United States       Effluent Guidelines Division    EPA 440/1-84/069-b
Environmental Protection    WH-552         February 1984
Agency         Washington DC 20460
Water
Development         Proposed
Document for
Effluent Limitations
Guidelines and
Standards for the

Plastics Molding
and Forming

Point Source Category

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               DEVELOPMENT DOCUMENT

                       for

  EFFLUENT LIMITATIONS GUIDELINES AND STANDARDS

                     for the

PLASTICS MOLDING AND FORMING POINT SOURCE CATEGORY
              William D. Ruckelshaus
                  Administrator
                  Jack E. Ravan
        Assistant Administrator for Water
                 Steven Schatzow
                     Director
    Office of Water Regulations and Standards
            Jeffery D. Denit, Director
           Effluent Guidelines Division
            Robert M. Southworth, P.E.
            Technical Project Officer
                  February 1984
       U.S.  Environmental Protection Agency
                 Office of Water
    Office of Water Regulations and Standards
           Effluent Guidelines Division
             Washington,  D.C.  20460

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                        TABLE OF CONTENTS


Section                                                     Page

I         SUMMARY AND CONCLUSIONS	      1

          CONTACT COOLING AND HEATING WATER SUBCATEGORY.  .      5

          Best Practical Technology (BPT) Effluent
          Limitations Guidelines 	      5
          Best Available Technology (BAT) Effluent
          Limitations Guidelines 	      5
          Best Conventional Technology (BCT) Effluent
          Limitations Guidelines 	      6
          New Source Performance Standards (NSPS)	      6
          Pretreatment Standards for Existing Sources
          (PSES) 	      6
          Pretreatment Standards for New Sources (PSNS).  .      7

          CLEANING AND FINISHING WATER SUBCATEGORY ....      7

          Best Practical Technology (BPT) Effluent
          Limitations Guidelines 	      7
          Best Available Technology (BAT) Effluent
          Limitations Guidelines 	      8
          Best Conventional Technology (BCT) Effluent
          Limitations Guidelines 	      8
          New Source Performance Standards (NSPS)	      8
          Pretreatment Standards for Existing Sources
          (PSES) 	      9
          Pretreatment Standards for New Sources (PSNS).  .      9

II        RECOMMENDATIONS	    11

III       INTRODUCTION	    19

          BACKGROUND	    19

          PURPOSE	    21

          AUTHORITY	    21

          STUDY APPROACH	    21

IV        CATEGORY PROFILE 	    23

          NPDES PERMITS	    23

          SAMPLING PROGRAM 	    25

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

          QUESTIONNAIRE SURVEYS	    25

          1978 and 1979 Questionnaire Surveys	    25
          1983 Telephone Survey	    26
          1983 Questionnaire Survey	    33
          Summary of Questionnaire Data Base .......    36

          LITERATURE REVIEW	    38

          INDUSTRY DESCRIPTION	    38

          PLASTICS MOLDING AND FORMING PROCESSES .....    40

          Extrusion Processes	    41
          Molding Processes	    43
          Coating and Laminating Processes 	    55
          Thermoforming Processes	    64
          Calendering Processes	    67
          Casting Processes	    69
          Foam Processes	    73
          Cleaning and Finishing  Processes	    74

V         SUBCATEGORIZATION	    75

          BASIS FOR SUBCATEGORIZATION SCHEME 	    75

          FACTORS CONSIDERED 	    75

          Raw Materials	    75
          Production Processes 	    76
          Products Produced	    76
          Size and Age of Plants	    77
          Geographic Location	    78
          Types of Water Use	    78
          Wastewater Characteristics 	    79

          SELECTED SUBCATEGORIZATION SCHEME	    80

VI        WATER USE AND WASTEWATER CHARACTERISTICS ....    83

          QUESTIONNAIRE DATA	    83

          PM&F CATEGORY DATA	    87

          Estimate of Number of Processes in PM&F
          Category That Use Process Water	    92
                               11

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                  TABLE OF CONTENTS (Continued)
Section                                                     Page

          Estimate of Number of Plants in PM&F Category
          With Processes That Use Process Water	    93
          Estimate of PM&F Category Process Water Use. . .    96
          Estimate of PM&F Category Process Wastewater
          Discharged	    98

          SAMPLING PROGRAMS	    98

          Plant Selection	    98
          Field Sampling	   101
          Sample Collection,  Preservation, and
          Transportation 	   101
          Sample Analysis	   101
          Field Quality Assurance/Quality Control (QA/QC).   101
          Laboratory Quality Assurance/Quality Control
          (QA/QC)	   121

          WASTEWATER POLLUTANT CHARACTERISTICS 	   122

          SAMPLED PLANTS WITH WASTEWATER TREATMENT
          SYSTEMS	   130

          SOLUTION CASTING/SOLVENT RECOVERY SAMPLING DATA.   130

VII       POLLUTANTS IN PLASTICS MOLDING AND FORMING
          WASTEWATER	   133

          CONVENTIONAL POLLUTANTS	   133

          NONCONVENTIONAL POLLUTANTS 	   133

          PRIORITY TOXIC POLLUTANTS	   133

          List of Pollutants	   133
          Exclusion of Pollutants and Subcategories. ...   134

          POLLUTANTS CONSIDERED FURTHER	   136

          Conventional Pollutants	   143
          Nonconventional Pollutants 	   146
          Priority Pollutants	   147

          MASS OF POLLUTANTS	   164

          Average Subcategory Production Rate	   164
          Estimated Number of Wet Processes	   164
                              111

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

          Subcategory Average Raw Waste Values 	    165
          Pollutant Detection Fraction 	    171
          Estimated Pollutant Masses in Process Water by
          Subcategory	    171

VIII      TREATMENT TECHNOLOGY AND FLOW REDUCTION OPTIONS.    173

          IN-PLANT TECHNOLOGY	    173

          Process Water Recycle	    173
          PM&F Process Modification	    176

          END-OF-PIPE TREATMENT TECHNOLOGY 	    178

          Activated Sludge	    178
          Fixed Growth Biological Treatment Systems. ...    185
          Package Aerobic Treatment Units	    186
          Sedimentation	    192
          Gravity Oil Separation 	    193
          Neutralization 	    196
          Carbon Adsorption	    196
          Granular Media Filtration	    197
          Septic Tank-Soil Absorption Bed	.  .    199
          Contract Haul	    199

IX        COSTS, ENERGY,  AND NON-WATER QUALITY ASPECTS .  .    201

          BPT TREATMENT TECHNOLOGY OPTIONS 	    201

          Contact Cooling and Heating Water Subcategory.  .    201
          Cleaning and Finishing Water Subcategory  . .  „  .    202
          Costs of Treatment Technology Options for
          BAT, BCT, and NSPS	    203

          COST ESTIMATES	    203

          Sources of Cost Data	    203
          Cost Components	    204
          Cost Estimates	  .    205

          TECHNOLOGY COSTS	  .    206

          Recycle Unit - Contact Cooling and Heating
          Water Subcategory	    206
          Quench Tank Technology 	    206
          Chiller Technology 	  .    208
                               IV

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                  TABLE OF CONTENTS  (Continued)


Section

          Cooling Tower Technology 	   209
          Recycle Unit - Cleaning and Finishing Water
          Subcategory	   210
          Equalization 	   211
          Package Activated Sludge Plant	   211
          pH Adjustment	   212
          Sedimentation	   213

          CALCULATION OF INDIVIDUAL  PLANT COSTS	   213

          ENERGY AND NON-WATER QUALITY IMPACTS 	   218

          Energy Requirements	   218
          Air Pollution	   219
          Solid Waste	   219
          Consumptive Water Loss 	   221

X         BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
          AVAILABLE	   223

          BACKGROUND	   223

          TECHNICAL APPROACH 	   224

          TREATMENT TECHNOLOGIES 	   226

          BPT TREATMENT TECHNOLOGY OPTIONS 	   228

          Contact Cooling and Heating Water Subcategory.  .   228
          Cleaning and Finishing Water Subcategory ....   234

          REGULATED POLLUTANTS OR POLLUTANT PROPERTIES  .  .   239

          EFFLUENT CONCENTRATION VALUES	   241

          BPT PRODUCTION NORMALIZED  FLOWS	   242

          Contact Cooling and Heating Water Subcategory.  .   242
          Cleaning and Finishing Water Subcategory ....   244

          BPT EFFLUENT LIMITATIONS GUIDELINES	   248

          Contact Cooling and Heating Water Subcategory.  .   250
          Cleaning and Finishing Water Subcategory ....   250

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                  TABLE OF CONTENTS (Continued)
Section
XI
XII
XIII
XIV

XV

XVI

XVII
                                                  Page
EXAMPLE OF THE APPLICATION OF THE BPT EFFLUENT
LIMITATIONS GUIDELINES 	   252

Example	   252

BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE	   255

Contact Cooling and Heating Water Subcategory.  .   255
Cleaning and Finishing Water Subcategory  ....   258

NEW SOURCE PERFORMANCE STANDARDS 	   261

TECHNICAL APPROACH TO NSPS	   261

NSPS OPTION SELECTION	   261

Contact Cooling and Heating Water Subcategory.  .   261
Cleaning and Finishing Water Subcategory  ....   263
Costs and Pollutant Removals for NSPS.	   263

REGULATED POLLUTANTS AND POLLUTANT PROPERTIES.  .   268

NEW SOURCE PERFORMANCE STANDARDS ...  	   268

Contact Cooling and Heating Water Subcategory.  .   269
Cleaning and Finishing Water Subcategory  ....   270

PRETREATMENT STANDARDS 	   273

PRETREATMENT STANDARDS FOR EXISTING SOURCES.  .  .   274

Contact Cooling and Heating Water Subcategory.  .   274
Cleaning and Finishing Water Subcategory  ....   276
Proposed PSES	   279

PRETREATMENT STANDARDS FOR NEW SOURCES  	   279

BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY  .   281

ACKNOWLEDGEMENTS 	   285

REFERENCES	   287

GLOSSARY	   305
                               VI

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

APPENDICES

   A      SAMPLING DATA	   A-1

   B      STATE INDUSTRIAL GUIDES	   B-1

   C      BENEFITS	   C-1

   D      TRANSFER OF TREATMENT TECHNOLOGY PERFORMANCE
          DATA AND CALCULATION OF PRODUCTION NORMALIZED
          FLOWS - PM&F CATEGORY	   D-1
                              VII

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                           LIST  OF  TABLES


Number                                                       Page

IV-1      SUMMARY OF MAJOR NPDES PERMITS  	     24

IV-2      SUMMARY OF PLASTICS MOLDING AND FORMING
          PROCESSES	     27

IV-3      DISTRIBUTION OF  THE NUMBER OF WET  PLASTICS
          MOLDING AND FORMING PROCESSES BY DISCHARGE
          MODE	     28

IV-4      RESULTS OF 1983  PLASTICS MOLDING AND  FORMING
          TELEPHONE SURVEY FIRST PART	     29

IV-5      RESULTS OF 1983  PLASTICS MOLDING AND  FORMING
          TELEPHONE SURVEY SECOND  PART  	     31

IV-6      DISTRIBUTION OF  THE NUMBER OF PLASTICS  MOLDING
          AND FORMING PROCESSES BY DISCHARGE MODE.  ....     32

IV-7      DISTRIBUTION OF  THE 330  1983 QUESTIONNAIRES.,  .  .     35

IV-8      COMMONLY USED ADDITIVES  IN POLYMER FORMULATIONS
          USING THE EXTRUSION PROCESS	„  .  .     44

VI-1      DISCHARGE MODE FOR WET PROCESSES IN QUESTION-
          NAIRE DATA BASE	     84

VI-2      WATER USE DATA	     85

VI-3      WASTEWATER DISCHARGE  DATA	     88

VI-4      DISTRIBUTION OF  NUMBER OF PROCESSES IN  QUES-
          TIONNAIRE DATA BASE WITH ZERO DISCHARGE	     89

VI-5      PM&F TREATMENT TECHNOLOGIES SUMMARY	     90

VI-6      DISCHARGE MODE FOR PROCESSES IN  QUESTIONNAIRE
          DATA BASE THAT RECYCLE WASTEWATER	     91

VI-7      DISTRIBUTION OF  PLANTS IN QUESTIONNAIRE DATA
          BASE BY DISCHARGE MODE	     94

VI-8      NUMBER OF PLANTS IN DATA BASE	     95

VI-9      PM&F CATEGORY PLANT PROJECTIONS  BY DISCHARGE
          MODE	     97
                              viii

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                    LIST OF TABLES (Continued)


Number                                                      Page

VI-10     ESTIMATED PM&F CATEGORY WATER USE	    99

VI-11     ESTIMATED WASTEWATER DISCHARGE - PM&F CATEGORY  .   100

VI-12     SAMPLED PROCESSES	   113

VI-13     POLLUTANTS FOR WHICH SAMPLES WERE ANALYZED  ...   114

VI-14     ANALYTICAL METHODS SUMMARY 	   115

VI-15     DETECTION LIMITS FOR PRIORITY POLLUTANTS ....   117

VI-16     CONTAINER AND GLASSWARE PREPARATION PROCEDURES  .   120

VI-17     SUMMARY OF SAMPLE DATA	   123

VI-18     DATA EDITING RULES AND AVERAGING METHODOLOGY -
          EXAMPLE CONTACT COOLING AND HEATING WATER
          SUBCATEGORY	   129

VII-1     PRIORITY POLLUTANTS EXCLUDED FROM CONTROL.  ...   137

VII-2     PRIORITY POLLUTANTS DETECTED IN PM&F WASTEWATER.   138

VII-3     EXCLUSION METHODOLOGY EXAMPLE - POLLUTANT X. .   .   139

VII-4     PRIORITY POLLUTANTS EXCLUDED FROM CONTROL.  ...   140

VII-5     POLLUTANTS CONSIDERED FOR CONTROL BY
          SUBCATEGORY	   141

VI1-6     EXAMPLE CALCULATION OF A SUBCATEGORY AVERAGE
          RAW WASTE VALUE POLLUTANT X	   166

VII-7     ESTIMATED POLLUTANT MASS IN PROCESS WATER.  ...   167

VIII-1    RECYCLE PERCENTAGES BY SUBCATEGORY 	   177

VIII-2    POLLUTANTS AND POLLUTANT PROPERTIES FOUND IN
          SIGNIFICANT CONCENTRATIONS IN PM&F WASTEWATER.   .   179

VIII-3    EFFLUENT CONCENTRATION VALUES FOR ACTIVATED
          SLUDGE PROCESS TRANSFERRED FROM THE ORGANIC
          CHEMICALS, PLASTICS AND SYNTHETIC FIBERS
          CATEGORY	   183
                               IX

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                    LIST OF TABLES (Continued)


Number                                                      Page
VI11-4    REMOVAL EFFICIENCIES FOR NONCONVENTIONAL
          POLLUTANTS AND TREATABILITY LIMITS FOR
          PRIORITY POLLUTANTS FOR ACTIVATED SLUDGE
          PROCESSES	  .   184

VII1-5    TRICKLING FILTER PERFORMANCE DATA FOR CERTAIN
          CONVENTIONAL, NONCONVENTIONAL, AND PRIORITY
          POLLUTANTS	   187

VIII-6    REMOVAL EFFICIENCIES FOR CERTAIN CONVENTIONAL
          AND NONCONVENTIONAL POLLUTANTS FOR ROTATING
          BIOLOGICAL CONTACTORS	   188

VIII-7    REMOVAL EFFICIENCIES FOR CERTAIN CONVENTIONAL,
          NONCONVENTIONAL, AND PRIORITY POLLUTANTS IN
          SEDIMENTATION TANKS	   194

IX-1      COST EQUATIONS FOR TREATMENT AND CONTROL
          TECHNOLOGIES 	   207

IX-2      BPT OPTION 2 COSTS CONTACT COOLING AND HEATING-
          WATER SUBCATEGORY	   215

IX-3      BPT OPTION 3 COSTS CONTACT COOLING AND HEATING
          WATER SUBCATEGORY	   215

IX-4      BPT OPTION 1  COSTS CLEANING AND FINISHING
          WATER SUBCATEGORY	   215

IX-5      BPT OPTION 2 COSTS CLEANING AND FINISHING
          WATER SUBCATEGORY	   216

IX-6      BPT OPTION 3 COSTS CLEANING AND FINISHING
          WATER SUBCATEGORY	   216

IX-7      BPT OPTION 2 COSTS FOR THE RANGE STANDARDIZED
          FLOW OF 150 GPM, CONTACT COOLING AND HEATING
          WATER SUBCATEGORY	   217

X-1       RECYCLE PROCESSES USED TO CALCULATE BPT PRODUC-
          TION NORMALIZED FLOWS CONTACT COOLING AND
          HEATING WATER SUBCATEGORY	   245

X-2       RECYCLE PROCESSES USED TO CALCULATE BPT
          PRODUCTION NORMALIZED FLOW CLEANING AND
          FINISHING WATER SUBCATEGORY - CLEANING WATER .  .   247

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                    LIST OF  TABLES  (Continued)
Number
X-3
                                                            Page
          RECYCLE PROCESSES USED TO CALCULATE BPT
          PRODUCTION NORMALIZED FLOW CLEANING AND
          FINISHING WATER SUBCATEGORY - FINISHING WATER.  .   249

X-4       ALLOWABLE DISCHARGE OF BOD5 FOR
          PLANT X	   254

XI-1      AMOUNT AND CONCENTRATION OF TOXIC POLLUTANTS
          IN WASTEWATER AFTER BPT TREATMENT
          CONTACT COOLING AND HEATING WATER SUBCATEGORY.  .   257

XI-2      AMOUNT AND CONCENTRATION OF TOXIC POLLUTANTS
          AFTER BPT TREATMENT
          CLEANING AND FINISHING WATER SUBCATEGORY  ....   260

XII-1     FLOW RATES FOR NSPS MODEL PROCESSES	   266

XI1-2     POLLUTANT MASS IN RAW WASTE FOR NSPS MODEL
          PROCESSES	   267

XII-3     ESTIMATED POLLUTANT REMOVALS FOR NSPS MODEL
          PROCESSES	   267

XI1-4     NSPS TREATMENT TECHNOLOGY COSTS PER MODEL
          PROCESSES	   268

XII1-1    COMPARISON OF BPT/BAT POLLUTANT REMOVALS
          TO POTW POLLUTANT REMOVALS
          CONTACT COOLING AND HEATING WATER SUBCATEGORY.  .   275
XIII-2
XIII-3
XIV-1
XIV-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. ,

          COMPARISON OF BPT/BAT POLLUTANT REMOVALS TO
          POTW POLLUTANT REMOVALS
          CLEANING AND FINISHING WATER SUBCATEGORY . .  .

          ANNUAL COSTS OF TREATMENT AND POLLUTANT MASSES
          AFTER TREATMENT CONTACT COOLING AND HEATING
          WATER SUBCATEGORY	
          ANNUAL COSTS OF TREATMENT AND POLLUTANT MASSES
          AFTER TREATMENT CLEANING AND FINISHING WATER
          SUBCATEGORY	
                                                             277
                                                             278
                                                             282
                                                             282
                              XL

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                    LIST OF TABLES (Continued)


Number                                                      Page

XVI1-1    THE GLASS TRANSITION AND MELTING TEMPERATURES
          OF SOME COMMON POLYMERS, AND THEIR MAIN USES  .  .    316
                               xn

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                         LIST OF FIGURES






Number                                                      Page




IV-1      EXTRUSION PROCESS	    42



IV-2      INJECTION MOLDING PROCESS	    47



IV-3      BLOW MOLDING PROCESS	    49



IV-4      COMPRESSION MOLDING PROCESS	    51



IV-5      TRANSFER MOLDING PROCESS 	    52



IV-6      REACTION INJECTION MOLDING PROCESS 	    54




IV-7      ROTATIONAL MOLDING PROCESS 	    56



IV-8      EXPANDABLE BEAD FOAM MOLDING PROCESS	    57



IV-9      PLASTISOL AND POWDER COATING PROCESSES 	    59



IV-10     SPREAD COATING PROCESS 	    60



IV-11     EXTRUSION COATING PROCESS	    61



IV-12     LAMINATING PROCESS 	    63




IV-1 3     CONTINUOUS LAMINATION PROCESS	    65



IV-14     THERMOFORMING PROCESS	    66



IV-15     CALENDERING PROCESS	    68



IV-16     CASTING PROCESSES	    70



IV-17     CHILLED FILM CASTING PROCESS	    71



VI-1      SAMPLING POINTS AT PLANT A	   102



VI-2      SAMPLING POINTS AT PLANT B	   103



VI-3      SAMPLING POINTS AT PLANT C	   104



VI-4      SAMPLING POINTS AT PLANT D	   105



VI-5      SAMPLING POINTS AT PLANT E	   106



VI-6      SAMPLING POINTS AT PLANT F	   107
                              X1L1

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                   LIST OF FIGURES (Continued)


Number                                                      Page

VI-7      SAMPLING POINTS AT PLANT G	    108

VI-8      SAMPLING POINTS AT PLANT H	    109

VI-9      SAMPLING POINTS AT PLANT I	    110

VI-10     SAMPLING POINTS AT PLANT J	    111

VI-11     SAMPLING POINTS AT PLANT K	    112

VIII-1    CROSSFLOW COOLING TOWER	    175

VIII-2    ACTIVATED SLUDGE TREATMENT TECHNOLOGY	    180

VIII-3    EXAMPLES OF EXTENDED AERATION PACKAGE PLANTS .  .    189

VIII-4    EXAMPLES OF FIXED GROWTH PACKAGE PLANTS	    191

VIII-5    GRAVITY OIL SEPARATOR	    195

VIII-6    GRANULAR MEDIA FILTRATION PROCESS	    198

X-1       CHILLER RECYCLE UNIT USED TO ACHIEVE 100
          PERCENT RECYCLE OF PROCESS WATER - BPT OPTIONS
          2 AND 3 CONTACT COOLING AND HEATING WATER
          SUBCATEGORY	    229

X-2       TREATMENT TECHNOLOGY FOR PROCESSES WITH A
          PROCESS WATER USAGE GREATER THAN 35 GPM -
          BPT OPTION 2 CONTACT COOLING AND HEATING
          WATER SUBCATEGORY	    230

X-3       TREATMENT TECHNOLOGY FOR PROCESSES WITH A
          PROCESS WATER USAGE GREATER THAN 35 GPM -
          BPT OPTION 3 CONTACT COOLING AND HEATING
          WATER SUBCATEGORY	    232

X-4       BPT OPTION 1 CLEANING AND FINISHING WATER
          SUBCATEGORY	    236

X-5       BPT OPTION 2 CLEANING AND FINISHING WATER
          SUBCATEGORY	    237

X-6       BPT OPTION 3 CLEANING AND FINISHING WATER
          SUBCATEGORY	    238
                              xiv

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                   LIST OF FIGURES (Continued)
Number                                                      Page

XI1-1     CHILLER RECYCLE UNIT USED TO ACHIEVE
          100 PERCENT RECYCLE - NSPS
          CONTACT COOLING AND HEATING WATER SUBCATEGORY. .    262

XI1-2     NSPS TECHNOLOGY BASIS FOR PROCESSES WITH A
          PROCESS WATER USAGE FLOW RATE GREATER THAN
          35 GPM CONTACT COOLING AND HEATING WATER
          SUBCATEGORY	    264

XII-3     NSPS TECHNOLOGY
          CLEANING AND FINISHING WATER SUBCATEGORY ....    265
                               xv

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                            SECTION  I

                     SUMMARY AND CONCLUSIONS


Pursuant to Sections 301, 304, 306,  307,  308,  and  501 of  the
Clean Water Act and the Settlement Agreement  in Natural Resources
Defense Council v. Train 8 ERG 2120  (D.D.C. 1976)  modified  12  ERG
1833 (D.D.C. 1979), modified by orders dated  October 26,  1982,
August 2, 1983, and January 6, 1984, the  Environmental Protection
Agency (EPA) collected and analyzed  data  for  plants in the  Plas-
tics Molding and Forming Point Source category.   (Throughout this
document the Plastics Molding and Forming category is referred to
as the "PM&F" category.)  There are  no existing effluent  limita-
tions guidelines or standards for this category.   This document
and the administrative record provide the technical basis for  the
proposed effluent limitations guidelines  for  existing direct
dischargers, pretreatment standards  for new and existing  indirect
dischargers, and standards of performance for new  source  direct
dischargers.

In the PM&F category there are an estimated 10,260 plants of
which 1,898 use process water (i.e., water that contacts  the
plastic material during processing).  These plants have approxi-
mately 2,522 processes that use process water.  Of these  pro-
cesses, 789 discharge water directly to rivers and streams; 1,117
discharge to publicly owned treatment works;  and 616 do not dis-
charge process water.  The other 8,362 plants  in the PM&F cate-
gory do not use process water (i.e., they are  dry).

To collect information regarding plant size,  age and production,
the production processes used, and the quantity, treatment, and
disposal of wastewater generated, EPA conducted three question-
naire surveys and a two-part telephone survey.  As a result of
these surveys, 408 plants were included in a  data  base from which
were derived technical, statistical, and  economic  information  to
evaluate the PM&F category.  In addition,  EPA sampled PM&F pro-
cesses at 11 plants:  four plants were sampled in  1980 and seven
plants were sampled in 1983.  Samples collected were analyzed  for
conventional, selected nonconventional, and priority toxic pollu-
tants to identify pollutants present in the PM&F wastewater.

The Agency examined data obtained from the questionnaire  surveys
and the wastewater sampling program  to characterize the PM&F
category.  The category is comprised of plants that employ eight
generic processes that blend, mold,   form, or  otherwise process
plastic materials.  These processes  are:

     1.  extrusion,
     2.  molding,
     3.  coating and laminating,

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     4,  thermoforming,
     5.  calendering,
     6.  casting,
     7.  foaming, and
     8.  cleaning and finishing.

Results of the sampling program  indicate  that, with  the  exception
of cleaning and finishing processes, process water is  used  to
cool or heat the products produced  in PM&F processes and that  the
contact cooling or heating water has similar pollutant character-
istics regardless of the type of process  or plastic  product pro-
duced.  Water used in cleaning and  finishing processes has
different pollutant characteristics than  contact  cooling and
heating water.  Because the characteristics are different,  a
different type of recycle unit has  to be  used  to  recycle contact
cooling and heating water and cleaning and finishing water.  For
these reasons, the PM&F category was divided into  two
subcategories:

     1.  contact cooling and heating water subcategory,  and
     2.  cleaning and finishing water subcategory.

The contact cooling and heating water subcategory  includes  those
processes where process water contacts raw materials or  plastics
products for the purpose of heat transfer during  plastics molding
and forming.  In identifying model  treatment technology  options
for this subcategory, the Agency found that further  division
based on average process water usage flow rate was required.
Thus, processes with an average process water  usage  flow rate  of
35 gpm or less are in one subdivision and processes with an
average process water usage flow rate greater  than 35 gpm are  in
a different subdivision.

The cleaning and finishing subcategory includes those processes
that use process water to clean or  finish the  plastic product  or
to clean shaping equipment that is  or has been in  contact with
the formed plastic product.  Process water used to clean the
plastic product or shaping equipment includes  water used in the
detergent wash cycle and water used in the rinse  cycle to remove
detergents and other foreign matter.  Finishing water consists of
water used to carry away waste plastic material or to lubricate
the product during finishing processes.

Only process water that contacts the plastic material, plastic
product, or shaping equipment used  to mold or  form plastic  mater-
ials is covered by the proposed regulation.  Non-contact cooling
water is not process water and thus is not controlled.   Permit-
ting and control authorities will establish limitations  for the
discharge of non-contact cooling water and other non-process
wastewater on a case-by-case basis.

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Plants in the PM&F category may have  processes  that  use  only  one
type of water and thus  fit within  one  subcategory.   However,  many
plants use both contact cooling and heating water  and  cleaning
and finishing water.  In this  instance, plants  must  comply  with
the proposed effluent limitations  guidelines  and  standards  for
both subcategories.

EPA studied the PM&F category  to characterize the  pollutants  in
the different types of  process water.   The conventional  and non-
conventional pollutants present in significant  concentrations
are:  (1) conventional  pollutants  - biochemical oxygen demand
(6005), suspended solids (TSS), oil and grease, and  pH (2)  non-
conventional pollutants - total organic carbon, chemical oxygen
demand, and total phenols.  The priority  toxic  pollutants found
in the process water are:  (1) contact  cooling  and heating  water,
benzene, carbon tetrachloride, 1,1,1-trichloroethane,  p-chloro-
m-cresol, chloroform, methylene chloride, phenol,  bis(2-ethyl-
hexyl) phthalate, di-n-butyl phthalate, tetrachloroethylene,
toluene, aldrin, dieldrin, 4,4'-DDE,  heptachlor, a-BHC,  B-BHC,
Y-BHC, 6-BHC, cadmium,  total chromium,  copper,  lead, mercury,
nickel, and zinc and, (2) cleaning and  finishing water - benzene,
chloroform, methylene chloride"N-nitrosodiphenylamine,  phenol,
bis(2-ethylhexyl) phthalate, toluene,  aldrin, heptachlor, a-BHC,
Y-BHC, 6-BHC, total chromium, copper, nickel, selenium,  and zinc.

The control and treatment technologies  available for this cate-
gory include both in-process and end-of-pipe  technologies.
These technologies were considered appropriate  for the treatment
of plastics molding and forming wastewater and  formed  the basis
of the technology options for the  model regulatory treatment
technologies.

The model in-process control technology basis for  the  proposed
effluent limitations guidelines and standards is recycle of the
process water (i.e., flow reduction).  Recycle  consists  of
returning the process water to the process so that it  can be  used
again for the same purpose.  By reducing  the  amount  of water
discharged, the size and cost of the  technologies used to treat
the discharge are reduced.  Additionally, treatment  technology
performance may be improved using  a recycle system because  the
concentrations of the pollutants in the discharge  from the  recy-
cle unit are higher than the concentrations in  the process  water.
Treatment technologies usually perform better with a more concen-
trated wastewater.

Process water that requires cooling prior to recycle is  recycled
through a technology that lowers the  temperature of  the  water.
One type of recycle unit is a holding tank.  Process water  is
held in the tank until the temperature drops through passive  heat
transfer to the environment.   Application of this recycle unit is
limited to low flow rate processes.

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Another type of recycle unit  is  a  chiller.   Chillers  cool  the
process water by mechanical refrigeration.   They  can  be  used with
higher flow rate processes simply  by  adding  the number  of
chillers needed to provide the required amount of refrigeration.
However, at the high flow rates, the  high  energy  cost per  unit  of
cooling makes the chiller less attractive  than other  recycle
units such as a cooling tower.

A cooling tower lowers water  temperature by  evaporative  cooling.
Water flows over the surfaces of the  cooling tower  and  is  cooled
when it contacts the air that is blown into  the tower.   This unit
is particularly appropriate for high  flow  rate processes because
of its small space and low energy  requirements.

A sedimentation tank may be used to recycle  process water  that
requires the removal of either solids or oil and  grease.   The
solids settle to the bottom of the tank and  are removed; oil and
grease are skimmed off of the tank water surface.   The  treated
water is then recycled to the process.

End-of-pipe technologies considered appropriate for PM&F waste-
water include pH adjustment,  sedimentation,  and the activated
sludge process.

pH Adjustment.  Acidic and basic materials are used to  control
the pH of the wastewater.  Proper pH  adjustment not only controls
a pollutant property but also serves  to ensure proper treatment
technology performance.

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  flow  in a large volume tank
so that gravitational settling can occur.  Floatable materials
such as oils can also be removed in this process  by skimming them
from the surface of the water in the  tank.

Biological Treatment (Activated Sludge).   The activated  sludge
process is a widely used biological treatment process character-
ized by a suspension of microorganisms maintained in a homogene-
ous state by mixing and turbulence induced by aeration.  The
microorganisms oxidize soluble and colloidal organic material to
carbon dioxide and water in the presence of  molecular oxygen.
This process treats dissolved pollutants such as  biochemical
oxygen demand (6005), total organic carbon,  and total phenols.
The activated sludge process, which is designed to  assure  optimal
removal of BOD5, also removes organic priority pollutants  in
the wastewater.

Activated sludge technology can be used with sedimentation tech-
nologies to make a package activated  sludge  plant.  These  are
self-contained plants that usually consist of a primary
                                4

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sedimentation unit,  an  activated  sludge  unit,  and a final sedi-
mentation unit.   Package  activated  sludge  plants  can be  used  to
treat  flows  from  as  low as  600  gallons per day to as high as
100,000  gallons  per  day.

Using  these  technologies  the  Agency developed  several treatment
options.  After consideration of  these options,  the Agency
selected the following  model  treatment technologies as the basis
for  this proposed regulation.

CONTACT COOLING AND HEATING WATER SUBCATEGORY

Best Practical Technology (BPT) Effluent Limitations Guidelines

For  the Best Practical  Control  Technology  (BPT)  effluent limita-
tions  guidelines,  the following technologies are  proposed as  the
model  treatment technologies:

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.

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.

Under  BPT, the Agency proposes  effluent  limitations guidelines
for biochemical oxygen  demand,  total suspended solids, oil and
grease, and  pH.   EPA estimates  that 79 percent of the nonconven-
tional pollutants  and 80  percent  of the  toxic  pollutants for  this
subcategory  are removed when  the  limitations for  the above pollu-
tants  are met.  The Agency  is proposing  mass-based BPT effluent
limitations  expressed in  terms  of the allowable mass of  pollutant
discharged per unit of  production.   This reflects  the reduction
in flow and  the reducion  in pollutant concentrations achieved by
application of the BPT  model  technology.

The proposed technology option  results in  no discharge of pollu-
tants  from processes with an  average process water usage flow
rate of 35 gpm or  less  and  significantly reduces  the concentra-
tion of conventional, nonconventional, and  priority pollutants
discharged by processes with  an average  process water usage flow
rate greater than  35 gpm.

Best Available Technology  (BAT) Effluent Limitations Guidelines

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

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quantities of toxic pollutants remaining  in contact  cooling  and
heating water after compliance with the applicable BPT effluent
limitations guidelines.  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.

Best Conventional Technology (BCT) Effluent Limitations
Guidelines

The Agency reviewed treatment technologies that could be used to
remove additional conventional pollutants after BPT  in contact
cooling and heating water.  The only technology considered feasi-
ble is flow reduction and zero discharge by contract haul of  the
discharge from the flow reduction unit.  The costs to achieve the
additional removal of conventional pollutants do not pass a  pro-
posed two-part "cost-reasonableness  test.  The Agency proposes,
therefore, that BCT equal BPT for contact cooling and heating
water and that no further controls be established for the
conventional pollutants beyond BPT.

New Source Performance Standards (NSPS)

The Agency believes that characteristics of wastewater discharged
by new PM&F processes in the contact cooling and heating water
subcateogry will be the same as the characteristics of wastewater
discharged by existing PM&F processes in this subcategory.   Thus ,
the Agency is proposing NSPS based on the same model treatment
technologies used to develop the proposed BPT/BAT effluent limi-
tations guidelines for this subcategory.  EPA is not proposing
NSPS more stringent than the effluent limitations guidelines  for
existing sources because the amount and toxicity of the toxic
pollutants remaining after treatment in the BPT model treatment
technologies for this subcategory do not justify more stringent
controls.

Pollutants controlled by NSPS include biochemical oxygen demand,
total suspended solids, oil and grease, and pH.  The Agency
believes that the toxic pollutants in contact cooling and heat-
ing water are effectively controlled when the NSPS for the above
pollutants are met.  NSPS are expressed in terms of  the allowable
mass of pollutant discharged per unit of plastic production.

Pretreatment Standards for Existing Sources (PSF.S)

The Agency is not proposing PSES for existing indirect dis-
chargers for this subcategory because the priority toxic pollu-
tants in contact cooling and heating water either do not pass
through a publicly owned treatment works (POTW) or the amount and
toxicity do not justify establishing pretreatment standards.

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Even though plants within  this  subcategory  are  not  regulated  by
categorical pretreatment standards,  they must comply  with  the
General Pretreatment Regulations  (40 CFR Part 403).

Pretreatment Standards for New  Sources  (PSNS)

The Agency is also not proposing  PSNS for new indirect  dis-
chargers in this subcategory because the priority  toxic  polutants
in contact cooling and heating  water either  do  not  pass  through  a
POTW or the amount and toxicity do not  justify  establishing pre-
treatment standards.  Plants within  this subcategory  must  comply
with General Pretreatment  Regulations (40 CFR Part  403)  even
though the Agency is not proposing to establish categorical pre-
treatment standards.

CLEANING AND FINISHING WATER SUBCATEGORY

Best Practical Technology  (BPT) Effluent Limitations  Guidelines

The Agency is proposing BPT effluent limitations guidelines for
this subcategory based on  recycle of process water  through a
sedimentation tank and treatment  of  the discharge  from  the recy-
cle unit in a package activated sludge  plant.   The  package plant
includes an equalization unit and pH adjustment.  A sedimentation
tank is used to remove suspended  solids so  that the wastewater
can be recycled.

Under BPT, the Agency proposes  to establish  limitations  guide-
lines for biochemical oxygen demand,  total  suspended  solids,  oil
and grease, and pH.  EPA believes that  the  toxic pollutants in
cleaning and finishing water are  effectively controlled  when  the
limitations for the above pollutants  are met.

The Agency is proposing mass-based BPT  effluent limitations
guidelines expressed in terms of  the allowable  mass of  pollutant
discharged per unit of production.   This reflects  the reduction
in flow and the reduction  in pollutant  concentrations achieved by
application of the BPT model treatment  technology.

The Agency determined that two  separate mass-based  effluent limi-
tations guidelines are necessary  for this subcategory because of
the difference in the amounts of wastewater  discharged  from
cleaning as opposed to finishing  processes.  Therefore,  mass-
based effluent limitations guidelines are proposed  for  processes
that use cleaning water and for processes that  use  finishing
water.   The effluent concentration value used to calculate the
allowable discharge mass are the  same for both  cleaning  and
finishing processes.  However,  the production normalized flows
are different for those processes.

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Best Available Technology  (BAT) Effluent Limitations  Guidelines

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 quan-
tities of toxic pollutants remaining  in cleaning  and  finishing
water  after compliance with the applicable  BPT effluent  limita-
tions  guidelines.  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.

Best Conventional Technology (BCT)  Effluent Limitations
Guidelines

The Agency reviewed treatment technologies that could be used  to
remove additional conventional pollutants after BPT in cleaning
and finishing water.  The only technology considered  feasible  is
flow reduction and zero discharge by  contract  haul of the  dis-
charge from the flow reduction unit.  The costs to achieve the
additional removal of conventional  pollutants  do not  pass  a
proposed two-part "cost-reasonableness" test.   The Agency  pro-
poses, therefore, that BCT equal BPT  for cleaning  and finishing
water and that no further controls be established  for the  con-
ventional pollutants beyond BPT.

New Source Performance Standards (NSPS)

The Agency believes that characteristics of wastewater discharged
by new PM&F processes in the cleaning and finishing water  sub-
category will be the same as the characteristics of wastewater
discharged by existing PM&F processes in this  subcategory.  Thus,
the Agency is proposing NSPS based on the same model  treatment
technologies as the proposed BPT/BAT  effluent  limitations  guide-
lines.  EPA is not proposing NSPS more stringent than the  efflu-
ent limitations guidelines for existing sources because  the
amount and toxicity of the toxic pollutants remaining after
treatment in the BPT/BAT treatment technologies for this subcate-
gory do not justify more stringent controls.

Pollutants controlled by NSPS include biochemical oxygen demand,
total suspended solids, oil and grease, and pH.  The Agency
believes that the toxic pollutants  for cleaning and finishing
water are effectively controlled when the NSPS for the above pol-
lutants are met.  NSPS are expressed  in terms  of the  allowable
mass of pollutant discharged per unit of production.

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Pretreatment Standards for Existing Sources  (PSES)

The Agency is not proposing PSES for  existing  indirect  dis-
chargers in this subcategory because  the priority  toxic pollu-
tants in cleaning and finishing water either do not  pass  through
a publicly owned treatment works (POTW) or the amount and  toxic-
ity do not justify pretreatment standards.   Even though plants
within this subcategory are not regulated by proposed categorical
pretreatment standards, they must comply with  General Pretreat-
ment Regulations (40 CFR Part 403).

Pretreatment Standards for New Sources  (PSNS)

The Agency is also not proposing PSNS for new  indirect dis-
chargers in this subcategory because  the priority  toxic polutants
in cleaning and finishing water either  do not  pass through a  POTW
or the amount and toxicity do not justify pretreatment standards.
Plants within this subcategory must comply with the  General Pre-
treatment Regulations (40 CFR Part 403) even though  the Agency is
not proposing to establish categorical  pretreatment  standards.

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                            SECTION II

                         RECOMMENDATIONS
1.  EPA has divided the plastics molding and forming category
    into two subcategories for the purpose of the proposed
    effluent limitations guidelines and standards.  They  are:

       contact cooling and heating water subcategory, and
       cleaning and finishing water subcategory.

2.  Best Practical Technology (BPT) effluent limitations  guide-
    lines are being proposed based on the treatment effective-
    ness achievable by the application of process water recycle
    and packaged activated sludge treatment for process water
    discharged from the recycle unit for both subcatgories.  In
    addition, 100 percent recycle of process water is being pro-
    posed for processes that use contact cooling and heating
    water and that have an average process water usage flow rate
    of 35 gpm or less.

    A.  BPT EFFLUENT LIMITATIONS GUIDELINES FOR THE CONTACT
        COOLING AND HEATING WATER SUBCATEGORY

    There shall be no discharge of wastewater pollutants  from
    contact cooling and heating water processes with an average
    process water usage flow rate of 35 gpm (132 liters per
    minute) or less.

    The mass of pollutants in process wastewater from contact
    cooling and heating water processes with an average process
    water usage flow rate greater than 35 gpm (132 liters per
    minute) shall not exceed the following values:


                Contact Cooling and Heating Water

                                      BPT effluent limitations
                                    Maximum for     Maximum for
Pollutant or pollutant property	any 1 day	monthly average
                                    mg/kg (pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                     78              35
Oil and Grease                          113              27
TSS                                     186              57
pH                                      (i)              (b


^Within the range of 6.0 to 9.0 at all times.


                               11

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    B.  BPT EFFLUENT LIMITATIONS GUIDELNES FOR THE CLEANING AND
        FINISHING WATER SUBCATEGORY

    The mass of pollutants in process water discharged from
    existing plastics molding and forming cleaning processes
    shall not exceed the following values:
                          Cleaning Water
                                      BPT effluent IT imitations
                                    Maximum for     Maximum for
Pollutant or pollutant property	any 1  day    monthly average
                                    mg/kg(pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                    220              99
Oil and Grease                          318              76
TSS                                     524             161
pH                                      (1)             (1)


1Within the range of 6.0 to 9.0 at all times.


    The mass of pollutants in process water discharged from
    existing plastics molding and forming finishing processes
    shall not exceed the following values:


                         Finishing Water

                                      BPT effluent limitations
                                    Maximum forMaximum for
Pollutant or pollutant property	any 1 day    monthly average
                                    mg/kg(pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                     52              23
Oil and Grease                           76              18
TSS                                     125              38
PH
                                                         38
                                                        (0
 Within the range of 6.0 to 9.0 at all times.
                               12

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3.   The Agency has determined that there are insignificant
    quantities of toxic pollutants in wastewaters discharged
    by processes in both subcategories after compliance with
    applicable BPT effluent limitations guidelines.  Accordingly,
    since BPT level of treatment provides adequate control, the
    Agency is not proposing more stringent Best Available Tech-
    nology (BAT) effluent limitations guidelines.

4.   EPA reviewed treatment technologies that could be used to
    remove additional conventional pollutants after BPT.  The
    only technology considered feasible is flow reduction and
    zero discharge by contract haul of the discharge from the
    flow reduction unit.  The removals by this technology did not
    pass the two-part cost test in the proposed BCT methodology.
    Therefore, the Agency proposes that BCT equal BPT for each
    subcategory and that no further controls be established for
    the conventional pollutants beyond BPT.

    The BCT effluent limitations guidelines for each subcategory
    are being proposed based on the treatment effectiveness
    achievable by the application of process water recycle and
    packaged activated sludge treatment for process water dis-
    charged from the recycle unit.  For processes with contact
    cooling and heating water that have an average process water
    usage flow rate of 35 gpm or less, 100 percent recycle of
    process water is being proposed.

    A.   BCT EFFLUENT LIMITATIONS GUIDELINES FOR THE CONTACT
        COOLING AND HEATING WATER SUBCATEGORY

    There shall be no discharge of conventional pollutants from
    contact cooling and heating processes with an average process
    water usage flow rate of 35 gpm (132 liters per minute) or
    less.

    The mass of conventional pollutants in process water dis-
    charged from contact cooling and heating water processes with
    an  average process water usage flow rate greater than 35 gpm
    (132 liters per minute)  shall not exceed the following
    values:
                               13

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                Contact Cooling and Heating Water
                                      BCT effluent limitations
                                    Maximum for     Maximum for
Pollutant or pollutant property	any 1  day    monthly average
                                    mg/kg(pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                     78              35
Oil and Grease                          113              27
TSS                                     186              57
pH                                      (1)             (1)


^Within the range of 6.0 to 9.0 at all times.


    B.  BCT EFFLUENT LIMITATIONS GUIDELINES FOR THE CLEANING AND
        FINISHING WATER SUBCATEGORY

    The mass of conventional pollutants in process water
    discharged from existing plastics molding and forming
    cleaning processes shall not exceed the following values:


                          Cleaning Water

~BCT effluent limitations
                                    Maximum for     Maximum for
Pollutant or pollutant property	any 1  day    monthly average
                                    mg/kg(pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                    220              99
Oil and Grease                          318              76
TSS                                     524             161
pH                                      (1)             (1)


1Within the range of 6.0 to 9.0 at all times.
                               14

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    The mass of conventional pollutants in process water
    discharged from existing plastics molding and forming
    finishing processes shall not exceed the following values:
                         Finishing Water
                                      BCT effluent limitations
                                    Maximum for     Maximum for
Pollutant or pollutant property	any 1 day	monthly average
                                    rag/kg(poundฅ per million
                                    pounds) of plastic material
                                    processed	

BOD5                                     52              23
Oil and Grease                           76              18
TSS                                     125              38
pH                                      (1)              (T)


1Within the range of 6.0 to 9.0 at all times.


5.  The EPA also proposes New Source Performance Standards (NSPS)
    based on process water recycle and package activated sludge
    treatment for process water discharged from the recycle unit
    for both subcategories.  Additionally, 100 percent recycle
    of process water is being proposed for processes with contact
    cooling and heating water that have an average process water
    usage flow rate of 35 gpm or less.

    A.  NSPS FOR THE CONTACT COOLING AND HEATING WATER
        SUBCATEGORY

    There shall be no discharge of wastewater pollutants from
    processes in the contact cooling and heating water subcate-
    gory at a new source with an average process water usage flow
    rate of 35 gpm (132 liters per minute) or less.

    The mass of pollutants in process water discharged from
    processes in the contact cooling and heating water subcate-
    gory at a new source with an average process water usage
    flow rate greater than 35 gpm (132 liters per minute) shall
    not exceed the following values:
                               15

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                Contact Cooling and Heating Water

                                 New Source Performance Standards
                                    Maximum for     Maximum for
Pollutant or pollutant property	any 1 day    monthly average
                                    rag/kg (pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                     78              35
Oil and Grease                          113              27
TSS                                     186
pH                                      (1)


^Within the range of 6.0 to 9.0 at all times.


    B.  NSPS FOR THE CLEANING AND FINISHING WATER SUBCATEGORY

    The mass of pollutants in process water discharged from
    plastics molding and forming cleaning processes at a new
    source shall not exceed the following values:


                          Cleaning Water

                                 New Source Performance Standards
                                    Maximum forMaximum for
Pollutant or pollutant property	any 1 day    monthly average
                                    mg/kg (pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                    220              99
Oil and Grease                          318              76
TSS                                     524             161
pH                                      (1)


1Within the range of 6.0 to 9.0 at all times.
                               16

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    The mass of pollutants in process water discharged  from
    plastics molding and forming finishing processes at a new
    source shall not exceed the following values:


                         Finishing Water

                                 New Source Performance Standards
                                    Maximum for     Maximum  for
Pollutant or pollutant property	any 1 day    monthly average
                                    mg/kg(pounds per million
                                    pounds) of plastic material
                                    processed	

BOD5                                     52              23
Oil and Grease                           76              18
TSS                                     125              38
pH                                      (1)             (l)


1 Within the range of 6.0 to 9.0 at all times.


6.  The Agency is not proposing to establish Pretreatment
    Standards for Existing Sources (PSES) for the PM&F category.
    Even though plants within this category are not regulated by
    PSES,  they must comply with the General Pretreatment
    Regulations (40 CFR Part 403).

7.  The Agency is not proposing to establish Pretreatment
    Standards for New Sources (PSNS) in the PM&F category.
    Although indirect discharges within this category are not
    subject to PSNS, they must comply with the General
    Pretreatment Regulations (40 CFR Part 403).
                               17

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                            SECTION  III

                            INTRODUCTION

BACKGROUND

The Federal Water Pollution Control Act  Amendments  of  1972  estab-
lished a comprehensive program  to "restore  and maintain  the chem-
ical, physical, and biological  integrity of the  Nation's waters,"
under Section  101(a).  By July  1, 1977,  existing industrial dis-
chargers were  required to achieve "effluent limitations  requiring
the application of the best practicable  control  technology  cur-
rently available" (BPT), under  Section 301(b)(1)(A); and by July
1, 1984, "effluent limitations  requiring the  application of the
best available technology economically achievable  .  .  .  which
will result in reasonable further progress  toward the  national
goal of eliminating the  discharge of  all pollutants"  (BAT),  under
Section 301(b)(2)(A).  New  industrial direct  dischargers were
required to comply with  Section 306 new  source performance  stand-
ards (NSPS), based on best  available  demonstrated technology;
existing and new dischargers  to publicly owned treatment works
(POTW) were subject to pretreatment standards under  Sections
307(b) (PSES)  and (c)  (PSNS), respectively,  of the Act.

The requirements for direct dischargers  were  to  be  incorporated
into National  Pollutant  Discharge Elimination System  (NPDES) per-
mits issued under Section 402 of the  Act while pretreatment
standards were made enforceable directly against dischargers to a
POTW (indirect dischargers).  Although Section 402(a)(1)  of the
1972 Act authorized the  setting of NPDES permit  requirements for
direct dischargers on a  case-by-case  basis,  Congress intended
that,  for the most part, effluent limitations guidelines be based
on the degree  of effluent reduction attainable through the  appli-
cation of BPT  and BAT.   Moreover, Sections  304(c) and  306 of the
Act required promulgation of new source  performance  standards;
and Sections 304(f), 307(b), and 307(c)  required promulgation of
pretreatment standards.  In addition  to  the  effluent limitations
guidelines and standards for designated  industry categories,
Section 307(a) of the Act required the Administrator to  promul-
gate effluent  standards  for toxic pollutants applicable  to  all
dischargers of these pollutants.  Finally,  Section 301(a) of the
Act authorized the Administrator to prescribe any additional
regulations "necessary to carry out his  functions" under the Act.

EPA was unable to promulgate many of  the  effluent limitations
guidelines and standards by the  dates contained  in the Act.  In
1976,  EPA was sued by several environmental groups and in settle-
ment of this lawsuit,  EPA and the plaintiffs executed  a  "Settle-
ment Agreement" that was approved by  the  Court.  This  agreement
required EPA to develop  a program and adhere to  a schedule  for
                               19

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promulgating BAT effluent limitations guidelines, pretreatment
standards, and new source performance standards for 65  "priority"
compounds and classes of compounds for 21 major industries.  See,
Settlement Agreement in Natural Resources Defense Council  Inc.
v. Train, 8 ERG 2120 (D.D.C. 1976), modified 12 ERG 1833  (D.D.C.
1979), modified by orders dated October 26, 1982, August  2,  1983,
and January 6, 1984.

On December 27, 1977, the President signed into law amendments  to
the Federal Water Pollution Control Act (P.L. 95-217).  The  Act,
as amended, is commonly referred to as the Clean Water  Act.
Although this Act makes several important changes in the  federal
water pollution control program, its most significant feature is
its incorporation of several of the basic elements of the Settle-
ment Agreement program for toxic pollution control.  Sections
301(b)(2)(C) and 301(b)(2)(D) of the Act now require the  achieve-
ment by July 1, 1984, of effluent limitations guidelines  requir-
ing application of BAT for toxic pollutants, including  the 65
priority compounds and classes of compounds (the same toxic  pol-
lutants as listed in Natural Resources Defense Council, Inc. v.
Train, supra) Congress declared toxic under Section 307(a)of the
Act.  Likewise, EPA's program for new source performance  stand-
ards is now aimed principally at control of these toxic pollu-
tants.  Pretreatment standards control the toxic pollutants  and
pollutants that are  incompatible with a POTW.  Moreover,  to
strengthen the toxics control program, Congress added Section
304(e) to the Act, authorizing the Administrator to prescribe
"best management practices" (BMP) to prevent the release  of  toxic
and hazardous pollutants from plant site runoff, spillage or
leaks, sludge or waste disposal, and drainage from raw material
storage associated with, or ancillary to, the manufacturing  or
treatment process.

In keeping with its  emphasis on toxic pollutants, the Clean  Water
Act also revised the control program for other types of pollu-
tants.  Instead of BAT for "conventional" pollutants identified
under Section 304(a)(4) (including biological oxygen demand,
suspended solids, oil and grease, fecal coliform, and pH), the
new Section 301(b)(2)(E) requires achievement, by July  1, 1984,
of "effluent limitations requiring the application of the best
conventional pollutant control technology" (BCT).  The  factors
considered in assessing BCT for an industry include a two-part
"cost-resonableness" test (Section 304(b)(4)(B).  See, American
Paper Institute v. EPA, 660 F.2d 954 (4th Cir. 198T77   The first
part compares the cost for private industry to reduce its conven-
tional pollutants with the costs for publicly owned treatment
works for similar levels of reduction of those pollutants.   The
second part examines the cost effectiveness of additional indus-
trial treatment beyond BPT.
                               20

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For nonconventional pollutants, Sections 301(b)(2)  (A)  and
(b)(2)(F) require achievement of BAT effluent limitations
guidelines within three years after their  establishment, or  not
later than July 1, 1984, whichever is later, but  in no  case  later
than July 1,  1987.

PURPOSE

This document presents the information and  data used  to  develop
the proposed effluent limitations guidelines and  standards for
the plastics molding and forming (PM&F) point source  catetgory.

AUTHORITY

Effluent limitations guidelines and standards for  the PM&F cate-
gory are proposed under authority of Sections 301, 304,  306,  307,
308, and 501  of the Clean  Water Act (the  Federal  Water  Pollution
Control Act Amendments of 1972, 33 U.S.C.  1251 et  s^ฃ.,  as
amended by the Clean Water Act of 1972, Pub. L. 95 -  217)  (the
"Act").  This regulation is also proposed  in response to the
Settlement Agreement in NaturalResources  Defense  Council, Inc.
v- Train, 8 ERG 2120 (D.D.C. 1~976) , modified 12 ERG 1833 (D.D.C.
1979), modified by orders dated October 26, 1982,  August 2,  1983
and January 6,  1984.

STUDY APPROACH

The study approach used to develop the proposed PM&F  effluent
limitations guidelines and standards included the  following:

     1.  The Agency conducted three questionnaire  surveys and a
         two part telephone survey to gather information on
         production, manufacturing processes, water use  and
         discharge practices, and wastewater treatment.

     2.  A PM&F category profile was developed using  the survey
         information and information from  literature  sources.

     3.  The PM&F category was subcategorized based on  informa-
         tion from the questionnaire surveys and  information
         from the wastewater sampling programs.

     4.  EPA sampled 11  PM&F plants to characterize PM&F process
         water.   Samples were analyzed for conventional,
         selected nonconventional,  and priority toxic pollutants.

     5.  Results of the sampling episodes were used to determine
         the  pollutants  in PM&F wastewater that have significant
         concentrations.
                               21

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 6.   Control and treatment technologies that effectively
     control the pollutants in PM&F wastewater were
     evaluated.

 7.   Costs, pollutant removals, energy, and non-water
     quality aspects were evaluated for the various treat-
     ment technologies.

 8.   A model treatment technology was selected for BPT,
     BAT, BCT,  and NSPS.

 9.   Effluent concentration data for the model treatment
     technologies were obtained.

10.   Production  normalized flows were developed for each
     subcategory.

11.   Mass-based  effluent  limitations guidelines and stand-
     ards were developed  by multiplying the effluent con-
     centration  data for  the selected model treatment tech-
     nology times the production normalized flows.
                           22

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                            SECTION IV

                         CATEGORY PROFILE


The plastics molding and forming (PM&F) category covers a large,
diverse industry that uses plastic materials  to produce a wide
variety of consumer and industrial products.  Since shortly after
the discovery of plastic materials, nearly 60 years ago, molding
and forming processes have been used to turn  those plastic
materials into usable items.  Originally, plastic products were
typically considered to be inexpensive substitutes for wood,
leather, and metal items.  However, in many cases, plastic
products have virtually replaced other products due to their
superior characteristics, such as light weight, durability, and
resistence to corrosion.  New product uses for plastics as well
as new plastic formulations are continually being developed. The
products produced by the plastics molding and forming category
are used in a wide variety of consumer and industrial markets
including:  automobiles, appliances and business machines, con-
struction materials, disposables, household furnishings, house-
wares, and medical products.  The PM&F category is classified as
Industry 3079, Miscellaneous Plastics Products, in the Standard
Industrial Classification Manual prepared by  the Office of
Management and Budget.

In the course of developing the proposed effluent limitations
guidelines and standards for the plastics molding and forming
category,  several data gathering efforts were undertaken to
characterize the category.  They included:

        reviewing existing National Pollutant Discharge
        Elimination System (NPDES) permits,
        sampling at PM&F plants,
        conducting questionnaire and telephone surveys, and
        reviewing various literature sources.

NPDES PERMITS

Existing NPDES permits for PM&F plants were reviewed to determine
the pollutants controlled and the allowable concentration values
for those  pollutants.  As of August 1983, there were 433 PM&F
plants with NPDES permits.  Eleven of those plants are major dis-
chargers.   Permits for eight of the major dischargers were
reviewed.   Table IV-1 lists the PM&F process, existing treatment
technology,  and pollutants controlled for these eight major
dischargers.
                               23

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                                       Table  IV-1

                       SUMMARY  OF MAJOR NPDES  PERMITS
  Permit
  Number

NJ 0031313


PA 0013218



DE 0000451




IN 000160





IN 0109541



TN 0001457
GA 0000329


KS 0003204
    Process

Not described in
permit

Extrusion of
packaging films
and bags

Manufacture of
vulcanized fiber
and waterleaf
paper

Manufacture of
food packaging
films and house-
hold product
containers

Not described in
permit
Manufacture of
cellulose pack-
aging films
Manufacture of
rubber

Manufacture of
cellophane films
Treatment Technology

No treatment is
described in permit

No treatment is
described in permit
Plant has an aeration
system for an inte-
grated facility
PM&F process wastewater
not treated; plant has
an activated sludge
system for domestic
waste

No treatment is
described in permit
No treatment is
described in permit;
from questionnaire
information, the plant
has a lime and settle
system as part of an
integrated treatment
facility

No treatment is
described in permit

Plant has an activated
sludge system; results
of telephone conversa-
tion indicate that a
large percentage of
wastewater treated in
an activated sludge
process is PM&F
wastewater
 Pollutants Limited by Permit

TOC, temperature, pH


Oil and grease, pH, zinc,
temperature
BOD, TSS, zinc,  temperature,
effluent flow
BOD, residual chloride, TSS,
total zinc, PCBs and dithiocarbo-
nates must be monitored for three
months before determining limits
TSS, oil and grease,  total and
hexavalent chromium,  total cya-
nide, total nickel, total copper

BOD, suspended solids, settleable
solids, aluminum,  iron,  manga-
nese, hydrogen sulfide,  total
dissolved sulfide,  pH
COD, BOD,  TSS,  oil and grease,
ammonia as N,  fecal coliform

BOD, COD,  TSS,  temperature, pH
                                           24

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 SAMPLING  PROGRAM

 Information  on  the  PM&F category was  gathered during the waste-
 water  sampling  programs for  this project.   Eleven PM&F plants
 were sampled, seven in 1983  and four  in 1980.   Flow measurements
 taken  at  the sampled plants  provided  information on water use and
 discharge practices.  Wastewater samples were collected and ana-
 lysed  for conventional,  nonconventional, and  priority pollutants.
 A  discussion of the sampling programs including results is
 presented in Section VI and  Appendix  A.

 QUESTIONNAIRE SURVEYS

 The plastics molding and forming category  was  surveyed to gather
 information  on  plant size and age,  production,  production pro-
 cesses used,  and  the quantity,  treatment,  and disposal of waste-
 water  generated at  PM&F plants.   This information was requested
 in three  questionnaires mailed  under  authority  of Section 308 of
 the Act to companies known or believed to  be  involved in plastics
 molding or forming.   A two-part  telephone  survey was used to
 develop the  sample  population for the third questionnaire survey.

 1978 and  1979 Questionnaire  Surveys

 In 1978,  8,450  firms were sent  a one-page  questionnaire.  The
 names  and addresses  of the plants on  the mailing list for this
 questionnaire were  compiled  from the  following  sources:

     1.   Dun &  Bradstreet, Inc.  and
     2.   Fortune  500.

 The questionnaire asked  if the  company was  a  plastics molder and
 former, if process  water was  used,  (i.e., water  that contacts the
 plastic product), what  type  of  discharge mode was  used,  what
 plastic materials were  used,  and what products were produced at
 the plant.   When  firms  had plastics molding and  forming  processes
 at more than one  location, a  questionnaire  was  completed for each
 plant.   A total of  5,138 questionnaires were  returned:   1,114
 indicated the plant  uses  process water in a PM&F process and
 4,024  indicated the  plant  did not use process water.

 From the  1,114  respondents to the 1978 survey that  indicated they
 use process  water,  750  plants were mailed a more detailed ques-
 tionnaire in  1979.   Approximately 59  percent of  the companies
 responded to  the  survey.   Of  the 440  respondents to the  survey,
 407 returned completed  questionnaires  and 33  indicated  they  had
 responded incorrectly  to  the  one page questionnaire and  had  only
 dry processes (i.e., process water did not  contact  the  formed
 plastic product).   Seventy five  of the 407  returned question-
naires  contained unclear  data.   Data  from the other 332  question-
 naires  were  included  in  the data base  for this project.
                               25

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Table IV-2 contains a distribution of the types of processes
reported on the 1979 questionnaire and indicates the number of
processes for each type that generate wastewater and that  do  not
generate wastewater.  The total number of processes is larger
than the number of questionnaires returned because many plants
employed more than one PM&F process.

As shown in Table IV-2, the type of process with the largest
number of wet processes was extrusion followed by cleaning and
finishing.  After those two types of processes, the number of wet
processes varied from 32 for molding to zero for foaming.

Table IV-3 contains a distribution of the number of wet processes
by discharge mode.  As shown in the table, a large percentage of
the wet PM&F processes discharge wastewater to either a publicly
owned treatment works (i.e., indirect discharge) or directly  to
surface waters.

1983 Telephone Survey

In 1983, a two-part telephone survey was conducted to screen  the
target population for the third questionnaire survey.  The first
part of the telephone survey consisted of calling:

     1.  232 plants that returned a completed 1979 questionnaire;

     2.  193 plants that received a questionnaire in 1979  but did
         not return a completed one; and

     3.  734 plants, which is one-half of the PM&F plants  that
         entered the market between January 1, 1978, and
         December 31, 1981, ("new plants") according to Dun and
         Bradstreet's list of plants with a primary SIC Code
         3079.

The ratio of plants that returned a completed questionnaire in
1979 to those that did not return a completed 1979 questionnaire
for the telephone survey (232:193) was the same as the actual
ratio of plants that returned a completed 1979 questionnaire  to
those that did not return a completed questionnaire (407:343).
All plants called in the telephone survey were asked whether  they
were plastics molders and formers and if they use process  water
in their PM&F processes.

Table VI-4 contains the results of the first part of the tele-
phone survey.  As shown in the table, 50 percent of the new
plants indicated they use process water.  This number was  viewed
with caution because the Agency believes that many of the
respondents did not completely understand the difference between
contact and noncontact cooling water.
                               26

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                            Table IV-2

         SUMMARY OF PLASTICS MOLDING AND FORMING PROCESSES*
Type of Wet
Process Processes
Extrusion
Molding
Coating and
Laminating
Thermofortning
Calendering
Casting
Foaming
Cleaning and
Finishing
TOTAL
323
32
28
12
5
19
0
137
556
(%)**
(71)
(15)
(36)
(17)
(25)
(29)
(0)
(88)
Dry
Processes (%)
129
176
49
59
15
46
4
18
496
(29)
(85)
(64)
(83)
(75)
(71)
(100)
(12)
Total
452
208
77
71
20
65
4
155
1052
(%)
(100)
(100)
(100)
(100)
(100)
(100)
(100)
(100)
            Wet Process
            Dry Process
Total

 556
 496

1052
  53
  47

(100)
 *Based on information from 1979 questionnaire,
**Percent of type of process.
                               27

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In the second part of the 1983 telephone survey, the other  half
of the new PM&F plants entered the market between January  1,
1978, and December 31, 1981, (according to Dun and Bradstreet's
listing of plants with a primary SIC 3079) were contacted.  They
were also asked if they were plastics molders and formers  and  if
they use process water.  However, they were asked more  specific
questions, such as what kind of PM&F processes they employ.
Since more time was spent asking detailed questions, information
from this part of the survey concerning the number of processes
that use process water (i.e., wet) and that do not use  process
water (i.e., dry) is more reliable than similar information  from
the first part of the survey.

In the second part of the telephone survey, 741 PM&F plants  were
contacted. Out of that number, 535 plants were plastic  molders
and formers, while the remaining 206 plants were not.   Eighty-
four (16 percent) of the 535 PM&F plants had wet processes  and
451 (84 percent) had dry processes.

Table VI-5 contains a distribution of the wet and dry processes
from the second part of the telephone survey by the type of
process.  The number of wet processes and the number of dry
processes are larger than the number of PM&F plants because  some
plants had more than one PM&F process.  Types of processes with
the largest number of wet processes were extrusion, molding, and
cleaning and finishing.  This corresponds to the types  of
processes that had the most wet processes in the 1979 detailed
questionnaire.

Results  of the second part of the telephone survey are  distrib-
uted by type of wet processes and discharge mode in Table VI-6.
Most PM&F processes in the second part of the telephone survey
discharged wastewater to POTW's or did not discharge wastewater,
(i.e.,  zero discharge).

Statistics from the 1978 single page questionnaire and  the  second
part of the 1983 phone survey were used to estimate the percent-
ages of  wet and dry plants in the PM&F category.  These were the
only two surveys not directed solely at plants believed to use
process  water.  Of the 5,138 PM&F plants that returned  the  single
page questionnaire in 1978,  21 percent indicated they had wet
PM&F processes.  This percentage was averaged with the  16 percent
of the PM&F plants from the second part of the 1983 telephone
survey that had wet processes to obtain an estimate of  18.5  per-
cent of the plants in the PM&F industry that are wet (i.e.,  use
process  water).  Multiplying that percentage times the  estimated
10,260 plants in the PM&F category provides an estimate of  1,898
wet plants in the category.

The total number of 10,260 PM&F plants in the United States  was
estimated from the State Industrial Guides (Appendix B  lists the
                               30

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                            Table IV-5

  RESULTS OF 1983 PLASTICS MOLDING AND FORMING TELEPHONE SURVEY
                           SECOND PART
Type of
Process
Extrusion
Molding
Coating and
Laminating
Thermoforming
Calendering
Casting
Foaming
Cleaning and
Finishing
TOTAL
Wet
Processes
52
18
1
0
0
1
0
14
86
(%)*
(48)
(5)
(3)
(0)
(0)
(14)
(0)
(16)
Dry
Processes
57
329
34
61
2
6
11
74
574
(%)
(52)
(95)
(97)
(100)
(100)
(86)
(100)
(84)
Total
109
347
35
61
2
7
11
88
660
(%)
(100)
(100)
(100)
(100)
(100)
(100)
(100)
(100)
           Wet Processes
           Dry Processes
Total

  86
 574

 660
 13
JJ7

100
*Percent of individual subcategory.
                               31

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                            Table IV-6

    DISTRIBUTION OF THE NUMBER OF PLASTICS MOLDING AND FORMING
                   PROCESSES BY DISCHARGE MODE*
Type of
Process
Extrusion
Molding
Coating and
Laminating
Casting
Cleaning and
Finishing
% of Total
Wet Processes
60.
20.
1.
1.
16.
4
9
2
2
3
Discharge
Direct
1
1
0
0
0
Indirect
15
7
0
1
4
Mode
Zero
31
10
1
0
10

Unknown
5
0
0
0
0
Total
52
18
1
1
14
        TOTAL
100.0
27
52
86
*Based on information from second part of 1983 telephone survey.
                               32

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guides used to develope this estimate).  For the purpose of
economic analysis, a sample of PM&F plants was  selected from  the
State Industrial Guides.  The sample, created by extracting every
20th plant listed as a producer of SIC 3079 products, formed  a
data base with 513 entries.  Since one of every 20 plants was
included, the 513 entries represent five percent of the category.
It follows that the PM&F category is comprised  of approximately
10,260 plants.  (20 x 513 = 10,260).  Approximately 77 percent of
the 513 randomly selected plants had a primary  SIC of 3079 and
approximately 23 percent had a secondary SIC of 3079.  Applying
these percentages to the total number of plants in the PM&F
industry yields 7,900 plants that are primary plastics molders
and formers and 2,360 that mold and form plastics as a secondary
operation.  The primary industrial classification of the plants
with a secondary plastics molding and forming operation include:
textiles, lumber and wood products, printing and publishing,
machinery, and transportation equipment.

1983 Questionnaire Survey

To further update the questionnaire data collected in 1978 and
1979 and the telephone survey data collected in 1983, 330 ques-
tionnaires were mailed in June 1983 to PM&F plants believed to
use process water.  The questionnaire sample was developed based
on the following criteria:

     1.  The sample was selected to obtain current information
         for plants in the category that used process water
         (wet plants).

     2.  The sample consisted of "new" PM&F plants (those
         entering the market between January 1, 1978, and
         December 31, 1981) and "old" PM&F Plants that use
         process water.

     3.  The number of "new" wet plants was based on data
         obtained through the two-part 1983 telephone survey.

     4.  The number of "old" wet plants was based on data
         obtained from the 1979 and 1979 questionnaire surveys
         and from the first part of the 1983 telephone survey.

All plants entering the market between January  1,  1978,  and
December 31,  1981, were called during the 1983  two-part telephone
survey.  Results of that telephone survey indicate that there are
317 new plants that have wet processes.

As previously mentioned,  a one-page questionnaire was mailed to
8,450 plants in 1978.  There were 1,114 respondents to that ques-
tionnaire that indicated they had wet PM&F processes.  A more
detailed questionnaire was mailed to 750 of the 1,114 respondents
in 1979.
                               33

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Four hundred seven of the plants that received the 1979 detailed
questionnaire returned completed questionnaires and 343 did not
return completed questionnaires.  Applying the percentage of the
plants that returned completed questionnaires and the percentage
of those that did not return completed questionnaires to the
1,114 wet plants reported in the 1978 one-page questionnaire
provides an estimate of the 1,114 plants that would have returned
a completed questionnaire and that would not have returned a com-
pleted questionnaire if all 1,114 wet plants were mailed a ques-
tionnaire.  Using those percentages, the Agency estimated that
605 of 1,114 wet plants would have returned a completed question-
naire and 509 would not have returned a completed questionnaire.

To determine the current status of the 750 plants that received
the 1979 questionnaire, 425 of those plants were called in 1983.
Two hundred thirty-two of the 425 plants returned a questionnaire
in 1979 and 193 did not return the questionnaire.  The ratio of
the plants that were called (i.e., 232:193) is the same ratio of
the plants that returned or did not return completed 1979 ques-
tionnaires (i.e., 407:343).

Results of this telephone survey indicated that 182 of the 232
plants that returned completed 1979 questionnaires were still in
business and had wet PM&F processes.  Twenty-nine of the 193
plants that did not return a completed 1979 questionnaire were
still in business and had wet PM&F processes.

The estimated number of the 1,114 wet plants from the 1978 ques-
tionnaire survey that would have returned a detailed question-
naire (i.e., 605) and the estimated number that would not have
returned the questionnaire (i.e., 509) if all 1,114 plants had
been mailed a questionnaire in 1979 were adjusted using the
results of the above telephone survey.  Based on those results,
the Agency estimates 475 (605 x 182/232) of the 1,114 wet plants
would have returned the questionnaire and 76 (509 x 29/193) would
not have returned the questionnaire.  Therefore,  the target popu-
lation for the 1983 survey was:

      317   new PM&F plants

      475   old PM&F plants that would have returned the
            1979 questionnaire

       76   old PM&F plants that would not have returned
     	  the 1979 questionnaire
      868   total

The numbers in each of these strata were used to determine the
distribution of the 330 detailed questionnaires that were mailed
in 1983.  That distribution is presented in Table IV-7.
                               34

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                            Table IV-7

           DISTRIBUTION OF THE 330 1983 QUESTIONNAIRES
Stratum
  Target     Number of 1983
Population   Questionnaires
New plants
   317*
119
Old plants that would have
returned 1979 questionnaire
   475**
182**
Old plants that would not have
returned the 1979 questionnaire
    76**
 29**
 *Based on results of 1983 telephone survey of new plants.

**Based on results of 1983 telephone survey of plants that did
  and did not return completed questionnaires.
                               35

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In the 1983 questionnaire survey, companies were requested  to
return a questionnaire for each plastics molding and forming
plant they operated.  A total of 346 questionnaires were
returned.  Of the 346 questionnaires, 324 indicated the plant
molds and forms plastic materials.  One hundred sixty-four  of
those plants use process water (i.e., they were wet) arid 160 do
not use process water (i.e., they are dry).  Since 49 percent of
the plants do not use process water and the survey was directed
at plants who said they did use process water in the first  part
of the 1983 telephone survey, the Agency's contention that  plants
did not understand the difference between contact and non-contact
cooling water during the first part of the telephone survey is
supported.

Most of the plants that received the 1979 and 1983 questionnaires
have a primary SIC of 3079, which means that a plant molds  and
forms plastics as a primary operation.  During a meeting with
representatives from the Society of Plastics Industries (SPI),
they indicated that additional information could be obtained from
plants with a secondary SIC of 3079 (i.e., the plant molds  and
forms plastics as a secondary operation) by sending a question-
naire to a sample of companies on the mailing list for the
magazine "Plastic World."  Therefore, in August 1983, 170 ques-
tionnaires were mailed to companies on that list.  As with  the
other questionnaire surveys, companies were requested to return a
questionnaire for each plastics molding and forming plant that
they operated, so that a total of 173 questionnaires were
returned.  Of these, 106 questionnaires indicated the plant molds
and forms plastics with 56 plants using process water and 50
plants having dry processes. Because the mailing list included
many subscribers not believed to mold or form plastics, such as
libraries and chambers of commerce, statistical information from
this survey were not used to characterize the PM&F category.
However,  information from this survey regarding water use prac-
tices at plants with wet processes was included in the project
data base.

Summary of Questionnaire Data Base

The questionnaire data base for this project consists of ques-
tionnaires from both the 1979 and 1983 surveys.  When a plant
returned a questionnaire in 1979 and again in 1983, only the
updated questionnaire from the 1983 survey was included in  the
data base.  Thus, only 196 of the original 332 questionnaires
from the 1979 questionnaire survey remain in the updated data
base.  The data base also contains 212 of the 220 1983 question-
naires returned by wet plants during the 1983 questionnaire
survey.   The other eight questionnaires were incomplete and it
was not possible to obtain additional data through further
contact with these plants.  Thus, the questionnaire data base
consists of 196 questionnaires from the 1979 survey and 212
                               36

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questionnaires from the  1983 survey for a  total of 408
questionnaires.

Each of the questionnaires were reviewed and the following data
were documented for future reference and evaluation:

        company name, plant address, and name of the  contact
        listed in the questionnaire.

        plant discharge  status  (i.e., direct, indirect, or zero
        discharge).

        production processes present at the plant, as well as
        associated wastewater flow rates;  production  rates;
        operating hours; wastewater treatment, reuse, or dis-
        posal methods; and the plastic materials processed.

        capital and annual treatment costs.

        any available pollutant monitoring data provided by
        the plant.

The summaries provided a consistent, systematic method of evalu-
ating the information.   In addition, procedures were  developed to
simplify subsequent analyses.  Using those procedures, informa-
tion in the data base was used to:

        select and list the plants containing specific
        production processes and associated types of waste-
        water and treatment technologies,

        sum the number of plants containing specific processes
        and associated types of wastewater and treatment
        combinations,

        calculate the percent recycle for specific flows and sum
        the number of plants recycling this flow within various
        percent recycle ranges.

        calculate annual production values associated
        with each process, and

        calculate water use and wastewater discharge  from
        individual processes.

The survey information was used to develop the category profile,
to develop subcategorization schemes,  to analyze treatment and
control technologies, to determine the water use and discharge
values, and to estimate statistics for the estimated 1,898 plants
in the PM&F category that use process  water.   A more detailed
description of the combined data base is presented in Section VI.
                               37

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LITERATURE REVIEW

The literature was examined for information on plastics molding
and forming processes and wastewater treatment systems.  Treat-
ment system effectiveness and investment and annual treatment
system costs were also obtained from the literature.

Many sources were reviewed for information on wastewater treat-
ment technologies.  EPA's Innovative and Alternative Technology
Assessment Manual provided most of the information on treatment
technologies.  Treatment technology performance data were
obtained from EPA's Treatability Manual, Volume III, Technol-
ogies for Control/Removal of Pollutants.  Additional data were
obtained from documents supporting the proposed organic chemi-
cals, plastics, and synthetic fibers category effluent limita-
tions guidelines and standards.  Treatment system information
obtained from these sources is presented in Section VIII.  Cost-
ing information was primarily obtained from EPA's Estimating
Water Treatment Costs, and vendor contacts.  Details on invest-
ment and annual costs are presented in Section IX.

A great variety of general references, texts, and articles were
used as sources of information on plastics molding and forming
processes.  The process descriptions derived from these sources
are presented later in this chapter.  Process information was
supplemented by trip reports of numerous site visits to PM&F
plants.  A complete list of references used to obtain both
process information and information on other aspects of the PM&F
category is presented in Section XVI.

INDUSTRY DESCRIPTION

The following description of the PM&F category, and the processes
used to mold and form plastic products is based on information
from three of the preceding sources of information.  The litera-
ture provided the foundation on which the descriptions are based.
Literature information has been augmented and updated where
appropriate by data gathered during the sampling and industry
survey efforts.

Plastic materials are a group of synthetic or natural organic
materials composed of high molecular weight, long chain mole-
cules.  The molecular composition along with the degree of
crosslinking and the pattern and amount of branching in the
molecule determines the material's characteristics.  The generic
category of plastic materials includes many types of resins,
resinoids, organic polymers, cellulose derivatives, casein
derivatives, and proteins.  However, except for some specialty
applications, the majority of plastic materials used in consumer
and industrial products are synthetically produced organic
polymers and copolymers.
                               38

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Plastic materials can be generally  classified  into  two  basic
groups:  thermoplastics and thermosets.   Thermoplastics become
soft when exposed to a sufficient amount  of  heat  and  they  harden
when cooled.  The heating and cooling process  can be  repeated
several times.  Thermoplastic materials can  be processed by a
large number of forming processes,  the most  common  being injec-
tion molding and extrusion.  They include:   acrylonitrile-buta-
diene-styrene, polyethylenes, polypropylene, polystyrene,  and
polyvinyl chloride.

Thermosetting plastics are set  into their permanent shape  when
heat and pressure are applied during molding or forming.   Unlike
thermoplastics, once set into shape, thermoset products cannot be
softened and reformed.  Thermoset plastic products  are  usually
formed by processes such as compression molding,  transfer  mold-
ing, and casting.  Thermoset plastic materials include  alkyd
resins, nylons, epoxy resins, phenolic resins,  and  silicon.

Some plastics can be formulated  into either  thermoplastics or
thermosetting products depending on the extent of crosslinking
permitted during their manufacture.  Once produced, these
materials exhibit the properties of the particular  type of plas-
tic and are processed accordingly.   Polyurethene  and  polyester
are two such plastic materials.

For the purpose of regulation, the  plastics  industry  is covered
by two industrial point source categories.   These categories are:
(1) the organic chemicals,  plastics, and  synthetic  fibers  cate-
gory which includes manufacturers who produce  and formulate the
basic plastic materials; and (2) the plastics  molding and  forming
category comprised of the processors that convert the plastic
materials into usable shapes.

Overlap of the organic chemicals, plastics,  and synthetic  fibers
category and the plastics molding and forming  category  occurs
during the production of crude plastic intermediates, such as
pelletized plastic resin.  When commonly  recognized plastic
molding and forming processes such  as pelletizing,  strand
cutting, or film extrusion are used to produce crude  plastic
intermediates in the final step of  a continuous plastic material
manufacturing operation before shipment off-site, the processes
are regulated under the organic chemicals, plastics,  and syn-
thetic fibers category.  Plastic molding  and forming  processes
used by plastic resin manufacturers  to process plastic materials
on-site into intermediate or final  plastic products by  further
molding and forming are controlled  by the effluent  limitations
guidelines and standards for the plastics molding and forming
category.

Processes that coat a plastic material onto  a  substrate may fall
within the definition of processes  in the electroplating and
                               39

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metal finishing point source categories.   For  the  purpose  of
regulation, these coating operations  are  excluded  from  the
effluent limitations guidelines  and  standards  for  the electro-
plating and metal finishing point source  categories  and are
included in the plastics molding and  forming point soiirce
category.

PM&F plants produce a wide variety of products  and range from
small plants with a single process and  a  few employees  to  large
plants with several hundred employees.  Plastics molding and
forming plants tend to be located near  the  sales centers of  the
United States so that finished consumer products need not  be
transported over long distances.  Sixty-five percent of the
plants are located in one of the following  four clusters:

     1.  New York, New Jersey, and Pennsylvania;
     2.  Illinois, Indiana, Michigan, and Ohio;
     3.  Louisianna, Oklahoma, and Texas; and
     4.  California and Washington.

PLASTICS MOLDING AND FORMING PROCESSES

The plastics molding and forming category consists of plants that
blend, mold, form, or otherwise  process a wide variety  of  plastic
materials into intermediate or final  plastic products.   There are
eight generic processes used to  process plastic materials.   They
are:

     1.  extrusion,
     2.  molding,
     3.  coating and laminating,
     4.  thermoforming,
     5.  calendering,
     6.  casting,
     7.  foaming, and
     8.  cleaning and finishing.

Each of these processes is described below  including discussion
of which PM&F processes use process water and  the  purpose  of such
use.  Process water is defined as any raw,  service, recycled, or
reused water that contacts the plastic product or  contacts shap-
ing equipment surfaces, such as molds and mandrels, that are or
have been in contact with the plastic product.  Noncontact cool-
ing water is not process water and thus is  not controlled  by the
proposed regulation.  Permitting and  control authorities will
estabish limitations for the discharge of noncontact cooling
water and other nonprocess wastewater on a  case-by-case  basis.
                               40

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Extrusion Processes

Extrusion processes force molten polymer under pressure  through  a
shaping die to produce products of uniform cross-sectional  area
such as pipe, tubing, sheet, film, and profile.  This process has
a number of different applications including  the compounding of
polymers, the production of pellets and parisons (blow molding
preforms) for later use, the production of finished  and  semi-
finished products, and the coating of substrate materials.

A wide range of polymers are extruded.  Thermoplastic polymers
are most commonly used and include acrylic resins, acrylonitrile-
butadiene-styrene (ABS), polyacetal, fluoroplastics, nylon,
polyphenylene oxide, polybutylene, polyethylene, polypropylene,
polystyrene, polyvinyl chloride, styrene-acrylonitrile,  and
thermoplastic polyesters.

Extruded thermoplastic foams are produced by  incorporating  a
gas-forming expanding agent in the thermoplastic and extruding
the mixture under carefully controlled conditions.  This  is an
extrusion process with the addition of a blowing agent at the
extrusion die.  Packaging and building products are the major
applications for extruded foam products.  The primary raw mater-
ials used to produce extruded foam products are acrylonitrile-
butadiene-styrene, high density polyethylene, polypropylene,
polystyrene, and polyvinyl chloride.

A schematic of the extrusion process is shown in Figure  IV-1.
Thermoplastic polymer granules, pellets, powder, or beads are fed
into the hopper of the extruder.  The polymer is picked up by a
rotating screw within the extruder cylinder and is forced toward
the die.  Heat provided to the cylinder walls begins the  soften-
ing of the polymer pellets.  As the material moves along  the
cylinder, friction becomes the primary source of heat.  During
this heating and compression period, the plastic material is
transformed into a homogeneous melt and is thoroughly mixed.

Prior to leaving the extruder cylinder, the melted polymer passes
through a screen pack that removes dirt and provides back pres-
sure control.  The melt enters the die at high pressure.  The
extrusion die is a streamlined orifice that reduces the melt to
the desired shape.   As the extrudate leaves the extruder, it is
transported over some type of roller or conveyor cooling  system
that cools the hot extrudate by use of air or water.

Approximately 50 percent of extrusion processes use contact
cooling water.  Contact cooling water is used when a high heat
transfer rate is required such as the extrusion of thick-walled
products or during pelletizing operations.
                               41

-------
  Polymer.
  Feed
r
1
) to
i
i


Extruder
1
1
1
1


Cooling




Conveyor
System
                    Noncontact
                     Cooling
                      Water
Contact
Cooling
 Water
                                    tExtruded
                                    Product
                 Polymer Feed
    Feed
    Hopper
                                                         Strainer
                                                                     Die
                                                                       Extruded
                                                                        Plastic
                                                       Blowing Agent for  Foams



                Mechanical Screw


Source:  Adpated from Masson, D.  (ed) .  The Study of the Plastics  Industry.   1973.
                                 Figure  IV-1

                             EXTRUSION  PROCESS
                                      42

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Extrusion processes are often used  to blend,  color,  and  pelletize
thermoplastic polymers.  Additives  required  for  special  applica-
tions and colors desired by the processor  are added  to the  resin
and are fed to the extruder to become a homogeneous  melt.   A
brief description of the most commonly used  classes  of additives
and specialty chemicals are presented in Table IV-8.  The melt  is
extruded through a multi-opening die and taken off as strands
that are cut into pellets of the desired size after  cooling.   In
many cases, the pellets are cut at  the face  of the die,  which  is
submerged in water for rapid cooling.  Pelletized polymers  can  be
in the form of round, cylindrical,  or cube-shaped particles and
can be used as feed material for extrusion,  molding, casting,
foaming, and other processes.  Commonly pelletized theromoplas-
tics are ABS, polyethylene, polypropylene, and polyvinyl
chloride.

Extrusion processes can use both contact and noncontact  cooling
water.  Noncontact cooling water is used to  remove excess heat
from the extrusion machinery caused by friction.  Direct contact
cooling water is used for product quenching.   Direct contact
cooling water is produced during pelletizing operations  when the
extruded strands are submerged to facilitate cooling and cutting.
Extruded profile, pipe, and tube are often cooled by a cooling
water bath.  Plastic jacketed wire  and cable is  also passed
through a water trough for direct contact  cooling.   The  use of
contact cooling water in extrusion  processes is  the  major use  of
process water in the plastics molding and  forming category.

Molding Processes

Molding is the most common process  used to produce finished or
semi-finished products from plastic materials.   Molded parts can
be solid, hollow, or foamed.  Plastic objects  of almost  any
desired shape can be produced commercially by  one of seven
different types of molding processes:

       1.  injection molding,
       2.  blow molding,
       3.  compression molding,
       4.  transfer molding,
       5.  reaction injection molding,
       6.  rotational molding, and
       7.  expandable bead foam molding.

Injection Molding.  Injection molding is used  to form intricate
plastic parts with excellent dimensional accuracy at very high
production rates. Injection molding involves  the plasticating  of
pelletized plastic materials with heat and the subsequent
injection of the melt into a mold.
                               43

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                                   Table  IV-8

         COMMONLY  USED ADDITIVES  IN  POLYMER  FORMULATION
                      USING  THE  EXTRUSION  PROCESS
    Additive

Antiblocking Agent


Ancioxldants




Antisatic Agents




Catalysts
Chemical Resistant
Additives
Colorants



Coupling Agents





Cure Retardants


Curing Agents



Fibrous Reinforcements



Fillers and Extenders



Flame Retardants
Foaming (blowing)  Agents
Heat Stabilizers
         Function

Prevents self-adhesion of films


Retard oxidative degradation of
plastic material during process-
ing and use
Reduce the accumulation of elec-
tronic charge on the  surface of
polymers
Affect the rate of  chemical reac-
tions without themselves being
consumed or undergoing  chemical
change

Descrease polymer susceptibility
to chemical degradation
Impart hue (shade), volume
(brightness),  and  chroma
(strength of  color) to plastics

Enhance polymer-mineral surface
bonds and increase the ability of
composites to retain properties
during prolonged exposure to
moisture

Reduce the cure rate for amino
resins

Improve the curing of thermo-
setting resins upon exposure to
heat

Impart tensile, flexural, and
compressive strength to plastics
Increase the bulkiness  and
decrease the total  cost of
plastic formulations

Act chemically or physically as
insulators by creating  endother-
mic cooling reactions,  by coating
the plastic to exclude  oxygen or
by influencing combustion through
reaction with materials that have
different physical  properties

Produce large quantities of gases
upon heating that form  cellular
plastics

Prevent the degradation of the
plastic material during process
heating and during  Its  useful
life
Silicate minerals
High melting point waxes

Alkylated phenols
Amines
Phosphates
Thio compounds

Amine
Quaternary ammonium
Anionic surface active
agents

Peroxides
Organo-tin compounds
Amines
Glass
Synthetic fibers
Graphite

Dyes
Organic and inorganic
pigments

Silane compounds
Titanate compounds
Amines
Peroxides
Amines
Azo compounds

Synthetic fibers
Carbon fibers
Glass fibers

Calcium carbonate
Silica
Nutshell flours

Antimony oxide
Chlorinated parafins
Halogenated organlcs
Nitrogen
Pentane
Azo bis formamide

Barium-cadmium compound!
Tin compounds
                                         44

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                          Table  IV-8   (Continued)

         COMMONLY  USED ADDITIVES  IN  POLYMER  FORMULATION
                      USING THE EXTRUSION  PROCESS
    Additive

Impact Resistant
Additives
Insulators


Lubricants




Mold Release Agents






Plasticizers
Preservatives and
Biocides

Casting Promoters
Sizing Agents


UV Stabilizers
         Function

Decrease a plastic materials
tendency to break or crack upon
impact

Improve the thermal or electrical
insulating properties of polymers

Enhance reain processibility  and
the appearance of the end product
Prevent sticking of newly formed
parts to a mold
Impart flexibility, resiliency
and increasing melt flow to  poly-
mers by reducing the intramolecu-
lar forces between polymer chains
Inhibit biological degradation of
polymers

Improve the cure of cast parts
Coatings that protect the polymer
surface

Absorb ultraviolet radiation and
reradiate it at a harmless wave-
length or consume the free radi-
cals generated by UV light
      Example
Acrylics
ABS
Silaceous  minerals
Ceramic oxides

Fatty acid esters
Hydrocarbon oils
Paraffin wax
Amides

Silicone
Mineral oil
Wax
Fatty acids
Mica
Talc

Phthalates
Adipates
Trimellitates
Glycolates
Fatty acid esters
Organic phosphates

Fungicides
Bacteriostats

Cobalt octoate
Dimethyl aniline
Tin salts

Waxes
Benzotriazoles
Benzophenones
                                      45

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Both thermoplastic and thermoset polymers are  injection  molded.
The majority of injection molded products are  produced from
polyethylene, polypropylene, polystyrene, and  acrylonitrile-
butadiene-styrene (ABS).  Other polymers that  are commercially
injection molded are acrylic resins, fluoroplastics, nylons,
phenolic resins, polyacetal, polycarbonate, polyesters,  poly-
phenylene sulfide, and styrene-acrylonitrile.  Typical injection
molded products include appliance parts, furniture parts, machine
parts, office and household items, and  toys and novelties.
Fillers can be added during the injection molding process to
produce reinforced plastic products such as appliance components
and sporting goods.

A schematic of the injection molding process is shown in Figure
IV-2 . The resin and additives are fed  into the heating  portion
of the injection molding machine where  the polymer is heated to
the temperature at which it becomes soft enough to flow.  An
injection system forces the melt through a nozzle, then  through
sprues and runners,  and finally into the cavities of the mold
where high pressure is held briefly to  allow the plastic to set.
As thermoplastics cool in the mold, they retain the desired
product shape.  Thermosets require that heat be applied  to the
mold to complete polymerization.

Structural foam molding is an injection molding process  where a
blowing agent is added to either the polymer input materials or
the polymer melt.  Polystyrene is the major material used in
structural foam molding.  The following polymers are also used:
acrylonitrile-butadiene-styrene, polyphenylene oxide, polycar-
bonate, high density polyethylene, polypropylene, and polysty-
rene.  Uses for structural foam include furniture, business
machines, and construction products.

There are four basic types of heating/injection systems  used for
commercial injection molding.  They are:  (1)  conventional injec-
tion molding machines, (2) piston-type  preplasticating machines,
(3) screw type preplasticating machines, and (4) reciprocating-
screw injection machines.  The reciprocating screw injection
machine is the most common machine for modern  plastics processing
due to its faster cycles, lower melting temperature requirements,
and better mixing.

In conventional injection molding machines the plastic granules
or pellets feed from a hopper into the  chamber of the heating
cylinder.  A plunger compresses the material forcing it  through
progressively hotter zones of the heating cylinder.  The material
flows from the heating cylinder through a nozzle and into the
mold.  In piston-type preplasticating machines a heater  is used
to preplasticate the plastic granules after which the plastic is
held in a holding chamber until it is molten enough to be forced
into the die.  A piston rams the plastic through the nozzle into
                               46

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1
1
1
Polvmer ] ^
Feed i
i
i

Heating/
Injection
System












	 1

Removal
Mold









                                                                     Injection
                                                                     Molded Part
                  Mold
Noncontact
Cooling
Water
                                                      Polymer
                                                       Feed
                                                                     Plunger or
                                                                     Screw
 Source:  Adpated from Masson, D. (ed).   The Study of the Plastics Industry.  1973.
                                 Figure  IV-2

                        INJECTION MOLDING PROCESS
                                      47

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the mold.   In  screw-type  preplasticating machines,  an  extruder  is
used to plasticize the plastic material.  A  rotating screw  feeds
the pellets  forward  into  the heated  interior surface of  the
extruder barrel.  The molten plastic  is extruded  into  a  holding
chamber and  is  forced into  the die by an injection  plunger.   In
reciprocating  screw  injection machines, a rotating  screw moves
the plastic  material forward through  a heated extruder barrel.  As
the molten plastic material moves forward, the  screw backs  up to
a  limit switch  that  determines the volume of material  collect-
ing in the front of  the barrel.  The  screw then acts as  a ram and
injects the  plastic material into the die.

The majority of all  injection molding operations  use noncontact
cooling water circulated  through channels in both the  injection
equipment and  the product mold.  Direct contact cooling  may be
used when molded parts require rapid  cooling.

Blow Molding.  Blow molding is used to produce hollow, thin  wall
objects from thermoplastic  resins; it has become  one of  the  major
processing methods of the plastics industry  for hollow articles.
Blow molding involves extruding or injection molding a preformed
shape that is then blown  into its final form by compressed  air.

Most thermoplastic materials can be blow molded;  however, high
density polyethylene has  traditionally been  the workhorse of the
blow molding industry.   Other thermoplastic  polymers commercially
used for blow molding include acrylic resins, acrylonitrile-buta-
diene-styrene,  polyacetal, polycarbonate, polyester, polyethy-
lenes, polypropylene, polystyrene, and polyvinyl  chloride.   Blow
molding processes are used  to produce a wide  range  of  hollow bot-
tles and containers.  Approximately 80 percent of the  blow mold-
ing processes produce packaging items.  These include  household
bottles and  containers for  cosmetics,  toiletries, pharmaceuti-
cals,  chemicals, and foods, as well as industrial containers.
The remaining 20 percent produce industrial  products such as
automobile fuel tanks,  lighting fixture globes, ornaments,  and
toys.

A schematic  of a blow molding process  is shown in Figure IV-3.
Blow molding processes can be divided  into two major types-.
extrusion blow molding and  injection  blow molding.  These two
processes are similar in that they both use  a parison, or pre-
shaped sleeve,  of plastic that is expanded by air pressure  to
fill the inside of a concave mold.   The difference  between  the
processes lies in the formation of the parison.   Extrusion  blow
molding uses an extruder to preform parisons whereas in  injection
blow molding the parisons are formed  in an injection mold.   Blow
molding processes use noncontact cooling water to cool the mold.
                               48

-------
Polymer
  and   ~H
Additives
Polymer
  and   ~
Additives
Extrusion

or



Injection
Molding of
Parison








i_ —


~*
01 nu

Molding

_*
	 | 	








_ J









                                                         Blow
                                                         Molded
                                                         Part
               Mold
       Noneontact
       Cooling
       Water
                                             Gripper
                                              Arm
                                          Parison
                                 Air Injection
                                    Pin
 Source:  Adapted from Seymour, W.B.  Modern Plastics Technology.  1975.
                        Figure  IV-3

                   BLOW  MOLDING PROCESS
                              49

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Compression Molding.  Compression molding  is one of  the  earliest
forms of molding, and requires only one major piece  of equipment:
the compression press.  Compression molding involves  shaping  a
measured quantity of plastic within a mold by applying pressure
and heat.  This molding process  is ideal for the production of
parts with large areas and relatively simple shapes.

Compression molding is primarily used for  processing  thermoset
resins, although it is used to mold thermoplastics for special
applications.  Polymers most commonly used in compression molding
include alkyd resins, amino resins, diallyl phthalate, epoxy
resins, phenolic resins, and polyester resins.  Other less fre-
quently used polymers include polytetrafluorethylene, polyure-
thane, silicone, and polyvinyl chloride.   Fillers such as glass
fibers, wood, cotton, and cellulose are often used during com-
pression molding to produce reinforced plastic products.  Typical
compression molded products include novelties, knobs, handles,
dinnerware, buttons, electrical  and electronic components, and
appliance parts.  Reinforced products include large  automotive
and appliance parts.

A schematic of the compression molding process is shown  in Figure
IV-4.  The plastic material is fed to the  compression mold either
in granular form or as a preform.  The mold halves are then
closed by a hydraulic press.  Pressure is maintained  and heat is
applied, causing the plastic to spread to  the shape of the mold.

Compression molding processes generally use noncontact cooling
water to cool the mold halves.   Some compression molding pro-
cesses may use contact cooling water sprays to rapidly cool newly
formed products.

Transfer Molding.  Transfer molding is much like compression
molding with the difference being that in  transfer molding the
resin is preheated in a separate chamber and is then  forced into
the mold cavity for curing.

Thermoset resins are most commonly transfer molded.   These
include alkyd resins, amino resins, diallyl phthalate resins,
epoxy resins, phenolic resins, and polyester resins.  Fillers
such as cellulose, clay, glass fiber, minerals, and  synthetic
fibers are often used during transfer molding to produce rein-
forced plastic products.  Transfer molding is especially well
suited for the production of small intricate thermoset parts and
is used extensively in the production of electrical  insulating
parts and connectors.  Reinforced products include appliance
housings and decorative parts.

A schematic of the transfer molding process is shown  in  Figure
IV-5.  Plastic preforms are preheated by heat lamps, hot air
ovens, or dielectric heaters.  That material is put  into a
                               50

-------
Premeasured
Polymer or
Preform

Compression
Hydraulic Press









Compression
Molded Part
                                                       	 Guide Pin
                                                          Premeasured
                                                          Polymer Charge
                            Mold Cavity


Source:  Adapted  fromMasson,  D. (ed).  The Study of the Plastics Industry.   1973.
                            Figure  IV-4

                 COMPRESSION MOLDING  PROCESS
                                 51

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Polymer ___
Preforms


Preform
Preheater




I 	

Transfer
Chamber






Mnl A





_ J

Removal
Trimming


Transfer
* Molded
Part

               Transfer Ram
                               Gui.de Pins
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       Figure IV-5




TRANSFER MOLDING  PROCESS
            52

-------
chamber  or  "transfer  pot" where  it  is  plasticized by heat and
pressure  into a viscous mass.  The  plastic  is  then forced through
sprues and  runners  into the mold cavity.  The  pot, sprues,
runners,  and cavity surfaces  are maintained at a temperature
suitable  for rapid  curing of  the material.   The plastic is  held
in the mold at its  cure temperature until the  part is capable of
maintaining its shape.  Transfer molding processes generally do
not use  contact water to cool  the product.

Reaction  Injection Molding.   Reaction  injection molding (RIM)
involves  the simultaneous high pressure  injection of two or more
reactive  liquids  into a mixing chamber followed by low pressure
injection into a  mold cavity.  Most commercial reaction injection
molding  is performed  with various urethane  formulations.   The
majority  of urethane  formulatons are comprised of two liquid
intermediate feeds:   the resin and  isocyanate.   When blowing
agents are  incorporated in the isocyanate feed,  foam products are
formed.   Fillers  are  added during reaction  injection molding to
produce  reinforced plastic products for  the automotive indus-
try.  Reaction injection molded  polyurethane products include
bumper systems, panelling, automotive  trim,  sporting goods,  and
machinery housing.

A schematic of a  reaction injection molding process  is shown in
Figure IV-6.  A reaction injection  molding  process consists  of
four integrally related units:   feed tanks,  a  metering system,  a
mixer, and the mold.   The feed tanks are where the raw material
components are stored and heated.   Agitators,  heat exchangers,
low-pressure pumps, and recirculation  equipment  are  used  to  main-
tain liquid temperature and uniformity.  Liquid  material  from the
feed tanks are metered to the  mixing head where  they are  mixed
under high-pressure.   The liquids are  then  injected  into  the mold
where polymerization  occurs.   Once  the part has  sufficiently
cured to  hold its shape, the mold is opened and  the  part  is
ejected.  Contact water is not used during  the  reaction injection
molding process.  The molded parts  can be sufficiently cooled by
air.

Rotational Molding.   Rotational  molding, sometimes termed roto-
molding or rotocasting, is used  to  make rigid  or flexible thin-
walled hollow objects  from thermoplastic materials.   Rotational
molding involves  rotating polymer powder or liquid in a heated
hollow mold.

Rotational molding is  performed  almost exclusively with thermo-
plastic resins such as polyamide  resins, polyacetal,  polycar-
bonate, low density polyethylene, and  polyvinyl  chloride.   The
rotational molding process is  used  to  produce  a  wide  range of
industrial and consumer goods  including arm rests, toys and
novelties, sporting goods,  and tanks and storage bins.
                               53

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A schematic of the rotational molding  process  is  shown  in  Figure
IV-7.  Premeasured amounts of the polymer  powder  or  liquid  are
put  into the preheated hollow mold  at  the  mold loading  station.
The mold is then put in the circulating hot  air oven where  it is
simultaneously rotated around two perpendicular axes.   The  heat
forces the thermoplastic to melt and the rotation uniformly
distributes the polymer over the entire mold surface.   The  mold
is then removed from the heating oven  and  is cooled.  After the
part has cooled sufficiently to hold the desired  shape,  the mold
is opened and the part is removed.

Most rotational molding processes use  noncontact  cooling water to
cool the outside surface of the mold.  Some  rotational  molding
processes may use direct contact water sprays  when rapid cooling
of the part is necessary.

Expandable Bead Foam Molding.  Expandable  bead foam  molding
processes produce a closed-cell, rigid plastic foam  material
characterized by fused polymer spheres.  The fused polymer  prod-
uct is produced by expanding beads  impregnated with  hydrocarbon
in a mold cavity.  The beads puff and  fuse together  filling the
mold cavity when heated.

Most bead foam molding processes use polystyrene  or  polyvinyl
chloride as raw materials.  Typical end products  are packaging
materials, flotation devices, insulation,  and  hot and cold
containers.

A schematic of an expandable bead foam process is shown  in  Figure
IV-8.  Polystyrene beads are usually pre-expanded to a bulk den-
sity close to the desired product bulk density prior to  further
processing.  Pre-expansion equipment commonly  consists  of a steam
chamber with baffles and mechanical agitation.  Condensate  is
discharged from the steam chamber.

The pre-expanded beads are fed to a preheated  split  cavity  mold.
Steam is supplied to the mold cavity through small holes in the
mold.  The heat supplied by the steam  causes the  impregnated
beads to expand to fill the confines of the  mold.  The  soft and
molten bead skins fuse together to  form a  single  polymer mass.
Condensed steam is discharged from  the mold  cavity.

Water is generally not used for the direct contact cooling  of
foam products.  Noncontact cooling water is  used  to  cool extruder
and mold assemblies.  However, the  steam that  heats  the  product
becomes a source of wastewater when condensed.

Coating and Laminating Processes

Coating and laminating processes combine polymeric materials with
other materials to produce products with special  properties such
                               55

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as chemical resistance, toughness, humidity  resistance,  corrosion
resistance, and electrical insulation.  Heat  is used  in  both
processes.  Lamination also requires high pressures.

Coating.  Polymer coatings are applied  in the  form of a  melt,
liquid, or finely divided powder onto numerous substrates  includ-
ing other plastic objects, metal, vrood, paper, fabric, leather,
glass, concrete, and ceramics.  Both thermoplastic and thermoset
resins can be coated.  The most common  resins  used are:  acrylic
resins, epoxy resins, fluoroplastics, amino  resins, polyesters,
low density polyethylene, polypropylene, and  polyvinyl chloride.
Typical products from coating processes include automotive  parts,
appliance parts, electrical supplies, furniture, and  housewares.

There are four types of coating processes:   plastisol  coating,
powder coating, spread coating, and extrusion  coating.   A  flow
diagram representing plastisol and powder coating is  presented  in
Figure IV-9.  Spread coating is illustrated  in Figure IV-10.  A
flow diagram of the extrusion coating process  is presented  in
Figure IV-11.

Plastisol Coating.  Plastisol coating involves the use of  a
liquid plastisol that consists of fine  particles of polyvinyl
chloride (PVC) dispersed in plasticizers.  Typical plastisol
coated products include housewares and  outdoor furniture.   The
plastisol is contained in a vat into which the object  to be
coated is dipped.  The objects are sometimes  preheated to  assure
sufficient polymer fusion.  The dipped  parts  then pass through  an
oven to complete fusion.  Some product  applications require that
the plastisol be applied to the object  surface with a  spray gun
or a brush.  Whether sprayed or brushed, the  coated object  must
subsequently be heated in an oven to fuse the polymer  coat.  The
dip coating process is very similar to  a dip  casting  process.
The difference lies in the nature of the mold.  In dip casting,
the plastic part, such as a glove, is stripped from the mold and
the mold is used to form another part.  In dip coating,  the mold
is actually part of the finished product, such as a metal  patio
chair that is dip coated with plastic.

Powder Coating.  Powder coating involves the use of a  homogeneous
blend of thermoset or thermoplastic resin, pigments,  fillers, and
additives in the form of a dry, fine, flour-like substance.
Three basic powder coating methods exist:  fluidized  bed,  elec-
trostatic spray, and electrostatic bed.  Fluidized bed coating
involves creating a fluidized bed of thermoplastic or  thermoset
resin powder by the flow of air through a porous plate at  the
bottom of a tank.  Objects to be coated are preheated  and  are
then dipped into the fluidized bed.  When the resin particles
touch the surface of the hot object they melt and fuse.  Electro-
static spraying is performed by charging the polymer  powder
either positively or negatively so that it is attracted  to  a
                               58

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grounded or oppositely charged object.  The  electrostatic  bed
process is a combination of the fluidized bed and electrostatic
spray methods. Electrodes located in the porous plate  at the
bottom of the fluidized bed tank transfer a  charge  to  the  powder
particles which are then attracted to the grounded  object  to be
coated.

Spread Coating.  Knife or spread coating uses a long blade or
knife to spread the molten thermoplastic polymer coating on a
moving substrate.  Thermoplastics such as low density  polyethy-
lene, polyvinyl chloride, and polypropylene  are used to coat
flexible materials such as fabric.

Extrusion Coating.  Extrusion coating involves the  extrusion of a
thin layer of polymer onto a moving substrate, which is usually
either a paper web, plastic sheet, or paper  sheet.  Polymers such
as low density polyethylene, polypropylene,  and polyethylene
terephthalate are used in extrusion coating  processes  to produce
the coatings.

Direct contact cooling water is often used to cool  newly coated
parts, particularly when the plastisol coating or powder coating
process has been used to produce the plastic covering.

Laminating.  Laminate structures are formed  from layers of resins
and fillers bonded together.  Thermosetting  resins  are the only
resin types commercially used for laminating.  Typical laminating
resins include alkyd resins, epoxy resins, melamine formaldehyde,
and phenolic resins.  Paper, cloth, glass fiber, and glass cloth
are typically used as the reinforcing substrate.  Lamination pro-
cesses are used to produce decorative panels and items requiring
good electrical insulating properties.  Process water  is
typically not used in lamination processes.

Laminating processes can be classified into  three types:   lamina-
tion of flat sheets, lamination of rods and  tubes,  and continuous
lamination.  A schematic of the laminating process  is  shown in
Figure IV-12.

Flat Sheet Lamination.  Flat laminate sheets are produced  by
impreganting the base sheets with liquid thermosetting resin.
Phenolics, melamines, alkyd, polyester, and  epoxies are all
commonly used.  The correct number of sheets for the specific
application are placed together with the resin between two
platens of a hydraulic laminating press.   The hydraulic press
closes and pressure and heat are applied to  the layers.  The
thermoset resin flows through the filler sheets and cures.  After
the sheets have sufficiently cured, the platens are allowed to
cool, the press is opened, and the sheets removed.
                               62

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Rod and Tube Lamination.  Laminate  rods  and  tubes  are produced
from filler webs  impregnated with thermoset  resin.   Solid rods
are made by winding  the  impregnated filler web  around a very thin
rod (mandrel) which  is then withdrawn.   The  preform  rods are then
placed in  a compression  mold where  heat  and  pressure are applied.
In some operations the rods are placed in an oven  and allowed to
cure without pressure over a long period of  time,  typically 12 to
24 hours.  In making a tube, the mandrel is  left  in  during the
compression molding  step.

Continuous Lamination.   Continuous  lamination processes are used
to produce large  volumes of structural grade sheets  for use as
residential and industrial panels.   Polyester resins are most
commonly used in  the continuous lamination process along with
chopped glass fibers.  Continuous lamination is performed by
combining  the resins and reinforcements  between two  moving
carrier films.  The  films are pulled  through a  set of squeeze
rolls to eliminate entrapped air. The laminate  cures in an oven
after which the carrier  film is stripped from the  newly formed
laminate.  Figure IV-13  depicts the continuous  lamination
process.

Thermoforming Processes

Thermoforming processes  involve the heating  of  thermoplastic
sheet or film to  a pliable state and  forcing it around  the con-
tours of a mold.  Vacuum, air pressure,  and/or mechanical force
are employed to aid  in the sheet forming.  The  input for thermo-
forming processes is foam sheet or  film  produced by  extrusion,
calendering, or casting  processes.   Sheet and film can  be
laminated  or printed prior to thermoforming.

A wide variety of sheet  and film plastic is  suitable for thermo-
forming.   Sheet and film for thermoforming is typically made from
acrylic,  acrylonitrile-butadiene-styrene, polycarbonate,  poly-
ethylenes,  polypropylene, polystyrene, and polyvinyl chloride.
Typical thermoformed products include appliance parts,  automotive
parts,  lighting fixtures, packaging, and signs and displays.

A schematic of thermoforming processes is shown in Figure IV-14.
Plastic sheet is  clamped into a frame prior  to  thermoforming to
provide support for the  plastic material throughout  the entire
process.   The plastic sheet is uniformly heated before  being
formed to be certain of uniform stretch  during forming.   One of
three heating methods are usually used:  radiant heating,  con-
vection heating,  and conduction heating, with radiant heating
being the most commonly used method.  When sufficiently heated,
the sheet is formed into the desired shape by one of three
forming processes:   (1) vacuum forming,  (2)  pressure forming,  and
(3) matched mold  forming.
                               64

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Vacuum Forming.  Vacuum  forming  is  the  most  versatile and most
commonly used process  for  thermoforming.   The  heated  sheet is
placed directly  above  a  concave  mold  and  pressure is  used to seal
the plastic material to  the  upper mold  edge.   Vacuum  is  applied
from beneath  the mold through small  holes in  the mold cavity
forcing the sheet against  the mold  contours.   Although many vari-
ations of vacuum forming exist,  they  all  employ a vacuum applied
from below the mold surface.  Common  variations are termed drape
forming, snap-back forming,  and  plug  assist  vacuum forming.

Pressure Forming.  Pressure  forming involves the use  of  air pres-
sure to force the softened plastic  sheet  against the  mold.  A
sheet of plastic is clamped  over a  pressure  box containing a
concave mold and is heated.  The sheet  is  then covered and com-
pressed air is blown through openings in  the cover.   The air
pressure forces  the sheet  against the mold contours.   A  variation
of pressure forming termed free  blowing is used to produce
bubble-like forms.

Matched Mold Forming.  Matched mold forming  is used to produce
products requiring excellent reproduction  detail.   The heated
sheet material is placed between convex and  concave mold halves.
The halves are brought together, thereby  forming the  sheet into
the mold shape.  Most  thermoforming processes  use noncontact
cooling water.  However, in  some instances,  the thermoformed
product may be spray cooled  with water.

Calendering Processes

Calendering is widely  used in the plastics molding and forming
category to produce uniform  thickness film and sheet  at  high
production rates.  Calendering processes  squeeze pliable thermo-
plastic between a series of  rotating  rolls to  produce the polymer
film and sheet, to emboss  sheet  and film,  to perform  compounding
and to coat textiles and papers.

Flexible and rigid polyvinyl chloride compounds are the  most com-
monly used input materials for the  manufacture of calendered
products.  Typical products  include building and construction
supplies, packaging supplies, and consumer and institutional
goods such as toys, seats, and coverings.  Acrylonitrile-buta-
diene-styrene, polyethylene, and polystyrene are also used to
produce various films.

A schematic of a calendering process  is shown  in Figure  IV-15.
Calendering processes  generally  consist of five units:   mixing,
calendering, cooling,  take-off,  and trimming.   The thermoplastic
resin and the appropriate additives are transferred from storage
facilities through a sieve to a  high  shear mixer or mill where
heat is supplied to soften and blend  the polymer mix.  The
polymer is then fed to the calendering  unit, which is usually
                               67

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Polymers
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 Source:  Adapted from Ilasson, D. (ed).  The  Study of the Plastics Industry.   1973.
                                Figure  IV-1-5

                          CALENDERING PROCESS
                                     68

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comprised of three to  five heated  cast  iron  rolls  that  squeeze
the softened polymer into a  sheet  or  film  of desired width  and
thickness.  The arrangement  of  the  calender  rolls  is determined
by the product requirements  as  are  the  number of rolls  and  the
roll spacings. The clearance between  rolls is progressively
decreased to slowly reduce the  thickness and increase the width
of the sheet or film.  Most  roll arrangements are  adjustable  to
allow versatility in production methods.   Newly calendered  sheet
is cooled by feeding the sheet  or  film  through a series  of  two  to
to ten cooling rolls cooled  with noncontact  cooling water.  The
take-off rolls feed the sheet and  film  to  edge trimming  opera-
tions, further finishing operations,  or roll-up.

Calendering is also used to  coat materials such as paper and
fabric with a polymer.  The  process is  similar to  that  described
above except that fabric or  paper  is  fed into the  calendering
rolls as the plastic film is formed.  The  plastic  and fabric  are
tightly bonded together by the heat and force of the rolls  and
emerge from the cooling rolls as a  single  composite sheet.

Most calendering processes use noncontact  water to cool  the cool-
ing rolls.  Contact cooling water may be used to cool the rubber
contact roller when embossing is performed.   Some  calendering
processes may also use contact cooling water to cool the newly
formed sheet or film.

Casting Processes

In the plastics molding and  forming category,  the  term  casting  is
used rather loosely to describe a wide variety of processes.
Casting involves liquid plastic materials  allowed  to cure at
atmospheric pressure in a mold or on  a mold  surface.

Both thermoplastic and thermoset resins can  be used in casting
processes.  Commonly cast thermoplastics include acrylics,
nylons,  and polyvinyl chlorides.  Commonly cast thermosets
include epoxy resins, polyesters, phenolics,  and polyurethanes.

Fillers are often used in casting processes  to produce reinforced
plastic products such as boats and recreational vehicles,
troughs,  ducts, bins and tubs, as well as  preforms for use  in the
compression molding of reinforced products.

There are six types of casting processes:  pot casting,  slush and
dip casting, cell casting,  chilled film casting, solvent casting,
and continuous casting.  A schematic of pot,   slush and dip, cell,
solvent,  and continuous casting processes  is  shown in Figure
IV-16.   The chilled film casting process is  illustrated in  Figure
IV-17.
                               69

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   Pot, Cell,  Slush,  and Dip Casting
Pot and Cell
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                               CASTING  PROCESSES
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Pot Casting.   Pot  casting  is  the  simplest  form of casting and is
used to produce a  wide variety  of products.   Polymers  used in pot:
casting include acrylic, alkyl  resins,  diallyl phthalate,  epoxy,
nylon, phenolic, polyester, polyurethane,  and silicone elastomer.
During pot casting a  liquid polymer  or  a monomer  solution is
poured into an open mold where  is  it  allowed  to cure.   The pot
cast part is  cured by the  addition of heat in an  oven,  exother-
mically by means of a catalyst, or by a combination  of both
methods.  Typical  pot cast products  include novelties,  plaques,
knobs, embedments,  electrical encapsulations,  optical  products,
bearings, gears, jewelry,  billiard balls,  seals and  gaskets,
housewares, and furniture  parts.

Slush and Dip Casting.  Slush and  dip casting involve  the  use of
liquid plastisol(fine particle polyvinyl  chloride dispersed  in
plasticizers  such  as  dioctyl  phthalate).   These plastisols are
viscous at room temperature.  In  slush  casting, a measured amount
of plastisol  is poured into a hollow  mold  that has been pre-
heated.  The mold  is  rotated  quickly  to cover all inside surfaces
and after a specific  period of  time,  excess plastisol  is poured
out into a storage vat for future  reuse.   The thickness of the
hollow part is determined  by  the  amount of time the  plastisol
remains in the mold.  The mold  is  then  placed in  an  oven and  is
heated for several minutes to complete  fusion.  Typical slush
cast products include housewares,  novelties,  doll  heads, fish
lures, and toys.

In dip casting, a  mold is  preheated and dipped into  the liquid
plastisol.  A polymer coating fuses around the mold  during immer-
sion.   The coated  mold is  then  placed in an oven  to  complete
fusion.  Typical dip  cast products include novelties,  boots,
gloves, coin purses,  and eye glass cases.

Cell Casting.   Cell casting is  used to  produce sheet,  tubes,  and
rods.   Acrylic sheet  is most commonly cell cast.   A  premeasured
amount of liquid acrylic, consisting  of a  small amount  of  polymer
in a monomer and additive  solution is poured  between two sheets
of polished or tempered plate glass that are   slightly  larger
than the desired acrylic sheet  product.  The  glass cell, which is
held together by tubing and spring clips,  is  then  placed
horizontally  in an oven for curing.

Chilled Film Casting.  Chilled  film casting is a  casting process
used to produce non-oriented,  thin, polymer films.   Thermoplastic
materials such as  polypropylene homopolymer,  propylene-ethylene
copolymer,  and low  density polyethylene are most  commonly used
to produce film.   The most common  form  of  chilled  film  casting is
termed chill roll  casting.   In  chill  roll  casting,, the  formulated
polymer is extruded through a slot die  onto a rotating,  chilled,
polished roll.  The movement of the roll draws  the molten  resin
away from the die without significantly stretching or  orienting
                               72

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the film.  The  extrudate  solidifies  into  a film as it passes over
the  chilled roll surface.   The  film  is trimmed as necessary and
wound onto rolls.   Chill  casting processes produce high clarity
film products.  Process water  is not  used during chill roll
casting.

A less commonly used  film casting process is  termed tubular water
bath casting.  A thin-walled vertical tube of formulated polymer
is extruded downward  from a  rotating  circular die over a water
cooled mandrel.  The  tube is quenched in  contact cooling water
and split open  to form a  film.   The  film  is then trimmed and
wound on rolls.

Solvent Casting.  Solvent casting, often  referred to as solution
casting, is used for  the  production  of film and sheet.  Polyvinyl
chloride (PVC) organosols are  the most commonly used polymers  for
this process. Organosols  are formed  by dispersing finely powdered
PVC in plasticizer  and organic solvents.   The solution is poured
onto a rotating drum  or an endless belt that  passes through an
oven.  The solvent  is evaporated in  the oven  in carefully
programmed heat zones and a  relatively solvent-free polymer film
leaves the oven.

Continuous Casting.   Continuous  casting processes produce thin
continuous acrylic  sheet.  It  is very similar to cell casting
except that the liquid acrylic is cured between two highly
polished moving stainless  steel  belts.  The acrylic,  trapped
between the stainless belts, travels  through  the oven and air
cooling stations.

Water may be used for the  direct contact  cooling of cast prod-
ucts.  Direct contact cooling water  sprays can  be used in slush
and dip casting processes  and  in some pot casting processes.
During tubular water bath casting, direct contact cooling water
can be used during  a  product quenching step.

Foam Processes

Foamed plastics (often called  cellular or expanded plastics) are
made by adding a blowing  agent to thermoplastics or thermosets
to form a spongelike material.   Blowing agents  are either added
to the input material and  vaporize due to heat  or are generated
as a by-product of  a  cure reaction.   Plastic  foam products have
wide commercial use for flotation devices,  packaging,  cushioning,
and insulation.  Plastic  foams can be either  rigid or flexible.
Foamed plastic products can be classified into  one of three
types:  extruded theromplastic foam,  structural foam,  and multi-
component thermoset foam.  The production of  extruded thermoplas-
tic foams is a variation  of  the  extrusion process where either
dry chemicals that  foam when heated are included in the resin
feed or a solvent blowing agent  is injected into the  polymer melt
                               73

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at the extrusion die.  Structural foam molding  is a variation  of
the injectin molding process where chemical blowing agents  or
injected gases form bubbles in the molded product.  Multicompo-
nent thermoset foams are formed in a carefully  controlled reac-
tion injection molding (RIM) process where blowing agents are
either generated as a by-product of the chemical reaction that
takes place in the mold of a RIM process or added with  the  input
materials and vaporized by the heat of reaction.

Cleaning and Finishing Processes

Parts produced by the various molding and forming processes may
require cleaning and finishing to become useful end products.

Cleaning.  Cleaning processes consist of washing plastic parts to
remove residual mold release agents and other matter prior  to
finishing, shipping, or further processing.  Washing is generally
divided into two segments; a detergent wash cycle and a rinse
cycle for the removal of detergents and other foreign matter.
Cleaning is usually performed in a batch mode and direct contact
wastewater is produced.  Parts may be cleaned in a washing
machine that operates cyclicly.  In the first cycle parts are
washed with detergent water, in subsequent cycles the parts are
rinsed.  When the wash-rinse cycle is complete  the parts are
removed from the machine and the whole process  is repeated  with
new parts.  The other type of cleaning process  is a continuous,
staged process.  The parts to be cleaned are conveyed through  a
detergent wash stage and then through a rinse stage.  Shaping
equipment such as molds may also be washed in a cleaning process.

Finishing.  Finishing processes are performed to render the plas-
tic products useful.  There are three general finishing pro-
cesses:  machining, decorating, and assembling.  Machining  is
used to drill, cut, mill, and otherwise shape products  to match
final product specifications.  Decorative finishes are  applied to
plastic parts by a variety of methods including painting, print-
ing, hot stamping, and vacuum metallizing.  Assembling  involves
joining two or more plastic parts by methods such as solvent
welding, ultrasonic welding, and electronic heat sealing. Process
water is often used in finishing processes as a lubricant and
carrier of waste particulates generated by the  finishing process.
                               74

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                            SECTION V

                        SUBCATEGORIZATION
BASIS FOR SUBCATEGORIZATION SCHEME

In developing regulations for the plastics molding  and  forming
category, the Agency considered whether  different effluent  limi-
tations guidelines and standards are appropriate for different
segments of the industry.  The Act allows EPA  to consider a
number of factors to determine if subcategorization is  needed.
These factors are:

     1.  raw materials,
     2.  production processes,
     3.  products,
     4.  size and age of plants,
     5.  geographic location,
     6.  types of water use, and
     7.  wastewater characteristics.

The Agency determined whether any of these individual factors
identified a need to subcategorize the PM&F category.   The  Agency
also evaluated the relationship between  different factors to
identify a need for subcategorization.   A discussion of each
factor is presented below.  After considering  all these factors,
the Agency determined that the plastics  molding and forming cate-
gory is most appropriately regulated using two subcategories.

FACTORS CONSIDERED

Raw Materials

The raw materials used in the plastics molding and  forming
category can be classified as:

        plastics and resins,
        chemical additives, and
        processing aids.

The type and combination of raw materials used in plastics  mold-
ing and forming are highly dependent on  the production  process
used and the end products desired.  Plastics molders and formers
can use many different raw material combinations to produce dif-
ferent end products at one production plant over a given period
of time.  Many different raw materials may also be used in  any
one type of PM&F process.
                               75

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The concentration of pollutants  in  PM&F wastewater  varies  because
of the raw materials used.  However,  the  types  of pollutants  in
these wastewaters are  similar  regardless  of  the material pro-
cessed.  Therefore, a  subcategorization based on raw materials  is
not needed to ensure equitable effluent limitations guidelines
and standards for the  PM&F category.   Further,  due  to the  propri-
etary nature of the raw material  combinations and the variability
of the end products, the Agency believes  that a subcategorization
scheme based on raw materials  is  not  feasible for the PM&F
category.

Production Processes

There are eight different generic production processes  used  in
the plastics molding and forming  category. They are:

     1.  extrusion,
     2.  molding,
     3.  coating and laminating,
     4.  thermoforming,
     5.  calendering,
     6.  casting,
     7.  foaming, and
     8.  cleaning and  finishing.

Each of the above processes uses  process  water  (i.e., water  that
contacts the plastic product).  Process water is used in the
first seven processes  to  cool or heat plastic  materials and
plastic products.  Process water  is used  in  cleaning and finish-
ing processes to clean plastic products,  to  clean shaping  equip-
ment, and to finish plastic products.

Data indicate that the wastewater discharged from contact  cooling
and heating processes  and from cleaning and  finishing processes
is similar regardless  of the process  used to process  the product.
Further, the volume of process water  needed  to  cool or  heat
plastic materials and  products and  to  clean  or  finish plastic
products is largely dependent on  the  amount  of  plastic  material
processed rather than  the type of process in which  the  plastic
material is processed.  For these reasons, the  Agency does not
believe that a subcategorization  scheme based on type of process
is appropriate or necessary to ensure  equitable  effluent limita-
tions guidelines and standards for  the PM&F  category.

Products Produced

An extremely wide range of products are produced in the plastics
molding and forming category.  The  products  can  be  classified
according to the following types:
                               76

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      1.  packaging materials,
      2.  building and  construction  components,
      3.  consumer and  institutional products
      4.  electrical and  electronics products,
      5.  appliances,
      6.  transportation  products,
      7.  furniture,
      8.  industrial equipment,  and
      9.  intermediate  products.

Products within any given  product type  can  generally  be  manufac-
tured  from several different plastic materials  and  in several
different production processes.  In addition, any given  plant may
produce a wide range of  products falling  into many  of the  above
product types.  The volume of water used  to cool or heat and  to
clean  or finish the various types of products and the amount  or
type  of wastewater pollutants discharged  by those processes  is
not dependent on the type  of product produced.  Thus,  a  subcate-
gorization scheme based  on product  type is  not  feasible  for  the
PM&F  category and does not appear to be necessary from a tech-
nical  viewpoint.

Size  and Age of Plants

The plastics molding and forming industry is a  relatively  new
industry that developed  following the development of  the polymer
and resins formulating industry.  To remain competitive  in an
industry that has steadily made technological improvements over
the past 30 years, PM&F  plants  have been  continually  modernized.
Thus,  since most PM&F plants were built in  the  same general time
frame  and are continually  modernized, neither plant age  nor
equipment age is a significant  factor that  requires subcategori-
zation to ensure equitable effluent limitations guidelines and
standards.

The number of employees  and amount  of production can  be  used  to
measure relative sizes of  PM&F  plants.  However, neither factor
provides an adequate basis for  subcategorization.

The amount of wastewater discharged and the types of  pollutants
in the wastewater are largely independent of the number  of plant
employees.   Variations in  staff occur for many  reasons including
shift  differences, the need for clerical  and administrative
support,  the need for maintenance support,  efficiency  of plant
operations, and market fluctuations. Due  to these and  other
factors,  the number of employees is  constantly  fluctuating,
making it difficult to develop  a correlation between  the number
of employees and the amount of wastewater generated.

While plant production can be used  to approximate the mass of
pollutants generated,  the  Agency has determined that  it  should
                              77

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not be used to establish different effluent  limitations  guide-
lines and standards for the plastics molding  and  forming category
for the following reasons:

     1.  The types of PM&F processes used and  the  characteristics
         of the wastewater discharged from those  processes  are
         not dependent on the total plant production.

     2.  While the amount of production affects the  total mass
         of pollutants discharged it has little effect on the
         types and range of concentrations of  pollutants found
         in the wastewater.  Therefore, there  is  little,  if
         any, difference between the type of  treatment technol-
         ogy required at small and large PM&F  plants where
         process water is treated and discharged.

Geographic Location

Plastics molding and forming plants are not  limited  to any  one
geographical location and are generally located near distribution
and sales centers so that the finished products need not be
transported over long distances.  A large percentage of  molding
and forming plants are located in the four geographical  clusters
of (1) New Jersey, New York, and Pennsylvania;  (2) Illinois,
Indiana, Michigan, and Ohio; (3) Louisiana,  Oklahoma, and Texas;
and (4) California and Washington.

There are no specific geographical factors that significantly
affect water use at PM&F plants or characteristics of PM&F
wastewater.  The physical space required for  the  treatment
systems evaluated is small compared to the overall plant size.
Therefore,  there are no consequences from the  construction  and
operation of a wastewater treatment system peculiar  to the
different geographical areas.  Therefore, it  is not  reasonable to
subcategorize the PM&F category based on geographic  location.

Types of Water Use

Results of the questionnaire surveys and the  sampling programs
for this project indicate that there are basically two types of
wastewater generated by processes in the PM&F  category.   They
are:

     1.  contact cooling and heating water, and
     2.  cleaning and finishing water.

Contact cooling and heating water is used to  either  cool or heat
plastic materials or plastic products.  Water  can be sprayed onto
a product or the product can be drawn through  a water bath.  In
either case, the volume of water needed for cooling or heating is
dependent on the amount of plastic material processed (i.e., the
amount that has to be cooled).
                               78

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Cleaning and finishing water  is used  to  clean  plastic  products,
to clean shaping equipment, or to  finish plastic  products.
Cleaning water  includes water used in the washing and  rinsing
cycles of a cleaning process.  Finishing water includes  water
used to carry away waste plastic materials during a finishing
process and to  lubricate a plastic product during finishing.

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.
The Agency believes that solvent recovery wastewater is  best  con-
trolled on a case-by-case basis by the permit  writer or  control
authority.  Solvent recovery wastewater  is discussed further  in
Section VI.

Information obtained from the questionnaire  surveys indicate  that
contact cooling and heating water  and cleaning and  finishing
water are handled differently when those process  waters  are
recycled.  The  different recycle methods  could influence the
equitable application of effluent  limitations  guidelines and
standards based on flow reduction  by  recycle.   For  this  reason,
the type of water use was considered  further as the basis  for the
PM&F subcategorization scheme.

Wastewater Characteristics

Results of the  sampling programs for  this  project  indicate  that
contact cooling and heating water  and cleaning and  finishing
water contain similar pollutants.   However,  the concentration of
those pollutants vary.  This variation in pollutant concentration
is not expected to influence the technology used  to treat  those
waters.

However, the characteristics of the wastewater do  influence the
type of recycle unit used to recycle  contact cooling and heating
water and cleaning and finishing water.   In particular,  the high
suspended solids concentration in  cleaning and finishing water
requires that those concentrations  be reduced  before the process
water is recycled.  This means that recycle units used to  recycle
contact cooling and heating water,  which  has a low  suspended
solids concentration, may not be used  to  recycle  cleaning  and
finishing water.  Because the recycle method could  influence  the
equitable application of effluent  limitations  guidelines and
standards based on flow reduction  by  recycle,  wastewater charac-
teristics were considered further  as  the  basis  for  the PM&F
subcategorization scheme.
                               79

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SELECTED SUBCATEGORIZATION SCHEME

The subcategorization scheme for the PM&F category  is  based  on
the types of water use and wastewater characteristics.   Both of
these factors influence the type of unit used  to  recycle contact
cooling and heating wastewater and cleaning and finishing process
water.  This can influence the volume of wastewater  discharged by
processes in the PM&F category.  Therefore, the equitable appli-
cation of effluent limitations guidelines and  standards  based on
recycle may be influenced by the type of water use  and the
characteristics of the wastewater.

The two subcategories for the PM&F category are based  on the type
of water use and wastewater characteristics.   They  are:

     1.  contact cooling and heating water subcategory,  and
     2.  cleaning and finishing water subcategory,.

The contact cooling and heating water subcategory includes those
processes where process water contacts raw materials or  plastics
products for the purpose of heat transfer during plastics molding
and forming.  In identifying model treatment technology  options
for this subcategory, the Agency found that further  subdivision
based on average process water usage flow rate was  required.
Thus, processes with an average process water  usage  flow rate of
35 gpm or less are in one subdivision and processes  with an  aver-
age process water usage flow rate greater than 35 gpm  are in a
different subdivision.  Further discussion of  the flow cut-off
for this subcategory is presented in Section X of this
development document.

Some molding and forming processes (e.g., extrusion  and  pelletiz-
ing) are used by plastic resin manufacturers to process  crude
intermediate plastic material.   For the purpose of  this  regula-
tion, plastic molding and forming processes used by  plastic  resin
manufacturers to process crude intermediate plastic  materials for
shipment off-site are excluded from this regulation  and  regulated
under the organic chemicals,  plastics,  and synthetic fibers  cate-
gory.  Plastic molding and forming processes used by plastic
resin manufacturers to process plastic materials on-site  into
intermediate or final plastic products by further molding and
forming are controlled by the proposed effluent limitations
guidelines and standards for the PM&F category.

In several instances, particular PM&F processes and  the  waste-
water generated by these processes may fall within this  and  other
industrial categories for which the Agency has established efflu-
ent limitations guidelines and standards.  Thus, for the  purpose
of regulatory coverage, the Agency has separated each process to
insure that it is clearly subject to one set of effluent  limita-
tions guidelines and standards.  Processes that coat a plastic
                               80

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material onto a substrate may  fall within  the  definition  of
electroplating and metal finishing as defined  in  40  CFR Parts  413
and 433 (see 48 FR 32485; July  15, 1983).  These  coating  opera-
tions are excluded from the effluent limitations  guidelines  and
standards for the electroplating and metal finishing point source
category and are included in the PM&F category.

Coating of plastic material onto a formed metal substrate  is also
covered by the PM&F effluent limitations guidelines  and standards
and is not covered by the specific metal forming  effluent  limita-
tions guidelines such as those  for aluminum  forming,  copper  form-
ing, and nonferrous metals forming.  However,  the PM&F regulation
applies only to the coating process; the prior forming operations
are subject to the specific metal forming regulation.

Plants in the PM&F category may have processes generating  only
one type of wastewater and thus fit within one subcategory.  How-
ever, many plants generate both contact cooling and  heating water
and cleaning and finishing water.  In this instance,  plants must
comply with the effluent limitations guidelines and  standards  for
both subcategories.

One advantage of this subcategorization scheme is  that plants  can
easily identify the types of water used in their  PM&F processes.
Having only two subcategories should also make it  less compli-
cated for the permit writer to write permits for  PM&F plants.

The following sections of this development document  present  sam-
pling data,  effluent limitations guidelines  and standards, and
other information based on this subcategorization  scheme.
                               81

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                             SECTION  VI

             WATER  USE AND  WASTEWATER CHARACTERISTICS


This section discusses the  water  use and  wastewater discharge
practices  for  the PM&F category and  presents  the  wastewater
treatment  technologies currently  used by  PM&F plants.   Data used
to characterize PM&F wastewater are  also  presented  in this
section.   The  data  were  obtained  from two sources:

     1.  questionnaires,  and
     2.  sampling and analysis programs.

QUESTIONNAIRE  DATA

From the survey data base for this project described in Section
IV, statistics were developed to  apply  to the plastics  molding
and forming plants  that  use process  water.  The data base  con-
tains questionnaires from 408 plants:   196 questionnaires  are
from the 1979  survey and 212 questionnaires are from the 1983
survey.

The 408 questionnaires were reviewed and  summarized to  determine
the discharge mode  (i.e., direct,  indirect, or zero discharge)
for the wastewater  generated by PM&F processes.   Table  VI-1
contains a distribution  of  the 542 wet  processes  reported  in the
questionnaires by discharge mode  for the  types of wastewater
generated.  As shown in  the table, 31 percent of  these  processes
are direct dischargers,  44  percent are  indirect dischargers,  and
25 percent have no  discharge.

Table VI-2 presents average production, average operating hours,
average water use,  and the  number of processes with recycle  by
process water usage flow range for the  various discharge modes.
To obtain this information,  the production  rate,  the  process
water usage flow rate, the  operating hours  per year,  recycle
information, and the discharge mode  were  listed for each process
in the data base by plant identification  code.  These data  were
then segregated by discharge mode and listed  in ascending order
of liters of water used  per hour.  The  process water  usage  flow
ranges were selected and the average production rates,  the  aver-
age water used and  the average operating  hours were calculated by
summing the parameters for  all processes  in a flow  range and
dividing the sum by the  number of processes in that flow range.
This information is presented for both  contact cooling  and
heating water and cleaning  and finishing  water.

Table VI-3 distributes the  average wastewater discharged by  flow
range for the direct and indirect dischargers.  There are a  dif-
ferent number of processes  in the process water usage flow  ranges
                                83

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                                         Table VI-2

                                    WATER  USE  DATA*
                          Contact Cooling and Heating Water  Subcategory
Process
Water Usage
Flow Range Number of
(gpm) Processes
X < 0.3 7
0.3 < X < 2 9
2 < X < "5 24
8 < X ? 20 35
20 < X~< 50 30
50 < X ^ 100 17
100 < X < 200 8
200 < X ? 300 6
300 < X 8
TOTAL 1 44
Process
Water Usage
Flow Range Number of
(gpm) Processes
X < 0.3 19
0.3 < X < 2 36
2 < X < S 36
8 < X ? 20 41
20 < X < 50 11
50 < X T 100 15
100 < X < 200 7
200 < X 
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                               Table  VI-2  (Continued)

                                   WATER  USE DATA*
                           Cleaning and Finishing Water Subcategory
Direct Dischargers
Process
Water Usage
Flow Range Number of
(gpm) Processes
X < 0.3 3
0.3 < X < 2 6
2 < X < 8" 5
8 < X ? 20 4
20 < X < 50 5
50 < X 7 100 1
100 < X < 200 1
200 < X 7 300 1
300 < X 0
TOTAL 26

X of
Processes in
Flow Range
11.54
23.07
19.23
15.38
19.23
3.85
3.85
3.85
0
100

Average Plastic
Production
(kkg/yr)
7,279
849
730
5,961
290
486
3,686
2,226
0


Average
Operating Hours
per Year
5,685
4,956
6,138
5,441
3,944
4,160
8,000
6,000
0

Indirect Dischargers
Process
Water Usage
Flow Range Number of
(gpm) Processes
X < 0.3 13
0.3 < X < 2 12
2 < X < 5 14
8 < X 7 20 6
20 < X < 50 3
50 < X 7 100 3
100 < X < 200 1
200 < X ? 300 1
300 < X 4
TOTAL 57

Process
Water Usage
Flow Range Number of
(gpm) Processes
X < 0.3 2
0.3 < X < 2 3
2 < X < 8" 2
8 < X 7 20 1
20 < X~< 50 0
50 < X ? 100 0
100 < X < 200 0
200 < X 7 300 0
300 < X ~ 3

% of
Processes in
Flow Range
22.8
21.0
24.5
10.5
5.3
5.3
1.8
1.8
7.0
100


% of
Processes in
Flow Range
18.2
27.3
18.2
9.0
0
0
0
0
27.3

Average Plastic
Production
(kkg/yr)
251
987
606
4,232
1.250
2.879
40
85.8
2,412

Zero Dischargers

Average Plastic
Production
(kkg/yr)
88
3,623
2,780
64
0
0
0
0
802

Average
Operating Hours
per Year
4,106
4,897
3.172
3,737
2,517
5,739
3,894
2,144
3.840



Average
Operating Hours
per Year
1 ,940
6,380
5,320
192
0
0
0
0
5,250
                                                                       Average
                                                                      Water  Use
                                                                       (1/hr)

                                                                            13
                                                                          227
                                                                          944
                                                                         2,920
                                                                         9,590
                                                                        11,600
                                                                        40,200
                                                                        50,000
                                                                            0
                                                                      . Average
                                                                      Water Use
                                                                       (1/hr)

                                                                           16
                                                                          290
                                                                         1,010
                                                                         2, 700
                                                                         5,430
                                                                        15,500
                                                                        23,400
                                                                        52,000
                                                                        89,100
                                                                       Average
                                                                      Water  Use
                                                                       (1/hr)
                                                                         1,
     34
    189
   ,470
  4,530
      0
      0
      0
      0
114.000
           Number of
           Processes
          With Recycle

                0
                0
                0
                0
                1
                0
                0
                1
                0
           Number of
           Processes
          With Recycle

                0
                0
                1
                0
                0
                0
                1
                1
                4
 Number  of
 Processes
With Recycle

      1
      1
      1
      0
      0
      0
      0
      0
      3
TOTAL
               11
                         100
*Based  on information obtained from the 19.79 and 1983  questionnaire surveys.
                                          86

-------
and the wastewater discharged flow ranges because  a  process  in  a
process water usage flow range with a recycle unit could  have a
discharge flow rate in a different flow range.   To calculate the
average wastewater discharged, the processes were  listed  in
ascending order of liters of wastewater discharged per hour by
discharge mode.  In each discharge flow range,  the liters  of
water discharged per hour for each process were summed and the
sum was divided by the number of processes in the  discharge flow
range to calculate the average wastewater discharged.  Similarly,
the average operating hours per year were calculated  for  those
processes in the wastewater discharge flow ranges  and are
presented in Table VI-3.

Table VI-4 contains a distribution of the number of wet processes
in the questionnaire data base that have no discharge by  the
method used to obtain no discharge.  As shown in the  table, most
of the processes with no discharge have 100 percent  recycle of
the wastewater.

The 408 questionnaires were also reviewed to determine the treat-
ment technologies currently used by plants in the  PM&F category.
A summary of those treatment technologies is presented in  Table
VI-5.  The 23 plants listed in the table are plants where  a sig-
nificant portion (i.e., 50 percent or more) of  the wastewater
treated is from PM&F processes.  Only 12 of those  plants  have
treatment technologies that treat only PM&F wastewater.   The
other plants have integrated treatment technologies  that  treat
wastewater from PM&F processes with wastewater  from other  indus-
trial processes.  The 23 plants where a significant portion of
the wastewater treated is from PM&F processes are  only six
percent of the plants in the data base.  The other 94 percent of
the plants are zero dischargers or had no treatment technology  or
are plants where more than 50 percent of the wastewater treated
was discharged by processes other than PM&F processes.

Of the 542 wet PM&F processes in the combined data base,  205
recycle process water.  Table VI-6 contains a distribution of the
number of processes that recycle wastewater by  discharge mode.
As shown in the table, 51 percent of those processes  do not dis-
charge wastewater, 21 percent are direct dischargers, and  28
percent are indirect dischargers.

PM&F CATEGORY DATA

The 408 plants in the questionnaire data base are  distributed
with respect to the processes that use a specific  type of  process
water in the following manner:

     (1)  332 plants (81.4 percent) have processes using  only
          contact cooling and heating water,
                               87

-------















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                             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
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X X
X

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          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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-------
                            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*
-ฎ-+
                                                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 	 ป,
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

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                     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

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                           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

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                     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

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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  4ฐC  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

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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

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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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-------
                           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-    ฉ    -NB-   -NB-


    3           2          ND     •*-     ฉ    •*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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-------
                           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

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                     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.
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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.
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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 80ฐC and  has  a vapor pressure
of 100 mm of mercury at  26ฐC.  It is  slightly soluble in water
(1.8 g/1  at 25ฐC) 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 77ฐC and has a vapor pressure  of 90
mm of mercury at 20ฐC.  It is slightly soluble in water (0.8 gm/1
at 25ฐC) 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
20ฐC and a boiling point of  74ฐC.  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 68ฐC.  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 61ฐC and has a vapor pressure of 200 mm of mercury  at
25ฐC.  It is slightly soluble in water (8.22 g/1 at 20ฐC) 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 40ฐC, and has a vapor pressure of 362
mm of mercury at 20ฐC.   It is slightly soluble in water  (20  g/1
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at 20ฐC) , 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 (40ฐC) of
methylene chloride makes  it difficult  to maintain  the compound at
37ฐC 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 66ฐC  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  387ฐC 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 340ฐC.  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 121ฐC and has a vapor pressure of  1 9 mm of
mercury at 20ฐC.  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 111ฐC  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 75ฐC 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
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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
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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.
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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
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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
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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 220ฐC.  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
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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.
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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

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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

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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

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

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                          Figure VIII-1

                     CROSSFLOW COOLING TOWER
Adapted from Cooling Tower Fundamentals, The Marley Cooling Tower
Company.
                               175

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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

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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

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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

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                           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

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        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.
ป
Sparger 	 Cr— 	
1* -' •. •-'.-.AfeUL'^. . TAv. .; -.-.-. , ...-J „.... .. .1 -. I. .'.


1 Air


ป
ป
ป


                             Figure VIII-2

               ACTIVATED  SLUDGE TREATMENT TECHNOLOGY
Figures  adapted  from Innovative and Alternative Technology
Assessment Manual,  EPA  430/9-78-009.
                                  180

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 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

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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

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                            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 55ฐF  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

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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

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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 mปjฉฃ gnvironwental  impact associated
with sedimentation Is the disposal ฎฃ tht solid material removed
from the

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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

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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  * •  ' ' .
                                    ซ • ง 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

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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

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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

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        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

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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 (ฐF  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
 75ฐF
  0 Btu/hr-ft2
100ฐF
 85ฐF
     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 10ฐF,  from 60ฐF to 70ฐF, based on  current
        industry practice.

        One ton of refrigeration can cool 2.4 gpm  of water 10ฐF
        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  -  75ฐF
               Thot                  -  95ฐF
               Tcold                 -  85ฐF
        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 10ฐF 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 10ฐF:
                              209

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                                  Recirculated Flow Rate  (gpm)
        Number of Evaporative _ 	x Range  (ฐF)	
             Tons Needed                 3 gpm x  10"?"	
                                    Standard Evaporative  Ton


Because the assumed temperature range is 10ฐF, 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.
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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
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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.
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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.
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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
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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.
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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).
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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 ง4005  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).
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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
     10780                           40
     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

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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

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                                     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

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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

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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

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                         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

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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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                                                               254

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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

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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

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                          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

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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

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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

-------
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

-------
                            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

-------
     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

-------
                            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-

-------
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

-------
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

-------
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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