACTS
The following are the energy and non-water quality environmental
impacts associated with the proposed regulation. EPA has deter-
mined that the impacts identified below are justified by the
benefits associated with compliance with the proposed effluent
limitations guidelines and standards.
Energy Requirements
The Agency estimates that the achievement of BPT effluent limi-
tations guidelines will result in a net increase in electrical
energy consumption of approximately 19.9 million kw-hr/yr, which
is less than one percent of the estimated total current energy
usage for the PM&F category. The net increase in electrical
energy consumption was estimated by adding the energy require-
ments of the equipment required for BPT for each direct dis-
charging plant in the questionnaire data base and then scaling-up
the estimated value for the number of plants in the category.
Total current energy usage for the PM&F category was projected
from the energy usage information supplied by plants in the
questionnaire survey.
Since the Agency is not proposing BAT or BCT effluent limitations
guidelines more stringent than BPT, no additional electrical
energy is required. There is no additional electrical energy
consumption associated with pretreatment standards since the
Agency is not proposing PSES and PSNS.
EPA believes that the energy used by a new direct discharging
plant will be the same amount used by an existing source at BPT.
Therefore, the estimated annual plant energy use for NSPS is the
same as the annual average energy use for BPT, which is 14,000
kw-hr/yr. This does not significantly add to the total energy
consumption for the PM&F category. The Agency concludes that the
increased energy used to comply with these proposed effluent
limitations guidelines and standards is insignificant and that
Affluent reduction benefits outweigh the increased energy use.
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Air Pollution
Technologies used as the basis for the proposed effluent limi-
tations guidelines and standards settle or biologically oxidize
pollutants found in PM&F wastewater. Some volatile organic
compounds (e.g., methylene chloride) may be emitted to the air
from these treatment technologies. However, those emissions are
not expected to cause air pollution problems. Accordingly, the
proposed effluent limitations guidelines and standards will not
create any substantial air pollution problems.
Solid Waste
EPA believes that only very small amounts of solid wastes are
currently generated by PM&F plants because of the limited use of
treatment technologies in the PM&F category. EPA estimates that
the proposed BPT effluent limitations guidelines will increase
the production of solid wastes by 42,000 metric tons (or kkg) per
year beyond that generated by treatment in place. These wastes
are comprised of settled solids that may contain toxic metals,
treatment process sludges containing biological solids, skimmed
oil, and residues from the periodic cleaning of the recycle
equipment. This increase in solid waste generation was estimated
by totaling the amount of solid waste that would be generated by
each plant in the questionnaire data base if those plants used
the model BPT treatment. This total was then scaled-up for the
number of plants in the category. Solid wastes are generated in
the sedimentation tanks of the recycle units for processes in the
cleaning and finishing water subcategory and in the sedimentation
units of the package activated sludge treatment plants. The pro-
posed BAT and BCT effluent limitations guidelines result in no
additional solid waste production because BAT and BCT are the
same as BPT.
EPA believes that the amount of solid wastes generated by a new
source will be the same as the amount generated by an existing
source at BPT. Therefore, the estimated annual average plant
production of solid wastes generated by compliance with NSPS is
the same as the annual average plant production for BPT, which is
22 metric tons per year. No additional solid wastes will be
generated by indirect dischargers because the Agency is not
proposing categorical pretreatment standards.
The Agency examined the solid wastes that would be generated at
PM&F plants by the proposed model treatment technologies and
believes they are not hazardous under Section 3001 of the
Resource Conservation and Recovery Act (RCRA). This judgment is
based on the recommended treatment technology of recycle of
wastewater treatment and discharge in a package activated sludge
plant consisting of primary sedimentation, activated sludge, and
final sedimentation.
219
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None of the toxic organic compounds for which the extrcict in the
Extraction Procedure (EP) toxicity test are analyzed are in PM&F
process water (see 40 CFR 261.24 (45 FR 33084; May 19, 1980)).
Only four of the eight metals for which the extracts from the EP
toxicity test are analyzed were found in contact cooling and
heating process water. Only two of those metals were found in
cleaning and finishing process water. EPA believes that the
estimated concentration of those metals in the treatment system
sludge will not cause the concentration of those metals in the EP
test extract to exceed the "allowable" concentration (i.e., the
concentration that makes the wastes hazardous) in the extract.
PM&F wastes are also not listed as hazardous pursuant to 40 CFR
Part 261.11 (45 FR 33121; May 19, 1980, as amended by 45 FR
76624; November 19, 1980). Since the PM&F wastes are not
believed to be hazardous, no estimates were made of the costs to
dispose of those wastes in accordance with RCRA hazardous waste
requirements.
Although it is the Agency's view that solid wastes generated as a
result of these guidelines are not expected to be classified as
hazardous under the regulations implementing Subtitle C of the
Resource Conservation and Recovery Act (RCRA), generators of
these wastes must test the waste to determine if they meet any of
the characteristics of hazardous waste. See 40 CFR Part 262.11
(45 FR 12732-12733; February 26, 1980). The Agency may also list
these sludges as hazardous pursuant to 40 CFR Part 261.11 (45 FR
at 33121; May 19, 1980, as amended at 45 FR 76624; November 19,
1980).
If these wastes are identified as hazardous, they will come
within the scope of RCRA's "cradle to grave" hazardous waste man-
agement program, requiring regulation from the point of genera-
tion to point of final disposition. EPA's generator standards
require generators of hazardous wastes to meet containerization,
labeling, record keeping, and reporting requirements; if plastics
molders or formers dispose of hazardous wastes off-site, they
would have to prepare a manifest that tracks the movement of the
wastes from the generator's premises to a permitted off-site
treatment, storage, or disposal facility. See 40 CFR Part 262.20
(45 FR 33142; May 19, 1980, as amended at 45 FR 86973; December
31, 1980). The transporter regulations require transporters of
hazardous wastes to comply with the manifest system to ensure
that the wastes are delivered to a permitted facility. See 40
CFR Part 263.20 (45 FR 33142; May 19, 1980, as. amended at 45 FR
86973; December 31, 1980). Finally, RCRA regulations establish
standards for hazardous waste treatment, storage, and disposal
facilities allowed to receive such wastes. See 40 CFR Part 264
(46 FR 2802; January 12, 1981, 47 FR 32274; July 26, 1982).
220
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Even if these wastes are not identified as hazardous, they still
must be disposed in a manner that will not violate the open
dumping prohibition of §4005 of RCRA. The Agency has calculated
as part of the costs for wastewater treatment the cost of hauling
and disposing of these wastes in accordance with this require-
ment.
Consumptive Water Loss
Recycle of contact cooling and heating water requires the use of
a cooling tower for PM&F processes with large flow rates. The
evaporative cooling mechanism in a cooling tower can cause water
loss and could contribute to water scarcity problems--a primary
concern in arid and semi-arid regions. While the proposed regu-
lation assumes water recycle through a cooling tower, the quan-
tity of water loss in the cooling tower is not regionally signif-
icant. Thus, EPA concludes that the consumptive water loss is
insignificant and that the effluent reduction benefits of recycle
technologies outweigh their impact on consumptive water loss.
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SECTION X
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
BACKGROUND
This section defines the effluent characteristics attainable
through the application of best practicable control technology
currently available (BPT), Section 301(b)(a)(A) of the Act.
Effluent limitations guidelines for the PM&F category based on
BPT reflect the existing treatment performance by plants of
various sizes, ages, and manufacturing processes within the
plastics molding and forming category and the performance of a
treatment technology transferred from the organic chemicals,
plastics, and synthetic fibers category.
The factors considered in identifying BPT include the total cost
of applying the technology in relation to the effluent reduction
benefits derived, the age of equipment and facilities involved,
the manufacturing processes employed, energy, and non-water
quality environmental impacts, and other factors EPA considers
appropriate. In general, the BPT level represents the average of
the best existing performance of plants of various ages, sizes,
processes, or other common characteristics. Where existing per-
formance is uniformly inadequate, BPT may be transferred from a
different subcatetory or category. Limitations based on transfer
of technology are supported by a conclusion that the technology
will be capable of achieving the prescribed effluent limitations
guidelines. See, Tanners' Council of America v. Train, 540 F.2d
1188 (4th Cir. 1976). BPT focuses on end-of-pipe treatment
rather than process changes or internal controls, except where
such practices are common to the industry.
The cost-benefit inquiry for BPT is a limited balancing, com-
mitted to EPA's discretion, that does not require the Agency to
quantify benefits in monetary terms. See, American Iron and
Steel Institute v. EPA, 526 F.2d 1027 TTrd Cir. 1975).In
balancing costs in relation to effluent reduction benefits, EPA
considers the volume and nature of existing discharges, the
volume and nature of discharges 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 industries, or water quality improvements in particular water
bodies. Accordingly, water quality considerations were not the
basis for selecting the proposed BPT effluent limitations guide-
lines for the PM&F category. See, Weyerhauser Company v. Costle,
590 F.2d 1011 (D.C. Cir. 1978).
223
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TECHNICAL APPROACH
The plastics molding and forming category was studied to identify
the manufacturing processes used and the type of wastewaters
generated during plastics molding and forming. Information was
collected from the PM&F industry using questionnaires and PM&F
wastewaters from selected plants were sampled and analyzed. EPA
used these data to subcategorize the PM&F category and to deter-
mine what constitutes an appropriate BPT model treatment technol-
ogy. Some of the key considerations reviewed to determine the
subcategorization scheme for this category are:
1. raw materials,
2. production processes,
3. products,
4. size and age of plants,
5. wastewater characteristics,
6. water utilization, and
7. geographic location of plants.
The PM&F category has been divided for the purpose of the pro-
posed regulation into two subcategories: (1) contact cooling and
heating water subcategory and (2) cleaning and finishing water
subcategory. Additional information on this subcategorization
scheme is presented in Section V.
In making technical assessments of data, reviewing manufacturing
processes, and assessing wastewater treatment technology options,
both indirect and direct dischargers were considered as a single
group. An examination of plants and processes did not indicate
any process differences based on the type of discharge, whether
it be direct or indirect. Therefore, it is appropriate to con-
sider the data from both direct and indirect dischargers to make
technical assessments for BPT.
The Agency is proposing mass-based BPT effluent limitations
guidelines for the plastics molding and forming category. The
objective of these effluent limitations guidelines and standards
is to reduce the total quantity of pollutants discharged to sur-
face waters. Mass-based effluent limitations guidelines and
standards also avoid the possibility of concentration-based
effluent limitations guidelines being met through dilution.
Because flow reduction by recycle of process water is an impor-
tant part of the selected model BPT treatment technologies, the
proposed effluent limitations guidelines for the PM&F category
are expressed in terms of the allowable mass of pollutants
discharged per unit of production. These mass-based effluent
limitations guidelines reflect the reduction in the amount of
pollutants discharged by PM&F processes through application of
the model BPT treatment technologies.
224
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Wastewater generated by processes in the contact cooling and
heating water subcategory contains significant concentrations of
BOD5, COD, total phenols, and priority toxic pollutants.
Wastewater generated by cleaning and finishing processes contains
significant concentrations of BOD5, oil and grease, TSS, COD,
TOG, total phenols, and priority toxic pollutants. The technol-
ogy options considered for BPT were analyzed for their ability to
treat the above pollutants. Potential technology options were
identified through examination of NPDES permits, questionnaire
responses, and the literature.
BPT for the plastics molding and forming category is based on
recycling contact cooling and heating water and cleaning and
finishing water. For processes in the contact cooling and
heating water subcategory with average process water usage flow
rates of 35 gpm or less, BPT is based on zero discharge through
100 percent recycle. The BPT effluent limitations guidelines for
recycle unit discharges that are treated and discharged are based
on treatment in a package activated sludge plant that contains an
equalization tank, a primary sedimentation unit, the activated
sludge process, and a secondary sedimentation unit. pH adjust-
ment is used as needed. Effluent concentrations for conventional
pollutants for the activated sludge process were transferred from
the organic chemicals, plastics, and synthetic fibers category.
The overall effectiveness of end-of-pipe treatment for the
removal of wastewater pollutants is improved by the application
of water flow controls within the process to limit the volume of
wastewater requiring treatment. The in-process technologies
under BPT include those measures that are commonly practiced
within the PM&F category or subcategories.
For each of the subcategories, a specific approach was followed
for the development of BPT effluent limitations guidelines. To
account for production and flow variability from plant to plant,
a unit of production or a production normalizing parameter was
determined that could be related to the flow discharged from a
process to determine a production normalized flow. Normalized
flows were analyzed to determine which flow should be used as
part of the basis for BPT effluent limitations guidelines. The
selected flow (referred to as the BPT production normalized flow)
reflects the water use controls that are currently used in the
category. The BPT production normalized flow is based on the
average of applicable data in the data base for this project.
Plants with normalized flows above the average may have to reduce
their flows. In most cases, this involves recycling a higher
percentage of the process water. Plants may also achieve the BPT
production normalized flow through more efficient water use
practices, such as allowing process water to run only during
production operations.
225
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Effluent limitations guidelines (milligrams of pollutant per
kilogram of plastic material processed) were developed for each
subcategory. They were calculated by multiplying the BPT produc-
tion normalized flow (1/kkg) by the concentration achievable
using the BPT model treatment system (mg/1) for each pollutant
regulated under BPT.
In summary, to establish the BPT effluent limitations guidelines
for the PM&F category the Agency:
1. Selected a treatment technology on which to base the
proposed BPT effluent limitations guidelines,
2. Selected pollutants that would be controlled,
3. Established effluent concentration values for the con-
trolled pollutants,
4. Calculated BPT production normalized flows, and
5. Calculated the allowed mass of pollutant that can
be discharged.
TREATMENT TECHNOLOGIES
Four treatment technologies were considered to treat the pollu-
tants in the PM&F wastewater. These technologies are discussed
in more detail in Section VIII of this document.
Technology 1: Sedimentation and pH Adjustment (if needed)
This technology consists of a tank in which the velocity of the
wastewater is reduced so that solid material can settle by gravi-
tational force. Oil and grease and other floatable material are
skimmed from the surface. If necessary, the pH of the water may
be adjusted by adding an acidic or basic material. Sedimentation
is effective in removing insoluble pollutants such as total sus-
pended solids and oil and grease but does not remove dissolved
pollutants (e.g., biochemical oxygen demand).
Sedimentation is the most widely demonstrated technology used to
treat PM&F wastewater. Sixty-five percent of the PM&F plants in
the questionnaire data base that treat their wastewater use this
technology.
Technology 2: Flow Reduction Through Recycle, Equalization,
and Activated Sludge Treatment
Technology 2 consists of flow reduction through recycle with
end-of-pipe treatment of the discharge from the recycle unit in a
package activated sludge plant. Package activated sludge plants
226
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are commercially available to treat flows that would be dis-
charged from the recycle units. A typical package activated
sludge plant consists of a primary sedimentation unit where
solids and oil and grease are removed; an aeration chamber where
biodegradable organics are oxidized; and a secondary sedimenta-
tion unit where biological sludge settles by gravity. The
biological sludge is returned to the aeration chamber. The
activated sludge process is effective in removing dissolved and
colloidal biodegradable organics from wastewater. The primary
and secondary sedimentation units also remove settleable solids
and floatable materials from wastewater.
Flow reduction through recycle is practiced at 42 percent of the
processes in the contact cooling and heating water subcategory
and 13 percent of the processes in the cleaning and finishing
water subcategory. Activated sludge treatment is used only at
integrated facilities where PM&F wastewater and other wastewater
are combined for treatment. However, activated sludge treatment
is widely demonstrated in other categories for the treatment of
wastewaters similar to PM&F wastewater. In particular, it has
been demonstrated in the treatment of wastewater generated by
processes in the plastics only subcategory of the organic chemi-
cals, plastics, and synthetic fibers category.
Activated sludge technology, when combined with sedimentation,
treats the pollutants in PM&F wastewater.
Technology 3: Zero Discharge by 100 Percent Recycle of
Process Water
Zero discharge is frequently achieved by processes in the contact
cooling and heating water subcategory through 100 percent recycle
of process water. There are 65 processes in the questionnaire
data base for this project with process water usage flow rates of
50 gpm or less that have 100 percent recycle systems for contact
cooling and heating water in place. These systems generally
recycle water through a chiller or a tank to allow for heat
transfer to the environment. Available information indicates
that 100 percent recycle may also be achieved by processes with
flow rates higher than 50 gpm.
Because of the characteristics of cleaning and finishing waste-
water (i.e., high concentrations of solids and oil and grease)
100 percent recycle is not appropriate for cleaning and finishing
water.
227
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Technology 4: Zero Discharge by Contract Haul of Recycle
Unit Discharge
Contract hauling of wastewater eliminates the discharge of waste-
water pollutants. Two plants in the PM&F questionnaire data base
currently contract haul cleaning and finishing water.
BPT TREATMENT TECHNOLOGY OPTIONS
Contact Cooling and Heating Water Subcategory
The Agency identified three technology options as the basis for
the proposed BPT effluent limitations guidelines for the contact
cooling and heating water subcategory. These options are based
on the above described technologies. They are:
Option 1:
The technology for this option consists of a tank in which the
velocity of the wastewater is reduced so that solid material can
settle by gravitational force. This option was rejected early in
the development of the proposed BPT effluent limitations guide-
lines because the suspended solids concentration in the contact
cooling and heating water is very low and because this technol-
ogy does not remove the dissolved pollutants (e.g., biochemical
oxygen demand) in the contact cooling and heating water.
Option 2:
For processes with an average process water usage flow rate of 35
gallons per minute (gpm) or less - Zero discharge by 100 percent
recycle of the process water using either a tank or chiller for
heat transfer. The chiller based recycle system is depicted in
Figure X-1.
For processes with an average process water usage flow rate
greater than 35 gpm - Recycle through a cooling tower and treat-
ment of the recycle unit discharge in a package activated sludge
plant. An equalization tank is included as part of the package
plant. The technology is represented by Figure X-2.
Data from the questionnaire surveys for this project indicate
that 65 processes in this subcategory with a flow rate up to 50
gpm achieve 100 percent recycle. Of these processes, eight have
a flow rate between 20 and 50 gpm and achieve 100 percent recycle
of process water through a chiller. They are:
228
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Average Process Water
Plant ID Usage Flow Rate (gpm)
1178 22
750 30
830 30
1061 30
10180 33.3
2020 33.3
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1945 50
The Agency considered the flow rates for these eight processes
the "best" flow rates for processes that recycle 100 percent of
the process water using chillers. To obtain the flow cut-off of
35 gpm, the Agency averaged the "best" flow rates. Above 50 gpm,
a cooling tower is most commonly used to recycle process water.
A cooling tower necessarily includes some amount of discharge,
which is treated in a package activated sludge plant in this
option.
Option 3:
For processes with an average process water usage flow rate of 35
gpm or less - Zero discharge by 100 percent recycle of the waste-
water through either a tank or a chiller. This is the same
technology as depicted in Figure X-1.
For processes with an average process water usage flow rate
greater than 35 gpm - Recycle through a cooling tower and zero
discharge by contract haul of the discharge from the recycle
unit. This technology is represented by Figure X-3.
The 35 gpm flow rate was used as the cut-off for this option for
the same reasons it was used in Option 2. A cooling tower is
also used in this option to recycle process water for processes
with an average process water usage flow rate greater than 35
gpm. However, the recycle unit discharge is contract hauled to
achieve zero discharge instead of being treated at the plant and
discharged.
Contract haul was used in this option to handle the discharge
from the recycle unit because treatment technologies other than
those used in Option 2 are not considered feasible for the PM&F
category. Technologies (e.g., activated carbon) that could be
used to treat PM&F wastewater are expensive and are difficult to
operate and maintain. The Agency considers contract haul more
practicable for this subcategory than those technologies.
The estimated amounts of pollutants remaining after treatment for
each technology option are:
231
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Discharged Remaining Remaining Remaining
in After After After
Type of Raw Water Option 1 Option 2 Option 3
Pollutant (kg/yr) (kg/yr) (kg/yr) (kg/yr)
Conventional 8,923,000 8,923,000 1,485,200 0
Nonconventional 27,243,000 27,243,000 5,753,200 0
Priority Toxic 123,845 123,845 24,469 0
The methodology used to calculate the pollutant removals for each
option is presented in Appendix C.
The estimated investment cost and annual pollution control costs
for BPT Options 2 and 3 are:
Cost ($ million, 1982 dollars)
Option 2 Option 3
Investment Costs 15.2 9.3
Annual Pollution Control Costs* 9.4 41.2
*Without water savings.
Detailed information on these costs is presented in Economic
Impact Analysis of Proposed Effluent Limitations and Standards
for the Plastics Molding and Forming Industry, EPA 440/2-84-001,
February 1984.
Option Selected. The Agency is proposing Option 2 as the model
technology basis for BPT effluent limitations guidelines for the
contact cooling and heating water subcategory. There are 65
processes in the contact cooling and heating water subcategory in
the questionnaire data base with flow rates of 50 gpm or less
that report 100 percent recycle. Further, those plants reported
that the only wastes from this technology result from occasional
cleaning of the recycle units (i.e., once every one to two
years).
The proposed BPT effluent limitations guidelines for processes
with an average process water usage flow rate of 35 gpm or less
require zero discharge of the wastewater. The "average process
water usage flow rate" is the volume of process water used per
year by a process divided by the total time per year the process
operates. The "average process water usage flow rate" for a
plant with more than one PM&F process that uses contact cooling
and heating water is the sum of the "average process water usage
flow rates" for each of these processes. The sum of the average
233
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process water usage flow rates determines if a plant has pro-
cesses in the contact cooling and heating water subcategory with
an average process water usage flow rate less than, equal to, or
greater than 35
The proposed BPT effluent limitations guidelines for processes
with an average process water usage flow rate greater than 35 gprn
are based on recycle through a cooling tower and treatment of the
recycle unit discharge in a package activated sludge plant. The
activated sludge process is only demonstrated at integrated
treatment facilities that treat PM&F wastewater combined with
wastewater discharged by other industrial processes. Treatment
at plants that discharge PM&F wastewater separately is uniformly
inadequate because these plants indicated that they use only
sedimentation and oil skimming, which does not remove dissolved
pollutants. Activated sludge technology has been demonstrated
in other categories to effectively treat the conventional pollu-
tants that are in PM&F wastewater. In particular, the activated
sludge process has been demonstrated in the organic chemicals,
plastics, and synthetic fibers category. Therefore, the acti-
vated sludge process and conventional pollutant performance data
for that process were transferred from the organic chemicals,
plastics, and synthetic fibers category to the PM&F category.
The Agency estimates that the proposed BPT effluent limitations
guidelines for this subcategory result in the removal of approxi-
mately 7.4 million kilograms of conventional pollutants per year,
21.5 million kilograms per year of nonconventional pollutants,
and 99,000 kilograms per year of priority toxic pollutants from
the raw wastes. The estimated investment costs and total annual
costs in 1982 dollars for the proposed BPT effluent limitations
guidelines are $15.2 million and $9.4 million, respectively. The
Agency has determined that the effluent reduction benefits asso-
ciated with compliance with BPT justify the costs.
The Agency has concluded that the increased production of solid
wastes caused by the implementation of the proposed BPT will not
cause any significant negative environmental impact. Increased
electrical engery usage will be insignificant. Support for these
conclusions is presented in Section IX of this document.
Cleaning and Finishing Water Subcategory
The Agency identified three technology options for the basis for
the proposed BPT effluent limitations guidelines for the cleaning
and finishing water subcategory. These options are based on
technologies described earlier in this section.
234
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Option 1:
The technology for this option consists of a sedimentation tank
in which the velocity of the wastewater is reduced so that solid
material can settle by gravitational force. Acidic or basic
material is added to either the tank influent or the tank
effluent to adjust the pH of the wastewater. The Option 1
technology is represented in Figure X-4.
Option 2:
This option consists of recycle through a sedimentation tank and
treatment of the discharge from the recycle unit in a package
activated sludge plant. The package plant includes an equaliza-
tion unit and pH adjustment. A sedimentation tank is used to
remove the suspended solids and oil and grease in the process
water so that the water can be recycled. Suspended solids and
oil and grease are found in high concentrations in cleaning and
finishing water. The Option 2 technology is represented in
Figure X-5.
Option 3:
Option 3 consists of recycle through a sedimentation tank and
contract haul of the discharge from the recycle unit. A sedimen-
tation tank is used to remove the suspended solids and oil and
grease in the process water so that the water can be recycled.
The Option 3 technology is represented in Figure X-6.
The estimated amounts of pollutants remaining for each technology
option are:
Discharged Remaining Remaining Remaining
in After After After
Type of Raw Water Option 1 Option 2 Option 3
Pollutant (kg/yr) (kg/yr) (kg/yr) (kg/yr)
Conventional 711,600 286,600 68,440 0
Nonconventional 939,200 413,600 134,680 0
Priority Toxic 890 633 104 0
The methodology used to calculate the pollutant removals for each
option are presented in Appendix C.
The estimated investment cost and annual pollution control costs
for BPT Options 1, 2, and 3 are:
235
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Cost ($million> 1982 dollars)
Option 1 Option 2 Option 3
Investment Costs 1.4 2.0 1.2
Annual Pollution Control Costs* 1.0 1.5 6.0
*Without water savings.
Detailed information on these costs are presented in Economic
Impact Analysis of Proposed Effluent Limitations and Standards
for the Plastics Molding and Forming Industry, EPA 440/2-84-001,
February 1984.
Option Selected. The Agency is proposing Option 2 as the tech-
nology basis for the BPT effluent limitations guidelines for this
subcategory. Thirteen percent of the cleaning and finishing pro-
cesses in the questionnaire data base recycle process water.
End-of-pipe treatment for cleaning and finishing water is uni-
formly inadequate because PM&F plants treating only PM&F waste-
water indicated that they currently use only sedimentation and
oil skimming, which does not treat dissolved pollutants (i.e.,
biochemical oxygen demand). Therefore, the activated sludge
process and conventional pollutant effluent data for that process
were transferred from the organic chemicals, plastics, and
synthetic fibers category to this subcategory.
The Agency estimates that the proposed BPT effluent limitations
guidelines result in the removal of 643,000 kilograms per year of
conventional pollutants, 804,000 kilograms per year of nonconven-
tional pollutants, and 786 kilograms per year of priority pollu-
tants from the raw waste. The estimated total investment costs
and total annual costs for the proposed BPT effluent limitations
guidelines are $2.0 million and $1.5 million, respectively. The
Agency has determined that the costs are justified by the efflu-
ent reduction benefits.
The Agency has concluded that the increased production of solid
wastes caused by the implementation of the proposed BPT will not
cause any significant negative environmental impact. Increased
electrical energy usage will be insignificant. Support for these
conclusions is presented in Section IX of this document.
REGULATED POLLUTANTS OR POLLUTANT PROPERTIES
Pollutants or pollutant properties were selected for regulation
in the plastics molding and forming subcategories because of
their frequency of occurrence and concentration in PM&F waste-
waters. Biochemical oxygen demand, total suspended solids, oil
and grease, and pH are controlled in the proposed regulation for
each subcategory.
239
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Biochemical oxygen demand (6005) was found in contact cooling
and heating water at concentrations up to 1,000 mg/1. Its pres-
ence was detected in cleaning and finishing water at concentra-
tions up to 540 mg/1. BOD5 is a parameter widely used to
determine the organic content of wastewater. BOD^ is also an
important control parameter for the activated sludge treatment
process; the reduction of BOD5 indicates an overall reduction
of organic pollutants.
Total suspended solids were found in contact cooling and heating
water at concentrations up to 104 mg/1. TSS was found Ln clean-
ing and finishing water at concentrations up to 16,400 ing/1.
Oil and grease was detected in contact cooling and heating water
at concentrations up to 73 mg/1 and in cleaning and finishing
water at concentrations up to 684 mg/1.
For protection of aquatic life and human welfare, pH of waste-
water should be between 6.0 and 9.0. The pH of PM&F wastewater
is regulated because the pH of contact cooling and heating water
was found to range between 5.4 and 8.3 and the pH of cleaning and
finishing water was found to range between 1.6 and 11.5.
The Agency proposes to establish effluent limitations guidelines
for biochemical oxygen demand, total suspended solids, oil and
grease, and pH. The Agency estimates that when these limitations
are met approximately 79 percent of the amount of noncoriventional
pollutants discharged by PM&F processes and approximately 80 per-
cent of the amount of priority toxic pollutants discharged will
be removed. These estimates are based on removal percentages
reported in the literature and previous EPA studies for the non-
conventional and priority toxic pollutants. The nonconventional
and priority toxic pollutants in PM&F wastewater are listed in
Table VII-5.
Although the proposed model treatment technology removes approxi-
mately 79 percent of the amount of nonconventional pollutants in
PM&F wastewater, a substantial amount of these pollutants remain
in the discharge. The Agency estimates that the remaining amount
of nonconventional pollutants results in a discharge of approxi-
mately 48 kilograms per day per direct discharger in this sub-
category. The impact of this amount is not known. For this
reason, the Agency plans to study the nonconventional pollutants,
particularly bulk organic parameters such as chemical oxygen
demand and total organic carbon. Depending on the results of
that work, the Agency may consider additional controls for the
nonconventional pollutants.
240
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EFFLUENT CONCENTRATION VALUES
The activated sludge treatment process is the end-of-pipe treat-
ment technology selected as BPT for both subcategories. The
activated sludge process and performance data for that process
were transferred from the organic chemicals, plastics, and
synthetic fibers category because wastewater generated by
processes in that category and PM&F wastewater had similar
conventional pollutant characteristics.
The transfer of the activated sludge process was analyzed by
comparing the sampling data obtained during the sampling program
for this project to process wastewater data from the organic
chemicals, plastics, and synthetic fibers category, particularly
the plastics only subcategory. That comparison showed that the
raw wastewater for the two categories have similar characteris-
tics. Specifically, data on raw waste concentrations of BOD^,
TSS, and oil and grease were examined statistically. A detailed
report on the statistical analysis is presented in Appendix D.
Results of that analysis show that the concentrations for these
pollutants in PM&F wastewater are neither significantly greater
nor more variable than the concentrations of those pollutants in
wastewater generated by processes at plants that manufacture
plastics. This supports the Agency's technical judgment that the
activated sludge process will treat PM&F wastewater effectively
and achieve the conventional pollutant effluent concentrations
achieved by activated sludge processes that treat wastewater
generated by processes at plastics manufacturing plants in the
organic chemicals, plastics, and synthetic fibers category. The
Agency's judgment that the activated sludge process will treat
PM&F wastewater was based on the literature and knowledge of the
performance of the activated sludge process.
Thus, the Agency transferred the activated sludge technology and
treated effluent data for that technology from the organic
chemicals, plastics, and synthetic fibers category to the PM&F
category. Effluent concentration values were transferred for
biochemical oxygen demand, total suspended solids, and oil and
grease. The transferred effluent concentration values are:
Maximum Maximum Monthly
Concentration Average
for One Day Concentration
Pollutant (mg/1) (mg/1)
BOD5 49 22
Oil and Grease 71 17
TSS 117 36
241
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The concentration values were used to calculate the mass based
effluent limitations guidelines for both subcategories.
BPT PRODUCTION NORMALIZED FLOWS
The BPT model treatment technologies for this category (Option 2
for both subcategories) reflect the water use controls currently
used by plants in the PM&F category. BPT production normalized
flows were established to relate the quantity of wastewater dis-
charged to a unit of production. When the quantity of wastewater
discharged is expressed as a volume per unit of production,
wastewater discharged by different sized processes can be com-
pared on an equal basis.
Contact Cooling and Heating Water Subcatgory
Production Normalizing Parameter. The production normalizing
parameter used to calculate the production normalized flows in
the contact cooling and heating water subcategory is mass of
plastic material processed. Mass of plastic material processed
was chosen as the normalizing parameter because in a cooling or
heating process the volume of cooling or heating water required
is directly related to the mass of plastic material processed.
The quantity of heat transferred from or to plastic material upon
cooling or heating under isobaric conditions can be expressed as:
f'2
Q = nr / Cp dT (Faires & Simmang)
where: Q = quantity of heat transferred
m = mass of plastic material processed
Cp = heat capacity of the material
T = temperature.
Thus the quantity of heat transferred, Q, is directly related to
the mass of plastic material processed, m.
The basic thermodynamic equation stated above is universal. It
can also be used to describe the quantity of heat transferred to
or from the contact cooling or heating water. The mass of cool-
ing or heating water required is directly related to the quantity
of heat to be supplied or removed by the water. Because the
quantity of heat transferred to the water is equal to the quan-
tity of heat transferred from the plastic material, the mass of
cooling or heating water required is directly related to the mass
of plastic material processed. Assuming the density of water is
constant, the volume of cooling or heating water required is also
directly related to the mass of plastic material processed.
242
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Examination of Discharge Flow Rates. To establish a baseline on
which to compare processes in the contact cooling and heating
water subcategory, the volume of water discharged by each process
in the data base for this subcategory was divided by the mass of
plastic material processed by that process. Individual produc-
tion normalized flows for each process were thus established in
terms of liters per metric ton (kkg) of plastic material
processed.
The production normalized flows for the processes in the contact
cooling and heating water subcategory exhibited some variability.
Processes with production normalized flows in both the low end
and high end of the spectrum were examined for factors that would
explain why they were either high or low. Particular attention
was given to the production process employed, such as molding,
extrusion of profiles and extrusion of wire and cable coating.
No trend was found among different processes indicating different
water use requirements. The types of plastic material processed
were also examined. There was nothing to indicate that the type
of plastic material processed influenced the quantity of water
discharged. Thus, the Agency concluded that the quantity of
cooling or heating water used is independent of the type of pro-
cess or type of plastic material processed. The only factor that
had a distinguishable bearing on the quantity of process water
discharged was the use of recycle units. As would be expected,
processes that recycled contact cooling and heating water dis-
charged less process water per metric ton of plastic material
processed than processes that do not recycle process water.
BPT Production Normalized Flows. The proposed BPT for processes
in the contact cooling and heating water subcategory with an
average process water usage flow rate of 35 gpm or less is 100
percent recycle. The BPT production normalized flow for these
processes is zero because no process water is discharged.
The proposed BPT for processes in the contact cooling and heating
water subcategory with an average process water usage flow rate
greater than 35 gpm is based on recycle of process water. The
BPT production normalized flow for these processes is the average
of the best production normalized flows for processes in the data
base that recycle process water.
The average of the best was calculated by averaging production
normalized flows for processes with recycle percentages between
90.0 and 99.9 percent (i.e., 48 of the 183 processes in the data
base that recycle process water). Ninety-five of the other 135
processes were not used to calculate the average because they
either had an average process water usage flow rate of 35 gpm or
less and thus, are controlled by effluent limitations guidelines
based on zero discharge (i.e., 100 percent recycle) or had a
recycle percentage below 90.0. The remaining 40 of the 135
243
-------
processes with an average process water usage flow rate greater
than 35 gpm were not used because the Agency is uncertain about
their reported recycle percentage of 100 percent. Most of those
processes indicated they achieved 100 percent recycle using a
cooling tower. The Agency questions whether 100 percent recycle
can be achieved using a cooling tower. When a cooling tower is
used to recycle water there is necessarily a discharge from the
cooling tower even though no discharge was shown in the
questionnaire.
The 48 processes that have an average process water usage flow
rate greater than 35 gpm and that recycle between 90.0 percent
and 99.9 percent of the process water are presented in Table X-1.
The average production normalized flow for these processes was
calculated by dividing the total volume of process water dis-
charged per year from these processes by their total annual
production. The average production normalized flow for these
processes is 1,589 1/kkg. This value is the BPT production nor-
malized flow for processes in the contact cooling and heating
water subcategory with average process water flows above 35 gpm.
The Agency compared the BPT production normalized discharge flow
of 1,589 1/kkg to the production normalized discharge flows of
the recycle processes in the data base. All of these processes
either have production normalized discharge flows below the BPT
production normalized flow or can reduce their flows to the BPT
production normalized flow by increasing their recycle rates
within demonstrated limits.
Cleaning and Finishing Water Subcategory
Production Normalizing Parameter. Before a regulatory flow
allowance was established for processes in the cleaning and
finishing water subcategory a production normalizing parameter
for the subcategory was chosen. Number of products processed,
surface area of material processed, and mass of plastic material
processed were considered as possible production normalizing
parameters.
The number of products processed was examined as a possible
production normalizing parameter. However, using the number of
products processed as a production normalizing parameter does not
account for the variations in size and shape of molded and formed
products. The cleaning or finishing of a large product does not
require the same amount of water needed to clean or finish a
small product. Therefore, the Agency concluded that the number
of products processed is not an appropriate production normal-
izing parameter.
Surface area was considered as a production normalizing parameter
for processes in the cleaning and finishing water subcategory.
244
-------
Table X-1
RECYCLE PROCESSES* USED TO CALCULATE
BPT PRODUCTION NORMALIZED FLOWS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Plant I.D.
3070
10781
10377
10376
833131K
3200
362544N
653769Y
653769AA
653769Z
76001A
3210
30
391771E
500
833131F
581
10371
510
10460
10791
1550
581
582
644737WW
280
275857
1945
4015940
10280
644737BB
958218G
958218B
1060
120
731687A
580
940
833131A
250
330
1945
10780
10780
2670
10000021
10720
644737BB
Production
(kkg/yr)
2,187
2,291
3,025
1,653
2,722
27,032
1,497
2,359
5,443
953
1,406
10,478
2,
11
,097
,902
2,412
12,701
17,533
1,665
,985
68,000
3,047
142
17,533
14,269
4,445
34,700
3,
5,
3.
21 ,
21
,402
,977
,039
,106
,221
2,495
7,504
14,866
1,858
3,428
13,918
5,718
30,495
12,076
2,744
1
031
348
523
798
738
513
41
Water Used
(l/yr)
227,572,597
14,200,000
88,600,000
46,600,000
95,468,394
8,759,671 ,247
141,770,000
104,360,000
275,960,000
51,515,403
388,080,000
1,364,855,988
5,905,224
1,143,072,000
307,680,000
142,090,000
583,780,000
76,900,000
741,710,000
5,360,000,000
59,000,000
62,079,018
651,920,000
1,307,100,000
572,350,000
373,940,000
340,690,000
183,000,000
380,430,000
753,000,000
2,697,900,000
122,650,000
379,520,000
1,007.300,000
97,163,647
587,380,000
1,479,900,000
583,900,000
3,372,800,000
883,970,000
385.510,000
275,000,000
48,100,000
72,100,000
380,309,693
270,480,000
102,000,000
102,700,000
Percent
Recycle
99.9
99.8
99.9
99.9
99.9
99.9
99.9
99.9
99.9
99.9
99.9
99.9
96.7
99.9
99.9
99
99.7
99.7
99.9
99.6
98
99.9
98
99.1
99.3
91.5
99
95.8
98.6
95.3
98.7
96.3
95.5
96.5
95.4
98
96
95.7
95
92
95
95.8
91.4
91.4
91.3
91.6
93
99
Water
Discharged
d/yr)
18,805
23,700
28,600
38,000
75,708
844,114
49,210
43,154
123,026
757
1 1 1 , 000
935,000
194,811
1,180,000
245,521
1,362,744
1,945,998
250,000
741,643
19,500,000
1,160,000
62,338
9,729,992
11,675,991
3,815,693
31,860,955
3,936,816
7,550,000
5,034,393
35,400,000
35,961,300
4,504,626
17,072,154
35,714,795
4,469,145
11,197,213
59,158,352
25,794,018
168,637,350
69,445,434
19,194,412
11,400,000
4,140,000
6,210,000
9,652,530
22,712,400
7,120,000
1,369,395
Production
Normalized
Flow
(1/kkg)
9
10
10
23
28
31
33
46
52
56
79
89
93
99
102
110
111
150
186
292
380
439
555
818
858
918
1 ,152
1,260
1 ,657
1,680
1,695
1,813
2,276
2,402
2,406
3,266
4,251
4,511
5,530
5,759
6,995
1 1 , 1 00
11 ,900
11 ,900
12,105
13,068
13,900
33,073
*Processes in project data base.
245
-------
The Agency believes there may be a correlation between the volume
of cleaning and finishing water used and the surface area of
plastic product cleaned or finished. However, records of the
area of the plastic product cleaned or finished are generally not
kept by industry. In some cases, such as for cast or molded
complex shapes, surface area is very difficult if not impossible
to determine. For these reasons, surface area is an inappropri-
ate production normalizing parameter for the cleaning and finish-
ing water subcategory.
Mass of plastic material processed was selected as the appropri-
ate production normalizing parameter for the cleaning and finish-
ing subcategory because even though data correlating mass of
pollutant discharged to mass of plastic materal processed are
limited, the Agency believes that the mass of pollutants gener-
ated is proportional to the mass of plastic material processed.
Additionally, the plastics molding and forming industry typically
maintains records on the basis of mass of plastic material
cleaned or finished.
Examination of Discharge Flow Rates. The proposed BPT for the
cleaning and finishing water subcategory is based on recycle.
Therefore, processes in the data base for the cleaning and
finishing water subcategory that currently recycle process water
were analyzed to establish regulatory flows for this subcategory.
To establish a baseline from which to compare the discharge flows
from the recycling processes, mass of plastic material processed
was used as the production normalizing parameter. The volume of
water discharged by each recycling process was divided by the
reported mass of plastic material processed in that process to
obtain a production normalized discharge flow in units of liters
per kilogram of plastic material processed. The production nor-
malized flows for processes in this subcategory (i.e., product
cleaning, shaping equipment cleaning, and finishing) were
reviewed. As a result of this review, different BPT production
normalized flows were calculated for the washing and rinsing of
molded or formed parts and shaping equipment and the finishing of
products because based on questionnaire data the washing and
rinsing of molded or formed parts and shaping equipment requires
more water than the finishing of plastic products.
BPT Production Normalized Flows
Cleaning Water:
The BPT production normalized flow for cleaning processes is the
average production normalized flow for all cleaning processes in
the questionnaire data base that recycle cleaning water. Data
for these processes are presented in Table X-2. The BPT produc-
tion normalized flow was calculated by dividing the total quan-
tity of wastewater discharged by total mass of plastic material
246
-------
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processed by those processes. The BPT production normalized flow
for cleaning processes in the cleaning and finishing water sub-
category is 4,483 1/kkg. A cleaning process includes both deter-
gent washing and rinsing operations.
The Agency compared the BPT production normalized flow of 4,483
1/kkg to the production normalized discharge flows of the seven
processes that recycle cleaning water. Five of those processes
either have production normalized discharge flows below the BPT
production normalized flow or can reduce their flows to the BPT
production normalized flow by increasing their recycle rates
within demonstrated limits. Two processes will have to reduce
their process water usage flow rates to meet the BPT production
normalized flow.
Finishing Water:
The BPT production normalized flow for finishing processes is the
average production normalized flow for all finishing processes in
the questionnaire data base that recycle finishing water. Data
for these processes are presented in Table X-3. The BPT produc-
tion normalized flow was calculated by dividing the total quan-
tity of wastewater discharged by the total mass of plastic mater-
ial processed by those processes. The BPT production normalized
flow for finishing processes in the cleaning and finishing water
subcategory is 1,067 1/kkg. This BPT production normalized flow
is based on a limited number of data points. However, the Agency
believes the allowance is reasonable based on a comparison of
this PNF to the PNFs for finishing processes that currently recy-
cle process water.
All finishing processes that recycle process water have produc-
tion normalized discharge flows below the BPT production normal-
ized discharge flow or can reduce their flows to the BPT produc-
tion normalized flow by increasing their recycle rates within
demonstrated limits.
BPT EFFLUENT LIMITATIONS GUIDELINES
BPT effluent limitations guidelines were calculated by multiply-
ing the BPT production normalized flow by the BPT effluent
concentration values transferred from the organic chemicals,
plastics, and synthetic fibers category (see Appendix D). Both
one day maximum and monthly average concentration values were
transferred. The BPT effluent limitations guidelines are
presented below.
248
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Contact Cooling and Heating Water Subcategory
Contact cooling and heating water is process water that contacts
the raw materials or plastic product for the purpose of heat
transfer during the plastic molding and forming process.
Average Process Water Usage Flow Rate of 35 gpm or Less. For
processes with an average process water usage flow rate of 35 gpm
or less, the BPT production normalized flow is zero discharge.
Therefore, no wastewater pollutants can be discharged from these
processes.
Average Process Water Usage Flow Rate Greater Than 35 gpm. For
processes with an average process water usage flow rate greater
than 35 gpm, the BPT effluent limitations guidelines are:
Contact Cooling and Heating Water
BPT Effluent Limitations
Pollutant or
Pollutant Property
BOD5
Oil and Grease
TSS
PH
(1) Between 6.0 and 9.0.
Maximum For
Any One Day
(mg/kg)
78
113
186
Maximum For
Monthly Average
(mg/kg)
35
27
The effluent limitations guidelines are expressed as milligrams
of pollutant per kilogram of plastic material processed.,
Kilograms of plastic material processed when used to determine
effluent limitations guidelines are the mass of plastic material
that process water comes in contact with for cooling or heating
purposes. If the same unit mass of plastic undergoes more than
one molding and forming process (for example, it is compounded
and pelletized, extruded, and blow molded), the mass of plastic
material processed in each process is added to obtain the total
mass of plastic material processed.
Cleaning and Finishing Water Subcategory
Cleaning Water. Cleaning water is process water used to clean an
intermediate or final plastic product or to clean the surfaces of
product shaping equipment, such as molds and mandrels, that are
or have been in contact with the -plastic product. It includes
250
-------
water used in both the detergent wash and rinse cycles of a
cleaning process.
The mass of pollutants discharged by existing processes in the
cleaning and finishing water subcategory that use cleaning water
shall not exceed:
Cleaning Water
BPT Effluent Limitations
Maximum For Maximum For
Pollutant or Any One Day Monthly Average
Pollutant Property (mg/kg) (mg/kg)
BOD5 220 99
Oil and Grease 318 76
TSS 524 161
pH (T) (T)
(1) Between 6.0 and 9.0.
These effluent limitations guidelines are expressed as milligrams
of pollutant per kilogram of plastic material processed. Kilo-
grams of plastic material processed when used to determine efflu-
ent limitations guidelines are the mass of plastic material that
process water comes in contact with for product cleaning pur-
poses. For the purpose of calculating limitations for water used
to clean shaping equipment, such as molds and mandrels, mass of
plastic material processed refers to the mass of plastic material
that was molded or formed by the shaping equipment being cleaned.
These discharge allowances apply to the combined discharge from
the detergent wash and rinse cycle of a cleaning process.
Separate allowances are not given for the wash and rinse cycles.
Finishing Water. Finishing water is process water used to remove
waste plastic material generated during a finishing process or to
lubricate a plastic product during a finishing process. It
includes water used to machine, to decorate, or to assemble
intermediate or final plastic products.
The mass of pollutants discharged by existing processes in the
cleaning and finishing water subcategory that use finishing water
shall not exceed:
251
-------
Finishing Water
BPT Effluent Limitations
Maximum For Maximum For
Pollutant or Any One Day Monthly Average
Pollutant Property (mg/kg) (mg/kg)
BOD5 52 23
Oil and Grease 76 18
TSS 125 38
pH (T) (T)
(1) Between 6.0 and 9.0.
These effluent limitations are expressed as milligrams of pollu-
tant per kilogram of plastic material processed. Kilograms of
plastic material processed are the mass of plastic material that
process water comes in contact with for finishing purposes.
EXAMPLE OF THE APPLICATION OF THE BPT EFFLUENT LIMITATIONS
GUIDELINES
The purpose of the BPT effluent limitations guidelines is to pro-
vide a uniform basis for regulating wastewater discharged from
processes in the plastics molding and forming category. For
direct dischargers, this is accomplished through NPDES permits.
The plastics molding and forming category is regulated on an
individual wastewater flow "building block" approach. An example
that illustrates how the effluent limitations guidelines are used
to determine the amount of pollutants that can be discharged from
plastics molding and forming plants is presented below.
Example
Plant X compounds and pelletizes 1,250,000 kilograms of polyethy-
lene per year. The pelletizing process uses contact cooling
water. Thirty percent of this amount is then extruded in a
process using contact cooling water; the remainder is processed
by injection molding in a process that uses non-contact cooling
water. The injection molds are cleaned with process water.
Fifty percent by weight of the injection molded plastic parts are
trimmed in a finishing process that uses process water. The
average process water usage flow rate for the pelletizing process
is 65 gpm; the average process water usage flow rate for the
extrusion process is 20 gpm. The plant operates 250 days per
year.
252
-------
The daily production from the compounding and pelletizing process
is 1,250,000 kg/year divided by 250 days/year or 5,000 kg/day.
Thirty percent of this amount, or 1,500 kg/day, is extruded in a
process using contact cooling water; 3,500 kg/day is injection
molded; and the injection molds in which 3,500 kg/day of plastic
material are molded are washed. Of the injection molded parts,
1,750 kg/day are trimmed in a finishing process.
Plant X processes 5,000 kg/day of polyethylene in a pelletizing
process using contact cooling water and 1,500 kg/day of
polyethylene in an extrusion process using contact cooling and
heating water. These processes are regulated under the contact
cooling and heating water subcategory. The "average process
water usage flow rate" of contact cooling and heating water for
this plant is 65 gpm for the pelletizing process plus 20 gpm for
the extrusion process. Thus, the effluent limitations guidelines
for processes with an "average process water usage flow rate"
greater than 35 gpm apply.
Plant X cleans injection molds with process water; 3,500 kg/day
of polyethylene are shaped by these molds. This process is
regulated under cleaning in the cleaning and finishing water
subcategory. Plant X trims 1,750 kg/day of polyethylene in a
process using process water. This process is regulated under
finishing in the cleaning and finishing water subcategory. Table
X-4 illustrates the calculation of the allowable discharge of
BOD5 for this plant.
253
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SECTION XI
BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
The factors considered in assessing best available technology
economically achievable (BAT) include the age of equipment and
facilities involved, the process employed, process changes, non-
water quality environmental impacts (including energy require-
ments) and the costs of applying such technology (Section 304(b)
(2)(B) of the Clean Water Act). At a minimum, the BAT technology
level represents the best economically achievable performance of
plants of various ages, sizes, processes, or other shared
characteristics. As with BPT, where the Agency has found the
existing performance to be uniformly inadequate, BAT may be
transferred from a different subcategory or category. BAT may
include feasible process changes or internal controls even when
not common industry practice.
The required assessment of BAT "considers" costs, but does not
require a balancing of costs against effluent reduction benefits
(See, Weyerhaeuser v. Costie, supra). In developing BAT,
however, EPA gave substantial weight to the reasonableness of
cost. The Agency considers the volume and nature of discharges
expected after application of BPT, the general environmental
effects of the pollutants, and the costs and economic impacts of
the additional pollution control levels.
Despite this expanded consideration of costs, the primary deter-
minant of BAT is effluent reduction capability. As a result of
the Clean Water Act of 1977, the achievement of BAT has become
the principal national means of controlling toxic pollutants.
The wastewaters generated by PM&F processes contain 28 priority
toxic pollutants that were considered for control including eight
toxic metals and 20 toxic organics.
Contact Cooling and Heating Water Subcategory
The Agency considered two technology options as the basis for the
proposed BAT effluent limitations guidelines. These options,
which are the same as BPT Option 2 and BPT Option 3 for this
subcategory, are:
Option 1:
For processes with an average process water usage flow rate of 35
gpm or less - Zero discharge by 100 percent recycle of the pro-
cess water using either a. tank or chiller.
255
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For processes with an average process water usage flow rate
greater than 35 gpm - Recycle through a cooling tower and treat-
ment of the recycle unit discharge in a package activated sludge
plant. An equalization tank is included as part of the package
plant.
Option 2:
For processes with an average process water usage flow rate of 35
gpm or less - Zero discharge by 100 percent recycle of the waste-
water through either a tank or chiller.
For processes with an average process water usage flow rate
greater than 35 gpm - Recycle through a cooling tower and zero
discharge by contract haul of the discharge from the recycle
unit.
The Agency is not proposing BAT effluent limitations guide-
lines more stringent than the proposed BPT effluent limitations
guidelines for this subcategory because there are insignificant
quantities of toxic pollutants remaining in contact cooling and
heating water after compliance with the applicable BPT effluent
limitations guidelines. As previously discussed, the proposed
BPT model technology (BPT Option 2) achieves significant removal
of toxic pollutants present in contact cooling and heating water.
Of the estimated 124,000 kilograms per year of toxic pollutants
currently discharged by direct dischargers in this subcategory,
99,000 kilograms per year of these pollutants will be removed by
compliance with the proposed BPT effluent limitations guidelines.
Thus, 25,000 kilograms per year of toxic pollutants will be dis-
charged after application of the BPT effluent limitations guide-
lines. This discharge equates to approximately 0.20 kilograms
per day of toxic pollutants per direct discharger in this sub-
category. Table XI-1 lists the estimated amount of the 26 toxic
pollutants found in contact cooling and heating water that would
be discharged per year by direct dischargers in this subcategory
after BPT treatment. Also shown on that table are the average
concentrations of the toxic pollutants in wastewater after BPT
treatment. The Agency believes that the amount and toxicity of
these pollutants do not justify establishing more stringent BAT
effluent limitations guidelines for the toxic pollutants.
Accordingly, EPA is proposing to exclude these pollutants from
further national regulation under Paragraph 8(a)(i) of the
Settlement Agreement in NRDC v. Train, supra.
EPA estimates that 79 percent of the projected 27,243,000 kilo-
grams per year of nonconventional pollutants in contact cooling
and heating water will be removed when plants in the PM&F cate-
gory comply with the BPT effluent limitations guidelines. The
remaining amount of nonconventional pollutants results in a
256
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Table XI-1
AMOUNT AND CONCENTRATION OF TOXIC POLLUTANTS IN
WASTEWATER AFTER BPT TREATMENT
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Priority Pollutant
4. benzene
6. carbon tetrachloride
(tetrachloromethane)
11. 1,1,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
65. phenol
66. bis(2-ethylhexyl)
phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE
100. heptachlor
102. a-BHC
103. 3-BHC
104. Y-BHC
105. 6-BHC
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
128. zinc
Estimated Amount
Remaining After
BPT Treatment
(kg/yr)
850
9,300
950
691
280
390
73
10,320
1
610
1,
37
6.8
2.3
0.07
0.9
4
1.7
0.95
3.6
16
60
23
230
0.005
158
460
Average Concen-
tration After
BPT Treatment
(mg/1)
0.010
0.318
0.010
0.025
0.010
0.010
0.025
0.200
0.010
0.010
0.010
0.252*
0.041*
0.044*
0.030*
0.056*
0.176*
0.074*
0.050*
0.004
0.012
0.041
0.042
0.0001
0.446
0.044
257
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discharge of approximately 48 kilograms per day per direct dis-
charger in this subcategory. The impact of this amount is not
known. Therefore, EPA will investigate the nonconventional
pollutants, particularly TOG and COD, between this proposal and
promulgation of the PM&F regulation to determine what contributes
to those pollutants (e.g., a toxic pollutant). Additional con-
trols may be imposed for the nonconventional pollutants depend-
ing on the results of that investigation.
As previously discussed, the 35 gpm cut-off for the selected
BPT/BAT option is the average flow rate of the eight processes
with the best flow rates that recycle 100 percent of the process
water using a chiller. Information obtained from the question-
naire surveys for this project indicate that processes with flow
rates as high as 500 gpm can recycle 100 percent of the process
water using a chiller. The Agency will evaluate that information
further to see if the 35 gpm cut-off should be higher under BAT
when the final regulation is promulgated.
Cleaning and Finishing Water Subcategory
The Agency considered two technology options for the basis for
the BAT effluent limitations guidelines for this subcategory.
These options, which are the same as BPT Option 2 and BPT Option
3 for this subcategory, are:
Option 1:
This option consists of recycle through a sedimentation tank and
treatment of the discharge from the recycle unit in a package
activated sludge plant. The package plant includes an equaliza-
tion unit and pH adjustment. A sedimentation tank is used to
remove the suspended solids in the wastewater so that the waste-
water can be recycled.
Option 2:
Option 2 consists of recycle through a sedimentation tank for all
processes and contract haul of the discharge from the recycle
unit.
The Agency is not proposing BAT effluent limitations guidelines
more stringent than the proposed BPT effluent limitations guide-
lines for this subcategory because there are insignificant
quantities of priority toxic pollutants remaining in cleaning and
finishing water after compliance with the proposed applicable BPT
effluent limitations guidelines. The Agency estimates that
compliance with the BPT effluent limitations guidelines results
in the removal of 786 kilograms per year of toxic pollutants from
the current discharge of 890 kilograms per year toxic pollutants
by plants in this subcategory. Thus, 104 kilograms per year of
258
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toxic pollutants would be discharged after application of the
proposed BPT effluent limitations guidelines. This equates to
less than 0.01 kilograms per day of toxic pollutants per direct
discharger. Table XI-2 lists the estimated amount of the 17
toxic pollutants found in cleaning and finishing water that would
be discharged per year by direct dischargers in this subcategory
after BPT treatment. Also shown on the table is the average
concentration of the toxic pollutants after BPT treatment. The
Agency has determined that the amount and toxicity of these pol-
lutants do not justify establishing more stringent BAT effluent
limitations guidelines for toxic pollutants. Accordingly, EPA is
proposing to exclude these pollutants from further national regu-
lation under Paragraph 8(a)(i) of the Settlement Agreement in
NRDC v. Train, supra.
EPA estimates that 86 percent of the 939,200 kilograms per year
of nonconventional pollutants in cleaning and finishing water
will be removed when plants comply with the BPT effluent limita-
tions guidelines. The remaining amount of nonconventional pollu-
tants result in a discharge of approximately one kilogram per day
per direct discharger in this subcategory. The Agency will
investigate what contributes to the nonconventional pollutants to
determine if additional controls for these pollutants are needed
when the final BAT effluent limitations guidelines are
promulgated.
259
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Table XI-2
AMOUNT AND CONCENTRATION OF TOXIC POLLUTANTS
AFTER BPT TREATMENT
CLEANING AND FINISHING WATER SUBCATEGORY
Priority Pollutant
4. benzene
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl)
phthalate
86. toluene
89. aldrin
100. heptachlor
102. a-BHC
104. Y-BHC
105. 6-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
Amount
Remaining After
BPT Treatment
(kg/yr)
0.20
4
40
4
1
10
0.14
0.14
<0.01
<0.01
0.10
0.12
2.3
3
6.5
0.38
32
Average Concen-
tration After
BPT Treatment
(mg/1)
0.01
0.01
0.01
0.01
0.025
0.059
0.010
0.041*
0.003*
0.002*
0.300*
0.052*
0.007
0.024
0.034
0.075
0.380
260
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SECTION XII
NEW SOURCE PERFORMANCE STANDARDS
The basis for new source performance standards (NSPS) under
Section 306 of the Act is the best available demonstrated tech-
nology. New plants have the opportunity to design and use the
best and most efficient plastics molding and forming processes
and wastewater treatment technologies without facing the added
costs and restrictions encountered in retrofitting an existing
plant. Therefore, Congress directed EPA to consider the best
demonstrated process changes, in-plant controls, and end-of-
pipe treatment technologies that reduce pollution to the
maximum extent feasible when developing NSPS.
TECHNICAL APPROACH TO NSPS
The Agency believes that characteristics of wastewater dis-
charged by new PM&F processes in each subcategory will be the
same as the characteristics of wastewater discharged by existing
PM&F processes in those subcategories. Thus, the treatment
options considered for new sources in each subcategory are the
same as those considered for existing sources. These options are
outlined in the BPT section of this development document.
NSPS OPTION SELECTION
The Agency is proposing NSPS based on the same model treatment
technologies as the proposed BPT effluent limitations guidelines
in each subcategory (BPT Option 2). EPA is not proposing NSPS
more stringent than the effluent limitations guidelines for
existing sources because the amount and toxicity of the priority
toxic pollutants remaining after treatment in the BPT/BAT model
treatment technologies for each subcategory do not justify more
stringent controls. See Tables XI-1 and XI-2 in the BAT section
of this development document. The proposed NSPS technology basis
for each subcategory are:
Contact Cooling and Heating Water Subcategory
For processes in the contact cooling and heating water subcate-
gory with an average process water usage flow rate of 35 gpm or
less the technology basis of NSPS is zero discharge. For pro-
cesses with an average process water usage flow rate equal to or
less than 0.3 gpm, zero discharge is achieved with a product
quench tank of proper surface area to allow for sufficient heat
transfer to the surrounding environment. For processes with an
average process water usage flow rate for flows greater than 0.3
gpm and less than or equal to 35 gpm, the zero discharge technol-
ogy basis is a chiller system with 100 percent recycle. The
chiller recycle system is depicted in Figure XII-1.
261
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For flows above 35 gpm, the technology basis of NSPS is a recycle
through a cooling tower and treatment of the recycle unit dis-
charge in an end-of-pipe treatment system consisting of equaliza-
tion followed by a package activated sludge plant. Figure XII-2
illustrates this technology.
The 35 gpm cut-off was used for NSPS for the same reasons it was
used for the BPT/BAT technology options. As discussed in Section
XI, the Agency will consider using a higher flow cut because
information from the questionnaire surveys indicates that the
recycle unit used to achieve 100 percent of the process water may
be used for flows up to 500 gpm.
Cleaning and Finishing Water Subcategory
The NSPS technology basis for the cleaning and finishing water
subcategory consists of a recycle through a sedimentation tank to
remove solids and floatable material. Sludge and scum that
accumulate in the tank are removed periodically by a contract
hauler. Recycle unit discharge flows to an equalization tank
where pH of the wastewater is controlled and is then treated in a
package activated sludge plant. A schematic of the NSPS technol-
ogy for the cleaning and finishing water subcategory is presented
in Figure XII-3.
Costs and Pollutant Removals for NSPS
The Agency conducted an economic analysis of the impact of the
proposed NSPS on new PM&F plants. The analysis was based on a
normal plant that contains four model processes. Each model
process represents one of the four segments of the category for
which technology options were developed. The model processes
consist of two processes that use contact cooling and heating
water and two processes that use cleaning and finishing water.
Two model processes were developed for the contact cooling and
heating water subcategory because that subcategory was subdivided
based on average process water usage flow rate (i.e., a 35 gpm
cut-off was used). Two model processes were developed for the
cleaning and finishing water subcategory because, as discussed in
Section IX, a cut-off of two gpm was used in this subcategory for
costing purposes. Even though the technology basis for NSPS for
all processes in the cleaning and finishing water subcategory is
flow reduction and treatment of the discharge from the recycle
unit, the technology basis for costing purposes for processes
with an average process water usage flow rate of two gpm or less
is flow reduction and contract haul of the recycle unit dis-
charge. This technology was costed for the low flow rate pro-
cesses because it is more economical than treatment of the
recycle unit discharge. The Agency believes that plastic molders
and formers will comply with the BPT effluent limitations guide-
lines in the least costly way.
263
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Thus, four model processes were chosen: one contact cooling and
heating water process with an average process water usage flow
rate greater than 35 gpm, one contact cooling and heating water
process with an average process water usage flow rate less than
35 gpm, one cleaning and finishing water process with an average
process water usage flow rate greater than two gpm, and one
cleaning and finishing water process with an average process
water usage flow rate less than two gpm. The actual flow rates
associated with the model processes are based on the median flow
rates of processes in the questionnaire data base. Those median
flow rates are presented in Table XII-1. The NSPS technology for
contact cooling and heating water processes with an average
process water usage flow rate of 35 gpm or less is depicted in
Figure XII-1; the technology for contact cooling and heating
water processes with a process water usage flow rate greater than
35 gpm is depicted in Figure XII-2. Figure XII-3 depicts the
NSPS technology for the cleaning and finishing water processes
with an average process water usage flow rate greater than two
gpm. These technologies are the same as the technologies for
existing sources.
Table XII-1
FLOW RATES FOR NSPS MODEL PROCESSES
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Model Process #1 (flows <35 gpm) 13 gpm
Model Process #2 (flows >35 gpm) 90 gpm
CLEANING AND FINISHING WATER SUBCATEGORY
Model Process #3 (flows <2 gpm) 0.8 gpm
Model Process #4 (flows >2 gpm) 16 gpm
The amount of pollutants in the raw wastewater of the model pro-
cesses are shown in Table XII-2. The pollutant removals for the
proposed NSPS technology for each of the model processes are
presented in Table XII-3. Data for existing sources were used to
estimate the percent removals.
266
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Table XII-2
POLLUTANT MASS IN RAW WASTE
FOR NSPS MODEL PROCESSES (kg/yr)
Pollutant
Conventional
Nonconventional
Priority Toxic
Contact Cooling and
Heating Water
Subcategory
Model
Process
18,800
57,400
261
Model
Process #2
30,100
91,900
418
Cleaning and Finishing
Water Subcategory
Model
Process #3
3,060
4,040
4
Mode]
Process #4
21,500
28,400
27
Table XII-3
ESTIMATED POLLUTANT REMOVALS
FOR NSPS MODEL PROCESSES (kg/yr)
Pollutant
Conventional
Nonconventional
Priority Toxic
Contact Cooling and
Heating Water
Subcategory
Model
Process #1
18,800
57,400
261
Model
Process #2
24,000
58,100
273
Cleaning and Finishing
Water Subcategory
Model
Process #3
3,060
4,040
4
Model
Process #4
19,700
23,800
23
The estimated investment cost and annual pollution control costs
for the proposed NSPS technology for each of the model processes
are presented in Table XI1-4. The average investment costs for
the normal plant is $26,070 and the average annual pollution
control costs for the normal plant is $10,900.
267
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Table XII-4
NSPS TREATMENT TECHNOLOGY COSTS PER MODEL PROCESSES
($ Million, 1982 Dollars)
Investment Cost
Annual Pollution
Control Costs
Contact Cooling and
Heating Water
Subcategory
Model
Process #
$10,200
$ 3,840
Model
Process #
$52,500
$20,072
Cleaning and Finishing
Water Subcategory
Model
Model
Process #3
$4,070
$3,702
Process #4
$37,500
$15,971
The data relied on for the economic analysis of NSPS were primar-
ily the data developed for existing sources, which includes costs
on a plant-by-plant basis along with retrofit costs where appli-
cable. The Agency believes that compliance costs could be lower
for new sources than costs for equivalent existing sources
because production processes can be designed to reduce the amount
of wastewater discharged and there would be no costs associated
with retrofitting a process. The Agency does not believe that
applying the proposed technology for NSPS to new sources, includ-
ing major modifications to existing sources, creates a barrier to
entry into the category because new sources will expend an amount
equal to, or possibly less than, the amount required by existing
sources to comply with this proposed regulation.
REGULATED POLLUTANTS AND POLLUTANT PROPERTIES
The Agency has no reason to believe that the pollutants that will
be found in significant quantities in PM&F wastewater from new
sources will be any different than pollutants found in wastewater
from existing sources. Consequently, pollutants selected for
regulation under NSPS are the pollutants controlled at: BPT for
each subcategory. They are: biochemical oxygen demand, total
suspended solids, oil and grease, and pH. Mass based NSPS are
being proposed for the same reasons that the BPT effluent limita-
tions guidelines are mass based (see Section X). The Agency
estimates that 79 percent of the nonconventional pollutants and
80 percent the toxic pollutants are removed when the NSPS for the
above pollutants are met.
NEW SOURCE PERFORMANCE STANDARDS
The regulatory production normalized flows and the activated
sludge effluent concentration values used to calculate NSPS are
268
-------
the same as those used at BPT for each subcategory. These efflu-
ent concentration values and production normalized flows for each
subcategory are discussed in more detail in Section X of this
development document.
NSPS were calculated by multiplying the NSPS regulatory produc-
tion normalized flow by the NSPS technology effluent concentra-
tion values.
Contact Cooling and Heating Water Subcategory
The effluent limitations guidelines and standards for this sub-
category are the mass of pollutant that may be discharged per
unit mass of plastic material processed by processes in the
contact cooling and heating water subcategory. Processes in the
contact cooling and heating water subcategory are processes in
which water contacts the plastic material for the purpose of heat
transfer. A discharge allowance is given each time water is used
for cooling or heating in a process. For example, if one unit
mass of plastic is extruded and then molded, and cooling water is
used in each process, the discharge allowance for a pollutant
would be based on the amount of plastic material processed in
both processes.
Average Process Water Usage Flow Rate of 35 gpm or Less. For
processes with an average process water usage flow rate of 35 gpm
or less, the regulatory production normalized flow is zero dis-
charge. Therefore, no wastewater pollutants shall be discharged
from these processes.
Average Process Water Usage Flow Rate Greater Than 35 gpm. For
processes with an average process water usage flow rate greater
than 35 gpm, NSPS are:
Contact Cooling and Heating Water
NSPS
Regulated Pollutant or
Pollutant Property
BOD5
Oil and Grease
TSS
pH
(1) Between 6.0 and 9.0.
Maximum For
Any One Day
(mg/kg)
78
113
186
Maximum For
Monthly Average
(mg/kg)
35
27
269
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The "average process water usage flow rate" of a process in gal-
lons per minute is equal to the volume of process water (gallons)
used per year by a process divided by the total time (minutes)
per year the process operates. The "average process water usage
flow rate" for a plant with more than one plastics molding and
forming process that uses contact cooling and heating water is
the sum of the "average process water usage flow rates" for those
plastics molding and forming processes. The "volume of process
water used per year" is the volume of process water that flows
through a process and comes in contact with the plastic product
over a period of one year.
Cleaning and Finishing Water Subcategory
The NSPS for this subcategory are the mass of pollutant that may
be discharged per unit mass of plastic material processed by
processes in the cleaning and finishing water subcategory. Pro-
cesses in the cleaning and finishing water subcategory are pro-
cesses that use process water to clean or finish plastic material
or processes that use process water to clean the surfaces of
product shaping equipment, such as molds and mandrels, that
contacted the plastic product. The mass of plastic material
processed by processes that use process water to clean or finish
plastic products is defined as the mass of plastic material
cleaned or finished. The mass of plastic material processed by
processes that use process water to clean shaping equipment is
defined as the mass of plastic that is processed in the shaping
equipment.
A discharge allowance is given each time water is used for clean-
ing or finishing in a distinct processing step. For example, if
one unit mass of plastic is washed with water and then polished
in a finishing process that uses process water, a discharge
allowance would be given for each process. Washing and then
rinsing is considered a single process step. Only one discharge
allowance is given for the wash and rinse operation.
Cleaning Water. Cleaning water is process water used to clean an
intermediate or final plastic product or to clean the surfaces of
product shaping equipment, such as molds and mandrels, that
contacted the plastic product. It includes water used in both
the detergent wash and rinse cycles of a cleaning process.
The mass of pollutants that can be discharged by PM&F processes
at new sources that use cleaning water is:
270
-------
Cleaning Water
NSPS
Regulated Pollutant or
Pollutant Property
BOD5
Oil and Grease
TSS
PH
(1) Between 6.0 and 9.0.
Maximum For
Any One Day
(mg/kg)
220
318
524
Maximum For
Monthly Average
99
76
161
Finishing Water. Finishing water is process water used to remove
waste plastic material generated during a finishing process or to
lubricate a plastic product during a finishing process. It
includes water used to machine, to decorate, or to assemble
intermediate or final plastic products.
The mass of pollutants that can be discharged by PM&F processes
at new sources that use finishing water is:
Finishing Water
NSPS
Regulated Pollutant or
Pollutant Property
BOD5
Oil and Grease
TSS
pH
(1) Between 6.0 and 9.0.
Maximum For
Any One Day
(mg/kg)
52
76
125
1
Maximum For
Monthly Average
(mg/kg) _
23
18
8
271
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SECTION XIII
PRETREATMENT STANDARDS
Section 307(b) of the Clean Water Act requires EPA to consider
pretreatment standards for existing sources (PSES) to be achieved
within three years of promulgation. PSES are designed to prevent
the discharge of pollutants that pass through, interfere with, or
are otherwise incompatible with the operation of publicly owned
treatment works (POTW). Congress directed that pretreatment
standards be technology based, analogous to the best available
technology for removal of toxic pollutants.
Section 307(c) of the Act requires EPA to consider whether to
establish pretreatment standards for new sources (PSNS) at the
same time that it establishes new source performance standards
for new direct dischargers. New indirect discharge facilities,
like new direct discharge facilities, have the opportunity to
incorporate the best available demonstrated technologies, includ-
ing process changes, in-plant controls, and end-of-pipe treatment
technologies, and to use plant site selection to ensure adequate
treatment system installation.
General Pretreatment Regulations for existing and new sources
were published in the Federal Register (Vol. 43, No. 123; June
26, 1978). These regulations (40 CFR Part 403) describe the
Agency's overall policy for establishing and enforcing cate-
gorical pretreatment standards for new and existing industrial
users of a POTW and delineate the responsibilities and deadlines
applicable to each party in this effort. In addition, Section
403.5(b) of 40 CFR Part 403 lists prohibited discharges that
apply to all users of a POTW.
Before proposing categorical pretreatment standards, the Agency
examines whether the toxic pollutants discharged by an industry
pass through the POTW or interfere with the POTW operation or its
chosen sludge disposal practices. In determining whether pollu-
tants pass through a POTW, the Agency compares the percentage of
a pollutant removed by POTWs to the percentage removed by direct
dischargers applying the best available technology economically
achievable. A pollutant is deemed to pass through the POTW when
the average percentage removed by well-operated POTWs meeting
secondary treatment requirements is less than the percentage
removed by direct dischargers complying with BAT effluent limi-
tation guidelines for that pollutant. For this category where
the Agency is proposing BAT equal to BPT, the Agency compared
POTW removals to BPT level removals.
273
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This definition of pass through satisfies two competing objec-
tives set by Congress: (1) that standards for indirect dis-
chargers be equivalent to standards for direct dischargers,
while, at the same time, (2) that the treatment capability and
performance of the POTW be recognized and taken into account in
regulating the discharge of pollutants from indirect dischargers.,
PRETREATMENT STANDARDS FOR EXISTING SOURCES
Contact Cooling and Heating Water Subcategory
BPT/BAT effluent limitations guidelines for PM&F processes in the
contact cooling and heating water subcategory with an average
process water usage flow rate greater than 35 gpm are based on
treatment in the activated sludge process. The Agency reviewed
performance data for that process and compared it to the perfor-
mance data of well operated publicly owned treatment works. The
comparison of activated sludge treatment performance to POTW
performance for contact cooling and heating water is shown in
Table XIII-1.
The sources of the performance data are referenced in the table.
Pass through occurs when the percent removal of a pollutant in
the BPT/BAT is greater than the percent removal Ln the POTW. As
can be seen from the data in the table, chloroform and methylene
chloride may pass through a POTW. However, the amount and toxic-
ity of these pollutants is such that the Agency does not believe
that additional pretreatment is necessary for the reduction of
these pollutants prior to indirect discharge. EPA estimates that
the amount of chloroform in contact cooling and heating water
discharged by indirect dischargers is 0.032 kg/plant per day.
The amount of methylene chloride discharged in contact cooling
and heating water is 0.037 kg/plant per day.
EPA believes that the methylene chloride concentration reported
for contact cooling and heating water is the result of laboratory
contamination. Methylene chloride is used in the laboratory to
prepare sample bottles, as a solvent in some extraction proce-
dures, and for other purposes. Therefore, the potential for a
sample to be contaminated in the laboratory with methylene
chloride is high. This high contamination potential supports
EPA's belief that methylene chloride is not in the process water
and that a categorical pretreatment standard is not needed to
control methylene chloride.
No performance data for either activated sludge treatment or
treatment in a POTW are available for dieldrin, 4,4'-DDE, and
6-BHC. However, the amount and toxicity of these pollutants in
the PM&F wastewater do not warrant categorical pretreatment
standards for those pollutants. The amount of dieldrin,
274
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Table XIII-1
COMPARISON OF BPT/BAT POLLUTANT REMOVALS
TO POTW POLLUTANT REMOVALS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Priority Pollutant
4. benzene
6. carbon tetrachloride
(tetrachloromethane)
11. 1,1,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
65. phenol
66. bis(2-ethylhexyl)
phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE
100. heptachlor
102. a-BHC
103. 6-BHC
104. Y-BHC
105. 6-BHC
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
128. zinc
BPT/BAT
Percent
Removal Source
POTW
Percent
Removal Source
66
73
73
40
90
88
92
40
17
67
38
20
No Data
No Data
85
77
No Data
44
52
83
76
82
83
75
35
77
1
2
1
4
1
1
1
2
2
2
2
2
1
3
3
1
1
3
3
99
73
94
88
62
56
99
58
51
85
96
20
No Data
No Data
85
77
No Data
44
52
93
76
82
97
85
35
77
3
2
3
2
3
3
3
3
3
3
2
2
2
2
2
3
3
3
3
3
3
3
Sources:
1. Percent removal is based on the analytical detection limit.
See Appendix C.
2. Average of data available from Fate of Priority Pollutants
in Publicly Owned Treatment Works, Final Report, Volume I,
EPA-440/1-82/303, September 1982.
3. Table 10, Fate of Priority Pollutants in Publicly Owned
Treatment Works. Final Report, Volume 1, EPA-440/1-82/303,
September 1982.
4. Based on treatability limits presented in "Contractors Engi-
neering Report, Analysis of Organic Chemicals and Plastics/
Synthetic Fiber Industries, Toxic Pollutants." See
Appendix C.
275
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4,4'-DDE, and B-BHC in contact cooling and heating water dis-
charged to a POTW are 0.03, 0.0009, 0.02 grams per plant per day,
respectively.
The BPT/BAT effluent limitations guidelines for processes in the
contact cooling and heating water subcategory with an average
process water usage flow rate of 35 gpm or less are based on zero
discharge by 100 percent recycle. Based on a comparison of the
average percentage removal of priority pollutants by well oper-
ated POTWs meeting secondary treatment requirements to the 100
percent removal of pollutants in the BPT/BAT technology, the
priority pollutants pass through a POTW. However, the amount of
pollutants discharged per day per indirect discharger in the
contact cooling and heating water subcategory with an average
process water usage flow rate of 35 gpm or less is estimated to
be 0.6 kilogram per day. Table XIII-2 contains a distribution of
this mass by individual pollutant. The Agency believes that the
amount and toxicity of the priority pollutants discharged by
those processes do not justify the development of PSES for this
segment of the PM&F category. Accordingly, PSES for this segment
of the contact cooling and heating water subcategory are not
being developed for those pollutants based on Paragraph 8(a)(iv)
of the Settlement Agreement in NRDC v. Train, supra. PSES are
also not being developed for chloroform, methylene chloride,
dieldrin, 4,4'-DDE, and B-BHC for this subcategory based on
Paragraph 8(a)(iv).
Cleaning and Finishing Water Subcategory
BPT/BAT effluent limitations guidelines for PM&F processes in the
cleaning and finishing water subcategory are based on treatment
in an activated sludge process. The Agency reviewed performance
data for the activated sludge process and compared it to the
performance data of well operated publicly owned treatment works.
That comparison is shown in Table XIII-3. The sources of the
performance data are referenced in the table.
As can be seen from the data in the table, only chloroform and
methylene chloride pass through a POTW. However, the amount and
toxicity of these pollutants do not justify categorical pretreat-
ment standards for these pollutants. EPA estimates that the
amount of chloroform in cleaning and finishing water discharged
to a POTW is 0.0008 kg/plant per day; the quantity of methylene
chloride in cleaning and finishing water discharged to a POTW is
0.01 kg/plant per day. EPA also believes that methylene chloride
is present in cleaning and finishing water because of laboratory
contamination of the samples.
Performance data are not available for the removal of N-nitroso-
diphenylamine in a POTW. However, the Agency believes that the
276
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Table XIII-2
ESTIMATED MASS OF POLLUTANTS DISCHARGED BY
INDIRECT DISCHARGING PROCESSES WITH AN AVERAGE PROCESS
WATER USAGE FLOW RATE OF 35 GPM OR LESS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Priority Pollutant
Amount Discharged
(kg/day per plant)
4.
6.
11.
22.
23.
44.
65.
66.
68.
85.
86.
89.
90.
93.
100.
102.
103.
104.
105.
118.
119.
120.
122.
123.
124.
128.
benzene
carbon tetrachloride (tetrachloromethane)
1,1,1 -trichloroethane
parachlorometa cresol
chloroform (trichloromethane)
methylene chloride (dichloromethane)
phenol
bis(2-ethylhexyl) phthalate
di-n-butyl phthalate
tetrachloroethylene
toluene
aldrin
dieldrin
4, 4 '-DDE
heptachlor
a-BHC
B-BHC
Y-BHC
6-BHC
cadmium
chromium (Total)
copper
lead
mercury
nickel
zinc
0.020
0.270
0.028
0.008
0.022
0.026
0.007
0.137
0.006
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
<0.001
0.002
0.001
0.011
<0.001
0.002
0.016
TOTAL
0.556
277
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Table XIII-3
COMPARISON OF BPT/BAT POLLUTANT REMOVALS TO POTW
POLLUTANT REMOVALS
CLEANING AND FINISHING WATER SUBCATEGORY
Priority Pollutant
4. benzene
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamlne
65. phenol
66. bis(2-ethylhexyl)
phthalate
86. toluene
89. aldrin
100. heptachlor
102. et-BHC
104. Y-BHC
105. 6-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
BPT/BAT
Percent
Removal Source
POTW
Percent
Removal Source
62
78
85
72
98
0
92
20
85
60
44
55
74
82
35
37
77
1
1
1
1
1
4
1
2
2
1
2
2
1
3
3
2
3
99
62
56
No Data
99
58
96
20
85
77
44
55
76
82
35
37
77
3
3
3
3
3
3
2
2
2
2
2
3
3
3
2
3
Sources :
4.
Percent removal is based on the analytical detection limit.
See Appendix C.
Average of data available from Fate of Priority Pollutants
in Publicly Owned Treatment Works, Final Report, Volume I,
EPA-440/1 -82/303, September 1982.
Table 10, Fate of Priority Pollutants in Publicly Owned
Treatment Works, Final Report. Volume 1, EPA-440/1 -82/303,
September 1982.
Based on treatability limits presented in "Contractors Engi-
neering Report, Analysis of Organic Chemicals and Plastics/
Synthetic Fiber Industries, Toxic Pollutants." See
Appendix C.
278
-------
amount and toxicity of this pollutant do not warrant a categori-
cal pretreatment standard. The amount of N-nitrosodiphenylamine
in cleaning and finishing water discharged to a POTW is 0.0005
kg/plant per day.
PSES are not being developed for chloroform, methylene chloride,
and N-nitrosodiphenylamine for this subcategory based on
Paragraph 8(a)(iv) of the Settlement Agreement in NRDC v. Train,
supra.
Proposed PSES
The Agency proposes no categorical pretreatment standards for
either the contact cooling and heating water subcategory or the
cleaning and finishing water subcategory. Even though no pre-
treatment standards are being proposed, existing indirect dis-
chargers in both subcategories must comply with the General
Pretreatment Regulations (40 CFR Part 403).
PRETREATMENT STANDARDS FOR NEW SOURCES
The Agency is not proposing PSNS for this category because the
pollutants for this category either do not pass through a POTW or
the amount and toxicity of the pollutants discharged to a POTW do
not justify establishing PSNS. The Agency believes that new and
existing indirect discharge sources will discharge the same pol-
lutants in similar amounts. The average percentage removal of
toxic pollutants by well operated POTWs meeting secondary treat-
ment requirements (i.e., 64 percent) is slightly greater than the
percentage removed (i.e., 62 percent) by a direct discharger in
the cleaning and finishing subcategory and by direct dischargers
with an average process water usage flow rate greater than 35 gpm
in the contact cooling and heating water subcategory when in com-
pliance with NSPS (which are equivalent to the BPT/BAT effluent
limitations guidelines). In addition, even though some toxic
pollutants discharged by plants with processes in the contact
cooling and heating water subcategory with average process water
usage flow rates of 35 gpm or less may pass through, the amount
and toxicity discharged to POTWs (0.6 kilograms per discharger
per day) do not justify establishing PSNS. Also, the amount and
toxicity of the pollutants in wastewater discharged by processes
in the contact cooling and heating water subcategory with an
average process water usage flow rate greater than 35 gpm and in
cleaning and finishing process wastewater do not justify estab-
lishing PSNS for those pollutants. Even though new indirect dis-
chargers are not subject to categorical pretreatment standards,
they must comply with the General Pretreatment Regulations (40
CFR Part 403).
279
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SECTION XIV
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
The 1977 amendments to the Clean Water Act added Section
301(b)(2)(E), establishing "best conventional pollutant control
technology" (BCT) for discharge of conventional pollutants from
existing industrial point sources. Section 304(a)(4) designated
the following as conventional pollutants: biochemical oxygen
demand (6005), total suspended solids (TSS), fecal coliform,
pH, and any additional pollutants defined by the Administrator as
conventional. The Administrator designated oil and grease
"conventional" on July 30, 1979 (44 FR 44501).
BCT is not an additional limitation but replaces BAT for the con-
trol of conventional pollutants. In addition to other factors
specified in Section 304(b)(4)(B), the Act requires that BCT
effluent limitations guidelines be assessed in light of a two
part "cost-reasonableness" test. See, American Paper Institute
v. EPA, 660 F.2d 954 (4th Cir. 1981). The first part of the test
compares the cost for private industry to reduce its conventional
pollutant discharge with the cost publicly owned treatment works
incur for similar levels of reduction. The second part of the
test examines the cost-effectiveness of additional industrial
treatment beyond BPT. EPA must find that the BCT effluent
limitations guidelines are "reasonable" under both parts of the
test before they are established. In no case may BCT be less
stringent than BPT.
EPA published its methodology for carrying out the BCT analysis
on August 29, 1979, (44 FR 50732). In the case mentioned above,
the Court of Appeals ordered EPA to correct data errors under-
lying EPA's calculation of the first test and to apply the second
cost test. (EPA had argued that a second cost test was not
required.)
On October 29, 1982, the Agency proposed a revised BCT methodol-
ogy (47 FR 49176). This proposed methodology was used to deter-
mine whether costs of additional controls for the conventional
pollutants beyond BPT in the PM&F category are "reasonable." EPA
will conduct the two-part cost test again when the final BCT
methodology is promulgated. That test will also be conducted
again if the BPT model treatment technology for the final PM&F
regulation is different than the selected technology for the
proposed regulation.
The Agency reviewed treatment technologies that could be used to
remove additional conventional pollutants after BPT. The only
technology considered feasible in each subcategory is flow reduc-
tion and zero discharge by contract haul of the discharge from
281
-------
the recycle unit. Thus, one BCT Option, which is the same as BPT
Option 3, was considered for each subcategory.
The Agency compared the BCT Option to BPT Option 2 in both sub-
categories using the proposed two part cost reasonable test.
Table XIV-1 presents the information required to perform the two
part cost test on the proposed BCT treatment technology for the
contact cooling and heating water subcategory. Table XIV-2
presents the information required to perform the cost test on the
proposed BCT treatment technology for the cleaning and finishing
water subcategory.
Table XIV-1
ANNUAL COSTS OF TREATMENT AND POLLUTANT MASSES AFTER TREATMENT
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Mass of
Pollutant
Discharged
Level of Treatment
Existing Treatment
BPT Option 2
BCT Option
Annual Cost
+ TSS, Incre- of Treatment Incre-
million Ibs) ment ($ millions) ment
17.5
2.6
14.9
2.6
0
9.4
41.2
9.4
31.8
Table XIV-2
ANNUAL COSTS OF TREATMENT AND POLLUTANT MASSES AFTER TREATMENT
CLEANING AND FINISHING WATER SUBCATEGORY
Mass of
Pollutant
Discharged Annual Cost
(BOD^ + TSS, Incre- of Treatment Incre-
million Ibs) ment ($ millions) ment
Level of Treatment
Existing Treatment
BPT Option 2
BCT Option
1.49
0.14
0
1.35
0.14
0
1.5
4.5
6.0
282
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Part 1 of the cost test, the POTW test, compares the cost for
industry to remove a pound of conventional pollutants to the cost
incurred by a POTW for removing a pound of conventional pollu-
tants. The Agency compared the costs by first calculating the
incremental annual costs incurred by industry for conventional
pollutant removals beyond BPT. Annual costs include operation
and maintenance expenses, interest, and depreciation. The Agency
also calculated the incremental removal of conventional pollu-
tants by determining the difference between the annual pounds of
conventional pollutants removed after compliance with BPT and the
pounds removed after compliance with the BCT option.
The conventional pollutants subject to this review fall into two
categories: total suspended solids (TSS) and oxygen demanding
substances (BOD5 and oil and grease). To avoid "double count-
ing" of the incremental amount of pollutants removed, pollutant
removals were calculated using only one pollutant from the oxygen
demanding substances group, as specified in the proposed method-
ology. The Agency used the incremental amount of BOD5 removed
in the BCT cost test calculation for both PM&F subcategories
because while both BOD5 and oil and grease are regulated, a
greater amount of BOD5 is removed by treatment.
The Agency calculated the ratio of incremental annual cost to
incremental conventional pollutant removal for each subcategory
as follows: (BCT Option annual cost minus BPT Option 2 annual
costs) divided by (BCT Option pounds of conventional pollutants
removed minus BPT Option 2 pounds of conventional pollutants
removed). The incremental removal cost must be equal to or less
than a proposed benchmark of $0.47 per pound to be considered
reasonable. The incremental removal cost was $12.23 per pound
(31.8/2.6) for contact cooling and heating water and $32.14 per
pound (4.5/0.14) for cleaning and finishing water. All costs are
calculated in 1982 dollars. These costs are considered
unreasonable.
Part 2 of the cost test, the industry cost test, compares the
compliance costs and the effluent reduction benefits at BPT to
those for the BCT Option. This ratio is calculated as follows:
(total annual cost per pound of conventional pollutant removed
between BPT and BCT) divided by (the total annual costs per pound
of pollutant removed between existing treatment and BPT). This
increasing cost ratio should not exceed a proposed benchmark of
1.43 if the costs of the BCT Option are to be considered
reasonable. The increasing cost ratio calculated for the contact
cooling and heating water subcategory is 19.4 ($12.23/$0.63).
The increasing cost ratio calculated for the cleaning and finish-
ing subcategory is 28.9 ($32.14/$1.11). Thus, the costs asso-
ciated with the BCT Option are also unreasonable based on results
of the second part of the proposed cost test.
283
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Based on the preliminary results of the proposed two-part BCT
cost test, costs associated with the additional removal of con-
ventional pollutants are not "reasonable." The Agency proposes,
therefore, that BCT equal BPT for each subcategory and that no
further controls be established for the conventional pollutants
beyond BPT.
284
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SECTION XV
ACKNOWLEDGEMENTS
This project was conducted by the Environmental Protection Agency
(EPA). EPA personnel who contributed to this project are:
Deveraux Barnes
Ernst P. Hall
Robert M. Southworth, P.E.
Jill Weller
Ann M. Watkins
R. Clifton Bailey
Alexandra G. Tarnay
Deputy Director, Effluent
Guidelines Division
Chief, Metals and Machinery
Branch, Effluent Guidelines
Division
Project Officer, Effluent
Guidelines Division
Attorney, Office of General
Counsel
Economics Project Officer,
Office of Analysis and
Evaluation
Statistician, Program Integra-
tion and Environmental Staff
Environmental Project Officer,
Monitoring and Data Support
Division
Contractor personnel who contributed to this project are:
Lee C. McCandless
David C. Kennedy
Thomas M. Lachajczyk
Daniel L. Logan
Robert A. Bessent
Albert P. Becker
Program Manager, Versar, Inc.
Vice President, Envirodyne
Engineers, Inc.
Senior Environmental Engineer,
Envirodyne Engineers, Inc.
Environmental Engineer,
Envirodyne Engineers, Inc.
Environmental Engineer,
Envirodyne Engineers, Inc.
Chemical Engineer,
Envirodyne Engineers, Inc.
285
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Cindy L. Dahl Environmental Engineer,
Envirodyne Engineers, Inc.
James S. Sherman Program Manager, Radian
Corporation
Calvin L. Spencer Project Director, Radian
Corporation
Roy E. Sieber Chemical Engineer, Radian
Corporation
Arlene A. Freyman Chemical Engineer, Radian
Corporation
Laura L. Murphy Chemical Engineer, formerly
with Radian Corporation
Sandra F. Moore Secretary, Radian Corporation
Daphne K. Phillips Secretary, Radian Corporation
The cooperation of the Society of Plastics Industry, Inc., the
individual PM&F companies whose plants were sampled, and the com-
panies who submitted detailed information in response to the
questionnaires is gratefully appreciated.
286
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SECTION XVI
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-------
SECTION XVII
GLOSSARY
This section contains the definitions of the technical terms used
in this document. Table XVII-1 lists some common plastic
polymers and their uses and properties.
Acidity
The acidity of water is its quantitative capacity to react with a
strong base to a designated pH. Various materials may contribute
to the measured acidity depending on the method of determination.
These materials include strong mineral acids, weak acids such as
carbonic and acetic acids, and hydrolyzing salts such as ferrous
or aluminum sulfates.
Alkalinity
Alkalinity of a water is its quantitative capacity to react with
a strong acid to a designated pH. It is an indication of the
concentration of any carbonate, bicarbonate and hydroxide ions
present.
Analytical Quantification Limit
The minimum concentration at which a pollutant can be accurately
measured. It is also known as the method detection limit.
Average Process Water Usage Flow Rate for Processes That Use
Contact Cooling and Heating Water
The average process water usage flow rate of a process in gallons
per minute is equal to the volume of the process water (gallons)
used per year by a process divided by the total time (minutes)
per year the process operates. The average process water usage
flow rate for a plant with more than one plastics molding and
forming process that uses contact cooling and heating water is
the sum of the average process water usage flow rates for those
plastics molding and forming processes.
Batch Treatment
Batch treatment is a waste treatment method where wastewater is
collected over a period of time and then treated prior to dis-
charge. Collection may be continuous even though treatment is
not. Batch treatment may be used because the processes generat-
ing wastewater are operated on a batch operation mode, or the
treatment system may be oversized for the amount of wastewater
generated.
305
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Biological Oxygen Demand (BODc;)
The biological oxygen demand (6005) test for wastewaters deter-
mines the oxygen required for the biochemical degradation of
organic material (carbonaceous demand) and the oxygen used to
oxidize inorganic material such as sulfides and ferrous iron.
The wastewater sample is incubated for a standard period of five
days, hence the common name 8005.
Blowing Agent
A blowing agent is the material injected into a plastic material
that cause the plastic material to expand with the application of
heat. Blowing agents can be gases introduced into the molten
plastic or a gas producing compound that is mixed with the
polymer before processing.
Blow Molding
Blow molding expands a parison into a desired shape with com-
pressed air. Hollow, thin-wall objects from thermoplastic resins
are formed.
BPT Regulatory Flow
The BPT regulatory flow is the production normalized flow chosen
to calculate the effluent limitations guidelines based on BPT.
Calendering Process
The calendering process squeezes pliable thermoplastic between a
series of rolls to produce uniform quality polymer film and
sheet, to emboss sheet and film, to perform compounding opera-
tions, and to coat textiles and papers.
Casting Process
A casting process forms products by allowing a liquid plastic to
cure at atmospheric pressure in a mold or on a mold surface.
Chemical Oxygen Demand (COD)
The chemical oxygen demand (COD) is a measure of the oxygen
equivalent of the organic matter content of a wastewater sample
that is susceptible to oxidation by a strong chemical oxidant.
Chiller System
A chiller system is a heat exchange device that uses a refrigera-
tion medium to lower the temperature of water. This system is
used in water recycle systems in the PM&F industry.
306
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Cleaning Process
A cleaning process is a process in which plastic parts and shap-
ing equipment are washed to remove residual mold release agents
and other matter prior to finishing or further processing. A
cleaning process contains a detergent wash cycle, and a rinse
cycle.
Cleaning Water
Cleaning water is process water used to clean an intermediate or
final plastic product or to clean equipment used in plastic mold-
ing and forming that contacts an intermediate or final product.
It includes water used in both the detergent wash and rinse
cycles of a cleaning process.
Coating Process
A coating process covers objects with a polymer layer that is in
the form of a melt, liquid, or finely divided powder. These
objects include other plastic materials, metal, wood, paper,
fabric, leather, glass, concrete, and ceramics.
Compounding
Compounding is the plastics processing step where a plastic resin
is mixed with additives or fillers.
Compression Molding
Compression molding shapes a measured quantity of plastic within
a mold by applying heat and pressure to form products with large
surface areas and relatively simple shapes.
Contact Cooling and Heating Water
Contact cooling and heating water is process water that contacts
the raw materials or plastic product for the purpose of heat
transfer during plastic molding and forming.
Conventional Pollutants
Conventional pollutants are the pollutants defined in Section
304(a)(4) of the Clean Water Act. They include biological oxygen
demand, oil and grease, suspended solids, fecal coliform, and pH.
307
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Cooling Tower
A cooling tower is a hollow vertical structure with internal
baffles designed to exchange the heat of water with counter or
cross-current flowing air.
Cooling Trough
A cooling trough is a long open box-like container that holds
water to quench a processed plastic product. It is commonly used
to contact cool extruded strands before they are pelletized, and
to cool extruded pipe.
Direct Discharger
A direct discharger is an industrial water user that discharges
wastewater directly in a navigable stream.
Dry Process
A dry process is a process that uses no proces water or uses
only noncontact water.
Effluent
Effluent is the discharge from a point source after treatment.
End-of-Pipe Treatment
End-of-pipe treatment is the treatment given wastewater before
the wastewater is discharged from the treatment plant.
Extrusion Process
Extrusion is the process that forces molten polymer under pres-
sure through a shaping die to produce products of uniform cross-
sectional area such as pipe, tubing, sheet, and film.
Filler
A filler is a material that when added to a plastic may reduce
the end product cost by occupying a fraction of the volume of the
plastic product. It may also act as a speciality additive to
improve the final product.
Finishing Process
A finishing process renders the plastic parts useful. There are
three types of finishing processes: machining, decorating, and
assembling.
308
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Finishing Water
Finishing water is process water used to remove waste plastic
material generated during a finishing process or to lubricate a
plastic product during a finishing process. It includes water
used to machine, to decorate, or to assemble intermediate or
final plastic products.
Foaming Agent
A foaming agent is a gas producing compound added to a polymer
that causes the polymer to foam when the gas is liberated by the
addition of heat or a reduction in pressure.
Foaming Process
A foaming process injects a blowing or foaming agent into a
thermoplastic or thermoset to form a sponge-like material.
Glass Transition Temperature
The temperature at which a polymer changes from a brittle glassy
solid to a rubberlike substance.
Indirect Discharger
An indirect discharger is an industrial source that discharges
wastewater to a publicly owned treatment works.
Influent
Influent is water used in a PM&F process. It can be the source
water for a plant or the source water combined with recycled
water.
Injection Molding
Injection molding forms intricate plastic parts by forcing a
heated plastic with pressure into a mold cavity.
In-Process Control Technology
In-process control technology is the conservation of water
throughout the production processes to reduce the amount of
wastewater discharged.
309
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Integrated Plant
An integrated plant is a plant that combines process water from
all sources in the plant for treatment in a wastewater treatment
process.
Laminating Process
The laminating process combines layers of polymeric materials
with other materials through high pressure. These structures are
formed from layers of resins and fillers bonded together as a
unit with the resin used as a reinforcing agent.
Mass of Plastic Material Processed In Cleaning and Finishing
Water Processes
The mass of plastic material processed (kg or Ibs) when used to
determine effluent limitations guidelines is the mass of plastic
material that process water comes in contact with for product
cleaning or finishing purposes. If the same unit mass of plastic
material undergoes more than one cleaning or finishing process
(for example, it is cleaned and finished), the mass of plastic
material processed in each process is added to obtain the total
mass of plastic material processed. For the purpose of calculat-
ing effluent limitations for water used to clean shaping equip-
ment, such as molds and mandrels, "mass of plastic material
processed" refers to the mass of plastic material that was molded
or formed by the shaping equipment being cleaned.
Mass of Plastic Material Procssed In Contact Cooling and Heating
Water Processes
The mass of plastic material processed (kg or Ibs) when used to
determine effluent limitations guidelines is the mass of plastic
material that process water comes in contact with for cooling or
heating purposes. If the same unit mass of plastic undergoes
more than one molding and forming process (for example, it is
compounded and pelletized, extruded, and blow molded), the mass
of plastic material processed in each process is added to obtain
the total mass of plastic material processed.
Melt Temperature
The temperature at which a polymer becomes fluid.
Monomer
A monomer is a chemical compound that during a polymerization
process becomes a repeating link in the polymer chain.
310
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New Source Performance Standards (NSPS)
NSPS for new industrial direct dischargers as defined by Section
306 of the Clean Water Act are based on the best available
demonstrated technology.
Nonconventional Pollutants
Nonconventional pollutants include pollutants that are not desig-
nated as either conventional or priority toxic pollutants.
Oil and Grease
Oil and grease are materials that are soluble in trichlorotri-
fluoroethane. They include nonvolatilized materials usch as
hydrocarbons, fatty acids, soaps, fats, waxes, and oils.
Parison
A parison is a preshaped sleeve usually made by extrusion. This
sleeve is an intermediate product often used as the starting
material for the blow molding process.
Pelletizing
Pelletizing is a process by which long extruded strands are cut
into pellets. These pellets are an intermediate product which
can be the feed material of other plastic molding and forming
processes.
21
pH is the negative logarithm of the hydronium ion concentration.
Values below seven represent an acid environment; a value of
seven represents a neutral environment; and values greater than
seven are indicative of a basic environment.
Pigments
A pigment is a compound that when well mixed with a polymer
imparts color to the polymer. To impart color, the pigment must
absorb light in the visible wavelength range.
Plastic
A plastic is a polymeric material of large molecular weight that
can be shaped by flow. A plastic material includes the pure
polymer and any fillers, plasticizers, pigments, or stabilizers.
311
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Plasticization - Internal
A copolymerization process by which a chain is made more flexi-
ble. The chain's rigidity is caused by steric factors.,
Plasticizer - External
An external plasticizer is usually a monomeric molecule that when
mixed with polar or hydrogen bonded polymer results in increasing
the flexibility of the rigid polymer.
Plastics Molding and Forming (PM&F) Processes
Plastic molding and forming processes are a group of manufactur-
ing processes in which plastic materials are blended, molded,
formed, or otherwise processed into intermediate or final plastic
products.
Plastisol
A plastisol is a low viscosity system of dispersed polyvinyl
chloride (PVC) in a plasticizer.
PM&F Category
Throughout this document, the PM&F abbreviation stands for the
Plastics Molding and Forming category.
Pollutant Concentration
A measure of the mass of pollutant per volume of wastewater.
Commonly used units are milligrams per liter.
Pollutant Effluent Limitations Guidelines
The pollutant effluent limitations guidelines is the mass of
pollutant allowed to be discharged per unit of plastic produc-
tion. For the PM&F category typical units are milligrams of
pollutant per kilogram of plastic production.
Polymer
A polymer is a macromolecule comprised of linked together repeat-
ing monomers. These macromolecules have molecular weights in the
range of 10^ to 107.
Polymer i zat ion
Polymerization is the chemical reaction that produces a polymer.
312-
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Priority Toxic Pollutants
Priority toxic pollutants are toxic pollutants selected for study
from 65 compounds and classes of compounds Congress declared
toxic under Section 307(a) of the Clean Water Act.
Process Water
Process water is any raw, service, recycled, or reused water that
contacts the plastic product or contacts shaping equipment sur-
faces such as molds and mandrels that are, or have been, in
contact with the plastic product.
Production Normalized Flow (PNF)
The PNF is the amount of wastewater discharged from a process
divided by the amount of plastic material processed in that
process (i.e., liters discahrged per kkg of plastic material
processed).
Publicly Owned Treatment Works (POTW)
A POTW is a wastewater treatment facility owned by a state or
municipality.
Reaction Injection Molding (RIM)
A RIM process simultaneously injects two or more reactive liquid
streams at high pressure into a mixing chamber and then injects
the plastic at a lower pressure into the mold cavity.
Recycle
Recycle is a water-saving technology that returns process water
that has been used in a process to that process.
Regrind
Regrind is processed plastic that is scrapped and mixed with pure
plastic and reprocessed.
Reinforcing Agent
A reinforcing agent primarily improves the strength and stiffness
of the base polymer.
Resin
A resin is the homogeneous polymer that forms the basis of a
plastic product. The resin does not include the fillers, plas-
ticizers, pigments or stabilizers.
313
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Rotational Molding
A rotational molding process rotates a polymer powder or liquid
inside a large, heated mold to form hollow objects from thermo-
plastic materials.
The sprue is the entrance into the mold through which the plastic
flows.
Stabilizer
A stabilizer is a compound which when added to a polymer protects
it from heat, light, or oxygen.
Thermoforming Process
A thermoforming process heats a thermoplastic sheet or film to a
pliable state and forces it around the contours of a mold.
Vacuum, air pressure, or mechanical force form the molten sheet
to the mold.
Thermoplastic Polymer
A thermoplastic polymer is a linear molecule that can melt and
flow with the addition of heat and pressure.
Thermoset Polymer
A thermoset polymer has crosslinks throughout the chain making it
stable to heat. The polymer will not melt or flow with heat.
Total Organic Carbon (TOG)
TOG is a measure of the organic material in a wastewater and is
determined by oxidizing the organic material to carbon dioxide.
Total Phenols
Phenols are hydroxy derivatives of benzene.
Total Suspended Solids (TSS)
TSS is a measure of the solids in wastewater.
Transfer Molding
Transfer molding uses a preheated plastic and moves it into the
mold cavity with pressure through a sprue. It is similar to
injection molding.
314
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Treatability Limit
The treatability limit is the lowest attainable concentration
achievable by a wastewater treatment process.
Volume of Process Water Used Per Year
The volume of process water used per year is the volume of pro-
cess water that flows through a process and comes in contact with
the plastic product over a period of one year.
Wastewater Discharged
Wastewater discharged is process water from a PM&F process that
is discharged to surface water or a POTW.
Water Quench
A water quench is a contact water cooling bath used to quickly
cool a material. It is often used in extrusion and injection
molding to cool the products.
Water Used
Water used is water that contacts the plastic material or prod-
uct. This includes any recycle and makeup water.
Wet Process
A wet process is a process in which the plastic comes into direct
contact with water.
Zero Discharger
A zero discharger is any industrial water user that does not
discharge wastewater.
315
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APPENDIX A
SAMPLING DATA
-------
APPENDIX A
SAMPLING DATA
This appendix presents the daily raw concentration data from the
11 plants in the plastics molding and forming category sampled
during this project. Table A-1 lists the data for the contact
cooling and heating water subcategory and Table A-2 presents the
data for the cleaning and finishing water subcategory. The
concentrations for days one, two, three, and the duplicate listed
in Tables A-1 and A-2 were used to develop Table VI-17.
Processes from Plant K have two source water concentrations
listed. The first value listed represents the concentration of a
make-up water flow and the second value represents a recirculated
water flow to the process. Some pollutants for process K-4 from
Plant K have two concentration values listed under each sampling
day. The first concentration is from an unpreserved sample and
the second listed value is from a preserved sample.
A wastewater treatment system that treats primarily PM&F waste-
water was sampled at one plant (i.e., Plant I) in 1980. Tables
A-3 and A-4 present influent and effluent data for two treatment
systems at that plant (see Figure VI-9).
Table A-5 presents solution casting solvent recovery sampling
data for Plant G. Data presented in Table A-5 may be used as a
guide by the permit writer to write permits for the solvent
recovery wastewater.
A-1
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A-97
-------
APPENDIX B
STATE INDUSTRIAL GUIDES
-------
APPENDIX B
STATE INDUSTRIAL GUIDES
Appendix B lists the State Industrial Guides used to estimate the
size of the PM&F category. This estimate is described in Section
IV.
State
Alabama
Arizona
Arkansas
California
Colorado
Connecticut
Delaware
Florida
Georgia
Edition Title and Publisher
1980-81 Alabama Director of Mining and Manu-
facturing,Industrial Research
Department, Alabama Development
Office
1982 Arizona Directory of Manufacturers,
Pheonix Metropolitan Chamber of
Commerce
1982 Arkansas Directory of Manufacturers,
Arkansas Industrial Development
Foundation
1983 California Manufacturer's Register,
California Manufacturer's Association
1982 Directory of Colorado Manufacturers,
University of Colorado,Boulder,
Business Division, College of
Business and Administration
1982 MacRae's Connecticut State Industrial
Directory
1981-82 Delaware Directory of Commerce and
Industry^Delaware State Chamber of
Commerce
1982 Directory of Florida Industries, The
Florida Chamber of Commerce c 1981
1980-81 Georgia Manufacturing Directory,
Georgia Department of Industry and
Trade, c. 1980
B-l
-------
State
Edition Title and Publisher
Idaho
Illinois
Indiana
Iowa
Kansas
Kansas
Kentucky
Louisiana
Maine
Maryland
Massachusetts
Michigan
Minnesota
1982 Idaho Manufacturing Directory
University of Idaho Center for Busi-
ness Development and Research
1983 Illinois Manufacturers Directory,
Manufacturer's News Inc., Chicago, IL
Editor, Louise M. West
1983 Harris Indiana Marketer's Industrial
Directory, Harris Publishing Company
(1983, Ohio), State Directory
Division
1981-82 Directory of Iowa Manufacturers,
Iowa Development Commission
1981-82 Directory of Kansas Manufacturers and
Products, Kansas Department of
Economic Development
1981-82 Directory of Kansas Manufacturers and
Products",Kansas Economic Development
Commission
1983 Kentucky Directory of Manufacturers,
Kentucky Department of Economic
Development
1982 Directory of Louisiana. Manufacturers,
Louisiana Department of Commerce
1981-82 Directory of New England Manufac-
turers , New England Council,
George D. Hall Company
1981-82 The Directory of Maryland Manufac-
turers , State of Maryland, Department
of Economic and Community Development
1981-82 Directory of Massachusetts Manufac-
turers , George D. Hall's Association
Industires of Mass c. 1981
1982 The Directory of Michigan Manufac-
turers ,Pick Publications, Inc.
1981 Minnesota Directory of Manufacturers,
Minnesota Department of Economic
Development
B-2
-------
State
Edition Title and Publisher
Mississippi
Missouri
Nebraska
Nevada
New Hampshire
New Jersey
New York
North Carolina
North Dakota
Ohio
Oklahoma
Pennsylvania
Rhode Island
1980 Mississippi Manufacturers Directory
Mississippi Research and Development
Center, printed 1979
1982 Missouri Directory, Mining and Manu-
facturing Industires Services and
Supplies^Information Data Company
1982-83 A Directory of Nebraska Manufacturers
and Their Products,Nebraska Depart-
ment of Economic Development
1981 Nevada Industrial Directory, Nevada
Department of Economic Development
1982-83 Made in New Hampshire, State of New
Hampshire, Office of Industrial
Development, Division of Economic
Development
1983 New Jersey State Industrial Directory
MacRae's Blue Book,Inc.
1983 New York State Industrial Directory,
MacRae's Blue Book,Inc.
Editor, Barbara Sadie
1981-82 Directory of North Carolina Manufac-
turing Firms, North Carolina Depart-
ment of Commerce
1978-79 Directory of North Dakota Manufactur-
ing, North Dakota Business and
Industrial Development Department
1983 Ohio Marketers Industrial Directory,
Harris Publishing Company
1980 Oklahoma Directory of Manufacturers
and Products,Industrial Development
Department
1982 MacRae's Pennsylvania State Indus-
trial Directory
1981-82
Rhode Island Directory of Manufac-
turers , Rhode Island Directory of
Economic Development
B-3
-------
State
South Carolina
South Dakota
Tennessee
Texas
Virginia
Washington
West Virginia
Wisconsin
Edition Title and Publisher
1983 South Carolina 1983 Industrial Direc-
tory, South Carolina State Develop-
ment Board
1981-82 South Dakota Manufacturers & Proces-
sors Directory, Department of
Economic and Tourism Development
1982 Tennessee Directory of Manufacturers,
Tennessee Department of Economic and
Community Development:
1983 Directory of Texas Manufacturers,
Bureau of Business Research,
University of Texas, Austin
1981-82 Virginia Industrial Directory,
Virginia State Chamber of Commerce
1982-83 Washington Manufacturers Register,
Times Mirror Press, Washington State
Department of Commerce and Economic
Development
1980 West Virginia Manufacturer's Direc-
tory, Governor's Office of Economic
and Community Development Department
1983 Classified Directory of Wisconsin
Manufacturers, Wisconsin Association
of Manufacturers and Commerce
B-4
-------
APPENDIX C
BENEFITS
-------
APPENDIX C
BENEFITS
This appendix explains how benefits (i.e., amount of pollutants
removed) were calculated for the BPT options. The BPT effluent
limitations guidelines apply only to direct dischargers. The
amount of pollutants generated by direct dischargers is 44 per-
cent of the total pollutant mass for the contact cooling and
heating water subcategory and 32 percent of the total pollutant
mass for the cleaning and finishing water subcategory. These
percentages represent the percentage of direct dischargers of the
total number of direct and indirect dischargers in the question-
naire data base; they were multiplied by the total mass of
pollutants generated by the PM&F category (see Table VII-7) to
determine the pollutant mass for direct dischargers. The pollu-
tant mass for indirect dischargers is the difference between the
total and direct discharge mass. Table C-1 lists the total
pollutant mass for the direct and indirect dischargers by
subcategory.
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Option 1
The technology for Option 1 consists of a tank in which the
velocity of the wastewater is reduced so that solid material can
settle by gravitational force. There are no benefits for this
option because the suspended solids concentration in the contact
cooling and heating water is very low and because the technology
does not remove the dissolved pollutants (e.g., biochemical oxy-
gen demand). The pollutant masses remaining after treatment are
equal to the total pollutant masses for direct dischargers listed
in Table C-1.
Option 2
The technology for this option consists of zero discharge by 100
percent recycle of the process water using either a tank or a
chiller for processes with an average process water flow rate of
35 gpm or less.
For processes with an average process water flow rate greater
than 35 gpm the technology is recycle through a cooling tower and
treatment of the recycle unit discharge in a package activated
sludge plant. An equalization unit is included in the package
activated sludge plant.
C-1
-------
Table C-1
TOTAL CATEGORY POLLUTANT MASS DISTRIBUTED
BY DISCHARGE MODE
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
TOTAL
Nonconventional Pollutants
COD
TOG
Total Phenols
TOTAL
Priority Pollutants
4. benzene
6. carbon tetrachloride
(tetrachloromethane)
11. 1,1,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
65. phenol
66. bis(2-ethylhexyl) phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE(p,p'DDX)
100. heptachlor
102. a-BHC
103. 6-BHC
104. Y-BHC
105. 6-BHC
Direct
Dischargers
Pollutant
Mass
(kg/yr)
7,920,000
708,000
295,000
8,923,000
19,400,000
7,610,000
233,000
27,243,000
4,390
60,300
6,200
2,020
4,840
5,680
1,
30
1,
610
200
290
6
105
15
4
0.
11
29
3
3
13
Indirect
Dischargers
Pollutant
Mass
(kg/yr)
10,080,000
902,000
375,000
11,357,000
24,700,000
9,690,000
296,000
34,686,000
5,590
76,700
7,900
2,580
6,160
7,220
2,
38,
1 ,
13
060
500
650
7
134
19
6
0,
13
36
3
3
16
17
C-2
-------
Table C-1 (Continued)
TOTAL CATEGORY POLLUTANT MASS DISTRIBUTED
BY DISCHARGE MODE
CONTACT COOLING AND HEATING WATER SUBCATEGORY (Continued)
Priority Polultants
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
128. zinc
TOTAL
Direct
Dischargers
Pollutant
Mass
(kg/yr)
167
440
223
2,360
0.04
426
3,510
123,845.17
Indirect
Dischargers
Pollutant
Mass
(kg/yr)
213
560
284
3,000
0.06
543
4,460
157,657.23
C-3
-------
Table C-1 (Continued)
TOTAL CATEGORY POLLUTANT MASS DISTRIBUTED
BY DISCHARGE MODE
CLEANING AND FINIHSING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
TOTAL
Nonconventional Pollutants
COD
TOG
Total Phenols
TOTAL
Priority Pollutants
Direct
Dischargers
Pollutant
Mass
(kg/yr)
299,000
34,600
378,000
711,600
480,000
416,000
43,200
939,200
4.
23.
44.
62.
65.
66.
86.
89.
100.
102.
104.
105.
119.
120.
124.
125.
128.
benzene
chloroform (trichloro-
methane)
methylene chloride
(dichloromethane)
N-nitrosodiphenylamine
phenol
bis(2-ethylhexyl) phthalate
toluene
aldrin
heptachlor
Y-BHC
6 -BHC
chromium (Total)
copper
nickel
selenium
zinc
TOTAL
0.6
22
303
15
73
12
2
0.2
0.03
0.002
0.2
0.3
40
64
30
1
327
890.332
Indirect
Dischargers
Pollutant
Mass
(kg/yr)
634,000
73,400
802,000
1,509,400
1,020,000
884,000
91,800
1,995,800
1.4
48
645
31
154
27
4
0.4
0.07
0.004
0.5
0.6
84
137
65
2
696
1,895.974
C-4
-------
Because Option 2 for the contact cooling and heating water sub-
category is a combination of zero discharge and activated sludge
treatment, a portion of the benefits for this option was attri-
buted to zero discharge and the remaining portions were obtained
by the treatment technology. These portions were based on the
percentage of plastic products produced and not the volume of
wastewater discharged since the pollutant masses are dependent on
the amount of plastic produced. For the contact cooling and
heating water subcategory, 43 percent of the total plastic is
formed by processes with a process water usage flow rate of 35
gpm or less. This percentage is for direct dischargers and was
obtained from the questionnaire data base. Thus, 43 percent of
the total pollutant mass is removed by the processes with a
process water usage flow rate of 35 gpm or less (i.e., zero dis-
charge of pollutants). The remaining 57 percent of the pollutant
mass was multiplied by the removal efficiencies for the activated
sludge process presented in Table C-2 to determine the additional
benefit derived from treating wastewaters discharged by processes
with an average process water usage flow rate greater than 35
gpm.
Also listed in Table C-2 are the sources of the percent removals.
The percent removals for conventional pollutants were determined
by using the effluent concentration values transferred from the
organic chemicals, plastics and synthetic fibers category (see
Section X). There is zero percent removal of TSS, because the
PM&F wastewater TSS concentration (17 mg/1) is below the TSS
effluent concentration value (36 mg/1). Percent removals for the
nonconventional pollutants were obtained from the source listed
in Table C-2. Priority toxic pollutant removals for the package
activated sludge plant were calculated in the following way:
1. Pollutant treatability limits were obtained from USEPA,
Contractors Engineering Report, Analysis of Organic
Chemicals and Plastics/Synthetic Fiber Industries,
Toxic Pollutants, November 16, 1981, Contract No.
68-01-6024. If a treatability limit was below the
analytical detection limit, the treatability limit was
made equal to the detection limit for a pollutant. A
percent removal was calculated using the influent
concentration to the package activated sludge plant and
the treatability limit. If a limit was not listed for
a pollutant, the next source was searched.
2. Percent removals of pollutants were obtained from
the USEPA, Fate of Priority Pollutants in Publicly
Owned Treatment Works, Volume I,September 1982,
440/1-83/303.
C-5
-------
Table C-2
OPTION 2 POLLUTANT PERCENT REMOVALS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
4. benzene
6. carbon tetrachloride
(tetrachloromethane)
11. 1,1,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
65. phenol
66. bis(2-ethylhexyl) phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE
100. heptachlor
102. a-BHC
103. 8-BHC
104. Y-BHC
105. 5-BHC
118. cadmium
Removal
78
19
0
63
63
60
66
73
73
40
90
88
92
40
17
67
38
20
0
0
85
77
0
44
52
83
Source
Percent removals
were calculated using
effluent concentration
data transferred from
the organic chemicals,
plastics, and synthe-
tic fibers category
5
5
5
1
2
1
3
1
1
1
2
4
4
2
2
4
2
2
1
C-6
-------
Table C-2 (Continued)
OPTION 2 POLLUTANT PERCENT REMOVALS
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Priority Pollutants Removal Source
119. chromium (Total) 76 2
120. copper 82 2
122. lead 83 1
123. mercury 75 1
124. nickel 35 2
128. zinc 77 2
1. Percent removal is based on the analytical detection limit.
2. Percent removal is from the USEPA, Fate of Priority Pollu-
tants in Publicly Owned Treatment Works, Volume I, September
1982, 440/1-82-303.
3. Percent removal is determined from the USEPA, Contractors
Engineering Report, Analysis of Organic Chemicals and
Plastics/Synthetic Fibers Industries Toxic Pollutants,
November 16, 1981, Contract No. 68-01-0624.
4. Removal efficiencies not presented in sources.
5. Percent removals are from USEPA, Treatability Manual,
Volume III, Technologies for Control/Removal of Pollutants,
July 1980, EPA 600/8-80-842c.
C-7
-------
3. If the percent removal from the POTW study resulted in
an effluent concentration below the pollutant analytical
quantification level, the effluent concentration was
made equal to the analytical quantification level, and
the percent removal was adjusted using that
concentration.
Table C-3 presents the pollutant mass removals for Option 2 and
the pollutant masses remaining after treatment. The calculation
procedure for 6005 removal is described below:
1. The total direct discharge mass for BOD5 is
7,920,000 kg/yr (from Table C-1).
2. Forty-three percent of the 6005 pollutant mass was
eliminated because of zero discharge of pollutants.
This benefit is 3,410,000 kg/yr (3,410,000 = 0.43 x
7,920,000).
3. The remaining pollutant mass available for treatment
in a package activated sludge plant is 4,510,000
kg/yr (4,510,000 = 7,920,000 - 3,410,000).
4. The pollutant percent removal in the package activated
sludge plant is 78 percent. Pollutant mass removals
in the package activated plant are 3,520,000 kg/yr
(3,520,000 - 0.78 x 4,510,000).
5. Total pollutant benefits are the portion of pollutants
removed by zero discharge and the portion removed by the
package activated sludge plant. These benefits equal
6,930,000 kg/yr (6,930,000 = 3,410,000 + 3,520,000).
6. The BOD5 pollutant mass remaining after treatment
is 990,000 kg/yr (7,920,000 - 6,930,000 = 990,000).
Other pollutant benefits were calculated using this procedure.
Table C-4 lists the Option 2 influent and effluent concentrations
for the contact cooling and heating water pollutants. The per-
cent removals listed in Table C-2 were applied to the influent
concentrations (see Table VII-5) to calculate the treatment
system effluent concentrations.
Option 3
The technology for Option 3 for contact cooling and heating water
is:
For processes with an average process water usage flow rate of 35
gpm or less the technology is zero discharge by 100 percent
recycle of the wastewater through either a tank or a chiller.
C-8
-------
Table C-3
POLLUTANT BENEFITS AND AMOUNTS REMAINING AFTER BPT OPTION 2
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Pollutant Mass
Conventional Pollutants
BOD5
Oil and Grease
TSS
TOTAL
Nonconventlonal Pollutants
COD
TOG
Total Phenols
TOTAL
Priority Pollutants
4. benzene
6. carbon tetrachloride
(tetrachloromethane)
11. 1,1,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
65. phenol
66. bis(2-ethylhexyl) phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE(p,p'DDX)
100. heptachlor
102. a-BHC
103. B-BHC
Option 2
Benefits
(kg/yr)
6,930,000
380,800
127,000
7,437,800
15,310,000
6,000,000
179,800
21,489,800
3,540
51 ,000
5,250
1,329
4,560
5,290
1,537
19,880
680
4.
68
8.
1.
0.
10.
25
1.
Remaining
After Treatment
(kg/yr)
990,000
327,200
168,000
1,485,200
4,090,000
1,610,000
53,200
5,753,200
850
9,300
950
691
280
390
73
10,320
610
9 1.1
37
2 6.8
7 2.3
06 0.07
1 0.9
4
3 1.7
C-9
-------
Table C-3 (Continued)
POLLUTANT BENEFITS AND AMOUNTS REMAINING AFTER BPT OPTION 2
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Priority Pollutants
104. Y-BHC
105. 6-BHC
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
128. zinc
TOTAL
Option 2
Benefits
(kg/yr)
Pollutant Mass
Remaining
After Treatment
(kg/yr)
2.05
9.4
151
380
200
2,130
0.035
268
3,050
99,375.745
0.95
3.6
16
60
23
230
0.005
158
460
24,469.425
C-10
-------
Table C-4
INFLUENT AND EFFLUENT POLLUTANT CONCENTRATIONS - OPTION 2
CONTACT COOLING AND HEATING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
4. benzene
6. carbon tetrachloride
(tetrachlorotne thane)
11. 1 ,1,1-trichloroethane
22. parachlorometa cresol
23. chloroform (trichloromethane)
44. methylene chloride
(dichloromethane)
65. phenol
66. bis(2-ethylhexyl) phthalate
68. di-n-butyl phthalate
85. tetrachloroethylene
86. toluene
89. aldrin
90. dieldrin
93. 4,4'-DDE(p,p'DDX)
100. heptachlor
102. a-BHC
103. 3-BHC
104. Y-BHC
105. 6-BHC
118. cadmium
119. chromium (Total)
120. copper
122. lead
123. mercury
124. nickel
128. zinc
Influent
Concentration
(mg/1)
102
21
17
241
74
149
0.029
1.176
0.037
0.042
0.097
0.086
316
333
012
030
016
0.
0.
0.
0.
0.
315t
411
44t
203t
250t
176t
132t
104t
0.023
0.050
228
248
0004
686
0.
0.
0.
0.
0.190
Effluent
Concentration
(mg/D
22
17
17
89
27
60
0.010
0.318
0.010
0.025
0.010
0.010
025
,200
010
,010
010
0
0
0
0
0
252t
411
44t
30t
56t
176t
74t
50t
0.004
0.01
0,
0.
0,
0.
2
041
042
0001
446
0.044
tConcentration is in nanograms per liter.
C-ll
-------
For processes with an average process water usage flow rate
greater than 35 gpm the technology is recycle through a cooling
tower and zero discharge by contract haul of the discharge from
the recycle tank.
This option results in zero discharge of pollutants from all pro-
cesses using process water for contact cooling and heating.
Benefits for this option are equal to the total pollutant masses
for direct dischargers listed in Table C-1.
CLEANING AND FINISHING WATER SUBCATEGORY
Option 1
The technology for Option 1 consists of a tank in which the
velocity of the wastewater is reduced so that solid material can
settle by gravitational force. Acidic or basic material is added
to either the tank influent or the tank effluent to adjust the pH
of the wastewater.
Pollutant removals for this option were calculated using percent
removals from the USEPA Treatability Manual, Volume III, Tech-
nologies for Control/Removal of Pollutants, July 1980, EPA-600-
8-80-042c, for sedimentation. Percent removals were applied to
conventional, nonconventional and priority toxic metal pollu-
tants. The percent removal for selenium was adjusted to 57 per-
cent from the treatability manual percent removal of 63 percent,
because the 63 percent removal reduced the effluent concentration
below the analytical detection limit for that pollutant. The
organic priority pollutants are not removed by sedimentation
because they are dissolved. Table C-5 lists the percent remov-
als. These percent removals were applied to the total pollutant
masses for direct dischargers listed in Table C-1 for the clean-
ing and finishing water subcategory to calculate the benefits.
The benefits and pollutant masses remaining after treatment for
Option 1 are presented in Table C-6. Concentrations before and
after Option 1 treatment are listed in Table C-7. The percent
removals in Table C-5 were applied to the raw wastewater average
concentration to calculate the effluent concentrations after
treatment.
Option 2
This option consists of recycle through a sedimentation tank and
treatment of the discharge from the recycle unit in a package
activated sludge plant. The package plant includes an equaliza-
tion unit and pH adjustment.
The benefits for Option 2 include pollutant mass removals in the
sedimentation tank and in the activated sludge plant. Because
processes with a process water usage flow rate of two gpm or less
C-12
-------
Table C-5
OPTION 1 POLLUTANT PERCENT REMOVALS
CLEANING AND FINISHING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
4. benzene
23. chloroform (trichloromethane)
44. methylene chloride (dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl) phthalate
86. toluene
89. aldrin
100. heptachlor
102. a-BHC
104. Y-BHC
105. 6-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
%*
Removal
33
47
82
71
40
43
0
0
0
0
0
0
0
0
0
0
0
0
76
66
61
57**
51
*Percent removals are from the USEPA, Treatability Manual,
Volume III, Technologies for Control/Removal of Pollutants,
July 1980, 600-8-80-042c.
**The percent removal for selenium is based on the analytical
detection limit because the Treatability Manual percent
removal reduces the effluent concentration below the analy-
tical detection limit for that pollutant.
C-13
-------
Table C-6
POLLUTANT BENEFITS AND AMOUNTS REMAINING AFTER BPT OPTION 1
CLEANING AND FINISHING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
TOTAL
Nonconventional Pollutants
COD
TOG
Total Phenols
TOTAL
Priority Pollutants
4. benzene
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl) phthalate
86. toluene
89. aldrin
100. heptachlor
102. ct-BHC
104. Y-BHC
105. 6-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
TOTAL
Option 1
Benefits
(kg/yr)
98,700
16,300
310,000
425,000
341,000
166,000
18,600
525,600
0
0
0
0
0
0
0
0
0
0
0
0
30
42
18
0.
167
57
257.57
Pollutant Mass
Remaining
After Treatment
(kg/yr)
200,300
18,300
68,000
286,600
139,000
250,000
24,600
413,600
0.6
22
303
15
73
12
2
0.2
0.03
0.002
0.2
0.3
10
22
12
0.43
160
632.762
C-14
-------
Table C-7
INFLUENT AND EFFLUENT POLLUTANT CONCENTRATIONS - BPT OPTION 1
CLEANING AND FINISHING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
4. benzene
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl) phthalate
86. toluene
89. aldrin
100. heptachlor
102. a-BHC
104. Y-BHC
105. 6-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
Influent
Concentration
(mg/1)
100
130
1,840
410
371
134
0.026
0.045
0.067
0.036
1.334
0.059
0.120
52t
18t
5t
535t
116t
0.112
401
,136
0,
0,
0.175
3.375
Effluent
Concentration
(mg/1)
67
69
331
119
823
76
0.026
0.045
0.067
0.036
1.334
0.059
0.120
52t
18t
5t
535t
116t
0.027
0.136
0.053
0.075
1.654
•(•Concentration is in nanograms per liter,
C-15
-------
were costed for zero discharge by contract haul, a portion of the
benefits after sedimentation was attributed to zero discharge and
the remaining portion was attributed to the treatment system. As
in the contact cooling and heating water subcategory, these por-
tions were determined using the percentage of plastics produced
and not the volume of wastewater discharged, because the pollu-
tant masses are dependent on the amount of plastics produced.
For the cleaning and finishing water subcategory, 12.7 percent of
the total plastic amount is processed by processes with an aver-
age process water usage flow rate of two gptn or less. This per-
centage for direct dischargers was obtained from the question-
naire data base.
The percent removals and benefits for BPT Option 1 apply to the
sedimentation tank (i.e., the recycle unit) in Option 2 (see
Tables C-5 and C-6). The percent removals for the package acti-
vated sludge plant in the cleaning and finishing subcategory were
determined as described in BPT Option 2 for the contact cooling
and heating water subcategory. The influent concentrations to
the activated sludge process are the concentrations after sedi-
mentation. Table C-8 lists the percent removals for the package
activated sludge plant for the cleaning and finishing water
subcategory.
The pollutant mass removals for BPT Option 2 and the pollutant
masses remaining are presented in Table C-9. The procedure used
to calculate for BOD5 removal is described below:
1. The total direct discharger BOD^ mass load is 299,000
kg/yr (from Table C-1).
2. The benefit for sedimentation is 33 percent 6005
removal or 98,700 kg/yr (98,700 = 0.33 x 299,000).
3. After sedimentation 200,300 kg/yr (200,300 = 299,000 -
98,700) remain.
4. Of this amount, 12.7 percent is removed from processes.
with an average process water usage flow rate of two gpm
or less by zero discharge of pollutants. Benefits for
zero dischargers are 25,400 kg/yr (25,400 = 0.127 x
200,300).
5. The remaining pollutant mass available for treatment
in a package activated sludge plant is 174,900
kg/yr (174,900 = 200,300 - 25,400).
6. The BODij percent removal in the package activated
sludge plant is 67 percent. BODs removal in that
process is 117,000 kg/yr (117,000 = 0.67 x 174,900).
C-16
-------
Table C-8
PACKAGE ACTIVATED SLUDGE PLANT PERCENT REMOVALS - BPT OPTION 2
CLEANING AND FINISHING WATER SUBCATEGORY
Conventional Pollutants
BOD5 '
Oil and Grease
TSS
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
% Removal Source
67 Percent removals
75 were calculated using
89 effluent concentration
data transferred from
the organic chemicals,
plastics, and synthe-
tic fibers category
63 5
63 5
60 5
4.
23.
44.
62.
65.
66.
86.
89.
100.
102.
104.
105.
119.
120.
124.
125.
128.
1
2.
4.
5.
benzene
chloroform (trichloro-
methane)
methylene chloride
(dichloromethane)
N-nitrosodiphenylamine
phenol
bis(2-ethylhexyl) phthalate
toluene
aldrin
heptachlor
a-BHC
Y-BHC
6-BHC
chromium (Total)
copper
nickel
selenium
zinc
62 1
78 1
85 1
72 1
98 1
0 3
92 1
20 2
85 2
60 1
44 2
55 2
74 1
82 2
35 2
0 4
77 2
Percent removal is based on the analytical detection limit.
Percent removal is from the USEPA, Fate of Priority Pollu-
tants in Publicly Owned Treatment Works, Volume I, September
1982, 440/1-82-303.
Percent removal is determined from the USEPA, Contractors
Engineering Report, Analysis of Organic Chemicals and Plas-
tics/Synthetic Fibers Industries Toxic Pollutants, November
16, 1981, Contract No. 68-01-6024.
The influent concentration is below the analytical detection
limit after sedimentation.
Percent removals are from USEPA, Treatability Manual, Volume
III, Technologies for Control/Removal of Pollutants,
July 1980, EPA 600/8-80-842c.
C-17
-------
Table C-9
POLLUTANT BENEFITS AND AMOUNTS REMAINING AFTER BPT OPTION 2
CLEANING AND FINISHING WATER SUBCATEGORY
Conventional Pollutants
BOD5
Oil and Grease
TSS
TOTAL
Nonconventional Pollutants
COD
TOG
Total Phenols
TOTAL
Priority Pollutants
4. benzene
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl) phthalate
86. toluene
89. aldrin
100. heptachlor
102. a-BHC
104. Y-BHC
105. 5-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
TOTAL
Option 2
Benefits
(kg/yr)
241,100
30,620
371,440
643,160
435,100
334,800
34,620
804,520
Pollutant Mass
Remaining
After Treatment
(kg/yr)
57,900
3,980
6,560
68,440
44,900
81,200
8,580
0.401
18
263
11
72
2
1.86
0.06
0.026
0.0013
0.102
0.182
37.7
61
23.5
0.62
295
786.4523
134,680
0.199
4
40
4
1
10
0.
0.
0.
0.
0.
0.
2.
3
6.
0.
32
14
14
004
0007
098
118
3
5
38
103.8797
C-18
-------
7. Total benefits are the removals in the sedimentation
tank, the portion of pollutants removed by zero
dischargers and the portion of pollutants removed in
the package activated sludge plant. These removals are
241,100 kg/yr (241,100 = 98,700 + 25,400 + 117,000).
8. The 6005 pollutant mass remaining after treatment
is 57,900 kg/yr (57,900 = 299,000 - 241,100).
Other pollutant removals were calculated using the above
procedure.
Table C-10 lists the pollutant concentrations before Option 2
treatment, after the sedimentation process, and after the package
activated sludge plant for Option 2. The percent removals listed
in Tables C-5 and C-8 were used to calculate the effluent concen-
trations from the sedimentation tank and the package activated
sludge plant, respectively.
Option 3
Option 3 consists of recycle through a sedimentation tank for all
processes and contract haul of the discharge from the recycle
unit. This option results in zero discharge of pollutants from
all processes that use process water for cleaning and finishing.
Benefits for this option are equal to the total pollutant mass
for direct dischargers listed in Table C-1.
BENEFITS SUMMARY
Table C-11 lists the total pollutant masses for conventional,
nonconventional, and priority pollutants for direct dischargers,
benefits, and the pollutant masses remaining after treatment for
each option by subcategory.
C-19
-------
Table C-10
POLLUTANT CONCENTRATIONS - BPT OPTION 2
CLEANING AND FINISHING WATER SUBCATEGORY
Option 2
Conventional Pollutants
BOD5
Oil and Grease
TSS
Nonconventional Pollutants
COD
TOG
Total Phenols
Priority Pollutants
Influent
Concen-
tration
(ing/1)
100
130
1,840
410
(371
134
4. benzene
23. chloroform (trichloro-
methane)
44. methylene chloride
(dichloromethane)
62. N-nitrosodiphenylamine
65. phenol
66. bis(2-ethylhexyl) phthalate
86. toluene
89. aldrin
100. heptachlor
102. a-BHC
104. Y-BHC
105. 6-BHC
119. chromium (Total)
120. copper
124. nickel
125. selenium
128. zinc
0.026
0.045
0.067
Concen-
tration
After
Sedimen-
tation
(mg/1)
67
69
331
119
823
76
Concen-
tration
After
Activated
Sludge
Treatment
0.026
0.045
0.067
22
17
36
44
304
30
0.010
0.010
0.010
0.036
1.334
0.059
0.120
52t
18t
5t
535t
116t
0.112
0.401
0.136
0.175
3.375
0.036
1.334
0.059
0.120
52t
18t
5t
535t
116t
0.027
0.136
0.053
0.075
1.654
0.010
0.025
0.059
0.010
41. 6t
2.7t
2t
300t
52. 2t
0.007
0.024
0.034
0.075
0.380
tConcentration is in nanograms per liter
C-20
-------
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C-21
-------
APPENDIX D
TRANSFER OF TREATMENT TECHNOLOGY PERFORMANCE DATA
AND CALCULATION OF PRODUCTION NORMALIZED FLOWS -
PM&F CATEGORY
-------
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
FEB IB 1984
MEMORANDUM
SUBJECT: Transfer of Treatment Technology Performance Data and Calculation
of Production Normalized Flows - PN&F Category
FROM: R. Clifton Bailey, Statistician
Program Integration and Evaluation Staff (WH-586)
TO: Robert M. Southworth, Project Officer
Effluent Guidelines Division (V«-552)
Purpose
This memorandum discusses the transfer of performance data for the
activated sludge process for biochemical oxygen demand (6005), total suspended
solids (TSS), and oil and grease (O&G) from the organic chemicals, plastics,
and synthetic fibers (OCPSF) category to the plastics molding and forming (PM&F)
category. It also discusses the production normalized flows (PNF) used to calcu-
late the proposed effluent limitations guidelines and standards for the PM&F
category.
Background
Effluent limitations guidelines and standards for processes in the PN&F
category that discharge wastewater to navigable waters (i.e., direct dis-
chargers) are currently being developed. For regulatory purposes, the PM&F
category has been divided into two subcategories:
0 contact cooling and heating water subcategory, and
0 cleaning and finishing water subcategory.
The technology basis for the best practicable technology currently available
(BPT) effluent limitations guidelines and standards for both subcategories is
flow reduction and treatment of the discharge from the flow reduction unit in
an activated sludge plant. However no effluent data on activated sludge treat-
ment of PM&F only wastewater were available.* Tb obtain effluent concentration
There are no plants in the Agency's data base that treat PM&F wastewter only
in an activated sludge system. Several integrated facilities are known to
combine PM&F wastewater with other industrial wastewater for treatment by
activated sludge. EPA does not have effluent data from these systems.
D-l
-------
-2-
data, we first compared the PM&F untreated wastewater data for BOD5, TSS and,
O&G to data for those pollutants at plastic manufacturing plants (PMP) in the
OCPSF category. Results of that comparison are presented in this memorandum.
Because the wastewaters from PM&F and PMP plants have similar 8005, TSS, and
O&G characteristics, it is appropriate to use activated sludge effluent data
for those pollutants from the OCPSF category to determine limitations for the
PM&F category. Those data are also presented in this memorandum.
To determine the amount of pollutants that can be discharged, effluent
concentration data for the activated sludge process were multipled by a product
normalized flow (liters discharged per mass of plastic material processed).
The amount of plastic material processed was selected as the normalizing para-
meter for the PM&F category because the amount of water used and the amount of
pollutants discharged are related to the amount of plastic material processed.
The PNFs for each PM&F subcategory were calculated by adding the amount of
wastewater discharged by plants in the PM&F data base that currently recycle
process water. The total amount of wastewater discharged was divided by the
total production reported for those plants to obtain the PNFs. Data used to
calculate the PNFs for each subcategory are presented in this memorandum.
Data
Plastics Molding and Forming Process Data;
Samples of untreated process water were collected at 11 plastics molding
and forming (PM&F) plants. The biological oxygen demand (8005), total suspended
solids (TSS), and oil and grease (O&G) concentrations found in these samples
are listed in Appendix IIIA. Concentration data for these pollutants are
presented for both contact cooling and heating water and cleaning and finishing
water.
Plastics Manufacturing Data;
The technical development document (Development Document for Effluent
Limitations Guidelines and Standards for the Organic Chemicals and Plastics,
and Synthetic Fibers Point Source Category, Volume 1 (Proposed BPT), EGD, EPA
440/1-83/0096 - hereafter referred to as the "Organics BPT Development Document11)
contains a summary of 8005 and TSS data used to establish proposed effluent
limitations guidelines for the plastics only subcategory of the OCPSF category.
The effluent limitations guidelines for that subcategory are based on data
from well-operated activated sludge processes at six plastics manufacturing
plants (Nos. 9, 44, 45, 96, 111, 126). These well-operated treatment processes
were identified through an engineering analysis of the performance data for
those processes (see page 190 of the Organics BPT Development Document for a
summary). 8005 and TSS data were available from effluent samples at five of
these six plants (Nos. 9, 44, 45, 111, 126). These data are presented in
Appendix IIIB.
Oil and grease (O&G) data were not available for the six well-operated
wastewater treatment systems at the plastics manufacturing plants in the plastics
only subcategory. Limitations for O&G were developed on the basis of data from
4 plants (3, 61, 124, 170) in the OCPSF data base that manufactured plastics
(not necessarily plastics only plants) and use activated sludge treatment.
D-2
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-3-
The limitations were developed on the basis of a lognormal distribution
fit to the data. The goodness-of-fit of the lognormal model for the O&G effluent
data was examined using a graphical procedure described in Appendix I. As
stated in Appendix I, the plots presented in Appendix IIC support the lognormal
distribution as a model for the O&G effluent data. The same graphical procedure
was used to demonstrate lognormality for 0005 and TSS in the Organics BPT
Development Document.
Plastics Molding and Forming Production and Flow Data;
In addition to the sampling data described above, the Agency conducted a
questionnaire survey of the PM&F industry. Production and wastewater discharge
data obtained in this survey for PM&F plants that currently recycle process
water are listed in Appendix IIIC for the two PM&F subcategories. These data
were used to calculate the production normalized flow for each PM&F category.
Process Wastewater Comparison
8005, TSS, and O&G concentration values in untreated PM&F process wastewater
were compared to the concentration values for those pollutants in untreated PMP
process wastewater. Plant averages and log-variances were used for the com-
parisons. The log-variance is a direct measure of the variability in the data
(see Appendix I). Together the plant averages and log-variances provide a
statistical summary of the process wastewater concentrations. The plant averages
and log-variances were computed for each of the PM&F subcategories and for the
plastics manufacturers plants (see Appendix I for a summary of the computational
procedures). The results, ordered from smallest to largest mean and log-variance,
are presented in Tables 1 and 2.
A nonparametric test, the Mann-Whitney U/Wilcoxon T test for two independent
samples, was used to make statistical comparisons. The comparisons (summarized
in Table 3) were made separately for plant means and plant log-variances. In
none of the test results was the median of the PM&F means and log-variances
found to be significantly greater than the PMP values. Consequently, PM&F pro-
cess wastewater is neither significantly greater in average concentration nor
more variable than the PMP process wastewater for 6005, TSS or O&G. This
statistical analysis supports the judgment that BOD^, TSS, and O&G effluent
concentrations for activated sludge treatment at PM&F process wastewater
should neither be greater nor more variable than the effluent concentrations
for those pollutants for an activated sludge process used to treat PMP process
wastewater. We conclude, therefore, that the 8005, TSS and O&G concentration
in PM&F process wastewater and PMP process wastewater are similar and that
activated sludge treatment of PM&F wastewater can achieve the effluent concen-
tration values for 8005, TSS, and O&G for the OCPSF category.
Effluent Concentration Values
The 8005, TSS, and O&G effluent concentration values for the activated
sludge processes that were transferred from the OCPSF category are presented
in Table 4. These values were used to calculate the PM&F effluent limita-
tions guidelines presented in Table 7. The BOD and TSS concentration limits
are the same as the plastics only limitations shown on page 280, Table 4-1 of
the Organics BPT Development Document. The Organics BPT Development Document
does not contain oil and grease effluent concentration values for the plastics
D-3
-------
-4-
only subcategory. Consequently, the effluent data for four plants that manu-
facture plastics and organics (3, 61, 124, 170) (see the Data Section above of
this memorandum) were used to compute the O&G effluent limitations shown in
Table 4. The O&G concentration values shown in Table 4 are the products of
the long-term median (median of the plant averages) and the average varibility
factors based on the lognormal distribution (from Table 5). The variability
factors for the four PHP plants are shown in Table 5. The computational
procedures described in Appendix I follow closely the procedures in Appendix B
of the Organics BPT Development Document.
Production Normalized Flow
The production normalized flow (PNF) for each subcategory (or portion of
subcategory) was calculated by dividing the amount of wastewater discharged by
PM&F processes that currently recycle process water by the total production
for those processes. Table 6 contains those PNFs. Data used to calculate
the PNFs are presented in Appendix II1C.
The Agency calculated and applies only one PNF to all the contact cooling
and heating water processes. The normalizing parameter used to calculate the
PNF is the mass of plastic material cooled or heated. Because the amount of
water needed to cool or heat a product is dependent on the mass of plastic
material and not the type of process or product one PNF is appropriate for all
cooling and heating processes. Two PNFs were calculated for the cleaning and
finishing water subcategory, one for cleaning processes and one for finishing
processes. Again, the normalizing parameter used is the mass of plastic
material. Two PNFs are needed for this subcategory because the water usage
requirements for cleaning operations were found to be substantially different
than those for finishing operations.
BPT Effluent Limitations
Table 7 lists the proposed BPT mass-based effluent limitations guidelines
for each subcategory. These limitations were calculated by multiplying the
transferred effluent concentration values for 8005, TSS, and O&G by the PNFs.
D-4
-------
-5-
TABLE 1
Sunmary of Process Wastewater Data for PM&F and Plastics Manufacturing Plants
Cleaning and Finishing Water Subcategory
D-5
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D-7
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-8-
TABLE 2
Summary of Process Wastewater Data for PM&F and Plastics Manufacturing Plants (PMP)
Contact Cooling and Heating Water Subcategory
D-8
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D-10
-------
-11-
TABLE 3
RESULTS OF THE COMPARISON OF PM&F AND PMP PROCESS WASTEWATER
Using Wilcoxon - T Test for 2 Independent Samples
One-Tailed Test HQ: PMF £ PMP
HA: PMF > PMP
SUBCATEGORY
PLANT MEANS
RANKED
Cleaning and
Finishing Water
Contact Cooling
and Heating
Water
PLANT VARIANCES
RANKED
Cleaning and
Finishing Water
Contact Cooling
and Heating
Water
POLLUTANT
BODs
O&G
TSS
BODs
O&G
TSS
BODs
O&G
TSS
BODs
O&G
TSS
NUMBER OF PLANTS
PMF
6
7
7
8
9
9
5
3
5
6
5
7
PMP
5
4
5
5
4
5
5
4
5
5
4
5
RANK MEAN
PMF
4.17
5.00
5.14
5.38
5.44
5.22
6.2
4.7
5.6
6.17
3.80
6.00
PMP
8.2
7.75
8.4
9.6
10.0
11.6
4.8
3.5
5.4
5.8
6.5
7.2
Tx
41
31
42
48
42
58
31
14
28
29
26
36
O
P 2
.974 NS
.885 NS
.926 NS
.967 NS
.983 NS
.998 NS
.274 NS
.314 NS
.500 NS
.465 NS
.915 NS
.691 NS
Conclusion: In all cases, there was no significant difference between rank
means.
1 As defined by Gibbons, J.D., "Nonparametric Methods for Quantitative Analysis,"
Holt, Rinehard and Winston, 1976, p. 163.
2 NS - not significant.
D-ll
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-12-
TABLE 4
601)5, O&G and TSS Effluent Concentration Values for
Plastics Molders and Formers
(Concentration Values Are the Same for the Two Subcategories:
Pollutant
BODS*
O&G
TSS*
Long-Term Median Maximum 30-Day (mg/1)
14.5
11.9
24
22
17
36
Maximum Daily (mg/1)
49
71
117
See Table 9-1, page 280, BPT Development Document.
TABLE 5
Variability Factors for O&G
Plant
N
Effluent Mean
Variability Factor
3
61
124
170
46
348
100
163
13.0
14.6
5.2
10.8
1-Day
AVERAGE
6.44
3.77
9.27
4.21
5.92
30-Day
1.37
*
1.37
* Not estimated. Fewer than five consecutive day-pairs available to estimate
the 1-day lag correlation for the variability factor (see Appendix I).
Subcategory
Cleaning & Finisning
Water
a) Cleaning
b) Finishing
Contact Cooling
and Heating Water
TABLE 6
Production Normalized Flow
Discharge Flow
(Liters/Year)
6115919
983333
13583148
Production
(KKG/Year)
1364.5
921.4
8548.3
Production Normalized
Flow
(Flow/Production)
(Liters/KKG)
4482
1067
1589
D-12
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-13-
TABLE 7
Effluent Limitations Guidelines by PM&F Subcategory
Cleaning and Finishing Water Subcategory 30-Day (mgAg) 1-Day (mg/kg)
•a) Cleaning Water
BODS 99 220
O&G 76 318
TSS 161 524
b) Finishing Water
BODS 23 52
O&G 18 76
TSS 38 125
Contact Cooling and Heating Water Subcategory
BODS 35 78
O&G 27 113
TSS 57 186
D-13
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-14-
APPENDICES
I. Statistical Procedures
II. Summary Statistics
A. PM&F Sampling Data
B. PMP Data
C. Probit Plots for PMP Oil and Grease Data
III. Data
A. PM&F Process Sampling Program Data: BOD, O&G, and TSS
B. PMP Data: Influent and Effluent BOD, O&G, and TSS
C. PM&F Questionnaire Survey Data for Production and Discharge Flow
D-14
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-15-
I. STATISTICAL PROCEDURES
Descriptive Statistics
Sane of the more commonly employed descriptive statistics are defined as
follows:
(1) N - number of valid observations used in a particular analysis (e.g.,
the total number of effluent samples at a particular plant for a
particular pollutant)
_ N
(2) Mean - arithmetic average: X = ]> Xj/to
i=l
9 N
(3) Variance - standard unbiased estimate: S^ = 1 £ (X; - X)z
N-l i=l
Log-variance - variance with X^ = loge (observation)
Daily variability factors depend directly on the log-variance (see the
section of this Appendix below on Variability Factors) .
(The standard deviation is S = / S^. )
(4) Minimum - the smallest value in a set of N observations
(5) Maximum - the largest value in a set of N observations
(6) Range - the minimum subtracted from the maximum
(7) Median - the middle value in a set of N observations. If N is odd
(N = 2k - 1 for some integer k), the median is the kth order statistic,
C(k). If N is even (N = 2k), the median is
[C(k) + C(k + l
(8) Stream Average - flow weighted average of sample concentrations
x = I wi Xi
where
Wi = fi/ I f i
for sample concentration Xj[ and stream flow f ^
(9) Plant average - flow weighted average of stream concentrations
X = I Wi Xi
where
D-15
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-16-
Wi = fi/ I fi
for sample average concentration xj_ and stream average f^. When
flows are missing the plant average is the plant mean.
Goodness-of-Fit Test
The goodness-of-fit of the lognormal model for the O&G effluent data (PMP)
was checked through a graphical procedure called a probability plot. Let Xj,
..., Xfl denote the n observed daily values of the parameter of interest (the
BOD or measurements from a given plant). Denote the rth largest of the n
values by X(r), and define a corresponding score called the "probit" by
Probit [X(r)] = t~l[r/(n +1)],
where *"!(•) is the inverse of the standard normal cumulative distribution
function. The probit score is the normal deviation (z-value) equivalent to
the value X(r). Probit scores are useful because plots of X values versus
corresponding probit scores tend to be straight lines when X is normally
distributed; this fact is the basis for probability plots. If X has a log-
normal distribution, a log-scale plot of X values versus probit scores tends
to be a straight line. Daniel and Wood (1971) give simulated examples of
probability plots to indicate the degree of random departure from a straight
line to expect for different sample sizes when X is normally distributed.
Probability plots for BOD and TSS are presented in Figures B-l to B-28 of the
BPT Development Document. Similar plots for O&G are presented in Appendix II C.
Based on the probability plots, it was concluded that the lognormal
distribution was a reasonable model for the PMP oil and grease effluent data.
Variability Factors
Assuming that the distribution of the concentration c is_lognormal, then
y = log(c) is normally distributed with mean M and variance o'- (Aitchison and
Brown, pages 8-9). Thus the 99th percentile on the natural log scale is
Y0.99 = v + 2-326 ° '
and the 99th percentile on the concentration scale is
c0.99 = exp(y0>99) = e^ + 2.326 o .
The mean and variance on the concentration scale are:
^ = ey + 1/2 o*
and
a2 = e2v + a2 (eo2 - 1).
c
Hence, the daily maximum variability factor under the lognormal model is
D-16
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-17-
VF(1) = cn.QQ = e2-326 a ~ I/2 a2 •
(2)
Estimates of any of the above quantities are calculated by substituting the
mean and variance of natural logs of the observations for y and 02r respec-
tively. Consequently, the daily maximum variability factor depends directly
on the log-variance of the concentration.
Variability factors for 30-day average concentrations, VF(30), are based
on the distribution of an average of values drawn from the distribution of daily
values and take day-to-day correlation into account. Positive autocorrelation
between concentrations measured on consecutive days means that such concentra-
tions tend to be similar. An average of positively correlated concentration
measurements is more variable than an average of independent concentrations.
The following formulas incorporate the autocorrelation between concentration
values measured on adjacent days.
The correlation fp) between adjacent days' measurements (i.e., the lag-1
autocorrelation) was estimated using the available data. Then using the
first-order autoregressive model commonly found to be appropriate in water
pollution modeling, the mean and variance of an average of n daily values,
denoted by c, were approximated by:
y_= exp( y -i- o2/2) (3)
c
and
o2
01 = — fn (P)' <4>
c n
with
n-1
fn( p ) = 1 + (2/n) V (n-k)(exp( pk 02 ) - D/(exp a2 - 1).
k=l
It can be seen in (4) that a2_ equals the variance of an average of n
c
uncorrelated observations, 02 /n, multiplied by a factor, fn( p] that adjusts for
c
the presence of autocorrelation. For oil and grease effluent data, the estimate
for the lag-1 autocorrelation between logs of the concentration measurements
was 0.5095 and the adjustment factor is 2.665. Similar adjustments were made
in the Organics BPT Development Document for 8005 and TSS concentration values.
Finally, since c is approximately normally distributed by the Central
Limit Theorem, the 95th percentile and variability factors of a 30-day average
are approximately
C0.95 = Me + !-64b oc
and
D-17
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-18-
VF(30) = cr
1/2
= 1 + 1.645[ea - Df30( P HO] (6)
^_ r\ ____
with Pc and o_ defined by equations (3) and (4). Estimates of 09.95 or
c"
VF(30) are calculated by substituting estimates of P, o2, and P into the
formulas above.
D-18
-------
-19-
References
Aitchison, J., and J.A.C. Brown (1957). The Lognormal Distribution, Cambridge
University Press, London, 8-9.
Bradley, J.V. (1968). Distribution Free Statistical Tests, Prentice-Hall,
Englewood Cliffs, NJ, 149-154, 326-330.
Daniel, C., and F.S. Wood (1971). Fitting Equations to Data, Wiley, New York,
34-43.
Kendall, M.G., and A. Stuart (1973). The Advanced Theory of Statistics, Vol. 2,
3rd Edition, Hafner, New York, 516-520.
D-19
-------
APPENDIX II A
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DATA APPENDIX III CONTENTS
A. PM&F Sampling Program: Influent BOD, O&G, and TSS
B. PMP Data: Influent and Effluent BOD, O&G, and TSS
C. MP&F Questinnaire Survey Data for Production and Discharge Flow
D-30
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APPENDIX III A
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