EPA 440/1-75/050-a
 Group II
      Development Document for
  Effluent Limitations Guidelines and
  New Source Performance Standards
               for the
      OIL BASE SOLVENT  WASH
   SUBCATEGORIES   OF THE PAINT
     FORMULATING  AND THE  INK
           FORMULATING
        Point Source Category
                     \
               *fc
                *L

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY

               JULY 1975

-------
               DEVELOPMENT DOCUMENT

                       for

         EFFLUENT LIMITATIONS GUIDELINES

                       and

         NEW SOURCE PERFORMANCE  STANDARDS

                     for the

   OIL  BASE SOLVENT WASH SUBCATEGORIES of the

   PAINT FORMULATING and the INK FORMULATING
             POINT SOURCE CATEGORIES
                 Russell E. Train
                  Administrator

                  James L. Agee
           Assistant Administrator for
          Water and Hazardous Materials

            Thomas Gallagher, Director
       National Field Investigations Center
                 Denver, Colorado
              Allen Cywin, Director
           Effluent Guidelines  Division

          David Becker, Project Officer
           Effluent Guidelines  Division

         Arthur N. Masse, Project Officer
       National Field Investigations Center
                 Denver, Colorado

                    July, 1975

           Effluent Guidelines  Division
     Office of Water and Hazardous Materials
       U.S. Environmental Protection Agency
             Washington, D.C.   20460
For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 - Price $1.65

-------
                          ABSTRACT
This document presents the findings of a study of the  paint
and ink formulation industries for the purpose of developing
effluent   limitations   guidelines,  Federal  standards  of
performance, and pretreatment standards for the industry  to
implement  Sections  301,  304  and 306 of the Federal Water
Pollution Control Act Amendments of 1972 (the "Act").

Effluent limitations guidelines are set forth for the degree
of effluent reduction attainable through the application  of
the   "Best   Practicable   Control   Technology   Currently
Available," and the "Best Available Technology  Economically
Achievable,"  which  must  be  achieved  by  existing  point
sources by July 1, 1977, and  July  1,  1983f  respectively.
The "Standards of Performance for New Sources" set forth the
degree of effluent reduction which is achievable through the
application  of  the  best  available  demonstrated  control
technology,   processes,   operating   methods,   or   other
alternatives.

The proposed regulations require that, for both the oil base
solvent  wash  subcategories  of  both  the  paint  and  ink
formulation industries, no discharge of  process  wastewater
pollutants to navigable waters be achieved by July 1, 1977.

For  the same subcategories of the paint and ink formulation
industries, the 1983 requirements and new  source  standards
are the same as the 1977 requirements.
Supportive   data  and  rationale  for  development  of  the
proposed effluent limitations guidelines  and  standards  of
performance are contained in this report.
                               11

-------
                     TABLE OF CONTENTS
SECTION

I.  CONCLUSIONS                                               1
         PAINT FORMULATING                                    1
         INK FORMULATING                                      2

II  RECOMMENDATIONS                                           3
         PAINT FORMULATING                                    3
         INK FORMULATING                                      3

III INTRODUCTION                                              5
         PURPOSE AND AUTHORITY                                5
              Legal Authority                                 5
                   Existing Point Sources                     5
                   New Sources                                6
              Basis of Proposed Effluent Limitations
              Guidelines for Existing Sources and
              Standards of Performance and Pretreatment
                Standards for New Sources                     6
                  General Methodology                         6
         GENERAL DESCRIPTION OF THE INDUSTRY                  8
              Paint Formulating Industry                      9
              Ink Formulating Industry                       15
         DISCUSSION OF DOCUMENT                              16

IV  INDUSTRY CATEGORIZATION                                  17
         PAINT FORMULATING INDUSTRY                          17
         PROFILE OF PRODUCTION PROCESSES                     17
         CATEGORIZATION                                      22
              Raw Materials and Products                     23
              Production Methods                             23
              Size and Age of Production Facilities          23
              Wastewater Constituents and Treatability       23
                of Wastes
         CONCLUSIONS                                         24
         INK FORMULATING INDUSTRY                            26
         PROFILE OF PRODUCTION PROCESSES                     26
         CATEGORIZATION                                      26
              Raw Materials and Products                     26
              Production Methods                             27
              Size and Age of Production Facilities          27
              Wastewater Constituents and Treatability       27
                of Wastes
         CONCLUSIONS                                         28

V   WATER USES AND WASTE CHARACTERISTICS                     29
                              ill

-------
SECTION                                                        PAGE

         PAINT  FORMULATING INDUSTRY                           29
         SPECIFIC WATER USES                                  29
         WASTE  CHARACTERISTICS                                32
         INK  FORMULATING                                      41

VI  SELECTION OF POLLUTANT PARAMETERS                         45
         PAINT  FORMULATING INDUSTRY                           45
         INK  FORMULATING INDUSTRY                             45
         RATIONALE  FOR SELECTION OF POLLUTANT PARAMETERS      45
              Biochemical Oxygen Demand (20°C, BODS)          45
              Chemical Oxygen Demand (COD)                     46
              pH                                               47
              Total Suspended Solids (TSS)                     48
              Oil and Grease                                  49
              Metals                                          50
                    Mercury                                    50
                    Lead                                       50
                    Zinc                                       50

VII CONTROL AND TREATMENT TECHNOLOGY                          53
         PAINT  FORMULATING INDUSTRY                           53
         CONTROL AND TREATMENT TECHNOLOGY                     57
         IDENTIFICATION OF WATER-POLLUTION RELATED
           MAINTENANCE AND OPERATIONAL PROBLEMS               59
         INK  FORMULATING INDUSTRY                             61
         CONTROL AND TREATMENT TECHNOLOGY                     62

VIII COST, ENERGY,  AND OTHER NON-WATER QUALITY ASPECTS        65
         PAINT  FORMULATING INDUSTRY                           65
         OIL-BASE PAINT PRODUCTION                            65
         WATER-BASE PAINT PRODUCTION                          66
              Best  Practicable Control Technology             66
                Currently Available (BPCTCA)
              Best  Available Technology Economically
                Achievable (BATEA)  and New Source             66
                Performance Standards  (NSPS)
              Non-Water Quality Considerations                66
         INK  FORMULATING INDUSTRY                             69

IX  EFFLUENT  REDUCTION ATTAINABLE THROUGH THE APPLICATION
    OF THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
    AVAILABLE                                                 71
         INTRODUCTION                                         71
         EFFLUENT REDUCTION ATTAINABLE THROUGH APPLICATION
         OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
         CURRENTLY  AVAILABLE                                  72
         PAINT  FORMULATING INDUSTRY                           72
         INK  FORMULATING INDUSTRY                             72
              Identification of the Best Practicable
                Control Technology Currently Available        72
                               IV

-------
SECTION                                                          PAG

         PAINT FORMULATING INDUSTRY                              73
              Total Cost of Application                         73
              Size and Age of  Equipment                         73
              Process Employed                                  73
              Engineering Aspects                                73
              Process Changes                                    73
              Non-Water Quality  Environmental Impact            73
         INK FORMULATING INDUSTRY                                75'
              Total Cost of Application                         75
              Size and Age of  Equipment                         75
              Process Employed                                  75
              Engineering Aspects                                75
              Process Changes                                    75
              Non-Water Quality  Environmental Impact            75

X   EFFLUENT REDUCTION ATTAINABLE  THROUGH THE APPLICATION
    OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY               77
    ACHIEVABLE
         INTRODUCTION                                            77
              EFFLUENT REDUCTION ATTAINABLE THROUGH THE
              APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
              ECONOMICALLY ACHIEVABLE                           78
                   PAINT FORMULATING INDUSTRY                   78
                   INK FORMULATING INDUSTRY                     78

XI  NEW SOURCE PERFORMANCE STANDARDS                            79
         INTRODUCTION                                            79
         EFFLUENT REDUCTION ATTAINABLE FOR NEW SOURCE           79
              PAINT FORMULATING  INDUSTRY                        79
              INK FORMULATNG INDUSTRY                           80

XII ACKNOWLEDGMENTS                                              81

XIII REFERENCES                                                  83
         PAINT FORMULATING INDUSTRY                              83
         INK FORMULATING INDUSTRY                                85

XIV GLOSSARY                                                     87
         Definitions                                             87
         Symbols                                                 89

-------
                       LIST  OF TABLES
Table No.                                                   Page

III-l         INDUSTRIES  IN  PAINT AND INK FORMULATION        6
              AND PRINTING CATEGORY BY SIC NUMBER

III-2         DISTRIBUTION OF PAINT PLANTS BY SIZE           9

III-3         U. S.  SHIPMENTS OF TRADE SALES PAINTS,        13
              VARNISHES,  AND LACQUERS BY END USE 1971

III-U         U. S.  SHIPMENTS OF INDUSTRIAL FINISHES        14
              BY END USE  1971

III-5         PRINCIPAL RAW  MATERIALS USED IN THE           15
              MANUFACTURE OF PAINTS, 1970


IV-1          COMPOSITION OF COMMON WATER-BASE PAINTS       20

V-l           DISPOSITION OF WASTEWATER IN PAINT PLANTS     30

V-2           AVERAGE VOLUME OF CLEANUP WATER DISCHARGED    31
              FROM  PLANTS OF VARIOUS SIZES

V-3           MAJOR CONTAMINANTS IN WASTEWATER DISCHARGE    32

V-4           DAILY RAW WASTE LOADING FROM PAINT PLANTS     34

V-5           CONSTITUENTS OF PAINT MANUFACTURING PLANT
               (SIC  2851)  WASTES IN EAST BAY MUNICIPAL
              UTILITIES DISTRICT                            36

V-6           WASTEWATER  CHARACTERISTICS OF A WATER-BASE
              PAINT PLANT, BERKELEY, CALIFORNIA             37

V-7           AVERAGE POLLUTANT LOAD FROM LARGE LATEX PAINT
              PLANT BASED ON 3-DAY COMPOSITION SAMPLING
               (OCTOBER 15-18, 1973)                         38

V-8           AVERAGE POLLUTANT LOAD FROM SMALL LATEX
              PAINT PLANT WITH LOW WATER USE BASED ON
              3-DAY SAMPLING PROGRAM  (OCTOBER 15-18, 1973)  39

V-9           AVERAGE POLLUTANT LOAD FROM SMALL LATEX
              PAINT PLANT BASED ON 3-DAY SAMPLING PROGRAM
               (OCTOBER 15-18, 1973)                         40
                                 VI

-------
Table No.

V-10          WASTE CHARACTERIZATION FROM AN INK TUB
              WASHER THAT RECYCLES THE WASH WATER
               (OCTOBER 15-18, 1973)                          42

V-ll          CONSTITUENTS OF INK MANUFACTURING PLANT
               (SIC 2893)  WASTES IN EAST BAY MUNICIPAL
              UTILITIES DISTRICT                             43

VII-1         TREATMENT TECHNOLOGY IDENTIFIED IN THE
              PAINT FORMULATING INDUSTRY                     54

VII-2         EXTENT OF CONTROL AND TREATMENT PRACTICED
              IN  PAINT PLANTS                                55

VII-3         WASTEWATER TREATMENT METHODS EMPLOYED IN
              THE PAINT INDUSTRY                             58

VII-4         TREATMENT TECHNOLOGY DETERMINED IN THE
              INK FORMULATING INDUSTRY                       63

VII1-1        OPERATING COSTS FOR A SOLVENT RECLAIMING
              SYSTEM IN A PAINT MANUFACTURING PLANT          67

XIV           METRIC UNITS CONVERSION TABLE                  90
                                Vll

-------
                       LIST OF FIGURES
Figure No.                                                   Page

III-l         U.S.  SHIPMENTS OF PAINTS AND ALLIED
              PRODUCTS  BY STATE 1967                        10

III-2         HISTORICAL AND PROJECTED GROWTH OF
              COATING PRODUCTS, 1955 to 1980               , 12

IV-1          FLOW  DIAGRAM OF MANUFACTURING PROCESS
              FOR OIL-BASE PAINTS                           18

IV-2          FLOW  DIAGRAM OF MANUFACTURING PROCESS
              FOR WATER-BASE PAINTS                         21
                                   Vlll

-------
                         SECTION I

                        CONCLUSIONS

For   the   purposes  of  establishing  Effluent  Limitation
Guidelines and Standards of Performance for New Sources, the
"Paint and Ink Formulation Industry" point source categories
were divided into two categories  (paint  and  ink)   and  six
subcategories.   The subcategories are: (1) Oil-Base Solvent
Wash Paint Manufacture;  (2)  Oil-Base  Caustic  Wash  Paint
Manufacture;   (3) Water-Base Paint Manufacture;  (4) Oil-Base
Solvent Wash Ink Manufacture;  (5) Oil-Base Caustic Wash  Ink
Manufacture;  and (6) Water-Base Ink Manufacture.  The Paint
and Ink Manufacturing industries were found to  use  similar
raw materials and manufacturing processes but were separated
principally  on  the basis of the end use of the product and
on treatment technology employed.  The major conclusions  in
each  of  these  categories  are  discussed in the following
paragraphs.

PAINT FORMULATING

The major conclusion for this industry  was  that  the  vast
majority of paint formulating plants discharge their process
wastewaters to municipal systems.  The initial survey turned
up  seven  manufacturers  discharging process wastewaters to
surface streams.  A more recent check  of  the  NPDS  permit
files    shows   twenty-seven   company   locations   direct
discharging wastewater to surface streams.  A more  detailed
check  of  these  companies  show  only one company location
direct discharging process wastewater.  There may be several
other plants that were not detected but the magnitude of the
problem, as far as direct pollution of  surface  streams  is
concerned, is essentially negligible.

Many  of the paint manufacturing plants located on municipal
sewer systems have elected to dispose of their process waste
by shipping it to a landfill or by recycling and reusing  it
within the plant.

It  was  anticipated  that  mercury,  lead, and other metals
would be a significant problem in the industry, but this has
not proven to be the case.  Many of the manufacturers  have,
in   recent   years,   switched   to  non-mercury-containing
preservatives because of the mercury pollution problem a few
years ago.  The "Lead-Based Paint Poisoning  Prevention  Act
of  1973," which reduces the allowable concentration of lead
in a dry  paint  film  to  0.5  percent,  has  significantly
decreased  the  magnitude of the lead problem.  Chromium and
other heavy metals  used  in  tinting  agents  during  paint

-------
manufacture  have also been significantly re;duced because of
the current trend in tinting paints  at  the  retail  store.
The  heavy metal-containing tinting agents are, for the most
part, manufactured  by  the  pigment  industry  and  shipped
directly  to  the  retail  stores.  Their manufacture is not
covered in this document.

The major pollutant parameters for the  paint  manufacturing
industry are BODjj, TSS, pH and selected metals.  The volumes
of  wastewater  discharged  are,  from  a  pollution control
standpoint, very small.

INK FORMULATING

The ink formulating industry bears many resemblances to  the
paint  formulating  industry,  although  it  is considerably
smaller.  A  check  of  the  NPDS  Permit  applications  and
consultation  with  industrial  representatives  led  to the
conclusion that there are less than 8  manufacturing  plants
in  the  country  discharging  process  wastes  directly  to
surface streams.

Again, as in the paint industry, many of the plants that are
on municipal systems practice  no  discharge  of  wastewater
pollutants.   Ink  process  wastewaters  are  either sent to
sanitary landfills  for  disposal  or  the  wastewaters  are
recycled  and  reused within the plant.  A limitation of "no
discharge of  wastewater  pollutants"  directly  to  surface
streams would have little, if any, effect on the industry.

The  major  pollutant  parameters  for the ink manufacturing
industry are BOD5, TSS, pH, and selected  metals.   As  with
the paint industry, the volumes of wastewater discharged are
very small.

-------
                         SECTION II
                      RECOMMENDATIONS
PAINT FORMULATING
The  effluent  limitations  for process wastes for the paint
formulating industry oil base solvent wash have been set  as
no  discharge  of  process  wastewater pollutants to surface
waters.  The other categories will have effluent limitations
and standards set at a later date.  This limitation has been
defined as  (1) Best Practicable Control Technology Currently
Available to be achieved no later than  July  1,  1977;   (2)
Best  Available  Treatment  Economically  Achievable  to  be
achieved no later than July 1,  1983;  and  (3)   New  Source
Performance  Standards  to  be achieved upon start-up of the
new source.  Pretreatment before discharge to publicly-owned
treatment works for new sources has been set as that  treat-
ment  necessary  to  meet  the  conditions  of  EPA  Federal
Regulation 40 CFR 128.
INK FORMULATING

The recommendations for the  ink  formulating  industry  are
identical  to  those  for the paint formulating industry set
forth above.

-------

-------
                        SECTION III

                        INTRODUCTION

PURPOSE AND AUTHORITY

Leg a1 Author!ty

Existing Point Sources — Section 301(b) of the Act requires
the achievement, by not later than July 1, 1977, of effluent
limitations for point  sources,  other  than  publicly-owned
treatment  works,  which require the application of the best
practicable  control  technology  currently   available   as
defined  by  the Administrator pursuant to section 304(b)  of
the Act.  Section 301(b)  also requires the  achievement,  by
not  later  than  July  1, 1983, of effluent limitations for
point sources, other than  publicly-owned  treatment  works,
which   require   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,  as  determined
in  accordance  with regulations issued by the Administrator
pursuant to section 304 (b) of the Act.

Section 304 (b) of  the  Act  requires  the  Adminstrator  to
publish   regulations   providing  guidelines  for  effluent
limitations setting forth the degree of  effluent  reduction
attainable  through  the application of the best practicable
control technology currently available  and  the  degree  of
effluent  reducton attainable through the application of the
best control measures  and  practices  achievable  including
treatment  techniques,  process  and  procedure innovations,
operating methods and other alternatives.   The  regulations
proposed  herein  set forth effluent limitations guidelines,
pursuant to section 304(b) of the Act, for the paint and ink
formulation industries.  The specific industries  for  which
limitations  are  proposed  are  listed  in  Table  III-l by
Standard Industrial Classification  (SIC) Code number (1).

-------
                        TABLE III-l

      INDUSTRIES IN PAINT AND INK FORMULATION CATEGORY
                       BY SIC NUMBER

PAINT FORMULATION

    2851 - Paints, Varnishes, Lacquers, Enamels, and  Allied
            Products

INK FORMULATION

    2893 - Printing Ink
New   Sources  —  Section  306  of  the  Act  requires  the
achievement from  new  sources  of  a  Federal  Standard  of
Performance  providing  for  the control of the discharge of
pollutants which reflects the greatest  degree  of  effluent
reduction  which  the Administrator determines to be achiev-
able through application of the best available  demonstrated
control  technology,  processes, operating methods, or other
alternatives,  including,  where  practicable,  a   standard
permitting no discharge of pollutants.

Section  307(c)   of  the  Act  requires the Administrator to
promulgate pretreatment standards for  new  sources  at  the
same  time that standards of performance for new sources are
promulgated pursuant to section 306.

Section 304 (c) of the  Act  requires  the  Administrator  to
issue  to the States and appropriate water pollution control
agencies  information  on  the  processes,   procedures   or
operating   methods  which  result  in  the  elimination  or
reduction  of  the  discharge  of  pollutants  to  implement
standards of performance under section 306 of the Act.  This
Development Document provides, pursuant to section 304 (c) of
the  Act,  information  on  such  processes,  procedures  or
operating methods.

Basis  of  Proposed  Effluent  Limitations  Guidelines   for
Existing   Sources   and   Standards   of   Performance  and
Pretreatment Standards for New Sources

General Methodology — The effluent  limitations  guidelines
and  standards of performance proposed herein were developed
in the following manner.   The  point  source  category  was
first   studied  for  the  purpose  of  determining  whether
separate  limitations  and  standards  are  appropriate  for
different  segments  within  the  category.   This  analysis

-------
included a  determination  of  whether  differences  in  raw
material   used,  product  produced,  manufacturing  process
employed,  age,  size,  wastewater  constituents  and  other
factors  require  development  of  separate  limitations and
standards  for  different  segments  of  the  point   source
category.   The  raw  waste  characteristics  for  each such
segment were then identified.  This included an analysis  of
(1)  the source, flow and volume of water used in the process
employed  and  the  sources  of waste and wastewaters in the
operation, and  (2) the constituents of all wastewaters.  The
constituents of the wastewaters which should be  subject  to
effluent limitations guidelines and standards of performance
were identified.

The  control and treatment technologies existing within each
segment were identified.  This included an identification of
each distinct control and  treatment  technology,  including
both  in-plant  and  end-of-process  technologies, which are
existing or capable of being designed for each segment.   It
also  included  an identification, in terms of the amount of
constituents  and  the  chemical,  physical  and  biological
characteristics   of   pollutants,  of  the  effluent  level
resulting from the application of each of the  technologies.
The  problems, limitations and reliability of each treatment
and control technology were also identified.   In  addition,
the  non-water  quality  environmental  impacts, such as the
effects of the application of such technologies  upon  other
pollution  problems,  including  air, solid waste, noise and
radiation, were identified.  The energy requirements of each
control and treatment technology were determined as well  as
the cost of the application of such technologies.

The  information,  as  outlined above, was then evaluated in
order to determine what levels of technology constitute  the
"best  practicable  control technology currently available",
the "best available technology economically achievable"  and
the   "best   available   demonstrated  control  technology,
processes, operating methods,  or  other  alternatives."  In
identifying   such   technologies,   various   factors  were
considered.  These included the total cost of application of
technology in relation to the effluent reduction benefits to
be achieved from such application, the age of equipment  and
facilities  involved,  the process employed, the engineering
aspects of the  application  of  various  types  of  control
techniques, process changes, non-water quality environmental
impact (including energy requirements) and other factors.

The  data  upon  which  the above analysis was performed was
derived from a number of sources.  These sources are  listed
as  references  and/or  are  included  in Supplement B.  The

-------
Refuse Act Permit Program Applications were of limited value
because they were too few in number and provided  incomplete
information.   The Southern Research Institute (1)  report on
the  paint  industry  and  the  materials  provided  by  the
National  Association  of  Printing  Ink  Manufacturers, the
National Paint and Coatings Association and  the  Federation
of  Societies  for  Paint  Technology  were  quite  helpful.
Detailed   telephone   and   personal   conversations   with
representatives  of the trade and technical associations and
with individual members of the industries  were  invaluable.
The cooperation of the East Bay Municipal Utilities District
(Oakland,   California)   in  opening  their  files  and  in
assisting in the sampling of waste streams  from  paint  and
ink  manufacturers  in  the  areas is appreciated,  as is the
cooperation of all of those industries visited and  sampled.
The  Metropolitan  Sanitary District of Greater Chicago also
supplied  information  from  their  files.    Twelve   paint
manufacturing  plants  and six ink manufacturing plants were
visited.  Composite 3-day sampling  was  conducted  at  four
paint  plants and one ink plant.  A record of all visits and
conversations is included in Supplement B.

The pretreatment standards for new sources  proposed  herein
are   intended  to  be  complementary  to  the  pretreatment
standards proposed for existing sources under  40  CFR  Part
128.   The  bases  for  such  standards are set forth in the
Federal Register of July 19, 1973, 38 FR 19236.

GENERAL DESCRIPTION OF THE INDUSTRY

Division of these industries into six subcategories   (water-
base,  oil-base  caustic  wash,  and  oil-base  solvent wash
paint, water-base,  oil-base  caustic  wash,  and  oil  base
solvent wash ink) was made.  The paint manufacturing and ink
manufacturing    industries   share   many   of   the   same
characteristics.    The   raw   materials,   processes   and
wastewater  charcteristics  are  quite similar.  The two in-
dustries are distinct, however, both because of the  product
manufactured  and  the  end  use of that product.  For these
reasons, and the fact that the paint and  ink  manufacturing
industries utilize distinct and separate trade and technical
associations, the decision was made to treat them separately
in this document.
    The rationale for further subdivision within each of the
subcategories discussed above is given in Section IV of each
subcategory.

-------
Paint. Formulating Industry
Paint manufacturing is essentially a product formulation in-
dustry;  that  is,  few,  if  any,  of the raw materials are
manufactured on site.  In practice, several  of  the  larger
manufacturers  make resins on the site for their own use and
for sale, but resin manufacture  is  not  included  in  this
document.   Effluent limitations for resin manufacturing are
covered in the proposed  guidelines  for  the  Plastics  and
Synthetics Industry.(4)

The  paint industry  (SIC Group 2851) consists of about 1,500
companies operating almost 1,700  plants.   In  1971,  total
industry  employment  was  nearly  63,000.   Because  of the
relatively simple  technology  and  low  capital  investment
required, the industry contains many small companies.  About
42  percent  of  the companies have fewer than 10 employees.
These small companies accounted for less than 5  percent  of
the  industry  sales  in  1967,  whereas  the  four  largest
companies   (Sherwin-Williams,   DuPont,   PPG   Industries,
Glidden-Durkee)  accounted  for about 22 pecent of sales and
the largest 50 accounted for 61 percent.  A distribution  of
plants by size is given in Table III-2.

                        TABLE III-2

          DISTRIBUTION OF PAINT PLANTS BY SIZE(3)
Size of plant  (total
number of employees)

   Fewer than 10
    10 to 19
    20 to 49
    50 to 99
    100 to 249
    250 to more
Number of
  plants

   710
   311
   350
   171
   133
    46
 Total number of
production workers

    1,700
    2,500
    6,100
    6,700
    9,200
   10,100
Although  the  industry  is  spread over a wide geographical
area, it is concentrated in  heavily  industrialized  areas.
Ten  states  accounted  for about 80 percent of the value of
shipments  in  1967.   A  map  illustrating   the   economic
concentration of the industry is given in Figure III-l.

The  major  products  of  the industry consist of trade-sale
paints,  which  are  primarily  off-the-shelf  exterior  and
interior  paints  for  houses  and buildings, and industrial
finishes  sold  to  manufacturers  of   such   products   as
automobiles, aircraft, appliances, furniture, machinery, and
metal containers.

-------
o
1^-
•o
                                                                                   CT>
                                                                                    0)
                                                                                   4J

                                                                                    CO
                                                                                   4-1
                                                                                   to
                                                                                    0)
                                                                                   4-1
                                                                                    o
                                                                                    a
                                                                                   -o
                                                                                    o
                                                                                    V
                                                                                    JO

                                                                                    w
                                                                                   4J
                                                                                    FS
                                                                                    m
                                                                                   4-1
                                                                                    e
                                                                                    0)
                                                                                    B
                                                                                    (X
                                                                                   CO
                                                                                   CO
                                                                                    0)
                                                                                    Vj

                                                                                    to
10

-------
In  1971,  the  value of trade-sale paints amounted to $1.56
billion and that of industrial finshes  was  $1.27  billion.
The  volume  of these products is expected-to increase at an
annual rate of 7.5 percent until 1980.  The  historical  and
projected  growth of these products is illustrated in Figure
III-2.

The industry produces paints, varnishes, and lacquers, which
consist of film-forming  binders  (resins  or  drying  oils)
dissolved  in  volatile  solvents or dispersed in water.  In
addition, all paints and most lacquers contain pigments  and
extenders  (calcium  carbonate,  clays  and silicates).  The
industry also produces  such  products  as  putty,  caulking
compounds,  sealants,  paint and varnish removers, and thin-
ner s.  The quantity and value of  shipments  of  trade  sale
products  in  1971  are  shown  in Table III-3.  Table III-U
shows similar information for industrial finishes.

The principal raw materials consumed  by  the  industry  are
oils,  resins, pigments, and solvents.  Drying oils, such as
linseed oil,  are used as the  film-forming  binder  in  some
oil-base paints.  Semi-drying oils, such as soybean oil, are
used  in  the  manufacture  of  alkyd  resins, which are the
principal binders in other oil-base paints.   Acylic  resins
are  used  in  the manufacture of water-base  (latex) paints.
Some industrial water-base paints contain a  third  type  of
resin, the water-soluble alkyd resins.

Pigments  are  used  to  impart  opacity  and  color  to the
coatings.  The  pigment  particles  are  finely  divided  to
provide  good  dispersion  in the oil or water medium and to
provide good coverage.  The four, basic  types  of  pigments
are:   1) prime white pigments, such as titanium dioxide and
zinc oxide, 2) colored inorganic and  organic  pigments,  3)
filler  and extender pigments, and 4)  metallic powders.  The
paint industry is the largest consumer of  titanium  dioxide
and inorganic pigments.

The  paint  industry  is  also a large consumer of solvents,
which are used as the  volatile  vehicles  in  all  coatings
except  water-base  paints.   The  major  solvents  used are
mineral spirits, toluene, xylene, naphtha, ketones,  esters,
alcohols, and glycols.

Consumption  of  the  principal  raw  materials  used by the
industry is shown in Table III-5.  In addition, the industry
consumes a wide variety of other additives such  as  driers,
bactericides  and fungicides, defoamers, antisettling agents
and thickeners.
                                11

-------
CO  10
u  >-i
C  fl
 -H
        3.0
       "2.0
1.0
       0.1
            1955
               1960
1965
1970
1975
1980
m ^
4J  CO
c  c
•rl  01}
x  oc
n
  «*-<
VM  o
O
   co
>» c
4J  O
C tH
rt nn
3  H
 '
700


600



500



AGO




300
       200
            1955
               1960
1965

YEAR
 1970
 1975
1980
                Figure III-2.   Historical  and Projected  Growth of

                                Coating Products, 1955  to 19801/
                                     12

-------
                             TABLE IIT-3

          U.S. SHIPMENTS OF TRADE SALES PAINTS, VARNISHES,
                   AND LACOUERS BY END USE 19 7L?/
                              Million       Million       Million
                               Liters       Gallons       Dollars

Interior finishes
  House paints
    Water emulsion
      Flat                      492           130          $  420
      Semigloss                  76            20              70
    Oil and Alkyd
      Flat                       57            15              55
      Semigloss                  76            20              80
      High-gloss                 57            15              75
    Primers, sealers, other      38            10              30
  Miscellaneous-^'                95            25              95

    Total, interior             891           235             825

Exterior finishes
  House paints
    Water emulsion              265            70             240
    Oil and alkyd paints        114            30             130
    Enamels                      57            15              60
    Primers, sealers, other      38            10              35
  Miscellaneous*!/                38            10              50

    Total, exterior             512           135             515

Other trade sales products
  Automotive refinishes         132            35             160
  Traffic paints                 76            20              40
  Other^/                        22           	6              23

    Total, other                230            61             223

           TOTAL               1633           431          $1,563
a/  Includes stains, varnishes, seamless flooring, and ceramic-like tiles
b/  Includes barn, roof, and fence coatings, bituminous products, metallic
    pigmented paints, stains, and varnishes
£/  Mostly marine shelf goods
                               13

-------
                             TABLE III-4

        U.S. SHIPMENTS OF INDUSTRIAL FINISHES BY END USE 1971-/
                              Million       Million      Million
                               Liters       Gallons      Dollars

Transportation equipment
  Motor vehicles                 246           65        $  190
  Marine                          76           20            65
  Railroad, aircraft, and other   57           15            45
                                 379          100           300

Industrial maintenance           189           50           170

Furniture
  Wood                           189           50            90
  Metal                           95           25            65
                                 284           75           155

Prefinished stock
  Metal                           95           25           100
  Wood                            95           25            55
                                 190           50           155

Metal decorating
  Packaging                      151           40           100
  Other                           38           10            30
                                 189           50           130

                       a/
Machinery and equipment-         132           35           100

Appliances                        76           20            85

Packaging, exc. metaj             38           10            30

Miscellaneous                    201           53           143

      TOTAL                     1678          443        $1,268
a/  Includes data for insulating varnishes and magnet wire  enamels
                             14

-------
Pigments
Prime white
Titanium dioxide
Zinc oxide
White lead
Extenders and fillers
Red lead
Carbon black
Oils in paint
Oils in paint resins
Natural resins
Total Selected solvents*

360.8
27.0
4.0
333.0
8.0
7.1
133.9
76.5
21.0
482.2
                        TABLE III-5
            PRINCIPAL RAW MATERIALS USED IN THE
               MANUFACTURE OF PAINTS, 197t) (3)

                        Thousands of   Thousands of
                            tons       metric tons
                                         327. 4
                                          24.5
                                           3.6
                                         302.0
                                           7.3
                                           6.4

                                         121.5
                                          69.4
                                          19.0
                                         437.6

* Includes glycol esters, alcohols, ketones, and esters
The trend in the industry  is  to  assist  the  customer  in
reducing  air  pollution  in  the  application of industrial
finishes.  This is resulting in the  development  of  water-
base  paints  for  industrial finishes and the production of
high-solids and even dry powder paints.  These  are  applied
by  new  techniques  such as electrocoating (electrophoretic
deposition  of  charged  particles  of  water-base   paint),
fluidized  bed  coating  and electrostatic spraying (both of
the latter use dry powder coatings).  This trend will result
in a decrease in the water pollution potential of the  paint
manufacturing industry.

Ink Formulating Industry

The  ink  manufacturing  industry  is  similar  to the paint
industry in that it is essentially a  formulation  industry.
Resins  are  made  by  some  of the major manufacturers but,
again,  resin  manufacture  will  not  be  covered  in  this
document.

Printing ink production in the United States now exceeds one
billioa  pounds  per  year.   The  major  components include
drying oils, resins, varnish,  shellac,  pigments  and  many
specialty   additives.   The  industry  comprises  over  250
printing ink producers.  However, seven companies share over
50 percent of the market:  Inmont, Sinclair  and  Valentine,
                              15

-------
Sun   Chemical,   Cities  Service  (F.  H.  Levey),  Tenneco
Chemicals (California Ink), Borden,  and  Flint  Ink.   Many
large-volume  users  are  captive producers as, for example,
American Can, Reuben H. Donnelly, Bemis Bag and others. (5)

Printing inks can be either water- or oil-base.  Many of the
raw materials are the same regardless of the  vehicle.   The
inks  are  made  with  the  same type of equipment as in the
paint  industry  and  by  the  same  processes.   The  waste
charactristics are similar to the paint counterpart.

The  largest  volume  single  type  of  ink is, as one would
expect, that used in the printing of newspapers.  This black
ink is produced by mixing finely divided  carbon  black  and
mineral   oil.    The   value   of  "newsblack"  however  is
overshadowed by the value of the  great  number  of  colored
inks  used  largely  by  publishers of newspapers,  books and
magazines and  by  package  manufacturers.   Most  of  these
colored  inks  are  mixed  on order but many of the pigments
used in them are staple quantity  products  such  as  lithol
reds, eosin reds, chrome yellows and peacock and iron blues.
A  large  number  of  more  specialized  inks,  which in the
aggregate make up a  considerable  volume,  are  also  used.
They  include  vat  colors  and even fluorscent colors.  The
general trend is toward greater use of color in printing. (5)

DISCUSSION OF DOCUMENT

Each section of this document is  divided  into  two  parts,
paint  formulation and ink formulation.  References for each
industry are separated and presented in section XIII.  It is
believed that this  arrangement  will  provide  clarity  and
enhance the report1s usefulness.

In  all  cases,  limitations proposed in this document apply
only to process wastewaters - that is, wastewater  that  has
come in direct contact with raw materials or intermediate or
finished  products.   The  limitations do not apply to once-
through cooling water, cooling tower blow-down, boiler blow-
down or other non-contact wastewaters.
                               16

-------
                        SECTION IV.
                  INDUSTRY CATEGORIZATION

                 Paint. Formulating Industry

PROFILE OF PRODUCTION PROCESSES

The paint manufacturing industry is very unique in the  fact
that  an  entrepreneur  can hire a few men, buy a minimum of
equipment and start  producing  a  respectable  quantity  of
paint,  providing,  of  course,  that  he  has  a good paint
formula.  A small plant with  less  than  30  employees  can
produce  between  7,600  and  11,400 liters (2,000 and 3,000
gal.) of paint per day.

Paints can be either oil-base or  water-base  but  there  is
little  difference  in  the  production processes used.  The
major production difference is in the carrying agent — oil-
base paints are dispersed in an oil  mixture,  while  water-
base  paints  are  dispersed  in  water with a biodegradable
surfactant  used  as  the  dispersing   agent.    The   next
significant difference is in the cleanup procedures.  As the
water-base  paints contain surfactants, it is much easier to
clean up the tubs with water.  The tubs used  to  make  oil-
base  paint  are  generally cleaned with an organic solvent,
but cleaning with a strong caustic solution is also a common
practice (1,2).

All  paints  are  generally  made  in  batches.   The  major
difference  in  the  size of a paint plant is in the size of
the batches.  A small paint plant will make  up  batches  of
from  400  to  1,900  liters  (10T) to 500 gal.) while a large
plant will manufacture batches of up to 23,000 liters  (6,000
gal.).  There are generally too many color  formulations  to
make a continuous process feasible.

There   are   three   major  steps  in  the  oil-base  paint
manufacturing process:    (1)  mixing  and  grinding  of  raw
materials,    (2)  tinting  and  thinning,  and   (3)  filling
operations.  The flow diagram  in  Figure  IV-1  illustrates
these steps.

At most plants, the mixing and grinding of raw materials for
oil-base  paints  are  accomplished  in one production step.
For high gloss paints, the pigments and  a  portion  of  the
binder  and  vehicle  are  mixed into a paste of a specified
consistency.   This  paste  is  fed  to  a  grinder,   which
disperses  the pigments by breaking down particle aggregates
rather than by reducing the particle  size.   Two  types  of
grinders  are  ordinarily  used for this purpose:  pebble or
                                17

-------
           PIGMENTS
OILS
RESINS
TINTS AND
 THINNERS
                    MIXING
                    TANK
                    STONE
                      OR
                    ROLLER
                     MILL
      PEBBLE
        OR
     BALL MILL
     DISPERSING

        TANK
                          THINNING
                             AND
                           TINTING
                            TANK
                           FILLING
                         PACKAGING
                             AND
                          SHIPMENT
Figure  IY-1.  Flow Diagram of Manufacturing  Process for Oil-Base Paints
                                 18

-------
steel ball mills, or  roll-type  mills.   Other  paints  are
mixed   and   dispersed  in  a  mixer  using  a  saw-toothed
dispersing blade.

In the next stage of production, the paint is transferred to
tinting  and  thinning  tanks,  occasionally  by  means   of
portable transfer tanks but more commonly by gravity feed or
pumping.   Here, the remaining binder and liquid, as well as
various additives and tinting colors, are incorporated.  The
paint is then analyzed and the composition  is  adjusted  as
necessary  to obtain the correct formulation for the type of
paint being produced.  The finished product is  then  trans-
ferred to a filling operation where it is filtered, packaged
and  labeled  (1,2).  In a large plant, these operations are
usually mechanized.  In a small  plant,  the  operation  may
entail  the  use of an overhead crane to lift the tub onto a
platform where an employee fills various-sized cans  from  a
spigot on the bottom of the tub while other employees hammer
lids on the can and paste on labels.

The paint remaining on the sides of the tubs or tanks may be
allowed  to  drain  naturally  and  the "cleavage", as it is
called, wasted or the sides may be cleaned with  a  squeegee
during  the filling operation until only a small quantity of
paint remains.  The final  cleanup  of  the  tubs  generally
consists  of  flushing with an oil-base solvent until clean.
The dirty solvent is treated in one of three ways: (1)  it is
used in the next paint batch as a part of  the  formulation;
(2)  it  is placed in drums that are sold to a company where
it is redistilled and resold; or   (3)  it  is  collected  in
drums with the cleaner solvent being decanted for subsequent
tank  cleaning  and  returned to the drums until only sludge
remains in the drum.  The drum of sludge is then sent  to  a
landfill for disposal  (1,2,3).  Cleanup of tanks by use of a
strong  caustic  solution is also practiced.  The caustic is
used to remove wastes which may have hardened in  the  tanks
and   would   not  be  amenable  to  cleanup  with  solvent;
wastewater from the caustic wash can  be  (1)  collected  in
holding tanks and treated before discharge;   (2) collected in
drums  and taken to a landfill; (3) discharged directly to a
sewer or receiving stream; or   (4)   reused  in  the  washing
operation.

Water-base  paints  are  produced  in  a  slightly different
method than oil-base paints.   The  pigments  and  extending
agents are usually received in proper particle size,  and the
dispersion  of  the  pigment, surfactant and binder into the
vehicle is accomplished with a  saw-toothed  disperser.   In
small  plants,  the  paint is thinned and tinted in the same
tub, while in larger plants  the  paint  is  transferred  to
                               19

-------
special  tanks  for  final  thinning  and tinting.  Once the
formulation is  correct,  the  paint  is  transferred  to  a
filling operation where it is filtered, packaged and labeled
in the same manner as for oil-base paints.

The  production  process for water-base paints is diagrammed
in Figure IV- 2.  The average composition  of  common  water-
base  paints  is  shown  in Table IV-1.  This table does not
include small quantities of preservatives or driers that may
contain trace quantities of heavy metals nor does it include
the organic biocides.
                        TABLE IV-1.
         COMPOSITION OF COMMON WATER-BASE PAINTS



Ingredient
Titanium Dioxide
Calcium Carbonate
Zinc Oxide
Silicates
Synthetic Latex
Solids
Acrylic Resin
Plasticizer
Soy Alkyd Resin
Water
Type
Polyvinyl
Acetate
Percent
10.2
3.4
-
20.4

11.2
-
2.6
-
52.2
of Paint

Acrylic
Percent
20.0
—
4.1
13.0

-
15.7
-
2.5
44.7
    Total Percent
      by Weight
100.0
100.0
As in the oil-base  paint  operation,  as  much  product  as
possible  may  be  removed from the sides of the tub or tank
before final cleanup  starts.   Cleanup  of  the  water-base
paint tubs is done simply by washing the sides with a garden
hose  or a more sophisticated washing device.  The washwater
may be:   (1)  collected  in  holding  tanks  treated  before
discharge;   (2)  collected in drums and taken to a landfill;
 (3) discharged directly to a sewer or receiving stream;   (4)
reused in the next paint batch; or  (5) reused in the washing
operation.
                                20

-------
   PIGMENTS
   RESINS
   OILS

SURFACTANTS
                                             WATER
                               DISPERSING

                                  TANK
                                 TINTING
                                  AND
                                THINNING
TINTS
                               PACKAGING
                                   AND
                                 FILLING
Figure   IY-2. Flow  Diagram of Manufacturing  Process for  Water-Base  Paints
                               21

-------
Some  of  the  larger paint plants manufacture the synthetic
resins used; either the usual alkyd resin,  a  water-soluble
alkyd  resin or an acrylic resin.  The manufacture of either
type involves an esterification process in  which  polybasic
acids  and  polyhydric  alcohols  react with various oils or
fatty acids.  The raw materials are fed into a large reactor
(kettle) equipped with an  agitator.   The  kettle  is  then
heated  to  the  specified reaction temperature.  Most alkyd
resins are manufactured at around 200°C (392°F).  The heated
resins are cooled, filtered, and stored  for  use  in  paint
production  or  for  sale  (1).  Although resiri manufacturing
may be associated with a  paint  formulation  facility,  the
guidelines  being  developed  in  this docximerit are only for
paint formulation.  The production of resins is  covered  in
the  proposed  Effluent Limitations Guidelines and Standards
of  Performance  and  Pretreatment  for  the  Plastics   and
Synthetics  Industries  (5).   Discharge  permits for plants
producing resins as well as paints will have to be based  on
two or more separate effluent limitations guidelines.

Varnish  orginally  was manufactured by the slow cooking and
polymerization of natural oils and resins.  This process  is
rapidly  being  replaced  by  the  manufacture  of synthetic
resins  (often called varnishes)  as  described  above.   The
only  water  pollution  loads  possible from these processes
would be from air pollution equipment and from  the  caustic
cleaning   of   the  cook  tubs.   Lacquer  is  produced  by
dissolving certain resins in a non-water solvent  base  with
the  desired  pigment.   No water is used in these processes
and no liquid wastes are discharged.

Allied products manufactured by the paint  industry  include
putty,  caulking  compounds,  paint  and  varnish  removers,
shellacs,  stains,  wood  fillers  and  wood  sealers.   The
manufacturing  process for these products does not generally
utilize water, except for some water-base stains  and  paint
removers.   The  types  of  wastes  generated  in cleanup of
equipment do not greatly  differ  from  those  generated  in
paint formulation.  As these categories are generally low in
water  use  and  are  very  similar  to paints, they will be
considered as being in the same category.

CATEGORIZATION

The following factors were considered in determining if  the
paint  industry should be divided into subcategories for the
purpose of application of  effluent  limitations  guidelines
and standards of performance:

    1.  Raw materials
                                22

-------
    2.  Products
    3.  Production methods
    4,  Size and age of production facilities
    5.  Wastewater constituents
    6.  Treatability of wastes

Raw Materials and Products

The  use  of  various  oils  and  resins, extenders (calcium
carbonate, silicates, clays), pigments and dispersing agents
are generally the same for all paints  and  enamels,  except
for  the  use  of  oil  or  water  as the dispersing medium.
Water- and  oil-base  paints  are  interchangeable  in  many
applications  except  that industrial finishes are primarily
oil-base.  Even this is changing, however,  because  of  the
air  pollution  problems  generated in the industrial use of
oil-base paints.

Production Methods

As previously mentioned, both oil- and water-base paints are
made in the same factory, use many of the same raw materials
and are produced with, generally, the same equipment.   Some
oil-base  pigments  may  be  dispersed in roll or ball mills
before blending into the dispersed calcium carbonate,  talcs
and  clays.   The  cleanup  procedure  varies.  For oil-base
paints both caustic washing and solvent washing systems  are
used.   For  water  base  paints  caustic  washing and water
rinsing are the major cleanout methods.

Size and Age of Production Facilities

This study showed that the size  of  a  production  facility
affects only the quantity of wastes - the characteristics of
the  wastes  are  similar regardless of plant size.  Because
the paint manufacturing process equipment  has  not  changed
appreciably  over the years, the age of the plant has little
bearing on the waste characteristics.

Wastewater Constituents and Treatability of Wastes

Oil-base paint waste solvent  discharges  contain  flammable
substances  whose entry into most municipal sewer systems or
surface waters is controlled by EPA Regulation 40  CFR  128.
Most  cities  have  waste  ordinances that have attempted to
deal  with  the  release  of  these  obviously   deleterious
substances.    In  most  paint  plants,  it  would  be  very
difficult for these substances to get into the sewer  system
because  there  is usually no direct connection.  Due to the
highly volatile nature and the odor of these materials,  the
                                23

-------
source  of  any  substances  that do find their way into the
sewer system through  accidental  spills  could  quickly  be
located.   The  general practice of the paint industry is to
practice no discharge of oil-base paint  solvent  wastes  to
waterways or sewers (4).

Latex is a substance that is forbidden from the sewer system
by some municipal ordinances and not by others.  Some plants
may  find  that  the  municipality,  while  not  prohibiting
discharge of latex wastes to the sewer system, may place the
waste under a surcharge.  It has been found that  the  latex
wastes  can  build up on the sides of the sewer laterals and
cause blockages.  The degree of control and enforcement  has
often  depended  on  the problems that the paint plants have
created for the municipality.
Latex materials generally enter the sewer system as a result
of the washing down of batch equipment.  When  there  is  no
change  of  formulation  from  one  batch to the next, as is
found often with small paint  manufacturers,  little  or  no
latex   enters  the  sewer  system.   Generally,  the  small
manufacturer can recycle most of his washwater into the next
batch, if he is engaged in the manufacture of  only  one  or
two  base  colors   (2) .   This  is  both  a  desirable water
conservation practice and an economic advantage because  the
valuable solid materials are thus recovered.

The   wastes   from  latex  paint  production  contain  only
biodegradable oils  and  surfactants  mixed  with  insoluble
inorganic  extenders  and  pigments.   The  concentration of
preservatives is diluted well below levels  of  significance
during  washing  operations.   Thus,  there is no problem in
treating the wastes using physical and biological  treatment
methods.
Although  the  equipment and raw materials used to make oil-
based and water-based paints are quite similar and could  be
classified  as  one  category,  the  problem of pretreatment
standards and the requirements to control fire and explosive
hazards would dictate that oil- and  water-based  paints  be
treated as separate categories.

CONCLUSION

On  the  basis  of  the  raw  materials  used,  the products
produced, the production methods, the cleanup  methods,  the
size  and age of facilities, the wastewater constituents and
the treatability of wastes, it is concluded that  the  paint
formulation  category  be  subcategorized into  (1) oil-based
                                24

-------
solvent wash paints,  (2) oil-base caustic  wash   paints   and
(3)  water-based paints.
                                25

-------
                  I nk Formulat ing Industry

PROFILE OF PRODUCTION PROCESSES

The  ink formulation industry differs only slightly from the
paint industry.  Many of the raw materials are the same  and
the  methods  of producing ink are nearly identical to those
for producing paint.  Milling is used more frequently in the
ink industry than in the  paint  industry  as  a  method  of
dispersing  pigments.   There  are  both large and small ink
formulators, and again, the size of  the  plant  appears  to
offer no economic advantage.

As  the processes and equipment used by the ink industry are
very similar to the paint industry,  there  is  no  need  to
discuss the methods of production.  The profile of the paint
industry   is  applicable  to  inks  also.   Although  resin
manufacturing may be  associated  with  an  ink  formulation
facility,  the  guidelines  being developed in this document
are only for ink formulation.  The production of  resins  is
covered in the Effluent Limitations Guidelines and Standards
of   Performance  and  Pretreatment  for  the  Plastics  and
Synthetics Industries  (1).   Discharge  permits  for  plants
producing  resins  as  well as inks will have to be based on
two or more separate effluent limitation guidelines.

CATEGORIZATION

With  respect  to  identifying  discrete   categories,   the
following  factors were considered in determining whether or
not the ink industry should be  divided  into  subcategories
for  the  purpose  of  application  of  effluent limitations
guidelines and standards of performance:

    1.  Raw materials
    2.  Products
    3.  Production methods
    H.  Size and age of production facilities
    5.  Wastewater constituents
    6.  Treatability of wastes

Raw Materials and Products

The  use  of  various  oils  and  resins,  lacquers,  clays,
pigments and dispersing agents are generally the same except
for the use of oil or water as the dispersing medium.
                               26

-------
Production Methods

Both  oil-  and  water-base  inks  can  be  made in the same
factory.  Many of the same raw materials are  used  and  the
inks are produced with, generally, the same equipment.   Some
oil-base  pigments  may  be  blended  into the extenders and
carriers before being dispersed by roll or ball mills.

The equipment methods vary.  For oil-base inks a caustic  or
solvent  washout  system  is  used.   For  water base inks a
caustic washout or water rinse methods of cleanout.

Size and Age of Production Facilities

Only the quantity of wastes is affected by the  plant  size.
The chemical composition is generally the same.  Some plants
recycle  and conserve water and have a negligible discharge,
while other plants use water lavishly  with  no  regard  for
conservation.   The  age  of  the plant has no effect on the
quantity or composition of the wastes generated.

Wastewater Constituents and Treatability of Wastes

Oil-base ink discharges contain substances whose entry  into
most municipal sewer systems or surface waters is controlled
by  EPA  Regulation  40 CFR 128.  As previously mentioned in
the section on paint,  most  cities  have  waste  ordinances
which  have  attempted  to  deal  with  the release of these
substances.

The wastes from water-base ink  formulation  have  generally
been accepted by municipalities as nearly all ink plants are
connected to municipal sewers.  As with paint, the metals in
inks  are  generally  part  of  the  suspended  solids.  The
organics in water-base inks are generally considered  to  be
biodegradable as they are basically the same as in paints.
CONCLUSIONS

It  is  concluded  that,  based  on  the  constituents, wash
procedures and treatability, the ink manufacturing  industry
must  be  considered  as  three  subcategories — water-base
inks, oil-base solvent wash and oil-base caustic wash inks.
                                27

-------

-------
                         SECTION V.

            WATER USES AND WASTE CHARACTERISTICS

                 Paint Formulating Industry

SPECIFIC WATER USES

On the basis of data from the  Southern  Research  Institute
(SRI)  report  (1)  on plants representing 26 percent of the
total industry paint production and 38 percent of the  total
industry  production  employees,  the  water  usage  for the
entire industry is estimated at 284 to  310  million  liters
(75  to  82  million  gal.) per day.  Cooling is the largest
single use of water, accounting for about 79 percent of  the
total usage.  Of the other uses for water, all are less than
that  used  for  sanitary purposes, which is about 6 percent
(1).  The total process water use for the  1,700  plants  is
from 42 to 45 million liters per day (11 to 12 mgd) .

A major source of water is municipal or public supply, which
accounts  for  about  43  percent of the total intake.  Well
water and surface water account for about 21 and 32 percent,
respectively.  Only about 4 percent of the total water  used
is  recycled;  however,  the  reported  figures are probably
somewhat low because  some  plants  responding  to  the  SRI
survey  did  not  include  the  water  used in recirculating
cooling systems.  In smaller plants, a greater proportion of
the water is used for purposes  other  than  cooling.   Very
large  plants—those  with  more than 250 employees—account
for nearly 70 percent of  the  total  industry  water  usage
while plants with fewer than 100 employees account for about
10 percent  (1).

Disposition of wastewater from the various uses in the paint
industry  is  shown  in  Table  V-l.   Since  cooling  water
normally does not contact the product or  raw  material,  it
should  not become contaminated if properly handled.  On the
other  hand,  water  used  for  cleanup  and  air  pollution
control,   which   accounts  for  4  percent  of  the  total
discharge, necessarily becomes contaminated in use  and  can
result  in  the discharge of pollutants.  Water used for air
pollution  control  (wet  scrubbers)  is  associated  almost
exclusively  with  the  production of resins and is therfore
not of concern in this document.  Dusts and powders  removed
from  paint  production  areas are recovered by dry methods.
Table V-l shows that about 70 percent of the  wastewater  is
discharged  untreated.   However, only 0.5 percent is likely
to be contaminated directly  from  the  paint  manufacturing
operation.  It is worth noting that approximately 25 percent
                              29

-------
                          "S  5
3
3
                         O  4J  O

                            c  o
                            M  n
                                           sr

                                           o
n

o
                <-i    r-

                o    o
                                                                                            o
                                                                                            g
                                     W    -H    U     C
                                     f-H    rH    
-------
of  the  industry's  wastewater  is  not  discharged, but is
disposed of by evaporation,  recycling,  or  by  some  other
method.   Only  larger plants show other wastewater sources,
such as air pollution control or process  water  from  resin
manufacturing (1) .

Most  cleanup waste results from cleaning the equipment used
to manufacture water-base paints.  The  types  of  equipment
most  frequently  cleaned  are filling machines, tinting and
thinning tanks,  and mixers.  The average quantity  of  water
used  in  cleanup  of  equipment ranges from 0.02 liters per
liter  (gal./gal.)  of paint produced for filling machines  to
0.8  liters  per  liter  (gal./gal.)  of  paint produced for
tinting and thinning tanks (1,2).

Other sources of wastewater generated in cleanup  operations
include  the  caustic  washing  of  equipment  used  in  the
preparation  of  solvent-base  paints,  resins,  and   other
products.   However,  the  equipment  used  to prepare these
products is frequently cleaned with  solvent  which  is  not
discharged.

The average volume of cleanup water discharged for plants of
various  sizes  is  shown  in Table V-2.  For small plants—
those with fewer than 50 employees—the volume discharged is
relatively small,  less than 1,000 liters (260 gal.) per day.
At plants with more than 250 employees, the  average  volume
of  cleanup  water  is  about  40 times this value, still an
extremely small volume when considering pollution potential.

                         TABLE V-2
              AVERAGE VOLUME OF CLEANUP WATER
         DISCHARGED FROM PLANTS OF VARIOUS SIZES(1)
Size of plant
(total number
of employees!

Fewer than 10
10 to 19
20 to 49
50 to 99
100 to 249
250 or more
Number of
 plants
reporting

   24
   30
   34
   21
   22
   20
 Cleanup water discharged	
liter/day         gal./day
   292
   769
   983
 4,679
11,957
40,490
           77
  200
  260
1,200
3,200
   11,000
    In addition to routine equipment cleanup, wastewater  is
generated  through  general plant cleanup and spills.  It is
not possible to estimate accurately the  volumes  of  waste-
water  arising  from  these  operations.  Settling tanks and
                             31

-------
other kinds of treatment are used for  treating  wastewaters
from   floor  drains  and  spills,  while  off-specification
batches are recovered and reused or sold (1).

WASTE CHARACTERISTICS

As determined by the Southern Research Institute survey, the
major contaminants of wastewater reported  by  paint  plants
are  listed  in  Table  V-3.   As  would  be expected, these
contaminants, except for  caustics  used  in  cleaning,  are
components  of  paint.  The materials listed most frequently
by plants as major contaminants are pigments and latex.  The
presence of one or both of these materials in the wastewater
was reported by about 90 percent of  the  71  plants.   Over
half  of  the  plants  also  reported  the  presence of such
materials as oils, resins, driers,  and  dispersing  agents.
Only  four  plants  reported  the  presence of solvents as a
major contaminant of the wastewater,  five  plants  reported
metals and six reported fungicides  (1).

                         TABLE V-3

       MAJOR CONTAMINANTS IN WASTEWATER DISCHARGE(1)
                     	Number of plants	
                     19 or   20 to   Greater than   Totals
Number of Employees  less	99	100	

Number of plants
  reporting           26      23          22          71

Major
Contaminants

Pigments              15      10          11          36
Latex                 12       8           6          26
Driers and
  wetting
  agents               3       a           8          15
Oils                   33           6          12
Resins                 73           1          11
Caustics               10           7           8
Fungicides
  (including
  mercury)             22           2           6
Metals
  (excluding
  mercury)             01           4           5
Solvents       .        0       3           1           H
                               32

-------
Table  V-4  summarizes  raw  waste  loadings calculated from
analyses of 22 parameters reported by n±ne plants.  Although
91 plants (of 153) reported that routine  effluent  analyses
were   conducted   by   either   plant   staff   or  outside
laboratories, only 29 reported  data  on  results  of  those
analyses.   Of the 29, 20 reported data on treated effluent.
No meaningful conclusions could be drawn from  the  analyses
of  treated  effluents  reported in the survey since too few
plants used the same treatment methods.  Almost all  of  the
nine    plants    providing   information   on   raw   waste
characteristics gave data on the  combined  plant  effluent;
therefore,   calculation  of  the  loading  in  relation  to
production of particular products  was  not  possible.   The
loadings  are therefore, expressed in kg/day rather than the
preferred units of weight per unit  of  product.   The  data
show  the  average,  minimum and maximum daily loadings, and
the number of plants reporting  (1).  The  NFIC-D  survey  of
selected paint plants was made to supplement this data.

As  indicated in Table V-4, suspended solids, primarily from
pigments  and  resin  particles,  is  the  most  significant
parameter.   The  high  loading  of  dissolved solids is not
readily explainable in terms  of  the  ingredients  used  in
paint  or  the  soluble constituents shown in the Table that
would constitute the dissolved solids.  Loadings of BOD5 and
COD, principally from biodegradable oils and resins, are not
as high as those of suspended and dissolved  solids.   While
oil and grease content appears high, it should be noted that
the  standard  test gives high results for oil and grease in
the effluents from this  industry  because  resin  particles
that  are  present are, at least partially, extracted by the
solvent used in the test.   However,  the  major  components
making up these high concentrations are easily biodegradable
and   thus   are  amenable  to  biological  treatment.   The
relatively high loadings of zinc, iron and titanium are  due
principally    to   the   pigments,   drying   agents,   and
preservatives.  Mercury is present  in  some  preservatives,
however,  these  are rapidly being phased out.  The ultimate
fate of the use  of  mercury  by  the  industry  is  unknown
pending  court appeals.  In addition to lead and zinc, shown
in the table, some drying agents  also  contain  cobalt  and
manganese.   All  of  the  metals  shown in the table, and a
number of others, are commonly present  in  at  least  trace
quantities in inorganic pigments  (1,6,7,8,9).

The  information  needed  to  supplement  the raw waste data
obtained from the Southern  Research  Institute  report  was
developed  through  a  study  of  the  files of the East Bay
Municipal Utilities District  (EBMUD) in Oakland, California,
and files  of  the  Greater  Chicago  Metropolitan  Sanitary
                                 33

-------



























!

'
^
I
**
1=3

1






















































^
B
3
t,
e
M
ft.
g
g

j?
rt
C
«
W
*^
*2t

3



?•*
(4
n
o




















o c
in rt
Vl U U
01 c u
*o 
K rt
S 13
ti
^J

•£
a
•a

n
01 rt
DC *^
a
V,
01
<
>•
rt
•O

6(
"*






V*
0)

01
V.
rt
ft.






fNv





\0
O
rt





(V-|
00





CM





ON





m
00
•»








0
CM
CM



n
•0
rt
rt
O
m

•a
o

^
o
m
rt
•o
to

0
l-i



ov co




CM in
CO CO
rt rt
r*





CO rt
CO VO
CM

CO


CO





co in
rt





CM 00
CO CO
CO








r^ O

CO




"O
rt
O "O
CO 0)
•a
•0 C
01 01
•o c.
C 10
01 3
c. m
w
3 01 01
(0 rt -O
rt rt
tO DO
*J rt CO
,2 5



in o* v£ cs c"i vo fo




»j o r~* rt vo r^. oo
o c^ o^ m r^ CM oo
rt rt CM ON
CM





r^. r^ *j co m r^ o
*^ r^ ** CM CM CM KT
rt CO

rt


CM rt • • •
O rt 0




CM sr co vo •» oo -a-
rt ...
O O 0




00 «^ CM CO IA ^ rt
CO *^ vO CO ON ON CO
«^








f*s o oo tn co **f ^*f
rt CM CM rt •» CM rt
CM



•O

T3 CJ C
0 E 0
>v 01 01 X>
*J 0) "O M
rt a
C Tl C O
rt Ol 01 0>
rt U 00 O 10
o rt X rt w
.* s x c «
rt rt O n H •
< rt 00 O
~~ 0 rt W 01
X o M o -o -a a
u a u rt c u
•0 E W O u-i
rt O 01 tJ rt rt rt
0 O f O f rt 3
< pa o t-< o o w



co rt 
,


ON O CM rt Ov
• 1 N
•O rt « rt J= K
rt C O C O. 3
vw fl 1-. o « O
rt CC U g o P
3 V4 rt E X 01
«i 0 2; 5 f* X



r^.





VO

n)
5



vO




in
vO
CM
O





O
CM
rt

O


o

o



o
o
o



03
rt
O
*
O






to
o
o

a












§
1

(9
U



CO





f^
•*
O





p»
rt
CM

O


CM
C
O



o
rt
C
o



^
» rt
ON rt
O O



vO CM
CM in
<* 0
o o



•* vO
• o
VO
CM







ON CO
• CO
CM Ol
.
O











E
3
rt
C
C flS
o u
kl rt
M H
34

-------
District,  and  by  a  plant sampling survey in the Oakland-
Berkeley, California area by National  Field  Investigations
Center-Denver (NPIC-D) (2).

The  results  of a waste discharge survey of paint plants by
the EBMUD  are  presented  in  Table  V-5.   All  data  were
developed by State certified laboratories.

The  typical waste characteristics of effluents from a large
plant  are  shown  in  Table  V-6.   As  can  be  seen,  the
concentrations of the pollutants are relatively large.  This
data  is  slightly in error as there is an employee washroom
that drains into the  sewer  ahead  of  the  EBMUD  sampling
point.   Subsequent  data  taken  from the NFIC-D survey for
this plant in  late  1973  was  collected  upstream  of  the
employee  washroom.   The  data,  presented  in  Table  V-7,
generally supports the range of data presented by Barrett et
al  (1) .  The wastewater characteristics of two small  plants
are shown in Table V-8 and V-9.  Table V-8 shows the effects
of  reducing  pollutant  load by removing as much product as
possible from the paint tubs before  washing  and  by  using
minimum  washwater  volume  as opposed to a more normal tub-
cleaning process shown by Table V-9.
                                35

-------
                                               TABLE V-5

                         CONSTITUENTS OF PAINT MANUFACTURING PI.ATJT (SIC 2851)
                           WASTES IN EAST BAY MUNICIPAL UTILITIES DISTRICT^'
Values (m!>/l)
Constituent
PH
BOD
Total COD
Dissolved COD
Total Solids
Settleable Solids
Total Suspended Solids
Ammonia
Total Kjeldahl Nitrogen
't
Oil & Grease
Total Phosphorus
Aluminum
Antimony
' % V
Barium
Cobalt
Chroniun
Copper
Iron
Lead
Manganese
Nickel
Silver
Tin
Zinc
Phenols
Surfactants
No. of
Entries
28
12
31
31
1
3
32
3
3
26
3
3
1
3
2
3
3
3
3
3
3
2
3
3
3
3
Min.
3.4
60
53
19
-
<£'
38
0
0
4
0.3
2.6
1.1
0.77
0.05
0.4
0.11
3.8
1.14
0.06
0.02
0
0
0.31
0
0.2
Max.
13.2
1,740
99, 99^
78,000
-
2
8,180
1.7
189
999
26.4
74.6
1.1
5.7
0.23
7.5
0.22
37.3
9.99
9.99
0.07
0
0.07
9.3
0.1
7.5
Mean
8.8
481
5,428
4,103
6,887
1
1,039
0.5
64
103
14
29.5
1.1
2.8
0.14
2.8
0.17
15.2
4.99
3.5
0.03
0
0.02
3.8
0.0
2.8
Std.
Dev. Median
3.2 6.7
474 450
17,649 5,145
13,787 4,466
-
-
1,759 612
1.7
232 7
26
11.4
5.7
-
6.4
0.11
4.6
1.1
0.06
0.02
-
-
1.7
-
7.5
a/ All data from East Bay Municipal Utilities District
W Series of 9's indicate number higher then allocated
c/ A zero Indicates a value below detectable limits of
files.
space in computer program.
analytical test.
                                                36

-------






/
/




\
\














•5.
g
«:£
*; t**



53 .
EG
v> »3
w W
f si

O PS
H <
9 * 8
H 6 §
0! P.
SB
BS
M
1
|
i
,--
(


\






















o :
o
*.» ^

rt
iJ U.
3 O
i~f
»-< •
0 f-
t>
U-l
O C
^ ^



CX C

C C
rt ^
*J Cu
t-< C
O

tw O
O O
O
to






«
-o


»-i


*j
*j
C
CO
S

S
IQ
T3
•^^
i



.„—,

• *H

4g
-.
V


*H 0
o *-*
•1
o S
2 in









S
tJ

rH
•H
O




o> IA n in o 1
. fH 0
2 r> ex 0 ^ ^
•-i
.
SO



y



to  o\ *o •

*y r-t o*
i , I

_/




R-* rH CN f-4
CM W> CN|







C €J «
€) i> •)
O. « «M O
S« OB
n u 10
CO T3 O • i4
•H o a e
iH H •« Z 0 3
no •-- u -i
o ca *j w •-! OP
8O O *^ H 0
« H o c. a




i i i i i i i
oooooooo
^XXXXKXK
•^
Cj • « • .
P O3 VO Cf 

* —
CO
t"*

r^
•H
P.
to
O
r-
|
u
tt
o
L.
*
c

a

0)
bo
a
t.
o
a
1
l-t
m
00


3
•a

to
o
o
oo
«0
4J
rt
0-
4J
c
v4
O
§

g
«

V
a
w
CO
S
•5
n
8
4)
U
|
n
g
c •
ej B
^ V
aj v
u X
o
0} *-(
Z» a
•D V

.-< O
•^ O
< -H
37

-------



































1*^
1


tc
rJ
to

H




























































Q
V.
1C

fe

0*
n
< C
W***-
^j ^ *0 I
t-3 C-i *"^
(- r <•">
<: < r-
tJ en CT
r-l
1C W
O H •
or (-1 OC
< CT. r-l
*"* C >A
S" y' rH
c c
p? o oi

>- (5
o < c
< C H
SI U
n o

t! 5= ""
2 c

13
d
o
PL.

&?
5
i
























u
c
Xi

c
o
•H
4-1
O
3
•o
O
V.
C-
41
•c
O
0


c.
K
•s

r- 1
o
(X.












4J
•H
C
19
3
cr








C
o
•rl

B
V*
4J
C
41
0
C
o
0





















t-H
rj
6.'

O
O
O

rH
*^
p
f~ 4





r-|

O
c
c
rH
•^
U





^.
(g
•o

.0
1-1









o
•a
e









rH
c.:














4J
C
a
s

fH
O
0-,



o vO ^^ *^ *J in
• *j • ill
in • r» o o o
in OO f^ t-l rH rH

XXX

•a- r^ rH
rH m •
rH f^






«^ rH CM ^ *^ VO
VO O O III
• • CCO

XXX
-^ vC CO
r-l • V
**•



r« CM sf 00 «J ST
00 • •* O . 0 1

m O o rH

X

m
V







o c o -a- n CM
o o o  O
rH • rH O C
CP rH rH V









e
•0 3
4) -rl
•o e
B 0

O. X
M O E
3 01 E 3
. CO TJ 3 rH tH
tH CO -rl <0 R
•H rH rH V4 J-l t:
no n n o a
O CJ UCOUOHO
K O O O 4»
a o £• H 5:
•
CO -3" M>  •  CO
r- vc -I CM co
•-I O wi O O-

o
c

m
•H
CO


n!
C



1

3 ><
:M -H ui
41 C 3
c TJ o cx n: c;
o a c a u ,.
lw 4) -rl 0 -H 41
M rJ N (J H T.

































•
^-^

•c
e.


0
VC
r-^

tn


ra
•o
t-i

o
o
00
t-H
CM

•c
4>
CC
a
OC
K
O

CO

o
t-H
VM

r<
41
U
a
Z
41
u
CO
13
3

c
(£

^j
0)
<
































•
x-\

•a
ex
tc

0
o
0

f"^


rt
•o
rH

O
o
in
\D
CM








C
0
T-t
4J
O
3
"G
O
V^
C-

U
C

n
CV.

41
CC

^J
OJ
<





























































CO
01
4)
>-
0
t-H

e
4)

o
0


o

u
c.:

^
a
<

























































•
i
o
rH

z

X
^>


41

o
3
•0
C
o
u

Ol
>

3


^^




















































to
4J
tH
C
3

13
ki
(3
T3
C
«

CO

to


•o
41

U
o
e.
01

o
3
t-H
O


1 —
38

-------






o
t/:
<
ea
u
CO
•""

w
b
*i.

o

X
H
M

£_l
Jr y
<  P- s: -
M OO
U3 X J rH

c: H * u-i
< < 
"^









*J
-H
c
T3 ^
rj
O B
rJ 0
*J U
C U
19 3
3 O
rH r4
rH O.
O
o
P,












>
v^

c

3
o*







B'
o
•H
u
03
V*
u
B
U
U
B
O
















rH
«
U
o
o
o

^
J3




rH

O
o
o

~-
tt






>
•a

XI
rH







^>
rt
•a

~e





rH

U








U
c
o
3
rH

O
(X,


oo co m
ST CM CM
• • •










O -3" CO
co o *o
. . .
°







\O «7 ^7
00 CM CT>
• " •








co r- o
^ O O*
OO rH r*
•t
rH





rO"!
CM O O O
• o o^ o
co oo co in
-^ rH rH
rH CO






tj
01
•o
c

rH O\





in m
1 1
0 C

X X
rH O
CM rH




-» .in
1 1
O O

X X






vO CO
O O

O O







O ON
• in

o






e
9
•H
jj

JC
e °
3 rH
W f-< fl
*-( W U
rt c CM -» -» m CM
1 1 1 1 1 rH
o o o o o
rH rH rH O
X X X X X

r- <
3
U

01




•
2

U

(Q

u%
g
0
IM

V.

IV
S
«
2

•rj
41
C
41

4)
O.
HI
V4
0
rH
a
E
rj
(O

»
•
n
u

u
u
CJ

B
•H
4J
B
•H
fi
C.
 > >










































,>
2
•rl
J
C TJ
1 V<
U rt
M -O
feg

rS 10
J
a)
•0 «

ti -a
U 4)
3 «
•o >H
C 0
o o.
U 4)

0 41
> 3
M rH
3 (d


"nl^o
39

-------

































t;

§
H










































S5
o

O
Id

<*
&
,_!
£»-

•J
A4
H
P
^ ^^>
P-i S rti
2 i""N
^ 2 f^
W C ^
f~* O OA
< c«: rH
,j PI
r-
tJ O CO
.J 52 rH
3 rH 1
5: ,J m
W C. rH
IE § «:
o w w
(V CO
fc r-i O

O O lj
o n ^


[_(
yr

i
c


W
<
2
U

<












^
iJ 0£
•H
c o
•C £D O
re o
o c •
.J O iH
4-» 4-1 J3
C 0 .H
re 3
AJ 13
D O

3£rH
Pu »-< O
CJ O
P- C
^
» —
w







^,
C3
t3

•O
r-4
^.
4J
•H
U
§
3

^
<0
•o
1



c
o
•H
•4J
r4 rH
C U

O
c
o
o




u
c

3
tH
tH
O




0 *t *t

CO • •
i-H CM in
rH










*>C O\ 00
m CM •
• tH
iH O








m tH \o
. • •
VO CO O*
rH rH










O O O

m co oo
r» rH 00





boo o
o o o
r- CM tH oo

*O CO O\
tH tH





•o
41
•8
41
O.
0)
3 m
v> -o
•H
rH tH
g) 0
Q U u «
ffi O O O
0. (J H H

I
O
rH

X

00
r^






-*
1
o
1^
X

•H
^/




f^
1
0
tH

X

rH
V





in

o
V





rH
V












e
3
10 i-<
tH r-t
CO efj
<-> CQ
U
y.

|
o
tH

X

o
\D






in
I
o

X

CM
r»




*^
1
o
rH

X

f~
r~!





tn
CO
O





-
O






e
3
•rl
6
O

6

rH
a

o
H


r~ rH co CM
1 -J 1 1
O O 0
rH O tH rH

X XX

03 a* «o
r~ tH






00 CM >* CO
1 1 1 1
O O O O

X X X X

CM O> CO CM
eo -» CM r—
V



• r^ CM co CM
1 mil
0 -00
i-H O rH tH

X XX

O> -9 
tH
.
O











CM
|
O

X

CO
CM

U
41
U
•» c
CM 4)
• r4
O 4)

U
4)
4J
C
•H

s
1

,

3 >N
•rH r-l
C 3
19 U
4J t-l
•H 4)
fH ^












a
41

ex
§
«

,0
S
60

>n
"O
4>
c
41
u
41

ex
41


41

I

in


10

s:
u
4J
A

e


iH
fl
O.

6C
C
•H
rt 6C
E C
TH
a 3

ex
CI
rH O

VJ ^


• •
Or

O
r&






























•

x~s *O
t3 ex
ex 60
60
o
C7\ f^
rH CM
rH rH
^-^ ^~*

X >>

T3 *O
-^ — .
rH rH
C?t O
•» CM
-» 00
•^
•O
41
60
n
60
0)
a
G
3 O  > <




































•
«J
c


•rH
ex

Jj
8
•rl

e e
u o
iH V

o -a c
1 b O
0 C3 K.

r« C
•Z a rH
4-1 "*^
X « 60

n
•O ed O
S "S °-

•o w
CO*
o ex 4)
O 41 3
^s td
41 41 >
> 3
1-1 rH 4)
3 n c
t/1 > O

"**«. **"*. ^"^.
fl|.fl| y
40

-------
                  Ink Formulating Industry

The predominant water use in ink  formulation  is  for  non-
contact  cooling  water  for ball or roller mills.  The only
process wastewater from ink formulation is  the  water  used
for  tub  washing  and plant cleanup.  Some water is used in
water-base ink product formulation but  this  water  is  not
discharged except during tub washing.

Because  these  tubs  are  identical  to those used by paint
formulators, the type of cleanup  and  quantities  of  water
used  are  identical.  Reference is made to Section V of the
discussion on  paints.   Limited  information  is  currently
available  on  the  actual  composition  of ink wastes.  The
composition of wastes from a tub washer  that  recycles  the
cleaning  water  is  shown in Table V-10.  These wastewaters
are not discharged.  Table V-ll gives  the  constituents  of
several  ink  manufacturing  plant  wastes  in  the Oakland,
California area.   There  is  no  information  available  to
determine  the  number  of  plants  the  data  in Table V-ll
covers.
    The quantities of water  used  were  very  difficult  to
determine  as  data  was limited.  For systems with no water
reuse, the range was from 4,400  to  8,900  liters/1,000  kg
(500  to  1,000  gals./I,000  Ib)  of ink including cooling,
boiler and process waters.  In the recycle system  of  Table
V-10,  the sludge was produced at a rate of 113 liters/1,000
kg (13.6 gals./I,000 Ib) of  ink.   If  the  sludge  were  3
percent  solids  as  indicated  in  the table, the washwater
discharged would be 110 liters/1,000  kg  (13.2  gals./I,000
Ib) of ink.
                               41

-------
                              TABLE V-10

            WASTE CHARACTERIZATION FROM AN INK TUB WASHER
                    THAT RECYCLES THE WASH WATER-'
                        (October 15-18, 1973)
                                              Concentration
                  Pollutant	(mg/1)
            COD                                  59,500

            TOC                                  32,000

            Total Suspended Solids               31,600

            pH                                     12.5-b-7


            Metals

              Barium                                6.7

              Total Chromium                        150

              Cadmium                              0.29

              Iron                                  134

              Lead                                  760

              Zinc                                  4.9

              Copper                                6.4

              Titanium                               <1
ji/Survey conducted by NFIC-D; daily production 18,400 Ib/day  (average
    of data from two grab samples).
b/  Value reported as standard units.
                             42

-------

























rH

1
£>

W
_)

H









































/-*-
O\ H
CO CJ
CM r-l
prj
O H
M CO
CO M
Y Q

H 10
fe w

»— 1 E~*
0, M
O M
55 H
M CJ
O r-1
fr"* ^
U P-r
<; M "
1*4 CJ
g M
a §
je 55
x >*
s ^
M «

H«4 C"^
O co
^
CO W
E_t
fc ps
U M
O
H co
M W
H H
CO CO
S5 <
o ^
o






















in
bC

x^

CO
u
3
H

>















*W
o

o

























B
rt
•H
T3
4)
JC
,;
V
a
•a
tf
CO


a
rt

jg





•
s
Jj^




•
a
•H
£



D)
(U
•H
jj
C












4*
B
4)
3
4J
•H
W
(D
B
O
U


r-l O in VO
• O^ ro f"^
iH •» CT> CO
1-1


o> n -n co
• ^D O^ ^J"
i-i m vo \o



^f C^ vO ^^
• r-l CM  r^





vD O O O
• vo r- co
l-H r-l CM OA
CM CO CM




vo in o O
• m 1-4 r^
m co rH







vO CM vO vO
















O
o
u

Q T3
O 4)
CJ >
rH 'O
**^f flj W
,0 a 4-1 m
« 0 0 •*
PL, « H a
oo r~» O ^o O O O
1 h* C7\ 1 1 1 O 1 1 1
•
o


CMCTi OOO OOO
ON ^
CM



lHvDr>-rHO>OrHvO^OrHOO
vomm «rH -o • CN o o
COrH »H • O • rH • • •
O O OOO




inOCOCOrHOrHvOCMCSIOrHO'O
OOCOOO 'CM «O "fOrHO
COCMrHrH- O • CM • • •
O O O O O




OOCOr-»inCOOrHvOvOvOcMrHOO
CO rH rH 0 • CM O O
CO ^5 • O * O • * *
o o • o o o






CMvO'«*CMCMrHCMrHCMCMCMCMCMCM
rH rH







M
•o
•H
rH
O
CO
•o
0)
•a
W B «
•a 4) w
•H D. «
rH CO 4) 4)
O 3 K B B 0)
CO CO U 3 3 4)
B *J -H l-i C rH M
i-lrHwa-HCi-HEd) 094)4)
3)
4->4JrH3WlJ3V4aOC<)BUrHC
O O-H»H OO^: O VJ4)S-H-HTH
HHO- B
03 a
cq iJ
CO
4J
CO CO
cr> fl)
u
•a
O 4-1
Lj Vj
U-t O
a
cd 4)
w M
CO

3
rH rH
rH rt

^1*1
43

-------
                        SECTION VI.

             SELECTION OF POLLUTANT PARAMETERS

                 Paint Formulating Industry

The  major  wastewater  parameters  of  significance for the
paint formulation industry are BOD5 (5-day 20°C  Biochemical
Oxygen  Demand),  TSS  (Total  Suspended  Solids),  pH,  and
selected metals.  Chemical Oxygen Demand (COD) may  be  used
as  a  substitute for BOD5 if a relatively constant COD/BOD5
ratio can be developed for a given plant.  On the  basis  of
the  evidence  reviewed,  there  appear  to  be  very  small
quantities of  potentially  hazardous  or  toxic  pollutants
released   by  the  paint  formulation  inustry.   Recycling
washwater and water conservation practices will  reduce  the
quantity  of  paint  wastes  discharged  to  the  sewers  or
receiving waters.

                  Ink Formulating Industry

As most ink formulators do not  discharge  wastes  to  water
courses  and  their  wastes  are  generally considered to be
compatible with municipal treatment, there  is  little  data
available  on  the  waste characteristics.   The practices of
recycling wastewater and water .conservation can  reduce  the
quantity of ink waste discharged to the sewers.

The  significant  parameters  for  measuring  the  pollution
potential of ink wastes are  BOD5   (5-day),  pH,  and  Total
Suspended  Solids.   Chemial Oxygen Demand (COD) may be used
as a substitute for BOD5 if a relatively  constant  BOD5/COD
ratio can be developed for a given plant.

RATIONALE FOR SELECTION OF POLLUTANT PARAMETERS

Biochemical Oxygen Demand (BOD5, 20°C)
Biochemical  oxygen  demand  (BOD) is a measure of the oxygen
consuming capabilities of organic matter.  The BOD does  not
in  itself  cause direct harm to a water system, but it does
exert an indirect effect by depressing the oxygen content of
the water.  Sewage and other organic effluents during  their
processes  of  decomposition  exert  a BOD, which can have a
catastrophic effect on the ecosystem by depleting the oxygen
supply.  Conditions are reached frequently where all of  the
oxygen  is  used and the continuing decay process causes the
production of noxious gases such  as  hydrogen  sulfide  and
methane.   Water  with  a high BOD indicates the presence of
                             45

-------
decomposing organic matter  and  subsequent  high  bacterial
counts that degrade its quality and potential uses.

Dissolved  oxygen  (DO) is a water quality constituent that,
in appropriate concentrations, is essential riot only to keep
organisms living but also to sustain  species  reproduction,
vigor,   and  the  development  of  populations.   Organisms
undergo stress at reduced DO concentrations that  make  them
less  competitive  and  able to sustain their species within
the  aquatic   environment.    For   example,   reduced   DO
concentrations  have  been  shown  to  interfere  with  fish
population through delayed hatching of  eggs,  reduced  size
and  vigor  of  embryos, production of deformities in young,
interference with  food  digestion,  acceleration  of  blood
clotting,  decreased tolerance to certain toxicants, reduced
food  efficiency  and  growth  rate,  and  reduced   maximum
sustained  swimming speed.  Fish food organisms are likewise
affected adversely in conditions with suppressed DO.   Since
all  aerobic  aquatic  organisms  need  a  certain amount of
oxygen, the consequences of total lack of  dissolved  oxygen
due  to  a high BOD can kill all inhabitants of the affected
area.

If a high BOD is  present,  the  quality  of  the  water  is
usually  visually  degraded  by  the presence of decomposing
materials and algae blooms due to  the  uptake  of  degraded
materials that form the foodstuffs of the algal populations.

It  was  thought  at  first  that  the  BOD5  test  would be
meaningless  because  of  the  action  of   the   biological
inhibitors  and heavy metals.  However, this does not appear
to be the case as the majority of the water-base paints  are
not  tinted  before  packaging  and  the  tinting  materials
contain most of the  troublesome  heavy  metals.   Also  the
inhibitor  is diluted to the point of ineffectiveness by the
washwater.  The oils used in water-base paint production are
generally  easily  oxidized   (9).   Thus,  control  of  this
parameter will also control oil and grease concentrations.

Chemical Oxygen Demand  (COD)

Chemical  oxygen  demand   (COD)  provides  a  measure of the
equivalent oxygen required to oxidize the materials  present
in  a  waste water sample under acid conditions with the aid
of a strong chemical oxidant, such as potassium dischromate,
and a catalyst  (silver sulfate).  One major advantage of the
COD test is that the results are available normally in  less
than  three  hours.   Thus, the COD test is a faster test by
which to estimate the maximum oxygen exertion demand a waste
can make on a stream.  However, one  major  disadvantage  is
                              46

-------
that   the   COD   rest   does   not  differentiate  between
biodegradable and  nonbiodegradable  organic  material.   In
addition,   the  presence  of  inorganic  reducing  chemical
(sulfides, reduciable metallic ions, etc.) and chlorides may
interfere with the COD test.  As a rough generalization,  it
may  be  said that pollutants which would be measured by the
BOD5> test will also show up under the  COD  test,  but  that
additional pollutants which are more resistant to biological
oxidation (refractory) will also be measured as COD.
Acidity  and  alkalinity  are  reciprocal terms.  Acidity is
produced  by  substances  that  yield  hydrogen  ions   upon
hydrolysis  and  alkalinity  is  produced by substances that
yield hydroxyl ions.  The terms "total acidity"  and  "total
alkalinity" are often used to express the buffering capacity
of  a  solution.   Acidity  in  natural  waters is caused by
carbon dioxide, mineral acids, weakly dissociated acids, and
the salts of strong acids and  weak  bases.   Alkalinity  is
caused  by strong bases and the salts of strong alkalies and
weak acids.

The term pH is a logarithmic expression of the concentration
of hydrogen ions.  At a pH of 7, the hydrogen  and  hydroxyl
ion  concentrations  are  essentially equal and the water is
neutral.  Lower pH  values  indicate  acidity  while  higher
values indicate alkalinity.  The relationship between pH and
acidity or alkalinity is not necessarily linear or direct.

Waters  with  a  pH  below  6.0 are corrosive to water works
structures,  distribution  lines,  and  household   plumbing
fixtures  and  can  thus  add  such constituents to drinking
water 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  bactericidal  effect  of
chlorine  is  weakened  as  the  pH  increases,  and  it  is
advantageous to keep the  pH  close  to  7.   This  is  very
significant for providing safe drinking water.

Extremes  of  pH  or  rapid  pH  changes  can  exert  stress
conditions  or  kill  aquatic  life  outright.   Dead  fish,
associated  algal  blooms,  and  foul stenches are aesthetic
liabilities of any waterway.   Even  moderate  changes  from
"acceptable"  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.
Metalocyanide complexes  can  increase  a  thousand-fold  in
toxicity  with  a drop of 1.5 pH units.  The availability of
                               47

-------
many nutrient substances  varies  with  the  alkalinity  and
acidity.  Ammonia is more lethal with a higher pH.

The   lacrimal   fluid   of  the  human  eye  has  a  pH  of
approximately 7.0 and a deviation of 0.1 pH  unit  from  the
norm   may   result  in  eye  irritation  for  the  swimmer.
Appreciable irritation will cause severe pain.

Total Suspended Solids
The bulk of the materials used  in  paint  formulations  are
nearly  insoluble  inorganic  compounds — titanium dioxide,
clays, calcium  carbonate,  and  silicates  —  which  could
occlude  the  bottom  of  the receiving body of waters.  The
parameter of suspended solids would measure  the  efficiency
of removal of these inorganic solids.

The  bulk  of  the  materials  used  in ink formulations are
insoluble  inorganic  compounds — clays  and  pigments — which
could  occlude  the  bottom  of the receiving body of water.
The  parameter  of  suspended  solids  would   measure   the
efficiency of removal of these inorganic solids.

Suspended   solids   include   both  organic  and  inorganic
materials.  The inorganic components include sand, silt, and
clay.  The  organic  fraction  includes  such  materials  as
grease, oil, tar, animal and vegetable fats, various fibers,
sawdust,  hair,  and  various  materials from sewers.  These
solids may settle out rapidly and bottom deposits are  often
a  mixture  of  both  organic  and  inorganic  solids.  They
adversely affect fisheries by covering  the  bottom  of  the
stream  or lake with a blanket of material that destroys the
fish-food bottom fauna  or  the  spawning  ground  of  fish.
Deposits  containing  organic  materials  may deplete bottom
oxygen  supplies  and  produce  hydrogen   sulfide,   carbon
dioxide, methane, and other noxious gases.

In  raw  water  sources for domestic use, state and regional
agencies generally specify that suspended solids in  streams
shall  not  be  present  in  sufficient  concentration to be
objectionable  or  to  interfere   with   normal   treatment
processes.   Suspended  solids  in  water may interfere with
many industrial processes, and cause foaming in boilers,  or
encrustations  on  equipment exposed to water, especially as
the temperature rises.  Suspended solids are undesirable  in
water  for  textile  industries;  paper and pulp; beverages;
dairy  products;  laundries;  dyeing;  photography;  cooling
systems,  and  power plants.  Suspended particles also serve
as a transport mechanism for pesticides and other substances
which are readily sorbed into or onto clay particles.
                              48

-------
Solids may be suspended in water for a time, and then settle
to the bed of the stream or lake.  These  settleable  solids
discharged   with   man's   wastes   may  be  inert,  slowly
biodegradable materials, or rapidly decomposable substances.
While in suspension, they  increase  the  turbidity  of  the
water,    reduce    light   penetration   and   impair   the
photosynthetic activity of aquatic plants.

Solids in suspension are  aesthetically  displeasing.   When
they  settle  to  form sludge deposits on the stream or lake
bed, they are often much more damaging to the life in water,
and they  retain  the  capacity  to  displease  the  senses.
Solids,  when  transformed  to  sludge  deposits,  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  occupy  the
habitat.   When  of  an  organic  and therefore decomposable
nature, solids use a portion or all of the dissolved  oxygen
available  in  the  area.  Organic materials also serve as a
seemingly inexhaustible  food  source  for  sludgeworms  and
associated organisms.

Turbidity  is  principally  a measure of the light absorbing
properties of suspended solids.  It is frequently used as  a
substitute  method of quickly estimating the total suspended
solids when the concentration is relatively low.
Oiland Grease

Oil and grease exhibit an oxygen demand.  Oil emulsions  may
adhere  to  the  gills  of fish or coat and destroy algae or
other plankton.  Deposition of oil in the  bottom  sediments
can   serve   to   exhibit   normal  benthic  growths,  thus
interrupting the aquatic food chain.  Soluble and emulsified
material ingested by fish may taint the flavor of  the  fish
flesh.   Water  soluble components may exert toxic action on
fish.  Floating oil may reduce the re-aeration of the  water
surface and in conjunction with emulsified oil may interfere
with  photosynthesis.  Water insoluble components damage the
plumage and costs of  water  animals  and  fowls.   Oil  and
grease   in   a   water  can  result  in  the  formation  of
objectionable surface slicks preventing the  full  aesthetic
enjoyment of the water.

Oil  spills  can damage the surface of boats and can destroy
the aesthetic characteristics of beaches and shorelines.
                              49

-------
Metals

Metals  are  used  in  paint  formulations   as   biological
inhibitors, driers, and as pigments (10).

Mercury  -  Mercury  compounds were the predominant biocides
used in the past but recent State and  Federal  restrictions
on  their  use  have  been  forcing  industry  to find other
biocides that  are  subject  to  environmental  degradation.
Mercury use can be expected to decrease,  but until such time
as it ceases to be used, it should be limited.

Lead  -  Lead  compounds  have been among the cheapest, most
stable and brightest tinting agents used in yellow  and  red
paints.   Lead  is  also  used  in  drying agents.  However,
recent legislation (Lead-Based  Paint  Poisoning  Prevention
Act  of 1973)  to reduce lead in paints has forced the search
for suitable replacements.  As with mercury, lead  usage  is
decreasing,  but,  as it inhibits biological life, it should
be limited.
Zinc - Occurring abundantly  in  rocks  and  ores,  zinc  is
readily  refined  into  a  stable  pure  metal  and  is used
extensively  for  galvanizing,  in  alloys,  for  electrical
purposes,  in  printing  plates, for dye-manufacture and for
dyeing processes, and for many  other  industrial  purposes.
Zinc   salts   are   used   in  paint  pigments,  cosmetics,
Pharmaceuticals, dyes, insecticides, and other products  too
numerous  to  list  herein.  Many of these salts  (e.g., zinc
chloride and zinc sulfate)   are  highly  soluble  in  water;
hence  it  is  to  be expected that zinc might occur in many
industrial wastes.  On the other hand, some zinc salts (zinc
carbonate, zinc oxide, zinc sulfide) are insoluble in  water
and  consequently  it  is to be expected that some zinc will
precipitate and be removed readily in most natural waters.

In zinc-mining areas, zinc  has  been  found  in  waters  in
concentrations  as  high  as  50  mg/1 and in effluents from
metal-plating works and small-arms ammunition plants it  may
occur  in  significant  concentrations.  In most surface and
ground waters, it is present only in trace  amounts.   There
is  some  evidence  that zinc ions are adsorbed strongly and
permanently on silt, resulting in inactivation of the zinc.

Concentrations of zinc in excess of 5 mg/1 in raw water used
for drinking water supplies cause an undesirable taste which
persists through conventional treatment.  Zinc can  have  an
adverse effect on man and animals at high concentrations.
                                50

-------
In  soft  water,  concentrations of zinc ranging from 0.1 to
1.0 mg/1 have been reported to be lethal to fish.   Zinc  is
thought  to  exert  its  toxic  action  by forming insoluble
compounds with the mucous that covers the gills,  by  damage
to the gill epithelium, or possibly by acting as an internal
poison.   The  sensitivity  of  fish  to  zinc  varies  with
species, age and condition, as well as with the physical and
chemical characteristics of the water.  Some acclimatization
to the presence of zinc  is  possible.   It  has  also  been
observed  that  the effects of zinc poisoning may not become
apparent  immediately,  so  that  fish  removed  from  zinc-
contaminated to zinc-free water (after 4-6 hours of exposure
to  zinc) may die 48 hours later.   The presence of copper in
water  may  increase  the  toxicity  of  zinc   to   aquatic
organisms,  but  the  presence  of  calcium  or hardness may
decrease the relative toxicity.

Observed values for the distribution of zinc in ocean waters
vary widely.  The  major  concern  with  zinc  compounds  in
marine  waters  is  not one of acute toxicity, but rather of
the long-term sub-lethal effects of the  metallic  compounds
and  complexes.   From  an  acute  toxicity  point  of view,
invertebrate marine animals seem to be  the  most  sensitive
organisms  tested.   The  growth  of  the  sea  urchin,  for
example, has been retarded by as little as 30 ug/1 of zinc.

Zinc sulfate has also  been  found  to  be  lethal  to  many
plants, and it could impair agricultural uses.

With  the  exception  of  mercury,  the metals used in paint
production  are  generally  insoluble  and  the  control  of
suspended  solids  concentrations will give adequate control
of these metals.

There are many different metals  used  in  paints  and  inks
depending  on  the  color   desired.   These metals, such as
boron, chromium, cadmium, copper, iron, and titanium  should
be  considered  for control on a case-by-case basis when the
application for  a  discharge  permit  is  considered.   The
plants  should be asked for a list of the metals they expect
to discharge.

There are possibly trace quantities  of  other  organic  and
metallic  compounds as the carriers are polymerized oils and
the pigments and  extenders  in  many  cases  are  processed
natural   minerals.    These   are   not  in  sufficient  or
controllable quantities so they are not considered  at  this
time.   This  does not preclude reopening the issue if, at a
later time, they are identified as problem compounds.
                              51

-------
                        SECTION VII.

              CONTROL AND TREATMENT TECHNOLOGY

                 Paint Formulating industry

The paint industry consists of about  1,500  companies  with
about  1,700 plants.  In 1971, total industry employment was
about 63,000.  Because of the relatively  simple  technology
and  low  capital investment required, the industry contains
many small companies.  About 42  percent  of  the  companies
have   fewer  than  10  employees.   These  small  companies
accounted for less than 5 percent of the industry  sales  in
1967, whereas the four largest companies accounted for about
22  percent  of  sales  and  the largest 50 accounted for 61
percent (1) .

Although the industry is spread over  a  large  geographical
area,  paint  plants  are,  in general, located close to the
point of use because of transportation costs.   This,  then,
places most plants in metropolitan areas; and, as such, most
of  the  plants  discharge to municipal systems.  A check of
the Refuse Act Permit Program  (RAPP) applications in the ten
EPA regions turned up only one plant that had process wastes
going to surface water courses in 1971.  The findings of the
NFIC-D survey of plants for  degree-of-treatment  technology
are presented in Table VII-1.

As  the  vast  majority  of  the  paint manufacturing plants
discharge to municipal systems, the degree of sophistication
of treatment  is  solely  a  function  of  the  restrictions
applied  by  the  municipal  system.   In  areas  where high
surcharges are placed on BOD5 and  TSS,  there  is  a  trend
toward  strict water conservation and reuse and the disposal
of  paint  wastes  to  landfills.    In   areas   where   no
restrictions  are  imposed, water use is lavish and there is
little or no treatment before discharge  (11,12).

The extent of control and treatment technology  reported  by
plants  of  various sizes is shown in Table VII-2.  About 20
percent of all plants generate no wastewater on  a  routine,
daily  basis,  except for sanitary, non-contact cooling, and
boiler blowdown water.  An  additional  22  percent  of  the
plants,  while  generating some wastewater, do not discharge
wastewater, but control  or  dispose  of  it  by  some  non-
discharge method  (1) .

Of  the  remaining  58  percent of the plants that discharge
wastewater, 30 percent  treat  all  wastewater,  15  percent
control  or  treat  some of their wastewater, and 13 percent
                                 53

-------















































r-t
1
M
r-l
£>
U
. T
M

frS



























































,'•"*•
rH
u~l
CO
Csl
O
M
to
v^

£
H
t/;

1
M
53
O
M
H

j_j
r-^
5d
C£
O


H

M
*^«
PJ

W
£

Ei
M

CP

r-l
M
H
•K
W
o
I j

JM
O
o
^J
o
g

u
w
H

H

IT)
»5?
£_|
^J
(l.l
erf
H
















f~^.
\^
O
4-1
«

W
c
O

"S
in
tt
£Q

^j
OJ
•u

^


£*•*
c;

o
_c
u
OI
H
4J
G
01
E

cd
0)
^4
H


/"•%
•o
01
CO
CO


r-l
•H
C
^X

W
4J
C
u

0
C/J













w
OJ
(U
^
0
r-l
B-
E
W

U-i
O

O





4J
C

p-



t3
•r^
3
D'
T-l
rH

•o
OI
rH
•H
^
C
c


01
u
T3
3
t-l
05

- -u
T3 01
Q) (0
rH 3
4-J (U
at





4J
n

rH
d.

rH
CO
•H
U

01

£3
0
u

tf\

•a
0

rH
•H
CO
l-l
•o
01




















o
^
rH








*
<





XI
01
1 — I
rH r-l
•r-l CO
14-) -H
C! *J
CO C w
"^ -S -a
-d *-> c
C U -H
CO 3
*x? c
*Q O *H
(V M
£ CX 13
H (U
U '"C W
1^ CJ 3
T? W d>
f3 M
W JD
QJ W
4_l V-*  (D 4J
C2 AJ f^3
S rt S
rH W
H O CC
< V. ^




4-t 4-1
C C
co n)
rH rH
o. a
4J
rH rH d
CO CO -H
T-l t-l CO
U CJ C.
M I-i
01 OI U
i^ E. C
fc E 01
O C 3
y o cr
0)
rV X W
pO rO Xl
3
T3 "O W
01 O
rH rH d
rH rH -H
jj 4J -a
CO CO 01
•H «H CO
T3 'O 3
O O 0)
fy| p>^ fv^



















o o m
VO OO CJ
V








* * *
« e_> o

-a
!P , CJ rH rH
S o) 4j 4j m r-i a>
4J V-l O O *H rH Cj_
W 4J -H C
i>i rH ^O 01 U_j Cl
CO *O CO t— 4 C^. (A TJ J>
41 4J C TJ C • «
0>rHOO>T-l3 CO (J .
CO rH 4-1 M CO i — 1 t rH CO
3 T-l cO n c/) I
C) **-! T3 1 O M O W V-<
rJTJCW^ *J Cl *•» Cl 0)
c rt M c • 4-1 t'. ti w:
••<3 Cj OJ C3 V-( QJ O C 4-J f^ fj
r-lCJpCCXCJ t^DfUCQJCJ
^ (rO £— * £ *J *x3 'C? I> O t> I>
to co p o*tJ n3OfOwcjr3
(0 cc -H  ao
ci > v-i- jr wcxwiMcow
C 
*O cO *X3
o y oi
tO rH CO rH
0) rH rH
x: c T-I o I i i i t i 1-1
y 3 4J 4J 1 1 1 1 1 1 4-1
^j O W CO
CO C 1-1 W 1-1
Xl .y TJ C *O
d oi o> oi
y— V rj^ r/> fv{
f-^
a
0

4J
y
J3
•a
o
M
a

•o
p.
tc

0
o
0
n o mmo-Oiooo
rH O «3-rHiriOOvOnCN
rH CM CM rH CN 1
A v-' IA
C *"*
0
_§
c
z*


* *
W f*. Olf-l'-J^rJXSS

iJ
c
OJ
w

a) o
C CO
"O TJ
3 3
rH rH
'

• •
0) 01
01 41
CO CO
rH
O rH O
4-1 -t-l 4J
U-<
c •« e

XI CO ,f"t r— I
i-l rH 4J >H
IK
- O ' T)
CC 4-1 tO d
c d rt
-H C rH
4J K 4J 4J
0) O
C/i C/)












c
•H
CO
rH 4-1
•U rH W
01 1-1

3 "O rH
01 C U
>-< CO d
rH -H
-o x:

CO 4J
d
•U 0) i-(
01 tt
4J T) T)
C 3 01 '
CO rH CO
y co 3
oi oi
C3 Crf



















o in
CN CM
1
in
I







4C *r>
O P-i





CJ
C
o
M U
U
' 3
Vj "S
01 J-*
& p-
W C
•H
0
4-1 T^
Cl

O 3
•H OI
4J VH
CO

•H ^-4
rH 0)
CO 4-1
3 CO
CD p
W rC
O Ul
M 6 S
rt i-H
U fc











r^
r-l
r— {
cfl
-H
y

OI
g
e
o
j

^3
41
rH
r-l
d T-I
2 4-1
O 05
d -H
rii T3
13 01
S C4



















m o
CM O
r-l
A








c/o:;
1






















































•
^
X?

•a
01
y
CO
4-1
d
o
y

CO
4J

cO
,_•!
ex

^
01
JC
4J
o

1

T>
U
. J
*Tl
CO
•H

CO
1 f
C
CO

X
•K
54

-------
M
t-l
>


S

9
















5|

|


i
A<
P.
t-i
O
8
M
13

Cu

H
H
y
p
^4
M
£2
p
B
55

1 ^
o
g
g

fx
0
1


























it)
o
H













^
VI
to c;
u V
c *>>
fl O
t—\ r— 4
p. c
M-< 0)
0
«_ o
to Wi
4-1 C)
C ja
Cl E
0 3
01
0. >

C *o
a v
K
W< 1-1
Cl lJ
.0 O
R tt
«
O















M
O
B
O
O

CM
en

CM
0
U
O
O
^


.
O




.
o
*
t~!



^
0
51



0
o
V
0
in
X



.
O




O">
•*
o
iJ

o

4-1 Cl ID C rH I/I
03 4-1 *r4 *r^ W W* tj
j-irt *o ti uvj *riO3
CI3 W (0 QJ 4-*
u u oc3 tx T-I -H
n5 to t) O *J to
to3 UM4J v)4j uiah
4J ijrlt/) U(/l jJOIfd
co nxfl crj ehx
DC IUU3 « S (0 4J O
r-l rH 1-1 r-l
Pu r^< O. (K
COl 0
H> S


Ol CM
CM in
1-1
o t f*"^
CM| •-(


•3-1 O
1 ^

•3\ m



COl CM
1 f


s| a
I— 1| r-»


COl CM
1 M



vOl CM
1 N




CM! sr
1 co




OJ ON
t-ll r-l


col o»
1 ^


8| S



ml m
1 N







U
3
o to

u C CD.
•HO) BJ 3
3 C r-l 0
01 OJ 00
4J O r-4
C V4 10 C
ID 4J 4J VH
r-J O
f^i H

-------
discharge without using any  control  or  treatment.   Thus,
about  87  percent  of the plants either do not generate any
wastewater or are treating or controlling at least  some  of
it.

About  a  third of the plants report reduction of wastewater
by reycling or by conservation of water through the  use  of
high-pressure   nozzles  for  cleaning,  self-contained  tub
washers or other conservation  methods.   In  several  small
plants  (less  than  50  employees)  the quantity of cleanup
wastewater  was  found  to   range   from   0.02   to   0.23
liters/liters  (gal./gal.)  of  paint.  Within these plants,
production equipment  and  cleaning  facilities  are  nearly
identical.   The  ten-fold  differences  in washwater volume
generated shows the effect of water conservation  practices.
There was no detectable difference in the cleanliness of the
tubs.   A  comparison  of  two  large plants of nearly equal
capacity showed that one discharges 0.86 liter of waste  per
liter  (gal./gal,) of product and the second discharges 0.08
liter  of  waste  per  liter  (gal./gal.)  of  product  (2).
Required   conservation   of   water   can  be  attained  by
modification of washing methods, as evidenced by  the  above
examples.

Another method for water reduction is the reuse of washwater
in  products   (2).   This  practice  is  possible under some
conditions.  If the paint formulation for the next batch  is
the  same  or  of a darker color, then the tub may be reused
without washing or a minimum of water can be used to  remove
the  residue  from  the walls of the tub.  Because bacterial
contamination of paint causes reduction of shelf life,  some
producers  are  hesitant to reuse the washwater as they feel
this water would contaminate subsequent batches.   In  other
words,  some  manufacturers  feel  that the replacements for
mercury-based biocides are not dependable.  There is  not  a
consensus  by  industry  members  on  this point.  One manu-
facturer has recently  installed  equipment  to  flocculate,
settle  and filter washwater.  The filtered water is exposed
to ultraviolet radiation to disinfect  the  water  which  is
then  reused  for  paint  manufacture.   Tests are currently
being conducted on a similar system in another paint plant.

One promising method for reducing water usage is the use  of
dry  pick-up  procedures  for  handling  spills  of  the raw
material and of the product. Several  plants have plugged all
floor drains and use vacuums to clean the floor area.   This
procedure  also  cuts  down on the accident potential as the
floors are always  dry.   Spills  of  oils  and  paints  are
handled by cleaning up with shovels or squeegees followed by
the use of a dry absorbent to pick up the residue.
                              56

-------
CONTROL AND TREATMENT TECHNOLOGY

A  general overview of the methods of treatment and disposal
employed by plants of various sizes is  presented  in  Table
VII-3.   Sedimentation  is  the most common treatment method
employed.  This is to be expected in view of the  fact  that
most  plants  discharge  to  municipal  systems  where  some
pretreatment is required.   In  about  half  of  the  plants
employing   sedimentation,  flocculaticn  is  also  used  to
increase the effectiveness  of  removing  suspended  solids.
Neutralization,  principally  of caustic cleaning solutions,
is employed in at least  eight  plants.   Of  the  remaining
treatment  methods,  no one method is widely employed.  Off-
site disposal, such as landfill, is the most common disposal
method and is practiced in at least  32  plants.   Reuse  of
cleanup  water  in  products  is  practiced  in  at least 26
plants.  At least ten plants evaporate wastewater and  three
more plants use incineration to dispose of wastewater (1).

The  effectiveness  of the treatment methods employed by the
paint industry  is  difficult  to  judge  on  the  basis  of
available  data.  However, the most significant constituents
of paint wastes  are  amenable  to  treatment  by  physical-
chemical (P-C)methods combined with biological treatment for
removal  of biodegradable organics.  As in other industries,
dissolved solids are not treated.

Physical-chemical methods are used by some  plants  to  meet
the   pretreatment   limitations  set  by  state  and  local
agencies.  Briefly, the plants using P-C  treatment  collect
the  flows  in  a  holding tank until sufficient quantity is
obtained to warrant treatment.  If necessary, pH  adjustment
is made before a coagulant (lime, alum or iron salts)  and/or
a  coagulant  aid  (polymer)   is added to the batch which is
then flocculated and settled.  The settled sludge is sent to
a landfill and the clarified water  goes  to  the  municipal
treatment   plant.   Another  variation  of  this  procedure
utilizes a settling  pond  to  obtain  clarification  before
discharge.    One plant follows the addition of the chemicals
by pressurization followed by  atmospheric  release  into  a
combination  settling-flotation basin where the oil froth is
skimmed and the solids are settled before  the  effluent  is
discharged.   Physical-chemical  treatment  methods  can  be
expected to produce an effluent with the following ranges of
characteristics: TSS = 1-150 mg/1; BOD5 = 5-60 mg/1;  COD  =
18-1,400 mg/1.  Metals can be expected to range from 0.01 to
0.1 mg/1 in the treated effluent  (13).

Several  plants  now practice no discharge by utilization of
solids separation and  washwater  reuse.  The  washwater  is
                                57

-------















— .
c >-
O (U
EC H
f— ( (/3
ro Jn^>
en H M
i 5?;

t* fc ^
*"* <5 <
W W p.
(J Pi
M H W
t^ fy^ fr _j
W
t~^ 5?"
< M
rz

ll
" 1




















rt
4J
o
H





(0
0>
o
>N
o
&
E
W QJ
C M j
« o

(u
° 3
»-< C
 tC OO(OV<
4J «H rt TO C -H >-i 4J
W4-1NCI-IO4J4-IT3
4JC}*HO •HCOCV'H
S*3 OjAj'Sfl-H 8« O
E; O ^ ^3 4-* ^ fH ^ *H
^HU4J4J(\}4J(OM*r(E
1SI £ ^2 I*S $6

CO CM rH


CM C*1 SO O iH





CM IO rH rH C)







CO ON VO C 0





rH r- «0- -i C
•O -H P. C O
(U T) O -H
•H C -H 4J

O ^H "O 2 «J
V 03 ft) O C
tX 1 « CX -H


-------
greatly  minimized  and collected in a tank where the solids
are settled.  The partially clarified water  is  used  as  a
first wash of the tubs.  This is followed with a clean rinse
at  the  end  to remove any residual solids.  The solids are
sent to a landfill operation.  Several other plants  collect
all  washwater  and send it to landfill operations in drums.
One plant manufacturing water-base industrial  coatings  has
no  discharge  as  it  reuses all waters in subsequent paint
batches (14).

The current trend by several water-base paint  manufacturers
is to give the purchaser of paints for home use a wide range
of  paint colors that are mixed in the retail store.  It was
estimated by several medium  to  large  sized  manufacturers
that  they  now produce as high as 90 percent of their trade
sale paint in the tint base form, with the tinting added  in
the  store  at  the time of sale.  This trend is expected to
continue throughout the water-base paint industry.   One  of
the  most  impressive  water  reuse  systems seen during the
NFIC-D survey was used  by  one  large  paint  manufacturing
company  with  a vertical flow plant.  It was an application
of a commerical caustic tub washer that allowed the cleaning
of either separate paint tubs or the  cleaning  in-place  of
the  piping  and  equipment  on that floor.  The caustic was
reused until spent, then more caustic was added.   The  only
output from the system was a thick sludge with a consistency
of  peanut  butter.   The  cleaned  tubs and mix tanks had a
light powder (spent caustic) on the surfaces but this caused
no product contamination.  The company had plugged all floor
drains and slop sinks within the plant.  Also they collected
any excess water,380-760 liters  (100-200 gal.) per week, and
reused  it   in   product.    They,   reported   no   product
contamination.

Oil-base  paint  manufacturers practice two basic methods of
equipment cleanup.  They are  solvent  washing  and  caustic
washing.   For  solvent  wash  plants there is no contact of
water with the process.  The waste solvents  are  reclaimed,
reused   or  incinerated.   Reclaiming  is  accomplished  by
distillation either by the plant  or  a  solvent  reclaiming
company.   The  use  of  caustic  wash  is  similar  to  the
description above for water base paints.  There are no known
dischargers of oil base solvent wash  paint  wastes  to  any
receiving streams or municipal systems.

IDENTIFICATION OF WATER-POLLUTION RELATED
MAINTENANCE AND OPERATIONAL PROBLEMS

There  are several maintenance and operational problems that
are associated with wastewater treatment.  One of  the  most
                               59

-------
visible  sources  of  pollution  is  leaking  pumps.  As the
material being pumped in the  paint  industry  is  abrasive,
pump  seals  wear  rapidly.   In plants where maintenance is
adequate, the quantity of paint lost is minimal.

Spill cleanup techniques can greatly affect the quality  and
quantity  of  the  wastewater.   Some plants hose the spills
into the floor drains while others use squeegees and shovels
to pick up the  waste  and  place  it  into  containers  for
discharge  to landfills.  Any residual materials left on the
floor are picked up by an  absorbing  agent.   Although  for
convenicence some plants wash down dry spills, a vacuum type
of pickup would keep the materials out of the sewer.

The  general plant cleanup can be accomplished by the use of
vacuums  and  minimum-water-use  floor  scrubbers.   Several
plants  have  covered  all  floor drains and use dry cleanup
techniques to keep from increasing the wastewater load.

There are some plants  that  conserve  water  and  discharge
either no water or very little water per unit of production.
Generally  speaking,  the  plants  using  water conservation
methods were as clean as those with  lavish  uses  of  water
 (15).
                                 60

-------
                  Ink Formulating Industry

In  recent years, there has been a proliferation of inks for
rather specific end uses, such as carbon  paper,  typewriter
ribbons,  textiles,  magnetic  applications as in bank check
processing,  and  conductive  coatings.   Improved  pigments
including  reactive  mixtures and fluorescent dyes have also
been developed.  Specialty inks likely account for  some  20
percent of the 1971 U.S. market.

However, large volume markets continue to be concentrated in
the  four basic classifications:  letterpress, lithographic,
rotogravure and flexographic.  Newsprint  (letterpress)  is,
of  course,  largest  in  volume,  but its low selling price
significantly  offsets  its  dollar  volume.   These   inks,
largely  comprised  of  carbon  black  and mineral oil, have
undergone very little change over the years.

Lithographic  inks  used  in  publications,  packaging   and
commercial  printing  now have a substantially larger dollar
volume  than  letterpress  inks.   The  use  of   web-offset
equipment  in  printing  newspapers and general publications
has accelerated this growth.

In the solvent-base inks, flexographic inks  are  increasing
their  market share at the expense of letterpress.  The inks
dry rapidly, affording efficient operation using  continuous
webs.   Flexographic  inks  are  used  on  corrugated boxes,
transparent films, foils and flexible laminates.

Gravure inks, historically used  to  print  the  newspapers'
Sunday  supplements,  are  now used to print many decorative
consumer  packages  such  as  cereal  cartons,  frozen  food
packaging and soap wrappers.  The printing ink industry is a
large  consumer of pigments due to the increasing demand for
color over the past few years (2).

The industry is almost exclusively located  in  metropolitan
areas, where the market exists.  Because of the proximity to
metropolitan  areas,  the wastes are generally discharged to
municipal sewers.  A check of the RAPP applications  in  the
ten  EPA  regions  failed  to  produce any ink manufacturing
plants that discharge other than cooling  water  to  surface
waters.   Contacts  with  the  industry  have supported this
finding.

As the ink manufacturing plants discharge only to  municipal
systems,  there  is  little  sophistication in the treatment
methods.  The complexity  of  the  treatment  process  is  a
function  of  the  restrictions applied by the municipality.
                               61

-------
In areas where high surcharges are placed on BOD^  and  TSS,
there is a trend toward strict water conservation,  reuse and
disposal  of  ink solids to landfills.  In other areas where
no restrictions are imposed, water use is lavish  and  there
is  little or no treatment before discharge.  Treatment con-
sists  of  sedimentation  or  coagulation-sedimentation   to
remove   solids  before  discharge  to  sewers.   Where  the
municipality is very restrictive, plants  have  gone  to  no
discharge of process wastewaters.  Washwater is recycled and
the   solids   are   sent  to  landfills.   Restrictions  on
landfilling are forcing the industry to examine incineration
as a method of reducing the organic content of  the  sludge.
The installation of a tub washer with reuse of the washwater
is  practiced in several plants, and results in no discharge
of process wastewaters  (3,U).

Another method  of  water  reduction  is  in  the  reuse  of
washwater  as  a raw material.  This practice is possible if
the ink formulation for the new batch is the same  or  of  a
darker color.  The tub can be reused without washing or with
a  minimum  of  washing,  or  the  washwater  can be used to
disperse the raw materials in the new  batch.   Some  plants
have  plugged all floor drains and use dry pickup methods to
dispose of spilled ink.

CONTROL AND TREATMENT TECHNOLOGY

Sedimentation is a common treatment method employed  due  to
the  large  numbers  of  plants  discharging  into municipal
sewers with pretreatment requirements.  Flocculation is also
used to increase the  effectiveness  of  removing  suspended
solids.   Neutralization,  principally  of  caustic cleaning
solutions, is employed to some degree.  Of  the  ten  plants
shown  in  Table  VII-4,  all  except two have achieved zero
discharge  of  process   wastewater   pollutants.    Solvent
cleaning wastes are reclaimed either on site or by a solvent
reclaimer.    Scavenger   pickup   and   disposal   was  the
predominant method found.  The  most  promising  as  far  as
water conservation is concerned is the recycling caustic tub
washer where only sludge is wasted.
                                62

-------
                                      TABLE VII- 4
                           TREATMENT TECHNOLOGY DETERMINED IN
                         THE INK FORMULATING INDUSTRY (SIC2893)
Plant-'
   Number
of Employees
               Treatment Technology
Solvent Based                        Water Based
A

B

C

D
F

G:

H

I

J
             Drummed and redistilled

             Drummed and redistilled

             Drummed and recycled

             Redistilled


             Redistilled
                       To Sewer

                       Recycling caustic tub-washer

                       Drummed and landfilled

                       Recycling caustic washer, rinse
                         water to sewer, sludge to landfill

                       Total recycling caustic washer,
                         excess water from rinses.
                         Evaporated with steam.  Sludge to
                         landfill.
             Scavenger and redistilled   Scavenger picked up

             Scavenger and redistilled   Scavenger picked up

             Scavenger and redistilled   Scavenger picked up

             Scavenger and redistilled   Scavenger picked up

             Scavenger and redistilled   Scavenger picked up
a?Plants A, B. C, D, and E visited.Others verified by phone or from Chicago
    Metropolitan Sanitary District Board.
                                      63

-------
One small ink manufacturer redistills all washwater from his
ink  process and uses it as boiler feed water.  In one plant
the volume of scrub water is greatly minimized and collected
in a tank where  the  solids  are  settled.   The  partially
clarified  water  is  used  to initially wash the tubs and a
final clean rinse is used to  remove  any  residual  solids.
The  sludge  (3  percent  solids)  is  sent  to  a  landfill
operation.  Several other small plants actually collect  all
washwater  in  drums  and  send  it  to  landfill operations
(3,4,5).
                                64

-------
                        SECTION VIII

     COST, ENERGY, AND OTHER NON-WATER QUALITY ASPECTS

                 Paint Formulating Industry

OIL-BASE PAINT PRODUCTION

Cleanup  of  oil-base  manufacturing  paint   equipment   is
accomplished by the use of solvents or by the use of caustic
solutions.    The   solvents  typically  are  flammable  and
disposal to navigable waters or municipal sewers is  usually
prohibited.   In  addition, the cleaning solvents are costly
and are usually either recovered or sold to a scavenger  for
recovery.  Caustic solutions are reused until spent.

For  those  waste  materials  considered to be non-hazardous
where land disposal is the choice  for  disposal,  practices
similar  to  proper  sanitary  land  fill  technology may be
followed.  The  principles  set  forth  in  the  EPA's  Land
Disposal  of  Solid Wastes Guidelines (CFR Title UO, Chapter
1; Part 241) may be used as  guidance  for  acceptable  land
disposal techniques.

For   those  waste  materials  considered  to  be  hazardous
disposal will require  special  precautions.   In  order  to
ensure   long-term  protection  of  public  health  and  the
environment, special preparation  and  pretreatment  may  be
required  prior  to  disposal.   If  land  disposal is to be
practiced, these sites must not allow movement of pollutants
to  either  ground  or  surface  waters.   Sites  should  be
selected that have natural soil-and geological conditions to
prevent  such  contamination  or,  if such conditions do not
exist, artidicial means  (e.g., liners) must be  provided  to
ensure   long-term   protection   of  the  environment  from
hazardous materials.  Where  appropriate,  the  location  of
solid   hazardous   materials   disposal   sites  should  be
permanently recorded in the appropriate office of the  legal
jurisdiction in which the site in located.

Best  practicable  control technology currently available in
oil-base solvent wash paint manufacturing is no discharge of
wastewater pollutants.  If the waste solutions are recovered
on site, the residual sludge must be adequately disposed  of
in a landfill.

Treatment  levels  for  Best  Practicable Control Technology
Currently  Available  (BPCTCA),  Best  Available  Technology
Economically  Achievable   (BATEA),  New  Source  Performance
Standards  (NSPS),  and  Pretreatment  of  New  and  Existing
                             65

-------
Sources  (NESPS)  for the control of process wastes from oil-
base solvent wash paint production are  all  defined  as  no
discharge  of wastewater pollutants to surface waters.  Good
housekeeping, with control of spills and leaks,  will  allow
all such waste materials to be collected in sumps, placed in
drums,  and  periodically  disposed of in a landfill.  Since
the best  practicable  level  of  treatment  is  already  no
discharge  of  process  waste  liquids,  the  added costs of
achieving BPCTCA, BATEA and NSPS are zero.   The  amount  of
plant  modification  and maintenance required to insure good
housekeeping and prevent  leaks  and  spills  from  entering
drains  and  being  discharged  to  surface  waters  can  be
achieved for a negligible cost.   The  costs  of  reclaiming
solvents  does  not have an impact since a profit or savings
is obtained.  The costs for  oil-base  caustic  wash  paints
will  be  developed  in the Development Document for all the
paint and ink subcategories.

WATER-BASE PAINT PRODUCTION

Costs  for  water-base  piants  will  be  developed  in  the
Development   Document   for   all   the   paint   and   ink
subcategories.

Best Practicable Control Technology Currently
Available fBPCTCA)

The  BPCTCA  for  plants  in  the  oil  base  solvent   wash
subcategory  is  no discharge of process water pollutants to
navigable  waters  through  solvent  recovery,  reclamation,
incineration  and  landfill.   The costs for three different
size solvent recovery plants are summarized in Table  VIII-1
(17).  Reclaimed solvents sell for 10-300/1 (400-$1.00/gal).
Compared to the cost of reclamation  1.0  -  3.80/1   (3.6  -
14.20/gal)(17)  it  is  beneficial  for  the  paint  and ink
industry ro practice this technology.

Best Available Technology Economically Achievable
(BATEA) and New Source Performance Standards;._ (NSPS)_

Since BPCTCA for the oil-base solvent wash subcategory is no
wastewater discharge, the same technology applies for  BATEA
and  NSPS.  The incremental cost of these technologies above
BPCTCA is zero for that subcategory.
Ngn Water Quality Considerations

The study found no instance where  the  proposed  guidelines
would significantly increase the noise or radiation levels.
                              66

-------
                               Table VIII-l
                OPERATING COSTS FOR A SOLVENT RECLAIMING SYSTEM
                       IN A PAINT MANUFACTURING PLANT
BASIS:                 Operation      -  230 eight-hour days per year
                 Operation Costs
                 (steam, electricity) -  1.2 cents per gallon recovered
                            Labor     -  1/3 to 1/2 operator
                         Overhead     -  100% of operating cost & labor
                      Maintenance     -  5% of installed cost
                     Depreciation     -  20% of installed cost
Solvent Recovery Rate
380 1/hr
(100 gph)
1500 1/hr
(400 gph)
6100 1/hr
(1600 gph)
Installed Cost                  $54,000        $71,000       $120,000

Solvent Recovered               760,000 1    3,000,000 1   12,000,000 1
  per year                     (200,000 gal.) (800,000 gal)(3,200,000 gal.)
Operating Cost
Labor
Overhead
Maintenance
Depreciation
Annual Operating Cost
Total Recovery Cost
$2,400
$5,000
$7,400
$2,700
$10,800
$28,300
3.8C/1
(14.2C/gal.)
$9,600
$5,000
$14,600
$3,550
$14,200
$46,950
1.6C/1
(5.9C/gal.)
$38,400
$5,000
$43,000
$6,000
$24,000
$116,800
l.OC/1
(3.6^/galJ
                                     67

-------
The  impact  of  the  paint  sludge  on  landfills  would be
minimal.  The range is from 0.08 m3 (0.1 yd3) each week  for
a  plant with 2,800 liters per day (750 gpd) paint to 0.8 m3
(1 yd3) for a plant with 26,000 liters per day   (7,000  gpd)
production.   Based  on  the information in Figure III-2 the
total sludge each year to landfills would be between  13,000
and  134,000 m3  (17rOOO and 175,000 yd3) if all paint plants
in the United States were to go to a total recycle system.

In reality the increase  in  sludge  disposal  to  landfills
would  be the difference between the quantitiy produced by a
total  recycle  wash  system  and  that  quantity  currently
removed in sewage treatment plants.
                                68

-------
                  Ink Formulating Industry

The   BPCTCA   for  plants  in  the  oil-base  solvent  wash
subcategory is no discharge of process water  pollutants  to
navigable  waters.   Costs  are the same as for the oil-base
solvent wash paint subcategory.

The study found no instance where  the  proposed  guidelines
would significantly increase the noise or radiation levels.

The  impact  of  ink sludge on landfills would be minimal as
the range is from 1.0 to 3.2 kg of ink solids per  1,000  kg
(lb/lrOOO   Ib)  of  product.   These  quantities  could  be
increased if flocculants were added.   Assuming  no  use  of
flocculants,  the  weight of sludge produced would vary from
0.1 to 0.32 percent of the weight of ink produced.
                              69

-------

-------
                        SECTION IX.

         EFFLUENT REDUCTION ATTAINABLE THROUGH THE
   APPLICATION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
                    CURRENTLY AVAILABLE

INTRODUCTION

The effluent limitations which must be achieved by  July  1,
1977  are  those  attainable  through the application of the
Best  Practicable  Control  Technology  Currently  Available
(BPCTCA).   Best  Practicable  Control  Technology Currently
Available is based upon the average  of  the  best  existing
performance  by  plants  of  various  sizes,  ages  and unit
processes within the industrial category and/or subcategory.
This average is not based on a broad range of plants  within
the  paint  processing industry, but upon performance levels
achieved by exemplary plants.

    Consideration must also be given to:

    a.   The total cost  of  application  of  technology  in
         relation  to  the effluent reduction benefits to be
         achieved from such application;

    b.   The  size  and  age  of  equipment  and  facilities
         involved;

    c.   The processes employed;

    d.   The  engineering  aspects  of  the  application  of
         various types of control techniques;

    e.   Process changes; and

    f.   Non-water quality environmental  impact  (including
         energy requirements).

Also,   Best   Practicable   Control   Technology  Currently
Available emphasizes treatment facilities at the  end  of  a
manufacturing  process  but  includes  control  technologies
within the process itself when the latter are considered  to
be normal practice within an industry.

A  further  consideration  is  the  degree  of  economic and
engineering reliability which must be  established  for  the
technology  to  be  "currently  available."   As a result of
demonstration projects, pilot plants and general use,  there
must  exist  a  high degree of confidence in the engineering
and economic practicability of the technology at the time of
                                71

-------
commencement of construction or installation of the  control
facilities.

EFFLUENT REDUCTION ATTAINABLE THROUGH THE
APPLICATION OF THE BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE

                 Paint Formulating Industry

Based  on  the information contained in Sections III through
VIII of this document, a determination has been made of  the
degree   of   effluent   reduction  attainable  through  the
application  of  the  Best  Practicabe  Control   Technology
Currently  Available  for  the  oil-base  solvent wash paint
subcategory of the paint formulating industry.  The effluent
limitations are  for  no  dischargee  of  process  wastewater
pollutants to navigable waters.

                  Ink Formulating Industry

Based  on  the information contained in Sections III through
VIII of this document, a determination has been made of  the
degree   of   effluent   reduction  attainable  through  the
applicaion  of  the  Best  Practicable  Control   Technology
Currently  Available  for  the  oil-base  solvent  wash  ink
subcategory of the ink manufacturing industry.  The effluent
limitations are  for  no  discharge  of  process  wastewater
pollutants to navigable waters^

Identification of the Best Practicable Control
Technology Currently Available

The  Best Practicable Control Technology Currently Available
for the oil-base solvent wash paint subcategory of the paint
formulating industry  and  the  oil-base  solvent  wash  ink
subcategory  of the ink formulating industry is no discharge
of process wastewater pollutants to receiving streams.  This
can be accomplished redistillation  and  reuse  of  solvents
utilized  in  tub washing either captively or by contractor,
with solids disposal to landfill or incineration.
                                72

-------
                 Paint Formulating Industry

Total Cost of Application

There will be no cost to the  paint  manufacturing  industry
for  oil-base  solvent  wash  paints  as it is profitable to
recover.

Size and Age of Equipment

The size of the paint formulating plant  would  have  little
effect   on  the  control  technology  applied.   Since  the
equipment  used  in  paint  formulating  has   not   changed
appreciably  over the years, the age of the equipment is not
a basis  for  differentiation  in  the  application  of  the
control technology.

Process Employed

There is no essential difference in methods of making water-
and  oil-base paints.  Larger plants may use gravity flow or
pumping  to  transfer  paints  where  the   small   operator
mechanically moves the paint tub from station to station.

The  main difference in the paint formulating process is the
washout methods used.  As discussed previously solvent wash,
caustic wash and water rinse are  the  primary  methods  and
have  been  utilized as a factor in the subcategorization of
the industry.

Engineering Aspects

The technology required to meet BPCTCA has been demonstrated
by most plants in the industry (15).

Process Changes

No major changes are expected in the formulation of  paints.
Any  minor  changes  would  reflect  water  conservation and
possible reuse of wastewater in the product.

Non-Water Quality Environmental Impact

There is  no  evidence  that  application  of  this  control
technology   will   result  in  any  unusual  air  pollution
problems, either in kind or magnitude.  The energy  required
to  apply  this  control  technology represents only a small
increment of the present total energy  requirements  of  the
industry.   In  fact the relcamation of solvents reduces the
demand for virgin solvents' many of which as petroleum  based
                               73

-------
and  energy  intensive to produce.   Solid waste control must
be considered.   Solid  residue  and  sludge  are  potential
probelms  because  of the need for periodic disposal.  Solid
waste must be handled properly to assure that no landfill or
associated  problems  develop.   Best  practicable   control
technology  and  best  available control technology, as they
are known today/ require disposal of the pollutants  removed
from  waste  waters  in  this  industry in the form of solid
wastes and liquid concentrates.  In  most  cases  these  are
non-hazardous  substances  requiring  only minimal custodial
care.  However, some constituents may be hazardous  and  may
require special consideration.  In order to ensure long term
protection  of  the  environment  from  these  hazardous  or
harmful  constituents,  special  consideration  of  disposal
sites must be made.  All landfill sites where such hazardous
wastes  are  disposed  should  be  selected so as to prevent
horizontal and vertical migration of these  contaminants  to
ground   or   surface   waters.   In  cases  where  geologic
conditions  may  not  reasonably   ensure   this,   adequate
precautions   (e.g.,  impervious  liners)  should be taken to
ensure  long  term  protection  of  the   environment   from
hazardous  materials.   Where  appropriate,  the location of
solid  hazardous  materials   disposal   sites   should   be
permanently  recorded in the appropriate office of the legal
jurisdiction in which the site is located.
                                74

-------
                  Ink Formulating Industry

                 Total Cost, of Application

There will be no cost to the Ink Manufacturing Industry.  It
is profitable to reclaim solvents.

Size and Age of Equipment

The size of the  ink  manufacturing  plants  would  have  no
effect  on  the  control technology applied.  The age of the
equipment  is  not  a  basis  for  differentiation  in   the
application of the control technology.

Process Employed

The  main  difference  in the ink formulating process is the
washout methods used.  As discussed previously solvent wash,
caustic wash and water rinse are  the  primary  methods  and
have  been  utilized as a factor in the subcategorization of
the industry.

Engineering Aspects

The technology required to meet BPCTCA has been demonstrated
by most plants in the industry  (3,4).

Process Changes

No major changes are expected in the  manufacture  of  inks.
Any  minor  changes  would  reflect  water  conservation and
possible reuse in the product.

Non-Water Quality Environmental Impact

There is  no  evidence  that  application  of  this  control
technology will result in any unusual air pollution or solid
waste  disposal  problems, either in kind or magnitude.  The
costs of avoiding problems in these areas are not excessive.
The  energy  required  to  apply  this  control   technology
represents  no  significant  increase  of  the present total
energy  requirements  of  the   industry.    In   fact   the
reclamation  of  solvents  reduces  the  demand  for  virgin
solvents many  of  which  are  petroleum  based  and  energy
intensive to produce.

Best  practicable  control  technology  and  best  available
control  technology  require  disposal  of  the   pollutants
removed  from  wastewaters  in  the form of solids.  In most
cases, these are  non-hazardous  substances  requiring  only
                               75

-------
minimal  custodial  care.  However, some constituents may be
hazardous and may require special consideration.    In  order
to ensure long-term protection of the environment from these
hazardous  or harmful constituents, special consideration of
disposal sites must be made.  All landfill sites where  such
hazardous  wastes  are  disposed should be selected so as to
prevent  horizontal  and   vertical   migration   of   these
contaminants to ground or surface waters.

In cases where geologic conditions may not reasonably ensure
this, adequate precaution (e.g. impervious liners) should be
taken to ensure long-term protection to the environment from
hazardous  materials.   Where  appropriate,  the location of
hazardous materials disposal  sites  should  be  permanently
recorded in the appropriate office of the legal jurisdiction
in which the site is located.
                               76

-------
                         SECTION X

         EFFLUENT REDUCTION ATTAINABLE THROUGH THE
        APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
                  ECONOMICALLY ACHIEVABLE

INTRODUCTION

The  effluent  limitations  which  must be achieved no later
than July 1, 1983 are not based on an average  of  the  best
performance   within  an  industrial  subcategory,  but  are
determined  by  identifying  the  very  best   control   and
treatment  technology  employed  by  a specific point source
within the industrial category or  subcategory,  or  by  one
industry  where  it  is  readily transferable to another.  A
specific finding must be made  as  to  the  availability  of
control measures and practices to eliminate the discharge of
pollutants,   taking   into   account   the   cost  of  such
elimination.

    Consideration must also be given to:

    a.   The age of the equipment and facilities involved;

    b.   The process employed;

    c.   The  engineering  aspects  of  the  application  of
         various types of control techniques;

    d.   Process changes;

    e.   The  cost  of  achieving  the  effluent   reduction
         resulting from application of the technology;

    f.   Non-water quality environmental  impact   (including
         energy requirements) .

In   addition.   Best   Available   Technology  Economically
Achievable emphasizes in-process controls as well as control
or additional treatment techniques employed at  the  end  of
the production process.

This level of technology considers those plant processes and
control  technologies which, at the pilot plant, semi-works,
or  other  level,  have  demonstrated   both   technological
performance  and economic viability at a level sufficient to
reasonably justify investing in such facilities.  It is  the
highest  degree of control technology that has been achieved
or has been demonstrated to be capable of being designed for
plant scale operation up to and including "no discharge"  of
                              77

-------
pollutants.   Although  economic  factors  are considered in
this development, the costs for this level  of  control  are
intended  to  be  the top-of-the-line of current technology,
subject to limitations imposed by economic  and  engineering
feasibility.  However, there may be some technical risk with
respect  to  performance  and  with  respect to certainty of
costs.  Therefore, some  industrially-sponsored  development
Work may be needed prior to its application.

EFFLUENT REDUCTION ATTAINABLE THROUGH THE
APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE

                 Paint Formulating Industry

The  effluent  reduction attainable for the oil-base solvent
wash paint subcategory of  the  paint  formulating  industry
through  the  application  of  the Best Available Technology
Economically Achievable is the same as BPCTCA  which  is  no
discharge  of  process  wastewater  pollutants  to navigable
waters, as developed in Section IX.  There is no incremental
cost of BATEA over BPCTCA.

                  Ink Formulating Industry

The effluent reduction attainable for the  oil-base  solvent
wash  ink  subcategory  of  the  ink  manufacturing industry
through the application of  the  Best  Available  Technology
Economically  Achievable  is  the same as BPCTCA which is no
discharge of  process  wastewater  pollutants  to  navigable
waters, as developed in Section IX.  There is no incremental
cost of BATEA over BPCTCA.
                               78

-------
                         SECTION XI
              NEW SOURCE PERFORMANCE STANDARDS
INTRODUCTION
The  effluent  limitations  that  must  be  achieved  by new
sources are termed performance standards.   The  New  Source
Performance   Standards   apply  to  any  source  for  which
construction starts after the publication  of  the  proposed
regulations   for   the  Standards.   The  Standards  become
effective upon start-up of the new  source.   The  Standards
are determined by adding to the consideration underlying the
identification  of  the  Best Practicable Control Technology
Currently Available a determination of what higher levels of
pollution control are available through the use of  improved
production  processes and/or treatment techniques.  Thus, in
addition to considering the best in-plant and end-of-process
control technology. New  Source  Performance  Standards  are
based  on  an  analysis  of how the level of effluent may be
reduced  by  changing   the   production   process   itself.
Alternative    processes,   operating   methods   or   other
alternatives are considered.  However, the end result of the
analysis is to identify  effluent  standards  which  reflect
levels  of  control  achievable  through the use of improved
production processes  (as well as control technology), rather
than prescribing a particular type of process or  technology
which  must  be  employed.   A further determination made is
whether a standard permitting no discharge of pollutants  is
practicable.

    Consideration must also be given to:

    a.   Operating methods;

    b.   Batch, as opposed to continuous, operations;

    c.   Use of alternative raw materials and mixes  of  raw
         materials;

    d.   Use of dry rather  than  wet  processes   (including
        • substitution of recoverable solvents for water) ;

    e.   Recovery of pollutants as byproducts.

EFFLUENT REDUCTION ATTAINABLE FOR NEW SOURCES

                 Paint Formulating Industry

The effluent reduction attainable for  new  sources  in  the
oil-base   solvent  wash  paint  subcategory  of  the  paint
                                79

-------
formulation industry is the  same  as  BPCTCA  which  is  no
discharge  of  process  wastewater  pollutants  to navigable
waters, as developed in Section IX.

                  Ink Formulating Industry

The effluent reduction attainable for  new  sources  in  the
oil-base solvent wash ink subcategory of the ink formulation
industry  is  the  same  as  BPCTCA which is no discharge of
process  wastewater  pollutants  to  navigable  waters,   as
developed in Section IX.
                                80

-------
                        SECTION XII

                       ACKNOWLEGMENTS
This  report  was  prepared  by the Environmental Protection
Agency's Branch of the National Field Investigations Center,
Denver Colorado, under the Management of  Thomas  Gallagher,
Director,  Art  Masse,  Project  Manager,  Lee Reid, Project
Engineer, and Robert King, Project Engineer made significant
contributions to the preparation of this report.

David Becker, Project Officer, Effluent Guidelines Division,
contributed to the overall coordination of  this  study  and
assisted in the preparation of this report.

Allen  Cywin,  Director, Effluent Guidelines Division, Ernst
P. Hall,  Deputy  Director,  Effluent  Guidelines  Division,
Walter  J.  Hunt,  Chief,  Effluent  Guidelines  Development
Branch offered guidance and helpful suggestions.

Members  of  the  Working  Group/Steering   Committee    who
coordinated the internal EPA Review are as follows:

    Walter J. Hunt, EGD  (Chairman)
    David Becker, EGD  (Project Officer)
    Art Masse, NFIC - Denver  (Project Manager)
    Lee Reid, NFIC - Denver
    Robert King, NFIC - Denver
    Herbert Shovronek, NERC - Cincinnati (Edison)
    Richard Stevenson, OPE
    Courtney Riorden, OEGC, Washington
    Jules Cohen, NFIC - Denver
    William Swithy, OTS, Washington
    Carol Wills, OEGC - Denver
    Matt Straus, OSWMP - Washington
    Irving Dzikowski, Region V - Chicago
    Alfred Galli, Region VI - Dallas
    John Dale, ESED - Durham

Acknowledgement and appreciation is given to the secretarial
staff for their efforts in the preparation of this report.

    Brenda Holmone, Effluent Guidelines Division
    Nancy Zrubek, Efffluent Guidelines Division
    Marsha O'Connor, NFIC - Denver

Special  recognition  is  due the National Paint and Coating
Association,  the  Federation   of   Societies   for   Paint
Technology,   the   National  Association  of  Printing  Ink
                                 81

-------
Manufacturers, the East Bay Municipal Utilities District and
the Metropolitan Sanitary District of  Greater  Chicago  for
their  role  in  facititating  contact  with  representative
segments of the industry and many other contributors.

Appreciation is extended to  the  .following  companies  that
participated in the study:

    Benjamin Moore and Company
    Boysen Paints
    Celanese Coatings Company
    Crosby Forest Products Company
    DeSoto Inc.
    Dixie - O'Brien Corporation
    E.I. duPont de Nemours & Company
    Exxon Chemical Company
    Flecto Corporation
    Frank Dunne Company
    Glidden Durkee Company
    Inmont Corporation
    Morwear Paint Company
    Porter Paints
    Sherwin Williams Company
    Sinclair - Valentine Inks
    Sun Chemical Corporation
    Tenneco Chemical Inc.
    U.S. Gypsum Company
                                82

-------
                        SECTION XIII

                         REFERENCES

                 Paint Formulating Industry
1.   Barrett, W. J.,  Mooneau,  Gf  A.,  and  Rodig,  J.  J.,
    "Waterborne  Wastes  of the Paint and Inorganic Pigments
    Industries," Southern  Research  Institute,  Birmingham,
    Alabama, July, 1973,  EPA 670/2-74-030.

2.   Environmental  Protection  Agency,  "Field   Notes   and
    Chemical   Analyses   -   Survey   of   Paint   and  Ink
    Manufacturers  in  Oakland,  California,"  collected  by
    National  Field Investigations Center, Denver, Colorado,
    October, 1973.

3.   Hine, W. R., "Disposal of Waste  Solvents,"  Journal  of
    Paint Technology,, 43  (558): 75-78, July, 1971.

4.   Williams, Rodney, "Latex Wastes  and  Treatment,"  Paper
    presented  at  the  meeting  of the Golden Gate Section,
    National Paint and Coatings Association, San  Francisco,
    California, June, 1972.

5.   Environmental Protection Agency,  "Development  Document
    for  Proposed  Effluent  Limitaitons  Guidelines and New
    Source Performance Standards for  the  Synthetic  Resins
    Segment   of   the   Plastics  and  Synthetic  Materials
    Manufacturing Paint Source Category," Washington,  D.C.,
    August, 1973.

6.   Bruhns, F., "The Paint Industry  vs.  Water  Pollution,"
    Paint and Varnishing Production, May, 1971, pp. 35-39.

7.   Lederer, S. J. and  Goll,  M.,  "The  Mercury  Problem,"
    Paint and Varnish Production, October, 1972, pp. 44-49.

8.   Mann, A., "Mercury Biocides:  Paint's Problem Material,"
    Paint and Varnish Production, March, 1971, pp. 26-35.

9.   Yazujian, D., "Chemicals in  Coatings,"  Chemical  Week^
    October, 1971, pp. 35-51.

10. Mann, A., "1972 Review-1973 Forcast," Paint and  Varnish
    Production, July 1973, pp. 23-36.
                              83

-------
11.  Larsen, D., Kunel, K., "COD Solids Removal  Exceeds  90%
    in  Effluent  From Coatings Plant," Chemical Processing,
    January, 1971, pp. 16-17.

12.  Maas, W. , "Solid Waste Disposal and Organic  Finishing,"
    Metal Finishing, March, 1972, pp. 4U, 45, 49.

13.  Desoto Corporation, Desoto Waste  Treatment  System  for
    Latex Paint Wastes, Chicago, Illinois.

11.  Reid, L. C., "Memorandum to Record,"  (Specifying  Plants
    Attaining  No discharge of Process Wastewater to Surface
    Waters),   National   Field    Investigations    Center,
    Environmental   Protection   Agency,  Denver,  Colorado,
    December, 1973 - January,  1974.

15.  Reid, L. C., and Masse, A., "Trip Reports,"  (Paint  and
    Ink  Plants in Chicago, Illinois and Oakland, California
    Areas),   National    Field    Investigations    Center,
    Environmental   Protection   Agency,  Denver,  Colorado,
    December, 1973 - January,  1974.

16.  "Water Quality  Criteria,   1972,"  National  Academy  of
    Sciences  and  National  Academy  of Engineering for the
    Environmental Protection Agency, Washington,  D.C.  1972
    (U.S. Government Printing Office Stock No. 5501-00520)

17.  "Assessment  of  Industrial  Hazardous  Waste  Practices
    Paint  and Coatings Manufacture, Solvent Reclaiming, and
    Factory - Applied  Costings  Operations"  DRAFT  REPORT.
    (Unpublished  Subject to Revision) Office of Solid Waste
    Managment  Programs.   EPA  Contract   No.   68-01-2656.
    WAPORA, Inc.
                                84

-------
                         REFERENCES

                  INK FORMULATING INDUSTRY
1.  Environmental Protection Agency,  "Development  Document
    for  Proposed  Effluent  Limitations  Guidelines and New
    Source Performance Standards for  the  synthetic  Resins
    Segment   of   the   Plastics  and  Synthetic  Materials
    Manufacturing Point Source Category," Washington,  D.C.,
    August, 1973.

2.  Williams, Alex, "Printing Inks," Noyes Data Corporation,
    Parkridge, N.J., 1972.

3.  Reid, L. C., "Memorandum to Record," (Specifying  Plants
    Attaining  No Discharge of Process Wastewater to Surface
    Waters),   National   Field    Investigations    Center,
    Environmental   Protection   Agency,  Denver,  Colorado,
    December, 1973 - January, 1974.

4.  Reid, L. C., and Masse, A., "Trip Reports,"  (Paint  and
    Ink  Plants in Chicago, Illinois and Oakland, California
    Areas),   National    Field    Investigations    Center,
    Environmental   Protection   Agency,  Denver,  Colorado,
    December, 1973 - January, 1974.

5.  King,   Robert,   "Trip    Report,"    National    Field
    Investigations  Center, Environmental Protection Agency,
    Denver, Colorado, November, 1973.

6.  "Water Quality  Criteria,  1972,"  National  Academy  of
    Sciences  and  National  Academy  of Engineering for the
    Environmental Protection Agency, Washington, D.C.  1972,
    (U.S. Government Printing Office Stock No. 5501-00520).
                                85

-------

-------
                        SECTION XIV

                          GLOSSARY
DEFINITIONS

Ball   Mill   —   A  horizontal  mounted  cylindrical  tank
containing steel or ceramic balls that reduce particle  size
of materials when the tank is rotated.

Binder  —  That  component  of  a  coating that contributes
primarily to the adhesive and  cohesive  properties  of  the
coating.

Biochemical  Oxygen  Demand  (BODj>)  — The amount of oxygen
required by microorganisms  while  stabilizing  decomposable
organic  matter under aerobic conditions.  The level of BOD!>
is usually measured as the demand for oxygen over a standard
five-day period.  Generally expressed as mg/1.

Biocide — Chemical toxic to biological life.

Biological Inhibitor — Chemical that inhibits  or  disrupts
biological processes.

Carbon  Black — Finely divided carbon obtained by burning a
gas in an oxygen deficient combustion chamber.   The  carbon
is mixed with oils to produce certain inks.

Chemical  Oxygen  Demand  (COD)  — A measure of the amount of
organic matter which can be oxidized to carbon  dioxide  and
water  by  a strong.oxidizing agent under acidic conditions.
Generally expressed as mg/1.

Cleavage — That quality of paint or ink left on  the  sides
of production tanks after the product is removed.

Disperser  —  Mixing  machine  that  acts  to  disperse the
components of paint or ink.

Dispersing Agent — A reagent that is  compatible  with  the
solvent  and  holds  finely  divided matter dispersed in the
solvent.

Esterif ication — The formation of an ester  by  elimination
of water between an acid and an alcohol.

Extender  —  Clays  and silicates used to give opacity to a
coating.
                                87

-------
Fungicide — Chemical used to inhibit growth of fungus.

Lacquer — A solution in an organic solvent of a natural  or
synthetic  resin,  a  cellulose  ester  or a cellulose ester
together  with  modifying  agents,  such  as   plasticizers,
resins, waxes, and pigments.

Latex  —  Aqueous  colloidal disperson of rubber or rubber-
like substances.

Oil- Base — Paints or inks that use oils or  resins  as  the
prime vehicle.

pH  — The reciprocal logarithum of the hydrogen ion concen-
tration in wastewater expressed as a standard unit.

Physical-Chemical —  The  method  of  treating  wastewaters
using   combinations   of   the  processes  of  coagulation,
sedimentation, carbon absorption, electrodialyses or reverse
osmosis.

Pigment — The colorant used to give  paints  and  inks  the
desired hue and colqr.

Process  Wastewater  —  Any  water  subsequently discharged
directly or indirectly, as through municipal sewers, to  the
environment  in  a  liquid  phase  which  (1) came in direct
contact with raw materials, intermediates or final  products
or  (2)  was  utilized  in  cleanups  of  the  manufacturing
equipment or area.

gesin — Any class of solid or semi-solid  organic  products
of  natural or synthetic origin, generally of high molecular
weight with no definite melting point.
     Mills — Machines with close- tolerance adjustable metal
rolls used to disperse and grind pigments to a certain  con-
sistency and size.

Total  Suspended Solids  (TSS) — Solids that eigher float on
the surface ofr or are in suspension in, water and which are
largely removable by filtering or sedimentation.

Varnish — A  fluid  that  dries  in  contact  with  air  by
evaporation of its volatile constituents by the oxidation of
its  oil  and  resin  ingredients  or  by  both methods to a
continuous protective coating when spread upon a surface  in
a thin film.
                                  88

-------
Water-Base
vehicle.
Paints  or  inks that use water as the prime
SYMBOLS

gal.

gm

gpd


gpm



kg

kg/day

1

1/m

Ib/day

m


m3/day


mgd



mg/1

TOG
   volume in gallons = 3.785 liters

   weight in grams = 0.03527 ounces

   flow rate in gallons per day  =  3.785  x
   10~3 cubic meters per day

   flow rate in gallons per minute =  0.0631
   liters  per  second  or  3.785 liters per
   minute

   weight in kilograms = 2.205 pounds

   mass flow rate in kilograms per day

   volume in liters = 0.2642 gallons

   flow rate in liters per minute

   mass flow rate in pounds per day

   length in meters = 3.281  feet  or  1.094
   yards

   flow rate in cubic meters per day = 264.2
   gallons per day

   flow rate in million gallons  per  day  =
   3,785  cubic meters per day = 43.7 liters
   per second

   concentration in milligrams per liter

   total organic carbon
                                 89

-------
                                    TABLE  XIV-1

                                   METRIC  TABLE

                                 CONVERSION  TABLE
MULTIPLY (ENGLISH UNITS)

    ENGLISH UNIT      ABBREVIATION
acre                    ac
acre - feet             ac ft
British Thermal
  Unit                  BTU
British Thermal
  Unit/pound            STU/lb
cubic feet/minute       cfm
cubic feet/second       cfs
cubic feet              cu ft
cubic feet              cu ft
cubic inches            cu in
degree Fahrenheit       °F
feet                    ft
gallon                  gal
gallon/minute           gpm
horsepower              hp
inches                  in
inches' of mercury       in Hg
pounds                  Ib
million gallons/day     mgd
mile                    mi
pound/square
  inch (gauge)          psig
square feet             sq ft
square inches           sq in
ton (short)             ton
yard                    yd
          by                TO OBTAIN (METRIC UNITS)

     CONVERSION   ABBREVIATION   METRIC UNIT
       0.405
    1233.5

       0.252
ha
cu m

kg cal
0.555
0.028
1.7
0.028
28.32
16.39
0.555(°F-32)*
0.3048
3.785
0.0631
0.7457
2.54
0.03342
0.454
785
1.609
kg cal/kg
cu m/nin
cu m/»in
cu m
1
cu cm
°C
m
1
I/sec
kw
cm
atm
kg
cu m/day
km
(0.06805 psig +1)*  atm
       0.0929       sq m
       6.452        sq cm
       0.907        kkg
       0.9144       m
hectares
cubic meters

kilogram - calories

kilogram calories/kilogram
cubic meters/minute
cubic meters/minute
cubic meters
liters
cubic centimeters
degree Centigrade
meters
liters
liters/second
killowatts
centimeters
atmospheres
kilograms
cubic meters/day
kilometer

atmospheres  (absolute)
square meters
square centimeters
metric ton  (1000 kilograms
meter
* Actual conversion, not a multiplier
                                            90
        * I) S GOVERNMENT PRINTING OFFICE 1975— 210-810/4

-------